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135D Excavator Repair

TECHNICAL MANUAL 135D Excavator Repair TM10743 09APR09 (ENGLISH)

For complete service information also see: 135D Excavator Operation and Tests. . . . . . TM10742 135D Excavator Operator’s Manual . . . . . . . OMT239673 Undercarriage Appraisal Manual . . . . . . . . . SP326 Super Caddy Oil Cleanup Procedure . . . . . . CTM310

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

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

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

DX,TMIFC –19–29SEP98–1/1

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Introduction

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TX,TM,FAX –19–03JUL01–1/1

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Introduction

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Contents 00

SECTION 00—General Information Group 0001—Safety Group 0003—Torque Values

SECTION 99—Dealer Fabricated Tools Group 9900—Dealer Fabricated Tools

SECTION 01—Tracks Group 0130—Track System

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

SECTION 04—Engine Group 0400—Removal and Installation SECTION 05—Engine Auxiliary Systems Group 0510—Cooling System Group 0520—Intake System Group 0560—External Fuel Supply Systems

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

SECTION 17—Frame or Supporting Structure Group 1740—Frame Installation Group 1749—Chassis Weights 07

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

SECTION 32—Bulldozers (Blades) Group 3201—Blades Group 3260—Hydraulic System SECTION 33—Excavator Group 3302—Buckets Group 3340—Frames Group 3360—Hydraulic System

SECTION 43—Swing or Pivoting System Group 4350—Mechanical Drive Elements Group 4360—Hydraulic System

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

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Section 00

General Information Contents Page

Group 0001—Safety . . . . . . . . . . . . . . . . . .00-0001-1 Group 0003—Torque Values Torque Value Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Torque Value Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4 Service Recommendations for 37° Flare and 30° Cone Seat Connectors . . . . . . . . .00-0003-5 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6 Service Recommendation O-Ring Boss Fittings In Aluminum HousingExcavators. . . . . . . . . . . . . . . . .00-0003-8 Service Recommendations For Flared Connections—Straight or Tapered Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10 Service Recommendations For Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11 Service Recommendation O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-13 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-15 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for High Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-17 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . .00-0003-19 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . .00-0003-20 Service Recommendation Inch Series Four Bolt Flange For High Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-21 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-22 Service Recommendations For O-Ring Boss Fittings With Shoulder . . . . . . . . . . .00-0003-24 Service Recommendation Metric 24 O-Ring Seal DIN 20078 . . . . . .00-0003-27

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Group 0001

Safety 00 0001 1

Recognize Safety Information –UN–28AUG00

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

T133555

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

–19–28AUG00

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

T133588

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

TX03679,00016CC –19–03JAN07–1/1

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

Be sure all operators of this machine understand every safety message. Replace operator’s manual and safety signs immediately if missing or damaged. Replacement safety signs are available from your authorized dealer.

Keep safety signs in good condition. Be sure new equipment components and repair parts include the current safety signs.

TX14740,0000019 –19–10JAN07–1/1

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

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

TX03679,00016FA –19–03JAN07–1/1

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

–UN–23AUG88

Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TS206

00 0001 2

TX03679,00016D0 –19–03JAN07–1/1

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere Parts, or any damage or failures resulting from their use are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect

machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

AM40430,00000A9 –19–29JUL08–1/1

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Safety 00 0001 3

T133733

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

–UN–15SEP00

Add Cab Guarding for Special Uses

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

TX03679,00016CE –19–03JAN07–1/1

Inspect Machine

T6607AQ

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

–UN–18OCT88

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

TX03679,0001734 –19–03JAN07–1/1

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

T133592

Entanglements in moving parts can cause serious injury.

–UN–12SEP01

Stay Clear of Moving Parts

TX03679,00016D2 –19–03JAN07–1/1

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Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–08DEC08

Escaping fluid under pressure can penetrate the skin causing serious injury.

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Oils

T133509

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

–UN–20SEP00

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

–UN–17MAR06

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

T133840

00 0001 4

TX03679,00016D3 –19–03NOV08–1/1

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Safety 00 0001 5

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

T133546

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

–UN–24AUG00

Beware of Exhaust Fumes

TX03679,00016D4 –19–03NOV08–1/1

T133552 T133554

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

–UN–07SEP00

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

T133553

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

–UN–07SEP00

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

–UN–14SEP00

Prevent Fires

TX03679,00016F5 –19–03NOV08–1/1

Prevent Battery Explosions

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

TS204

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

–UN–23AUG88

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

TX03679,000174A –19–03NOV08–1/1

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Safety

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

T133580

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

–UN–25AUG00

Handle Chemical Products Safely

TX03679,00016D7 –19–03JAN07–1/1

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

T133567

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

–UN–25AUG00

Dispose of Waste Properly

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

TX03679,0001733 –19–03JAN07–1/1

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

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TS291

00 0001 6

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Safety 00 0001 7

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

T133468

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

–UN–30AUG00

Use Steps and Handholds Correctly

TX03679,00016F2 –19–15MAR07–1/1

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

T133715

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

–UN–07SEP00

Start Only From Operator’s Seat

TX03679,0001799 –19–03JAN07–1/1

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

T133716

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses.

–19–14SEP00

Use and Maintain Seat Belt

The complete seat belt assembly should be replaced every 3 years, regardless of appearance.

TX03679,00016DD –19–03NOV08–1/1

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Be careful not to accidentally actuate control levers when coworkers are present. Pull pilot control shutoff lever to locked position during work interruptions. Pull pilot control shutoff lever to locked position and stop engine before allowing anyone to approach machine. Always lower work equipment to the ground and pull pilot control shutoff lever to locked position before standing up or leaving the operator’s seat. Stop engine before exiting.

–UN–22NOV05

Prevent Unintended Machine Movement

T216779

00 0001 8

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Safety 00 0001 9

Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position travel motors away from the hole. Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc). At high speeds, hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt.

T134986 –UN–27SEP00

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine.

T133650

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

–UN–24AUG00

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

T133549

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

–UN–31OCT00

Avoid Work Site Hazards

TX03679,0001748 –19–29JUL08–1/1

Keep Riders Off Machine

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

T7273AH

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

–UN–08JUN90

Only allow operator on machine.

TX03679,0001726 –19–03JAN07–1/1

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Safety

T133548

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

–UN–24AUG00

Avoid Backover Accidents

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

TX03679,00016F3 –19–03JAN07–1/1

Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip. Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.

T133716 –UN–15SEP00

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

T133545

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

–UN–27SEP00

Use seat belt at all times.

–19–14SEP00

Avoid Machine Tip Over

T133803

00 0001 10

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Safety 00 0001 11

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

T133839

Never use this machine to lift people.

–UN–27SEP00

Use Special Care When Lifting Objects

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

TX03679,00016E1 –19–03JAN07–1/1

Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.

TX03679,00016F0 –19–12FEB07–1/1

TX1023216

Avoid serious injury or death from an explosion hazard. Deactivate all cellular or radio frequency devices on equipment stored or operating in an area, such as a blasting zone, where the use of radio transmitting devices are prohibited.

–UN–07MAY07

Prevent Unintended Detonation of Explosive Devices

VD76477,0001543 –19–08JAN08–1/1

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Safety

Park and Prepare for Service Safely

T133332

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

–19–14DEC01

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

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

–UN–23AUG88

Securely support machine or attachment before working under it.

TS229

00 0001 12

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Safety 00 0001 13

Service Cooling System Safely

CAUTION: Prevent possible injury from hot spraying water. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. Release all pressure before you remove cap.

TS281

Do not service radiator through the radiator filler cap. Fill through the recovery tank filler cap.

–UN–23AUG88

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

If recovery tank is empty, check for leaks. Repair as required. Only remove radiator filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely. Add coolant to the radiator and the recovery tank.

