200clc, 230clc, and 270clc repair tm1931

200CLC230CLC

and270CLC

ExcavatorRepair

TECHNICAL MANUAL200CLC, 230CLC, and 270CLC

Excavator Repair

TM1931 09JAN04 (ENGLISH)

For complete service information also see:

200CLC, 230CLC, and 270CLC ExcavatorOperation and Tests . . . . . . . . . . . . . . . . . . . TM1930POWERTECH 4.5 L & 6.8 L (4045 and 6068)Diesel Engines, Base Engine . . . . . . . . . . . . CTM104POWERTECH 4.5 L & 6.8 L (4045 and 6068)Diesel Engines, Level 4 Electronic FuelSystems with Bosch VP44 Pump . . . . . . . . . CTM170Alternators and Starting Motors . . . . . . . . . . CTM77Undercarriage Appraisal Manual . . . . . . . . . SP326

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

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

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable 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 specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.

TM1931 (09JAN04) 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=2

Introduction

TX,TM,FAX –19–19JUN00–1/1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.

SEND TO: John Deere Dubuque WorksP.O. Box 538Attn: Publications Supervisor, Dept. 303Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one)

Poor Fair Good Very Good Excellent1 2 3 4 5 6 7 8 9 10

Company Name:

Technician Name:

Address:

Phone:

Fax No.:

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THANK YOU!


PN=3

Introduction


PN=4

Contents00

SECTION 00—General InformationGroup 0001—SafetyGroup 0003—Torque Values

SECTION 01—Tracks01Group 0130—Track System

SECTION 02—Axles and Suspension Systems(Propel)

Group 0250—Axle Shaft, Bearings, and ReductionGears

Group 0260—Hydraulic System

SECTION 04—EngineGroup 0400—Removal and Installation

02

SECTION 05—Engine Auxiliary SystemGroup 0510—Cooling SystemGroup 0520—Intake SystemGroup 0560—External Fuel Supply System

SECTION 07—Dampener Drive (Flex Coupling)Group 0752—Elements

SECTION 17—Frame or Supporting StructureGroup 1740—Frame InstallationGroup 1749—Chassis Weights

04

SECTION 18—Operator’s StationGroup 1800—Removal and InstallationGroup 1810—Operator EnclosureGroup 1821—Seat and Seat BeltGroup 1830—Heating and Air Conditioning

SECTION 33—ExcavatorGroup 3302—BucketsGroup 3340—FramesGroup 3360—Hydraulic System

05

SECTION 43—Swing or Pivoting SystemGroup 4350—Mechanical Drive ElementsGroup 4360—Hydraulic System

SECTION 99—Dealer Fabricated ToolsGroup 9900—Dealer Fabricated Tools

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

07

COPYRIGHT 2004DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2001

17

18

33

43

TM1931 (09JAN04) i 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=1

Contents

00

01

02

04

05

07

17

18

33

43

TM1931 (09JAN04) ii 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=2

Contents

99

INDX

TM1931 (09JAN04) iii 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=3

Contents

99

INDX

TM1931 (09JAN04) iv 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=4

00

Section 00General Information

Contents

Page

Group 0001—Safety . . . . . . . . . . . . . . . . . .00-0001-1

Group 0003—Torque ValuesUnified Inch Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1Metric Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Additional Metric Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-5Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6Service Recommendations for Flat Face

O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-8Service Recommendations for 37° Flare

and 30° Cone Seat Connectors . . . . . . . . .00-0003-9Service Recommendations For Flared

Connections—Straight or TaperedThreads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10

Service Recommendations For InchSeries Four Bolt Flange Fittings. . . . . . . .00-0003-11

Service Recommendations for MetricSeries Four Bolt Flange Fitting . . . . . . . .00-0003-12

TM1931 (09JAN04) 00-1 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=1

Contents

00


PN=2

Group 0001Safety

0000011

TX03679,00016CC –19–21AUG00–1/1

Recognize Safety Information

T13

3555

–UN

–28A

UG

00T

1335

88–1

9–28

AU

G00

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

Follow the precautions and safe operating practiceshighlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — isused with the safety alert symbol. DANGER identifies themost serious hazards.

On your machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located nearspecific hazards. General precautions are on CAUTIONlabels.

TX03679,00016F9 –19–28AUG00–1/1

Follow Safety Instructions

T13

3556

–UN

–24A

UG

00

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

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

TX03679,00016FA –19–30OCT00–1/1

Operate Only If Qualified

Do not operate this machine unless you have read theoperator’s manual carefully and you have beenqualified by supervised training and instruction.

Familiarize yourself with the job site and yoursurroundings before operating. Try all controls and

machine functions with the machine in an open areabefore starting to work.

Know and observe all safety rules that may apply toyour work situation and your work site.

TM1931 (09JAN04) 00-0001-1 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=9

Safety

000001

2

TX03679,00016D0 –19–30OCT00–1/1

Wear Protective Equipment

TS

206

–UN

–23A

UG

88

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

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

TX03679,00016B7 –19–30OCT00–1/1

Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition ofunapproved products or attachments, may affectmachine stability or reliability, and may create a hazardfor the operator or others near the machine.

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

TX03679,00016CE –19–30OCT00–1/1

Add Cab Guarding For Special Uses

T13

3733

–UN

–15S

EP

00Special work situations or machine attachments maycreate 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 theoperator.

FOPS (falling object protective structures) and specialscreens or guarding should be installed when falling orflying objects may enter or damage the machine. Contactyour authorized dealer for information on devices intendedto provide protection in special work situations.


PN=10

Safety

0000013

TX03679,0001734 –19–25SEP00–1/1

Inspect Machine

T66

07A

Q–U

N–1

8OC

T88

Inspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition andproperly installed. Fix damage and replace worn or brokenparts immediately. Pay special attention to hydraulichoses and electrical wiring.

TX03679,00016D2 –19–30OCT00–1/1

Stay Clear Of Moving Parts

T13

3592

–UN

–12S

EP

01Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintainingany part of machine with moving parts.

Keep guards and shields in place. Replace any guard orshield that has been removed for access as soon asservice or repair is complete.

TX03679,00016D3 –19–30OCT00–1/1

Avoid High-Pressure Fluids

T13

3509

–UN

–31O

CT

00T

1338

40–U

N–2

0SE

P00

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

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

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


PN=11

Safety

000001

4

TX03679,00016D4 –19–14SEP00–1/1

Beware Of Exhaust Fumes

T13

3546

–UN

–24A

UG

00

Prevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in a building, provide adequateventilation. Use an exhaust pipe extension to remove theexhaust fumes or open doors and windows to bringoutside air into the area.

TX03679,00016F5 –19–25SEP00–1/1

Prevent Fires

T13

3552

–UN

–14S

EP

00T

1335

53–U

N–0

7SE

P00

T13

3554

–UN

–07S

EP

00

Handle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or whennear sparks or flame.

Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines and electrical wiring. Never storeoily rags or flammable materials inside a machinecompartment.

Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.

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

TX03679,000174A –19–14SEP00–1/1

Prevent Battery Explosions

TS

204

–UN

–23A

UG

88

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

Never check battery charge by placing a metal objectacross the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).


PN=12

Safety

0000015

TX03679,00016D7 –19–14SEP00–1/1

Handle Chemical Products Safely

T13

3580

–UN

–25A

UG

00

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

If uncertain about safe handling or use of these chemicalproducts, contact your authorized dealer for a MaterialSafety Data Sheet (MSDS). The MSDS describes physicaland health hazards, safe use procedures, and emergencyresponse techniques for chemical substances. FollowMSDS recommendations to handle chemical productssafely.

TX03679,0001733 –19–14SEP00–1/1

Dispose Of Waste Properly

T13

3567

–UN

–25A

UG

00

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

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

Air conditioning refrigerants can damage the atmosphere.Government regulations may require using a certifiedservice center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact yourlocal environmental or recycling center or your authorizeddealer for more information.

TX03679,000174B –19–14SEP00–1/1

Prepare For Emergencies

TS

291

–UN

–23A

UG

88

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

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


PN=13

Safety

000001

6

TX03679,00016F2 –19–14SEP00–1/1

Use Steps And Handholds Correctly

T13

3468

–UN

–30A

UG

00

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

Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount ordismount a moving machine.

TX03679,0001799 –19–02MAY01–1/1

Start Only From Operator’s Seat

T13

3715

–UN

–07S

EP

00Avoid unexpected machine movement. Start engine onlywhile sitting in operator’s seat. Ensure all controls andworking tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the startersolenoid terminals.

TX03679,00016DD –19–17OCT00–1/1

Use And Maintain Seat Belt

T13

3716

–19–

14S

EP

00Use seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.

Examine seat belt frequently. Be sure webbing is not cutor torn. Replace seat belt immediately if any part isdamaged or does not function properly.

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


PN=14

Safety

0000017

TX03679,0001746 –19–30OCT00–1/1

Prevent Unintended Machine Movement

T13

3863

–UN

–20S

EP

00

Be careful not to accidentally actuate control levers whenco-workers are present. Pull pilot control shut-off lever tolocked position during work interruptions. Pull pilot controlshut-off lever to locked position and stop engine beforeallowing anyone to approach machine.

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

TX03679,0001748 –19–30OCT00–1/1

Avoid Work Site Hazards

T13

4986

–UN

–31O

CT

00T

1336

50–U

N–2

7SE

P00

T13

3549

–UN

–24A

UG

00

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

Prepare work site properly. Avoid operating nearstructures or objects that could fall onto the machine.Clear away debris that could move unexpectedly if runover.

Avoid boom or arm contact with overhead obstaclesor overhead electrical lines. Never move any part ofmachine or load closer than 3 m (10 ft) plus twice the lineinsulator length to overhead wires.

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

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


PN=15

Safety

000001

8

TX03679,0001726 –19–14SEP00–1/1

Keep Riders Off Machine

T72

73A

H–U

N–0

8JU

N90

Only allow operator on machine.

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

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

TX03679,00016F3 –19–14SEP00–1/1

Avoid Backover Accidents

T13

3548

–UN

–24A

UG

00

Before moving machine, be sure all persons are clearof both travel and swing paths. Turn around and lookdirectly for best visibility. Use mirrors to assist in checkingall around machine. Keep windows and mirrors clean,adjusted, and in good repair.

Be certain travel alarm is working properly.

Use a signal person when backing if view isobstructed or when in close quarters. Keep signalperson in view at all times. Use prearranged hand signalsto communicate.


PN=16

Safety

0000019

TX03679,00016DF –19–12APR01–1/1

Avoid Machine Tip Over

T13

3716

–19–

14S

EP

00T

1335

45–U

N–1

5SE

P00

T13

3803

–UN

–27S

EP

00

Use seat belt at all times.

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

Load and unload from trucks or trailers carefully. Besure truck is wide enough and on a firm level surface. Useloading ramps. Properly attach ramps to truck bed. Avoidtrucks with steel beds because tracks slip more easily onsteel.

Be careful on slopes. Use extra care on soft, rocky orfrozen ground. Machine may slip sideways in theseconditions. When traveling up or down slopes, keep thebucket on uphill side and just above ground level.

Be careful with heavy loads. Using oversize buckets orlifting heavy objects reduces machine stability. Extendinga heavy load or swinging it over side of undercarriagemay cause machine to tip.

Ensure solid footing. Use extra care when operatingnear banks or excavations that may cave-in and causemachine to tip or fall.

TX03679,00016E1 –19–02OCT00–1/1

Use Special Care When Lifting Objects

T13

3839

–UN

–27S

EP

00

Never use this machine to lift people.

Never lift a load above another person. Keep bystandersclear 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 andin this manual. Extending heavy loads too far or swingingover undercarriage side may cause machine to tip over.

Use proper rigging to attach and stabilize loads. Be sureslings or chains have adequate capacity and are in goodcondition. Use tether lines to guide loads and prearrangedhand signals to communicate with co-workers.


PN=17

Safety

000001

10

TX03679,00016F0 –19–14SEP00–1/1

Add And Operate Attachments Safely

Always verify compatibility of attachments bycontacting your authorized dealer. Adding unapprovedattachments may affect machine stability or reliability,and may create a hazard for others near the machine.

Ensure that a qualified person is involved inattachment installation. Add guards to machine ifoperator protection is required or recommended. Verify

that all connections are secure and attachmentresponds properly to controls.

Carefully read attachment manual and follow allinstructions and warnings. In an area free ofbystanders and obstructions, carefully operateattachment to learn its characteristics and range ofmotion.

TX03679,00016E9 –19–12APR01–1/1

Park And Prepare For Service Safely

T13

3332

–19–

14D

EC

01T

S22

9–U

N–2

3AU

G88

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

• Park machine on a level surface and lower equipmentto the ground.

• Place pilot control shut-off lever in “lock” position. Stopengine and remove key.

• Attach a “Do Not Operate” tag in an obvious place inthe operator’s station.

Securely support machine or equipment before workingunder it.

• Do not support machine with boom, arm, or otherhydraulically actuated attachments.

• Do not support machine with cinder blocks or woodenpieces that may crumble or crush.

• Do not support machine with a single jack or otherdevices that may slip out of place.

Understand service procedures before beginning repairs.Keep service area clean and dry. Use two peoplewhenever the engine must be running for service work.


PN=18

Safety

00000111

DX,RCAP –19–04JUN90–1/1

Service Cooling System Safely

TS

281

–UN

–23A

UG

88

Explosive release of fluids from pressurized coolingsystem can cause serious burns.

Shut off engine. Only remove filler cap when cool enoughto touch with bare hands. Slowly loosen cap to first stopto relieve pressure before removing completely.

TX03679,0001732 –19–06SEP00–1/1

Remove Paint Before Welding or Heating

T13

3546

–UN

–24A

UG

00

Hazardous fumes can be generated when paint is heatedby welding or using a torch. Dust from sanding or grindingpaint can also be hazardous.

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

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

TX03679,00016D5 –19–02OCT00–1/1

Make Welding Repairs Safely

T13

3547

–UN

–31A

UG

00

NOTE: Disable electrical power before welding. Turn offmain battery switch or disconnect positive batterycable. Separate harness connectors to engine andvehicle microprocessors.

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

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


PN=19

Safety

000001

12

TX03679,0001745 –19–25SEP00–1/1

Drive Metal Pins Safely

T13

3738

–UN

–14S

EP

00Always wear protective goggles or safety glasses andother protective equipment before striking hardened parts.Hammering hardened metal parts such as pins andbucket teeth may dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer andobject to prevent chipping.


PN=20

Safety

00000113

TX14740,0001D0E –19–09APR01–1/1

Safety Signs

T14

1213

–19–

17A

PR

01


PN=21

Safety

000001

14


PN=22

Group 0003Torque Values

0000031

DX,TORQ1 –19–01OCT99–1/1

Unified Inch Bolt and Cap Screw Torque Values

TO

RQ

1A–U

N–2

7SE

P99

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings

Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)

1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)

5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)

3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)

7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)

1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)

9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)

5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)

3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)

7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)

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 Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical grade. 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 thefull torque value.

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


PN=23

Torque Values

000003

2

DX,TORQ2 –19–01OCT99–1/1

Metric Bolt and Cap Screw Torque Values

TO

RQ

2–U

N–0

7SE

P99

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

Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) 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)

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 Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical property class. 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 thefull torque value.

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


PN=24

Torque Values

0000033

04T,90,M170 –19–29SEP99–1/2

Additional Metric Cap Screw Torque Values

T68

73A

A–U

N–1

8OC

T88

T68

73A

B–U

N–1

8OC

T88

T68

73A

C–U

N–1

8OC

T88

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

Check tightness of cap screws periodically. Torque valueslisted are for general use only. Do not use these values ifa different torque value or tightening procedure is listedfor a specific application.

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

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

Make sure fastener threads are clean and you properlystart thread engagement. This will prevent them fromfailing when tightening.

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

Continued on next page


PN=25

Torque Values

000003

4

04T,90,M170 –19–29SEP99–2/2

METRIC CAP SCREW TORQUE VALUESa

T-Bolt H-Bolt M-Bolt

NominalDia N•m lb-ft N•m lb-ft N•m lb-ft

8 29 21 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 687aTorque tolerance is ±10%.


PN=26

Torque Values

0000035

TX,90,DH1559 –19–01AUG94–1/1

Check Oil Lines And Fittings

X98

11–U

N–2

3AU

G88

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Avoidthe hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.

If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis 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 ordamage. Make sure all clamps are in position and tight.Make sure hoses are not twisted or touching movingmachine parts. If abrasion or wear occurs, replaceimmediately.

Tubing with dents may cause the oil to overheat. If youfind tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specified in torquechart.

When you tighten connections, use two wrenches toprevent bending or breaking tubing and fittings.


PN=27

Torque Values

000003

6

04T,90,K66 –19–29SEP99–1/2

Service Recommendations for O-Ring BossFittings

T62

43A

E–U

N–1

8OC

T88

Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring overtape and into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.



PN=28

Torque Values

0000037

04T,90,K66 –19–29SEP99–2/2T

6520

AB

–UN

–18O

CT

88

Angle Fitting

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

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

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

NOTE: Do not allow hoses to twist when tighteningfittings.

4. Hold fitting head-end with a wrench and tighten locknutand 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%.


PN=29

Torque Values

000003

8

04T,90,K67 –19–29SEP99–1/1

Service Recommendations for Flat FaceO-Ring Seal Fittings

T62

43A

D–U

N–1

8OC

T88

1. Inspect the fitting sealing surfaces. They must be freeof dirt or defects.

2. Inspect the O-ring. It must be free of damage ordefects.

3. Lubricate O-rings and install into groove usingpetroleum jelly to hold in place.

4. Push O-ring into the groove with plenty of petroleumjelly so O-ring is not displaced during assembly.

5. Index angle fittings and tighten by hand pressing jointtogether to insure O-ring remains in place.

6. Tighten fitting or nut to torque value shown on thechart per dash size stamped on the fitting. Do not allowhoses to twist when tightening fittings.

FLAT FACE O-RING SEAL FITTING TORQUE

Thread SizeNominal Tube O.D. Dash Size in. Swivel Nut Bulkhead Nut

mm in. N•m lb-ft N•m 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%.


PN=30

Torque Values

0000039

T82,BHMA,EL –19–29SEP99–1/1

Service Recommendations for 37° Flare and30° Cone Seat Connectors

T62

34A

C–U

N–1

8OC

T88

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

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

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

4. Lubricate male threads with hydraulic fluid or petroleumjelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torquechart. Do not allow hoses to twist when tighteningfittings.

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 - 12 190 140

1-7/8 - 12 UN 217 160

NOTE: Torque tolerance is ± 10%.


PN=31

Torque Values

000003

10

04T,90,M171 –19–28JAN92–1/1

Service Recommendations For FlaredConnections—Straight or Tapered Threads

T68

73A

E–U

N–1

8OC

T88

Straight Thread

T68

73A

D–U

N–1

8OC

T88

Tapered Thread

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

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

3. Align the tube with the fitting before attempting to startthe nut.

4. Lubricate the male threads with hydraulic fluid orpetroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tighteningfittings.

TORQUE CHART a

Straight Thread b Tapered Thread

ThreadSize N•m lb-ft N•m lb-ft

1/8 15 11

1/4 20 15 45 33

3/8 29 21 69 51

1/2 49 36 93 69

3/4 69 51 176 130

1 157 116 343 253

1-1/2 196 145 539 398

2 255 188 588 434aTorque tolerance is ±10%.bWith seat face.

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


PN=32

Torque Values

00000311

04T,90,K174 –19–01AUG94–1/1

Service Recommendations For Inch Series Four Bolt Flange Fittings

T68

90B

B–U

N–0

1MA

R90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

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

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

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

5. Tighten one cap screw, then tighten the diagonallyopposite cap screw. Tighten two remaining capscrews. Tighten all cap screws as specified in thechart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHART

N•m lb-ft

Nominal Cap ScrewFlange Size

Size Min Max Min Max

1/2 5/16-18 20 31 15 23UNC

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 47 85 35 63UNC

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


PN=33

Torque Values

000003

12

04T,90,K175 –19–29SEP99–1/1

Service Recommendations for Metric Series Four Bolt Flange Fitting

T68

90B

B–U

N–0

1MA

R90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install the correct O-ring (and backup washer ifrequired) into groove using petroleum jelly to hold itin place.

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

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

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

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

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHARTa

Threadb N•m lb-ft

M6 12 9

M8 30 22

M10 57 42

M12 95 70

M14 157 116

M16 217 160

M18 334 246

M20 421 318aTolerance ± 10%. The torques given are enough for the givensize connection with the recommended working pressure.Increasing cap screw torque beyond these amounts will result inflange and cap screw bending and connection failures.bMetric standard thread.


PN=34

Section 01Tracks

Contents 01

Page

Group 0130—Track SystemTrack Roller, Front Idler, and Carrier

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


PN=1

Contents

01


PN=2

Group 0130Track System

010130

TX,45,DH5142 –19–06NOV01–1/1

Track Roller, Front Idler, and Carrier RollerOil

Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105E).

1

OUOE049,0000063 –19–19NOV01–1/6

Track Roller Repair

Remove and Install Track Roller

1. Swing upperstructure 90° and lower bucket to raisetrack off ground. Keep angle between boom and arm90—110° and position round side of bucket on ground.

CAUTION: Prevent possible injury fromunexpected machine movement. Put shopstands under frame to support machine whileremoving lower track roller.

Track Roller—SpecificationMachine (200CLC)—Weight 20 298 kg (44,750 lb)

approximate....................................

Machine (230CLC)—Weight 23 773 kg (52,410 lb)approximate

....................................


....................................

2. Place shop stands under machine.

OUOE049,0000063 –19–19NOV01–2/6

T73

96D

Z–U

N–2

8NO

V90

A—Grease FittingB—ValveC—Bleed Hole

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

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


PN=37


Track System

010130

2

OUOE049,0000063 –19–19NOV01–3/6

T65

85T

N–U

N–2

5OC

T88

A—Cap Screw (4 used)B—Track Roller

CAUTION: Heavy component; use a hoist.

Track Roller—SpecificationTrack Roller (200CLC and230CLC)—Weight 35 kg (77 lb) approximate..............................................Track Roller (270CLC)—Weight 54 kg (120 lb) approximate......................

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

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

6. Repair or replace parts as necessary.

7. Tighten cap screws.

Track Roller—SpecificationRoller-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—SpecificationRock Guard Cap Screw (200CLCand 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.)



PN=38

Track System

0101303

OUOE049,0000063 –19–19NOV01–4/6

T83

10A

H–U

N–2

1SE

P94

A—Plug (2 used) C—Pin (2 used) E—Metal Face Seal (2 used) G—RollerB—Bracket (2 used) D—O-Ring (2 used) F—Bushing (2 used) H—Axle

Disassemble and Assemble Track Roller

1. Remove plug (A) and drain oil.

2. Remove pin (C).

3. Remove bracket (B) using a bearing pullerattachment and adapters from puller set.

IMPORTANT: Metal face seals can be reused ifthey are not worn or damaged. Aused seal must be kept together as aset because of wear patterns on sealring face.

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

5. Inspect metal face seals. See Metal Face SealsRepair. (See procedure in this group.) For sealsthat will be reused, put a piece of cardboardbetween seal rings to protect seal face.

6. Remove axle (H) from roller.

NOTE: Only remove bushing if replacement isnecessary.

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

8. Replace parts as necessary.

Apply a thin film of oil to bushings (F) and install.

IMPORTANT: O-rings and seat surfaces forO-rings must be clean, dry, and oilfree so O-rings do not slip whenroller is turning.

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

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


PN=39


Track System

010130

4

OUOE049,0000063 –19–19NOV01–5/6

11. Wipe finger prints and foreign material off seal ringface using clean oil and lint-free tissues. Apply athin film of oil to each seal ring face.

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

13. Install axle to bracket.

14. Apply NEVER-SEEZ anti-seize lubricant orequivalent to pin (C). Install pin even with flatsurface of bracket.

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

16. Apply cure primer and pipe sealant to threads ofplug. Install and tighten plug.

Track Roller—SpecificationPlug—Torque 20 N•m (177 lb-in.).........................................................

NEVER-SEEZ is a trademark of Emhart Chemical Group.

OUOE049,0000063 –19–19NOV01–6/6

T10

9691

B–U

N–0

2JU

N97

A—Plug, Barbed Adapter and ConnectorB—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 GaugeE—Snubber (Needle) ValveF—Air Pressure Regulator

Test Track Roller for Oil Leakage

1. Hold the shaft and turn shell several turns to seatmetal face seals.

2. Remove the plug.

3. Install parts (A—F). Plug, barbed adapter andconnector are from a leak detector kit such as theD05361ST Rubber Stopper/Leak Detector Kit.

4. Holding plug so it is not pushed out, slowly pressurizeoil cavity using air.

Track Roller—SpecificationOil 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 airpressure has decreased.

6. If there is leakage, disassemble roller and replaceparts as necessary.

7. Apply cure primer and pipe sealant to threads. Installplug.


PN=40

Track System

0101305

OUOE049,0000064 –19–19NOV01–1/4

Track Carrier Roller Repair

T73

96D

Z–U

N–2

8NO

V90


Remove and Install Track Carrier Roller



2. Raise track link, using a jack, enough to permit carrierroller removal.

CAUTION: Prevent accidental lowering of trackby securely supporting track before attemptingservice procedure.

3. Install wooden blocks between track link and frame.

OUOE049,0000064 –19–19NOV01–2/4

T65

57D

K–U

N–2

5OC

T88

A—Carrier RollerB—Cap Screw

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

5. Measure track carrier roller tread diameter. See200CLC Carrier Roller Tread Diameter, 230CLCCarrier Roller Tread Diameter, or 270CLC CarrierRoller Tread Diameter. (SP326 UndercarriageAppraisal Manual.)


7. Install carrier roller and tighten cap screws (B).

Track Carrier Roller—SpecificationRoller-to-Frame Cap Screw—Torque 270 N•m (200 lb-ft).........................................................................




PN=41

Track System

010130

6

OUOE049,0000064 –19–19NOV01–3/4

T11

4725

–UN

–30A

PR

98

A—Plug C—Cap Screw (2 used) E—Bushing G—Metal Face SealB—Cover D—Thrust Washer F—Roller H—Support

Disassemble and Assemble Track Carrier Roller

1. Remove plug (A) and drain oil.

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

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

IMPORTANT: Replace entire roller assembly ifbushing (E) and shaft surfaces aredamaged. Bushing (E) is no longerserviceable because cover (B)cannot be removed.

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


PN=42


Track System

0101307

OUOE049,0000064 –19–19NOV01–4/4


5. Remove metal face seal (G).

6. Inspect metal face seal. See Metal Face SealsRepair. (See procedure in this group.) For sealsthat will be reused, put a piece of cardboardbetween seal rings to protect seal face.


IMPORTANT: O-rings may slip when roller isturning if O-rings and seat surfacesare not clean, dry and oil free.

8. Thoroughly clean the O-rings and seat surfaces inroller, 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 atapered fit. There is no longer the “pop” intoplace fit previously used.

A volatile, non-petroleum base solvent ortalcum 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 eachhalf of the seal.

12. Install the other half of metal face seal on the halfalready in place in support (H).

13. Install roller (F) over shaft on support (H) beingsure to keep cap screws (C) in alignment withholes on shaft.

14. Tighten cap screws (C).

Track Carrier Roller—SpecificationThrust Washer-to-Support ShaftCap Screw—Torque 64 N•m (47 lb-ft).................................................

15. For 200CLC and 230CLC, fill carrier roller with 70mL (0.018 gal) of clean oil through plug (A) hole.For 270CLC, fill carrier roller with 75 mL (0.020gal) of oil.

16. Apply cure primer and pipe sealant to threads ofplug. Install plug.


PN=43

Track System

010130

8

T47,0130,5939HQ –19–19NOV01–1/3

Metal Face Seals Repair

T85

079

–UN

–24A

UG

93

A—Seal RingB—Worn Area (Shaded Area)C—Seal Ring FaceD—Outer Half of Seal Ring FaceE—Sealing Area (Dark Line)

Inspect Metal Face Seals

1. Inspect for the following conditions to determine ifseals can be reused:

a. The narrow, highly polished sealing area (E) mustbe in the outer half of seal ring face (D).

b. Sealing area must be uniform and concentric withthe ID and OD of seal ring (A).

c. Sealing area must not be chipped, nicked, orscratched.

T47,0130,5939HQ –19–19NOV01–2/3

T85

080

–UN

–05D

EC

96

A—Seal RingB—Worn area (Shaded Area)C—Inner Half of Seal Ring FaceD—Sealing Area (Dark Line)

2. Illustration shows examples of worn seal rings (A).

I—Sealing area (D) is in inner half of seal ring face (C).

II—Sealing area (D) not concentric with ID and OD ofseal ring.



PN=44

Track System

0101309

T47,0130,5939HQ –19–19NOV01–3/3

T82

840

–UN

–23F

EB

89

A—Seal Face

3. Clean reusable seals by removing all foreign materialfrom seal rings, except seal face (A), using a scraperor a stiff bristled fiber brush.

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

Apply a thin film of oil to seal ring face. Put face of sealrings together and hold using tape.

TX,01,SB384 –19–19SEP00–1/1

Track Shoe Repair

T67

94A

M–U

N–2

3FE

B89

T63

52A

H–U

N–2

3FE

B89

A—Rounded EdgeB—Chamfered Edge

Remove and Install Track Shoe

1. Measure grouser height. See 200CLC Three BarGrouser Height, 230CLC Three Bar Grouser Height, or270CLC Three Bar Grouser Height 800 mm (31.5 in.)Width. (SP326 Undercarriage Appraisal Manual.)

2. Apply a light coat of oil to cap screw threads and installshoe.

3. Install all track shoe nuts with rounded corners (A)against the link and chamfered edges (B) away fromthe link. Be sure nut is properly positioned in the linkso there is full contact between the nut and the link.

4. Tighten cap screws in pattern shown.

Track Shoe—SpecificationShoe-to-Link Cap Screw (18 mm)(200CLC)—Torque Turn 210 ± 21 N•m (155 ± 16 lb-ft)

plus 1/2 (180°) turn..............................

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

(180°) turn...................................................


PN=45

Track System

010130

10

OUOE049,0000065 –19–20JUN01–1/5

Track Chain Repair

Remove and Install Track Chain

1. Swing upperstructure to side. Lower boom to raisetrack 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 fromunexpected machine movement. Put blocks orshop stands under machine frame to supportmachine while measuring track sag.

Track Chain—SpecificationMachine (200CLC)—Weight 20 298 kg (44,750 lb)

approximate....................................


....................................


....................................

2. Place blocks or shop stands under the machine tosupport machine.

OUOE049,0000065 –19–20JUN01–2/5

T73

96D

Z–U

N–2

8NO

V90





PN=46


Track System

01013011

OUOE049,0000065 –19–20JUN01–3/5

T14

3215

B–U

N–2

0JU

L01

1—Bushing (2 used)2—Master Pin3—Dimple

NOTE: The master pin (2) can be identified by the largedimple (3) on the pin’s end.

4. Move track chain so master pin (2) is over front idler orsprocket.

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

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

7. Remove master pin using a 50-Ton Master Pin PusherInstaller. Remove bushings (1).


Track Chain—SpecificationTracks 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.........................

8. Remove track chain.

9. Measure track chain link, bushing, and pitch. (SeeSP326 Undercarriage Appraisal Manual.)


11. Position track chain so section on ground has pinboss on links toward rear of machine.

12. Install end of chain on sprocket and slowly turnsprocket in forward direction to pull chain across topof frame to front idler.

13. Pull ends of chain together. Install bushings andmaster pin (2) using 50-Ton Master Pin PusherInstaller.

14. Install track shoe. See Track Shoe Repair. (Seeprocedure in this group.)



PN=47


Track System

010130

12

OUOE049,0000065 –19–20JUN01–4/5

T11

7027

–UN

–09S

EP

98

A—Track Link (49 used) D—Snap Ring G—Track Link (48 used) J—Shoe (49 used)B—Master Track Link E—Master Bushing H—Seal (96 used) K—Pin (48 used)C—Master Pin F—Spacer (2 used) I—Bushing (48 used)

Disassemble and Assemble Track Chain

1. Measure track components (A—K). See TrackChain. (SP326 Undercarriage Appraisal Manual.)


PN=48


Track System

01013013

OUOE049,0000065 –19–20JUN01–5/5

NOTE: Wear on pins and bushings does not extendover the entire surface. Turning pins andbushing is determined by the amount of wear.

2. Turn pins (C and K) and bushings (E and I) asrequired.

3. Clean any dust or rust from the surfaces of tracklink pin bores and counterbores and the ends ofbushings.

4. Apply grease to the counterbore in track links, theseals, and the ends of bushings.

5. For each joint, fill the clearance between the pinOD and bushing ID with grease.

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

OUOE003,0000008 –19–28OCT01–1/4

Broken Track Chain Part Repair

T58

21A

G–U

N–2

6OC

T88

A—Cut LocationsB—Broken Link

Disassemble and Assemble Track Chain to ReplaceBroken Part

1. Remove track shoes from each side of broken linkassembly. See Track Shoe Repair. (See procedure inthis group.)

IMPORTANT: When making cuts using cutting torch,be careful not to cut or gouge goodparts.

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

OUOE003,0000008 –19–28OCT01–2/4

T58

21A

H–U

N–2

6OC

T88

A—Bushing

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



PN=49

Track System

010130

14

OUOE003,0000008 –19–28OCT01–3/4

T58

21A

I–U

N–2

6OC

T88

A—Pin StubB—Hammer

4. Burn holes through center of pin stubs (A).

5. Hold a heavy hammer (B) against the link while pinstub is being driven out.

OUOE003,0000008 –19–28OCT01–4/4

T58

21A

J–U

N–2

4MA

Y89

A—Master PinB—SpacerC—Right LinkD—Master BushingE—Left Link

6. Install links (C and E) on master bushing (D). Checkcap screw hole spacing using a track shoe.

7. Instal spacers (B) into counterbore of links.

8. Install link assembly. Install master pins (A).

9. Install track shoes. See Track Shoe Repair. (Seeprocedure in this group.)

OUOE003,0000009 –19–09NOV01–1/2

Sprocket Repair

Remove and Install Sprocket



PN=50

Track System

01013015

OUOE003,0000009 –19–09NOV01–2/2

T14

3369

B–U

N–2

0JU

L01

1—Cap Screw (16 used)

IMPORTANT: Sprocket must be replaced when thetooth tips become excessively rounded,worn, or chipped to prevent excessivewear to chain. If machine is driven inone direction a majority of the time,wear will be on one side of teeth. Toextend service life, change sprocketsfrom one side of machine to the other.

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

2. Lift side of machine so sprocket teeth clear chain.


Sprocket—SpecificationSprocket (200CLC and230CLC)—Weight 46 kg (101 lb) approximate............................................Sprocket (270CLC)—Weight 70 kg (150 lb) approximate...........................

3. Remove cap screws (1) and sprocket.

4. Apply cure primer and thread lock and sealer (highstrength) to threads of cap screws (B).

5. Install sprocket and tighten cap screws (1).

Sprocket—SpecificationSprocket-to-Propel Gearbox CapScrew—Torque 490 N•m (360 lb-ft)............................................................

6. Lower machine.

7. Install track chain. See Track Chain Repair. (Seeprocedure in this group.)


PN=51

Track System

010130

16

TX,01,SB395 –19–15NOV01–1/4

Front Idler Repair

T68

76B

U–U

N–2

5OC

T88

A—Front Idler

Remove and Install Front Idler

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

2. Slide front idler (A) forward, using pry bar.


Front Idler—SpecificationFront Idler (200CLC and230CLC)—Weight 100 kg (240 lb) approximate..........................................Front Idler (270CLC)—Weight 160 kg (350 lb) approximate.......................

3. Attach front idler to hoist and remove from frame.

4. Measure front idler wear. See Front Idler FlangeHeight. (SP326 Undercarriage Appraisal Manual.)

5. Repair or replace idler as necessary.

6. Install front idler.

7. Connect track chain. See Track Chain Repair. (Seeprocedure in this group.)



PN=52

Track System

01013017

TX,01,SB395 –19–15NOV01–2/4

T83

12A

A–U

N–2

1SE

P94

A—Pin (2 used) D—Plug (2 used) G—O-Ring (2 used) I—YokeB—Bushing (2 used) E—Bracket (Bearing) (2 used) H—Axle J—Cap Screw (4 used)C—Idler F—Metal Face Seal (2 used)

Disassemble and Assemble Front Idler

1. Remove cap screws (J) and yoke (I).

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


3. Remove pins (A), brackets (E), O-rings (G) andmetal face seals (F).

4. Inspect metal face seals. See Metal Face SealsRepair. (See procedure in this group.) Keep sealrings together as a matched set with seal ring facestogether to protect surfaces.

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

NOTE: Remove bushings only if replacement isnecessary.

6. Remove bushing using a 2-jaw puller and adaptersfrom 17-1/2 and 30-ton puller set.


8. Apply a thin film of oil to bushings (B). Installbushings so flange is tight against shoulder of idler.

9. Install O-rings (G) on axle.

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

NEVER-SEEZ is a trademark of Emhart Chemical Group.


PN=53


Track System

010130

18

TX,01,SB395 –19–15NOV01–3/4

11. Install axle into bracket.

12. Apply NEVER-SEEZ anti-seize lubricant orequivalent to pin (A). Install pin.

IMPORTANT: Metal face seal O-rings and seatsurfaces for O-rings must be clean,dry, and oil free so O-rings do notslip when idler is turning.

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

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

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

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

16. Wipe finger prints and foreign material off seal ringface using clean oil and lint-free tissues. Apply athin film of oil to each seal face.

17. For 200CLC and 230CLC, fill front idler with 265mL (8.96 oz) of oil. For 270CLC, fill front idler with300 mL (10.14 oz) of oil.

18. Install axle (H) into idler.

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

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

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

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

NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page


PN=54

Track System

01013019

TX,01,SB395 –19–15NOV01–4/4T

1097

91B

–UN

–13J

UN

97

A—Plug, Adapter and ConnectorB—Connector 1/8 M NPT x 7/16-20 M 37°C—HoseD—Pressure GaugeE—Snubber (Needle) ValveF—Air Pressure RegulatorG—Drain Plug

Test Front Idler for Oil Leakage

1. Turn the shaft several turns to seat metal face seals.

2. Remove the plug (G).

3. Install parts (A—F) as shown. Plug barbed adapter,and connector are from a leak detector kit such as theD05361ST Rubber Stopper/Leak Detector Kit.

4. Holding plug so it is not pushed out, slowly pressurizeoil cavity using air.

Front Idler—SpecificationOil Cavity Air Test—Pressure 110 ± 28 kPa (1.1 ± 0.3 bar) (16

± 4 psi)................

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

6. If there is external leakage, disassemble idler andreplace parts as necessary.

7. Check oil level in idler. If the oil level is down and thereis no external leakage, check for a leak from oil cavityto interior of idler wheel.

8. Apply cure primer to threads of plug.

9. Apply thread lock and sealer (medium strength) tothreads of plug. Install and tighten plug.

OUOE003,000000A –19–09NOV01–1/6

Track Adjuster and Recoil Spring Repair

Remove and Install Track Adjuster and Recoil Spring

1. Remove track chain. See Track Chain Repair. (Seeprocedure in this group.)

2. Remove front idler. See Front Idler Repair. (Seeprocedure in this group.)


PN=55


Track System

010130

20

OUOE003,000000A –19–09NOV01–2/6

T65

57C

X–U

N–2

5OC

T88

A—Track Adjuster

CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot. Weak spots may resultin immediate or eventual failure creating a riskof personal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling trackadjuster.

A compression tool must be used fordisassembly and assembly because of theextreme preload on spring.

3. Slide track adjuster (A) forward, using a pry bar.


Track Adjuster and Recoil Spring—SpecificationTrack Adjuster Cylinder andRecoil Spring (200CLC and230CLC)—Weight 129 kg (280 lb) approximate..........................................Track Adjuster Cylinder andRecoil Spring (270CLC)—Weight 180 kg (400 lb) approximate..................

4. Attach track adjuster to hoist and remove from frame.


6. Install front idler. See Front Idler Repair. (Seeprocedure in this group.)

7. Install track chain. See Track Chain Repair. (Seeprocedure in this group.)



PN=56

Track System

01013021

OUOE003,000000A –19–09NOV01–3/6T

6557

DY

–UN

–25O

CT

88

A—ST4920 Track Recoil Spring Disassembly andAssembly Tool

B—NutC—Top Plate

Disassemble and Assemble Track Adjuster and RecoilSpring

CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot. Weak spots may resultin immediate or eventual failure creating a riskof personal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling trackadjuster.



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

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

NOTE: It is not necessary to remove the recoil spring toreplace wear ring and U-ring packing on piston.To replace O-ring in the cylinder, remove recoilspring and rod.

2. Remove nuts (B). Remove top plate (C).



PN=57

Track System

010130

22

OUOE003,000000A –19–09NOV01–4/6

T77

20A

F–U

N–2

8AP

R92

A—Lifting StrapB—Track AdjusterC—DFT1110 Spacer


Track Adjuster and Recoil Spring—SpecificationTrack Adjuster Cylinder andRecoil Spring (200CLC and230CLC)—Weight 129 kg (280 lb) approximate..........................................Track Adjuster Cylinder andRecoil Spring (270CLC)—Weight 180 kg (400 lb) approximate..................

3. Connect track adjuster (B) to a hoist using a liftingstrap (A).

4. Put track adjuster in assembly tool with cylinder end onDFT1110 Spacer (C). (Group 9900.)

5. Remove lifting strap.



PN=58

Track System

01013023

OUOE003,000000A –19–09NOV01–5/6

T77

20A

G–U

N–2

8AP

R92

A—Top PlateB—Nut (8 used)C—ValveD—NutE—Special PlugF—DFT1087 Track Recoil Spring Disassembly and

Assembly Guard Tool

6. Install DFT1087 Track Recoil Spring Disassembly andAssembly Guard Tool (F). (Group 9900.)

7. Install plate top (A) and nuts (B) with smallest openingto allow access to nut (D).

8. Extend jack ram to provide enough travel to releasespring to the approximate free length.

Track Adjuster and Recoil Spring—SpecificationRecoil Spring (200CLC and230CLC)—Free Length 626 mm (24.64 in.) approximate..........................Recoil Spring (270CLC)—FreeLength 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).



PN=59

Track System

010130

24

OUOE003,000000A –19–09NOV01–6/6

T77

20A

H–U

N–2

8AP

R92

A—Top PlateB—Nut (8 used)D—NutF—DFT1087 Track Recoil Spring Disassembly and

Assembly Guard Tool

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.


15. If disassembly of track adjuster cylinder is necessary,seeTrack Adjuster Cylinder Repair. (See procedure inthis group.)

16. Put track adjuster cylinder in assembly tool withcylinder end on spacer.

17. Install spacer on rod.

18. Install spring using a hoist and lifting strap.

19. Install retainer plate.

20. Install guard tool.

21. Install top plate. Install nuts.

22. Raise upper half of guard tool. Tighten T-handles.

23. Operate jack to compress spring to the compressedlength.

Track Adjuster and Recoil Spring—SpecificationRecoil Spring (200CLC and230CLC)—Compressed Length 521 mm (20.51 in.)..................................Recoil Spring (270CLC)—Compressed Length 557 mm (21.92 in.)....................................................