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Safety

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

Remove paint before heating: • Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

–UN–23AUG88

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

TS220

00 0001 14

Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

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Safety 00 0001 15

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

T133547

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

–UN–31AUG00

Make Welding Repairs Safely

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

TX03679,00016D5 –19–25APR08–1/1

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

T133738

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

–UN–14SEP00

Drive Metal Pins Safely

TX03679,0001745 –19–03JAN07–1/1

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Safety 00 0001 16

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Group 0003

Torque Values 00 0003 1

TORQ2

–UN–07SEP99

Metric Bolt and Cap Screw Torque Values

Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified Class 4.8 Thread Size

Lubricateda Nm (lb-ft)

Class 8.8 or 9.8

Dryb Nm (lb-ft)

Class 10.9

Lubricateda Nm (lb-ft)

Dryb Nm (lb-ft)

Class 12.9

Lubricateda Nm (lb-ft)

Dryb Nm (lb-ft)

Lubricateda Nm (lb-ft)

Dryb Nm (lb-ft) 19.5 (14.5)

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)

11.5 (8.5)

14.5 (10.7)

22 (16)

28 (20.5)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

M10

23 (17)

29 (21)

43 (32)

55 (40)

63 (46)

80 (59)

75 (55)

95 (70)

M12

40 (29.5)

50 (37)

75 (55)

95 (70)

110 (80)

140 (105)

130 (95)

165 (120)

M14

63 (46)

80 (59)

120 (88)

150 (110)

175 (130)

220 (165)

205 (150)

260 (190)

M16

100 (74)

125 (92)

190 (140)

240 (175)

275 (200)

350 (255)

320 (235)

400 (300)

M18

135 (100)

170 (125)

265 (195)

330 (245)

375 (275)

475 (350)

440 (325)

560 (410)

M20

190 (140)

245 (180)

375 (275)

475 (350)

530 (390)

675 (500)

625 (460)

790 (580)

M22

265 (195)

330 (245)

510 (375)

650 (480)

725 (535)

920 (680)

850 (625)

1080 (800)

M24

330 (245)

425 (315)

650 (480)

820 (600)

920 (680)

1150 (850)

1080 (800)

1350 (1000)

M27

490 (360)

625 (460)

950 (700)

1200 (885)

1350 (1000)

1700 (1250)

1580 (1160)

2000 (1475)

M30

660 (490)

850 (625)

1290 (950)

1630 (1200)

1850 (1350)

2300 (1700)

2140 (1580)

2700 (2000)

M33

900 (665)

1150 (850)

1750 (1300)

2200 (1625)

2500 (1850)

3150 (2325)

2900 (2150)

3700 (2730)

M36

1150 (850)

1450 (1075)

2250 (1650)

2850 (2100)

3200 (2350)

4050 (3000)

3750 (2770)

4750 (3500)

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

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

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

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

OUT3035,TORQUE2 –19–19JUL04–1/1

TM10743 (09APR09)

00-0003-1

135D Excavator Repair 040909

PN=25

Torque Values

–UN–18OCT88

Additional Metric Cap Screw Torque Values

T6873AA

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

–UN–18OCT88

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

T6873AB

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

–UN–18OCT88

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening. Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.

T6873AC

00 0003 2

Continued on next page

TM10743 (09APR09)

00-0003-2

04T,90,M170 –19–29SEP99–1/2

135D Excavator Repair 040909

PN=26

Torque Values 00 0003 3

METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

Nominal Dia

N•m

lb-ft

12 14

N•m

lb-ft

M-Bolt N•m

lb-ft

108

176

130

137

101

265

195

206

152

392

289

294

217

118

539

398

392

289

167

125

735

542

539

398

216

159

931

687

686

506

274

202

1372

1012

1029

759

392

289

1911

1410

1421

1049

539

398

2548

1890

1911

1410

735

542

3136

2314

2401

1772

931

687

Torque tolerance is ±10%.

04T,90,M170 –19–29SEP99–2/2

TM10743 (09APR09)

00-0003-3

135D Excavator Repair 040909

PN=27

Torque Values

–UN–27SEP99

Unified Inch Bolt and Cap Screw Torque Values

TORQ1A

00 0003 4

Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified Grade 2a (No Mark)

Grade 1 (No Mark) Thread Size

Lubricated Nm (lb-ft)

Dry Nm (lb-ft)

Lubricatedb Nm (lb-ft)

Grade 5, 5.1 or 5.2

Dryc Nm (lb-ft)

Lubricatedb Nm (lb-ft)

Dryc Nm (lb-ft)

Grade 8 or 8.2 Lubricatedb Nm (lb-ft)

Dryc Nm (lb-ft)

1/4

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

305 (225)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

285 (210)

360 (265)

285 (210)

360 (265)

730 (540)

920 (680)

1030 (760)

1300 (960)

1-1/8

400 (300)

510 (375)

400 (300)

510 (375)

910 (670)

1150 (850)

1450 (1075)

1850 (1350)

1-1/4

570 (420)

725 (535)

570 (420)

725 (535)

1280 (945)

1630 (1200)

2050 (1500)

2600 (1920)

1-3/8

750 (550)

950 (700)

750 (550)

950 (700)

1700 (1250)

2140 (1580)

2700 (2000)

3400 (2500)

1-1/2

990 (730)

1250 (930)

990 (730)

1250 (930)

2250 (1650)

2850 (2100)

3600 (2650)

4550 (3350)

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

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

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

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

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

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

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

OUT3035,TORQUE1 –19–14JAN04–1/1

TM10743 (09APR09)

00-0003-4

135D Excavator Repair 040909

PN=28

Torque Values 00 0003 5

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

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

T6234AC

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

–UN–18OCT88

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

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

N•m

lb-ft

3/8 - 24 UNF

7/16 - 20 UNF

1/2 - 20 UNF

9/16 - 18 UNF

3/4 - 16 UNF

7/8 - 14 UNF

1-1/16 - 12 UN

102

1-3/16 - 12 UN

122

1-5/16 - 12 UN

142

105

1-5/8 - 12

190

140

1-7/8 - 12 UN

217

160

NOTE: Torque tolerance is ± 10%.

T82,BHMA,EL –19–29SEP99–1/1

TM10743 (09APR09)

00-0003-5

135D Excavator Repair 040909

PN=29

Torque Values

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

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

T6243AE

00 0003 6

3. Tighten fitting to torque value shown on chart.

Continued on next page

TM10743 (09APR09)

00-0003-6

04T,90,K66 –19–29SEP99–1/2

135D Excavator Repair 040909

PN=30

Torque Values 00 0003 7

Angle Fitting

3. Turn fitting head-end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings.

T6520AB

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

–UN–18OCT88

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

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

N•m

lb-ft

3/8-24 UNF

7/16-20 UNF

1/2-20 UNF

9/16-18 UNF

3/4-16 UNF

7/8-14 UNF

1-1/16-12 UN

102

1-3/16-12 UN

122

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

NOTE: Torque tolerance is ± 10%.

04T,90,K66 –19–29SEP99–2/2

TM10743 (09APR09)

00-0003-7

135D Excavator Repair 040909

PN=31

Torque Values

–UN–17NOV03

O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators

T196315

00 0003 8

O-Ring Boss Straight and Adjustable Fittings 1—Straight Fitting 2—O-Ring

3—Stud End 4—Adjustable Fitting

5—Hex Nut

6—Backup Washer

O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH METRIC THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified Thread Size mm

Hex Nut Size mm

Nm (lb-ft)

M12 x 1.5

39 (29)

M14 x 1.5

39 (29)

M16 x 1.5

55 (41)

M22 x 1.5

75 (55)

M27 x 2

110 (81)

M30 x 2

141 (104)

M33 x 2

165 (122)

M38 x 2

165 (122)

M42 x 2

275 (203)

Continued on next page

TM10743 (09APR09)

00-0003-8

OUT3035,0000353 –19–14JAN04–1/2

135D Excavator Repair 040909

PN=32

Torque Values O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified Thread Size in.

Nm (lb-ft)

1/8

—

1/4

28 (20)

3/8

39 (29)

1/2

75 (55)

3/4

126 (93)

165 (122)

1-1/8

—

1-1/4

259 (191)

1-3/8

—

1-1/2

330 (243)

1-3/4

—

2. Back the stud end hex nut (5) off as far as possible. Push backup washer (6) towards the nut to fully expose the turn down section of stud end. Washer must fit turned down section and not be too loose 3. Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape. Apply hydraulic oil to the threads of stud end, turned down section, and O-ring. 4. Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and contacts face of boss. Loosen an adjustable fitting no more than one turn for alignment.

O-RING BOSS PLUG STUD END WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified Thread Size in.

1. Inspect fitting and O-ring boss sealing surfaces and the O-ring. They must be free of dirt, scratches, nicks, or burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition.

5. Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when tightening hex nut.

Nm (lb-ft)

1/8

7.8 (5.80)

1/4

11.8 (8.70)

3/8

23 (17)

1/2

39 (29)

3/4

55 (41)

86 (64)

1-1/4

126 (93)

1-1/2

157 (116)

204 (150)

OUT3035,0000353 –19–14JAN04–2/2

TM10743 (09APR09)

00-0003-9

135D Excavator Repair 040909

PN=33

00 0003 9

Torque Values

Service Recommendations For Flared Connections—Straight or Tapered Threads

–UN–18OCT88

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

T6873AE

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

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

–UN–18OCT88

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

Tapered Thread

Thread Size

N•m

lb-ft

N•m

lb-ft

1/8

1/4

3/8

1/2

3/4

176

130

157

116

343

253

1-1/2

196

145

539

398

255

188

588

434

Torque tolerance is ±10%.

With seat face.

T6873AD

00 0003 10

Tapered Thread

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

04T,90,M171 –19–28JAN92–1/1

TM10743 (09APR09)

00-0003-10

135D Excavator Repair 040909

PN=34

Torque Values 00 0003 11

Service Recommendations For Flat Face O-Ring Seal Fittings 1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects. 2. Lubricate O-rings and install into grove using petroleum jelly to hold in place. 3. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings. IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise. Tighten fittings to 50% of listed torque value if used in aluminum housing. FLAT FACE O-RING SEAL FITTING TORQUE* Nomial Tube O.D.

Thread Size

Swivel Nut

Bulkhead Nut

in.

N•m

lb-ft

N•m

lb-ft

6.35

0.250

9/16-18

9 18

9.52

0.375

11/16-16

12.70

0.500

13/16-16

15.88

0.625

1-14

19.05

0.750

1 3/16-12

102

22.22

0.875

1 3/16-12

102

25.40

1.000

1 7/16-12

142

105

142

105

31.75

1.250

1 11/16-12

190

140

190

140

38.10

1.500

2-12

217

160

217

160

*Torque tolerance is +15 -20% unless otherwise specified.

Continued on next page

TM10743 (09APR09)

00-0003-11

OUO6092,00010A4 –19–02JAN08–1/2

135D Excavator Repair 040909

PN=35

Torque Values 00 0003 12

Stud End O-ring Seal Torque for Straight and Adjustable Fittings* Thread Size

Straight Hex Size

Locknut Hex Size

Inch

Straight Fitting or Locknut Toque N•m

lb-ft

3/8-24

5/8

9/16

7/16-20

5/8

1/2-20

3/4

11/16

9/16-18

3/4

3/4-16

7/8

15/16

7/8-14

1 1/16

104

1 1/16-12

1 1/4

1 3/8

176

130

1 3/16-12

1 3/8

1 1/2

230

170

1 5/16-12

1 1/2

1 5/8

285

210

*Torque tolerance is +15 -20% unless otherwise specified.

OUO6092,00010A4 –19–02JAN08–2/2

TM10743 (09APR09)

00-0003-12

135D Excavator Repair 040909

PN=36

Torque Values 00 0003 13

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations A

–UN–12DEC01

G E F

H70406

F E

A—90° Swivel Elbow and Tube Nut B—90° Adjustable Stud Elbow

C—Stud Straight and Tube Nut D—Bulkhead Union and Nut

E—Stud End F—Tube Nut

G—Swivel Nut H—Hex Nut

O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Nominal Tube OD or Hose ID Metric Tube OD

Inch Tube OD or Hose ID

O-Ring Face Seal Hose or Tube Swivel Nut

Bulkhead Nut

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

Nm (lb-ft)

in.

Nm (lb-ft)

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

11/16

24 (18)

13/16

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

13/16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

15/16

75 (55)

1-1/8

93 (69)

-10

15.88 (0.625)

1-14

1-1/8

103 (76)

1-5/16

118 (87)

-12

19.05 (0.750)

1-3/16-12

1-3/8

152 (112)

1-1/2

175 (129)

-14

22.23 (0.875)

1-3/16-12

—

152 (112)

—

175 (129)

-16

25.40 (1.000)

1-7/16-12

1-5/8

214 (158)

1-3/4

247 (182)

-20

31.75 (1.250)

1-11/16-12

1-7/8

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

2-1/4

326 (240)

2-3/8

374 (276)

Continued on next page

TM10743 (09APR09)

00-0003-13

OUT3035,0000420 –19–14JAN04–1/2

135D Excavator Repair 040909

PN=37

Torque Values 00 0003 14

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Thread Size

Straight Hex Sizea

Adjustable Nut Hex Size

Steel or Gray Iron Torque Nm (lb-ft)

in.

3/8-24

5/8

9/16

18 (13)

7/16-20

5/8

24 (18)

1/2-20

3/4

11/16

30 (22)

9/16-18

3/4

37 (27)

3/4-16

7/8

15/16

75 (55)

7/8-14

1-1/16

103 (76)

1-1/16-12

1-1/4

1-3/8

177 (131)

1-3/16-12

1-3/8

1-1/2

231 (170)

1-5/16-12

1-1/2

1-5/8

270 (199)

1-5/8-12

1-3/4

1-7/8

286 (211)

1-7/8-12

2-1/8

326 (240)

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

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

To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. 4. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment. Hold connections together while tightening nut to ensure O-ring remains in place. 5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut.

OUT3035,0000420 –19–14JAN04–2/2

TM10743 (09APR09)

00-0003-14

135D Excavator Repair 040909

PN=38

Torque Values 00 0003 15

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations 1

1—90° Swivel Elbow 2—90° Adjustable Stud Elbow 3—Stud Straight

T196337

4—Bulkhead Union and Nut 5—External Hex Stud End Plug 6—Tube Nut

T196337

–UN–18NOV03

7—Swivel Nut 8—Stud End 9—Hex Nut

10—O-Ring 11—Identification Groove

O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Nominal Tube OD or Hose ID Metric Tube OD

Inch Tube OD or Hose ID

O-Ring Face Seal Hose or Tube Swivel Nut

Bulkhead Nut

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

Nm (lb-ft)

-2

3.18 (0.125)

—

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

16 (12)

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

24 (18)

42 (31)

-8

12.70 (0.500)

13/16-16

50 (37)

93 (69)

-10

15.88 (0.625

1-14

69 (51)

118 (87)

-12

19.05 (0.750)

1-3/16-12

102 (75)

175 (129)

-14

22.23 (0.875)

1-3/16-12

102 (75)

175 (129)

-16

25.40 (1.000)

1-7/16-12

142 (105)

247 (182)

—

-20

31.75 (1.250)

1-11/16-12

190 (140)

328 (242)

-24

38.10 (1.500)

2-12

217 (160)

374 (276)

-32

50.80 (2.000)

—

Continued on next page

TM10743 (09APR09)

00-0003-15

OUT3035,0000366 –19–14JAN04–1/2

135D Excavator Repair 040909

PN=39

Torque Values 00 0003 16

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Thread Sizea

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque

Aluminum or Brass Torque

mm.