24. Install nut (D) so hole is aligned with hole in rod.Install special plug.

25. Tighten valve.

Track Adjuster and Recoil Spring—SpecificationValve—Torque 88 N•m (65 lb-ft).................................................................


PN=60

Track System

01013025

TX,01,SB407 –19–25JUN01–1/2

Track Adjuster Cylinder Repair

Disassemble and Assemble Track Adjuster Cylinder

CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot. Weak spots can resultin immediate or eventual failure of spring or rodcreating a risk of personal injury. Put a heavyprotective covering around spring assemblywhen handling, transporting, or disassembling.


NOTE: It is not necessary to remove the recoil spring toreplace wear ring (4) and U-ring packing (5). It isnecessary to remove the recoil spring to replaceO-ring (8).

1. Remove recoil spring if necessary. See Track Adjusterand Recoil Spring Repair. (See procedure in thisgroup.)



PN=61

Track System

010130

26

TX,01,SB407 –19–25JUN01–2/2

T143380

1 2

3

45

6

7

8

9

T14

3380

–UN

–20J

UL0

1

1—Cap Screw (3 used)2—Flange3—Piston Rod4—Wear Ring5—U-Ring6—Retaining Ring7—Rod8—O-Ring9—Cylinder

2. If necessary, remove rod (7) from cylinder (9) using apress.


4. Apply multi-purpose grease to U-ring packing (5), wearring (4) and O-ring (8). Fill grooves inside flange (2)with grease.

5. Install U-ring packing (5) with lip towards inside ofcylinder.

6. Tighten cap screws (1).

Track Adjuster Cylinder—SpecificationFlange-to-Cylinder Cap Screw—Torque 50 N•m (37 lb-ft).............................................................................


PN=62

Section 02Axles and Suspension Systems (Propel)

Contents

Page

Group 0250—Axle Shaft, Bearings, and ReductionGears 02

Propel Gearbox . . . . . . . . . . . . . . . . . . . . . . .02-0250-1

Group 0260—Hydraulic SystemPropel Motor . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1

Start-Up Procedure . . . . . . . . . . . . . . . . .02-0260-22Rotary Manifold . . . . . . . . . . . . . . . . . . . . . .02-0260-22


PN=1

Contents

02


PN=2

Group 0250Axle Shaft, Bearings, and Reduction Gears

0202501

OUOE049,0001000 –19–19NOV01–1/14

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 pressurizedsystem can cause serious burns or penetratinginjury.

3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.)

4. Disconnect hydraulic lines.



PN=65

Axle Shaft, Bearings, and Reduction Gears

020250

2

OUOE049,0001000 –19–19NOV01–2/14

T14

2702

B–U

N–1

5JU

N01

200CLC Machine Shown

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

5. Attach JDG909 Lifting Bracket to gearbox as shown.


Propel Gearbox—SpecificationPropel 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..........................................................

NOTE: Make alignment marks between propel gearboxand undercarriage to aid in installation.

6. Remove cap screws (1). Remove propel gearbox andpropel motor.


NOTE: Align marks made during removal.

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

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

9. Connect lines. See Propel System ComponentLocation. (Group 9025-15.)

10. Fill propel gearbox with oil. See Check PropelGearbox Oil Level. (Operator’s Manual.)

11. Do Propel Motor Start-Up Procedure. (Group 0260.)



PN=66


0202503


PN=67


020250

4

OUOE049,0001000 –19–19NOV01–3/14

31

30

32

33

30

29

28

2526

27

2625

24

23

2022

2120

19

18

17

16

15

14

13

12

911

10

9

8

21

34

53

6

7

T142270

T14

2270

–UN

–15J

UN

01


PN=68



0202505

OUOE049,0001000 –19–19NOV01–4/14

1—Third Planet Carrier 9—Spacer (2 used) 18—Spring Pin (3 used) 26—Needle Bearing (6 used)2—Third Planet Sun Gear 10—Second Planet Sun Gear 19—Pin (3 used) 27—Third Planet Gear3—Thrust Plate (6 used) 11—First Planet Carrier 20—Thrust Plate (6 used) 28—Propel Motor4—Second Planet Gear (3 12—Shaft 21—Needle Bearing (3 used) 29—Metal Face Seal

used) 13—Ring Gear 22—First Planet Gear (3 used) 30—Bearing (2 used)5—Needle Bearing (3 used) 14—Thrust Pad 23—Spring Pin (3 used) 31—Drum6—Pin (3 used) 15—Cap Screw (12 used) 24—Pin (3 used) 32—Bearing Nut7—Spring Pin (3 used) 16—Cover 25—Thrust Plate (6 used) 33—Dowel Pin8—Second Planet Carrier 17—Cap Screw (24 used)

Disassemble and Assemble Propel Gearbox—200CLC and 230CLC

1. Remove cap screws (15) and cover (16).

2. Remove shaft (12) and first planet carrier (11).

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


Propel Gearbox—SpecificationRing Gear (200CLC and230CLC)—Weight 41 kg (90 lb) approximate.......................................

4. Install JT01748 Lifting Brackets to ring gear (13).Remove cap screws (17) and ring gear.


Propel Gearbox—SpecificationThird Planet Carrier (200CLCand 230CLC)—Weight 39 kg (85 lb) approximate................................

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

NOTE: Disassembly of first, second, and third planetcarriers are similar. Repeat procedure asrequired.

6. Remove spring pins, pins, thrust plates, needlebearings, and planetary gears.

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

OUOE049,0001000 –19–19NOV01–5/14

T14

2429

–UN

–22J

UN

011—Slit

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

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


PN=69



020250

6

OUOE049,0001000 –19–19NOV01–6/14

T14

2380

–UN

–15J

UN

01

32—Bearing Nut34—DFT1109 Holding Bar35— DF1036A Propel Gearbox Nut Wrench

9. Remove bearing nut (32) from propel motor (28) usingDF1036A Propel Gearbox Nut Wrench (35) andDFT1109 Holding Bar (34). Fasten holding bar to ringgear. (Group 9900.)


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

10. Remove drum (31) using JT01748 Lifting Brackets.

IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. A used sealmust be kept together as a set becauseof wear patterns on seal ring face.

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

NOTE: Further disassembly is not necessary unlessbearing replacement is required. Bearing will bedestroyed during removal, replace with newbearing.

12. Inspect bearing (30) and race inside housing (31).


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 orheating element to come in direct contact withthe 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 againstshoulder.

Propel Gearbox—SpecificationBearing Cone (200CLC and230CLC)—Temperature 50—70°C (122—158°F).......................................


PN=70



0202507

OUOE049,0001000 –19–19NOV01–7/14

IMPORTANT: Metal face seal O-rings and seatsurfaces 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 seatsurfaces in propel motor housing, drum, and seal ringusing volatile, non-petroleum base solvent andlint-free tissues.

NOTE: A volatile, non-petroleum base solvent or talcumpowder can be used as a lubricant. Solvent mustnot damage the O-ring or leave an oil residue.

16. Install O-ring and metal face seal on propel motorhousing and drum. Apply equal pressure with fingersat four equally spaced points on seal face. Seal must“pop” down into place so O-ring is tight against sealbore 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 threadsof bearing nut (32). Install bearing nut with machinedsurface towards bearing.

19. Tighten bearing nut using DF1036A Propel GearboxNut Wrench and DFT1109 Holding Bar. Fastenholding bar to ring gear. (Group 9900.) Seat bearings.

Propel Gearbox—SpecificationBearing Nut (200CLC and230CLC)—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.



PN=71


020250

8

OUOE049,0001000 –19–19NOV01–8/14

T14

2422

–UN

–15J

UN

01

35

T14

2944

–UN

–15J

UN

01

28—Propel Motor32—Bearing Nut33—Dowel Pin35—Hole

21. Ensure center of dowel pin (33) is aligned with centerof spline on propel motor shaft. If centers are notaligned tighten bearing nut until dowel pin centeraligns with center of the next spline.

22. Install third planet carrier so dowel pin (33) entershole (35) on third planet carrier.

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

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

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

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

26. Apply rigid from-in-place gasket to flange surface oncover.

27. Apply thread lock and sealer (medium strength) tothread of cap screws (15). Tighten cap screws.

Propel Gearbox—SpecificationCover-to-Ring Gear Cap Screw(200CLC and 230CLC)—Torque 110 N•m (83 lb-ft)...................................



PN=72


0202509


PN=73


020250

10

OUOE049,0001000 –19–19NOV01–9/14

T10

9286

–UN

–25A

PR

97


PN=74



02025011

OUOE049,0001000 –19–19NOV01–10/14

00—Propel Motor 17—Thrust Washer (6 used) 31—Thrust Washer (6 used) 44—Cover02—Propel Gearbox Housing 18—Pin (3 used) 32—Pin (3 used) 45—Pin03—Seal 19—Spring Pin (3 used) 33—Spring Pin (3 used) 46—Roller Bearing05—Drum 20—Third Planet Sun Gear 34—Second Planet Sun Gear 47—Snap Ring06—Sprocket 21—Needle Bearing (6 used) 35—Thrust Washer 48—Cap Screw and Lock07—Lock Washer (20 used) 23—Ring Gear 36—First Planet Carrier Washer (12 used)08—Cap Screw (20 used) 25—Cap Screw (24 used) 37—First Planet Gear (3 used) 49—Plug (3 used)09—Roller Bearing (2 used) 27—Second Planet Carrier 38—Needle Bearing (3 used) 51—O-Ring10—Nut 28—Thrust Washer (2 used) 39—Thrust Washer (6 used) 52—Cap Screw (4 used)11—Lock Plate 29—Second Planet Sun Gear 40—Pin (3 used) 53—Lock Washer (4 used)12—Cap Screw (2 used) (3 used) 41—Spring Pin (3 used) 55—Name Plate14—Third Planet Carrier 30—Needle Bearing (3 used) 42—Propel Shaft 56—Cap Screw (2 used)15—Third Planet Gear (3 used)

Disassemble and Assemble Propel Gearbox—270CLC

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

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

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

4. Remove second planet sun gear (34) and secondplanet carrier (27).


Propel Gearbox—SpecificationRing Gear (270CLC)—Weight 55 kg (120 lb) approximate..................

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


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

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

NOTE: Disassembly of first, second, and third planetcarriers are similar. Repeat procedure asrequired.

7. Remove spring pins, pins, thrust plates, needlebearings, and planetary gears.

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

OUOE049,0001000 –19–19NOV01–11/14

T14

2429

–UN

–22J

UN

01

1—Slit

IMPORTANT: There is a mark on one side of thirdplanet gear (15). Be sure that thismarked side faces the hole for thespring pin.

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

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


PN=75



020250

12

OUOE049,0001000 –19–19NOV01–12/14

T14

2380

–UN

–15J

UN

01

10. Remove bearing nut (10) using DF1036A PropelGearbox Nut Wrench (35) and DFT1109 Holding Bar(34). Fasten holding bar to ring gear. (Group 9900.)


Propel Gearbox—SpecificationDrum (270CLC)—Weight 65 kg (140 lb) approximate................................

11. Remove drum (05) using JT01748 Lifting Brackets.

IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. A used sealmust be kept together as a set becauseof wear patterns on seal ring face.

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

NOTE: Further disassembly is not necessary unlessbearing replacement is required. Bearing will bedestroyed during removal, replace with newbearing.

13. Inspect bearings (09) and races inside housing.



15. Heat inner bearing cone. Install cone tight againstshoulder.

Propel Gearbox—SpecificationBearing Cone (270CLC)—Temperature 50—70°C (122—158°F).........................................................



PN=76


02025013

OUOE049,0001000 –19–19NOV01–13/14

IMPORTANT: Metal face seal O-rings and seatsurfaces 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 seatsurfaces in propel motor housing, drum, and seal ringusing volatile, non-petroleum base solvent andlint-free tissues.

NOTE: A volatile, non-petroleum base solvent or talcumpowder can be used as a lubricant. Solvent mustnot damage the O-ring or leave an oil residue.

17. Install O-ring and metal face seal on propel motorhousing and drum. Apply equal pressure with fingersat four equally spaced points on seal face. Seal must“pop” down into place so O-ring is tight against sealbore and seal ring is installed squarely.

18. Clean seal ring face. Apply a thin film of clean oil.

IMPORTANT: Install bearing nut with stepped surfacetowards bearing.

19. Apply a thin coat of multi-purpose grease to bearingnut. Tighten bearing nut using DF1036A PropelGearbox Nut Wrench and DFT1109 Holding Bar.Fasten holding bar to ring gear. (Group 9900.)

Propel Gearbox—SpecificationBearing 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 thebearings.

..............

20. To seat bearings, tap on drum using a plastichammer. Then turn drum three times to the right andleft to seat the bearings.

Repeat steps to ensure bearings are seated properly.



PN=77


020250

14

OUOE049,0001000 –19–19NOV01–14/14

NOTE: If lock plate (11) will not engage with spline ofhousing tighten bearing nut until lock plateengages.

21. Install lock plate (11). Apply thread lock and sealer(high strength) to threads of cap screws (12). Tightencap screws.

Propel Gearbox—SpecificationLock Plate-to-Bearing Nut CapScrew (270CLC)—Torque 88 N•m (65 lb-ft)...............................................

22. Apply rigid from-in-place gasket to flange surface onring gear.

Apply thread lock and sealer (high strength) to capscrews (25). Tighten cap screws.

Propel Gearbox—SpecificationRing Gear-to-Drum Cap Screw(270CLC)—Torque 265 N•m (195 lb-ft)......................................................

23. Install second and first planet carriers, sun gears andshaft.

24. Apply rigid from-in-place gasket to flange surface oncover.

Apply thread lock and sealer (medium strength) tothread of cap screws (48). Tighten cap screws.

Propel Gearbox—SpecificationCover-to-Ring Gear Cap Screw(270CLC)—Torque 110 N•m (83 lb-ft)........................................................


PN=78

Group 0260Hydraulic System

0202601

ouoe049,0001010 –19–19NOV01–1/26

Propel Motor Repair

Remove and Install Propel Motor—200CLC and230CLC

NOTE: Propel motor is an integral part of propel gearbox.

If removal is required. See Propel Gearbox Repair. (Group0250.)

Remove and Install Propel Motor—270CLC

CAUTION: Prevent possible injury fromunexpected machine movement. Block bothtracks when removing propel motors. Whenpropel motors are removed, machine has nobrakes and can move. The machine will roll freeon a slope or while being towed.

1. Block tracks.

2. Drain oil from propel gearbox. Approximate capacity is6.0 L (6.5 qt).

CAUTION: The hydraulic oil tank is pressurized.High pressure release of oil can cause seriousburns or penetrating injury.


4. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See 270CLC Drainand Refill Capacities. (Operator’s Manual.)



PN=79

Hydraulic System

020260

2

ouoe049,0001010 –19–19NOV01–2/26

T14

7509

B–U

N–1

9NO

V01

T83

18A

C–U

N–2

0SE

P94

Right Side Shown

1—Cap Screw and Lock Washer (4 used)

5. Disconnect lines.


Propel Motor—SpecificationPropel Motor Cover (270CLC)—Weight 90 kg (200 lb) approximate..............................................................

NOTE: Cap screws (1) used to hold propel motor andpark brake to propel gearbox have heads longerthan those holding propel motor cover to housing.

6. Loosen cap screws and lock washers (1).

7. Connect propel motor and park brake to a hoist usinglifting straps or chains and DF1063 Lift Bracket andDFT1130 Adapter. (Group 9900.)

8. Remove cap screws (1) and remove propel motor, parkbrake and remove O-ring.


10. Install O-ring.

Install propel motor and park brake.

11. Install and tighten cap screws (1).

Propel Motor—SpecificationPropel Motor Cover-to-PropelGearbox Cap Screw (270CLC)—Torque 265 N•m (195 lb-ft).........................................................................


13. Fill propel gearbox with oil. See Check PropelGearbox Oil Level. (Operator’s Manual.)

14. Do Propel Motor Start-Up Procedure. (See procedurein this group.)



PN=80

Hydraulic System

0202603

ouoe049,0001010 –19–19NOV01–3/26

18

17

16

2019

3

2

1

5

4

23

22

21

25

24

87

6

6

10

9

2827

26

30

30

29

29

13

12

11

15

14

T142484T

1424

84–U

N–2

0JU

L01

1—Shaft 9—Housing 17—Swash Plate 24—Needle Bearing2—Retaining Ring (2 used) 10—Pin (2 used) 18—Pin 25—Disc Spring3—Roller Bearing 11—Valve Plate 19—Plate 26—O-Ring4—Oil Seal 12—Rotor 20—Ball (2 used) 27—Brake Piston5—O-Ring 13—Spring (6 used) 21—Piston (2 used) 28—O-Ring6—O-Ring (3 used) 14—Bushing 22—Cap Screw (9 used) 29—Friction Plate (4 used)7—Brake Release Passage 15—Retainer 23—Propel Motor Cover 30—Plate (4 used)8—Speed Change Passage (2 16—Piston (9 used)

used)


PN=81


Hydraulic System

020260

4

ouoe049,0001010 –19–19NOV01–4/26

Disassemble and Assemble Propel Motor—200CLCand 230CLC

1. If required, remove propel gearbox. See PropelGearbox Repair. (Group 0250.)


Propel Motor—SpecificationPropel Motor (200CLC and230CLC)—Weight 92 kg (203 lb) approximate.....................................

IMPORTANT: Use care when removing propelmotor cover (23), valve plate (11) iseasily damaged.

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

IMPORTANT: Remove needle bearing (24) only ifreplacement is necessary. Do notre-use needle bearing as it may havebeen damaged during removal.

3. Remove needle bearing (24) as required.

4. Remove disc spring (25).

Inspect part for wear or damage.

Propel Motor—SpecificationDisc Spring (200CLC and230CLC)—Height 7.0—6.9 mm (0.276—0.272 in.)..............................

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

6. Remove friction plates (29) and plates (30).

7. Inspect parts for wear or damage.

Propel Motor—SpecificationFriction Plate (200CLC and230CLC)—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: Pistons must be installed into thesame bores because of wearpatterns. Mark location of pistonswith respect to bores to aid inassembly.

8. Remove parts (12—18).

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


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

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



PN=82

Hydraulic System

0202605

ouoe049,0001010 –19–19NOV01–5/26

15

14

T14

2996

–UN

–20J

UL0

1

14—Bushing15—Retainer

13. Lubricate parts (12—18) with hydraulic oil and install.Insure that pistons (16) are installed in their originalbores. Install bushing (14) and retainer (15) asshown.

14. Install parts (25—30).

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

NOTE: Apply petroleum jelly to mating surface of valveplate to adhere it to propel motor cover duringassembly.

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—SpecificationPropel Motor Cover-to-PropelMotor Housing Cap Screw(200CLC and 230CLC)—Torque 300 N•m (225 lb-ft).................................



PN=83

Hydraulic System

020260

6

ouoe049,0001010 –19–19NOV01–6/26

910

1112

1415

18

17

16

41

42

242322

2120

19

2526

2728

29

30

39

38

28

37

36

35

34

33

32

31

13

40

T146684

12

3

45

66

8

77

T14

6684

–UN

–01N

OV

01

Propel Motor and Park Brake Components—270CLC


PN=84


Hydraulic System

0202607

ouoe049,0001010 –19–19NOV01–7/26

1—O-Ring 12—Roller Bearing 22—Piston Seal 33—Spring2—Disk Spring 13—Nut 23—Piston Seal 34—Piston (7 used)3—Brake Piston 14—Propel Motor Housing 24—Servo Piston 35—Rotor4—O-Ring 15—O-Ring 25—Cap Screw (4 used) 36—Bushing5—O-Ring 16—Brake Releasing Oil 26—O-Ring 37—Valve Plate6—Plate (5 used) Passage 27—Plug 38—Plate7—Friction Plate (4 used) 17—Lip Seal 28—Pivot Plug (2 used) 39—Pin (2 used)8—Spacer 18—Snap Ring 29—Shoulder Bolt 40—Propel Motor Cover9—Motor Drive Shaft 19—Cap Screw (4 used) 30—Link 41—Plug10—Roller Bearing 20—Cover 31—Pin 42—O-Ring11—Spacer 21—O-Ring 32—Center Shaft

Disassemble and Assemble Propel Motor—270CLC

IMPORTANT: Valve plate and pistons havemachined surfaces. Do not let valveplate and pistons drop.

1. Remove propel motor cover (40) from propel motorhousing (14). Make sure valve plate in valvehousing is not damaged.

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

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

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

NOTE: Remove pin (31) only if necessary.

4. Remove pistons (34).

NOTE: Remove piston evenly from bore. Do notscratch or damage piston or bore.

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

6. Remove brake parts (3—8).

NOTE: If parts are not within specification, replaceparts.

7. Inspect brake parts for wear or damage.

Propel Motor—SpecificationDisk 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—0.071in.)

...............

8. Remove parts (17 and 18).



PN=85

Hydraulic System

020260

8

ouoe049,0001010 –19–19NOV01–8/26

T83

20A

E–U

N–1

1OC

T94

A—Motor Drive ShaftB—NutC—Roller BearingD—SpacerE—Roller Bearing

9. Remove nut (B) using JDG911 Spanner Wrench.

10. Use a puller and a press to remove parts (C—E) fromshaft (A).

ouoe049,0001010 –19–19NOV01–9/26

T83

21A

F–U

N–2

0SE

P94

A—CoverB—Plug and O-RingC—Shoulder BoltD—Valve Plate and Link Assembly

IMPORTANT: Valve plate and slide plate havemachined surfaces. Do not let platesdrop.

11. Remove parts (A—D).


PN=86


Hydraulic System

0202609ouoe049,0001010 –19–19NOV01–10/26

T76

85IE

–UN

–27A

PR

92

A—PlugB—O-RingC—SpoolD—SpringE—Piston Ring (2 used)

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

ouoe049,0001010 –19–19NOV01–11/26

T83

21A

H–U

N–2

0SE

P94

A—Pivot PlugB—BushingC—Valve Plate

13. Inspect bushing (B) and replace if necessary.

IMPORTANT: Thread lock and sealer (high strength)is used on pivot plugs (A).

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


ouoe049,0001010 –19–19NOV01–12/26

T83

21A

H–U

N–2

0SE

P94

A—Pivot Plug (2 used)B—BushingC—Valve Plate

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

15. Install bushing (B) using disk drivers, until bushing iseven with valve plate (C).

16. If removed, apply thread lock and sealer (highstrength) to threads of pivot plugs (A).

IMPORTANT: DO NOT allow thread lock and sealer onsmooth portion of pivot plugs.

17. Install valve plate and pivot plugs (A) in link. Tightenpivot plugs.

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


PN=87


Hydraulic System

020260

10 ouoe049,0001010 –19–19NOV01–13/26

T76

85IE

–UN

–27A

PR

92

A—PlugB—O-RingC—SpoolD—SpringE—Piston Ring (2 used)

IMPORTANT: Piston seals are brittle. Use care not tochip, crack or break seals.

18. Assemble servo piston parts (A—E).

ouoe049,0001010 –19–19NOV01–14/26

T83

21A

G–U

N–2

0SE

P94A—Valve Plate and Link Assembly

B—PlateC—Pin (2 used)D—Servo PistonE—Piston Seal (2 used)

19. Apply clean oil to all internal parts.

20. Install parts (D and E).

IMPORTANT: Valve plate and slide plate havemachined surfaces. Use care notdamage or scratch machined surfaces.

21. Apply petroleum jelly to both sides of plate (B).

22. Install parts (A—C). Align link assembly with servopiston.



PN=88

Hydraulic System

02026011

ouoe049,0001010 –19–19NOV01–15/26

T83

21A

F–U

N–2

0SE

P94A—Cover

B—Plug and O-RingC—Shoulder BoltD—Valve Plate and Link Assembly

23. Install shoulder bolt (C) through link assembly (D) atend of servo piston. Install plug and O-Ring . Tightenshoulder bolt (C) and plug (B).

Propel Motor—SpecificationShoulder Bolt (270CLC)—Torque 49 N•m (36 lb-ft)...................................

24. Install O-ring and cover (A). Tighten cover capscrews.

Propel Motor—SpecificationServo Piston Cover Cap Screw(270CLC)—Torque 88 N•m (65 lb-ft)..........................................................



PN=89

Hydraulic System

020260

12

ouoe049,0001010 –19–19NOV01–16/26

TS

227

–UN

–23A

UG

88T

8320

AE

–UN

–11O

CT

94

A—Motor Drive ShaftB—NutC—Roller BearingD—SpacerE—Roller Bearing


25. Heat bearing cones (C and E).

Propel Motor—SpecificationBearing 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 towardslarger bearing.

27. Apply clean oil to threads of nut (B).

Install nut with thin shoulder away from bearing.



PN=90

Hydraulic System

02026013

ouoe049,0001010 –19–19NOV01–17/26

T83

20A

O–U

N–2

6SE

P94

T83

20A

P–U

N–1

1OC

T94

A—Nut B—DF1038 Torque Adapter C—JDG911 Spanner Wrench

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

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

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

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



PN=91

Hydraulic System

020260

14

ouoe049,0001010 –19–19NOV01–18/26

T83

19B

Y–U

N–2

0SE

P94

A—Snap RingB—Oil Seal

31. Apply rigid form-in-place gasket to outer diameter ofoil seal (B).

32. Install seal with spring side into bore first. Use a diskdriver to push seal to bottom of bore.

33. Apply multi-purpose grease to seal lips.

34. Install snap ring (A).

NOTE: Use a soft faced hammer to make sure bearingsare tight against bottom of bore.

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

ouoe049,0001010 –19–19NOV01–19/26

T83

19B

R–U

N–2

0SE

P94

A—Brake PortB—Brake PistonC—O-RingD—O-RingE—Plate (4 used)F—Friction Plate (5 used)G—Spacer

36. Install spacer (G) with notches to bottom of bore andaligned with notches in housing.

37. Install friction plates (F) and plates (E):

• Begin with one friction plate and align notches infriction plate with notches in gear.

• Install one plate.• Repeat step, alternating friction plates and plates.

Keep notches of plates aligned with one another.

38. Apply petroleum jelly to O-rings (C and D). InstallO-rings on piston (B) with rounded side out.

IMPORTANT: Make sure brake port (A) is clear toallow air to exit as piston is installed.

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

39. Install piston (B) evenly into bore.


PN=92


Hydraulic System

02026015

ouoe049,0001010 –19–19NOV01–20/26

T83

19B

P–U

N–2

0SE

P94

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

41. Assemble parts (32) and (33) and align pin (31) withslot in rotor (35).

42. Install rotor (35).

43. Install disk spring (2) so inner diameter contacts thebrake piston.

44. Install O-rings (1 and 15).



PN=93

Hydraulic System

020260

16

ouoe049,0001010 –19–19NOV01–21/26

T83

22B

C–U

N–2

0SE

P94

T83

22B

D–U

N–2

0SE

P94

A—Plug and O-RingB—Pressure Reducing ValveC—SpringD— Propel Motor CoverE—Alignment PortF—Wooden Dowel or RodG—Center Shaft

45. Remove parts (A—C) from alignment port (E) ofpropel motor cover (D).

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

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

48. Lift propel motor cover into position over propel motorhousing. Align cover to housing and install dowel intobore of center shaft (G).

49. Install and tighten four housing cap screws.

Propel Motor—SpecificationPropel Motor Cover-to-MotorHousing Cap Screw (270CLC)—Torque 390 N•m (290 lb-ft).........................................................................

50. Remove dowel (F) and install parts (A—C). Tightenplug.

Propel Motor—SpecificationBrake Pressure Reducing ValvePlug (270CLC)—Torque 69 N•m (51 lb-ft)..................................................

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

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



PN=94

Hydraulic System

02026017

ouoe049,0001010 –19–19NOV01–22/26

34

5

1

12

54

3

7

6

1011

8

12

1314

1516

9

2

T143007

T14

3007

–UN

–20J

UL0

1

1—Counterbalance Valve 5—Spring Seat (2 used) 9—Poppet (2 used) 13—Propel Speed Change2—Counterbalance Valve Plug 6—Spool 10—Spring (2 used) Plug

(2 used) 7—Propel Motor Cover 11—Relief Valve (2 used) 14—O-Ring3—O-Ring (2 used) 8—Crossover Relief Valve (2 12—Propel Speed Change 15—Spring4—Spring (2 used) used) Valve 16—Spool

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

NOTE: Valves may be removed with propel motor inmachine.

• Apply a film of clean hydraulic oil to parts beforeassembly.

Propel Motor Cover—SpecificationCounterbalance Valve Plug(200CLC and 230CLC)—Torque 440 N•m (325 lb-ft)...................................................................Relief Valve (200CLC and230CLC)—Torque 310 N•m (230 lb-ft).................................................Propel Speed Change Plug(200CLC and 230CLC)—Torque 34 N•m (25 lb-ft).......................................................................



PN=95

Hydraulic System

020260

18

ouoe049,0001010 –19–19NOV01–23/26

T83

22B

E–U

N–2

6SE

P94

A—Plug (2 used) G—O-Ring (4 used) M—Check Valve Poppet (2 R—O-Ring (10 used)B—O-Ring (2 used) H—Ball Seat (2 used) used) S—PlugC—Counterbalance Spring (2 I—Ball (2 used) N—Relief Valve (2 used) T—O-Ring

used) J—Plug (2 used) O—Propel Motor Cover U—Brake Pressure ReducingD—Spool Plug (2 used) K—O-Ring (2 used) P—O-Ring (2 used) Valve SpoolE—Counterbalance Spool L—Check Valve Spring (2 Q—Plug (10 used) V—Pressure Reducing SpringF—Plug (4 used) used)

Disassemble and Assemble Propel Motor Cover—270CLC


PN=96


Hydraulic System

02026019

ouoe049,0001010 –19–19NOV01–24/26

T83

23A

B–U

N–2

0SE

P94

A—Plug with O-RingB—Ball SeatC—Ball

1. Park Brake Release Shuttle Valve

NOTE: Valve can be removed with propel motor onmachine.

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

b. Install ball (C) and tighten seat (B).

Propel Motor—SpecificationBall Seat (270CLC)—Torque 14.5 N•m (128 lb-in.)....................................

c. Install and tighten plug (A).

Propel Motor—SpecificationPark Brake Release Shuttle ValvePlug (270CLC)—Torque 34 N•m (25 lb-ft)..................................................



PN=97

Hydraulic System

020260

20

ouoe049,0001010 –19–19NOV01–25/26

T83

23A

J–U

N–2

0SE

P94

A—Plug with O-RingB—Ball SeatC—Ball

2. Servo Piston Operating Shuttle Valve


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

b. Install ball (C) and tighten seat (B).

Propel Motor—SpecificationBall Seat (270CLC)—Torque 14.5 N•m (128 lb-in.)....................................

c. Install and tighten plug (A).

Propel Motor—SpecificationServo Piston Operating ShuttleValve Plug (270CLC)—Torque 34 N•m (25 lb-ft).......................................


3. Counterbalance Valve (E)

a. Apply clean oil to spool.

b. Install O-ring and tighten plug.

Propel Motor—SpecificationCounterbalance Valve Plug(270CLC)—Torque 340 N•m (250 lb-ft)......................................................

NOTE: Valves can be removed with propel motor onmachine.

4. Relief Valves (N)

Tighten relief valve.

Propel Motor—SpecificationRelief Valve (270CLC)—Torque 540 N•m (398 lb-ft)..................................


PN=98


Hydraulic System

02026021

ouoe049,0001010 –19–19NOV01–26/26

NOTE: Valves can be removed with propel motor onmachine.

5. Check Valves (M)

Install parts and tighten plug.

Propel Motor—SpecificationCheck Valve Plug (270CLC)—Torque 235 N•m (173 lb-ft).........................................................................


6. Brake Pressure Reducing Valve (U)

Install parts and tighten plug.

Propel Motor—SpecificationBrake Pressure Reducing ValvePlug (270CLC)—Torque 69 N•m (51 lb-ft)..................................................


PN=99

Hydraulic System

020260

22

CED,OUOE023,169 –19–19NOV01–1/1

Propel Motor Start-Up Procedure

T14

6686

C–U

N–0

1NO

V01

200CLC and 230CLC Propel Motor Drain Line

T13

9271

D–U

N–0

3MA

Y01

270CLC Propel Motor Drain Line

1—Propel Motor Drain Line

IMPORTANT: Propel motor will be damaged if notfilled with oil before operating propelfunction. Procedure must be performedwhenever a new propel motor isinstalled or oil has been drained fromthe motor.

1. Disconnect drain line (1).

2. Fill motor with hydraulic oil until oil reaches top of drainport.

NOTE: Use a funnel with suitable diameter neck to allowair to escape while filling.

3. Connect drain line (1).

OUOE049,0000051 –19–19NOV01–1/5

Rotary Manifold Repair

Remove and Install Rotary Manifold

CAUTION: The hydraulic oil tank is pressurized.High pressure release of oil from pressurizedsystem can cause serious burns or penetratinginjury.


2. Disconnect upper hydraulic lines.


PN=100


Hydraulic System

02026023

OUOE049,0000051 –19–19NOV01–2/5

T14

3108

B–U

N–2

0JU

L01

1—Bracket2—Cap Screw (2 used)

3. Remove cap screws (2) and bracket (1).

4. Attach the rotary manifold to a hoist using a lifting strapand two Rotary Manifold Lifting Tool. (Group 9900.)

5. Disconnect lower hydraulic lines.

OUOE049,0000051 –19–19NOV01–3/5

T76

85JC

–UN

–27A

PR

92


Rotary Manifold—SpecificationRotary Manifold—Weight 27 kg (60 lb) approximate...................................

6. Remove four mounting cap screws. Lower rotarymanifold.


8. Install rotary manifold. Tighten four mounting capscrews.

Rotary Manifold—SpecificationManifold-to-Frame Cap Screw—Torque 34 N•m (25 ft-lb).............................................................................

9. Install stop bracket. Tighten cap screws.

Rotary Manifold—SpecificationStop Bracket-to-Frame CapScrew—Torque 40 N•m (30 lb-ft)................................................................

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


PN=101


Hydraulic System

020260

24

OUOE049,0000051 –19–19NOV01–4/5

T11

5530

–UN

–17J

UN

98

A—PlugB—Spindle AssemblyC—Oil SealD—O-RingE—BushingF—Oil Seal Rings (6 used)G—HousingH—RingI—Snap RingJ—O-RingK—CoverL—Cap Screw (4 used)

Disassemble and Assemble Rotary Manifold

1. Make alignment marks on spindle (B), housing (G) andcover (K) to aid in assembly.

2. Remove parts (H—L). Carefully remove spindleassembly (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), aligningmarks made during disassembly.

8. Install parts (H—L), aligning marks made duringdisassembly and tighten cap screws.

Rotary Manifold—SpecificationCover-to-Housing Cap Screw—Torque 49 N•m (36 lb-ft).............................................................................

9. Install plugs.



PN=102

Hydraulic System

02026025OUOE049,0000051 –19–19NOV01–5/5

T65

57JB

–UN

–01N

OV

88

Rotary Manifold Air Test

1. Install a plug in one port.

2. Apply air pressure using JDG185 Air Test Plug andshop air pressure through the other port in thatpassage.

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


PN=103

Hydraulic System

020260

26


PN=104

Section 04Engine

Contents

Page

Group 0400—Removal and InstallationEngine Repair . . . . . . . . . . . . . . . . . . . . . . .04-0400-1

Fuel Injection Pump Repair . . . . . . . . . . . . . .04-0400-4Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-5

04


PN=1

Contents

04


PN=2

Group 0400Removal and Installation

0404001

TX,04,DH5305 –19–19NOV01–1/4

Engine Repair

TS

281

–UN

–23A

UG

88

Remove and Install Engine

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns.

Shut off engine. Remove filler cap when cool totouch. Slowly loosen filler cap to first stop torelieve pressure, then remove.

1. Disconnect battery ground (negative) cable.

2. Drain coolant. Approximate capacity of cooling systemis 23.0 L (24.3 qt). See Drain Cooling System.(Operator’s Manual.)

3. Remove fan guard, radiator shroud, fan blade andspacer. 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 airconditioning system.

9. Disconnect air conditioner compressor bracket fromengine. Secure compressor and bracket so it will notinterfere with engine removal.

10. Relieve Fuel System Pressure. (CTM170.)

11. Disconnect fuel filter input line, fuel filter overflowtube, and fuel pump overflow tube.

12. Disconnect heater hoses.


PN=107


Removal and Installation

040400

2

TX,04,DH5305 –19–19NOV01–2/4

T10

4491

–UN

–17O

CT

96

A—DFT1119 Pump SupportB—Hoist Winch


Engine—SpecificationHydraulic Pump and DriveGearbox—Weight 170 kg (375 lb) approximate..........................................

13. Support main hydraulic pump and drive gearbox usingDFT1119 Pump Support (A) and a small hoist winch(B). (Group 9900.)

TX,04,DH5305 –19–19NOV01–3/4

T14

3006

B–U

N–2

0JU

L01

1—Engine Lifting Sling


Engine—SpecificationEngine—Weight 954 kg (2100 lb) approximate...........................................

IMPORTANT: The recommended method for lifting theengine is using the JDG23 Lifting Sling.The lifting force must be at 90° at thelifting points.

14. Attach JDG23 Lifting Sling (1) to engine as shown.

15. Remove cap screws securing main hydraulic pumpand drive gearbox to engine flywheel housing.


PN=108



0404003

TX,04,DH5305 –19–19NOV01–4/4

54

2

5

4

3

14

5

5

4

3

T143012

T14

3012

–UN

–19N

OV

01

1—Bracket, Right Front 3—Bracket, Rear (2 used) 4—Cap Screw (14 used) 5—Washer (14 used)2—Bracket, Left Front

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

17. Raise engine slightly. Move engine away fromhydraulic pump and drive gearbox. Lift andremove engine when disengaged from hydraulicpump drive coupling.

18. Repair or replace parts as necessary. Ifdisassembly is necessary, see EngineDisassembly Sequence. (CTM104.)

CAUTION: Heavy component; lift engineusing JDG23 Lifting Sling. Lifting force mustbe 90° to engine lift points.

Engine—SpecificationEngine—Weight 954 kg (2100 lb) approximate....................................

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

Tighten cap screws.

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

20. Align hydraulic pump and drive gearbox to engineand tighten cap screws.

Engine—SpecificationDrive Gearbox-to-FlywheelHousing Cap Screw—Torque 50 N•m (37 lb-ft)...................................

21. Connect engine wiring. See Machine Harness(W2) Component Location Diagram. (Group9015-10.)

22. Fill radiator and reservoir with coolant. SeeCooling System Fill and Deaeration Procedure.(Operator’s Manual.)

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


PN=109


040400

4

TX,04,DH5307 –19–10NOV03–1/1

Fuel Injection Pump Repair

Remove and Install Fuel Injection Pump

IMPORTANT: Never steam clean or pour cold wateron injection pump while pump isrunning or still warm to prevent pumpseizure.

For replacement of fuel injection pump, see the following:

• 200CLC (S.N. —504000), 230CLC and 270CLC SeeRemove Bosch VP44 Fuel Injection Pump. (CTM170.)

• 200CLC (S.N. 504001—) Perform Remove InjectionPump. (CTM331.)


PN=110


0404005

TX,04,DH5312 –19–19NOV01–1/1

Starter Repair

T14

4796

B–U

N–1

5AU

G01

1—Starter

Remove and Install Starter

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

1. Disconnect battery ground (negative) cable.

2. Disconnect ground strap and electrical connectors.


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

3. Remove starter (1).


5. Install starter (1).


Starter—SpecificationStarter Mounting Cap Screw—Torque 47 N•m (35 lb-ft).............................................................................

7. Connect ground strap and electrical connectors. SeeSystem Functional Schematic, Component Location,and Wiring Diagram Master Legend. (Group 9015-10.)

8. Connect battery ground (negative) cable.


PN=111


040400

6


PN=112

Section 05Engine Auxiliary SystemContents

Page

Group 0510—Cooling SystemRadiator . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1Fan, Fan Guard and Fan Shroud . . . . . . . . .05-0510-1Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-2

Group 0520—Intake SystemAir Intake System Leakage Test . . . . . . . . . .05-0520-1Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-2

Group 0560—External Fuel Supply SystemFuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1Primary Fuel Filter (Water Separator) . . . . . .05-0560-3Final Fuel Filter . . . . . . . . . . . . . . . . . . . . . . .05-0560-4 05


PN=1

Contents

05


PN=2

Group 0510Cooling System

0505101

TX,05,DH5317 –19–19NOV01–1/1

Radiator Repair

TS

281

–UN

–23A

UG

88T

1426

81–U

N–0

2AU

G01

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

Remove and Install Radiator


Shut off engine. Only remove filler cap whencool enough to touch with bare hands. Slowlyloosen cap to first stop to relieve pressurebefore removing completely.

1. Drain coolant from radiator. Approximate capacity is28.4 L (30 qt).

2. Remove upper and lower radiator hoses and overflowhose.

3. Remove cap screws (1—3).


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

4. Attach radiator to hoist and remove.

5. Repair or replace as necessary.

6. Install radiator and tighten cap screws (1—3).

7. Fill radiator and reservoir with coolant. See CoolingSystem Fill and Deaeration Procedure. (See Operator’sManual.)

8. Start engine and check for leaks.

TX,05,DH5318 –19–19NOV01–1/2

Fan, Fan Guard, and Fan Shroud Repair

Remove and Install Fan, Fan Guard, and Fan Shroud


PN=115


Cooling System

050510

2

TX,05,DH5318 –19–19NOV01–2/2

TS

281

–UN

–23A

UG

88T

1429

94B

–UN

–02A

UG

01

Fan Guard—200CLC and 230CLC

T14

7134

B–U

N–1

9NO

V01

Fan Guard—270CLC

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


Shut off engine. Only remove filler cap whencool enough to touch with bare hands. Slowlyloosen cap to first stop to relieve pressurebefore removing completely.

1. Remove cap screws (1). Remove fan guard.

2. Remove cap screws (3). Slide fan shroud towardengine.

3. Remove cap screws (2). Remove fan, and fan shroud.


5. Install fan. Tighten cap screws.

Fan—SpecificationEngine Fan-to-Pulley CapScrew—Torque 70 N•m (50 lb-ft)................................................................

TX,05,DH5319 –19–19NOV01–1/2

Fan Belt Repair

Remove and Install Fan Belt



PN=116

Cooling System

0505103

TX,05,DH5319 –19–19NOV01–2/2

T10

8219

–UN

–25M

AR

97

A—Hex Head of Cap Screw

1. Remove fan guard. See Fan, Fan Guard, and FanShroud 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.


PN=117

Cooling System

050510

4


PN=118

Group 0520Intake System

0505201

TX,05,GG2309 –19–19NOV01–1/1

Air Intake System Leakage Test

T59

06A

P–U

N–2

3FE

B89

T60

89A

R–U

N–2

5OC

T88

A—JDG51 Inlet Air Adapter

1. Remove air cleaner cover. Remove primary filterelement.

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

3. Remove fitting for start aid nozzle from intake manifold.

4. Install the JDG51 Inlet Air Adapter (A).

5. Connect air pressure regulator to adapter using hoseand fitting.

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

6. Pressurize air intake system to 14—21 kPa (0.14—0.21 bar) (2—3 psi). If intake system cannot bepressurized, turn engine crankshaft slightly to closevalves.