Nm (lb-ft)

M8 x 1

8 (6)

5 (4)

M10 x 1

15 (11)

10 (7)

M12 x 1.5

25 (18)

17 (12)

M14 x 1.5

40 (30)

27 (20)

M16 x 1.5

45 (33)

30 (22)

M18 x 1.5

50 (37)

33 (25)

M22 x 1.5

69 (51)

46 (34)

M27 x 2

100 (74)

67 (49)

M30 x 2

130 (96)

87 (64)

M33 x 2

160 (118)

107 (79)

M38 x 2

176 (130)

117 (87)

M42 x 2

210 (155)

140 (103)

M48 x 2

260 (192)

173 (128)

M60 x 2

315 (232)

210 (155)

Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

OUT3035,0000366 –19–14JAN04–2/2

TM10743 (09APR09)

00-0003-16

135D Excavator Repair 040909

PN=40

Torque Values 00 0003 17

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations 1

1—90° Swivel Elbow 2—90° Adjustable Stud Elbow 3—Stud Straight

T196337

4—Bulkhead Union and Nut 5—External Hex Stud End Plug 6—Tube Nut

T196337

–UN–18NOV03

7—Swivel Nut 8—Stud End 9—Hex Nut

10—O-Ring 11—Identification Groove

O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Nominal Tube OD or Hose ID Metric Tube OD

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Bulkhead Nut

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

Nm (lb-ft)

-2

3.18 (0.125)

—

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

24 (18)

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

75 (55)

93 (69)

-10

15.88 (0.625)

1-14

103 (76)

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

175 (129)

-14

22.23 (0.875)

1-3/16-12

152 (112)

175 (129)

-16

25.40 (1.000)

1-7/16-12

214 (158)

247 (182)

—

-20

31.75 (1.250)

1-11/16-12

—

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

—

326 (240)

374 (276)

Continued on next page

TM10743 (09APR09)

00-0003-17

OUT3035,0000421 –19–14JAN04–1/2

135D Excavator Repair 040909

PN=41

Torque Values 00 0003 18

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 KPA (275.8 BAR) (4,000 PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Thread Sizea

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque Nm (lb-ft)

mm.

M8 x 1

8 (6)

M10 x 1

15 (11)

M12 x 1.5

35 (26)

M14 x 1.5

45 (33)

M16 x 1.5

55 (41)

M18 x 1.5

70 (52)

M22 x 1.5

100 (74)

M27 x 2

170 (125)

M30 x 2

215 159)

M33 x 2

260 (192)

M38 x 2

320 (236)

M42 x 2

360 (266)

M48 x 2

420 (310)

Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

OUT3035,0000421 –19–14JAN04–2/2

TM10743 (09APR09)

00-0003-18

135D Excavator Repair 040909

PN=42

Torque Values 00 0003 19

T6890BB

–UN–01MAR90

Service Recommendations for Metric Series Four Bolt Flange Fitting

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

D—Single Piece Flange

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

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

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

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

TORQUE CHARTa

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

Thread

N•m

M10

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

M12

M14

157

116

M16

217

160

M18

334

246

M20

421

318

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

lb-ft

Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. a

Metric standard thread.

04T,90,K175 –19–29SEP99–1/1

TM10743 (09APR09)

00-0003-19

135D Excavator Repair 040909

PN=43

Torque Values

–UN–01MAR90

Service Recommendations For Inch Series Four Bolt Flange Fittings

T6890BB

00 0003 20

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

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

D—Single Piece Flange TORQUE CHART N•m

lb-ft

Nominal Flange Size

Cap Screw Size Min

Max

Min

Max

1/2

5/16-18 UNC

3/4

3/8-16 UNC

1-1/4

7/16-14 UNC

1-1/2

1/2-13 UNC

131

1/2-13 UNC

131

2-1/2

1/2-13 UNC

107

131

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

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

04T,90,K174 –19–01AUG94–1/1

TM10743 (09APR09)

00-0003-20

135D Excavator Repair 040909

PN=44

Torque Values 00 0003 21

T6890BB

–UN–01MAR90

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES— Tolerance is ± 10% unless otherwise specified Nominal Flange Size

Cap Screw Sizea

Min—Max Torque

in.

Nm (lb-ft)b

1/2

5/16-18 UNC

20—31 (15—23)

3/4

3/8-16 UNC

34—54 (25—40)

7/16-14 UNC

57—85 (42—63)

1-1/4

1/2-13 UNC

85—131 (63—97)

1-1/2

5/8-11 UNC

159—264 (117—195)

3/4-10 UNC

271—468 (200—345)

D—Single Piece Flange

2. Install the O-ring (and backup ring, if used) into groove. Use petroleum jelly to hold it in place. IMPORTANT: DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold flange halves and line in place. Do not pinch O-ring (C).

JDM A17D, SAE Grade 5 or better cap screws with plated hardware. Lock washers are permissible but not recommended. b

Minimum torques given are enough for the given size connection with the recommended working pressure. Torques can be increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond the maximum will result in flange and cap screw bending and connection failures.

1. Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat causes O-ring extrusion. If imperfection cannot be polished out, replace component.

Single piece flange (D): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand tighten cap screws to hold flange and line in place. Do not pinch O-ring. 4. Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap screws within the specified torque values.

OUT3035,0000422 –19–14JAN04–1/1

TM10743 (09APR09)

00-0003-21

135D Excavator Repair 040909

PN=45

Torque Values

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings 1. Inspect all fitting sealing surfaces. They must be free of dirt and defects. 2. Inspect O-ring (A). It must be free of damage or defects. 3. Inspect sealing ring (B) for damage or defects.

–UN–06MAR98

4. Hold body in desired position while tightening stud by hand. 5. Tighten stud (C) to torque value shown on the chart. Do not allow body to twist when tightening stud. NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting.

T113948

00 0003 22

Torque Value Tube Fitting O.D. Size

Metric Thread

N•m

lb-ft

M 10 x 1

M 12 x 1.5

10 L

M 14 x 1.5

12 L

M 16 x 1.5

100

15 L

M 18 x 1.5

130

18 L

M 22 x 1.5

160

118

22 L

M 26 x 1.5

250

184

28 L

M 33 x 2

400

295

35 L

M 42 x 2

600

443

42 L

M48 x 2

800

590

M 12 x 1.5

M 14 x 1.5

10 S

M 16 x 1.5

100

12 S

M 18 x 1.5

130

14 S

M 20 x 1.5

160

118

16 S

M 22 x 1.5

160

118

20 S

M 27 x 2

250

184

25 S

M 33 x 2

400

295

30 S

M 42 x 2

600

443

38 S

M 48 x 2

800

590

Continued on next page

TM10743 (09APR09)

00-0003-22

CED,OUO1002,562 –19–09MAR98–1/2

135D Excavator Repair 040909

PN=46

Torque Values 00 0003 23

Torque Value Tube Fitting O.D. Size

Inch Size

N•m

lb-ft

1/8

1/4

10 L

1/4

12 L

3/8

15 L

1/2

130

18 L

1/2

150

111

22 L

3/4

250

184

28 L

400

295

35 L

1-1/4

600

443

42 L

1-1/2

800

590

1/4

10 S

3/8

12 S

3/8

100

14 S

1/2

130

16 S

1/2

150

111

20 S

3/4

250

184

25 S

400

295

30 S

1-1/4

600

443

38 S

1-1/2

800

590

CED,OUO1002,562 –19–09MAR98–2/2

TM10743 (09APR09)

00-0003-23

135D Excavator Repair 040909

PN=47

Torque Values

Service Recommendations For O-Ring Boss Fittings With Shoulder 1. Inspect component seal boss seat for dirt or defects. –UN–06MAR98

2. Inspect EOlastic seal (A) for damage. Replace seal or fitting as necessary. To replace seal, put electrical tape over threads to protect seal. Slide seal over tape and into seal groove of fitting. Remove tape.