Air Intake System—SpecificationLeakage Test—Pressure 14—21 kPa (0.14—0.21 bar)

(2—3 psi)..............................

7. Spray a soap solution over all connections from the aircleaner to turbocharger and intake manifold. Check forleaks. Correct all leaks

8. When installing start aid nozzle, be certain arrow onnozzle is pointing against intake air flow.


PN=119

Intake System

050520

2

OUOE027,0000040 –19–19NOV01–1/1

Air Cleaner Repair

T14

4782

–UN

–19N

OV

01

1—Valve 5—Hose 8—Inner Filter Element 11—Gasket2—Air Cleaner 6—Hose 9—Wing Nut (3 used) 12—Clip3—Indicator 7—Cap Screw (4 used) 10—Outer Filter Element 13—Cover4—Clamp (3 used)

Remove and Install Air Cleaner

NOTE: Tighten hose clamps until rubber hose beginsto deform.


PN=120

Group 0560External Fuel Supply System

0505601

TX,05,GG2307 –19–19NOV01–1/2

Fuel Tank Repair

T10

5203

–UN

–19N

OV

96

1—Fuel Strainer 10—Cap Screw 15—Switch 22—Cap Screw (4 used)2—Filler Cap 11—Float (Fuel Level Sender) 16—Sealing Washer 23—Lock Washer (4 used)3—Fuel Tank 12—Cap Screw (5 used) 18—Drain Valve 25—Washer (4 used)4—Plug 13—Gasket 19—Fitting 26—Wiring Connector9—Bracket 14—Lock Washer 20—Plug


PN=121


External Fuel Supply System

050560

2

TX,05,GG2307 –19–19NOV01–2/2

Remove and Install Fuel Tank

1. Drain fuel from fuel tank. Approximate capacity is360 L (95 gal).

2. Disconnect wiring connector (26).


Fuel Tank—SpecificationFuel Tank—Weight 91 kg (200 lb) approximate

without fuel...................................

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


5. Apply thread lock and sealer (medium strength) tothread of cap screws (12).

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

Fuel Tank—SpecificationFloat (Fuel Level Sender) andGasket-to-Fuel Tank CapScrew—Torque 4.5 N•m (40 lb-in.).......................................................

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

Fuel Tank—SpecificationFrame-to-Fuel Tank CapScrew—Torque 205 N•m (152 lb-ft).....................................................

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

9. Bleed Fuel System. (CTM 170.)


PN=122


0505603

TX,05,GG2315 –19–19NOV01–1/1

Primary Fuel Filter (Water Separator) Repair

T14

2498

B–U

N–0

2AU

G01

200CLC Shown

1—Cap Screw, Lock Washer and Washer (2 used)2—Clamp (2 used)3—Primary Filter-to-Fuel Tank4—Primary Filter-to-Final Fuel Filter5—Primary Fuel Filter (Water Separator)

Remove and Install Primary Fuel Filter (WaterSeparator)

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 andassemble primary fuel filter as required. See Final FuelFilter Assembly - Tier 2. (CTM170.)

5. Install primary fuel filter and tighten cap screws.



PN=123


050560

4

TX,05,GG2314 –19–19NOV01–1/1

Final Fuel Filter Repair

T14

2510

B–U

N–0

2AU

G01

1—Transfer Pump Electrical Connector2—Cap Screw (2 used)3—Transfer Pump4—Final Fuel Filter-to-Injector Pump Line5—Injector Return Port-to-Final Fuel Filter Line6—Final Fuel Filter7—Fuel Pressure Sensor Electrical Connector8—From Primary Fuel Filter Line9—Clamp

Remove and Install Final Fuel Filter

1. Loosen drain valve to drain fuel into a container.Dispose of fuel properly.

2. Disconnect electrical connectors (1 and 7).

3. Disconnect lines (4, 5 and 8).

4. Remove cap screws (2) and remove final fuel filter (6).

5. Replace parts as necessary. Disassemble andassemble final fuel filter as required. See Final FuelFilter Assembly - Tier 2. (CTM170.)

6. Install final fuel filter (6) and tighten cap screws (2).

7. Connect electrical connectors (1 and 7).

8. Connect lines (4, 5 and 8).



PN=124

Section 07Dampener Drive (Flex Coupling)

Contents

Page

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

07


PN=1

Contents

07


PN=2

Group 0752Elements

0707521

TX,07,DH5336 –19–19NOV01–1/1

Dampener Drive (Flex Coupling) Repair

T10

5285

–UN

–20N

OV

96

A—CouplingB—Set Screw (2 used)C—Flex CouplingD—Cap Screw (4 used)E—Insert (4 used)F—Spring Pin (4 used)G—Cap Screw (4 used)H—Insert (4 used)

Remove and Install Dampener Drive (Flex Coupling)

1. Remove hydraulic pump. See Hydraulic Pump andDrive Gearbox Repair. (Group 3360.)

NOTE: Flex coupling may come off with pump or stay onflywheel.

2. Remove parts (A—H).


4. Install parts (A—H). Apply thread lock and sealer(medium strength) to set screws (B) and to cap screws(D and G).

NOTE: Spring pin (F) is for alignment of insert (E) toflywheel.

5. Tighten set screws (B).

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

6. Tighten cap screws (D and G).

Dampener Drive (Flex Coupling)—SpecificationInsert-to-Flywheel and CouplingCap Screw—Torque 215 N•m (160 lb-ft)....................................................

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


PN=127

Elements

070752

2


PN=128

Section 17Frame or Supporting Structure

Contents

Page

Group 1740—Frame InstallationWelding On Machine. . . . . . . . . . . . . . . . . . .17-1740-1Welding Repair of Major Structure. . . . . . . . .17-1740-2

Group 1749—Chassis WeightsCounterweight . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1

17


PN=1

Contents

17


PN=2

Group 1740Frame Installation

TX,16,UU3948 –19–16OCT00–1/2

Welding On Machine

IMPORTANT: Electrical current traveling from thewelder through the machine electricalsystem may damage the machineelectrical system, including battery,EPC controller. Disconnect batteryground cable and EPC electricalconnectors before welding on themachine.

Before welding on the machine, follow the steps listedbelow to protect the machine electrical system.

1717401

TX,16,UU3948 –19–16OCT00–2/2

T14

3053

B–U

N–2

0JU

L01

1—EPC connector (4 used).

1. Disconnect the battery ground and positive cables.

NOTE: Console cover located behind seat in cab, mustbe removed to gain access to engine and pumpcontroller connectors.

2. Remove rear console cover.

3. Disconnect electrical connectors (1) from engine andpump controller.

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


PN=131

Frame Installation

171740

2

TX,17,GG2439 –19–19SEP98–1/1

Welding Repair of Major Structure

CAUTION: Avoid potentially toxic fumes anddust. Hazardous fumes can be generatedwhen paint is heated by welding, soldering,or using a torch. Do all work outside or in awell ventilated area. Dispose of paint andsolvent properly.

If you sand or grind paint, avoid breathingthe dust. Wear an approved respirator. If youuse solvent or paint stripper, removestripper with soap and water before welding.Remove solvent or paint stripper containersand other flammable material from area.Allow fumes to disperse at least 15 minutesbefore welding or heating.

1. Remove paint before welding or heating.

IMPORTANT: Disconnect battery ground strap orturn battery disconnect switch to"OFF". Also disconnect the wiringharness connectors to the engineand pump controller.

Have only a qualified welder do thisjob. Connect welder ground clampclose to each weld area so electricalcurrent does not pass through anybearings. Remove or protect all partsthat can be damaged by heat or weldsplatter.

2. Use one of the following weld processes:

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

• AWS-ER-70S-3 wire electrode with gas metal arcwelding (GMAW) process.

• AWS-E70T-1 or E71T-1 wire electrode with fluxcore arc welding (FCAW) process.

Welding Repair of Major Structure—SpecificationWeld 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 bepreheated to allow better weldpenetration.

3. To repair weld metal failure, remove failed weldmetal using arc or grinding equipment. Thoroughlyclean area to be welded. Preheat structuralassemblies to a minimum of 38°C (100°F). Preheatground engaging tools (cutting edges, skid shoes,and teeth shanks) to 177°C (350°F).

To repair base metal failure remove enoughmaterial to allow weld to penetrate to the bottom ofcrack. Preheat structural assemblies to a minimumof 38°C (100°F). Preheat ground engaging tools(cutting edges, skid shoes, and teeth shanks) to177°C (350°F).

Welding Repair of Major Structure—SpecificationStructural Assemblies—PreheatTemperature 38°C (100°F)...................................................................Ground Engaging Tools—Preheat Temperature 177°C (350°F)....................................................


PN=132

Group 1749Chassis Weights

1717491

OUOE027,000003C –19–19NOV01–1/1

Counterweight Repair

T14

3043

–UN

–20J

UL0

1T

1430

44–U

N–0

3SE

P02

T14

3045

–UN

–20J

UL0

1

1—Counterweight2—Hoist3—Spreader Bar4—Cap Screw and Washer (4 used)

Remove and Install Counterweight

1. Park machine on level ground.

2. Remove two plastic caps from top of counterweight (1).


The lifting capacity of a lifting eyeboltdecreases as the lift angle increases fromvertical. A spreader bar should be used toobtain, as close as possible, a vertical lift fromeyebolts.

Counterweight—SpecificationCounterweight (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.........

NOTE: For 270CLC, use JT05558 Metric Lifting Eyeboltwith spreader bar.

3. Connect the counterweight to a hoist (2) using aspreader bar (3).

4. Remove cap screws and washers (4).

5. Remove counterweight.


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

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


PN=133

Chassis Weights

171749

2


PN=134

Section 18Operator’s Station

Contents

Page

Group 1800—Removal and InstallationCab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1

Group 1810—Operator EnclosureWindowpane

Two Piece Molding . . . . . . . . . . . . . . . . . .18-1810-1One Piece Molding . . . . . . . . . . . . . . . . . .18-1810-2

Sliding Windows . . . . . . . . . . . . . . . . . . . . . .18-1810-3Windowpanes . . . . . . . . . . . . . . . . . . . . . . . .18-1810-4

Group 1821—Seat and Seat BeltSeat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-1

Group 1830—Heating and Air ConditioningRefrigerant Cautions and Proper

Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1Flush and Purge Air Conditioner System. . . .18-1830-3R134a Refrigerant Oil Information . . . . . . . . .18-1830-6R134a Refrigerant Recovery/Recycling

and Charging Station InstallationProcedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7

Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-8Evacuate R134a System. . . . . . . . . . . . . . . .18-1830-9Charge R134a System . . . . . . . . . . . . . . . .18-1830-10Compressor. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11Receiver-Dryer . . . . . . . . . . . . . . . . . . . . . .18-1830-12Air Conditioner and Heater . . . . . . . . . . . . .18-1830-14Condenser . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-16

18


PN=1

Contents

18


PN=2

Group 1800Removal and Installation

SMCLEAN,000000B –19–19NOV01–1/4

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 InstallMonitor Controller and Display (A5). (Group 9015-20.)

3. Disconnect electrical connectors.

4. Remove fresh air intake cowl.

5. Disconnect windshield washer hose.


1818001


PN=137


181800

2

SMCLEAN,000000B –19–19NOV01–2/4

5

6

4

2

3

2

3

2

3

2

1

T143008

T14

3008

–UN

–20J

UL0

1

1—Cap Screw (2 used) 3—Cap Screw (7 used) 5—Washer (4 used) 6—Rubber Mount (4 used)2—Washer (9 used) 4—Lock Nut (4 used)


PN=138



SMCLEAN,000000B –19–19NOV01–3/4

6. Remove lock nuts (4) securing cab to rubbermounts at all four corners. Discard lock nuts.

7. Remove cap screws (1 and 3).

1818003

SMCLEAN,000000B –19–19NOV01–4/4

T10

6453

–UN

–15J

AN

97


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

8. Use lifting straps and connect cab to hoist.

NOTE: Move cab forward slightly to clear propel pedalsduring removal.

9. Remove cab.


NOTE: Check that all lines and cables are out of the waybefore installing cab.

11. Install cab.

12. Install cap screws (1 and 3).

Cab—SpecificationCab-to-Platform Cap Screw—Torque 50 N•m (37 lb-ft).............................................................................

13. Install washers (5) and new lock nuts (4).

Cab—SpecificationCab 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.)

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


PN=139


181800

4


PN=140

Group 1810Operator Enclosure

TX,1800,VV2501 –19–21SEP98–1/4

Windowpane and Two Piece Molding Repair

T59

03A

I–U

N–1

9OC

T88

A—Locking Strip

Remove and Install Windowpane and Two PieceMolding

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

TX,1800,VV2501 –19–21SEP98–2/4

T59

03A

J–U

N–1

9OC

T88

IMPORTANT: Extreme care is required preventwindowpane damage.

2. Carefully push windowpane out from molding.

3. Inspect molding for damage; replace if necessary.

1818101

TX,1800,VV2501 –19–21SEP98–3/4T

5903

AK

–UN

–19O

CT

88

A—Window PaneB—Windowpane Insertion Tool

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

5. Install windowpane using insertion tool (A) and soaplubricant.

TX,1800,VV2501 –19–21SEP98–4/4

T59

03A

L–U

N–1

9OC

T88

A—Locking StripB—Weather Strip Installation Tool

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


PN=141

Operator Enclosure

TX,18,VV2502C –19–10JAN97–1/2

Windowpane and One Piece Molding Repair

T64

39X

E–U

N–1

9OC

T88

Remove and Install Windowpane and One PieceMolding

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

2. Remove molding from windowpane; replace ifnecessary.

TX,18,VV2502C –19–10JAN97–2/2

T64

39X

D–U

N–1

9OC

T88

181810

2

A—Drain Notches

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

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


PN=142

Operator Enclosure

OUOE047,0000044 –19–11APR01–1/1

Sliding Windows Repair

T14

0968

–UN

–30A

PR

01

1—Window Frame2—Bottom Spacer (4 used)3—Molding4—Adhesive

Remove and Install Sliding Windows

1. Remove molding (3) from inside of window.

2. Use putty knife to cut adhesive (4) between cab flangeand window frame (1).

IMPORTANT: Work carefully to avoid damaging frameand windowpane. Two technicians arerequired during window removal; one topush window out of cab, and one toprevent window from falling.

3. Carefully remove window frame from cab.

4. Lift frame slightly at top-center to remove and installwindowpanes.

5. Apply instant gel adhesive to cab flange.

6. Install windows and frame with spacers (2) at thebottom.

7. Using water as a lubricant, push window frame tightagainst cab flange.

8. Install molding (3) around window and cab flange.

1818103


PN=143

Operator Enclosure

T52,1810,C19 –19–05JUN98–1/1

Windowpanes Repair

Remove and Install Windowpanes

The adhesive used to secure windowpanes is aurethane adhesive used on automobile windshields.Urethane adhesive manufactured by LoctiteCorporation or equivalent is recommended. DO NOTuse any other type of adhesive. It is recommendedthat an auto glass dealer install windowpanes.

IMPORTANT: Windowpanes must include anultra-violet barrier around edge soadhesive will not deteriorate.Windowpanes ordered through JohnDeere Parts have this ultra-violetbarrier. If windowpane is purchasedthrough glass dealer, the dealermust incorporate an ultra-violetbarrier on the glass. DO NOT paintborder of glass.

If auto glass dealer does not install windowpanes,proceed as follows:

1. Remove windowpane frame from cab.

2. Scrape any broken glass off existing adhesive. DONOT remove adhesive from window frame or cab.

IMPORTANT: Adhesive will not stick to bare metal.

3. If existing adhesive is removed and paint isscraped, paint window frame. Paint must be fullycured before installing windowpane.

4. Trim existing adhesive to form a smooth surface.

IMPORTANT: Follow manufacturer’s instructionsfor using adhesive.

5. Apply 6 mm (1/4 in.) bead of adhesive over existingadhesive.

6. Position windowpane in cab frame. Use handpressure to force windowpane down until edges areeven with metal frame.

7. Secure windowpane with duct tape until adhesivecures. Allow adhesive to cure for 24 hours beforeoperating machine.

181810

4


PN=144

Group 1821Seat and Seat Belt

1818211

TX,18,GG2447 –19–14JAN97–1/2

Seat Belt Repair

TP

4811

3–U

N–0

5AU

G96


PN=145


Seat and Seat Belt

TX,18,GG2447 –19–14JAN97–2/2

0—Seat Belt 4—Belt 6—Spacer (Sleeve) (2 used) 11—Cap Screw (2 used)1—Bracket 5—Spacer (Sleeve) 8—Cap Screw 12—Spring Washer (4 used)3—Belt

181821

2


PN=146

Group 1830Heating and Air Conditioning

1818301

TX,9031,DY5073 –19–19NOV01–1/2

Refrigerant Cautions and Proper Handling

CAUTION: DO NOT allow liquid refrigerant tocontact eyes or skin. Liquid refrigerant willfreeze eyes or skin on contact. Weargoggles, gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, DONOT rub the area. Splash large amounts ofCOOL water on affected area. Go to aphysician or hospital immediately fortreatment.

DO NOT allow refrigerant to contact openflames or very hot surfaces such as electricwelding arc, electric heating element andlighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) ina closed container. Heated refrigerant willdevelop high pressure which can burst thecontainer.

Keep refrigerant containers away from heatsources. Store refrigerant in a cool place.

DO NOT handle damp refrigerant containerwith your bare hands. Skin may freeze tocontainer. Wear gloves.

If skin freezes to container, pour COOLwater over container to free the skin. Go to aphysician or hospital immediately fortreatment.

IMPORTANT: To meet government standardsrelating to the use of refrigerants,

R134a is used in the air conditioningsystem. Because it does not containchlorine, R134a is not detrimental tothe ozone in the atmosphere.However, it is illegal to dischargeany refrigerant into the atmosphere.It must be recovered using theappropriate recovery stations.

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

Use only John Deere approvedR134a refrigerant products. Mixing ofproducts not compatible will causesystem damage and contaminaterecovery, recycling and chargingstation equipment. Care must betaken to identify and use equipment,refrigerant oil and refrigerantdesigned only for R134a refrigerantsystems. Refrigerant should betested for type and purity beforerecovery, recycling or charging ofsystem. JT02167A refrigerant testinstrument should be used beforeany testing or repair to system ispreformed.



PN=147

Heating and Air Conditioning

TX,9031,DY5073 –19–19NOV01–2/2

Prism Pro Refrigerant IdentificationInstrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A

To safely identify type and check purity of refrigerantprior to recovery, recycling and recharging of A/Csystems.

181830

2


PN=148


1818303

TX,18,DU2461 –19–19NOV01–1/3

Flush and Purge Air Conditioner System

CAUTION: Liquid refrigerant will freeze eyesor skin on contact. Wear goggles, glovesand protective clothing.

See Refrigerant Cautions and ProperHandling. (See procedure in this group.)

NOTE: Flushing can be performed on machine.

1. Recover R134a Refrigerant. (See procedure in thisgroup.)

Add flushing solvent to system with JT02075Flusher and JT02098 Flusher Fitting Kit.

2. Remove and discard receiver/dryer.

3. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102 Adapter.

4. Fill flusher tank with solvent and fasten allconnections. Dispose of solvent properly.

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

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

Flush and Purge Air Conditioner System—SpecificationAir Pressure—Pressure 620 kPa (90 psi) (6.2 bar)

minimum for flushing andpurging

.............................

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

6. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty when hosepulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.

7. Clean compressor as follows:

a. Remove compressor and measure oil drainedfrom both manifold ports.

b. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102Adapter.

c. Pour flushing solvent into suction port anddischarge port. Plug both ports in compressormanifold, using JT02099 and JT03194 Caps.

Flush and Purge Air Conditioner System—SpecificationFlushing Solvent in SuctionPort—Volume 240 mL (8 fl oz).............................................................Flushing Solvent in DischargePort—Volume 120 mL (4 fl oz).............................................................

d. Turn compressor end for end and roll it side toside.

e. Remove both plugs from manifold ports anddrain solvent from compressor.

f. Connect battery power to compressor clutch coil.Rotate pulley at least five revolutions to movesolvent out of cylinders.

g. Invert compressor. Roll end for end and side toside. Drain thoroughly.

h. Repeat previous two steps at least three times.

8. Divide system into two circuits:

• Condenser circuit, including inlet and outlethoses.

• Evaporator circuit, including inlet and outlethoses.

9. Condenser:

IMPORTANT: DO NOT attempt to flush throughcompressor or receiver/dryer.Flushing through expansion valve isacceptable if refrigerant oil has anormal odor and appearance.

a. Flush/Purge Condenser:


PN=149



181830

4

TX,18,DU2461 –19–19NOV01–2/3

b. Remove and discard receiver/dryer.

c. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102Adapter.

d. Fill flusher tank with solvent and fasten allconnections.


NOTE: Air pressure must be at least to specificationfor flushing and purging.


minimum for flushing andpurging.

.............................

e. Connect a supply line of moisture-freecompressed air or dry nitrogen to flusher airvalve.

f. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty whenhose pulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.

g. Attach a return hose and aerator nozzle to endof receiver/dryer inlet hose using JT03197Adapter. Put nozzle in container to collectflushing solvent.

NOTE: Purging the condenser circuit takes 10—12minutes to thoroughly remove solvent.

h. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to a piece ofcardboard; continue purging until cardboard isdry.

10. See flush evaporator, if evaporator requiresflushing.

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

11. Flush evaporator:

a. Remove evaporator and expansion valve. SeeAir Conditioner and Heater Repair. (Seeprocedure in this group.)

b. Force flushing solvent through evaporator inletwith compressed air.

c. Purge system until dry.

d. Install evaporator and then go to step 13.

12. Flush evaporator through expansion valve:

a. Connect flusher outlet hose to connection ofreceiver/dryer outlet hose using JT03188adapter.

b. Fill flusher tank and fasten all connections.


NOTE: Air pressure must be at least to specificationfor flushing and purging.


minimum for flushing andpurging.

.............................

c. Connect a supply line of moisture-freecompressed air or dry nitrogen to flusher airvalve.

d. Attach a hose and aerator nozzle tocompressor inlet line using JT02101 adapter.Put nozzle in a container to collect solvent.


PN=150



TX,18,DU2461 –19–19NOV01–3/3

NOTE: Purging evaporator circuit takes 12—15minutes to thoroughly remove solvent.

13. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to a piece ofcardboard and continue purging until cardboard isdry.

14. Install a new receiver/dryer compatible with R134arefrigerant. Fasten connections and mounting

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

15. Add required oil. See R134a Refrigerant OilInformation. (See procedure in this group.)

16. Install compressor and connect refrigerant lines tomanifold.

17. Connect clutch coil wire and install drive belt.

1818305


PN=151


181830

6

TX,9031,QQ2365 –19–19NOV01–1/1

R134a Refrigerant Oil Information

CAUTION: All new compressors are chargedwith a mixture of nitrogen, R134a refrigerantand TY22025 (R134a) refrigerant oil. Wearsafety goggles and discharge thecompressor slowly to avoid possible injury.

IMPORTANT: Do not add any more oil thanrequired or maximum cooling will bereduced.

DO NOT leave system or R134acompressor oil containers open.Refrigerant oil easily absorbsmoisture. DO NOT spill R134acompressor oil on acrylic or ABSplastic. This oil will deteriorate thesematerials rapidly. Identify R134a oilcontainers and measures toeliminate accidental mixing ofdifferent oils.

A new compressor from parts depot contains new oil.The oil level visible through the suction port normally isbelow the drive shaft.

Normal operating oil level of a compressor removedfrom operation cannot be seen through suction port ofcompressor.

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

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

Determining the amount of system oil charge prior toinstallation of compressor on a machine.

When complete system, lines, and components areflushed add correct amount of oil as described.

Refrigerant Oil Capacity—SpecificationOil—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 orreplaced, measure length of hose and use formula 3mL per 30 cm (0.1 fl oz per ft ) to determine correctamount of oil to be added.

Drain compressor oil into graduated container whilerotating compressor shaft and record amount.

If oil drained from a compressor removed fromoperation is very black or amount of oil is less than 6mL (0.2 fl oz), perform the following and discard oilproperly:

❒ Determine if R134a leakage was detected, removecomponent 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 inports and internally wash out old oil and discard oilproperly.

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

Install required amount of TY22025 Refrigerant Oil incompressor.

Connect all components, evacuate and charge system.See Evacuate R134a System and Charge R134aSystem. (See procedures in this group.)


PN=152


1818307

TX,9031,DU1693 –19–19NOV01–1/1

R134a Refrigerant Recovery/Recycling andCharging Station Installation Procedure

T81

18A

G–U

N–0

6DE

C93

A—High Pressure Hose Charge Port CapB—Red HoseC—Blue HoseD—High Pressure Relief ValveE—Refrigerant Recovery/Recycling and Charging

Station

CAUTION: Liquid refrigerant will freeze eyes orskin on contact. Wear goggles, gloves andprotective clothing.

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

IMPORTANT: Use only John Deere approved R134arefrigerant products. Mixing of productsnot compatible will cause systemdamage and contaminate recovery,recycling and charging stationequipment.

CAUTION: Do not remove high pressure reliefvalve (D). Air conditioning station will dischargerapidly causing possible injury.

IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling andcharging stations. DO NOT mixrefrigerant, hoses, fittings, componentsor refrigerant oils.

1. Follow procedures. See Refrigerant Cautions andProper Handling. (See procedure in this group.)

2. Close both high-side and low-side valves on refrigerantrecovery/recycling and charging station (E).

3. Remove cap from low-side charge port.

4. Connect blue hose (C) from refrigerantrecovery/recycling and charging station (E) to low-sidetest port.

5. Remove cap (A) from charge port on high pressurehose and connect red hose (B).

6. Follow the manufacturers’ instructions when usingrefrigerant recovery/recycling and charging station.


PN=153


181830

8

TX,9031,DU1694 –19–19NOV01–1/1

Recover R134a Refrigerant

CAUTION: Liquid refrigerant will freeze eyes orskin on contact. Wear goggles, gloves andprotective clothing.

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

CAUTION: Do not remove high pressure reliefvalve. Air conditioning system will dischargerapidly causing possible injury.

IMPORTANT: Use correct refrigerantrecovery/recycling and chargingstations. DO NOT mix refrigerant,hoses, fittings, components orrefrigerant oils.

1. Run air conditioning system for three minutes to help inrecovery process. Turn air conditioning system offbefore proceeding with recovery steps.

2. With engine OFF identify refrigerant type usingJT02167A Refrigerant Identification Instrument.

3. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and Charging StationInstallation Procedure. (See procedure in this group.)

4. Follow manufacturers’ instructions when usingrefrigerant recovery/recycling and charging station.


PN=154


1818309

TX,1830,DT474 –19–19NOV01–1/1

Evacuate R134a System



Do not remove high pressure relief valve. Airconditioning system will discharge rapidlycausing possible injury.

1. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and ChargingStation Installation Procedure. (See procedure inthis group.)

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

3. Follow manufacturers’ instructions and evacuatesystem.

NOTE: Vacuum specifications listed are for sea levelconditions. Subtract 3.4 kPa (34 mbar) (1 in.Hg) from 98 kPa (980 mbar) (29 in. Hg) foreach 300 m (1000 ft) elevation above sealevel.

Air Conditioning System—SpecificationEvacuate 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 sealevel

................

4. Evacuate system until low-side gauge registers 98kPa (980 mbar) (29 in. Hg) vacuum.

Air Conditioning System—SpecificationEvacuate System—Vacuum 98 kPa (980 mbar) (29 in. Hg)...............

If above specification vacuum cannot be obtained in 15minutes, test the system for leaks. See RefrigerantLeak Test. (Group 9031-25.)

5. When vacuum reaches above specification, closelow-side and high-side valves. Turn vacuum pumpoff.

6. If vacuum decreases more than specification in 5minutes, there is a leak in system.

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

7. Repair leak.

8. Evacuate system for 30 minutes after 98 kPa (980mbar) (29 in. Hg) vacuum is reached.

9. Close low-side and high-side valves. Stopevacuation.

10. Charge system. See Charge R134a System. (Seeprocedure in this group.)


PN=155


181830

10

TX,18,DU2481 –19–19NOV01–1/1

Charge R134a System



IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling andcharging stations. DO NOT mixrefrigerant, hoses, fittings,components or refrigerant oils.

1. Identify refrigerant type using JT02167A RefrigerantIdentification Instrument.

2. Connect R134a Refrigerant Recovery/Recyclingand Charging Station. See R134a RefrigerantRecovery/Recycling and Charging StationInstallation Procedure. (See procedure in thisgroup.)

3. Evacuate system. See Evacuate R134a System.(See procedure in this group.)

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

Engine STOPPED, the pump must be capableof pulling at least 28.6 in. Hg vacuum (sealevel). Subtract 3.4 kPa (34 mbar) (1 in. Hg)from 98 kPa (980 mbar) (29 in. Hg) for each300 m (1000 ft) elevation above sea level.

Air Conditioning System—SpecificationEvacuate 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 sealevel

................

4. Follow manufacturer’s instructions and chargesystem.

5. Add refrigerant to system .

Air Conditioning System—SpecificationAir Conditioning SystemRefrigerant—RefrigerantQuantity 0.85 kg (1.87 lb)......................................................................

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


PN=156


18183011

OUOE003,00000E5 –19–16JUL01–1/1

Compressor Repair

T14

3114

B–U

N–2

0JU

L01

1—Hi and Low Pressure Lines2—Cap Screw, Lock Washer and Washer3—Cap Screw, Lock Washers and Washers (4

used)4—Compressor5—Power Lead6—Electrical Connector

Remove and Install Compressor

1. Recover refrigerant from the system. See RecoverR134a Refrigerant. (See procedure in this group.)

2. Disconnect electrical connector (6) and power lead (5).

3. Remove belt.

4. Remove cap screw, lock washer and washer (2).Disconnect high and low pressure lines (1).

5. Remove cap screws, lock washers and washers (3)and remove compressor (4).


7. Install compressor (4) and tighten cap screw (3).

Compressor—SpecificationPressure Line Cap Screw—Torque 28 N•m (247 lb-in)...........................................................................

8. Install high and low pressure lines (1).

9. Inspect and adjust compressor belt tension. SeeInspect Fan Belt. (Operator’s Manual.)

10. Evacuate and charge the system. See EvacuateR134a System and Charge R134a System. (Seeprocedures in this group.)


PN=157


181830

12

OUOE003,00000E6 –19–25JUL01–1/1

Receiver-Dryer Repair

T14

3115

B–U

N–2

0JU

L01

1—Receiver-Dryer2—Cap Screw, Lock Washer and Washer3—High Pressure Input Line4—Cap Screw, Lock Washer and Washer5—Electrical Connector6—High Pressure Output Line7—Cap Screw (2 used)8—Bracket

Remove and Install Receiver-Dryer


2. Disconnect electrical connector (5).

3. Remove cap screw, lock washer, washer (2) andhigh-pressure input line (3).

4. Remove cap screw, lock washer, washer (4) andhigh-pressure output line (6).

5. Loosen cap screws (7) and remove receiver-dryer (1)from bracket (8).


7. Install receiver-dryer (1).

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

Receiver-Dryer—SpecificationHigh-Pressure Output and InputLine Cap Screw—Torque 5 N•m (44 lb-in)..................................................



PN=158


18183013


PN=159


181830

14

OUOE003,00000E7 –19–25APR01–1/2

Air Conditioner and Heater Repair

T145044

5

6

7

8

9

10

11

4

3

21

27

26

25

2423

22 21

2015

19

18

17

16

15 14

13

12

T14

5044

–UN

–27A

UG

01


PN=160



OUOE003,00000E7 –19–25APR01–2/2

1—Duct 8—Air Conditioner 14—Hose 21—Cap Screw (2 used)2—Air Conditioner Low 9—Cap Screw (6 used) 15—Hose Clamp (4 used) 22—Filter

Pressure Hose 10—Air Conditioner High 16—Nipple 23—Clip3—Cap Screw (4 used) Pressure Hose 17—Gasket 24—Clip4—Air Conditioning Controller 11—Cap Screw 18—Hose 25—Cap Screw (2 used)5—Duct 12—Bushing 19—Hose 26—Duct6—Duct 13—Hose 20—Duct 27—Cap Screw (2 used)7—Cap Screw (2 used)

Remove and Install Air Conditioner and Heater

1. Drain coolant from radiator. Approximate capacity is23.0 L (6.1 gal).

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


3. Remove air conditioner (8).


5. Install air conditioner.


18183015


PN=161


181830

16

OUOE003,00000E8 –19–19NOV01–1/1

Condenser Repair

T14

3116

B–U

N–2

0JU

L01

1—Cap Screw (2 used)2—Receiver-Dryer3—Condenser4—High Pressure Gas Input Line5—Cap Screw, Lock Washer, Washer6—High Pressure Liquid Output Line7—Cap Screw, Lock Washer, Washer8—Cap Screw (4 used)Lock Washer (4 used)Washer (4 used)

Remove and Install Condenser


2. Remove cap screws (1). Secure receiver-dryer (2) andbracket so it will not interfere with condenser removal.

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

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

5. Remove cap screws, lock washers, washers (8) andcondenser (3).

6. Repair or replace condenser as necessary.

7. Install condenser (3).

8. Tighten high pressure liquid output line (6) cap screw(7).

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

9. Tighten high pressure gas input line (4) cap screw (5).

Condenser—SpecificationInput Line Cap Screw—Torque 23 N•m (204 lb-in.)....................................



PN=162

Section 33Excavator

Contents

PagePage

Group 3302—Buckets Arm Cylinder Disassemble and Assemble—200CLC, 270CLC . . . . . . . . . . . . . . . . .33-3360-104Bucket

Arm Cylinder Disassemble andRepair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1Assemble—230CLC. . . . . . . . . . . . . . . .33-3360-118Adjust Pivot End Play . . . . . . . . . . . . . . . .33-3302-3

Bucket Cylinder Remove and Install . . . . .33-3360-124Pin-Up Data. . . . . . . . . . . . . . . . . . . . . . . .33-3302-4Bucket Cylinder Disassemble and

Assemble—200CLC, 270CLC . . . . . . . .33-3360-130Group 3340—FramesBucket Cylinder Disassemble andBucket Links . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-1

Assemble—230CLC. . . . . . . . . . . . . . . .33-3360-144Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-3Hydraulic Cylinder Bleed Procedure . . . . .33-3360-152Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-6

Inspect Boom, Arm, and Bucket Pins,Bushings and Bosses . . . . . . . . . . . . . . .33-3340-11

Bushings and Seals . . . . . . . . . . . . . . . . . .33-3340-14

Group 3360—Hydraulic SystemHydraulic Oil Tank Pressure Release

Procedure . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-1Hydraulic Oil Cleanup Procedure Using

Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-2Hydraulic Pump and Drive Gearbox

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3Start-Up Procedure . . . . . . . . . . . . . . . . .33-3360-20

Pilot Pump Drive Shaft and Gear . . . . . . . .33-3360-21Hydraulic Pump Regulator. . . . . . . . . . . . . .33-3360-22Pilot Pump . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-27Pilot Pressure Regulating Valve and Filter

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-30Pilot Shut-Off Valve. . . . . . . . . . . . . . . . . . .33-3360-31Power Boost, Propel Speed, Swing

Priority, and Arm Regenerative SolenoidValve . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-35

Pilot Controller . . . . . . . . . . . . . . . . . . . . . .33-3360-37Propel Pilot Controller . . . . . . . . . . . . . . . . .33-3360-40

33Pilot Signal Manifold . . . . . . . . . . . . . . . . . .33-3360-43Control Valve . . . . . . . . . . . . . . . . . . . . . . .33-3360-49Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . .33-3360-66Restriction Valve Repair . . . . . . . . . . . . . . .33-3360-69Oil Cooler Bypass Valve . . . . . . . . . . . . . . .33-3360-71Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-74Remove and Install Boom Cylinder . . . . . . .33-3360-75Boom Cylinder Disassemble and Assemble—

200CLC, 270CLC . . . . . . . . . . . . . . . . . .33-3360-80Boom Cylinder Disassemble and Assemble—

230CLC . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-94Arm Cylinder Remove and Install . . . . . . .33-3360-100


PN=1

Contents

33


PN=2

Group 3302Buckets

3333021

TX,33,GG2401 –19–19NOV01–1/3

Bucket Repair

5

4

53

81

2

3

7

3

6

4

32

1

T142450

T14

2450

–UN

–24J

UL0

1

1—Bushing (4 used) 3—O-Ring (4 used) 5—Pin (2 used) 7—Pin2—Dust Seal (2 used) 4—Ring (2 used) 6—Pin 8—Bucket

Remove and Install Bucket


Bucket—SpecificationBucket (200CLC)—Weight 670 kg (1480 lb) approximate...................Bucket (230CLC and270CLC)—Weight 953 kg (2100 lb) approximate.................................

1. Position bucket (8) on level surface.

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

3. Remove bucket.


5. Align pin bores in bucket with pin bores in arm linkto prevent damage to dust seals (2) when pins areinstalled.

6. Adjust bucket pivot end play. See Adjust BucketPivot End Play. (See procedure in this group.)

7. Adjust bucket to arm joint. See Adjusting Bucket toArm Joint. (Operator’s Manual.)



PN=165

Buckets

333302

2

TX,33,GG2401 –19–19NOV01–2/3

10

5

67

8

9

11

12

6

3

2

13

4

1

23

T142451

T14

2451

–UN

–24J

UL0

1


PN=166


Buckets

TX,33,GG2401 –19–19NOV01–3/3

1—Side Cutter (2 used) 4—Cap Screw (12 used) 7—Cap Screw (6 used) 10—Boss (2 used)2—Nut (12 used) 5—Boss (2 used) 8—Washer (6 used) 11—Stopper (2 used)3—Washer (12 used) 6—Shims (as required) 9—Plate (2 used) 12—Boss (2 used)

3333023

TX,33,GG2403 –19–19NOV01–1/1

Adjust Bucket Pivot End Play

T95

775

–UN

–10N

OV

88T

6879

DU

–UN

–06D

EC

88T

9578

8–U

N–1

0NO

V88

A—BucketB—BushingC—PinD—ClearanceE—Shim (As Required)F—Plate

1. Slide O-ring up on boss of bucket.

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

Adjust clearance as close to specification.

Bucket—SpecificationBucket Pivot Bushing-to-Arm—Clearance As close to but not less than 0.5

mm (0.020 in.)...............................................

NOTE: Alternate buckets may have different adjustmentprocedures.

3. Remove plate (F).

4. Remove shims (E) as needed to allow bushing tomove in to adjust clearance and take up excessiveplay.

5. Install plate. Tighten cap screws.

Bucket—SpecificationBucket Pivot Shim-to-Plate CapScrew—Torque 88 N•m (65 lb-ft)................................................................

6. Slide O-ring back into position.


PN=167

Buckets

333302

4

TX,33,GG2405 –19–19NOV01–1/1

Bucket Pin-Up Data

T14

2485

–19–

19N

OV

01


PN=168

Group 3340Frames

3333401

TX,33,GG2406 –19–19NOV01–1/2

Bucket Links Repair

1

23

4

5

1

2

6

78

9

10

11

5

43

12

T142977

T14

2977

–UN

–24J

UL0

1

1—Nut (4 used) 4—Dust Seal (2 used) 7—Cylinder Pin 10—Right Side Link2—Cap Screw (2 used) 5—Bushing (2 used) 8—Wooden Block 11—Left Side Link3—Thrust Plate (2 used) 6—Thrust Plate (4 used) 9—Center Link 12—Pin

Remove and Install Bucket Links

NOTE: Removal of bucket is not necessary forremoval of just bucket links.

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

arm to hold cylinder up when cylinder pin (7) isremoved.


As cylinder pin (7) is removed, lower links (10 and11) to ground.



PN=169

Frames

333340

2

TX,33,GG2406 –19–19NOV01–2/2

33

1

2

2

1

3

4

11

4

1

T14

2978

–UN

–19N

OV

01

200CLC and 230CLC

1

2

5

1 6

3

3

1 5

1

6

1

5

12

7

T14

7422

–UN

–19N

OV

01

270CLC

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


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

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


PN=170

Frames

TX,33,GG2407 –19–19NOV01–1/3

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 onground.



5. Loosen bucket cylinder hydraulic lines to release anyresidual pressure.

Remove bucket cylinder and linkage only if necessaryto repair arm. See Bucket Cylinder Remove and Install.(Group 3360.)


7. Remove bucket links and bucket cylinder. See BucketLinks Repair. (See procedure in this group.) SeeBucket Cylinder Remove and Install. (Group 3360.)

3333403



PN=171

Frames

TX,33,GG2407 –19–19NOV01–2/3

T66

26JC

–UN

–31O

CT

88

Arm With Bucket Cylinder


Arm—SpecificationStandard Arm (200CLC)—Weight 593 kg (1310 lb) approximate...............Bucket Cylinder (200CLC)—Weight 145 kg (320 lb) approximate............................................................

Arm—SpecificationLong Arm (230CLC)—Weight 878 kg (1936 lb) approximate.....................Standard Arm (230CLC)—Weight 685 kg (1510 lb) approximate...............Short Arm (230CLC)—Weight 182 kg (400 lb) approximate.......................Bucket Cylinder (230CLC)—Weight 182 kg (400 lb) approximate............................................................

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

8. Attach hoist to arm.

333340

4



PN=172

Frames

TX,33,GG2407 –19–19NOV01–3/3

4

5

6

4

1

3

2

T14

2652

–UN

–27S

EP

01

710

11

12

13 12

89

T14

2653

–UN

–24J

UL0

1

3333405

1—Nut (2 used)2—Stopper3—Cap Screw4—Thrust Plate (2 used)5—Thrust Plate6—Cylinder Pin7—Cap Screw8—Washer9—Plate10—Block11—Pin12—Thrust Plate (2 used)13—Thrust Plate

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

10. Remove parts (1-13).

11. Remove arm and lower to floor.

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

13. Repair or replace parts as necessary. See Bushingsand Seals Repair. (See procedure in this group.)

14. Install thrust plates (4 and 12) equally on each side ofarm to get minimal amount of clearance betweenboom and arm.

15. Connect lines. See Main Hydraulic SystemComponent Location. (Group 9025-15.)

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


PN=173

Frames

TX,33,GG2408 –19–19NOV01–1/7

Boom Repair

Remove and Install Boom

1. Remove bucket and arm. See Bucket Repair and ArmRepair. (See procedures in this group, and group3302.)

2. Lower boom to ground.



333340

6

TX,33,GG2408 –19–19NOV01–2/7

X98

11–U

N–2

3AU

G88

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

4. Loosen hydraulic lines at frame end of boom to releaseany residual pressure.


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.)



PN=174

Frames

TX,33,GG2408 –19–19NOV01–3/7

T10

5828

–UN

–30D

EC

96

F—Boom Cylinder (2 used)


Boom—SpecificationBoom Cylinder (200CLC)—Weight 171 kg (377 lb) approximate............................................................