T113957

00 0003 24

3. Tighten fitting to torque value shown on chart. IMPORTANT: Do not allow hoses to twist when tightening fittings. NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting. Torque Value Tube Fitting O.D. Size

Metric Thread

N•m

lb-ft

M 10 x 1

M 12 x 1.5

10 L

M 14 x 1.5

12 L

M 16 x 1.5

15 L

M 18 x 1.5

18 L

M 22 x 1.5

130

22 L

M 26 x 1.5

190

140

28 L

M 33 x 2

300

221

35 L

M 42 x 2

600

443

42 L

M48 x 2

800

590

M 12 x 1.5

M 14 x 1.5

10 S

M 16 x 1.5

12 S

M 18 x 1.5

110

14 S

M 20 x 1.5

140

103

16 S

M 22 x 1.5

170

125

20 S

M 27 x 2

250

184

25 S

M 33 x 2

450

332

30 S

M 42 x 2

600

443

38 S

M 48 x 2

800

590

Continued on next page

TM10743 (09APR09)

00-0003-24

CED,OUO1002,563 –19–09MAR98–1/3

135D Excavator Repair 040909

PN=48

Torque Values 00 0003 25

Torque Value Tube Fitting O.D. Size

Inch Size

N•m

lb-ft

1/8

1/4

10 L

1/4

12 L

3/8

15 L

1/2

140

103

18 L

1/2

100

22 L

3/4

180

133

28 L

300

221

35 L

1-1/4

600

443

42 L

1-1/2

800

590

1/4

10 S

3/8

12 S

3/8

14 S

1/2

160

118

16 S

1/2

140

103

20 S

3/4

250

184

25 S

400

295

30 S

1-1/4

650

479

38 S

1-1/2

800

590

Continued on next page

TM10743 (09APR09)

00-0003-25

CED,OUO1002,563 –19–09MAR98–2/3

135D Excavator Repair 040909

PN=49

Torque Values 00 0003 26

Hex Socket Head Plugs Only Torque Value Thread Size

N•m

lb-ft

M 10 x 1

M 12 x 1.5

M 14 x 1.5

M 16 x 1.5

M 18 x 1.5

M 20 x 1.5

M 22 x 1.5

100

M 26 x 1.5

120

M 27 x 2

150

111

M 33 x 2

250

184

M 42 x 2

400

295

M 48 x 2

500

369

1/8

1/4

3/8

1/2

3/4

150

111

220

162

1-1/4

600

443

1-1/2

800

590

CED,OUO1002,563 –19–09MAR98–3/3

TM10743 (09APR09)

00-0003-26

135D Excavator Repair 040909

PN=50

Torque Values 00 0003 27

Metric 24° O-Ring Seal DIN 20078 Service Recommendations METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES Heavy Fitting Size

Light Fitting Size

Turns

—

M12 x 1.5

Hand tighten so O-ring contacts seat plus an additional 1/4—1/3 turn using a wrench

M16 x 1.5

M14 x 1.5

M18 x 1.5

M16 x 1.5

M20 x 1.5

M18 x 1.5

M22 x 1.5

—

M22 x 1.5

M24 x 1.5

—

M26 x 1.5

M30 x 2

—

M30 x 2

M36 x 2

—

M36 x 2

M42 x 2

—

M45 x 2

M52 x 2

—

Torque

–UN–06MAR98

Fitting Tube OD Size

T113889

NOTE: These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings. IMPORTANT: In this style of fittings, there are “heavy” and “light” designs. Usually “heavy” is used for pressure lines and “light” for return lines. Some “heavy” and “light” sizes can be threaded together but do not seal properly. Be sure not to mix “heavy” and “light” fittings. 1. Inspect the fitting sealing surfaces. They must be free of dirt scratches, nicks, and burrs.

Continued on next page

TM10743 (09APR09)

00-0003-27

CED,OUO1002,517 –19–14JAN04–1/2

135D Excavator Repair 040909

PN=51

Torque Values 00 0003 28

2. Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition. 3. Lubricate O-rings using a thin film of clean hydraulic oil. 4. Align an adjustable fitting with the tube. Hold connections together while tightening nut to ensure proper seal. 5. Tighten nut (A) hand tight so O-ring contacts seat and then an additional 1/4—1/3 turn using a wrench.

CED,OUO1002,517 –19–14JAN04–2/2

TM10743 (09APR09)

00-0003-28

135D Excavator Repair 040909

PN=52

Section 01

Tracks Contents

Page

Group 0130—Track System Track Roller Remove and Install . . . . . . . . . .01-0130-1 Track Roller Disassemble and Assemble . . .01-0130-2 Track Roller Pressure Test . . . . . . . . . . . . . .01-0130-5 Track Carrier Roller Remove and Install . . . .01-0130-6 Inspect Metal Face Seals . . . . . . . . . . . . . . .01-0130-8 Track Shoe Remove and Install . . . . . . . . . .01-0130-9 Track Chain Remove and Install . . . . . . . . .01-0130-10 Track Chain Disassemble and Assemble . .01-0130-12 Track Chain Repair . . . . . . . . . . . . . . . . . . .01-0130-14 Sprocket Remove and Install. . . . . . . . . . . .01-0130-16 Front Idler Remove and Install . . . . . . . . . .01-0130-18 Front Idler Disassemble and Assemble . . . .01-0130-19 Track Adjuster and Recoil Spring Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .01-0130-20 Track Adjuster and Recoil Spring Disassemble and Assemble. . . . . . . . . . .01-0130-22 Track Adjuster Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-29

TM10743 (09APR09)

01-1

135D Excavator Repair 040909

PN=1

Contents

TM10743 (09APR09)

01-2

135D Excavator Repair 040909

PN=2

Group 0130

Track System Track Roller Remove and Install 1. Swing upperstructure 90° and lower bucket to raise track off ground. Keep angle between boom and arm 90—110° and position round side of bucket on ground.

01 0130 1

CAUTION: Prevent possible injury from unexpected machine movement. Put floor stands under frame to support machine while removing lower track roller. 2. Place floor stands under machine. Specification 135D—Weight (approximate) ..................................................... 16 794 kg 37 034 lb

AC12469,0000585 –19–18APR08–1/3

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

–UN–28NOV90

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

T7396DZ

A—Grease Fitting B—Valve C—Bleed Hole

Continued on next page

TM10743 (09APR09)

01-0130-1

AC12469,0000585 –19–18APR08–2/3

135D Excavator Repair 040909

PN=55

Track System 4. Remove cap screws (A) and track roller (B).

–UN–25OCT88

6. Repair or replace parts as necessary. See Track Roller Disassemble and Assemble. (Group 0130.) 7. Install track roller and tighten cap screws to specification.

T6585TN

01 0130 2

5. Measure track roller tread diameter. See 120C, 135C, 120D, and 135D Standard Track Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.)

Specification Track Roller-to-Frame Cap Screws—Torque ........................................................................... 310 N•m 230 lb-ft

A—Cap Screw (4 used) B—Track Roller

8. Tighten track adjuster valve to specification. Specification Track Adjuster Valve—Torque ....................................................... 90 N•m 66 lb-ft

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

AC12469,0000585 –19–18APR08–3/3

Track Roller Disassemble and Assemble 1. Remove track roller. See Track Roller Remove and Install. (Group 0130.) Continued on next page

TM10743 (09APR09)

01-0130-2

AC12469,0000586 –19–18APR08–1/3

135D Excavator Repair 040909

PN=56

Track System

TX1040224

–UN–24APR08

01 0130 3

Track Roller Components 1—Plug (2 used) 2—Pin (2 used) 3—Cap Screw (4 used)

4—Bracket (2 used) 5—Metal Face Seal (2 used)

2. Remove plugs (1) and drain oil. 3. Make alignment marks on brackets (4) and axle (7). Remove pin (2). 4. Remove bracket (4) using a bearing puller attachment and adapters from D01047AA 17-1/2 and 30-Ton Puller Set. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

6—O-Ring (2 used) 7—Axle

8—Bushing (2 used) 9—Roller

6. Inspect metal face seals. For seals that will be reused, put a piece of cardboard between seal rings to protect seal face. See Inspect Metal Face Seals. (Group 0130.) 7. Remove axle (7) from roller. NOTE: Only remove bushings if replacement is necessary. 8. Remove bushings (F) using a 2 jaw puller and adapters from D01047AA 17-1/2 and 30-Ton Puller Set. 9. Inspect and replace parts as necessary.