9. Attach hoist to boom cylinder (F) using lifting strap.

TX,33,GG2408 –19–19NOV01–4/7

T14

2979

–UN

–24J

UL0

1

3333407

1—Nut (4 used)2—Retainer (2 used)3—Cap Screw (2 used)4—Boom Cylinder Rod End-to-Boom Pin5—Thrust Plate (4 used)6—Boom Cylinder (2 used)

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.Repeatprocedure for second boom cylinder.



PN=175

Frames

TX,33,GG2408 –19–19NOV01–5/7

T66

26JW

–UN

–31O

CT

88

CAUTION: Heavy components; use a hoist.

Boom—SpecificationBoom (200CLC)—Weight 1230 kg (2712 lb) approximate..........................Arm Cylinder (200CLC)—Weight 259 kg (571 lb) approximate..................



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

Arm end of boom is heavy end with arm cylinderinstalled. Frame end is heavy end when arm cylinderis removed.

333340

8



PN=176

Frames

3333409

TX,33,GG2408 –19–19NOV01–6/7

T14

3018

–UN

–24J

UL0

1

1—Cap Screw2—Spacer3—Block4—Boom-to-Frame Pin5—Washer (As Required)6—Washer7—Bracket

14. Remove parts (1—3 and 6).

15. Insert bar between plate of boom-to-frame pin (4) andbracket (6). Pull plate out.

16. Remove boom-to-frame pin. Remove washers (5).

17. Remove boom.

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

19. Repair or replace parts as necessary. See Bushingsand Seals Repair. (See procedure in this group.)

20. Install washers (5) equally on each side of boom toget minimal amount of clearance between boom andframe.

21. Install boom. Tighten boom-to-frame cap screws.

Boom—SpecificationBoom-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 getminimum amount of clearance between boom andcylinder rod end.

23. Tighten nuts (1) against each other allowing capscrew (3) to be free to turn in hole.

Boom—SpecificationBoom Cylinder Rod End-to-BoomPin Retainer Nut—Torque 550 N•m (405 lb-ft) (tighten nut

against nut)........................


25. Connect wiring harness. See System FunctionalSchematic, Component Location, and Wiring DiagramMaster Legend. (Group 9015-10).

26. Connect lubrication lines at rod end of cylinders.


PN=177


Frames

TX,33,GG2408 –19–19NOV01–7/7

27. Apply multi-purpose grease to all pivot joints. SeeTrack Adjuster, Working Tool Pivot, Swing Bearing,and Swing Bearing Gear Grease. (Operator’sManual.)

333340

10


PN=178

Frames

33334011

CED,TX08227,3206 –19–19NOV01–1/4

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

T77

79A

C–U

N–1

1JU

N92

A—Boom Cylinder Head D—Boom-to-Arm Joint G—Bucket Cylinder Head I—Side Links-to-Arm JointEnd-to-Frame Joint E—Arm Cylinder Head End-to-Arm Joint J—Center Link-to-Bucket Joint

B—Boom Cylinder Rod End-to-Boom Joint H—Bucket Cylinder Rod K—Bucket-to-Arm JointEnd-to-Boom Joint F—Arm Cylinder Rod End-to-Side and Center

C—Boom-to-Frame Joint End-to-Arm Joint Links Joint

Boom (200CLC)—SpecificationBoom Cylinder HeadEnd-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 HeadEnd-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 HeadEnd-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 RodEnd-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 RodEnd-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 RodEnd-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)—SpecificationArm Cylinder HeadEnd-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 HeadEnd-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 HeadEnd-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-ArmJoint 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-ArmJoint 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-ArmJoint Boss (200CLC)—ID 80.0 mm (3.15 in.) nominal.........................ID 81.5 mm (3.21 in.) limit of use.........................................................

Bucket (200CLC)—SpecificationBucket Cylinder HeadEnd-to-Arm Joint Pin(200CLC)—OD 71.0 mm (2.80 in.) nominal.........................................OD 70.0 mm (2.76 in.) limit of use........................................................


PN=179


Frames

333340

12

CED,TX08227,3206 –19–19NOV01–2/4

Bucket Cylinder HeadEnd-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 HeadEnd-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 RodEnd-to-Side and Center LinksJoint Pin (200CLC)—OD 80.0 mm (3.15 in.) nominal..........................OD 79.0 mm (3.11 in.) limit of use........................................................Bucket Cylinder RodEnd-to-Side and Center LinksJoint 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 JointBushing (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 JointBushing (200CLC)—ID 80.0 mm (3.15 in.) nominal.............................ID 81.5 mm (3.21 in.) limit of use.........................................................Bucket-to-Arm Joint Pin(200CLC)—OD 80.0 mm (3.15 in.) nominal.........................................OD 79.0 mm (3.11 in.) limit of use........................................................Bucket-to-Arm Joint Bushing(200CLC)—ID 80.0 mm (3.15 in.) nominal...........................................ID 81.5 mm (3.21 in.) limit of use.........................................................

Boom (230CLC)—SpecificationBoom Cylinder HeadEnd-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 HeadEnd-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 HeadEnd-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 RodEnd-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 RodEnd-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 RodEnd-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)—SpecificationArm Cylinder HeadEnd-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 HeadEnd-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 HeadEnd-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-ArmJoint 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-ArmJoint 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-ArmJoint Boss (230CLC)—ID 90.0 mm (3.54 in.) nominal.........................ID 91.5 mm (3.60 in.) limit of use.........................................................

Bucket (230CLC)—SpecificationBucket Cylinder HeadEnd-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 HeadEnd-to-Arm Joint Bushing(230CLC)—ID 80.0 mm (3.15 in.) nominal...........................................ID 81.5 mm (3.21 in.) limit of use.........................................................


PN=180


Frames

33334013

CED,TX08227,3206 –19–19NOV01–3/4

Bucket Cylinder HeadEnd-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 RodEnd-to-Side and Center LinksJoint Pin (230CLC)—OD 90.0 mm (3.54 in.) nominal..........................OD 89.0 mm (3.50 in.) limit of use........................................................Bucket Cylinder RodEnd-to-Side and Center LinksJoint 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 JointBushing—ID 80.0 mm (3.15 in.) nominal..............................................ID 81.5 mm (3.21 in.) limit of use.........................................................Center Link-to-Bucket JointPin—OD 90.0 mm (3.54 in.) nominal....................................................OD 89.0 mm (3.50 in.) limit of use........................................................Center Link-to-Bucket JointBushing—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)—SpecificationBoom Cylinder HeadEnd-to-Frame Joint Pin—OD 100.0 mm (3.94 in.) nominal..................OD 99.0 mm (3.90 in.) limit of use........................................................Boom Cylinder HeadEnd-to-Frame Joint Bushing—ID 100.0 mm (3.94 in.) nominal............................................................ID 101.5 mm (4.0 in.) limit of use.........................................................Boom Cylinder HeadEnd-to-Frame Joint Boss—ID 100.0 mm (3.94 in.) nominal.................ID 101.5 mm (4.0 in.) limit of use.........................................................Boom Cylinder RodEnd-to-Boom Joint Pin—OD 100.0 mm (3.94 in.) nominal...................OD 99.0 mm (3.90 in.) limit of use........................................................Boom Cylinder RodEnd-to-Boom Joint Bushing—ID 100.0 mm (3.94 in.) nominal.............ID 101.5 mm (4.0 in.) limit of use.........................................................Boom Cylinder RodEnd-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 JointBushing—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)—SpecificationArm Cylinder HeadEnd-to-Boom Joint Pin—OD 90.0 mm (3.54 in.) nominal.....................OD 89.0 mm (3.50 in.) limit of use........................................................Arm Cylinder HeadEnd-to-Boom Joint Bushing—ID 90.0 mm (3.54 in.) nominal...............ID 91.5 mm (3.60 in.) limit of use.........................................................Arm Cylinder HeadEnd-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-ArmJoint Pin—OD 90.0 mm (3.54 in.) nominal...........................................OD 99.0 mm (3.90 in.) limit of use........................................................Arm Cylinder Rod End-to-ArmJoint Bushing—ID 90.0 mm (3.54 in.) nominal.....................................ID 91.5 mm (3.60 in.) limit of use.........................................................Arm Cylinder Rod End-to-ArmJoint Boss—ID 90.0 mm (3.54 in.) nominal..........................................ID 91.5 mm (3.60 in.) limit of use.........................................................

Bucket (270CLC)—SpecificationBucket Cylinder HeadEnd-to-Arm Joint Pin—OD 80.0 mm (3.15 in.) nominal.......................OD 79.0 mm (3.11 in.) limit of use........................................................Bucket Cylinder HeadEnd-to-Arm Joint Bushing—ID 80.0 mm (3.15 in.) nominal.................ID 81.5 mm (3.21 in.) limit of use.........................................................Bucket Cylinder HeadEnd-to-Arm Joint Boss—ID 80.0 mm (3.15 in.) nominal......................ID 81.5 mm (3.21 in.) limit of use.........................................................Bucket Cylinder RodEnd-to-Side and Center LinksJoint Pin—OD 90.0 mm (3.54 in.) nominal...........................................OD 89.0 mm (3.50 in.) limit of use........................................................Bucket Cylinder RodEnd-to-Side and Center LinksJoint 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 JointBushing—ID 80.0 mm (3.15 in.) nominal..............................................ID 81.5 mm (3.21 in.) limit of use.........................................................


PN=181


Frames

CED,TX08227,3206 –19–19NOV01–4/4

Center Link-to-Bucket JointPin—OD 90.0 mm (3.54 in.) nominal....................................................OD 89.0 mm (3.50 in.) limit of use........................................................Center Link-to-Bucket JointBushing—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.........................................................

333340

14

CED,OUOE023,2178 –19–19NOV01–1/1

Bushings and Seals Repair

T95

237

–UN

–01N

OV

88T

6641

CW

–UN

–31O

CT

88A—Hydraulic RamB1—Pipe—Minimum ID to Clear Bushing ODB2—Pipe—Maximum ODB3—Pipe—Length of BushingC—BushingD—DisksE—Bushing Stop (Disk)F—Pilot (Disk)G—Ram Stop (Disk)H—Thickness of Dust Seal

Remove and Install Bushings and Seals

IMPORTANT: Only install bushings using press asshown. Bushings will be damaged ifinstalled with driver.

NOTE: Bushing can also be removed by welding three tofive weld beads on the inside of bushing. Bushingwill shrink enough to permit removal using ahammer.

1. Remove bushings (C) and dust seals using bushing,bearing, and seal driver set.

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

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

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


PN=182


OUOE054,000000F –19–07OCT02–1/1

Hydraulic Oil Tank Pressure ReleaseProcedure

T13

5189

–UN

–06N

OV

00

3333601

1—Cap2—Aligning Marks3—Case Assembly4—4 mm Hex Key Wrench5—Hole

CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by SLOWLYloosening cap (1).

1. Insert 4 mm hex wrench (4) into hole (5) and turncounterclockwise to release locking pin.

2. Slowly turn cap (1) counterclockwise a few degrees torelieve pressure.

3. Remove cap.


PN=183

Hydraulic System

333360

2

OUOE027,000001D –19–19NOV01–1/2

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

SPECIFICATIONS

Hydraulic Oil Tank (200CLC)

Hydraulic Oil Tank Capacity 130 L (34 gal) approximate

Hydraulic Oil Tank Filtering 11 minutes approximateTime

Hydraulic System Capacity 200 L (52.4 gal) approximate

Hydraulic System Filtering Time 17 minutes approximate

Hydraulic Oil Tank (230CLC and 270CLC)

Hydraulic Oil Tank Capacity 148 L (39 gal) approximate

Hydraulic Oil Tank Filtering 13 minutes approximateTime

Hydraulic System Capacity 250 L (66 gal) approximate

Hydraulic System Filtering Time 22 minutes approximate

SERVICE EQUIPMENT AND TOOLS

Portable Filter Caddy

3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2used)

Quick Disconnect Fittings

Suction Wand

Discharge Wand

1. Install new return filter elements.

NOTE: For a failure that creates a lot of debris,remove access cover from hydraulic tank.Drain hydraulic tank. Connect filter caddysuction line to drain port. Add a minimum of 19L (5 gal) of oil to reservoir. Operate filter caddyand wash out the hydraulic tank.

IMPORTANT: The minimum ID for a connector is13 mm (1/2 in.) to prevent cavitationof filter caddy pump.

2. Put filter caddy suction and discharge wands intohydraulic tank filler hole so ends are as far apart aspossible to obtain a thorough cleaning of oil.

3. Start the filter caddy. Check to be sure oil is flowingthrough the filters.

Operate filter caddy until all the oil in hydraulic tankhas been circulated through the filter a minimum of

four times.

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

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

NOTE: Filtering time for hydraulic tank is 0.089 minutex number of liters (0.33 minutes x number ofgallons).

4. Leave filter caddy operating for the next step.

5. Start the engine and run it at fast idle.

IMPORTANT: For the most effective results,cleaning procedure must start withthe smallest capacity circuit thenproceed to the next larger capacitycircuit.

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

Repeat procedure until the total system capacityhas circulated through filter caddy seven times.Each function must go through a minimum of threecomplete cycles for a thorough cleaning of oil.

Hydraulic Oil Tank (200CLC)—SpecificationHydraulic System—Capacity 200 L (52.4 gal) approximate................Filtering Time 17 minutes approximate.................................................

Hydraulic Oil Tank (230CLC and 270CLC)—SpecificationHydraulic System—Capacity 250 L (66 gal) approximate...................Filtering Time 22 minutes approximate.................................................

NOTE: Filtering time for complete hydraulic system is0.158 minute x number of liters (0.6 minute xnumber of gallons). Filtering time for machineswith auxiliary hydraulic functions must beincreased because system capacity is larger.

7. Stop the engine. Remove the filter caddy.

8. Install new return filter elements.


PN=184


Hydraulic System

OUOE027,000001D –19–19NOV01–2/2

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

3333603

OUOE027,0000017 –19–19NOV01–1/21

Hydraulic Pump and Drive Gearbox Repair

Remove and Install Hydraulic Pump and DriveGearbox


1. Do Hydraulic Oil Tank Vent Procedure. (See procedurein this group.)

2. Drain hydraulic oil tank. Approximate capacity is 130 L(34 gal) for 200CLC and 148 L (39 gal) for 230CLCand 270CLC.

3. Drain pump drive gearbox. Approximate oil capacity is1.0 L (1.1 qt).

4. Remove hood, hood support and covers.

5. Remove muffler and muffler bracket.




Hydraulic Pump and Drive Gearbox—SpecificationHydraulic Pump and DriveGearbox—Weight 168 kg (370 lb) approximate..........................................

8. Install lifting eyebolts to pump. Connect a hoist toeyebolts using lifting straps.



PN=185

Hydraulic System

333360

4

OUOE027,0000017 –19–19NOV01–2/21

T14

2503

–UN

–20J

UL0

1


9. Remove cap screws (1) and remove pump.


IMPORTANT: Align dampener drive on drive gearboxwith mating part on engine flywheel.


Hydraulic Pump and Drive Gearbox—SpecificationPump Drive Gearbox-to-FlywheelHousing Cap Screw—Torque 49 N•m (36 lb-ft)..........................................

12. Connect electrical connectors. See System FunctionalSchematic, Component Location, and Wiring DiagramMaster Legend. (Group 9015.)


14. Install split flange and tighten cap screws.

Hydraulic Pump and Drive Gearbox—SpecificationSplit 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 plugthreads.

IMPORTANT: Hydraulic pump and drive gearbox willbe damaged if not filled with oil beforestarting engine. Start-up proceduremust be performed whenever a newpump or gearbox is installed or oil hasbeen drained from the pump, gearboxor hydraulic oil tank.

16. Fill pump housing and pump drive gearbox with oil.See Hydraulic Pump and Drive Gearbox Start-UpProcedure. (See procedure in this group.)

17. Check pump regulator adjustments. (Group 9025-25.)

For minimum flow:


PN=186


Hydraulic System

OUOE027,0000017 –19–19NOV01–3/21

• See Hydraulic Pump Regulator Test andAdjustment—Minimum Flow—200CLC. (Group9025-25.)



For maximum flow:

• See Hydraulic Pump Regulator Test andAdjustment—Maximum Flow—200CLC. (Group9025-25.)



Disassemble and Assemble Hydraulic Pump and DriveGearbox

3333605



PN=187

Hydraulic System

333360

6

OUOE027,0000017 –19–19NOV01–4/21

7 8 9

10

11

6

12

5

13

4

13

14

1516

1718

19 2021

22 23

24

2322

2125

1826

1716

15

2728

2930

2827

3132

1

23

33

37

3635

3456

5554

57

58

44

35

3840

41

42

5153 52

5150

49

48

4746

45

39

43

32

20

T142373

T14

2373

–UN

–20J

UL0

1


PN=188


Hydraulic System

OUOE027,0000017 –19–19NOV01–5/21

1—Pump Housing 15—Bearing Nut (2 used) 28—Plug (2 used) 43—Drain Plug2—Lock Washer (6 used) 16—Roller Bearing (2 used) 29—O-Ring 44—O-Ring3—Cap Screw (6 used) 17—Ring (2 used) 30—Special Fitting 45—Cap Screw (2 used)4—Spring Pin (4 used) 18—Roller Bearing (2 used) 31—Spring Pin (2 used) 46—Lock Washer (2 used)5—O-Ring (10 used) 19—Pump 1 (Front) Drive 32—Oil Seal (2 used) 47—Washer (2 used)6—O-Ring (2 used) Shaft 33—Snap Ring (2 used) 48—Pilot Pump7—Cap Screw (4 used) 20—Pin (2 used) 34—Fill Plug 49—Snap Ring8—Right Regulator Pump 1 21—Center Shaft (2 used) 35—Snap Ring (2 used) 50—Snap Ring

(Front) 22—Spring (2 used) 36—Pump 1 (Front) Driven 51—Ball Bearing9—Cap Screw (2 used) 23—Piston (14 used) Gear 52—Pilot Pump Drive Gear10—Cap Screw (2 used) 24—Cylinder Block (Rotor) 37—Gasket 53—Pilot Pump Drive Shaft11—Cap Screw (2 used) (2 used) 38—Cap Screw (2 used) 54—Snap Ring12—Left Regulator Pump 2 25—Pump 2 (Rear) Drive Shaft 39—Pump 2 (Rear) Drive Gear 55—Oil Seal

(Rear) 26—Spacer Ring (Pump 2 40—Dipstick 56—Pump Drive Gearbox13—O-Ring (4 used) [Rear] Drive Shaft only) 41—Dipstick Tube 57—Set Screw (2 used)14—O-Ring (6 used) 27—O-Ring (2 used) 42—Gasket 58—Dampener Drive Coupling


3333607


PN=189

Hydraulic System

333360

8

OUOE027,0000017 –19–19NOV01–6/21

82

82

59

60

61

60

6660

81

80

79

77

78

76

69

67

68

70

71

72

73

74

71

75

6263

6563

6260

6263

6463

62

60

66

59

6061

60

T142375

T14

2375

–UN

–20J

UL0

1

59—Dowel Pin 65—Pump 2 (Rear) Valve Plate 71—O-Ring (4 used) 77—Servo Piston (2 used)60—Snap Ring (12 used) 66—Dowel Pin (4 used) 72—Cap Screw (8 used) 78—Pin (2 used)61—Dowel Pin (2 used) 67—Backup Ring 73—Cover (2 used) 79—O-Ring (2 used)62—Lever (4 used) 68—O-Ring 74—O-Ring (2 used) 80—Stop (2 used)63—Dowel Pin (4 used) 69—Spring Pin (2 used) 75—Cap Screw (12 used) 81—Cap Screw (8 used)64—Pump 1 (Front) Valve 70—Cylinder Head (Cover) 76—Set Screw (2 used) 82—Feedback Link (2 used)

Plate


PN=190


Hydraulic System

OUOE027,0000017 –19–19NOV01–7/21


Hydraulic Pump and Drive Gearbox—SpecificationHydraulic Pump and DriveGearbox—Weight 168 kg (370 lb) approximate...................................

1. Loosen set screws (57) and remove dampenerdrive coupling (58).

2. Remove pilot pump (48).

3. Remove cap screws (3) and lock washers (2) toremove pump housing (1) from pump drive gearbox(56).


3333609


PN=191

Hydraulic System

333360

10

OUOE027,0000017 –19–19NOV01–8/21

T10

5624

–UN

–11D

EC

96

A—Pump 1 (Front) Drive Shaft-to-Driven GearTiming Mark

B—Driven Gear-to-Drive Gear Timing MarkC—Pump 2 (Rear) Drive Shaft-to-Drive Gear

Timing MarkD—Snap Ring (2 usedE—Drive GearF—Driven Gear

4. To aid in reassembly, make timing marks on driveshafts (A and C), and mark (B) on drive (E) and driven(F) gears. The gears are not interchangeable.

Measure amount of backlash between gears.

Hydraulic Pump and Drive Gearbox—SpecificationPump 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. SeeHydraulic Pump Regulator Repair. (See procedure inthis group.)


Hydraulic Pump and Drive Gearbox—SpecificationCylinder Head—Weight 30 kg (66 lb) approximate.....................................

IMPORTANT: The valve plates (64 and 65) areconnected to the feedback linkage andmust remain on the cylinder blocks (24).The valve plates and end of cylinderblocks are made with highly machinedsurfaces and can be damaged.

6. Remove cap screws (75) and carefully remove cylinderhead (70).

7. Remove servo pistons (77) only if replacement isnecessary.

Heat set screw (76) to loosen thread lock and sealer(medium strength) used. Remove set screw using a 6mm hex key wrench. Remove pin (78).



PN=192

Hydraulic System

OUOE027,0000017 –19–19NOV01–9/21

IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)(65) valve plates are notinterchangeable. Take notice of thelocation and position of ports in plate.The inlet port in valve plate is locatedtowards the center and top of pumphousing.

8. Remove pump 1 (front) (64) and pump 2 (rear) (65)valve plates. Protect machined surfaces of plates fromdamage.

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 SpannerWrench.

12. Remove roller bearings (16 and 18) from pump 1(front) (19) and pump 2 (rear) (25) drive shafts usinga knife edge puller and a press.

33336011

OUOE027,0000017 –19–19NOV01–10/21

T10

5725

–UN

–09J

AN

97

A—Oil Seal Contact SurfaceB—Oil Seal Contact SurfaceC—Pump 2 (Rear) Drive ShaftD—Oil Seal Contact SurfaceE—Pump 1 (Front) Drive Shaft

13. Measure diameter of oil seal contact surfaces (A, B,and D) on pump 1 (front) (E) and pump 2 (rear) (C)drive shafts.

Hydraulic Pump and Drive Gearbox—SpecificationPump 2 (Rear) Drive Shaft OilSeal Contact Surface (A)—OD 45 mm (1.77 in.) nominal..........................

44.8 mm (1.76 in.) limit of usePump 2 (Rear) Drive Shaft OilSeal Contact Surface (B)—OD 55 mm (2.17 in.) nominal..........................

54.8 mm (2.16 in.) limit of usePump 1 (Front) Drive Shaft OilSeal Contact Surface—OD 55 mm (2.17 in.) nominal................................



PN=193


Hydraulic System

OUOE027,0000017 –19–19NOV01–11/21

T10

5726

–UN

–09J

AN

97

F—Piston Connecting RodG—Rear Drive ShaftH—Play

14. Measure play (H) between piston connecting rod (F)and socket in front and rear drive shafts (G).

Hydraulic Pump and Drive Gearbox—SpecificationPiston-to-Drive Shaft Socket—Play 0.058 mm (0.0023 in.) nominal............................................................


333360

12

OUOE027,0000017 –19–19NOV01–12/21

T65

57E

M–U

N–1

8OC

T88

T65

57E

N–U

N–1

8OC

T88

15. Measure ID of cylinder block piston bore. MeasureOD of piston. Subtract the OD from the ID forclearance.

Hydraulic Pump and Drive Gearbox—SpecificationCylinder Block Bore-to-Piston—Clearance 0.043 mm (0.0017 in.) nominal..................................................




PN=194

Hydraulic System

OUOE027,0000017 –19–19NOV01–13/21

T65

57E

K–U

N–1

8OC

T88

16. Clamp the connecting rod end of a piston in a visewith soft-jaw faces. Measure play between connectingrod and piston.

Hydraulic Pump and Drive Gearbox—SpecificationPiston-to-Connecting Rod—Play 0.150 mm (0.0059 in.) nominal...............


OUOE027,0000017 –19–19NOV01–14/21

T10

5727

–UN

–19D

EC

96

33336013

A—Cylinder HeadB—IDC—ODD—Servo Piston

17. Measure OD (C) of small and large end of servopiston (D). Measure ID (B) of small and large end ofbore in cylinder head (A). Subtract the OD from theID for clearances.

Hydraulic Pump and Drive Gearbox—SpecificationServo Piston-to-Cylinder HeadBore—Clearance 0.079 mm (0.0033 in.) nominal.......................................




PN=195

Hydraulic System

OUOE027,0000017 –19–19NOV01–15/21

T10

5729

–UN

–09J

AN

97

A—Valve PlateB—Piston PinC—ODD—ID

18. Measure OD (C) of servo piston pin (B). Measure ID(D) of bore in valve plate (A). Subtract the OD fromthe ID for the clearance.

Hydraulic Pump and Drive Gearbox—SpecificationServo Piston Pin-to-Valve PlateBore—Clearance 0.051 mm (0.0020 in.) nominal.......................................



333360

14


PN=196

Hydraulic System

OUOE027,0000017 –19–19NOV01–16/21

T10

5658

–UN

–12D

EC

96T

1056

60–U

N–1

2DE

C96

33336015

3—Pump 2 (Rear) Drive Shaft4—Pump 1 (Front) Drive Shaft6—Roller Bearing7—Spacer Ring8—Roller Bearing9—Bearing Nut

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 orheating element to come in direct contact withthe oil. Heat the oil in a well-ventilated area.Plan a safe handling procedure to avoid burns.

19. Heat roller bearings (6 and 8).

Hydraulic Pump and Drive Gearbox—SpecificationRoller Bearing Heat—Temperature 50—80°C (122—176°F).........................................................

20. Apply oil to bearing. Push roller bearing (6) on driveshaft so inner race is tight against shoulder.

21. Install spacer ring (7) and roller bearing (8).

22. Apply oil to threads of bearing nut (9).

23. Tighten bearing nut using JDG769 Spanner Wrench.

Hydraulic Pump and Drive Gearbox—SpecificationPump Drive Shaft Bearing Nut—Rolling Drag Torque 2.16 ± 0.49 N•m (19 ± 4 lb-in.)..................................

OUOE027,0000017 –19–19NOV01–17/21

T10

5628

–UN

–11D

EC

96

10—Spacer Ring

24. Install spacer ring (10) into housing bore for pump 2(rear) drive shaft.


PN=197


Hydraulic System

OUOE027,0000017 –19–19NOV01–18/21

T10

5626

–UN

–11D

EC

96

3—Drive Shaft4—Drive Shaft15—Special Fitting (2 used)

25. To help installation of drive shafts (3 and 4), heatpump housing using a heat gun such as the JT07010Two Temperature Heat Gun.

Hydraulic Pump and Drive Gearbox—SpecificationPump Housing Heat—Temperature 50—80°C (122—176°F).........................................................

26. Apply a film of oil to outer race of bearings. Install thedrive shafts.

27. Install and tighten special fittings (15).

Hydraulic Pump and Drive Gearbox—SpecificationSpecial Plug-to-Pump HousingSpecial Fitting—Torque 34 N•m (300 lb-in.)................................................

28. Apply multi-purpose grease to lips of oil seals. Installoil seals with lip (spring side) toward inside ofhousing. Install snap rings.

333360

16



PN=198

Hydraulic System

33336017

OUOE027,0000017 –19–19NOV01–19/21

T10

5624

–UN

–11D

EC

96T

8323

AQ

–UN

–04O

CT

94

A—Pump 1 (Front) Drive Shaft-to-Driven GearTiming Mark

B—Driven Gear-to-Drive Gear Timing MarkC—Pump 2 (Rear) Drive Shaft-to-Drive Gear

Timing MarkD—Snap Ring (2 used)E—Drive GearF—Driven GearG—JDG1054 Aligning Bar (Pump Timing Tool)H—Pump 2 (Rear) Drive ShaftI—SocketJ—SocketK—Pump 1 (Front) Drive ShaftL—Socket Alignment DowelM—Socket Alignment DowelN—M8-1.25 Cap Screw (2 used)

29. For original parts, install drive (E) and driven (F)gears on shafts so timing marks (A, B, and C) arealigned.

For new parts, install the JDG1054 Aligning Bar onthe socket (I and J) end of drive shafts.

Install aligning bar so end marked “Long Shaft Side”is to pump 2 (rear) drive shaft (H). Turn shafts sosocket alignment dowels (L and M) engage a socketin drive shafts. The socket for pump 1 (front) driveshaft is slightly below the centerline of socket forpump 2 (rear) drive shaft when shafts are timedcorrectly.

Install cap screws (N) to hold bar in position.

30. From the splined end of shafts, turn shafts to the leftto remove any play between socket alignment dowelsand sockets.

31. Install gear on pump 2 (rear) drive shaft. Install thesnap ring.

Install gear on pump 1 (front) drive shaft. Asnecessary, turn shaft slightly or turn gear to anotherposition so teeth on gears engage. Install snap ring.

32. Apply oil to center shaft (21), pistons (23) andcylinder blocks (24). Use petroleum jelly to hold pin(20) in hole in center shaft.

33. Install cylinder block so pin engages slot in cylinderblock.

34. Apply thread lock and sealer (medium strength) tothreads of dowel pins (63). Tighten dowel pins intopump 1 (front) (64) and pump 2 (rear) (65) valveplates.

Hydraulic Pump and Drive Gearbox—SpecificationDowel Pin-to-Pump 1 (Front) andPump 2 (Rear) Valve Plate—Torque 9.8 N•m (86 lb-in.)...........................................................................


PN=199


Hydraulic System

333360

18

OUOE027,0000017 –19–19NOV01–20/21

IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)(65) valve plates are notinterchangeable. The inlet port in valveplate is located toward the center andtop of pump housing.

35. Apply oil to valve plates.

Install valve plates so inlet port is toward the centerand top of pump housing.

Connect levers (62) for feedback linkage to valveplates.

36. Install servo pistons (77) and pins (78).

Apply thread lock and sealer (medium strength) tothreads of set screw (76).

Tighten set screw (76) using a 6 mm hex key wrench.

Hydraulic Pump and Drive Gearbox—SpecificationServo 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—SpecificationStop and Cover-to-Cylinder HeadCap Screw—Torque 19.5 N•m (180 lb-in.)..................................................

37. Install cylinder head (70) checking to be sure thatpins engage middle hole in valves plates.

Tighten cap screws (75).

Hydraulic Pump and Drive Gearbox—SpecificationCylinder Head-to-Pump HousingCap Screw—Torque 108 N•m (80 lb-ft)......................................................

38. Remove air bleed plugs from pump regulators (8 and12).

Install regulators making sure groove in remotecontrol sleeve and load sleeve engage dowel pin (61)in feedback link (82). Check through hole that groovein sleeves engage dowel pin.


PN=200


Hydraulic System

33336019

OUOE027,0000017 –19–19NOV01–21/21

Tighten cap screws.

Hydraulic Pump and Drive Gearbox—SpecificationRegulator-to-Pump Housing CapScrew—Torque 49 N•m (36 lb-ft)................................................................

39. Tighten pump pressure sensors.

Hydraulic Pump and Drive Gearbox—SpecificationPump Pressure Sensor-to-PumpHousing—Torque 98 N•m (72 lb-ft).............................................................


Hydraulic Pump and Drive Gearbox—SpecificationPump Housing-to-GearboxHousing Cap Screw—Torque 147 N•m (109 lb-ft)......................................

41. Apply rigid form-in-place gasket to mounting surfacefor pilot pump (48).

Tighten cap screws (45).

Hydraulic Pump and Drive Gearbox—SpecificationPilot Pump-to-Gearbox CapScrew—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 ofhousing.

43. Apply thread lock and sealer (medium strength) tothreads of set screws (57) in dampener drive coupling(58).

Tighten set screws. For assembly of dampener drive.See Dampener Drive (Flex Coupling) Repair. (Group0752.)

Hydraulic Pump and Drive Gearbox—SpecificationDampener 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. SeeHydraulic Pump and Drive Gearbox Start-UpProcedure. (See procedure in this group.)


PN=201

Hydraulic System

TX,25,GG2226 –19–19NOV01–1/2

Hydraulic Pump and Drive Gearbox Start-UpProcedure

T10

1875

–UN

–15J

UL9

6

C—Air Bleed Plug (2 used)

IMPORTANT: Hydraulic pump and drive gearbox willbe damaged if not filled with oil beforestarting engine. Procedure must beperformed whenever a new pump orgearbox is installed or oil has beendrained from the pump, gearbox orhydraulic oil tank.

Procedure is to ensure the pumps andgearbox are filled with oil and air is bledfrom suction side of pumps to preventcavitation.

1. Remove air bleed plugs (C) from the top of pumpregulators to allow housing to fill with oil from thehydraulic oil tank and to let air escape.

2. When pump housing is full of oil, install plugs.

3. As necessary, add oil to hydraulic oil tank until it isbetween marks on sight glass. See Hydraulic Oil.(Operator’s Manual). Tighten tank cap. Tighten ventplug.

4. Start engine and run at slow idle. Slowly raise boom tofull height and then lower to pressurize hydraulic oiltank.

5. Purge air from the hydraulic system by slowlyoperating each function through three cycles. Air inpilot circuits are purged automatically.

333360

20

TX,25,GG2226 –19–19NOV01–2/2

T10

1493

–UN

–15J

UL9

6A—DipstickB—Filler Pipe

6. Fill pump drive gearbox with oil through filler pipe (B)so level is above “H” mark on dipstick (A). See SwingGearbox, Propel Gearbox and Pump Gearbox Oils.(Operator’s Manual.)


PN=202

Hydraulic System

OUOE027,0000018 –19–19NOV01–1/1

Pilot Pump Drive Shaft and Gear Repair

T10

5640

–UN

–12D

EC

96T

1056

57–U

N–1

2DE

C96

T14

2290

–UN

–20J

UL0

1

33336021

1—Pump Drive Gearbox Case3—Pilot Pump Drive Gear4—Pilot Pump Drive Shaft5—Ball Bearing (2 used)6—Snap Ring7—Snap Ring

Disassemble and Assemble Pilot Pump Drive Shaftand Gear

1. Remove snap rings (6 and 7).

2. Remove pilot pump drive shaft (4) and upper ballbearing (5) using a blind-hole puller or an internalpuller. Ball bearings are a press fit on drive shaft andin housing.

3. Remove pilot pump drive gear (3) through opening forhydraulic pump.


PN=203

Hydraulic System

OUOE027,000001A –19–19NOV01–1/5

Hydraulic Pump Regulator Repair

Remove and Install Hydraulic Pump Regulator

NOTE: Pump 1 (front) and pump 2 (rear) regulators aresimilar in design. Removal of pump 2 (rear)regulator is shown.



2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See 200CLC Drainand Refill Capacities, 230CLC Drain and RefillCapacities, or 270CLC Drain and Refill Capacities.(Operator’s Manual.)



333360

22



PN=204

Hydraulic System

OUOE027,000001A –19–19NOV01–2/5

T14

2278

B–U

N–2

0JU

L01

1—Cap Screw (8 used)2—Hydraulic Pump Regulator (2 used)

5. Remove cap screws (1) and regulator (2).


7. Install regulators making sure groove in remote controlsleeve and load sleeve engage dowel pin in feedbacklink. Check through hole that groove in sleeves engagedowel pin.


Pump Regulator—SpecificationPump 1 (Front) and Pump 2(Rear) Regulator-to-PumpHousing Cap Screw—Torque 49 N•m (36 lb-ft)..........................................

9. Connect electrical connectors. See System FunctionalSchematic, Component Location, and Wiring DiagramMaster Legend. (Group 9015-10.)

10. Connect lines. See Pilot Signal Manifold-to-ControlValve Component Location. (Group 9025-15.)

IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Procedure must be performed whenevera new pump installed or oil has beendrained from the pump or hydraulic oiltank.

11. Fill pump housing with oil. See Hydraulic Pump andDrive Gearbox Start-Up Procedure. (See procedure inthis group.)

33336023



PN=205

Hydraulic System

333360

24

OUOE027,000001A –19–19NOV01–3/5

T14

2272

B–U

N–2

0JU

L01

Pump 2 (Rear) Regulator Shown

1—Cap Screw (4 used) 8—O-Ring (3 used) 15—Spring (2 used) 22—Piston2—Nut 9—Load Adjusting Screw 16—Remote Control Spool 23—Load Piston3—Nut (2 used) (Stop) 17—Remote Control Sleeve 24—Cylinder4—Minimum Flow Adjusting 10—Regulator Body 18—O-Ring 25—Load Sleeve

Screw 11—Cap Screw (4 used) 19—Backup Ring 26—Load Spool5—Cover 12—End Plate 20—O-Ring 27—Inner Spring6—Nut (2 used) 13—Flow Adjusting Cartridge 21—Cylinder7—Load Adjusting Cartridge 14—Maximum Flow Adjusting

Screw (Stop)

Disassemble and Assemble Hydraulic PumpRegulator

NOTE: Pump 1 (front) and pump 2 (rear) regulatorsare similar. Pump 2 (rear) regulator is shown,

IMPORTANT: Removal of adjusting screws (4, 9and 14) and cartridges (7 and 13)from end plate (12) and cover (5) willrequired the adjustment of pumpregulators. Only remove parts fromend plate and cover if replacement isnecessary.

1. Remove the end plate (12) and cover (5) with theadjusting screws and cartridges installed.


3. Tighten cap screws (1 and 11).

Pump Regulator—SpecificationPump 1 (Front) and Pump 2(Rear) End Plate andCover-to-Housing Cap Screw—Torque 19.8 N•m (180 lb-in.).................................................................


PN=206


Hydraulic System

33336025

OUOE027,000001A –19–19NOV01–4/5

T10

5706

–UN

–09J

AN

97

2—Load Sleeve 13—Load Adjusting Screw 24—Maximum Flow Adjusting 34—Nut3—Load Spool (Stop) Screw (Stop) 35—End Plate5—Cylinder 15—Spring 27—Remote Control Sleeve 36—Cover6—Load Piston 16—Nut (2 used) 28—Remote Control Spool 37—Cap Screw (8 used)12—Load Adjusting Cartridge 17—Nut (2 used) 29—Minimum Flow Adjusting 47—Outer Spring

(Stop) 20—Piston Screw 48—Inner Spring—Flow Adjusting Cartridge 21—Cylinder

(Stop)


5. Tighten air bleed plug.

Pump Regulator—SpecificationPump 1 (Front) and Pump 2(Rear) Air BleedPlug-to-Housing—Torque 78 N•m (58 lb-ft).........................................

IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before startingengine. Procedure must beperformed whenever a new pumpinstalled or oil has been drainedfrom the pump or hydraulic oil tank.

6. Fill pump housing with oil. See Hydraulic Pump andDrive Gearbox Start-Up Procedure. (See procedurein this group.)

7. Check pump regulator adjustments. (Group9025-25.)

For minimum flow:

• See Hydraulic Pump Regulator Test andAdjustments—Minimum Flow—200CLC. (Group9025-25.)

• See Hydraulic Pump Regulator Test andAdjustments—Minimum Flow—230CLC. (Group9025-25.)


For maximum flow:

• See Hydraulic Pump Regulator Test andAdjustments—Maximum Flow—200CLC. (Group9025-25.)

• See Hydraulic Pump Regulator Test andAdjustments—Maximum Flow—230CLC. (Group9025-25.)


PN=207


Hydraulic System

OUOE027,000001A –19–19NOV01–5/5


333360

26


PN=208

Hydraulic System

33336027

OUOE027,000001B –19–19NOV01–1/4

Pilot Pump Repair

T14

2279

B–U

N–2

0JU

L01

1—Adapter2—Cap Screw (2 used)3—Pilot Pump

Remove and Install Pilot Pump



2. Drain pump drive gearbox. Approximate oil capacity is1.0 L (1.1 qt).



5. Remove adapter (1).

6. Remove cap screws (2) and pilot pump (3).


8. Apply Rigid Form-In-Place Gasket to mounting surfacefor pilot pump.

9. Tighten cap screw (2).

Pilot Pump—SpecificationPump-to-Drive Gearbox CapScrew—Torque 49 N•m (36 lb-ft)................................................................

10. Install adapter (1) and O-ring.


12. Fill pump drive gearbox so level is above “H” mark ondipstick. See Change Pump Drive Gearbox Oil.(Operator’s Manual.)


PN=209


Hydraulic System

333360

28

OUOE027,000001B –19–19NOV01–2/4

TP

4790

1–U

N–1

3MA

Y96

0—Pilot Pump 5—Snap Ring 10—Key (2 used) 16—Cap Screw and Washer2—Flange 6—Seal (2 used) 12—O-Ring (2 used) (4 used)3—Oil Seal 9—Backup Retainer (2 used) 15—Washer (4 used)


PN=210


Hydraulic System

OUOE027,000001B –19–19NOV01–3/4

Disassemble and Assemble Pilot Pump

OUOE027,000001B –19–19NOV01–4/4T

7685

IX–U

N–1

3MA

Y92

A—Drive GearB—Keys (2 used)C—Driven GearD—Bushing

IMPORTANT: Be careful not to lose keys (B).

1. Check bushings (D). If inside diameter and surfacetoward gear are rough or worn, replace pump.

2. Check gears (A and C) and housing. If gear teeth,shaft, and inside of housing is rough or worn, replacepump.

IMPORTANT: Apply clean hydraulic oil to all parts.Pump failure can result if pump isassembled dry.

3. Apply clean hydraulic oil to all parts.

4. Apply multi-purpose grease to lip of oil seal. Install oilseal with lip (spring side) towards inside of housing.


Pilot Pump—SpecificationCover-to-Flange Cap Screw—Torque 41 N•m (31 lb-ft).............................................................................

6. Check pilot pressure setting. See Pilot PressureRegulating Valve Test and Adjustment. (Group9025-25.)

33336029


PN=211

Hydraulic System

OUOE027,000001F –19–19NOV01–1/3

Pilot Pressure Regulating Valve and FilterRepair

Remove and Install Pilot Pressure Regulating Valveand Filter




333360

30

OUOE027,000001F –19–19NOV01–2/3

T14

3074

B–U

N–2

0JU

L01

1—Cap Screw (2 used)2—Pilot Pressure Regulating Valve3—Pilot Filter

3. Remove cap screws (1) and remove pilot pressureregulating valve (2) and pilot filter (3).


5. Install cap screws (1).

Pilot Pressure Regulating Valve and Filter—SpecificationFilter Head-to-Support CapScrew—Torque 49 N•m (36 lb-ft)................................................................

6. Replace pilot filter (3) element.

Pilot Pressure Regulating Valve and Filter—SpecificationPilot Filter ElementHousing-to-Filter Head—Torque 25 N•m (220 lb-in.)..................................

7. Connect lines. See Main Hydraulic System ComponentLocation. (Group 9025-15.)

8. Check pilot pressure setting. See Pilot PressureRegulating Valve Test and Adjustment. (Group9025-25.)



PN=212

Hydraulic System

OUOE027,000001F –19–19NOV01–3/3

1

23

45

6

T14

3094

–UN

–20J

UL0

1

1—Pilot Pressure Regulating Valve Housing2—Poppet3—Shim (As required)4—Spring5—O-Ring6—Plug

Disassemble and Assemble Pilot Pressure RegulatingValve and Filter

1. Remove plug (6) with O-ring (5).


3. Inspect, clean and replace parts as necessary.

4. Check that poppet (2) slides smoothly in pilot pressureregulating valve housing (1).

5. Tighten plug (6).

Pilot Pressure Regulating Valve and Filter—SpecificationPlug-to-Housing—Torque 49 N•m (36 lb-ft)................................................

33336031

OUOE027,000001C –19–19NOV01–1/4

Pilot Shut-Off Valve Repair

Remove and Install Pilot Shut-Off Valve

1. Turn upperstructure 90° to tracks.




4. Disconnect spring.



PN=213

Hydraulic System

OUOE027,000001C –19–19NOV01–2/4

1

T14

2504

–UN

–20J

UL0

1

333360

32


5. Remove cap screws (1) and remove valve with leverattached.


7. Install valve. Tighten cap screws.

Pilot Shut-Off Valve—SpecificationValve Housing-to-Cab PlatformCap Screw—Torque 49 N•m (36 lb-ft)........................................................

8. Connect spring.

9. Connect lines. See Pilot Controllers-to-Pilot SignalManifold Component Location—Excavator Pattern.(Group 9025-15.)



PN=214

Hydraulic System

33336033

OUOE027,000001C –19–19NOV01–3/4

T14

3031

–UN

–17J

UL0

1

1—Washer 5—Lever Stop Cap Screw 8—Backup Ring 11—Bracket2—Backup Ring 6—Retaining Ring 9—O-Ring 12—Pin3—O-Ring 7—Washer 10—Spool 13—Cap Screw (3 used)4—Body

Disassemble and Assemble Pilot Shut-Off Valve

1. Remove spring pin and remove lever from valve.


PN=215


Hydraulic System

OUOE027,000001C –19–19NOV01–4/4

NOTE: Make alignment marks on body (4) andbracket (11) to aid in reassembly.

2. Remove parts (6—9) and remove spool (10) frombody (4).

3. Remove parts (1—3) from body.

4. Remove cap screws (13) and bracket (11) fromspool (10).

NOTE: Remove pin (12) and cap screw (5) only ifnecessary.

5. Inspect and replace parts as necessary.

6. If cap screw (5) has been removed, apply threadlock and sealer (medium strength) to threads andtighten.

Pilot Shut-Off Valve—SpecificationLever Stop Cap Screw—Torque 29.4 N•m (21.5 lb-ft)........................

7. Position bracket (11) on spool (10).

8. Apply thread lock and seal (medium strength) tothreads of cap screws (13) and tighten.

Pilot Shut-Off Valve —SpecificationBracket-to-Spool Cap Screw—Torque 3.9 N•m (2.9 lb-ft).....................................................................

9. Install parts (1—3) into body (4).

10. Apply hydraulic oil to spool (10) and install intobody (4).

11. Install parts (7—9) in body (4) and retaining ring(6) to spool (10).

12. Align marks on bracket (11) with body (4).

13. Install lever and spring pin to valve.

333360

34


PN=216

Hydraulic System

OUOE027,000001E –19–19NOV01–1/2

Power Boost, Propel Speed, Swing Priority,and Arm Regenerative Solenoid Valve Repair

T14

3099

B–U

N–2

0JU

L01

1—Cap Screw (8 used)2—Solenoid Valve Coil (4 used)

Remove and Install Power Boost, Propel Speed,Swing Priority, and Arm Regenerative Solenoid Valve



2. Disconnect electrical connector.

3. Remove cap screws (1) and remove solenoid valve coil(2). Be careful not to lose spring and O-ring.

4. Keep parts for each individual solenoid valve together.

5. Install solenoid valve coil (2) with O-ring (8) and spring(7).


Solenoid Valve—SpecificationSolenoid Valve Coil-to-ManifoldCap Screws—Torque 3 N•m (24 lb-in.).....................................................

7. Connect electrical connectors.

8. Check pressure setting of solenoid valves. See PowerBoost, Propel Speed, Swing Priority, and ArmRegenerative Solenoid Valve Test and Adjustment.(Group 9025-25.)

33336035



PN=217

Hydraulic System

333360

36

OUOE027,000001E –19–19NOV01–2/2

T14

3123

–UN

–20J

UL0

1

1—Cap Screw (2 used) 5—Adjusting Screw 10—Spool 15—O-Ring2—Proportional Solenoid 6—Spring 11—Washer 16—Sleeve

Valve Coil 7—Spring 12—Spring 17—Plate3—O-Ring 8—O-Ring 13—O-Ring 18—Washer4—Lock Nut 9—Diaphragm 14—O-Ring

Disassemble and Assemble Proportional SolenoidValve


NOTE: Only remove the lock nut (4) and adjustingscrew (5) if replacement of O-ring (3) isnecessary. If disassembled, pressure setting ofproportional solenoid valve will need to beadjusted. See Power Boost, Propel Speed,Swing Priority, and Arm Regenerative SolenoidValve Test and Adjustment. (Group 9025-25.)


3. Apply clean oil to sleeve (16), O-rings (13, 14 and15) and spool (10).

After installing spool, push spool against spring tocheck that spool slides smoothly in sleeve.

4. Install sleeve (16) so ports align with ports inmanifold.

5. Install washer (11) and spring (12) on spool andinstall spool.

6. Install spring (7), O-ring (8) and diaphragm (9).


PN=218

Hydraulic System

33336037

OUOE027,0000020 –19–19NOV01–1/3

Pilot Controller Repair

Remove and Install Pilot Controller



2. Remove covers.

3. Disconnect wiring harness and remove lever.

4. Remove cap screws and remove pilot controller fromconsole.



7. Connect lines. See Main Hydraulic System ComponentLocation. (Group 9025-15.)

NOTE: Position cap screw with spring pin, in lower righthole of controller.

8. Install pilot controller and tighten cap screws.

Pilot Controller—SpecificationPilot Controller-to-Console CapScrew—Torque 10 N•m (7.2 lb-ft)...............................................................

9. After pilot controller is installed, check operation of allfunctions to be sure they operate as shown on decalmounted on console.



PN=219

Hydraulic System

333360

38

OUOE027,0000020 –19–19NOV01–2/3

13

12

14

1115

11

10

98

716

6

5

3

4

2

1

21

20

19

21

20

18

17

T143186

T14

3186

–UN

–17J

UL0

1

1—Spacer (4 used) 7—Retaining Ring (4 used) 12—Cam 17—Spool (4 used)2—Shim (As required) 8—Pusher A (2 used) 13—Coupling 18—Housing3—Balance Spring A (2 used) 9—Pusher B (2 used) 14—U-Joint 19—O-Ring4—Balance Spring B (2 used) 10—Block 15—Oil Seal (4 used) 20—Dowel Pin (2 used)5—Return Spring A (2 used) 11—Cap Screw (2 used) 16—Spring Guide (4 used) 21—O-Ring (2 used)6—Return Spring B (2 used)


PN=220


Hydraulic System

OUOE027,0000020 –19–19NOV01–3/3

Disassemble and Assemble Pilot Controller

IMPORTANT: The housing (18) and spools (17) arereplaced as an assembly becausethe spools are select fitted to boresin housing.

Some parts from ports 1 and 3 aredifferent than parts from ports 2 and4. Parts for each port must be kepttogether and installed into the sameport from which it was removed. Theport numbers are stamped on thehousing.

Remove U-joint (14) only ifnecessary.

Note port location and quantity ofshims (2) when removing. Samenumber of shims must be used wheninstalling.

1. Remove parts from housing. Remember to keepparts removed from each port together. Identifyeach group of parts by port numbers stamped onhousing.


NOTE: Install spring guides (16) with protrusion facingup.

3. Install parts.

4. Apply multi-purpose grease to oil seals.

5. Install pushers (8 and 9). Pushers with grooves gointo ports 1 and 3. Pushers without grooves go intoports 2 and 4.


Pilot Controller—SpecificationBlock-to-Housing Cap Screw—Torque 19.6 N•m (14.5 lb-ft).................................................................

7. Apply multi-purpose grease to the end of eachpushers (8 and 9) and to the joint of U-joint (14).

8. Install cam (12) on U-joint (14). Adjust clearancebetween pushers (8 and 9) and cam.

Pilot Controller—SpecificationCam-to-Pusher—Clearance 0—0.20 mm (0—0.008 in.)......................

Hold cam (12) and tighten coupling (1).

Pilot Controller—SpecificationCoupling-to-Cam and U-Joint—Torque 88.2 N•m (65 lb-ft)....................................................................

33336039


PN=221

Hydraulic System

333360

40

OUOE027,0000021 –19–19NOV01–1/4

Propel Pilot Controller Repair

T14

3206

B–U

N–2

0JU

L01

1—Propel Pilot Controller2—Cap Screw (2 used)3—Cap Screw (4 used)

Remove and Install Propel Pilot Controller




3. Remove cap screws (3) and remove pedals and levers.

4. Remove cap screws (2) and remove propel pilotcontroller (1).



Propel Pilot Controller—SpecificationController-to-Cab Platform CapScrew—Torque 49 N•m (36 lb-ft)................................................................


Propel Pilot Controller—SpecificationPropel Pedal-to-Lever CapScrew—Torque 49 N•m (36 lb-ft)................................................................


9. After propel pilot controller is installed, check theoperation of all functions to be sure they operatecorrectly.



PN=222

Hydraulic System

33336041

OUOE027,0000021 –19–19NOV01–2/4

T143207

1

235

34

33

32

31

30

2425

26

27 2829

10

16

15

14

17

18

19

20 21

22

23

13

12

11

9

8

7

6 54

3

T14

3207

–UN

–17J

UL0

1

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


PN=223


Hydraulic System

333360

42

OUOE027,0000021 –19–19NOV01–3/4

Disassemble and Assemble Propel Pilot Controller

IMPORTANT: The casing (14) and spools (17) arereplaced as an assembly becausethe spools are select fitted to boresin housing.

Parts for each port must be kepttogether and installed into the sameport from which it was removed. Theport numbers are stamped on thehousing.

Note port location and quantity ofshims (20) when removing. Samenumber of shims must be used wheninstalling.

1. Remove parts from casing. Remember to keepparts removed from each port together. Identifyeach group of parts by port numbers stamped oncasing.

NOTE: Spring pins (24 and 25) are stepped and canonly be removed from one direction.

Remove spring pin (27) and bushings (31) onlyif necessary.


3. Install spools (17), springs (18), spacers (19), shims(20) and balance springs (21) into casing (14).

Use number of shims (20) removed.

Install spring guides (22) with stepped end facingdown.

4. Apply multi-purpose grease to the end of eachpushers (23) and to oil seals (11).

IMPORTANT: Note direction of insertion for springpins (34 and 35).

5. Assemble cam (32) in holder (10) with spring pins(34 and 35), and pin (3). Install spring pins with slits90° apart.

6. Lock pins (34 and 35) in position by displacing thebore 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—SpecificationHolder-to-Casing Cap Screw—Torque 49 N•m (36 lb-ft).......................................................................

8. Adjust clearance between cams (32) and pushers(23) .

Propel Pilot Controller—SpecificationCams-to-Pusher—Clearance 0—0.20 mm (0—0.008 in.)....................

9. Tighten lock nut (33).

Propel Pilot Controller—SpecificationCam 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) andtighten.

Propel Pilot Controller—SpecificationDampener-to-Holder CapScrew—Torque 7 N•m (5.1 lb-ft)..........................................................

IMPORTANT: Note direction of insertion for springpins (24 and 25).

Spring pins must be positioned withslits 90° apart.

Align brackets with marks madeduring disassembly.

13. Install brackets (26) and spring pins (24 and 25).

14. Lock pins (24 and 25) in position by displacing thebore above spring pin using a punch and hammer.


PN=224


Hydraulic System

OUOE027,0000021 –19–19NOV01–4/4

15. Install cover (2) and cap screws (1) and tighten.

Propel Pilot Controller—SpecificationCover-to-Holder Cap Screw—Torque 5 N•m (3.6 lb-ft)........................................................................

16. Apply multi-purpose grease to spring pin (27).

OUOE027,0000027 –19–19NOV01–1/6

Pilot Signal Manifold Repair

Remove and Install Pilot Signal Manifold






33336043



PN=225

Hydraulic System

OUOE027,0000027 –19–19NOV01–2/6

T14

3184

C–U

N–2

0JU

L01

1—Pilot Signal Manifold2—Bracket3—Cap Screw (4 used)

5. Remove cap screws (3).


7. Position manifold (1) on bracket (2) and tighten capscrews (3).

Pilot Signal Manifold—SpecificationPilot Signal Manifold-to-BracketCap Screw—Torque 50 N•m (37 lb-ft)........................................................

8. Connect electrical connectors. See System FunctionalSchematic, Component Location, and Wiring DiagramMaster Legend . (Group 9015.)

9. Install hose and tube adapters and tighten.

Pilot Signal Manifold—SpecificationHose and Tube Adapter-to-PilotSignal Manifold—Torque 39 N•m (347 lb-in.)..............................................

10. Connect lines. See Pilot Controllers-to-Pilot SignalManifold Component Location—Excavator Pattern.(Group 9025-15.)

333360

44



PN=226

Hydraulic System

33336045


PN=227

Hydraulic System

333360

46

OUOE027,0000027 –19–19NOV01–3/6

14

13

15

1619

20

1617

19

18

2012

11

1

23

5

4

6 7

22

23

24

21 14

8

9

10

20 14

25

2619

2716

15

28

17

29

19

1716

15

17

A

B

C

D

T143485

T14

3485

–UN

–17J

UL0

1


PN=228


Hydraulic System

OUOE027,0000027 –19–19NOV01–4/6

1—Cap Screw (10 used) 9—Gasket 16—O-Ring (7 used) 23—Valve2—Body 10—Body 17—Spring (4 used) 24—O-Ring3—Gasket 11—Name Plate 18—Spring 25—Spring4—Body 12—Screw (4 used) 19—Spring Seat (7 used) 26—Spool5—Gasket 13—Plate 20—Spool (6 used) 27—Spring6—Body 14—Cap Screw (11 used) 21—Plate 28—Spring7—Gasket 15—Plug (7 used) 22—O-Ring 29—Plate8—Body

Disassemble and Assemble Pilot Signal Manifold


33336047


PN=229

Hydraulic System

333360

48

OUOE027,0000027 –19–19NOV01–5/6

A B

C D

30 32

31

32

31

30

3130

T143486

T14

3486

–UN

–17J

UL0

1

30—Filter (17 used) 31—Shuttle Valve (21 used) 32—Spring (4 used)


PN=230


Hydraulic System

OUOE027,0000027 –19–19NOV01–6/6

Install hose and tube adapters and tighten.

Pilot Signal Manifold—SpecificationHose and Tube Adapter-to-PilotSignal Manifold—Torque 39 N•m (347 lb-in.).......................................

TX,33,UU4002 –19–19NOV01–1/18

Control Valve Repair

Remove and Install Control Valve



2. Drain hydraulic oil tank. See 200CLC Drain and RefillCapacities, 230CLC Drain and Refill Capacities or270CLC Drain and Refill Capacities. (Operator’sManual.)

33336049

TX,33,UU4002 –19–19NOV01–2/18

T14

3184

B–U

N–2

4JU

L01

1—Control Valve2—Cap Screw (3 used)3—Washer (3 used)4—Pilot Signal Manifold5—Bracket6—Electrical Connector (4 used)

3. Disconnect hydraulic tubes.

4. Disconnect electrical connectors (6).

5. Remove cap screws (2) and washers (3). Place pilotsignal manifold (4) with bracket (5) to side.

6. Attach hoist to control valve using lifting strap.


PN=231


Hydraulic System

TX,33,UU4002 –19–19NOV01–3/18

T143187

2

1

4

1

2

3

T14

3187

–UN

–02A

UG

01

1—Cap Screw (4 used)2—Washer (4 used)3—Front Mounting Bracket4—Rear Mounting Bracket


Control Valve—SpecificationControl Valve—Weight 183 kg (400 lb) approximate..................................

7. Remove cap screws (1) and washers (2). Removecontrol valve.



Control Valve—SpecificationMounting Bracket-to-ControlValve Cap Screw—Torque 210 N•m (152 lb-ft)..........................................

10. Install pilot signal manifold with bracket. Tighten capscrews.

Control Valve—SpecificationPilot Signal ManifoldBracket-to-Control Valve CapScrew—Torque 137 N•m (101 lb-ft)............................................................

11. Connect hydraulic tubes. See Main Hydraulic SystemComponent Location. (Group 9025-15.)

12. Connect electrical connectors. See Cab Harness (W1)Component Location Diagram. (Group 9015-10.)

13. Check Hydraulic Oil. (Operator’s Manual.)

14. Do Hydraulic Pump and Drive Gearbox Start-UpProcedure. (See procedure in this group.)

333360

50



PN=232

Hydraulic System

33336051

TX,33,UU4002 –19–19NOV01–4/18

T143188

5152

5354

555657

5859

5049

44

45

46

47

48

41

61

62

63 60

64

65

43

42

40

31

32

33

34

35

37

38

39

36

25

J

E

C

A

11

109

8

14

68

69

12

13

17

7

6

5

4

3

2

1

DB

F

G

H

66

67

A

16

21

20

18

19

22

23

24

2627

2829

30

15

B

HD C

FE

J

GI

T14

3188

–UN

–19N

OV

01

Control Valve—5-Spool

Disassemble and Assemble Control Valve 5-Spool



PN=233

Hydraulic System

333360

52

TX,33,UU4002 –19–19NOV01–5/18

T143190

9596

97

94

93

104

105106

100101

102103

107

108

109

110111 112

113114

115

116

106

105

104

118119

120121

122

117

123

8584

83

82

81

80

7879

77

8687

8991

9088

92

7172

7374

70

75

85

84

8687

89

83

82

81

80

78

79

77

76

91

9088

92

99

98

T14

3190

–UN

–19N

OV

01

5-Spool—Side Components



PN=234

Hydraulic System

33336053

TX,33,UU4002 –19–19NOV01–6/18

1—Auxiliary Function Flow 35—Swing Spool 67—O-Ring 97—PoppetCombiner Valve 36—Special Cap Screw (5 68—O-Ring 98—Auxiliary Flow Combiner

2—Cap Screw (2 used) used) 69—Arm In Circuit Relief and Valve Check Valve3—Cap 37—Spring Seat (5 used) Anti-Cavitation Valve 99—Cap Screw (2 used)4—O-Ring 38—Spring (5 used) 70—Lift Check (Boom II Power 100—Flange5—Spring Seat 39—Spring Seat (5 used) Passage) 101—O-Ring6—Spring 40—Spool 71—Cap Screw (4 used) 102—Spring7—Spool 41—Arm Reduced Leakage 72—Flange 103—Poppet8—Bottom Pilot Cap (5 used) Valve 73—O-Ring 104—Cap Screw (8 used)9—Cap Screw (10 used) 42—Cap Screw (4 used) 74—Spring 105—Cover (2 used)10—Plug 43—O-Ring 75—Poppet 106—O-Ring (2 used)11—O-Ring 44—Plug 76—Auxiliary Flow Rate Valve 107—Lift Check (Arm I Power12—Plug 45—O-Ring 77—Plug (2 used) Passage)13—O-Ring 46—Piston 78—O-Ring (2 used) 108—Plug14—O-Ring (5 used) 47—Spring 79—Cap Screw (8 used) 109—O-Ring15—Plug 48—Body 80—Housing (2 used) 110—Arm I Power16—O-Ring 49—O-Ring 81—Spool (2 used) Passage-to-Housing Lift17—Housing 50—O-Ring 82—Spring (2 used) Check Cap Screw (418—O-Ring 51—Sleeve 83—Spring Seat (2 used) used)19—System Relief and Power 52—Backup Ring 84—O-Ring (2 used) 111—Flange

Boost Valve 53—O-Ring 85—Plug (2 used) 112—O-Ring20—O-Ring 54—O-Ring 86—O-Ring (2 used) 113—Spring21—Plug 55—Backup Ring 87—Sleeve (2 used) 114—Poppet22—O-Ring 56—Spool 88—Spring (2 used) 115—Housing23—Plug 57—Poppet 89—Plug (2 used) 116—O-Ring (6 used)24—Cap Screw (6 used) 58—Washer 90—Spring (2 used) 117—Lift Check (Swing Neutral25—O-Ring (5 used) 59—Spring 91—Poppet (2 used) Passage)26—Top Pilot Cap 60—Lift Check and Orifice 92—Poppet (2 used) 118—Cap Screw (4 used)27—O-Ring (Left Propel Power 93—Lift Check (Left Propel 119—Flange28—Plug Passage) Neutral Passage) 120—O-Ring29—Plug 61—Plug 94—Left Propel Neutral 121—Spring30—O-Ring 62—Backup Ring Passage-to-Housing Lift 122—Poppet31—Left Travel Spool 63—O-Ring Check Plug 123—Arm Priority Flow Rate32—Auxiliary Spool 64—Spring 95—O-Ring Valve33—Boom II Spool 65—Poppet 96—Spring34—Arm I Spool 66—Arm Out Circuit Relief and

Anti-Cavitation Valve

1. Remove cap screws (24) and top pilot cap (26).

2. Remove cap screws (9) and bottom pilot caps (8).

3. Spool —5 Spool (31—35):

IMPORTANT: The spool (31—35) are select fittedto bores in housing and are adifferent design for each function.Spools must be installed into thesame bores from which they wereremoved for proper operation ofmachine.

a. Remove spool (31—35).

NOTE: Hold the spool in a vise by the spool endbetween wooden blocks.

The procedures for disassembly and assemblyof spool (31—35) are the same.

b. Remove parts (36—39)

c. Inspect control valve spools for wear anddamage.

d. Replace parts as necessary.

e. Assemble parts (36—40). Tighten special capscrews (36).


PN=235


Hydraulic System

333360

54

TX,33,UU4002 –19–19NOV01–7/18

Control Valve—SpecificationSpecial Cap Screw-to-Controlvalve Spool—Torque 15 N•m (11 lb-ft)................................................

NOTE: Apply hydraulic oil to spools before installation.

f. Install spool (31—35) into housing (17) whilerotating them slowly.

g. After installing spool (31—35) into housing (17),push them by hand to confirm smoothness.

h. Repeat procedure for remaining spool

4. Auxiliary Function Flow Combiner Valve (1):

a. Inspect parts (2—7) for wear and damage.

b. Replace parts as necessary.

c. Tighten cap screws (2).

Control Valve—SpecificationAuxiliary Function FlowCombiner Valve-to-HousingCap Screw—Torque 11 N•m (7 lb-ft)...................................................

5. Lift Check And Orifice (Left Propel PowerPassage) (60):

a. Inspect parts (61—65) for wear and damage.


6. Arm Reduced Leakage Valve (41):

a. Remove cap screws (42) and body (48).


c. Apply petroleum jelly to washer (62) and spring(63) to hold in place.

IMPORTANT: Install spool (56) with the hole sidetowards poppet (57) for properoperation of valve.

d. Install plug (44) loosely.

e. Tighten cap screws (42).

Control Valve—SpecificationArm Reduced Leakage ValveBody-to-Housing Cap Screw—Torque 62 N•m (46 lb-ft).......................................................................

f. Tighten plug (44).

Control Valve—SpecificationPlug-to-Arm Reduced LeakageValve—Torque 108 N•m (80 lb-ft)........................................................

7. Auxiliary Flow Combiner Valve Check Valve(98):

a. Remove parts (99—103).

b. Install flange (100) and tighten cap screws (99).

Control Valve—SpecificationAuxiliary Flow Combiner ValveCheck Valve-to-Housing CapScrew—Torque 61 N•m (46 lb-ft).........................................................

8. Lift Check (Left Propel Neutral Passage) (93):

a. Remove plug (94).

b. Remove parts (95—97).

c. Replace parts as necessary

d. Install plug (94) and tighten.

Control Valve—SpecificationLeft Propel NeutralPassage-to-Housing Lift CheckPlug—Torque 76 N•m (56 lb-ft)............................................................

9. Lift Check (Arm I Power Passage) (107):


PN=236


Hydraulic System

TX,33,UU4002 –19–19NOV01–8/18

a. Remove cap screws (110) and flange (111).


c. Install flange (111) and tighten cap screws (110).

Control Valve—SpecificationArm I PowerPassage-to-Housing Lift CheckCap Screw—Torque 61 N•m (46 lb-ft).................................................

10. Lift Check (Boom II Power Passage) (70) andLift 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 capscrews (71 and 118).

Control Valve—SpecificationPower Passage-to-HousingCap Screw—Torque 61 N•m (46 lb-ft).................................................

11. Auxiliary Flow Rate Valve (76) And Arm PriorityFlow Rate Valve (123):

a. Remove cap screws (79) and housing (80).


c. Install housing (80) and tighten cap screws(79).

Control Valve—SpecificationFlow Rate ValveHousing-to-Housing CapScrew—Torque 61 N•m (46 lb-ft).........................................................

d. Tighten plug (85).

Control Valve—SpecificationFlow Rate Valve HousingPlug—Torque 98 N•m (72 lb-ft)............................................................

33336055



PN=237

Hydraulic System

333360

56

TX,33,UU4002 –19–19NOV01–9/18

T143388

1

2

6

11

13

15

3

4

5

7

8

9

10

12

14

1617

T14

3388

–UN

–02A

UG

01

1—First Adjusting Plug2—O-Ring3—Piston4—Nut5—Second Adjusting Plug6—O-Ring7—Pilot Poppet Spring8—Pilot Poppet9—Nut10—Cartridge11—O-Ring12—Pilot Poppet Seat13—Backup Ring14—O-Ring15—Main Poppet Spring16—Main Poppet17—Main Poppet Seat

12. System Relief and Power Boost Valve (19)

NOTE: Disassemble valve for cleaning and inspectiononly. Valve is serviced as an assembly.

a. Tighten nuts (4 and 9).

System Relief Valve—SpecificationSystem 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).....................................................................

b. Tighten valve cartridge (10).

System Relief Valve—SpecificationSystem Relief ValveCartridge-to-Housing—Torque 83 N•m (61 lb-ft)........................................

c. Check and adjust pressure setting for system reliefvalve and power boost. See System Relief andPower Boost Valve Test and Adjustment. (Group9025-25.)


14. Install top pilot cap (26) and tighten cap screws (24).

Control Valve—SpecificationTop Pilot Cap-to-Housing CapScrew—Torque 42 N•m (32 lb-ft)................................................................

15. Install bottom pilot caps (8) and tighten cap screws(9).

Control Valve—SpecificationBottom Pilot Caps-to-HousingCap Screw—Torque 42 N•m (32 lb-ft).......................................................



PN=238

Hydraulic System

33336057

TX,33,UU4002 –19–19NOV01–10/18

T143189

19

7172

7374

757677

7879

70 61

C

64

65

66

67

68

6962

55

54

53

52

50

47

44

37

63

E

D

82

81

83

84

85

80

9

8

7

6

5

4

1

3

11

12

10

8786

2B

43

42

41

40

39

38

35

59

60

18

17

16

15

14

57

58

56

49

48

46

45

36

F

G

H

23

24

20

25

2627

28

29

30

34

51

21

22C

31H

G F ED

BB

13

33

32

T14

3189

–UN

–19N

OV

01

Control Valve—4-Spool

Disassemble and Assemble Control Valve 4-Spool



PN=239

Hydraulic System

333360

58

TX,33,UU4002 –19–19NOV01–11/18

T143191

88

97

98

99

9695

94

93

9291

90

89

102100

101

103104

105

108110

111

112113 114

116 118

117115

107

119120

121100

122

123124

125126

127

128

123124

125126

127

136135

134133

132131

130 129

139138

137

106

T14

3191

–UN

–19N

OV

01

4-Spool—Side Components



PN=240

Hydraulic System

33336059

TX,33,UU4002 –19–19NOV01–12/18

1—Propel Flow Combiner 33—O-Ring 69—O-Ring 105—PlugValve 34—Right Travel Spool 70—O-Ring 106—O-Ring

2—Cap Screw (2 used) 35—Bucket Spool 71—Sleeve 107—Lift Check and Orifice3—Cap 36—Boom I Spool 72—Backup Ring (Arm II Power Passage)4—O-Ring 37—Arm II Spool 73—O-Ring 108—Poppet5—Cap Screw 38—Plug 74—O-Ring 109—Spring6—Spring Seat 39—Backup Ring 75—Backup Ring 110—O-Ring7—Spring 40—O-Ring 76—Spool 111—O-Ring (3 used)8—Spring Seat 41—Sleeve 77—Poppet 112—O-Ring9—Spool 42—Spring 78—Washer 113—Housing10—Cap Screw (8 used) 43—Poppet 79—Spring 114—O-Ring11—O-Ring 44—Special Cap Screw (4 80—Arm Regenerative Valve 115—Screw12—Plug used) 81—Spring 116—O-Ring13—Bottom Pilot Cap (4 used) 45—Spring Seat (3 used) 82—Spacer 117—Nut14—Arm Regenerative Valve 46—Plug 83—O-Ring 118—Nut

Check Valve 47—Spring Seat (4 used) 84—Backup Ring 119—Cap Screw (4 used)15—Plug 48—Backup Ring 85—Spool 120—O-Ring16—O-Ring 49—O-Ring 86—Boom Up Circuit Relief 121—Plug17—Spring 50—Spring Seat and Anti-Cavitation Valve 122—Lift Check (Boom I18—Poppet 51—Spool 87—Bucket Load Circuit Relief Power Passage)19—O-Ring (4 used) 52—Spring and Anti-Cavitation Valve 123—Poppet20—Housing 53—Spring 88—Housing 124—Spring21—O-Ring 54—Spring Seat 89—Bucket Flow Rate Valve 125—O-Ring22—Plug 55—Spring Seat 90—Poppet 126—Flange23—O-Ring 56—Poppet (2 used) 91—Poppet 127—Cap Screw (4 used)24—Bucket Dump Circuit 57—Spring (2 used) 92—Spring 128—Lift Check (Arm II Neutral

Relief and Anti-Cavitation 58—O-Ring (2 used) 93—Plug Passage)Valve 59—Backup Ring (2 used) 94—Spring 129—By-Pass Shut-Off Valve

25—O-Ring (4 used) 60—Plug (2 used) 95—Sleeve 130—Spool26—Top Pilot Cap 61—Boom Reduced Leakage 96—O-Ring 131—Spring27—Plug Valve 97—Plug 132—O-Ring28—O-Ring 62—O-Ring 98—O-Ring 133—Flange29—Pressure Sensor (Arm 63—Cap Screw (4 used) 99—Spring Seat 134—Cap Screw (2 used)

Roll-In) 64—Plug 100—Spring 135—O-Ring30—Cap Screw (6 used) 65—O-Ring 101—Spool 136—Plug31—O-Ring 66—Piston 102—Housing 137—Cap Screw (4 used)32—Boom Down Circuit Relief 67—Spring 103—Cap Screw (4 used) 138—Flange

and Anti-Cavitation Valve 68—Body 104—O-Ring 139—O-Ring

1. Remove cap screws (30) and top pilot cap (26).

2. Remove cap screws (10) and caps (13) fromhousing (20).

3. Spool —4 Spool (34—37):

NOTE: When disassembling spool (35, and 36), heatplugs (38, 46, and 60) to 200—300 °C (392—482 °F) to melt the thread lock and sealer.

IMPORTANT: The spool (34—37) are select fittedto bores in housing and are adifferent design for each function.

Spools must be installed into thesame bores from which they wereremoved for proper operation ofmachine.

a. Remove spool (34—37).

NOTE: Hold the spool in a vise by the spool end,using wooden blocks.

b. Remove special cap screw (44) and spools.

c. Heat plugs (38, 46, and 60) with heat gun tomelt threadlock and sealer and remove plugs.


PN=241


Hydraulic System

333360

60

TX,33,UU4002 –19–19NOV01–13/18

d. Inspect control valve spools for wear anddamage.

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—SpecificationSpecial Cap Screw-to-ControlValve Spool—Torque 15 N•m (11 lb-ft)................................................

g. For bucket and boom I spool (35 and 36):

Apply threadlock and sealer (high strength) onplugs (38, 46, and 60).

h. Install plugs (38, 46, and 60) onto spool (35 and36) and tighten.

Control Valve—SpecificationPlugs-to-Control Valve Spool—Torque 15 N•m (11 lb-ft).......................................................................

i. Install special cap screw (44) into spool andtighten.

Control Valve—SpecificationSpecial Cap Screw-to-ControlValve Spool—Torque 15 N•m (11 lb-ft)................................................

NOTE: Apply hydraulic oil to spools before installation.

j. Install spool (34—37) into housing (20) whilerotating them slowly.

IMPORTANT: After installing spool (34—37) intohousing (20), push them by hand toconfirm smoothness.

4. Propel Function Flow Combiner Valve (1):

a. Remove cap screws (2) and spool (9).


c. Inspect valve spools for wear and damage.

d. Replace parts as necessary.

e. Assemble parts (6—8) and tighten cap screw(5).

Control Valve—SpecificationCap Screw-to-Flow CombinerValve Spool—Torque 11 N•m (7 lb-ft)..................................................

f. Install spool (9), cap (3) and tighten cap screws(2).

Control Valve—SpecificationCap-to-Housing Cap Screw—Torque 10 N•m (7 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—SpecificationArm RegenerativeValve-to-Housing Plug—Torque 76 N•m (56 lb-ft)...............................

6. Arm Regenerative Valve (80):

NOTE: Do not disassemble spool (85) unlessnecessary.

a. Inspect valve spool for wear and damage.


7. Boom Reduced Leakage Valve (61):

a. Replace parts as necessary.

b. Install spool (76), with hole side towards poppet(77).


PN=242


Hydraulic System

33336061

TX,33,UU4002 –19–19NOV01–14/18

Apply petroleum jelly to washer (78) and spring(79) to hold them in place.

c. Loosely install plug (64).

d. Install and tighten cap screws (63).

Control Valve—SpecificationBoom Reduced Leakage ValveBody-to-Housing Cap Screw—Torque 62 N•m (46 lb-ft).......................................................................

e. Tighten plug (64).

Control Valve—SpecificationBoom Reduced LeakageValve-to-Body Plug—Torque 108 N•m (80 lb-ft)..................................

8. Bucket Flow Rate Valve (89):



c. Install housing (102) and tighten cap screws(103).

Control Valve—SpecificationBucket Flow Rate ValveHousing-to-Housing CapScrew—Torque 61 N•m (46 lb-ft).........................................................

d. Tighten plug (97).

Control Valve—SpecificationFlow Rate Valve HousingPlug—Torque 98 N•m (72 lb-ft)............................................................

9. Lift Check and Orifice (Arm II Power Passage)(107):


NOTE: Do not remove nuts (117 and 118) and screw(115) from housing (113) unless necessary.


c. Tighten screw (115).

d. Tighten 13 mm nut (117) and 4 mm nut (118).

Control Valve—SpecificationLift Check and Orifice (Arm IIPower Passage) 4 mm Nut—Torque 7 N•m (5 lb-ft)...........................................................................

Control Valve—SpecificationLift Check and Orifice (Arm IIPower Passage) 13 mm Nut—Torque 13 N•m (10 lb-ft).......................................................................

e. Install housing (113) and tighten cap screws(119).

Control Valve—SpecificationLift Check and Orifice (Arm IIPower Passage)Housing-to-Housing CapScrew—Torque 61 N•m (46 lb-ft).........................................................

10. By-Pass Shut-Off Valve (129):



c. Install flange (133) and tighten cap screws(134).

Control Valve—SpecificationBy-Pass Shut-OffValve-to-Housing Cap Screw—Torque 61 N•m (46 lb-ft).......................................................................



PN=243


Hydraulic System

TX,33,UU4002 –19–19NOV01–15/18

12. Install top pilot cap (26) and tighten cap screws(30).

Control Valve—SpecificationTop Pilot Cap-to-Housing CapScrew—Torque 42 N•m (32 lb-ft).........................................................

13. Install bottom pilot caps (13) and tighten capscrews (10).

Control Valve—SpecificationBottom Pilot Cap-to-HousingCap Screw—Torque 42 N•m (32 lb-ft)................................................


333360

62


PN=244

Hydraulic System

33336063

TX,33,UU4002 –19–19NOV01–16/18

T143217

4

3

26

25

24

6

2022

13

18 17

1615

14

2119

8

23910

1

2

4

4

4

3

3

3

7

127

8

10

5

9

10

11

9

127

8

43

T14

3217

–UN

–02A

UG

01

Disassemble and Assemble 5-Spool and 4-Spool

1— Housing—5-Spool 9—Flange (3 used) 14—Poppet 22—Plug2—Cap Screw (6 used) 10—Cap Screw (6 used) 15—Spring 23—System Relief Valve3—Plug (6 used) 11—System Relief Valve 16—O-Ring Isolation Check Valve—4—O-Ring (6 used) Isolation Check Valve— 17—Flange 4-Spool5—Propel Flow Combiner 5-Spool 18—Cap Screw (2 used) 24—O-Ring (15 used)

Valve Check Valve 12—Poppet 19—Poppet 25—O-Ring (16 used)6—Poppet (2 used) 13—Right Propel and Bucket 20—Spring 26—Housing—4-Spool7—Spring (3 used) Combined Function Check 21—O-Ring8—O-Ring (3 used) Valve and Orifice


PN=245


Hydraulic System

333360

64

TX,33,UU4002 –19–19NOV01–17/18

Disassemble and Assemble Control Valve 5-Spooland 4-Spool Sections

1. Right Propel And Bucket Combined FunctionCheck Valve And Orifice (13):



c. Replace parts as necessary.

d. Install and tighten plug (22).

Control Valve—SpecificationRight Propel and BucketCombined Function CheckValve and Orifice-to-4-SpoolHousing Plug—Torque 76 N•m (56 lb-ft).............................................

e. Install flange (17) and tighten cap screws (18).

Control Valve—SpecificationRight Propel and BucketCombined Function CheckValve and OrificeFlange-to-4-Spool Housing CapScrew—Torque 61 N•m (46 lb-ft).........................................................

2. System Relief Valve Isolation Check Valve—4-Spool (23):




Control Valve—SpecificationSystem Relief Valve andIsolation CheckValve-to-4-Spool Housing CapScrew—Torque 61 N•m (46 lb-ft).........................................................

3. Propel Flow Combiner Valve Check Valve (5)and System Relief Valve Isolation Check Valve(11):




Control Valve—SpecificationPropel Flow Combiner ValveCheck Valve CapScrew-to-5-Spool Housing—Torque 61 N•m (46 lb-ft).......................................................................System Relief Valve IsolationCheck Valve CapScrew-to-5-Spool Housing—Torque 61 N•m (46 lb-ft).......................................................................


Control Valve—Specification5-Spool Housing—Weight 75 kg (165 lb) approximate........................

Control Valve—Specification4-Spool Housing—Weight 74 kg (163 lb) approximate........................

d. Remove cap screws (2). Separate 5-spoolhousing (1) from 4-spool housing (26).

e. Remove plugs (3) and O-rings (4)


5. Combine 5-spool housing (1) and 4-spool housing(26) and tighten cap screws (2).

Control Valve—Specification5-Spool-to-4-Spool CapScrew—Torque 167—177 N•m (123—130 lb-ft)..................................


PN=246


Hydraulic System

33336065

TX,33,UU4002 –19–19NOV01–18/18

T79

96A

E–U

N–0

4MA

Y93

A—Nut F—O-Ring K—Piston and Main Poppet O—Pilot Poppet SpringB—Plug G—Backup Ring Spring P—O-RingC—O-Ring (2 used) H—Anti-Cavitation Sleeve L—Cartridge Q—Adjusting ScrewD—Backup Ring I—Piston M—Pilot PoppetE—O-Ring J—Main Poppet N—Anti-Cavitation Sleeve

Spring

6. Circuit Relief and Anti-Cavitation Valve 5-Spooland 4-Spool

NOTE: Disassemble valves for cleaning andinspection only. Valves are serviced asassemblies.

a. Tighten valve into housing.

Circuit Relief and Anti-Cavitation Valve—SpecificationCircuit Relief andAnti-Cavitation Valve-to-ControlValve Housing—Torque 83 N•m (61 lb-ft)............................................

b. Check and adjust pressure setting. See CircuitRelief Valve Test and Adjustment. (Group9025-25.)


PN=247

Hydraulic System

OUOE027,0000022 –19–19NOV01–1/4

Hydraulic Oil Tank Repair

Remove and Install Hydraulic Oil Tank



2. Drain hydraulic oil tank. See 200CLC Drain and RefillCapacities, 230CLC Drain and Refill Capacities, or270CLC Drain and Refill Capacities. (Operator’sManual.)


4. Disconnect electrical connector on bottom of tank.

333360

66



PN=248

Hydraulic System

33336067

OUOE027,0000022 –19–19NOV01–2/4

3

2

1

4

T14

3359

–UN

–20J

UL0

1

1—Cap Screw (4 used)2—Lock Washer (4 used)3—Washer (4 used)4—Hydraulic Oil Tank

5. Remove cap screws (1), lock washers (2) and washers(3).


Hydraulic Oil Tank—SpecificationHydraulic Oil Tank—Weight 150 kg (330 lb) approximate..........................

6. Remove hydraulic oil tank using a hoist and liftingstraps.


8. Install hydraulic oil tank (4).


Hydraulic Oil Tank—SpecificationOil Tank-to-Frame Cap Screw—Torque 205 N•m (152 lb-ft).........................................................................


Hydraulic Oil Tank—SpecificationT-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 RefillCapacities, 230CLC Drain and Refill Capacities ,270CLC Drain and Refill Capacities, and HydraulicOil. (Operator’s Manual.)

IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.




PN=249

Hydraulic System

333360

68

OUOE027,0000022 –19–19NOV01–3/4

T143368

6

5

4

7

8

9

1011

12

13

14

15

16

17

2

3

2

38

37 36

3534

33

32

31 3029

27

28

24

26 26 25

23

22

21

20

19

18

1

T14

3368

–UN

–20J

UL0

1


PN=250


Hydraulic System

OUOE027,0000022 –19–19NOV01–4/4

1—Suction Strainer 11—Cap Screw (6 used) 21—O-Ring 30—Plug2—Nut (3 used) 12—Cover 22—Filter Element 31—Cap Screw (4 used)3—Rod 13—O-Ring 23—Hydraulic Oil Tank 32—Lock Washer (4 used)4—Cap Screw (4 used) 14—Bracket 24—Level Gauge 33—Washer (4 used)5—Cover 15—Washer 25—Cap Screw (2 used) 34—Plug6—Cap 16—Lock Washer 26—Seal (4 used) 35—Elbow7—Nut 17—Cap Screw 27—Gasket 36—Adapter (3 used)8—Element 18—Cap Screw (6 used) 28—Sensor 37—Elbow9—Body 19—Cover 29—Plug 38—Tee10—O-Ring 20—Spring

Disassemble and Assemble Hydraulic Oil Tank

1. Tighten cap screws (11 and 18).

Hydraulic Oil Tank—SpecificationCovers-to-Hydraulic Oil TankCap Screws—Torque 49 N•m (36 lb-ft)...............................................