5. Remove metal face seal (5) from roller and bracket. Keep seal rings together as a matched set with seal ring faces together to protect surfaces.

10. Apply clean oil to bushings (8) and install.

Continued on next page

TM10743 (09APR09)

01-0130-3

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135D Excavator Repair 040909

PN=57

Track System IMPORTANT: O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-rings do not slip when roller is turning. 01 0130 4

11. Thoroughly clean O-rings and seat surfaces in brackets (4) and in seal rings using volatile, non-petroleum base solvent and lint-free tissues. 12. Install metal face seals (5) in brackets (4) and in roller (9). Apply equal pressure with fingers at four equally spaced points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore. A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. 13. Wipe finger prints and foreign material off seal ring face using clean oil and lint-free tissues. Apply clean oil to each seal ring face.

15. Install pins even with flat surface of bracket. 16. Fill roller with specified amount of clean engine oil. Specification Roller Oil—Capacity ................................................................ 200 mL 6.8 oz

17. Clean threads of plug using PM37509 Cure Primer. Apply PM37397 Pipe Sealant to threads of plug. Install plug and tighten to specification. Specification Track Roller Plug—Torque ...................................................... 20 N•m 177 lb-in.

18. Install track roller. See Track Roller Remove and Install. (Group 0130.)

14. Apply PT569 Anti-Seize Lubricant to pins (2). Install brackets on axle.

AC12469,0000586 –19–18APR08–3/3

TM10743 (09APR09)

01-0130-4

135D Excavator Repair 040909

PN=58

Track System

Track Roller Pressure Test 1. Remove track roller. See Track Roller Remove and Install. (Group 0130.) –UN–02JUN97

2. Hold the shaft and turn shell several turns to seat metal face seals.

T109691B

3. Remove the plug. 4. Install parts (A—F). Plug, barbed adapter and connector are from a leak detector kit such as the D05361ST Rubber Stopper/Leak Detector Kit. 5. Holding plug so it is not pushed out, slowly pressurize oil cavity using specified air pressure. Specification Track Roller Test—Pressure ................................................. 92—128 kPa 0.8—1.4 bar 12—20 psi

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

6. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has decreased. 7. If leakage is detected, disassemble roller and replace parts as necessary. See Track Roller Disassemble and Assemble. (Group 0130.) 8. If no leakage is detected, apply PM37509 Cure Primer and PM37397 Thread Sealant to threads of plug and install plug. 9. Install track roller. See Track Roller Remove and Install. (Group 0130.)

AC12469,0000587 –19–18APR08–1/1

TM10743 (09APR09)

01-0130-5

135D Excavator Repair 040909

PN=59

01 0130 5

Track System

Track Carrier Roller Remove and Install

–UN–28NOV90

1. Loosen valve (B) one to one and a half turns to release grease through bleed hole (C). 2. Raise track link to permit carrier roller removal.

T7396DZ

01 0130 6

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

CAUTION: Prevent accidental lowering of track by securely supporting track before attempting service procedure.

A—Grease Fitting B—Valve C—Bleed Hole

3. Install wooden blocks between track link and frame to support track.

Continued on next page

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PN=60

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

–UN–25OCT88

5. Measure track carrier roller tread diameter. See 120C, 135C, 120D, and 135D Standard Carrier Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.) IMPORTANT: Carrier roller replaced as assembly only.

T6557DK

6. Inspect and replace parts as necessary. 7. Install carrier roller and tighten cap screws (B). Specification Track Carrier Roller-to-Frame Cap Screw—Torque ....................................................................... 98 N•m 72 lb-ft

A—Carrier Roller B—Cap Screw (4 used)

8. Remove wooden blocks and jack. 9. If a new track carrier roller is installed, fill track carrier roller with specified amount of clean engine oil. Specification Track Carrier Roller—Capacity ........................................................ 40 mL 1.35 oz

10. Install new plug in cover of track carrier roller if removed and tighten to specification. Specification Track Carrier Roller Plug— Torque ......................................................................................... 29.5 N•m 22 lb-ft

11. Tighten track adjuster valve to specification. Specification Track Adjuster Valve—Torque ....................................................... 90 N•m 66 lb-ft

12. Adjust track sag. See Check and Adjust Track Sag. (Operator’s Manual.)

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01 0130 7

Track System

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

T85079

–UN–24AUG93

A—Seal Ring B—Worn Area (shaded area) C—Seal Ring Face D—Outer Half of Seal Ring Face E—Sealing Area (dark line)

Ring Sealing Area

AC12469,0000589 –19–18APR08–1/3

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

–UN–05DEC96

II—Sealing area (D) not concentric with inside diameter and outside diameter of seal ring. A—Seal Ring B—Worn Area (shaded area) C—Inner Half of Seal Ring Face D—Sealing Area (dark line)

T85080

01 0130 8

Metal Face Seals

Continued on next page

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Track System 3. Clean reusable seals by removing all foreign material from seal rings, except seal face (A), using a scraper or a stiff bristled fiber brush.

–UN–23FEB89

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

T82840

5. Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape. No Scraper On Seal Face

A—Seal Face

AC12469,0000589 –19–18APR08–3/3

Track Shoe Remove and Install

–UN–23FEB89

1. Measure grouser height. See 120C, 135C, 120D, and 135D Standard Three Bar Grouser Height. (SP326 Undercarriage Appraisal Manual.) 2. Remove cap screws securing track shoes to links.

T6794AM

3. Repair or replace track shoes as necessary. 4. Apply a light coat of oil to cap screw threads and install shoe. 5. Install all track shoe nuts with rounded edges (A) against the link and chamfered edges (B) away from the link. Be sure nut is properly positioned in the link so there is full contact between the nut and the link.

–UN–23FEB89

6. Tighten cap screws to specification in pattern shown.

T6352AH

Specification Track Shoe-to-Link Cap Screw 1st step—Torque .......................................................................... 163 N•m 120 lb-ft Track Shoe-to-Link Cap Screw Second Step—Torque Turn ................................................................ 180° A—Rounded Edge B—Chamfered Edge

AC12469,000058A –19–18APR08–1/1

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01 0130 9

Track System

Track Chain Remove and Install 1. Swing upperstructure to side. Lower boom to raise track off the ground. Keep the angle between boom and arm at 90—110° with the round side of bucket on 01 the ground. 0130 10

CAUTION: Prevent possible injury from unexpected machine movement. Machine must be supported before removing track chain. 2. Place blocks or floor stands under the machine to support machine while track chain is removed. Specification 135D—Weight (approximate) ..................................................... 16 794 kg 37 034 lb

AC12469,000058B –19–18APR08–1/4

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

–UN–28NOV90

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

T7396DZ

A—Grease Fitting B—Valve C—Bleed Hole

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Track System NOTE: Disconnect track chain at the end of track frame where the work is to be done.

–UN–25OCT88

4. Move track chain so master pin (A) is over front idler or sprocket. 5. Remove the track shoe on each side of master pin. See Track Shoe Remove and Install. (Group 0130.)

T6585TH

6. If removing chain at idler, put wooden blocks in front of idler and under chain so chain does not fall when master pin is removed. 7. Remove snap ring (G).

–UN–23APR93

IMPORTANT: Master pin can be removed in one direction only. Track chain or pin will be damaged if master pin is removed incorrectly.