2. Adjust the length of rod (3) on suction strainer (1).

Hydraulic Oil Tank—SpecificationSuction Strainer Rod—Length 683 mm (26.9 in.)................................

Tighten nuts (2).

Hydraulic Oil Tank—SpecificationSuction Strainer Rod Nuts—Torque 17 N•m (153 lb-in.)....................................................................

33336069

OUOE027,0000023 –19–24OCT01–1/3

Restriction Valve Repair

Remove and Install Restriction Valve



2. Pull vacuum in hydraulic oil tank using vacuum pumpor drain hydraulic oil tank. See 200CLC Drain andRefill Capacities, 230CLC Drain and Refill Capacities,or 270CLC Drain and Refill Capacities. (See Operator’sManual.)



PN=251

Hydraulic System

333360

70

OUOE027,0000023 –19–24OCT01–2/3

T143376

5

1

2

3

4

T14

3376

–UN

–02A

UG

01


1—Coupling 3—Restriction Valve 4—Hydraulic Oil Tank 5—Oil Cooler2—Snap Ring

3. Repair or replace restriction valve (3) and snap ring(2).


PN=252


Hydraulic System

OUOE027,0000023 –19–24OCT01–3/3

4. Tighten nuts on coupling (1).

Restriction Valve—SpecificationOil Cooler-to-Hydraulic Oil TankReturn Line Coupling Nut—Torque 10.3—12.4 N•m (91—110

lb-in.).........................................................

5. Fill and check Hydraulic Oil level. See 200CLCDrain and Refill Capacities, 230CLC Drain andRefill Capacities, or 270CLC Drain and RefillCapacities. (See Operator’s Manual.)

IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before starting.Procedure must be performed to fillpump housing whenever oil hasbeen drained from the pump orhydraulic oil tank.


OUOE027,0000024 –19–19NOV01–1/3

Oil Cooler Bypass Valve Repair

Remove and Install Oil Cooler Bypass Valve



2. Pull vacuum in hydraulic oil tank using vacuum pumpor drain hydraulic oil tank. See 200CLC Drain andRefill Capacities, 230CLC Drain and Refill Capacities,or 270CLC Drain and Refill Capacities. (Operator’sManual.)

33336071



PN=253

Hydraulic System

333360

72

OUOE027,0000024 –19–19NOV01–2/3

T143377

5

1

23

4

6

T14

3377

–UN

–02A

UG

01


1—Control Valve 3—O-Ring 5—Coupling 6—Hydraulic Oil Tank2—Oil Cooler Bypass Valve 4—Cap Screw (2 used)

3. Repair or replace oil cooler bypass valve (2).


PN=254


Hydraulic System

OUOE027,0000024 –19–19NOV01–3/3

4. Tighten nuts on coupling (5).

Oil Cooler Bypass Valve—SpecificationControl Valve-to-Hydraulic OilTank Return Line CouplingNut—Torque 10.3—12.4 N•m (91—110

lb-in.)...............................................


Oil Cooler Bypass Valve—SpecificationSplit Coupling-to-Control ValveCap Screw—Torque 50 N•m (37 lb-ft).................................................

6. Fill and check Hydraulic Oil level. See 200CLCDrain and Refill Capacities, 230CLC Drain and

Refill Capacities, or 270CLC Drain and RefillCapacities. (Operator’s Manual.)

IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before starting.Procedure must be performed to fillpump housing whenever oil hasbeen drained from the pump orhydraulic oil tank.


33336073


PN=255

Hydraulic System

333360

74

OU90U48,0000028 –19–19NOV01–1/1

Oil Cooler Repair

T14

2696

–UN

–02A

UG

01

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

Remove and Install Oil Cooler

1. Remove radiator. See Radiator Repair. (Group 0510.)





5. Remove cap screws (1 and 2).


Oil Cooler—SpecificationOil Cooler—Weight 32 kg (70 lb) approximate............................................

6. Remove oil cooler.


8. Install radiator. See Radiator Repair. (Group 0510.)

9. Install oil cooler.



12. Fill and check Hydraulic Oil level. See 200CLC Drainand Refill Capacities, 230CLC Drain and RefillCapacities, or 270CLC Drain and Refill Capacities.(Operator’s Manual.)


PN=256

Hydraulic System

FR91424,0000002 –19–04NOV03–1/6

Remove and Install Boom Cylinder

T10

6031

–UN

–10J

AN

97

NOTE: Procedure is the same for both boom cylinders.

1. Park machine on firm, level surface.

2. Retract arm and bucket cylinders and lower bucket toground.


3. Perform Hydraulic Oil Tank Pressure ReleaseProcedure. (Group 3360.)

4. Loosen boom cylinder hydraulic lines at frame end ofboom to release any residual pressure.


6. Disconnect lubrication line at rod end of cylinder.

33336075

FR91424,0000002 –19–04NOV03–2/6

T10

5828

–UN

–30D

EC

96

F—Boom Cylinder


SpecificationBoom Cylinder—200CLC—Weight 171 kg approximate.........................................................................

377 lb approximateBoom Cylinder—230CLC—Weight 217 kg approximate.........................................................................

480 lb approximateBoom Cylinder—270CLC—Weight 247 kg approximate.........................................................................

540 lb approximate

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



PN=257

Hydraulic System

FR91424,0000002 –19–04NOV03–3/6

T14

2979

–UN

–24J

UL0

1

1—Nut (2 used)2—Retainer3—Cap Screw4—Boom Cylinder-to-Boom Pin5—Shim (2 used)6—Boom Cylinder

8. Remove parts (1—3, and 5).

9. Push pin (4) into boom.

Lower boom cylinder (6) on floor stand.


333360

76


PN=258

Hydraulic System

33336077

FR91424,0000002 –19–04NOV03–4/6

9

107 7

6

11

11

8 8

T14

3048

–UN

–02A

UG

01

6—Boom Cylinder7—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)

10. Disconnect hydraulic lines (7) from head end of boomcylinder (6).

11. Mark location of shims (8) to aid in assembly.

12. Remove parts (8—11) and remove boom cylinder (6).


14. Install shims equally on each side of cylinder headend to get the minimum amount of clearance in joint.

15. Align pin bores so Shims are not damaged as pin(10) is installed.

16. Connect boom cylinder head end to frame.

17. Tighten nuts (11) against each other allowing capscrews (9) to be free to turn in hole.

SpecificationBoom Cylinder-to-Frame PinRetainer Nut—200CLC—Torque 271 N•m (tighten nut against nut)...........

200 lb-ft (tighten nut against nut)

SpecificationBoom Cylinder-to-Frame PinRetainer Nut—230CLC,270CLC—Torque 549 N•m (tighten nut against nut)...................................



Tighten boom cylinder hoses.

SpecificationBoom Cylinder Hose—200CLC—Torque 175 N•m..........................................................................................

130 lb-ft

SpecificationBoom Cylinder Hose—230CLC,270CLC—Torque 206 N•m..........................................................................

152 lb-ft



PN=259

Hydraulic System

333360

78

FR91424,0000002 –19–04NOV03–5/6

IMPORTANT: Trapped air suddenly compressed in acylinder is heated and ignites the oilused for assembly causing cap seal andring damage. Start with cylinder rodretraced and the rod end filled withclean oil. Connect the cylinder head endand lines. Operate function to slowlyextend rod. Procedure will eliminatemost of the air and reduce thepossibility of damage.

19. Start engine.

20. Slowly extend boom cylinder (6) to align pin bores soshims (5) are not damaged as pin (4) is installed.

21. Install Shims to get the minimum amount of clearancebetween boom and boom cylinder rod end.

22. Connect boom cylinder rod end to boom.


SpecificationBoom Cylinder-to-Boom PinRetainer Nut—200CLC—Torque 271 N•m (tighten nut against nut)...........


SpecificationBoom Cylinder-to-Boom PinRetainer Nut—230CLC,270CLC—Torque 549 N•m (tighten nut against nut)...................................


24. Connect lubrication line.

SpecificationBoom Cylinder Pivot LubricationLine—Torque 29.5 N•m...............................................................................

21.5 lb-ft

25. Lubricate all pivot joints. See Track Adjuster, WorkingTool Pivot, Swing Bearing, And Swing Bearing GearGrease. (Operator’s Manual.)

26. Bleed air from cylinder. See Hydraulic Cylinder BleedProcedure. (Group 3360.)


PN=260


Hydraulic System

FR91424,0000002 –19–04NOV03–6/6

27. Check hydraulic oil level . See Check Hydraulic OilLevel. (Operator’s Manual.)

33336079


PN=261

Hydraulic System

333360

80

FR91424,0000003 –19–05NOV03–1/20

Boom Cylinder Disassemble and Assemble—200CLC, 270CLC

T19

0994

–UN

–09M

AY

03

Boom Cylinder—200CLC, 270CLC—Right Cylinder Shown


PN=262


Hydraulic System

FR91424,0000003 –19–05NOV03–2/20

1—Cylinder Barrel and 11—Back-Up Ring 21—Nut 32—O-RingBushings 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (4 used)

2—Rod and Bushings 13—Cushion 23—Steel Ball 34—Band3—Rod Guide 14—Cushion Seal 25—Seal (2 used) 35—Clamp4—Wear Ring 15—Piston 26—Retainer Ring 36—Cap Screw (2 used)5—Snap Ring 16—Cap Seal and O-Ring 27—Seal (2 used) 37—Lock Washer (2 used)6—Buffer Ring Seal 17—Back-Up Ring (2 used) 28—Hydraulic Line 38—Half Clamp (2 used)7—U-Cup Seal 18—Buffer Seal (2 used) 29—Hydraulic Line 39—Cap Screw8—Back-Up Ring 19—Wear Ring (2 used) 30—O-Ring 40—Lock Washer9—Wiper Seal 20—Shim 31—Cap Screw (4 used) 41—Lubrication Fitting10—O-Ring

NOTE: Disassemble and assemble procedures are thesame for both right and left boom cylinders.


SpecificationBoom Cylinder—Weight 171 kg approximate......................................

377 lb approximate

1. Fasten head end of cylinder to JT30043 cylinderservice stand.

33336081

FR91424,0000003 –19–05NOV03–3/20

T65

57H

I–U

N–2

7OC

T88

A—Cap ScrewB—Line

2. Remove line (B).

3. Pull rod out so piston is against rod guide.

4. Connect rod to a hoist using a lifting strap.

5. Remove cap screws (A).

6. Remove rod, rod guide and piston from barrel.



PN=263

Hydraulic System

FR91424,0000003 –19–05NOV03–4/20

T65

57H

K–U

N–2

7OC

T88

B—Sliding Housing

7. Install rod eye in sliding housing (B) and install housingin the JT30043 cylinder service stand.

FR91424,0000003 –19–05NOV03–5/20

T65

85X

I–U

N–2

7OC

T88

A—Set ScrewB—Steel Ball

8. Remove the staked material from set screw (A) holeusing a small air grinder or a drill and bit.

9. Remove set screw (A) and steel ball (B).


333360

82


PN=264

Hydraulic System

FR91424,0000003 –19–05NOV03–6/20

T77

68A

G–U

N–2

2MA

Y92

33336083

B—Nut

IMPORTANT: To avoid damaging the tapped hole forset screw, the cap screw in theJT30043-30 Hex Piston Nut Wrenchmust be tightened against a side of thenut without the tapped hole.

To avoid gouging side of nut, install apiece of steel flat stock between nutand cap screw.

10. Install JT30043-30 Hex Piston Nut Wrench so capscrew is tightened against side of nut (B) withouttapped hole.

11. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) pieceof steel flat stock between nut and cap screw. Tightencap screw.

12. Loosen nut (B).

SpecificationBoom Cylinder Piston-to-RodNut—Torque 4780 N•m...............................................................................

3,525 lb-ft



PN=265

Hydraulic System

FR91424,0000003 –19–05NOV03–7/20

T65

85X

K–U

N–2

7OC

T88

T82

86B

L–U

N–1

6JU

L94

333360

84

A—NutB—ShimC—PistonD—CushionE—Flat FaceF—NotchG—Cushion Seal

13. Remove parts (A—D and G).

NOTE: Note direction of flat face (E) on cushion andnotches (F) in cushion seal and cushion forassembly.

14. Remove parts from rod guide and piston.

NOTE: Inspect the piston, inside the rod guide and barrelfor wear, scratches and nicks that may cut ordamage a seal or wear ring.



PN=266

Hydraulic System

33336085

FR91424,0000003 –19–05NOV03–8/20

T65

57H

R–U

N–2

7OC

T88

T65

85X

G–U

N–2

7OC

T88

A—Dust SealB—Bushing

15. Remove and inspect dust seals (A) and bushings (B)for wear or damage. See Boom, Arm, and BucketPins, Bushings and Bosses Inspection. Repair orreplace parts as necessary. (Group 3340.)

Boom Cylinder—200CLC—SpecificationBoom Cylinder Head EndBushing—ID 80.0 mm nominal....................................................................

3.15 in. nominalID 81.5 mm limit of use...............................................................................

3.21 in. limit of useBoom Cylinder Rod EndBushing—ID 90.0 mm nominal....................................................................


3.60 in. limit of use

Boom Cylinder—270CLC—SpecificationBoom Cylinder Head EndBushing—ID 100.0 mm nominal..................................................................

3.94 in. nominalID 101.5 mm limit of use.............................................................................

4.0 in. limit of useBoom Cylinder Rod EndBushing—ID 100.0 mm nominal..................................................................

3.94 in. nominalID 101.5 mm limit of use.............................................................................


16. Check for rod curvature on V-blocks using dialindicator.

SpecificationBoom 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—SpecificationBoom Rod Allowable Scratch—Depth 0.1 mm (enough to detect by a

fingernail)........................................................

0.004 in. (enough to detect by afingernail)

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.



PN=267


Hydraulic System

333360

86

FR91424,0000003 –19–05NOV03–9/20

T19

0994

–UN

–09M

AY

03

Boom Cylinder—200CLC, 270CLC—Right Cylinder Shown

19.


PN=268


Hydraulic System

FR91424,0000003 –19–05NOV03–10/20T

1062

11–U

N–1

6JA

N97

Boom Cylinder—200CLC, 270CLC

1—Cylinder Barrel and 11—Back-Up Ring 21—Nut 32—O-RingBushings 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (4 used)

2—Rod and Bushings 13—Cushion 23—Steel Ball 34—Band3—Rod Guide 14—Cushion Seal 25—Seal (2 used) 35—Clamp4—Wear Ring 15—Piston 26—Retainer Ring 36—Cap Screw (2 used)5—Snap Ring 16—Cap Seal and O-Ring 27—Seal (2 used) 37—Lock Washer (2 used)6—Buffer Ring Seal 17—Back-Up Ring (2 used) 28—Hydraulic Line 38—Half Clamp (2 used)7—U-Cup Seal 18—Buffer Seal (2 used) 29—Hydraulic Line 39—Cap Screw8—Back-Up Ring 19—Wear Ring (2 used) 30—O-Ring 40—Lock Washer9—Wiper Seal 20—Shim 31—Cap Screw (4 used) 41—Lubrication Fitting10—O-Ring

Install boom cylinder barrel and rod bushings to adepth equal to the thickness of seals (25 and 27).

NOTE: The left and right boom cylinders are the sameexcept for the head (28) and rod (29) endlines, and clamps (34 and 35).

NOTE: Use a cylinder repair kit when assembling acylinder.

20. Install seals (25 and 27) tight against bushing withseal lip outward.

33336087



PN=269

Hydraulic System

FR91424,0000003 –19–05NOV03–11/20

T65

85X

N–U

N–2

7OC

T88

333360

88

A—Back-Up RingB—Snap RingC—Wear RingD—O-Ring

21. Push wear ring (C) to bottom of bore using a driverdisk and a press.

22. Install the snap ring (B).

23. Install back-up ring (A) and O-ring (D).



PN=270

Hydraulic System

33336089

FR91424,0000003 –19–05NOV03–12/20

T79

63A

K–U

N–0

1AP

R93

T76

23A

F–U

N–2

2OC

T91

A—Snap RingB—Wear RingC—Notched SideD—Black Buffer RingE—Green Buffer RingF—U-Cup SealG—Back-Up RingH—Wiper SealI—Buffer Ring SealJ—Rod GuideK—Bending Method Seal Installation

24. Install buffer ring seal (I) with notched side towardswear 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 ofcylinder.

30. Install rod guide (J) on the rod.


PN=271


Hydraulic System

FR91424,0000003 –19–05NOV03–13/20

T79

64A

Q–U

N–1

8MA

R93

333360

90

A—JDG901-3 Pusher—JDG917 Installer—200CLC—JDG842-1 Installer—270CLC

B—Cap SealC—O-RingD—Wear Ring

31. Install O-ring (C) into the middle groove of piston.

32. Install the buffer seals (D). The buffer seal in grooveabove helps support the thin section of installer. Thebuffer seal below keeps the cap seal from going intothat groove if pushed too far.

33. Apply clean oil to installer.

34. Push the cap seal (B) down the installer and into themiddle groove over the O-ring (C) using the correctsize pusher (A).

FR91424,0000003 –19–05NOV03–14/20

T63

96A

C–U

N–2

7OC

T88

35. Check the cap seal, seal must fit tight against O-ringand not turn. If seal can be turned, it has beenstretched too much and can be damaged duringassembly into cylinder barrel.

36. For a cap seal that has been stretched too much,shrink it to its original size using a ring compressor ora plastic tie band and hose clamp.

When using a ring compressor, put a piece of shimstock between cap seal and compressor at the jointso it does not damage seal.

When using a plastic tie band and hose clamp, grinda taper on one end of tie band. Install tie band withthe taper against cap seal. Before tightening the hoseclamp, check to be sure tie band is under hose clampall around piston.


PN=272


Hydraulic System

FR91424,0000003 –19–05NOV03–15/20

T65

57H

V–U

N–2

7OC

T88

A—Wear Ring (2 used)B—Buffer Seal (2 used)C—Back-Up Ring (2 used)

37. Install a back-up ring (C) on each side of cap seal.

38. Install the buffer seals (B) and wear rings (A).

Turn the seals and rings so the slits are 180° fromeach other

FR91424,0000003 –19–05NOV03–16/20

T82

86B

L–U

N–1

6JU

L94

Boom Cylinder Rod

33336091

D—CushionE—Flat FaceF—NotchG—Cushion Seal

39. Install cushion seal (G) so notches (F) are towardsthe piston and threaded section of rod.

40. Install cushion (D) so wide end of flat face (E) istowards the rod guide and narrow end is towards thepiston.

FR91424,0000003 –19–05NOV03–17/20

T65

85X

K–U

N–2

7OC

T88

A—NutB—ShimC—PistonD—Cushion

41. Install piston (C) so flat side is against the cushion(D)

42. Install shim (B).

43. Install nut (A).


PN=273


Hydraulic System

FR91424,0000003 –19–05NOV03–18/20

T77

68A

H–U

N–2

2MA

Y92

333360

92

B—Nut



44. Tighten nut using the JT30043-30 Hex Piston NutWrench. Install wrench so cap screw is tightenagainst 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.) pieceof steel flat stock between nut and cap screw. Tightencap screw.

SpecificationBoom Cylinder Piston-to-RodNut—Torque 4780 N•m...............................................................................

3525 lb-ft

FR91424,0000003 –19–05NOV03–19/20

T65

85X

I–U

N–2

7OC

T88


45. Install steel ball (B).

46. Tighten set screw (A).

SpecificationBoom Cylinder Nut-to-Rod SetScrew—Torque 57 N•m..............................................................................

42 lb-ft

47. Stake set screw in two places 90° from previousstake marks.


PN=274


Hydraulic System

FR91424,0000003 –19–05NOV03–20/20

T65

57H

I–U

N–2

7OC

T88

A—Cap ScrewB—Lines

48. Apply clean oil to piston and seals. Attach a hoist torod using a lifting strap. Carefully install piston, rodand rod guide into barrel.

49. Tighten cap screws (A).

SpecificationBoom Cylinder RodGuide-to-Barrel Cap Screw—Torque 267 N•m.........................................................................................

197 lb-ft

50. Install the lines (B).

33336093


PN=275

Hydraulic System

333360

94

FR91424,0000006 –19–11NOV03–1/8

Boom Cylinder Disassemble and Assemble—230CLC

2

34

32

36

37

40

5

4

715

31

33

26

4225

28

29

2829

30

30

311

910

1314

2118

2221

20

2320

1

1

44

T196495 T19

6495

–UN

–26N

OV

03

Boom Cylinder—230CLC—Right Cylinder Shown


PN=276


Hydraulic System

FR91424,0000006 –19–11NOV03–2/8

1—Bushings (2 used) 11—Snap Ring 23—Packing 33—Clamp2—Rod and Bushings 13—Bushing 25—Cap Screw (6 used) 34—Cap Screw (2 used)3—Seal 14—Snap Ring 26—Hydraulic Line 36—Clamp4—Rod Guide 15—Cushion Ring 28—Cap Screw (4 used) 37—Cap Screw5—Cap Screw (12 used) 18—Piston 29—Cap Screw (4 used) 40—Lubrication Fitting7—O-Ring 20—Piston Ring (2 used) 30—O-Ring (2 used) 42—Washer (6 used)9—Seal 21—Wear Ring (2 used) 31—Hydraulic Line 44—Hydraulic Cylinder Barrel10—Ring 22—Seal Ring 32—Clamp

NOTE: Disassemble and assemble procedures are thesame for both right and left boom cylinders.


SpecificationBoom Cylinder—Weight 217 kg approximate......................................

480 lb approximate


FR91424,0000006 –19–11NOV03–3/8T

6557

HI

–UN

–27O

CT

88

33336095


2. Remove line (B).







PN=277

Hydraulic System

FR91424,0000006 –19–11NOV03–4/8

T65

57H

K–U

N–2

7OC

T88

B—Sliding Housing


8. Remove cap screws (25) and washers (42) from piston(18).

9. Remove piston (18), cushion ring (15), rod guide (4)from rod (2).

10. Remove piston rings (20), wear rings (21), seal ring(22), and O-ring (23) from piston (18).


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 cylinderbarrel bushings (1) for wear or damage. See Boom,Arm, and Bucket Pins, Bushings and BossesInspection. Repair or replace parts as necessary.(Group 3340.)

Boom Cylinder—230CLC—SpecificationBoom Cylinder Head EndBushing—ID 90.0 mm nominal....................................................................


3.60 in. limit of useBoom Cylinder Rod EndBushing—ID 90.0 mm nominal....................................................................



333360

96



PN=278

Hydraulic System

FR91424,0000006 –19–11NOV03–5/8

T65

85X

G–U

N–2

7OC

T88


SpecificationBoom Rod—Curvature 0.5 mm per 1 m....................................................

0.020 in. per 3.25 ft


Boom Cylinder—SpecificationBoom Rod Allowable Scratch—Depth 0.1 mm (enough to detect by a

fingernail)........................................................


Boom Rod—230CLC—OD 89.910—90.0 mm...........................................3.536— 3.540 in.


33336097



PN=279

Hydraulic System

333360

98

FR91424,0000006 –19–11NOV03–6/8

2

34

32

36

37

40

5

4

715

31

33

26

4225

28

29

2829

30

30

311

910

1314

2118

2221

20

2320

1

1

44

T196495 T19

6495

–UN

–26N

OV

03

Boom Cylinder—230CLC—Right Cylinder Shown

16.


PN=280


Hydraulic System

33336099

FR91424,0000006 –19–11NOV03–7/8

T19

6497

–UN

–10D

EC

03

Boom Cylinder—230CLC

1—Bushings (2 used) 11—Snap Ring 23—Packing 33—Clamp2—Rod and Bushings 13—Bushing 25—Cap Screw (6 used) 34—Cap Screw (2 used)3—Seal 14—Snap Ring 26—Hydraulic Line 36—Clamp4—Rod Guide 15—Cushion Ring 28—Cap Screw (4 used) 37—Cap Screw5—Cap Screw (12 used) 18—Piston 29—Cap Screw (4 used) 40—Lubrication Fitting7—O-Ring 20—Piston Ring (2 used) 30—O-Ring (2 used) 42—Washer (6 used)9—Seal 21—Wear Ring (2 used) 31—Hydraulic Line 44—Hydraulic Cylinder Barrel10—Ring 22—Seal Ring 32—Clamp

Install boom cylinder head end and rod end bushings.

NOTE: The left and right boom cylinders are the sameexcept for the hydraulic lines (26 and 31), andclamps (32 and 33).


17. Install bushing (13) to bottom of bore in rod guide(4) using a driver disk and a press.

18. Install the snap ring (14).

IMPORTANT: Ring (10), seal (9), and seal (3) mustbe installed in the correct direction.

Ensure that ring and seals areinstalled so that slotted side isfacing toward cylinder head end(pressure side).

19. Install ring (10), seal (9), seal (3), and snap ring(11).

20. Install O-ring (7).

21. Install packing (23), seal ring (22), wear rings (21),and piston rings (20) on piston (18).

22. Install rod guide assembly on rod (2).


PN=281


Hydraulic System

FR91424,0000006 –19–11NOV03–8/8

IMPORTANT: Cushion ring (15) must be installedin the correct direction. Ensure thatcushion ring is installed so thatslotted end is facing toward piston(18).

23. Install cushion ring (15) on rod (2).

24. Secure rod assembly on bench and install piston(18) assembly to rod (2). Install cap screws (25)and washers (42).

SpecificationPiston-to-Rod Cap Screw—Torque 395 N•m....................................................................................

290 lb-ft

25. Apply clean oil to piston and seals. Attach a hoistto rod using a lifting strap. Carefully install piston,rod and rod guide into barrel.


SpecificationBoom Cylinder RodGuide-to-Hydraulic CylinderBarrel Cap Screw—Torque 395 N•m..................................................

290 lb-ft

27. Install hydraulic lines (26 and 31).

FR91424,0000004 –19–11NOV03–1/6

Arm Cylinder Remove and Install


333360,100

FR91424,0000004 –19–11NOV03–2/6

T10

6031

–UN

–10J

AN

97

2. Retract arm and bucket cylinders and lower bucket toground.



4. Loosen arm cylinder hydraulic lines at frame end ofboom to release any residual pressure.




PN=282

Hydraulic System

FR91424,0000004 –19–11NOV03–3/6

T14

3063

–UN

–02A

UG

01

1—Arm Cylinder2—Boom3—Wood Block

6. Insert wood block (3 ) between arm cylinder (1) andboom (2).


SpecificationArm Cylinder—200CLC—Weight 259 kg approximate...............................

570 lb approximateArm Cylinder—230CLC—Weight 285 kg approximate...............................

630 lb approximateArm Cylinder—270CLC—Weight 307 kg approximate...............................

680 lb approximate

7. Attach arm cylinder to hoist using lifting straps.

FR91424,0000004 –19–11NOV03–4/6

T14

3064

–UN

–02A

UG

01

333360,101

1—Nut (2 used)2—Cap Screw3—Shim (as required)4—Arm Cylinder-to-Arm Pin


NOTE: Note location of shims (3) to aid in assembly.

9. Push pin (4) out and remove shims.

10. Disconnect lubrication line.



PN=283

Hydraulic System

333360,102

FR91424,0000004 –19–11NOV03–5/6

T14

3065

–UN

–02A

UG

01

1—Nut (2 used)2—Cap Screw3—Shim (as required)4—Arm Cylinder-to-Boom Pin


NOTE: Note location of shims (3) to aid in assembly.

12. Push pin (4) out and remove shims.

13. Remove arm cylinder

14. Repair or replace parts as necessary. See ArmCylinder Disassemble and Assemble—200CLC,270CLCor see Arm Cylinder Disassemble andAssemble—230CLC. (Group 3360.)

15. Install shims equally on each side of cylinder to getminimum amount of clearance in joint. There must besome clearance in the joint.

16. Align pin bores so shims are not damaged as pin (4)is installed.


SpecificationArm Cylinder Pivot LubricationLine—Torque 29.5 N•m...............................................................................

21.5 lb-ft

18. Connect arm cylinder head end to boom.


SpecificationArm Cylinder-to-Boom PinRetainer Nut—200CLC—Torque 550 N•m (tighten nut against nut)...........

405 lb-ft (tighten nut against nut)Arm Cylinder-to-Boom PinRetainer Nut—230CLC,270CLC—Torque 750 N•m (tighten nut against nut)...................................




PN=284

Hydraulic System

333360,103

FR91424,0000004 –19–11NOV03–6/6


20. Slowly extend arm cylinder to align pin bores soshims are not damaged as pin is installed.

21. Connect arm cylinder rod end to arm.


SpecificationArm Cylinder-to-Arm Pin RetainerNut—200CLC—Torque 550 N•m (tighten nut against nut).........................

405 lb-ft (tighten nut against nut)Arm Cylinder-to-Arm Pin RetainerNut—230CLC, 270CLC—Torque 750 N•m (tighten nut against nut)..........



SpecificationArm Cylinder Pivot LubricationLine—Torque 29.5 N•m...............................................................................

21.5 lb-ft

24. Connect lines.

25. Lubricate all pivot joints. See Track Adjuster, WorkingTool Pivot, Swing Bearing, And Swing Bearing GearGrease. (Operator’s Manual.)


27. Check hydraulic oil level. See Check Hydraulic OilLevel. (Operator’s Manual.)


PN=285

Hydraulic System

333360,104

FR91424,0000005 –19–11NOV03–1/22

Arm Cylinder Disassemble and Assemble—200CLC, 270CLC

T19

0996

–UN

–09M

AY

03

Arm Cylinder


PN=286


Hydraulic System

FR91424,0000005 –19–11NOV03–2/22

1—Cylinder Barrel and 11—Back-Up Ring 21—Nut 32—O-RingBushing 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (8 used)

2—Rod and Bushings 13—Cushion 23—Steel Ball 34—Band3—Rod Guide 14—Cushion Seal 24—Cushion 35—Band4—Wear Ring 15—Piston 25—Cushion Seal 36—Cap Screw (2 used)5—Snap Ring 16—Cap Seal and O-Ring 26—Retainer Ring 37—Lock Washer (2 used)6—Buffer Ring Seal 17—Back-Up Ring (2 used) 27—Ring 38—Clamp7—U-Cup Seal 18—Buffer Seal (2 used) 29—Seal 39—Cap Screw8—Back-Up Ring 19—Wear Ring (2 used) 30—Shoulder Fitting 40—Lock Washer9—Wiper Seal 20—Shim 31—Hydraulic Line 41—Lubrication Fitting10—O-Ring


SpecificationArm Cylinder—200CLC—Weight 259 kg approximate..................................................................

571 lb approximate

Arm Cylinder—270CLC—Weight 307 kg approximate..................................................................

680 kg approximate


FR91424,0000005 –19–11NOV03–3/22T

6557

HI

–UN

–27O

CT

88

333360,105


2. Remove line (B).





FR91424,0000005 –19–11NOV03–4/22

T65

57H

K–U

N–2

7OC

T88

B—Sliding Housing



PN=287


Hydraulic System

FR91424,0000005 –19–11NOV03–5/22

T65

85X

I–U

N–2

7OC

T88




333360,106

FR91424,0000005 –19–11NOV03–6/22

T77

68A

G–U

N–2

2MA

Y92

B—Nut





12. Loosen nut (B).

SpecificationArm Cylinder Piston-to-Rod Nut—200CLC, 270CLC—Torque 10 200 N•m.....................................................

7,520 lb-ft



PN=288

Hydraulic System

FR91424,0000005 –19–11NOV03–7/22

T65

85X

K–U

N–2

7OC

T88

T82

86B

L–U

N–1

6JU

L94

333360,107


13. Remove parts (A—D and G).

NOTE: Note direction of flat face (E) on cushion andnotches (F) in cushion seal and cushion forassembly.

FR91424,0000005 –19–11NOV03–8/22

T77

78A

U–U

N–1

0JU

N92

Arm Cylinder Rod End Cushion

A—RingB—Retainer RingC—CushionD—Cushion Seal

14. Remove ring (A).

Push cushion (C) against shoulder.

Remove retainer ring (B) and remove cushion.

NOTE: Note direction of flat face on cushion and notchesin cushion seal for assembly.

Remove cushion seal (D).





PN=289

Hydraulic System

333360,108

FR91424,0000005 –19–11NOV03–9/22

T65

57H

R–U

N–2

7OC

T88

T65

85X

G–U

N–2

7OC

T88


16. Remove and inspect dust seals (A) and bushing (B)for wear or damage. Replace parts as necessary. SeeBoom, Arm, and Bucket Pins, Bushings and BossesInspection. (Group 3340.)

Arm Cylinder—200CLC—SpecificationArm Cylinder Head End and RodEnd Bushing—ID 80.0 mm nominal............................................................



Arm Cylinder—270CLC—SpecificationArm Cylinder Head End and RodEnd Bushing—ID 90.0 mm nominal............................................................




SpecificationArm Rod—Curvature 0.5 mm per 1 m.......................................................

0.020 in. per 3.25 ft


Arm Cylinder—200CLC—SpecificationArm Rod Allowable Scratch—Depth 0.1 mm (enough to detect by a

fingernail)........................................................


Arm Rod—OD 94.973—95.0 mm..............................................................3.739—3.740 in.

Arm Cylinder—270CLC—SpecificationArm Rod Allowable Scratch—Depth 0.1 mm (enough to detect by a

fingernail)........................................................


Arm Rod—OD 99.91—100 mm.................................................................3.936—3.940 in.



PN=290


Hydraulic System

333360,109

FR91424,0000005 –19–11NOV03–10/22

T19

0996

–UN

–09M

AY

03

Arm Cylinder

20.


PN=291


Hydraulic System

FR91424,0000005 –19–11NOV03–11/22

T10

6126

–UN

–16J

AN

97

Arm Cylinder

1—Cylinder Barrel and 11—Back-Up Ring 21—Nut 32—O-RingBushing 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (8 used)

2—Rod and Bushings 13—Cushion 23—Steel Ball 34—Band3—Rod Guide 14—Cushion Seal 24—Cushion 35—Band4—Wear Ring 15—Piston 25—Cushion Seal 36—Cap Screw (2 used)5—Snap Ring 16—Cap Seal and O-Ring 26—Retainer Ring 37—Lock Washer (2 used)6—Buffer Ring Seal 17—Back-Up Ring (2 used) 27—Ring 38—Clamp7—U-Cup Seal 18—Buffer Seal (2 used) 29—Seal (4 used) 39—Cap Screw8—Back-Up Ring 19—Wear Ring (2 used) 30—Shoulder Fitting 40—Lock Washer9—Wiper Seal 20—Shim 31—Hydraulic Line 41—Lubrication Fitting10—O-Ring

Install arm cylinder barrel and rod bushings to a depthequal to the thickness of seals (29).


21. Install seals (29) tight against bushing with seal lipoutward.

333360,110



PN=292

Hydraulic System

FR91424,0000005 –19–11NOV03–12/22

T65

85X

N–U

N–2

7OC

T88

333360,111







PN=293

Hydraulic System

333360,112

FR91424,0000005 –19–11NOV03–13/22

T79

63A

K–U

N–0

1AP

R93

T76

23A

F–U

N–2

2OC

T91



Install black buffer ring (D) with notched side (C)towards the wear ring.

Install green buffer ring (E).


Install back-up ring (G).




PN=294


Hydraulic System

FR91424,0000005 –19–11NOV03–14/22

T79

64A

Q–U

N–1

8MA

R93

333360,113

A —JDG901-3 Pusher—JDG842-1 Installer—200CLC—JDG843-1 Installer—270CLC






FR91424,0000005 –19–11NOV03–15/22

T63

96A

C–U

N–2

7OC

T88






PN=295


Hydraulic System

FR91424,0000005 –19–11NOV03–16/22

T65

57H

V–U

N–2

7OC

T88


35. Install a back-up ring (C) on each side of cap sealand O-ring.



FR91424,0000005 –19–11NOV03–17/22

T77

78A

V–U

N–1

0JU

N92

Arm Cylinder Rod

333360,114

A—Cushion SealB—NotchC—Cushion Seal

37. Install cushion seals (A and C) so notches (B) aretowards the piston and threaded section of rod.



PN=296

Hydraulic System

FR91424,0000005 –19–11NOV03–18/22

T77

78A

U–U

N–1

0JU

N92

Arm Cylinder Rod Cushion

A—RingB—Retainer RingC—CushionD—Cushion Seal

38. Install cushion (C) so wide end of flat face is towardsthe end of rod and narrow end is towards the piston.

39. Install retainer ring in groove.

40. Pull cushion out against retainer ring.

41. Install ring (A).

FR91424,0000005 –19–11NOV03–19/22T

6585

XK

–UN

–27O

CT

88

333360,115







PN=297

Hydraulic System

FR91424,0000005 –19–11NOV03–20/22

T77

68A

H–U

N–2

2MA

Y92

333360,116

B—Nut





SpecificationArm Cylinder Piston-to-Rod Nut—Torque 10 200 N•m.....................................................................................

7,520 lb-ft

FR91424,0000005 –19–11NOV03–21/22

T65

85X

I–U

N–2

7OC

T88




SpecificationArm Cylinder Nut-to-Rod SetScrew—Torque 57 N•m..............................................................................

42 lb-ft



PN=298


Hydraulic System

FR91424,0000005 –19–11NOV03–22/22

T65

57H

I–U

N–2

7OC

T88




SpecificationArm Cylinder Rod Guide-to-BarrelCap Screw—Torque 365 N•m....................................................................

270 lb-ft

51. Install the lines (B).

333360,117


PN=299

Hydraulic System

333360,118

FR91424,0000010 –19–21NOV03–1/8

Arm Cylinder Disassemble and Assemble—230CLC

3939

40

36

5

46

30 32

54

51

31

25

34

34

37

37

711

910

1314

4849

53

35

40

29

27

46

2

5221

22

2152

15

1

1

T196496

56

T19

6496

–UN

–26N

OV

03

Arm Cylinder—230CLC


PN=300


Hydraulic System

FR91424,0000010 –19–21NOV03–2/8

1—Bushing (2 used) 13—Bushing 31—Cap Screw (2 used) 46—Lubrication Fitting2—Rod and Bushings 14—Snap Ring 32—O-Ring 48—Stop4—Rod Guide 15—Cushion Ring 34—Clamp (2 used) 49—Ball5—Cap Screw (14 used) 21—Piston Ring (2 used) 35—Clamp 51—Piston6—O-Ring 22—Seal Ring 36—Clamp 52—Ring (2 used)7—Seal 25—Cap Screw (6 used) 37—Cap Screw (4 used) 53—Plunger9—Seal 27—Spring 39—Clamp (2 used) 54—Washer (6 used)10—Scraper Ring 29—Hydraulic Line 40—Cap Screw (4 used) 56—Hydraulic Cylinder Barrel11—Snap Ring 30—Cap Screw (2 used)


SpecificationArm Cylinder—Weight 285 kg approximate.........................................

630 lb approximate


FR91424,0000010 –19–21NOV03–3/8T

6557

HI

–UN

–27O

CT

88

A—Cap ScrewB—Hydraulic Line

2. Remove line (B).




IMPORTANT: To avoid damaging sliding surfaces, besure to pull out rod, rod guide, andpiston straight out of cylinder barrel.


333360,119



PN=301

Hydraulic System

333360,120

FR91424,0000010 –19–21NOV03–4/8

T65

57H

K–U

N–2

7OC

T88

B—Sliding Housing




10. Remove spring (37), stop (48), ball (49), and plunger(53) from piston (51).

11. Remove piston rings (21), wear rings (52), and sealring (22) from piston (51).




Arm Cylinder—230CLC—SpecificationArm Cylinder Head EndBushing—ID 90.0 mm nominal....................................................................


3.60 in. limit of useArm Cylinder Rod End Bushing—ID 90.0 mm nominal....................................................................................





PN=302

Hydraulic System

FR91424,0000010 –19–21NOV03–5/8

T65

85X

G–U

N–2

7OC

T88


SpecificationArm Rod—Curvature 0.5 mm per 1 m.......................................................

0.020 in. per 3.25 ft


Arm Cylinder—SpecificationArm Rod Allowable Scratch—Depth 0.1 mm (enough to detect by a

fingernail)........................................................


Arm Rod—230CLC—OD 104.910—105.0 mm..........................................4.126— 4.130 in.


333360,121



PN=303

Hydraulic System

333360,122

FR91424,0000010 –19–21NOV03–6/8

3939

40

36

5

46

30 32

54

51

31

25

34

34

37

37

711

910

1314

4849

53

35

40

29

27

46

2

5221

22

2152

15

1

1

T196496

56

T19

6496

–UN

–26N

OV

03


17.


PN=304


Hydraulic System

333360,123

FR91424,0000010 –19–21NOV03–7/8

T19

6498

–UN

–09D

EC

03


1—Bushing (2 used) 13—Bushing 31—Cap Screw (2 used) 46—Lubrication Fitting2—Rod and Bushings 14—Snap Ring 32—O-Ring 48—Stop4—Rod Guide 15—Cushion Ring 34—Clamp (2 used) 49—Ball5—Cap Screw (14 used) 21—Piston Ring (2 used) 35—Clamp 51—Piston6—O-Ring 22—Seal Ring 36—Clamp 52—Wear Ring (2 used)7—Seal 25—Cap Screw (6 used) 37—Cap Screw (4 used) 53—Plunger9—Seal 27—Spring 39—Clamp (2 used) 54—Washer (6 used)10—Scraper Ring 29—Hydraulic Line 40—Cap Screw (4 used) 56—Hydraulic Cylinder Barrel11—Snap Ring 30—Cap Screw (2 used)

Install arm cylinder head end and rod end bushings.




IMPORTANT: Ring (10), seal (9), and seal (7) mustbe installed in the correct direction.Ensure that ring and seals areinstalled so that slotted side is

facing toward cylinder head end(pressure side).



22. Install seal ring (22), piston rings (21), and wearrings (52) on piston (51).

23. Install plunger (53), ball (49), stop (48), and spring(27).


PN=305


Hydraulic System

FR91424,0000010 –19–21NOV03–8/8






400 lb-ft



SpecificationArm Cylinder RodGuide-to-Hydraulic CylinderBarrel Cap Screw—Torque 395 N•m..................................................

290 lb-ft

29. Install hydraulic line (29).

333360,124

FR91424,0000011 –19–21NOV03–1/5

Bucket Cylinder Remove and Install

T10

6031

–UN

–10J

AN

97T

1061

35–U

N–0

9JA

N97

B—Bucket CylinderC—End of ArmD—Wood Block


2. Retract arm cylinder and bucket cylinder (B) and lowerbucket to ground. Position end of arm (C) on woodblock (D).




PN=306


Hydraulic System

FR91424,0000011 –19–21NOV03–2/5

T14

3075

–UN

–02A

UG

01

1—Side and Center Links-to-Bucket Cylinder Pin2—Cap Screw3—Shim (as required)4—Bucket Cylinder Rod End-to-Bucket Section Top

Port Line5—Wood Block6—Nut (2 used)7—Side Link


5. Connect center link to hoist using lifting strap.

6. Put wood block (5) between bucket cylinder and arm tohold cylinder up when pin (1) is removed.


NOTE: Mark location of shims (3) to aid in assembly.

8. Push pin (1) out and remove shims (3).


333360,125


PN=307

Hydraulic System

333360,126

FR91424,0000011 –19–21NOV03–3/5

2

1

3

5

4

6

T14

3076

–UN

–02A

UG

01

1—Bucket Cylinder Rod End Hose2—Bucket Cylinder3—Nut (2 used)4—Shim (as required)5—Cap Screw6—Bucket Cylinder-to-Arm Pin


Bucket Cylinder—SpecificationBucket Cylinder—200CLC—Weight 145 kg approximate.........................................................................

320 lb approximateBucket Cylinder—230CLC—Weight 182 kg approximate.........................................................................

400 lb approximateBucket Cylinder—270CLC—Weight 216 kg approximate.........................................................................

480 lb approximate

9. Disconnect bucket cylinder rod end hose (1).

10. Connect bucket cylinder (2) to hoist using lifting strap.


NOTE: Mark location of shims (4) to aid in assembly.

12. Push pin (6) out and remove shims (4).

13. Remove bucket cylinder.

14. Repair or replace parts as necessary. See BucketCylinder Disassemble and Assemble—200CLC,270CLC or see Bucket Cylinder Disassemble andAssemble—230CLC. (Group 3360.)

15. Install shims equally on each side of bucket cylinderhead end to get minimum amount of clearance injoint.

16. Align pin bores so shims are not damaged as pin isinstalled.

17. Connect bucket cylinder head end to arm.


Bucket Cylinder—SpecificationBucket Cylinder-to-Arm PinRetainer Nut—200CLC—Torque 271 N•m (tighten nut against nut)...........

200 lb-ft (tighten nut against nut)Bucket Cylinder-to-Arm PinRetainer Nut—230CLC,270CLC—Torque 750 N•m (tighten nut against nut)...................................



PN=308


Hydraulic System

333360,127

FR91424,0000011 –19–21NOV03–4/5


Tighten bucket cylinder hoses.

Bucket Cylinder—SpecificationBucket Cylinder Hose—200CLC—Torque 175 N•m..........................................................................

130 lb-ftBucket Cylinder Hose—230CLC,270CLC—Torque 205 N•m..........................................................................

152 lb-ft


20. Start engine.

21. Slowly extend bucket cylinder to align pin bores soshims are not damaged as pin is installed.

22. Install shims equally on each side of cylinder rod endand side links to get minimum amount of clearance injoint.

23. Connect bucket cylinder head end to arm.

24. Tighten nuts against each other allowing cap screw tobe free to turn in hole.

Bucket Cylinder—SpecificationBucket Cylinder-to-Pin RetainerNut—Torque 550 N•m (tighten nut against nut)..........................................


25. Lubricate all pivot joints. See Track Adjuster, WorkingTool Pivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)



PN=309


Hydraulic System

FR91424,0000011 –19–21NOV03–5/5


333360,128


PN=310

Hydraulic System

333360,129


PN=311

Hydraulic System

333360,130

FR91424,0000012 –19–21NOV03–1/20

Bucket Cylinder Disassemble and Assemble—200CLC, 270CLC

T19

0997

–UN

–09M

AY

03

Bucket Cylinder


PN=312


Hydraulic System

FR91424,0000012 –19–21NOV03–2/20

1—Cylinder Barrel and 10—O-Ring 20—Nut 29—O-Ring (2 used)Bushings 11—Back-Up Ring 21—Set Screw 30—Cap Screw (8 used)

2—Rod and Bushings 12—Cap Screw (12 used) 22—Steel Ball 31—Band3—Rod Guide 13—Cushion 23—Lubrication Fitting (2 32—Band4—Wear Ring 14—Piston used) 33—Cap Screw (2 used)5—Snap Ring 15—Cap Seal and O-Ring 24—Seal (2 used) 34—Lock Washer (2 used)6—Buffer Ring Seal 16—Back-Up Ring (2 used) 26—Seal (2 used) 35—Clamp7—U-Cup Seal 17—Buffer Seal (2 used) 27—Elbow Fitting 36—Cap Screw8—Back-Up Ring 18—Wear Ring (2 used) 28—Hydraulic Line 37—Lock Washer9—Wiper Seal 19—Shim


SpecificationBucket Cylinder—200CLC—Weight 145 kg approximate..................................................................

320 lb approximate

Bucket Cylinder—270CLC—Weight 216 kg approximate..................................................................

480 lb approximate


FR91424,0000012 –19–21NOV03–3/20T

6557

HI

–UN

–27O

CT

88

333360,131


2. Remove line (B).





FR91424,0000012 –19–21NOV03–4/20

T65

57H

K–U

N–2

7OC

T88

B—Sliding Housing



PN=313


Hydraulic System

FR91424,0000012 –19–21NOV03–5/20

T65

85X

I–U

N–2

7OC

T88




333360,132

FR91424,0000012 –19–21NOV03–6/20

T77

68A

G–U

N–2

2MA

Y92

B—Nut





12. Loosen nut (B).

SpecificationBucket Cylinder Piston-to-RodNut—Torque 6570 N•m..............................................................................

4,850 lb-ft



PN=314

Hydraulic System

FR91424,0000012 –19–21NOV03–7/20

T65

85X

K–U

N–2

7OC

T88

T82

86B

L–U

N–1

6JU

L94

333360,133


13. Remove parts (A—D).





PN=315

Hydraulic System

333360,134

FR91424,0000012 –19–21NOV03–8/20

T65

57H

R–U

N–2

7OC

T88

T65

85X

G–U

N–2

7OC

T88


15. Remove and inspect dust seals (A) and bushing (B)for wear or damage. Replace parts as necessary. SeeBoom, Arm, and Bucket Pins, Bushings and BossesInspection. (Group 3340.)

Bucket Cylinder—200CLC—SpecificationBucket Cylinder Head EndBushing—ID 71.0 mm nominal....................................................................


2.85 in. limit of useBucket Cylinder Rod EndBushing—ID 80.0 mm nominal....................................................................









SpecificationBucket Rod—Curvature 0.5 mm per 1 m...................................................

0.020 in. per 3.25 ft


Bucket Cylinder—SpecificationBucket Rod Allowable Scratch—Depth 0.1 mm (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.



PN=316


Hydraulic System

333360,135

FR91424,0000012 –19–21NOV03–9/20

T19

0996

–UN

–09M

AY

03

Bucket Cylinder

19.


PN=317


Hydraulic System

FR91424,0000012 –19–21NOV03–10/20

T10

6212

–UN

–17J

AN

97

Bucket Cylinder

1—Cylinder Barrel and 10—O-Ring 20—Nut 29—O-Ring (2 used)Bushings 11—Back-Up Ring 21—Set Screw 30—Cap Screw (8 used)

2—Rod and Bushings 12—Cap Screw (12 used) 22—Steel Ball 31—Band3—Rod Guide 13—Cushion 23—Lubrication Fitting (2 32—Band4—Wear Ring 14—Piston used) 33—Cap Screw (2 used)5—Snap Ring 15—Cap Seal and O-Ring 24—Seal (2 used) 34—Lock Washer (2 used)6—Buffer Ring Seal 16—Back-Up Ring (2 used) 26—Seal (2 used) 35—Clamp7—U-Cup Seal 17—Buffer Seal (2 used) 27—Elbow Fitting 36—Cap Screw8—Back-Up Ring 18—Wear Ring (2 used) 28—Hydraulic Line 37—Lock Washer9—Wiper Seal 19—Shim

Install cylinder barrel and rod bushing to a depth equalto the thickness of seals (24 and 26).


20. Install seals (24 and 26) tight against bushing withseal lip outward.

333360,136



PN=318

Hydraulic System

FR91424,0000012 –19–21NOV03–11/20

T65

85X

N–U

N–2

7OC

T88

333360,137







PN=319

Hydraulic System

333360,138

FR91424,0000012 –19–21NOV03–12/20

T79

63A

K–U

N–0

1AP

R93

T76

23A

F–U

N–2

2OC

T91



25. Install black buffer ring (D) with notched side (C)towards the wear ring.

26. Install green buffer ring (E).


28. Install back-up ring (G).




PN=320


Hydraulic System

FR91424,0000012 –19–21NOV03–13/20

T79

64A

Q–U

N–1

8MA

R93

333360,139

A—JDG840-6 Pusher—JDG840-4 Installer—200CLC—JDG842-1 Installer—270CLC






FR91424,0000012 –19–21NOV03–14/20

T63

96A

C–U

N–2

7OC

T88






PN=321


Hydraulic System

FR91424,0000012 –19–21NOV03–15/20

T65

57H

V–U

N–2

7OC

T88


37. Install a back-up ring (C) on each side of cap seal.



FR91424,0000012 –19–21NOV03–16/20

T82

86B

L–U

N–1

6JU

L94

Boom Cylinder Rod Shown

333360,140

D—CushionE—Flat FaceF—Notch (not on bucket cylinder)G—Cushion Seal (not on bucket cylinder)

NOTE: For bucket cylinder, no cushion seal is used underthe cushion.

39. Install cushion (D) so wide end of flat face (E) istowards the rod guide and narrow end is towards thepiston.

FR91424,0000012 –19–21NOV03–17/20

T65

85X

K–U

N–2

7OC

T88






PN=322


Hydraulic System

FR91424,0000012 –19–21NOV03–18/20

T77

68A

H–U

N–2

2MA

Y92

333360,141

B—Nut





SpecificationBucket Cylinder Piston-to-RodNut—Torque 6570 N•m..............................................................................

4,850 lb-ft

FR91424,0000012 –19–21NOV03–19/20

T65

85X

I–U

N–2

7OC

T88




SpecificationBucket Cylinder Nut-to-Rod SetScrew—Torque 57 N•m..............................................................................

42 lb-ft



PN=323


Hydraulic System

FR91424,0000012 –19–21NOV03–20/20

T65

57H

I–U

N–2

7OC

T88




SpecificationBucket Cylinder RodGuide-to-Barrel Cap Screw—Torque 267 N•m..........................................................................................

197 lb-ft

333360,142


PN=324

Hydraulic System

333360,143


PN=325

Hydraulic System

333360,144

FR91424,0000013 –19–21NOV03–1/9

Bucket Cylinder Disassemble and Assemble—230CLC

5

4

6

27

3435

30

32

31

25

41

711

910

1314

24

44

42

28

26

2

19

20

2021

18

1922

15

1

1

46

T196499 T19

6499

–UN

–26N

OV

03

Bucket Cylinder—230CLC


PN=326


Hydraulic System

FR91424,0000013 –19–21NOV03–2/9

1—Bushings (2 used) 11—Snap Ring 22—Packing 32—Cap Screw (2 used)2—Rod and Bushings 13—Bushing 24—Cap Screw (6 used) 34—Clamp4—Rod Guide 14—Snap Ring 25—Hydraulic Line 35—Cap Screw (2 used)5—Cap Screw (12 used) 15—Cushion Ring 26—Cap Screw (2 used) 41—Lubrication Fitting6—O-Ring 18—Piston 27—Cap Screw (2 used) 42—Lubrication Fitting7—Seal 19—Piston Ring (2 used) 28—O-Ring 44—Washer (6 used)9—Seal 20—Wear Ring (2 used) 30—Clamp 46—Hydraulic Cylinder Barrel10—Ring 21—Seal Ring 31—Clamp


SpecificationBucket Cylinder—Weight 182 kg approximate.....................................

400 lb approximate


FR91424,0000013 –19–21NOV03–3/9T

6557

HI

–UN

–27O

CT

88


2. Remove line (B).




IMPORTANT: To avoid damaging sliding surfaces, besure to pull out rod, rod guide, andpiston straight out of cylinder barrel.


333360,145



PN=327

Hydraulic System

FR91424,0000013 –19–21NOV03–4/9

T65

57H

K–U

N–2

7OC

T88

B—Sliding Housing




10. Remove piston rings (19), wear rings (20), seal ring(21), and packing (22) from piston (18).









333360,146



PN=328

Hydraulic System

FR91424,0000013 –19–21NOV03–5/9

T65

85X

G–U

N–2

7OC

T88


SpecificationBucket Rod—Curvature 0.5 mm per 1 m...................................................

0.020 in. per 3.25 ft


Bucket Cylinder—SpecificationBucket Rod Allowable Scratch—Depth 0.1 mm (enough to detect by a

fingernail)........................................................


Bucket Rod—230CLC—OD 89.910—90.0 mm.........................................3.536— 3.540 in.


333360,147



PN=329

Hydraulic System

333360,148

FR91424,0000013 –19–21NOV03–6/9

5

4

6

27

3435

30

32

31

25

41

711

910

1314

24

44

42

28

26

2

19

20

2021

18

1922

15

1

1

46

T196499 T19

6499

–UN

–26N

OV

03



PN=330


Hydraulic System

FR91424,0000013 –19–21NOV03–7/9


16.


333360,149


PN=331

Hydraulic System

333360,150

FR91424,0000013 –19–21NOV03–8/9

T19

6860

–UN

–10D

EC

03


1—Bushings (2 used) 11—Snap Ring 22—Packing 32—Cap Screw (2 used)2—Rod and Bushings 13—Bushing 24—Cap Screw (6 used) 34—Clamp4—Rod Guide 14—Snap Ring 25—Hydraulic Line 35—Cap Screw (2 used)5—Cap Screw (12 used) 15—Cushion Ring 26—Cap Screw (2 used) 41—Lubrication Fitting6—O-Ring 18—Piston 27—Cap Screw (2 used) 42—Lubrication Fitting7—Seal 19—Piston Ring (2 used) 28—O-Ring 44—Washer (6 used)9—Seal 20—Wear Ring (2 used) 30—Clamp 46—Hydraulic Cylinder Barrel10—Ring 21—Seal Ring 31—Clamp

Install bucket cylinder head end and rod end bushings.




IMPORTANT: Ring (10), seal (9), and seal (7) mustbe installed in the correct direction.Ensure that ring and seals are

installed so that slotted side isfacing toward cylinder head end(pressure side).



21. Install packing (22), seal ring (21), wear rings (20),and piston rings (19) on piston (18).



PN=332


Hydraulic System

FR91424,0000013 –19–21NOV03–9/9





290 lb-ft



SpecificationBucket Cylinder RodGuide-to-Hydraulic CylinderBarrel Cap Screw—Torque 395 N•m..................................................

290 lb-ft

27. Install hydraulic line (25).

333360,151


PN=333

Hydraulic System

TX,33,GG2374B –19–26NOV03–1/1

Hydraulic Cylinder Bleed Procedure


NOTE: Bleed air at initial start-up, whenever major repairsor maintenance (oil change) is done on hydraulicsystem, or when machine has been in storage fora period of time.

1. Run engine at slow idle.

2. Slowly operate function to move cylinder to the mosthorizontal position possible.

3. Slowly extend and retract cylinder several times toapproximately 100 mm (4 in.) from end of stroke.

4. Operate cylinder several times to full stroke.


333360,152


PN=334

Section 43Swing or Pivoting System

Contents

Page

Group 4350—Mechanical Drive ElementsSwing Gearbox . . . . . . . . . . . . . . . . . . . . . . .43-4350-1

Start-Up Procedure . . . . . . . . . . . . . . . . .43-4350-11Upperstructure . . . . . . . . . . . . . . . . . . . . . .43-4350-12Swing Bearing. . . . . . . . . . . . . . . . . . . . . . .43-4350-19

Group 4360—Hydraulic SystemSwing Motor and Park Brake. . . . . . . . . . . . .43-4360-1Crossover Relief Valve and Make-Up

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-11Swing Motor

Start-Up Procedure . . . . . . . . . . . . . . . . .43-4360-13Brake Release Valve—270CLC . . . . . . . . .43-4360-13

43


PN=1

Contents

43


PN=2

Group 4350Mechanical Drive Elements

AGALLARDO,0000039 –19–19NOV01–1/14

Swing Gearbox Repair

Remove and Install Swing Gearbox



2. Pull vacuum in hydraulic oil tank using vacuum pumpor drain hydraulic oil tank. See 200CLC Drain andRefill Capacities, 230CLC Drain and Refill Capacities,or 270CLC Drain and Refill Capacities. (Operator’sManual.)



4343501


PN=337

Mechanical Drive Elements

434350

2

AGALLARDO,0000039 –19–19NOV01–2/14

T14

3498

B–U

N–0

2AU

G01


1—Cap Screw and Washer (12 used)


NOTE: Swing motor may be removed by itself or withswing gearbox. To remove swing motor. SeeSwing Motor and Park Brake Repair. (Group4360.)

Mark swing gearbox housing to machineupperstructure to aid in installation.

4. Install JT01748 Lifting Brackets and connect to hoist.

Swing Gearbox—SpecificationSwing Motor, Brake, andGearbox—200CLC—Weight 230 kg (507 lb) approximate.........................Swing Motor, Brake, andGearbox—230CLC—Weight 275 kg (610 lb) approximate.........................Swing Motor, Brake, andGearbox—270CLC—Weight 355 kg (780 lb) approximate.........................

5. Remove cap screws and washers (1).

6. Remove swing gearbox.


8. Apply rigid-form-in place gasket to mating surfaces ofswing gearbox housing and upperstructure.

9. Install swing gearbox.


Swing Gearbox—SpecificationSwing Gearbox-to-UpperstructureCap Screw—Torque 500 N•m (370 lb-ft)....................................................

11. Connect electrical connector.


13. If hydraulic oil tank was drained, fill hydraulic oil tank.See 200CLC Drain and Refill Capacities, 230CLCDrain and Refill Capacities, or 270CLC Drain andRefill Capacities. (Operator’s Manual.)


PN=338



AGALLARDO,0000039 –19–19NOV01–3/14

14. Do Swing Gearbox Start-Up Procedure. (Seeprocedure in this group.) See Swing Motor Start-UpProcedure . (Group 4360.)


4343503


PN=339


434350

4

AGALLARDO,0000039 –19–19NOV01–4/14

23

24

25

26

31

27

28

29

30

22

1

4

3 5

21

2

6

7

8

11

12

13

1910

18

20

9

17

14

15

16

T142044

T14

2044

–UN

–14M

AY

01


PN=340



AGALLARDO,0000039 –19–19NOV01–5/14

1—Swing Motor 9—Pin (3 used) 17—Cap Screw (2 used) 25—Housing2—First Planet Sun Gear 10—Spring Pin (3 used) 18—Second Planet Carrier 26—Oil Seal3—Thrust Plate 11—Thrust Plate (6 used) 19—Thrust Plate 27—Roller Bearing4—Pin (3 used) 12—Bearing (3 used) 20—Second Planet Sun Gear 28—Sleeve5—Spring Pin (3 used) 13—Planetary Gear (3 used) 21—First Planet Carrier 29—O-Ring6—Needle Bearing (3 used) 14—Roller Bearing 22—Cap Screw (8 used) 30—Shaft7—Planetary Gear (3 used) 15—Bearing Nut 23—Cap Screw (12 used) 31—Drain Valve8—Thrust Plate (3 used) 16—Lock Plate 24—Ring Gear

Disassemble and Assemble Swing Gearbox—200CLC and 230CLC

1. Make alignment marks between swing motor (1),ring gears (24), and between ring gear (24) andhousing (25) to aid in assembly.


Swing Gearbox—SpecificationSwing Motor—200CLC and230CLC—Weight 46 kg (100 lb) approximate......................................

2. Remove cap screws (22) and swing motor (1) fromswing gearbox.

3. Remove first planet carrier (21) from ring gear (24).

NOTE: First planet sun gear may be removedseparately or along with carrier.


Swing Gearbox—SpecificationRing Gear—200CLC and230CLC—Weight 23 kg (50 lb) approximate......................................

4. Remove cap screws (23) and ring gear (24).

5. Remove second planet carrier (18).

NOTE: Second planet sun gear may be removedseparately 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 andsecond 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.

10. Remove thrust plate (3) from carrier.

IMPORTANT: Damaging the surface of pin (4) cancause bearing failure, use care whenhandling pin.

11. Using wood blocks, clamp pin (4) in vise. Tapspring pin (5) out.

12. Remove cap screws (17) and lock plate (16).

4343505

AGALLARDO,0000039 –19–19NOV01–6/14

T14

2064

–UN

–14M

AY

01

15—Bearing Nut

13. Remove bearing nut (15) from shaft (30) usingDFT1220 Swing Gearbox Nut Spanner Wrench.(Group 9900.)


PN=341



AGALLARDO,0000039 –19–19NOV01–7/14

T14

6941

–UN

–19N

OV

01

1—Shaft2—Housing

NOTE: Bearing and sleeve are pressed onto shaft.

14. Using press, push upper end of shaft (1) and removefrom housing (2). Inner race of roller bearing (27) andsleeve (28) are removed with shaft (30).

15. Remove oil seal (26).

16. Remove outer race from housing by inserting barthrough oil passage in housing, and tap it out.

434350

6

AGALLARDO,0000039 –19–19NOV01–8/14

3

2

1

T14

6899

–UN

–19N

OV

01

1—Shaft2—Roller Bearing3—Sleeve

17. Inspect shaft (1), roller bearing (2), and sleeve (3).

18. If disassembly is necessary, use press to push upperend of shaft to remove roller bearing and sleeve.


20. Apply rigid form-in-place gasket to OD of oil seal (26).

21. Install oil seal so lip (spring side) is toward bottom ofbore. Push seal to bottom of bore.

22. Apply thin layer of multi-purpose grease to O-ring (29)and lip of oil seal.

23. Apply hydraulic oil to all internal parts.

24. Apply film of grease on threaded surface of bearingnut (15). Install bearing nut on shaft (30) with steppedside of bearing nut towards roller bearing (14).

25. Tighten bearing nut so splines of lock plate (16) andshaft (30) are aligned. Use DFT1220 Swing GearboxNut Spanner Wrench. (Group 9900.)

Swing Gearbox—SpecificationBearing Nut—200CLC and230CLC—Torque 490 N•m (360 lb-ft).........................................................


PN=342



AGALLARDO,0000039 –19–19NOV01–9/14

T14

2429

–UN

–22J

UN

01

1—Slit

26. Install spring pins (5 and 10) with slit towards end ofpin.

27. Install thrust plate (19) with oil grooves towardssecond planet sun gear (20).

28. Install second planet carrier (18) so notch is alignedwith lock plate (16).

29. Install second planet sun gear (20) into second planetcarrier (18) assembly with small diameter part ofsecond planet sun gear towards up.

30. Install first planet sun gear (2) into first planet carrier(21) assembly with stepped side of sun gear towardsdown.

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) tocap screws (22 and 23). Tighten Cap Screws.

Swing Gearbox—SpecificationRing Gear-to-Housing CapScrew—200CLC and 230CLC—Torque 206 N•m (152 lb-ft).........................................................................

Swing Gearbox—SpecificationSwing Motor-to-Ring Gear CapScrew—Torque 88 N•m (65 lb-ft..................................................................

4343507



PN=343


434350

8

AGALLARDO,0000039 –19–19NOV01–10/14

T146719

1

2

43

6

9

8

5

7

10

11

12

13

14

15

16

1718

21

22

23

21

27

28

32

33

34

29

31

30

29

26

25 24

20

19

T14

6719

–UN

–19N

OV

01


PN=344



43AGALLARDO,0000039 –19–19NOV01–11/14

1—Shaft 10—Housing 19—First Planet Carrier 27—Second Planet Carrier2—Sleeve 11—Ball Bearing 20—Second Planet Sun Gear 28—O-Ring3—Cap Screw (10 used) 12—Snap Ring 21—Thrust Plate (6 used) 29—Thrust Plate (6 used)4—O-Ring 13—Swing Motor 22—Needle Bearing (3 used) 30—Bushing (3 used)5—Oil Seal 14—Cap Screw (12 used) 23—Planetary Gear (3 used) 31—Planetary Gear (3 used)6—Cover 15—First Planet Sun Gear 24—Thrust Plate 32—Cap Screw (12 used)7—Ball Bearing 16—Thrust Plate 25—Pin (3 used) 33—Ring Gear8—Drain Plug 17—Pin (3 used) 26—Spring Pin (3 used) 34—O-Ring9—Pipe 18—Spring Pin (3 used)

Disassemble and Assemble Swing Gearbox—270CLC

1. Make alignment marks between swing motor (13),ring gears (33), and between ring gear (33) andhousing (10) to aid in assembly.


Swing Gearbox—SpecificationSwing Motor—270CLC—Weight 66 kg (150 lb) approximate.......................................................

2. Remove cap screws (14) and swing motor (13)from swing gearbox.

3. Remove first planet carrier assembly (19) from ringgear (33).

NOTE: First planet sun gear may be removedseparately or along with carrier.


Swing Gearbox—SpecificationRing Gear—270CLC—Weight 36 kg (80 lb) approximate....................

4. Remove cap screws (32) and ring gear (33).

5. Remove second planet carrier (27).

NOTE: Second planet sun gear may be removedseparately 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 andsecond planetary carriers is the same.

8. Remove pin (17), planetary gear (23), needlebearing (22), and thrust plate (21) from first planetcarrier (19).

9. Inspect needle bearing for wear.

10. Remove thrust plate (16) from carrier.

IMPORTANT: Damaging the surface of pin (17) cancause bearing failure, use care whenhandling pin.

11. Using wood blocks, clamp pin (17) in vise. Tapspring pin (18) out.

12. Remove snap ring (12).

43509



PN=345


AGALLARDO,0000039 –19–19NOV01–12/14

T14

6941

–UN

–19N

OV

01

1—Shaft2—Housing

NOTE: Bearing and sleeve are pressed onto shaft.

13. Using press, push upper end of shaft (1) and removefrom housing (2). Ball bearing (7) and sleeve (2) areremoved with shaft (1).

14. Secure cover (6) in vise and remove oil seal (5).

AGALLARDO,0000039 –19–19NOV01–13/14

1

23

T14

6889

–UN

–19N

OV

01

1—Sleeve2—Ball Bearing3—Shaft

15. Inspect sleeve (1), ball bearing (2), and shaft (3) forwear. Repair or replace parts as necessary.

16. Use press to push at upper end of shaft and removeball bearing and sleeve.

17. Apply rigid form-in-place gasket to OD of oil seal (5).

18. Install oil seal so lip (spring side) is toward bottom ofbore. Push seal to bottom of bore.

19. Apply thin layer of multi-purpose grease to O-ring (4)and lip of oil seal.

20. Apply hydraulic oil to all internal parts.

434350

10



PN=346


AGALLARDO,0000039 –19–19NOV01–14/14

T14

2429

–UN

–22J

UN

01

1—Slit

21. Install spring pins (18 and 26) with slit towards end ofpin.

22. Install thrust plate (24) with oil grooves towardssecond planet sun gear (20).

23. Install second planet sun gear (20) into second planetcarrier (27) assembly with small diameter part ofsecond planet sun gear towards up.

24. Install first planet sun gear (15) into first planet carrier(19) assembly with stepped side of sun gear towardsdown.

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) tocap screws (14 and 32). Tighten cap screws.

Swing Gearbox—SpecificationRing Gear-to-Housing CapScrew—270CLC—Torque 400 N•m (300 lb-ft)...........................................

Swing Gearbox—SpecificationSwing Motor-to-Ring Gear CapScrew—Torque 88 N•m (65 lb-ft)................................................................

43435011

TX,25,GG2228 –19–19NOV01–1/1

Swing Gearbox Start-Up Procedure

IMPORTANT: Swing gearbox will be damaged if notfilled with oil before operating swingfunction. Procedure must be performedwhenever a new swing gearbox isinstalled or oil has been drained fromthe 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’sManual.)

3. Install fill cap. Check oil level on dipstick.


PN=347


TX,43,SB524 –19–19NOV01–1/10

Upperstructure Repair

Remove Upperstructure

NOTE: Procedure requires two technicians. The cementfloor must be a minimum of 102 mm (4 in.) thick.Area must be large enough so the upperstructurecan be turned 180° with the angle between boomand arm at 90—100° and the tracks laid out flaton the floor.

1. Clean machine thoroughly.

43TX,43,SB524 –19–19NOV01–2/10

T77

12A

G–U

N–2

4FE

B92

CAUTION: Keep the angle between boom andarm at 90—100° to prevent machine from slidingbackwards.

2. Park machine with boom to left side (cab side towardsprocket) of undercarriage.

3. Disconnect tracks and lay out flat on floor to sprocketend of undercarriage. See Track Chain Repair. (Group0130.)

NOTE: To make removal of main frame-to-swing bearingcap screws easier after machine is raised intoposition, loosen the cap screws one turn at thistime.

4. Turn upperstructure and raise right side of machine,using boom down function.

435012



PN=348


TX,43,SB524 –19–19NOV01–3/10

T77

20A

M–U

N–0

7MA

Y92

A—Track RollersB—Hardwood BlocksC—Track Chain

5. Put hardwood blocks (B), approximately 254 mm (10in.) between lower track rollers (A) and track chain (C).

6. Turn upperstructure back to left side so it is 90° totrack.

43TX,43,SB524 –19–19NOV01–4/10

T77

20A

S–U

N–0

7MA

Y92

D—CounterweightE—Bridge Plank (As Required)F—Hardwood Block (As Required)G—DFT1089 Barrel Support (4 used)


Upperstructure—Specification200CLC Machine—WithoutTracks—Weight 17 330 kg (38,200 lb)

approximate.......................................................

230CLC Machine—WithoutTracks—Weight 20 329 kg (44,818 lb)

approximate.......................................................

270CLC Machine—WithoutTracks—Weight 22 453 kg (49,500 lb)

approximate.......................................................

7. Put two DFT1089 Barrel Support under counterweight(D). (Group 9900.)

To provide enough clearance, use bridge planks (E)and hardwood blocks (F) to raise height of supportsand planks to 1.4 m (55 in.). Height is approximateclearance needed to clear bottom of rotary manifold.Do not put blocks under cap screw heads. Keep heightbelow maximum.

Upperstructure—SpecificationFloor-to-Bottom of Main Frame—Height 1.4 m (55 in.) minimum....................................................................Height 1.45 m (57 in.) maximum.................................................................

435013



PN=349


43TX,43,SB524 –19–19NOV01–5/10

T77

20A

O–U

N–0

7MA

Y92

A—DFT1089 Barrel Support (4 B—3.7 m (12 ft) Length of W8 C—Hardwood Block (Use asused) x 28 lb Wide Flange Beam Required)

(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) undermain frame at right boom cylinder and right cornerof cab. (Group 9900.)

For maximum support, barrel supports must bepositioned so beam is under main frame and cornerof cab as far as possible.

Install hardwood blocks (C) as needed to make upfor any unevenness.

10. Lower machine so main frame and corner of cabare on beam.

Check that bottom of main frame is 1.4 m (55 in.)off floor and level. Keep height to maximum of1.45 m (57 in.).

435014



PN=350


TX,43,SB524 –19–19NOV01–6/10

T71

49A

J–U

N–0

5OC

T89

11. Install 13 mm (1/2 in.) chain around boom cylinderhead end boss on frame and rod end boss on boom.Tighten chain just enough to remove slack usingchain binder.

12. Disconnect negative battery cables.


13. Do Hydraulic Oil Tank Vent Procedure. (Seeprocedure in this group.)

14. Disconnect lines and fittings from rotary manifold.

43435015

TX,43,SB524 –19–19NOV01–7/10

T10

5961

–UN

–20D

EC

96

A—Swing BearingB—Cap Screw (31 used)


Upperstructure—SpecificationUndercarriage—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.........

15. Raise undercarriage into position using two 18-t(20-ton) service jacks.

16. Remove cap screws (B) from swing bearing (A).

17. Slowly lower undercarriage onto track chain.

18. Lift sprocket end of undercarriage so sprocket clearstrack chain.

19. Pull undercarriage out from under upperstructure.



PN=351



434350

16

TX,43,SB524 –19–19NOV01–8/10

T10

5961

–UN

–20D

EC

96

A—Swing BearingB—Cap Screw (31 used)

Install Upperstructure


1. Push undercarriage under upperstructure.

Upperstructure—SpecificationUndercarriage—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 swingbearing (A) with holes in main frame. (Group 9900.)

3. Raise undercarriage into position using two 18-t(20-ton) service jacks. It may be necessary to turnswing bearing inner race to align teeth on swing motorpinion shaft.

4. Install cap screws (B) and tighten.

Upperstructure—SpecificationSwing Bearing-to-UpperstructureCap Screw—200CLC—Torque 510 N•m (375 lb-ft)...................................Swing Bearing-to-UpperstructureCap Screw—230CLC and270CLC—Torque 640 N•m (470 lb-ft).........................................................

If all cap screws are not accessible, tighten them aftermachine has been lowered and supports have beenremoved.

5. Connect fittings and lines to rotary manifold. SeePropel System Component Location. (Group 9025-15.)

6. Install stop on rotary manifold.


Upperstructure—SpecificationRotary Manifold Stop CapScrew—Torque 140 N•m (105 lb-ft)............................................................

8. Connect negative battery cable.


PN=352



TX,43,SB524 –19–19NOV01–9/10

T77

20A

M–U

N–0

7MA

Y92

A—Track RollersB—Wooden BlocksC—Track Chain

9. Put hardwood blocks (B) between lower track rollers(A) and track chain (C) on counterweight side.


43435017


PN=353


434350

18

TX,43,SB524 –19–19NOV01–10/10

T77

20A

O–U

N–0

7MA

Y92

A—DFT1089 Barrel Support (4 B—3.7 m (12 ft) Length of W8 C—Hardwood Block (use asused) x 28 lb Wide Flange Beam required)

(2 used)

10. Raise machine just enough to remove hardwoodblocks (C), wide flange beam (B), and barrelsupports (A).

11. Lower machine so lower track rollers and frontidler are on track chain.

12. Remove bridge planks and barrel supports fromother side.

13. Turn upperstructure to other side and raisemachine just enough to remove hardwood blocksbetween roller and track chain.

14. Lower machine so lower track rollers and frontidler are on track chain.

15. Tighten any remaining swing bearing-to-mainframe cap screws.

Upperstructure—SpecificationSwingBearing-to-Upperstructure CapScrew—200CLC—Torque 510 N•m (375 lb-ft)....................................SwingBearing-to-Upperstructure CapScrew—230CLC and270CLC—Torque 640 N•m (470 lb-ft)..................................................

16. Install track chains. See Track Chain Repair. (SeeGroup 0130.)



PN=354


TX,43,SB526 –19–19NOV01–1/8

Swing Bearing Repair

T77

64A

B–U

N–0

7MA

Y92

C—JT01748 Lifting BracketsD—Cap Screw and Lock Washer

Remove and Install Swing Bearing

1. Remove upperstructure. See Upperstructure Repair.(See procedure in this group.)


Swing Bearing—SpecificationSwing Bearing—200CLC—Weight 220 kg (485 lb) approximate................Swing Bearing—230CLC and270CLC—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 removeswing bearing.

4. Check and replace swing bearing upper and lowerseals if necessary. SeeSwing Bearing Repair. (Seeprocedures in this group.)

5. Replace steel balls and ball supports as necessary.


7. Clean mating surfaces of swing bearing,upperstructure, and undercarriage.

43435019



PN=355


TX,43,SB526 –19–19NOV01–2/8

T59

25A

A–U

N–1

1AP

R90

A—ToothB—Loading Plug

IMPORTANT: The tooth marked with the letter “G” or“S” or equivalent is the starting andstopping point for the hardeningprocess. The tooth and the bearingloading plug must be installed on theright side of the machine so the use ofthat part of the swing bearing isminimized.

8. Install swing bearing on undercarriage so tooth (A)marked “G” or “S” or equivalent and bearing loadingplug (B) is to right side of machine.

9. Install cap screws and lock washers and tighten.

Swing Bearing—SpecificationUndercarriage-to-Swing BearingCap Screw—200CLC—Torque 490 N•m (360 lb-ft)...................................Undercarriage-to-Swing BearingCap Screw—230CLC and270CLC—Torque 640 N•m (470 lb-ft).........................................................

10. Apply multi-purpose grease to swing bearing teethand pinion shaft. See Track Adjuster, Working ToolPivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)

11. Install upperstructure. See Upperstructure Repair.(See procedure in this group.)

434350

20



PN=356


TX,43,SB526 –19–19NOV01–3/8T

6626

JP–U

N–0

7NO

V88

A—Lubrication Fitting (2 used) —Spacer—270CLC (90 used) —Steel Ball—270CLC (90 F—Inner RaceB—Outer Race D—Steel Ball—200CLC & used) G—Upper SealC—Spacer—200CLC & 230CLC 230CLC (121 used) E—Lower Seal

(121 used)

Disassemble and Assemble Swing Bearing

1. Check swing bearing upper seal (G) and lower seal(E). If damaged, replace. See Swing BearingRepair. (See procedures in this group.)

43435021



PN=357


TX,43,SB526 –19–19NOV01–4/8

T68

76F

I–U

N–0

7MA

Y92

A—Tack WeldB—Taper PinC—Loading Plug

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.

434350

22

TX,43,SB526 –19–19NOV01–5/8

T68

76F

K–U

N–0

7MA

Y92

T77

63A

B–U

N–0

7MA

Y92

A—Spacer—200CLC & 230CLC (121 used)—Spacer—270CLC (90 used)

B—Steel Ball—200CLC & 230CLC (121 used)—Steel Ball—270CLC (90 used)

5. Remove steel balls (A) and spacers (B).

6. Turn inner race to remove remaining steel balls andspacers.

7. Lift outer race off inner race.


9. Install spacers (B) and steel balls (A).

Turn inner race as needed to install spacers and steelballs.


PN=358



TX,43,SB526 –19–19NOV01–6/8

T68

76F

I–U

N–0

7MA

Y92

A—Tack WeldB—Taper PinC—Loading Plug

10. Install loading plug (C).

11. Install taper pin (B) even with top of swing bearing.

12. Tack weld pin (A) to swing bearing.

13. Add multi-purpose grease to swing bearing throughlubrication fittings. See Track Adjuster, Working ToolPivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)


43435023


PN=359


43TX,43,SB526 –19–19NOV01–7/8

T59

25A

M–U

N–1

1AP

R90

A—Seal

Install Swing Bearing Upper Seal


2. Remove old seal (A).

3. Scrape old adhesive from seal groove.

Thoroughly clean seal groove and new seal using cureprimer.

4. Apply instant gel adhesive sparingly to seal groove.

5. Install seal with lip against inner bearing race.

Start about 76 mm (3 in.) from end of seal using bluntinstrument to force seal into groove. Push seal indirection of portion already installed to avoid stretchingseal.

6. Before bringing ends of seal together, cut off excesslength.

7. Apply instant gel adhesive to both ends of seal. Pushends into seal groove making sure they come together.

IMPORTANT: To avoid pulling seal out of groove,adhesive must cure for at least 24hours before using swing function.

8. Install upperstructure. See Upperstructure Repair. (Seeprocedure in this group.)

Install Swing Bearing Lower Seal


435024



PN=360


TX,43,SB526 –19–19NOV01–8/8T

5936

BA

–UN

–17M

AY

89

A—SealB—Seal Groove

NOTE: Part of swing bearing shown cut away to showlower seal in groove.

2. Remove old seal (A).

3. Scrape old adhesive from seal groove (B).

Thoroughly clean seal groove and new seal using cureprimer.

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 bluntinstrument to force seal into groove. Push seal indirection of portion already installed to avoid stretchingseal.

6. Before bringing ends of seal together, cut off excesslength.

7. Apply adhesive to both ends of seal. Push ends intoseal groove making sure they come together.

IMPORTANT: To avoid pulling seal out of groove,adhesive must cure for at least 24hours before using swing function.

8. Install upperstructure. See Upperstructure Repair. (Seeprocedure in this group.)

43435025


PN=361


434350

26


PN=362


4343601

TX,4360,DV1356 –19–19NOV01–1/10

Swing Motor and Park Brake Repair

T14

3358

B–U

N–2

0JU

L01


1—Cap Screw (8 used)2—Electrical Connector

Remove and Install Swing Motor and Park Brake



2. Drain hydraulic oil tank. See 200CLC Drain and RefillCapacities, 230CLC Drain and Refill Capacities,or270CLC Drain and Refill Capacities. (Operator’sManual.)



CAUTION: Heavy Component; use a hoist.

Swing Motor and Park Brake—SpecificationSwing Motor and Park Brake(200CLC and 230CLCMachine)—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 andpark brake.


7. Install swing motor and brake.


Swing Motor and Park Brake—SpecificationSwing Motor-to-Ring Gear CapScrew—Torque 88 N•m (65 lb-ft)................................................................

9. Connect electrical connector (2).



PN=363


Hydraulic System

TX,4360,DV1356 –19–19NOV01–2/10

11. Fill hydraulic oil tank. See 200CLC Drain and RefillCapacities, 230CLC Drain and Refill Capacities, or270CLC Drain and Refill Capacities. (Operator’sManual.)

12. Do Swing Motor Start-Up Procedure. (See procedurein this group).


434360

2


PN=364

Hydraulic System

4343603


PN=365

Hydraulic System

434360

4

TX,4360,DV1356 –19–19NOV01–3/10

12

3

28

21

30

29

31

32

33

1517

16

1819

1213 14

18

20

24

22

23

25

2627

1716

15

4

5

67

8

9

10

11

10

T142065

T14

2065

–UN

–22J

UN

01


PN=366


Hydraulic System

TX,4360,DV1356 –19–19NOV01–4/10

1—Housing 10—Plate (4 used) 19—Valve Housing 26—O-Ring2—Oil Seal 11—Friction Plate (3 used) 20—Crossover Relief Valve (2 27—O-Ring3—Bearing 12—Cap Screw (4 used) used) 28—O-Ring4—Shaft 13—O-Ring (2 used) 21—O-Ring 29—Piston5—Trust Plate 14—Plug (2 used) 22—Bearing 30—Spring6—Piston (9 used) 15—Plug (2 used) 23—Valve Plate 31—Ball7—Plate 16—O-Ring (2 used) 24—Spring (24 used) 32—Plug (2 used)8—Retainer 17—Spring (2 used) 25—Brake Piston 33—Snap Ring9—Cylinder Block 18—Poppet (2 used)

Disassemble Swing Motor and Park Brake—200CLC and 230CLC

1. Drain oil. Approximate capacity is 1.5 L (1.6 qt).


Swing Motor and Park Brake—SpecificationSwing Motor and Park Brake(200CLC and 230CLC)—Weight 46.4 kg (100 lb) approximate....................................................

CAUTION: Swing motor valve housing andcover is under spring pressure. Remove capscrews evenly to release spring force.

2. Mark alignment of swing motor housing and valvehousing assembly. Loosen cap screws (12).

IMPORTANT: Valve plate has a polished surface.Valve plate may remain on valvehousing or stay with cylinder block.Valve plate may be damaged if

dropped. Hold valve plate duringdisassembly.

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 ofbearing (3).