T7945AA

8. Remove master pin using D01030AA 50-Ton Master Pin Pusher Installer. Pin is removed by pressing toward snap ring side. 9. Remove bushings (B). A—Master Pin B—Bushing (2 used) C—Link D—Master Bushing E—Link F—Master Link G—Snap Ring

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 10. Remove track chain. If chain was disconnected at front idler, operate travel lever in reverse direction to remove chain from top of track frame. Specification Track Chain—Weight (approximate)................................................................................. 1470 kg 3250 lb

11. Inspect track chain and repair or replace parts as required. See Track Chain Disassemble and Assemble. (Group 0130.) 12. Position track chain so section on ground has pin boss on links toward rear of machine.

Continued on next page

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01 0130 11

Track System 13. Install end of chain on sprocket and slowly turn sprocket in forward direction to pull chain across top of frame to front idler. 01 0130 12

14. Pull ends of chain together. Install bushings. IMPORTANT: Snap ring is deformed during removal and must not be reused. 15. Install master pin using D01030AA 50-Ton Master Pin Pusher Installer from snap ring side of track. Install new snap ring. 16. Install track shoes. See Track Shoe Remove and Install. (Group 0130.) 17. Tighten track adjuster valve to specification. Specification Track Adjuster Valve—Torque ....................................................... 90 N•m 66 lb-ft

18. Adjust track sag. See Check and Adjust Track Sag. (Operator’s Manual.)

AC12469,000058B –19–18APR08–4/4

Track Chain Disassemble and Assemble 1. Remove track chain. See Track Chain Remove and Install. (Group 0130.) Continued on next page

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Track System 4 2

01 0130 13

1 6 9 10

9 6 7 6

11 7 1 1

–UN–29FEB08

TX1037497

12 12 TX1037497 Track Chain Components 1—Track Link (44 used) 2—Master Link 3—Master Pin 4—Snap Ring

5—Pin (43 used) 6—Track Link (43 used) 7—Seal (86 used)

8—Bushing (43 used) 9—Spacer (2 used) 10—Master Track Bushing

11—Nut (176 used) 12—Cap Screw (176 used) 13—Track Shoe (44 used)

2. Measure track components.

Continued on next page

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Track System 4. Clean any dust or rust from the surfaces of track link pin bores and counterbores and the ends of bushings.

See 120C, 135C, 120D, and 135D Standard Bushing Outer Diameter. (SP326 Undercarriage Appraisal Manual.)

5. Apply grease to the counterbore in track links, the seals, and the ends of bushings.

See 120C, 135C, 120D, and 135D Standard Track Chain Pitch—171.45 mm (6.750 in.). (SP326 Undercarriage Appraisal Manual.)

6. For each joint, fill the clearance between the pin outside diameter and bushing inside diameter with grease. 7. Install seal (7) so tapered side is toward bushing.

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

8. Install track chain. See Track Chain Remove and Install. (Group 0130.)

3. Turn pins (3 and 5) and bushings (8 and 10) as required.

AC12469,000058C –19–18APR08–3/3

Track Chain Repair 1. Remove track shoes from each side of broken link assembly. See Track Shoe Remove and Install. (Group 0130.)

AC12469,000058D –19–18APR08–1/5

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

–UN–26OCT88

2. Cut links, bushing, and pin at cut locations (A) to remove broken link (B). A—Cut Locations B—Broken Link

T5821AG

01 0130 14

See 120C, 135C, 120D, and 135D Standard Track Chain Link Height. (SP326 Undercarriage Appraisal Manual.)

Continued on next page

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

T5821AH

–UN–26OCT88

A—Bushing

AC12469,000058D –19–18APR08–3/5

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

T5821AI

–UN–26OCT88

A—Pin Stub B—Hammer

AC12469,000058D –19–18APR08–4/5

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

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

T5821AJ

9. Install track shoes. See Track Shoe Remove and Install. (Group 0130.)

–UN–24MAY89

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

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

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01 0130 15

Track System

Sprocket Remove and Install IMPORTANT: Sprocket must be replaced when the tooth tips become excessively rounded, worn, or chipped to prevent excessive 01 wear to chain. If machine is driven in 0130 one direction a majority of the time, 16 wear will be on one side of teeth. To extend service life, change sprockets from one side of machine to the other. 1. Disconnect track chain. See Track Chain Remove and Install. (Group 0130.) CAUTION: Prevent possible injury from unexpected machine movement. Machine must be supported before removing track chain. 2. Lift side of machine so sprocket teeth clear chain. Specification 135D—Weight (approximate) ..................................................... 16 794 kg 37 034 lb

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Track System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Support sprocket and remove cap screws (1).

01 0130 17

–UN–01FEB02

Specification Sprocket—Weight (approximate) ...................................................... 41 kg 90 lb

4. Remove sprocket.

T145912B

5. Inspect and replace sprocket as necessary. 6. Clean mounting surfaces of sprocket and drum. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

1—Cap Screw (16 used)

IMPORTANT: Chamfered side of sprocket must face drum or sprocket will not sit flush with travel motor. 7. Install sprocket and align cap screw holes. Specification Sprocket—Weight (approximate) ...................................................... 41 kg 90 lb

8. Apply PM37509 Cure Primer and PM38623 Heavy-Duty Thread Lock and Sealer to threads of cap screws (1). 9. Install cap screws and tighten to specification. Specification Sprocket Cap Screw—Torque...................................................... 265 N•m 195 lb-ft

10. Lower machine. 11. Connect track chain. See Track Chain Remove and Install. (Group 0130.)

AC12469,000058E –19–18APR08–2/2

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Track System

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

AC12469,000058F –19–18APR08–1/2

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

–UN–25OCT88

3. Attach front idler to hoist and remove from track frame. Specification Front Idler—Weight (approximate) .................................................... 82 kg 180 lb

T6876BU

01 0130 18

4. Measure front idler wear. See 120C, 135C, 120D, and 135D Standard Front Idler Flange Height. (SP326 Undercarriage Appraisal Manual.) A—Front Idler

5. Repair or replace idler as necessary. See Front Idler Disassemble and Assemble. (Group 0130.) 6. Clean sliding surfaces of front idler and track frame. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Install front idler. Specification Front Idler—Weight (approximate) .................................................... 82 kg 180 lb

8. Connect track chain. See Track Chain Remove and Install. (Group 0130.)

AC12469,000058F –19–18APR08–2/2

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Track System

Front Idler Disassemble and Assemble 3 2 1

01 0130 19

4 8

5 7

7 9 6 4

5 –UN–24APR08

3 2 1

TX1040240

TX1040240 Front Idler Exploded View 1—Drain Plug (2 used) 2—Bracket (bearing) (2 used) 3—Pin (2 used)

4—Metal Face Seal (2 used) 5—O-Ring (2 used) 6—Axle

1. Remove front idler. See Front Idler Remove and Install. (Group 0130.) 2. Remove cap screws (10) and yoke (9). 3. Remove drain plugs (1) and drain oil.

7—Bushing (2 used) 8—Idler

9—Yoke 10—Cap Screw (4 used)

5. Inspect metal face seals. See Inspect Metal Face Seals. (Group 0130.) Keep seal rings together as a matched set with seal ring faces together to protect surfaces. 6. Remove axle (6). Inspect axle and bushing for scoring or excessive wear.

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

NOTE: Remove bushings only if replacement is necessary. 7. Remove bushing using a 2-jaw puller and adapters from D01047AA 17-1/2 and 30-ton Puller Set.

IMPORTANT: Put matching marks on brackets and axle for assembly.

8. Replace parts as necessary.

4. Remove pins (3), brackets (2), O-rings (5) and metal face seals (4).

9. Apply a thin film of clean oil to bushings (7). Install bushings so flange is tight against shoulder of idler.

Continued on next page

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Track System 10. Apply a thin layer of PT569 Anti-Seize Lubricant to end of axle from O-ring to end of axle and to bore in bracket (2).