8. Remove inner race of bearing from shaft.

NOTE: Filter and orifice are mounted inside of piston(29). Unless clogged or deformed, do notdisassemble. Do so only when absolutelyneeded. If internal parts need to be replaced,replace piston as an assembly.


4343605



PN=367

Hydraulic System

434360

6

TX,4360,DV1356 –19–19NOV01–5/10

T146945

49

48

4746

45

44

43

42

41

40

35

33

3231

30

2928

2726

25 2422

21

20

18

19

34

1

23

5

109

8

7

13

1216

17

15

14

11

6

4

39

38

37

36

23

T14

6945

–UN

–19N

OV

01


PN=368


Hydraulic System

TX,4360,DV1356 –19–19NOV01–6/10

1—Bearing 13—O-Ring (2 used) 26—Spacer 38—Cap Screw (3 used)2—Snap Ring 14—Plate 27—Spring 39—Brake Release Valve3—Dowel Pin (2 used) 15—Cap Screw (4 used) 28—Washer 40—Housing4—O-Ring 16—O-Ring (2 used) 29—Cylinder Block 41—Shaft5—Crossover Relief Valve (2 17—Plug (2 used) 30—Pin (12 used) 42—Snap Ring

used) 18—Valve Plate 31—Washer 43—Spacer (2 used)6—Valve Housing 19—Spring (22 used) 32—Ball Bushing 44—Bearing7—Poppet (2 used) 20—Brake Piston 33—Retainer 45—Snap Ring8—Spring (2 used) 21—O-Ring 34—Piston (9 used) 46—O-Ring9—O-Ring (2 used) 22—O-Ring 35—Thrust Plate 47—Oil Seal10—Drain Plug (2 used) 23—Friction Plate (3 used) 36—Plug 48—Cover11—Cap Screw (4 used) 24—Plate (4 used) 37—O-Ring 49—Snap Ring12—O-Ring (2 used) 25—Snap Ring

Disassemble Swing Motor and Park Brake—270CLC


Swing Motor and Park Brake—SpecificationSwing Motor and Park Brake(270CLC Machine)—Weight 66 kg (150 lb) approximate.....................

CAUTION: Swing motor valve housing andcover is under spring pressure. Remove capscrews evenly to release spring force.

1. Mark alignment of swing motor housing and valvehousing assembly. Loosen cap screws (11).

IMPORTANT: Valve plate has a polished surface.Valve plate may remain on valvehousing or stay with cylinder block.Valve plate may be damaged if

dropped. Hold valve plate duringdisassembly.

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) toremove 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 fromhousing (40). Bearing (44), snap rings (42 and 45),and spacers (43) are removed with shaft.


4343607



PN=369

Hydraulic System

TX,4360,DV1356 –19–19NOV01–7/10

T14

2067

–UN

–22J

UN

01

Inspect Swing Motor and Park Brake

1. Measure clearance between outer diameter of pistonand inner bore of cylinder.

Swing Motor and Park Brake—SpecificationPiston-to-Cylinder—Clearance 0.027 mm (0.0011 in.) new........................

0.052 mm (0.0020 in.) maximumused

434360

8

TX,4360,DV1356 –19–19NOV01–8/10

T14

2069

–UN

–22J

UN

01

2. Measure clearance between piston and slipper atcaulked position.

Swing Motor and Park Brake—SpecificationPiston-to-Slipper—Clearance 0.0 mm (0.0 in.) new....................................

0.3 mm (0.0118 in.) maximumused


PN=370


Hydraulic System

4343609

TX,4360,DV1356 –19–19NOV01–9/10

T14

2072

–UN

–22J

UN

01

Slipper Thickness

T14

2073

–UN

–22J

UN

01

Friction Plate Thickness

3. Measure thickness of slipper.

Swing Motor and Park Brake—SpecificationSlipper—Thickness 5.5 mm (0.22 in.) new..................................................

5.3 mm (0.21 in.) minimum

4. Measure thickness of friction plate.

Swing Motor and Park Brake—SpecificationFriction Plate—Thickness 2.0 mm (0.08 in.) new........................................

1.8 mm (0.07 in.) minimum

Assemble Swing Motor and Park Brake—200CLC and230CLC

1. Align spline teeth of friction plates (11) with cylinderblock (9) and outer tabs of plates (10) with housing (1).

2. Apply petroleum jelly to valve plate (23).

3. Install thrust plate (5) with chamfered edge towardshousing (1).

4. Align mating marks on valve housing (19) and housing(1) and tighten cap screws (12).

Swing Motor and Park Brake—SpecificationValve 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.

Swing Motor and Park Brake—SpecificationPoppet Plug (200CLC and230CLC)—Torque 330 N•m (245 lb-ft).......................................................

6. Install crossover relief valves (20) into valve housing(19).

Swing Motor and Park Brake—SpecificationCrossover 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 cylinderblock and outer tabs of plates (24) with housing (40).

2. Apply petroleum jelly to valve plate (18).


PN=371


Hydraulic System

TX,4360,DV1356 –19–19NOV01–10/10

3. Install thrust plate (35) with chamfered edge towardshousing (40).

4. Align mating marks on valve housing (6) and housing(40) and tighten cap screws (11).

Swing Motor and Park Brake—Specification270CLC Valve Housing CapScrew—Torque 400 N•m (300 lb-ft)............................................................

5. Install poppet (7) and spring (8). Tighten plug (10) withO-ring (9) attached.

Swing Motor and Park Brake—Specification270CLC Poppet Plug—Torque 400 N•m (300 lb-ft)...................................

6. Install crossover relief valves (5) into valve housing (6).

Swing Motor and Park Brake—SpecificationCrossover Relief Valve—Torque 175 N•m (130 lb-ft).................................

434360

10


PN=372

Hydraulic System

TX,4360,DV2980 –19–19NOV01–1/4

Crossover Relief Valve and Make-Up Valve Repair

4

31

2

T139645

T13

9645

–UN

–30A

PR

01

1—Make-Up Valve 2—Make-Up Valve 3—Crossover Relief Valve 4—Crossover Relief Valve

43436011

TX,4360,DV2980 –19–19NOV01–2/4

T14

7132

B–U

N–1

9NO

V01


1—Crossover Relief Valve (2 used)

Remove and Install Crossover Relief Valve

1. Tighten crossover relief valve (1).

Crossover Relief and Make-Up Valves—SpecificationCrossover Relief Valve—Torque 175 N•m (130 lb-ft).................................

2. Check crossover relief valve pressure setting. SeeSwing Motor Crossover Relief Valve Test andAdjustment—200CLC and 230CLC or Swing MotorCrossover Relief Valve Test and Adjustment—270CLC.(Group 9025-25.)


PN=373


Hydraulic System

TX,4360,DV2980 –19–19NOV01–3/4

T14

2068

–UN

–22J

UN

01

1—Shim2—Piston3—Sleeve4—Plug5—O-Ring6—O-Ring7—O-Ring

Disassemble and Assemble Crossover Relief Valve

Tighten plug (4).

Crossover Relief and Make-Up Valves—SpecificationCrossover Relief Valve Plug—Torque 118 N•m (88 lb-ft)...........................................................................

TX,4360,DV2980 –19–19NOV01–4/4

T14

7132

C–U

N–1

9NO

V01


434360

12

1—Make-Up Valve (2 used)

Remove and Install Make-Up Valve

Tighten make-up valve (1).

Crossover Relief and Make-Up Valves—Specification200CLC and 230CLC Make-UpValve—Torque 332 N•m (245 lb-ft).............................................................270CLC Make-Up Valve—Torque 400 N•m (300 lb-ft)...............................


PN=374

Hydraulic System

OUOE027,000003D –19–19NOV01–1/1

Swing Motor Start-Up Procedure

T14

3358

D–U

N–2

0JU

L01


1—Hydraulic Line

IMPORTANT: Swing motor will be damaged if notfilled with oil before operating swingfunction. Start-up procedure must beperformed whenever a new swing motoris installed or oil has been drained fromthe 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 oilreaches level of port. (Operator’s Manual.)

NOTE: Air must be allowed to escape from the swingmotor while filling.

3. Connect hydraulic line (1).

43OUOE054,0000021 –19–19NOV01–1/2

Brake Release Valve Repair—270CLC

T14

7133

B–U

N–1

9NO

V01

436013

1—Electrical Connector2—Cap Screw (3 used)3—Hydraulic Line4—Brake Release Valve

Remove and Install Brake Release Valve


2. Disconnect hydraulic line (3).

3. Remove cap screws (2) and remove brake releasevalve (4).




PN=375

Hydraulic System

OUOE054,0000021 –19–19NOV01–2/2

8

9

10

11

12

12 3 4

5

6

7

T14

7146

–UN

–19N

OV

01

1—O-Ring2—O-Ring3—Poppet4—Spring5—O-Ring6—Spring7—Spool8—Housing9—Bushing10—Filter11—Spacer12—Orifice

Disassemble and Assemble Brake Release Valve

434360

14


PN=376

Section 9999Dealer Fabricated Tools

Contents

Page

Group 9900—Dealer Fabricated ToolsDF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-1ST4920 Track Recoil Spring

Disassembly and Assembly Tool . . . . . . . .99-9900-3DFT1087 Track Recoil Spring

Disassembly and Assembly Guard Tool. . .99-9900-7DFT1110 Spacer. . . . . . . . . . . . . . . . . . . . . .99-9900-8DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .99-9900-9DF1036A Propel Gearbox Nut Wrench . . . .99-9900-10DF1038 Torque Adapter . . . . . . . . . . . . . . .99-9900-11DFT1109 Holding Bar . . . . . . . . . . . . . . . . .99-9900-12Rotary Manifold Lifting Tool. . . . . . . . . . . . .99-9900-13DFT1089 Barrel Support . . . . . . . . . . . . . . .99-9900-14DFT1144 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-15DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-16DFT1220 Swing Gearbox Nut Spanner

Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-18


PN=1

Contents

99


PN=2

Group 9900Dealer Fabricated Tools

9999001

CED,OUTX818,81 –19–11MAY00–1/2

DF1063 Lift Bracket

T83

18A

C–U

N–2

0SE

P94

Tool is the same as used on other machines. Only the liftbracket of the tool is used for this machine with adapterDFT1130.

Lift Bracket is used to remove and install propel motor.

Material required:

• 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16in.) 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)



PN=379

Dealer Fabricated Tools

999900

2

CED,OUTX818,81 –19–11MAY00–2/2

T72

47B

W–1

9–25

AP

R90


PN=380


9999003

TX,99,SB548 –19–08JAN97–1/4

ST4920 Track Recoil Spring Disassembly andAssembly Tool

T65

85U

Y–U

N–2

4MA

R98

A—Nut (12 used)B—Stud (4 used)C—HolderD—Eyebolt (2 used)E—Supporting PlateF—Base PlateG—Base (4 used)H—Cap Screw (4 used)I—Lock Washer (8 used)

NOTE: It is recommended that DFT1087 Track RecoilSpring Disassembly and Assembly Guard Tool beused with track recoil spring disassembly andassembly tool.

Dimensions given are metric.

Tool is the same as used on other machines except theholder (C). For each track adjuster use the holder with thecorrect size hole for the nut on that track adjuster.

Track Recoil Spring Disassembly and Assembly Tool(compression tool) is used with hydraulic jack to compressrecoil spring in track adjuster repair.

Material required:

• 1020 HR Steel for Holder (C), Supporting Plate (E),Base Plate (F), and Base (G).

• “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A),and Cap Screws (H).

• “F” Grade (SAE Grade 8) for Studs (B).

Print Numbers:

• A-ST4050 Nut• B-ST4045 Bolt• C-ST4035 Holder (Plate)• C-ST4036 Holder (Plate)• C-ST4037 Holder (Plate)• D-ST4047 Eyebolt• E-ST4040 Supporting Base• F-ST4042 Base Plate• G-ST4041 Base• H-ST4046 Cap Screw• I-ST4049 Lock Washer



PN=381


999900

4

TX,99,SB548 –19–08JAN97–2/4

T70

29C

I–U

N–0

6JU

L89



PN=382


9999005

TX,99,SB548 –19–08JAN97–3/4

T70

29C

H–U

N–0

6JU

L89


PN=383



999900

6

TX,99,SB548 –19–08JAN97–4/4

T70

29C

G–U

N–0

6JU

L89


PN=384


9999007

TX,99,SB542 –19–08JAN97–1/1

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

T71

62A

F–U

N–1

7OC

T89

A—3/16 in. 1020 CR Steel Plate C—1/2 in. Nut (2 used) D—1/2 x 2 in. Cap Screw (2 E—1/2 x 3 in. Steel RoundB—9/16 in. Hole (2 places) used) Stock (2 used)

Track Disassembly and Assembly Guard Tool is usedwith ST4920 Track Recoil Spring Disassembly andAssembly Tool.

Material required:

• 3/16 in. 1020 CR Steel Plate (A)• 9/16 in. Hole (2 places) (B)• 1/2 in. Nut (2 used) (C)• 1/2 x 2 in. Cap Screw (D) (2 used)• 1/2 x 3 in. Steel Round Stock (E) (2 used)


PN=385


999900

8

TX,99,SB549 –19–08JAN97–1/1

DFT1110 Spacer

T77

08A

C–U

N–2

3FE

B92

Spacer is used with ST4920 Track Recoil SpringDisassembly and Assembly Tool. Spacer is installedon the bottom plate so force is applied to spring flangeon cylinder and not to the piston.

Cut the ends of spacer so they are parallel to eachother.

Material Required:

• 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) HeavyWall Steel Pipe


PN=386


9999009

CED,OUTX818,84 –19–11MAY00–1/1

DFT1130 Adapter

T83

19B

N–U

N–2

0SE

P94

A—Adapter Plate B—Tube C—Stop Plate

Adapter is used with DF1063 Lift Bracket to removeand 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)


PN=387


999900

10

TX,99,SB544 –19–19NOV01–1/1

DF1036A Propel Gearbox Nut Wrench

T76

81F

Z–U

N–2

8FE

B92

Propel Gearbox Nut Wrench is used to remove andinstall 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)


PN=388


99990011

CED,OUTX818,83 –19–11MAY00–1/1

DF1038 Torque Adapter

T65

57C

H–U

N–2

5OC

T95

Torque Adapter is used to check rolling drag torque onrotor drive shaft.

Material required:

• 17 mm (0.125 in.) hex head driver


PN=389


999900

12

TX,99,SB550 –19–23MAY00–1/1

DFT1109 Holding Bar

T76

90A

A–U

N–2

7FE

B92

Holding Bar is used with the DF1036A Propel GearboxNut Wrench as a guide when loosening thehub-to-housing nut in the propel gearbox.

Material required:

• 16 mm (5/8 in.) Flat Bar Stock


PN=390


99990013

TX,99,SB546 –19–08JAN97–1/1

Rotary Manifold Lifting Tool

T66

41D

O–U

N–2

4OC

T88

A—Threads

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


PN=391


999900

14

TX,99,SB551 –19–08JAN97–1/1

DFT1089 Barrel Support

T71

49A

C–U

N–0

9JA

N97

A—2 x 4 in. Slotted Hole, RecessedB—1/2 x 4 x 24 in. 1020 CR PlateC—1/2 x 4 x 12 in. 1020 CR PlateD—1/4 in. Fillet WeldE—One Empty 3 lb Coffee Can or Equivalent

Barrel supports are used to support the upperstructurewhen removing the undercarriage.

CAUTION: Cutting tops off barrels thatcontained flammable or explosive material cancause serious injury or death.

Material required:

• Clean metal 55 gallon barrels of equal height with lidsremoved. (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.

Insert hook assembly into barrel before cement is set.Hold assembly in position, using a steel plate or wire, untilcement 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 eachbarrel support is 385 560 kg (850,000 lb).


PN=392


99990015

TX,99,SB552 –19–08JAN97–1/1

DFT1144 Guide Pin

T66

41E

K–U

N–2

4OC

T88

A—230 mm (9 in.)B—100 mm (4 in.)

Guide pin is used to align cap screw holes in swingbearing and upperstructure.

Remove threads for a distance (B) and then grind a taperon same end.

Materials required:

• M20-2.5 x 230 mm (9 in.) Threaded Rod


PN=393


999900

16

TX,99,SB553 –19–08JAN97–1/1

DFT1119 Pump Support

T79

55A

A–U

N–2

3AP

R93

Pump support is used with a hand hoist to support apump(s) when an engine is removed.

Two end stands are needed.

Drill the holes through the square steel tubing so theyare 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.) SquareSteel Tubing

• 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) SquareSteel Tubing

• 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) SquareSteel 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)


PN=394


99990017


PN=395


999900

18

OUOE047,000000E –19–19NOV01–1/2

DFT1220 Swing Gearbox Nut Spanner Wrench

T14

3704

–UN

–17J

UL0

1


PN=396



99990019

OUOE047,000000E –19–19NOV01–2/2

1—Weld (4 Places)

Material required:

• 159.4 x 82.5 mm (6.275 x 3.25 in.) Steel Tubing

• 159.4 x 38.1 x 6.35 mm (6.65 x 1.5 x .25 in.)


PN=397


999900

20


PN=398

IndexPage Page

A Belt, seatRemove and install . . . . . . . . . . . . . . . . .18-1821-1

Bleed procedureAdjuster, trackHydraulic cylinder . . . . . . . . . . . . . . . .33-3360-152Disassemble and assemble . . . . . . . . .01-0130-21

BoomRemove and install . . . . . . . . . . . . . . . .01-0130-19Remove and install . . . . . . . . . . . . . . . . .33-3340-6Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-2

Boom cylinder IndxAir conditioner1Bleed procedure . . . . . . . . . . . . . . . . .33-3360-152Compressor, remove and install . . . . . .18-1830-11

Inspect pins and bushings. . . . . . . . . . .33-3340-11Condenser, remove and install . . . . . . .18-1830-16Remove and install . . . . . . . . . . . . . . . .33-3360-75Receiver-dryer, remove and install . . . .18-1830-12

Boom cylinder—200CLC, 270CLCRemove and install . . . . . . . . . . . . . . . .18-1830-15Disassemble and assemble . . . . . . . . .33-3360-80Air conditioner and heater

Boom cylinder—230CLCRemove and install . . . . . . . . . . . . . . . .18-1830-15Disassemble and assemble . . . . . . . . .33-3360-94Air conditioner system

Boom pins and bushingsFlush and purge . . . . . . . . . . . . . . . . . . .18-1830-3Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Air conditioning

Boom, arm, and bucket bushings and bossesCharge R134a system . . . . . . . . . . . . .18-1830-10Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Evacuate R134a system . . . . . . . . . . . . .18-1830-9

Boom, arm, and bucket pinsRecover R134a refrigerant . . . . . . . . . . .18-1830-8Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Refrigerant handling and cautions. . . . . .18-1830-1

BucketR134a refrigerant oil information . . . . . . .18-1830-6Adjust pivot end play. . . . . . . . . . . . . . . .33-3302-3R134a station installation . . . . . . . . . . . .18-1830-7Pin-up data . . . . . . . . . . . . . . . . . . . . . . .33-3302-4Air intake systemRemove and install . . . . . . . . . . . . . . . . .33-3302-1Leakage test . . . . . . . . . . . . . . . . . . . . . .05-0520-1

Bucket cylinderAir testBleed procedure . . . . . . . . . . . . . . . . .33-3360-152Rotary manifold. . . . . . . . . . . . . . . . . . .02-0260-25Inspect pins and bushings. . . . . . . . . . .33-3340-11ArmRemove and install . . . . . . . . . . . . . . .33-3360-124Remove and install . . . . . . . . . . . . . . . . .33-3340-3

Bucket cylinder—200CLC, 270CLCArm cylinderDisassemble and assemble . . . . . . . .33-3360-130Bleed procedure . . . . . . . . . . . . . . . . .33-3360-152

Bucket cylinder—230CLCInspect pins and bushings. . . . . . . . . . .33-3340-11Dissassemble and assemble. . . . . . . .33-3360-144Remove and install . . . . . . . . . . . . . . .33-3360-100

Bucket linksArm cylinder—200CLC, 270CLCRemove and install . . . . . . . . . . . . . . . . .33-3340-1Disassemble and assemble . . . . . . . .33-3360-104

Bucket pinsArm cylinder—230CLCInspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Disassemble and assemble . . . . . . . .33-3360-118

Bushings and sealsArm pins and bushingsRemove and install . . . . . . . . . . . . . . . .33-3340-14Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11

Arm regenerative solenoid valveRemove and install . . . . . . . . . . . . . . . .33-3360-35

C

CabB Remove and install . . . . . . . . . . . . . . . . .18-1800-1

Carrier roller, trackBearing, swing Disassemble and assemble . . . . . . . . . .01-0130-6

Disassemble and assemble . . . . . . . . .43-4350-21 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . . .01-0130-5Remove and install . . . . . . . . . . . . . . . .43-4350-19 Chain sprocket, trackUpper seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . .01-0130-14

Belt, fan Chain, trackDisassemble and assemble . . . . . . . . .01-0130-12Remove and install . . . . . . . . . . . . . . . . .05-0510-2

TM1931 (09JAN04) Index-1 200CLC, 230CLC & 270CLC Excavator Repair010904

PN=1

Index

Page Page

Disassemble and assemble to replace broken Controller, propel pilotDisassemble and assemble . . . . . . . . .33-3360-42part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13Remove and install . . . . . . . . . . . . . . . .33-3360-40Remove and install . . . . . . . . . . . . . . . .01-0130-10

Cooler, oilCharge R134a system . . . . . . . . . . . . . . .18-1830-10Remove and install . . . . . . . . . . . . . . . .33-3360-74Cleaner, air

Counterbalance valve, propel motorRemove and install . . . . . . . . . . . . . . . . .05-0520-2Disassemble and assemble—200CLC andCleanup procedure, hydraulic oil

230CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-17Using portable filter caddy. . . . . . . . . . . .33-3360-2Disassemble and assemble—Compressor

Indx2

270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18Remove and install . . . . . . . . . . . . . . . .18-1830-11CounterweightCondenser, air conditioner

Remove and install . . . . . . . . . . . . . . . . .17-1749-1Remove and install . . . . . . . . . . . . . . . .18-1830-16Coupling, flex (dampener drive)Control valve

Remove and install . . . . . . . . . . . . . . . . .07-0752-1Arm priority flow rate valve . . . . . . . . . .33-3360-51Crossover relief valveArm reduced leakage valve. . . . . . . . . .33-3360-51

Disassemble and assemble . . . . . . . . .43-4360-12Arm regenerative valve . . . . . . . . . . . . .33-3360-57Remove and install . . . . . . . . . . . . . . . .43-4360-11Arm regenerative valve check valve . . .33-3360-57

Crossover relief valve, propel motorAuxiliary flow combiner valve checkDisassemble and assemble—200CLC andvalve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51

230CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-17Auxiliary flow rate valve . . . . . . . . . . . .33-3360-51Disassemble and assemble—Auxiliary function flow combiner

270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51CylinderBoom reduced leakage valve . . . . . . . .33-3360-57

Arm, remove and install . . . . . . . . . . .33-3360-100Bucket flow rate valve . . . . . . . . . . . . . .33-3360-57Arm—200CLC, 270CLC, disassemble andBypass shut-off valve . . . . . . . . . . . . . .33-3360-57

assemble. . . . . . . . . . . . . . . . . . . . .33-3360-104Circuit relief and anti-cavitationArm—230CLC, disassemble andvalve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64

assemble. . . . . . . . . . . . . . . . . . . . .33-3360-118Lift check and orifice (arm II powerBleed procedure . . . . . . . . . . . . . . . . .33-3360-152passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-57Boom, remove and install . . . . . . . . . . .33-3360-75

Lift check and orifice (left propel powerBoom—200CLC, 270CLC, disassemble and

passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51assemble. . . . . . . . . . . . . . . . . . . . . .33-3360-80

Lift check (arm I power passage) . . . . .33-3360-51Boom—230CLC, disassemble and

Lift check (boom II power passage) . . .33-3360-51 assemble. . . . . . . . . . . . . . . . . . . . . .33-3360-94Lift check (left propel neutral Bucket, remove and install . . . . . . . . .33-3360-124

passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Bucket—200CLC, 270CLC, disassemble andLift check (swing neutral passage) . . . .33-3360-51 asemble. . . . . . . . . . . . . . . . . . . . . .33-3360-130Propel flow combiner valve check Bucket—230CLC, disassemble and

valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 assemble. . . . . . . . . . . . . . . . . . . . .33-3360-144Propel function flow combiner valve . . .33-3360-57 Bushings and seals, remove andRemove and install . . . . . . . . . . . . . . . .33-3360-49 install . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-14Right propel and bucket combined function

check valve and orifice . . . . . . . . . . .33-3360-64Spool assemblies (4-spool) . . . . . . . . . .33-3360-57Spool assemblies (5 spool) . . . . . . . . . .33-3360-51 DSystem relief and power boost valve. . .33-3360-51System relief valve isolation check Dampener drive

valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 Remove and install . . . . . . . . . . . . . . . . .07-0752-14-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-57 Dealer fabricated tools5-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 DFT1087 track recoil spring disassembly and

Controller, pilot assembly guard tool . . . . . . . . . . . . . .99-9900-7Disassemble and assemble . . . . . . . . .33-3360-39 DFT1089 barrel support . . . . . . . . . . . .99-9900-14

DFT1109 holding bar . . . . . . . . . . . . . .99-9900-12Remove and install . . . . . . . . . . . . . . . .33-3360-37


PN=2

Index

Page Page

DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-8 Flush air conditioner system. . . . . . . . . . . .18-1830-3Front idlerDFT1114 guide pin . . . . . . . . . . . . . . . .99-9900-15

DFT1119 pump support . . . . . . . . . . . .99-9900-16 Disassemble and assemble . . . . . . . . .01-0130-17Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9

DFT1220 swing gearbox nut spanner Remove and install . . . . . . . . . . . . . . . .01-0130-16wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-18 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19

IndxDF1036A propel gearbox nut Fuel filter, final3wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10 Remove and install . . . . . . . . . . . . . . . . .05-0560-4

DF1038 torque adapter . . . . . . . . . . . . .99-9900-11 Fuel filter, primaryRemove and install . . . . . . . . . . . . . . . . .05-0560-3DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1

Rotary manifold lifting tool. . . . . . . . . . .99-9900-13 Fuel injection pumpRemove and install . . . . . . . . . . . . . . . . .04-0400-4ST4920 track recoil spring disassembly and

assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3 Fuel tankRemove and install . . . . . . . . . . . . . . . . .05-0560-2Drive gearbox and hydraulic pump

Disassemble and assemble . . . . . . . . . .33-3360-5Remove and install . . . . . . . . . . . . . . . . .33-3360-3

Drive, dampener (flex coupling) GRemove and install . . . . . . . . . . . . . . . . .07-0752-1

GearboxPump drive, pilot pump drive shaft . . . .33-3360-21

Gearbox, drive and hydraulic pumpEDisassemble and assemble . . . . . . . . . .33-3360-5Remove and install . . . . . . . . . . . . . . . . .33-3360-3End play, bucket pivot

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-3 Gearbox, propelDisassemble and assemble—200CLC andEngine

Remove and install . . . . . . . . . . . . . . . . .04-0400-1 230CLC. . . . . . . . . . . . . . . . . . . . . . . .02-0250-5Disassemble and assemble—Engine air cleaner

Remove and install . . . . . . . . . . . . . . . . .05-0520-2 270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0250-11Remove and install . . . . . . . . . . . . . . . . .02-0250-1Evacuate R134a system. . . . . . . . . . . . . . .18-1830-9

Gearbox, swingDisassemble and assemble—200CLC and

230CLC. . . . . . . . . . . . . . . . . . . . . . . .43-4350-5FDisassemble and assemble—270CLC . .43-4350-9Remove and install . . . . . . . . . . . . . . . . .43-4350-1

FanRemove and install . . . . . . . . . . . . . . . . .05-0510-1

Fan beltRemove and install . . . . . . . . . . . . . . . . .05-0510-2 H

Fan guardRemove and install . . . . . . . . . . . . . . . . .05-0510-1 Heater

Remove and install . . . . . . . . . . . . . . . .18-1830-15Fan shroudRemove and install . . . . . . . . . . . . . . . . .05-0510-1 Hydraulic

Fittings, 30° cone seat . . . . . . . . . . . . . .00-0003-9Filter, final fuelRemove and install . . . . . . . . . . . . . . . . .05-0560-4 Fittings, 37° flare. . . . . . . . . . . . . . . . . . .00-0003-9

Hydraulic cylinderFilter, pilotDisassemble and assemble . . . . . . . . .33-3360-31 Bleed procedure . . . . . . . . . . . . . . . . .33-3360-152

Hydraulic fittingRemove and install . . . . . . . . . . . . . . . .33-3360-30Filter, primary fuel Flared connections . . . . . . . . . . . . . . . .00-0003-10

Hydraulic oilRemove and install . . . . . . . . . . . . . . . . .05-0560-3Final fuel filter Cleanup procedure using portable filter

caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-2Remove and install . . . . . . . . . . . . . . . . .05-0560-4Flex coupling Hydraulic oil tank

Disassemble and assemble . . . . . . . . .33-3360-69Remove and install . . . . . . . . . . . . . . . . .07-0752-1


PN=3

Index

Page Page

Pressure release procedure . . . . . . . . . .33-3360-1 Disassemble and assemble—270CLC . .02-0260-7Remove and install—200CLC andRemove and install . . . . . . . . . . . . . . . .33-3360-66

Hydraulic pump 230CLC. . . . . . . . . . . . . . . . . . . . . . . .02-0260-1Remove and install—270CLC . . . . . . . . .02-0260-1Start-up procedure . . . . . . . . . . . . . . . .33-3360-20

Hydraulic pump and drive gearboxDisassemble and assemble . . . . . . . . . .33-3360-5Remove and install . . . . . . . . . . . . . . . . .33-3360-3 O

Hydraulic pump regulatorDisassemble and assemble . . . . . . . . .33-3360-24

Indx4

O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6Remove and install . . . . . . . . . . . . . . . .33-3360-22

OilCarrier roller, specification. . . . . . . . . . . .01-0130-1Front idler, specification . . . . . . . . . . . . .01-0130-1Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-5ITrack roller, specification . . . . . . . . . . . .01-0130-1

Oil coolerIdler, frontRemove and install . . . . . . . . . . . . . . . .33-3360-74Disassemble and assemble . . . . . . . . .01-0130-17

Oil cooler bypass valveRemove and install . . . . . . . . . . . . . . . .01-0130-16Remove and install . . . . . . . . . . . . . . . .33-3360-71Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19

Oil informationInch torque values . . . . . . . . . . . . . . . . . . .00-0003-1R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6Injection pump

Oil leakage testRemove and install . . . . . . . . . . . . . . . . .04-0400-4Front idler . . . . . . . . . . . . . . . . . . . . . . .01-0130-19Track roller . . . . . . . . . . . . . . . . . . . . . . .01-0130-4

Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-5L Oil tank, hydraulic

Disassemble and assemble . . . . . . . . .33-3360-69Leakage test Remove and install . . . . . . . . . . . . . . . .33-3360-66

Air intake system . . . . . . . . . . . . . . . . . .05-0520-1Links, bucket

Remove and install . . . . . . . . . . . . . . . . .33-3340-1P

Pilot controllerM Disassemble and assemble . . . . . . . . .33-3360-39

Remove and install . . . . . . . . . . . . . . . .33-3360-37Pilot controller, propelManifold, pilot signal

Disassemble and assemble . . . . . . . . .33-3360-47 Disassemble and assemble . . . . . . . . .33-3360-42Remove and install . . . . . . . . . . . . . . . .33-3360-40Remove and install . . . . . . . . . . . . . . . .33-3360-43

Manifold, rotary Pilot filterDisassemble and assemble . . . . . . . . .33-3360-31Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25

Disassemble and assemble . . . . . . . . .02-0260-24 Remove and install . . . . . . . . . . . . . . . .33-3360-30Pilot filter and pilot pressure regulating valveRemove and install . . . . . . . . . . . . . . . .02-0260-22

Metal face seals Disassemble and assemble . . . . . . . . .33-3360-31Remove and install . . . . . . . . . . . . . . . .33-3360-30Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8

Metric torque values . . . . . . . . . . . . . . . . . .00-0003-2 Pilot pressure regulating valve and filterDisassemble and assemble . . . . . . . . .33-3360-31Motor cover, propel

Disassemble and assemble—200CLC and Remove and install . . . . . . . . . . . . . . . .33-3360-30Pilot pump230CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-17

Disassemble and assemble— Disassemble and assemble . . . . . . . . .33-3360-29Drive shaft and gear, disassemble . . . .33-3360-21270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18

Motor, propel Remove and install . . . . . . . . . . . . . . . .33-3360-27Pilot shut-off valveDisassemble and assemble—200CLC and

230CLC. . . . . . . . . . . . . . . . . . . . . . . .02-0260-4 Disassemble and assemble . . . . . . . . .33-3360-33


PN=4

Index

Page Page

Remove and install . . . . . . . . . . . . . . . .33-3360-31 Pump, pilotDisassemble and assemble . . . . . . . . .33-3360-29Pilot signal manifold

Disassemble and assemble . . . . . . . . .33-3360-47 Remove and install . . . . . . . . . . . . . . . .33-3360-27Purge air conditioner system . . . . . . . . . . .18-1830-3Remove and install . . . . . . . . . . . . . . . .33-3360-43

Pin-up dataBucket. . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4

IndxPortable filter caddy R 5Hydraulic oil cleanup procedure . . . . . . .33-3360-2Power boost solenoid valve

RadiatorRemove and install . . . . . . . . . . . . . . . .33-3360-35

Remove and install . . . . . . . . . . . . . . . . .05-0510-1Pressure release procedure

Receiver-dryerHydraulic oil tank . . . . . . . . . . . . . . . . . .33-3360-1

Remove and install . . . . . . . . . . . . . . . .18-1830-12Primary fuel filter

Recoil spring, trackRemove and install . . . . . . . . . . . . . . . . .05-0560-3

Disassemble and assemble . . . . . . . . .01-0130-21Propel gearbox

Remove and install . . . . . . . . . . . . . . . .01-0130-19Disassemble and assemble—200CLC and

Recover R134a refrigerant . . . . . . . . . . . . .18-1830-8230CLC. . . . . . . . . . . . . . . . . . . . . . . .02-0250-5

RefrigerantDisassemble and assemble—

Cautions and proper handling . . . . . . . . .18-1830-1270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0250-11

Recover R134a, air conditioning . . . . . . .18-1830-8Remove and install . . . . . . . . . . . . . . . . .02-0250-1

Refrigerant oil informationPropel motor

R134a. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6Disassemble and assemble—200CLC and

Refrigerant recovery/recycling and charging230CLC. . . . . . . . . . . . . . . . . . . . . . . .02-0260-4

Charging station installationDisassemble and assemble—

procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7270CLC. . . . . . . . . . . . . . 02-0260-7, 02-0260-18

Regulator, hydraulic pumpRemove and install—200CLC and

Disassemble and assemble . . . . . . . . .33-3360-24230CLC. . . . . . . . . . . . . . . . . . . . . . . .02-0260-1

Remove and install . . . . . . . . . . . . . . . .33-3360-22Remove and install—270CLC . . . . . . . . .02-0260-1

Relief valve, crossover, propel motorStart-up procedure . . . . . . . . . . . . . . . .02-0260-22

Disassemble and assemble—200CLC andPropel motor cover

230CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-17Disassemble and assemble—200CLC and

Disassemble and assemble—230CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-17

270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18Disassemble and assemble—

Restriction valve270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18

Remove and install . . . . . . . . . . . . . . . .33-3360-69Propel motor, counterbalance valve

Roller, trackDisassemble and assemble—200CLC and

Disassemble and assemble . . . . . . . . . .01-0130-3230CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-17

Oil leakage test . . . . . . . . . . . . . . . . . . . .01-0130-4Disassemble and assemble—

Remove and install . . . . . . . . . . . . . . . . .01-0130-1270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18

Rotary manifoldPropel pilot controller

Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25Disassemble and assemble . . . . . . . . .33-3360-42

Disassemble and assemble . . . . . . . . .02-0260-24Remove and install . . . . . . . . . . . . . . . .33-3360-40

Remove and install . . . . . . . . . . . . . . . .02-0260-22Propel speed solenoid valve

R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8Remove and install . . . . . . . . . . . . . . . .33-3360-35

R134a refrigerant recovery and charging stationPump

Installation procedure . . . . . . . . . . . . . . .18-1830-7Fuel injection, remove and install . . . . . .04-0400-4

R134a system charge. . . . . . . . . . . . . . . .18-1830-10Pump regulator, hydraulic

R134a system evacuate . . . . . . . . . . . . . . .18-1830-9Disassemble and assemble . . . . . . . . .33-3360-24Remove and install . . . . . . . . . . . . . . . .33-3360-22

Pump, hydraulic and drive gearboxDisassemble and assemble . . . . . . . . . .33-3360-5 SRemove and install . . . . . . . . . . . . . . . . .33-3360-3Start-up procedure . . . . . . . . . . . . . . . .33-3360-20 Safety signs . . . . . . . . . . . . . . . . . . . . . . .00-0001-13


PN=5

Index

Page Page

Seals, metal face Swing motor make-up valveRemove and install . . . . . . . . . . . . . . . .43-4360-12Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8

Seat beltRemove and install . . . . . . . . . . . . . . . . .18-1821-1

Shoe, track TRemove and install . . . . . . . . . . . . . . . . .01-0130-9

Shut-off valve, pilotTank pressure release procedure . . . . . . . .33-3360-1

Disassemble and assemble . . . . . . . . .33-3360-33Tank, fuel

Remove and install . . . . . . . . . . . . . . . .33-3360-31

Indx6

Remove and install . . . . . . . . . . . . . . . . .05-0560-2Signal manifold, pilot

Tank, hydraulic oilDisassemble and assemble . . . . . . . . .33-3360-47


Remove and install . . . . . . . . . . . . . . . .33-3360-66Sliding window

Torque valueRemove and install . . . . . . . . . . . . . . . . .18-1810-3

Flared connections . . . . . . . . . . . . . . . .00-0003-10Specification

Flat face O-ring seal fitting . . . . . . . . . . .00-0003-8Carrier roller oil . . . . . . . . . . . . . . . . . . . .01-0130-1

Inch SAE four bolt flange fitting. . . . . . .00-0003-11Front idler oil. . . . . . . . . . . . . . . . . . . . . .01-0130-1

Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3Track roller oil . . . . . . . . . . . . . . . . . . . . .01-0130-1

Metric four bolt flange fitting . . . . . . . . .00-0003-12Spring, track recoil

O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6Disassemble and assemble . . . . . . . . .01-0130-21

30° cone seat hydraulic fittings . . . . . . . .00-0003-9Remove and install . . . . . . . . . . . . . . . .01-0130-19

37° flare hydraulic fittings . . . . . . . . . . . .00-0003-9Sprocket

Torque valuesRemove and install . . . . . . . . . . . . . . . .01-0130-14

Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1Start-up procedure

Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Hydraulic pump. . . . . . . . . . . . . . . . . . .33-3360-20

Track adjusterPropel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22

Disassemble and assemble . . . . . . . . .01-0130-21Swing gearbox . . . . . . . . . . . . . . . . . . .43-4350-11

Remove and install . . . . . . . . . . . . . . . .01-0130-19Swing motor . . . . . . . . . . . . . . . . . . . . .43-4360-13

Track adjuster cylinderStarter

Disassemble and assemble . . . . . . . . .01-0130-25Remove and install . . . . . . . . . . . . . . . . .04-0400-5

Track carrier rollerSwing bearing

Disassemble and assemble . . . . . . . . . .01-0130-6Disassemble and assemble . . . . . . . . .43-4350-21

Remove and install . . . . . . . . . . . . . . . . .01-0130-5Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24

Track chainRemove and install . . . . . . . . . . . . . . . .43-4350-19

Disassemble and assemble . . . . . . . . .01-0130-12Upper seal, install . . . . . . . . . . . . . . . . .43-4350-24

Disassemble and assemble to replace brokenSwing gearbox

part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13Disassemble and assemble—200CLC and

Remove and install . . . . . . . . . . . . . . . .01-0130-10230CLC. . . . . . . . . . . . . . . . . . . . . . . .43-4350-5

Track chain sprocketDisassemble and assemble—270CLC . .43-4350-9

Remove and install . . . . . . . . . . . . . . . .01-0130-14Remove and install . . . . . . . . . . . . . . . . .43-4350-1

Track rollerStart-up procedure . . . . . . . . . . . . . . . .43-4350-11

Disassemble and assemble . . . . . . . . . .01-0130-3Swing motor

Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1Start-up procedure . . . . . . . . . . . . . . . .43-4360-13

Remove and install . . . . . . . . . . . . . . . . .01-0130-1Swing motor and park brake

Test for oil leakage . . . . . . . . . . . . . . . . .01-0130-4Assemble—200CLC and 230CLC . . . . . .43-4360-9

Track shoeAssemble—270CLC . . . . . . . . . . . . . . . .43-4360-9

Remove and install . . . . . . . . . . . . . . . . .01-0130-9Disassemble—200CLC and 230CLC . . .43-4360-5Disassemble—270CLC . . . . . . . . . . . . . .43-4360-7Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-8Remove and install . . . . . . . . . . . . . . . . .43-4360-1 U

Swing motor brake release valveDisassemble and assemble . . . . . . . . .43-4360-14 Upperstructure

Install . . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-16Remove and Install . . . . . . . . . . . . . . . .43-4360-13


PN=6

Index

Page

Remove . . . . . . . . . . . . . . . . . . . . . . . .43-4350-12

V

Valve IndxDisassemble and assemble— 7

270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18Valve, brake release, swing motor


Valve, controlRemove and install . . . . . . . . . . . . . . . .33-3360-49

Valve, counterbalance, propel motorDisassemble and assemble—

270CLC. . . . . . . . . . . . . . . . . . . . . . .02-0260-18Valve, crossover relief


Valve, make-up, swing motorRemove and install . . . . . . . . . . . . . . . .43-4360-12

Valve, oil cooler bypassRemove and install . . . . . . . . . . . . . . . .33-3360-71

Valve, pilot pressure regulatingDisassemble and assemble . . . . . . . . .33-3360-31Remove and install . . . . . . . . . . . . . . . .33-3360-30

Valve, pilot shut-offDisassemble and assemble . . . . . . . . .33-3360-33Remove and install . . . . . . . . . . . . . . . .33-3360-31

Valve, restrictionRemove and install . . . . . . . . . . . . . . . .33-3360-69

W

Water separator, primary fuel filterRemove and install . . . . . . . . . . . . . . . . .05-0560-3

Welding on machine. . . . . . . . . . . . . . . . . .17-1740-1Window, sliding

Remove and install . . . . . . . . . . . . . . . . .18-1810-3Windowpane and one piece molding

Remove and install . . . . . . . . . . . . . . . . .18-1810-2Windowpane and two piece molding

Remove and install . . . . . . . . . . . . . . . . .18-1810-1Windowpanes

Remove and install . . . . . . . . . . . . . . . . .18-1810-4


PN=7

Index

Indx8


PN=8

200clc, 230clc, and 270clc repair tm1931

Documents