18. Apply PT569 Anti-Seize Lubricant to pins (3). Install pins. 19. Install metal face seal O-ring on seal rings.

IMPORTANT: Metal face seal O-rings and seat 01 surfaces for O-rings must be clean, 0130 dry, and oil free so O-rings do not 20 slip when idler is turning. 11. Thoroughly clean the metal face seal (4) O-rings and seat surfaces in idler, brackets, and seal rings using volatile, non-petroleum base solvent and lint-free tissues. NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. 12. Install metal face seals (4) in bracket and idler. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must "pop" down into place so O-ring is tight against seal bore. 13. Wipe finger prints and foreign material off seal ring face using clean engine oil and lint-free tissues. Apply a thin film of oil to each seal face. 14. Repeat previous steps for other bracket. 15. Install axle into idler.

20. Fill brackets with specified quantity of oil. Specification Front Idler Bracket Oil— Capacity ................................................................................... 235 mL 8 oz

21. Apply PM37509 Cure Primer and PM37418 Medium-Strength Thread Lock and Sealer to threads of drain plug (1). 22. Install drain plug and tighten to specification. Specification Drain Plug—Torque ................................................................. 30 N•m 22 lb-ft

23. Install yoke (9) and tighten cap screws to specification. Specification Yoke-to-Bracket Cap Screw— Torque.................................................................................... 206 N•m 152 lb-ft

24. Install front idler. See Front Idler Remove and Install. (Group 0130.)

16. Install O-rings on axle. 17. Install brackets onto axle.

AC12469,0000590 –19–18APR08–2/2

Track Adjuster and Recoil Spring Remove and Install 1. Remove track chain. See Track Chain Remove and Install. (Group 0130.) 2. Remove front idler. See Front Idler Remove and Install. (Group 0130.)

Continued on next page

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Track System

T6557CX

–UN–25OCT88

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

A—Track Adjuster

3. Slide track adjuster (A) forward using a pry bar. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Support track adjuster and remove from track frame. Specification Track Adjuster Cylinder and Recoil Spring—Weight (approximate)..................................................................................... 60 kg 135 lb

5. Inspect and repair parts as necessary. See Track Adjuster and Recoil Spring Disassemble and Assemble. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 6. Install track adjuster in track frame. Specification Track Adjuster Cylinder and Recoil Spring—Weight (approximate)..................................................................................... 60 kg 135 lb

7. Install front idler. See Front Idler Remove and Install. (Group 0130.)

Continued on next page

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01 0130 21

Track System 8. Install track chain. See Track Chain Remove and Install. (Group 0130.)

01 0130 22

AC12469,0000591 –19–18APR08–3/3

Track Adjuster and Recoil Spring Disassemble and Assemble NOTE: It is not necessary to remove the recoil spring to replace wear ring and U-ring packing on piston. To replace O-ring in the cylinder, remove recoil spring and rod. 1. Disconnect track chain. See Track Chain Remove and Install. (Group 0130.) 2. Remove front idler. See Front Idler Remove and Install. (Group 0130.) 3. Remove track adjuster and recoil spring from track frame. See Track Adjuster and Recoil Spring Remove and Install. (Group 0130.)

Continued on next page

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Track System

01 0130 23

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

–UN–25OCT88

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

T6557DY

4. Place a 30 ton hydraulic jack on bottom of ST4920 Track Recoil Spring Disassembly and Assembly Tool. See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.) Specification ST4920 Track Recoil Spring Disassembly and Assembly Tool—Weight (approximate)............................................................ 161 kg 355 lb

A—ST4920 Track Recoil Spring Disassembly and Assembly Tool B—Nut (8 used) C—Top Plate

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

Continued on next page

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Track System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 6. Connect track adjuster (B) to a hoist using a lifting strap (A). Specification Track Adjuster Cylinder and Recoil Spring—Weight (approximate)..................................................................................... 60 kg 135 lb

7. Position track adjuster in assembly tool with cylinder end on DFT1112A Spacer (C). See DFT1112A Spacer. (Group 9900.) 8. Remove lifting strap.

–UN–28APR92

A—Lifting Strap B—Track Adjuster C—DFT1112 Spacer

T7720AF

01 0130 24

Continued on next page

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PN=78

Track System 9. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool on ST4920 Track Recoil Spring Disassembly and Assembly Tool as shown. See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. (Group 9900.)

01 0130 25

10. Install top plate (A) and nuts (B) with smallest opening to allow access to nut (D). 11. Extend jack ram to provide enough travel to release spring to the specified free length. Specification Recoil Spring Free—Length (approximate)................................................................................. 479 mm 18.9 in.

12. Tighten nuts (B) so plate is tight against retainer plate. –UN–28APR92

13. Remove valve (C) and special plug (E).

T7720AG

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

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PN=79

Track System 14. Raise upper half of DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (F). Tighten T-handles. 15. Operate jack to compress spring just enough so nut (D) can be removed. 16. Lower jack ram to release spring force. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 17. Remove recoil spring and track adjuster from ST4920 Track Recoil Spring Disassembly and Assembly Tool.

–UN–28APR92

Specification Recoil Spring—Weight (approximate)..................................................................................... 31 kg 70 lb Track Adjuster—Weight (approximate)..................................................................................... 30 kg 65 lb

18. Inspect and replace parts as necessary.

T7720AH

01 0130 26

19. Repair track adjuster cylinder if necessary. See Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.)

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

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 20. Position track adjuster in ST4920 Track Recoil Spring Disassembly and Assembly Tool with cylinder end on spacer. Specification Track Adjuster—Weight (approximate)..................................................................................... 30 kg 65 lb

21. Install DFT1112 Spacer on rod.

Continued on next page

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PN=80

Track System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 22. Install spring on track adjuster.

01 0130 27

Specification Recoil Spring—Weight (approximate)..................................................................................... 31 kg 70 lb

23. Install retainer plate. 24. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool on ST4920 Track Recoil Spring Disassembly and Assembly Tool. 25. Install top plate. Install nuts. 26. Raise upper half of DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. Tighten T-handles. 27. Operate jack to compress spring to the specified length. Specification Recoil Spring Compressed— Length (approximate) .................................................................... 407 mm 16 in.

28. Install nut (D) so hole is aligned with hole in rod. Install special plug and tighten to specification. Specification Special Plug—Torque..................................................................... 15 N•m 133 lb-in.

29. Install valve and tighten to specification. Specification Valve—Torque ................................................................................ 90 N•m 66 lb-ft

30. Release 30 ton jack.

Continued on next page

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PN=81

Track System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 01 0130 28

31. Remove track adjuster and recoil spring from ST4920 Track Recoil Spring Disassembly and Assembly Tool. Specification ST4920 Track Recoil Spring Disassembly and Assembly Tool—Weight (approximate)............................................................ 161 kg 355 lb Track Adjuster Cylinder and Recoil Spring—Weight (approximate)..................................................................................... 60 kg 135 lb

32. Install track adjuster and recoil spring from track frame. See Track Adjuster and Recoil Spring Remove and Install. (Group 0130.) 33. Install front idler. See Front Idler Remove and Install. (Group 0130.) 34. Connect track chain. See Track Chain Remove and Install. (Group 0130.)

AC12469,0000592 –19–22APR08–7/7

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PN=82

Track System

Track Adjuster Cylinder Disassemble and Assemble 1 2 3

01 0130 29

10 12 11 TX1040238

TX1040238

–UN–24APR08

Track Adjuster Cylinder Exploded View 1—Holder 2—Dust Seal 3—U-Ring

4—Piston 5—Rod 6—Cylinder

7—Spacer 8—Spring 9—Washer

CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots can result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling. A compression tool must be used for disassembly and assembly because of the extreme preload on spring. NOTE: It is not necessary to remove the recoil spring to replace dust seal (2) and U-ring packing (3).

10—Nut 11—Fitting Plug 12—Grease Valve

It is necessary to remove the recoil spring to replace rod (5). 1. Disconnect track chain. See Track Chain Remove and Install. (Group 0130.) 2. Remove front idler. See Front Idler Remove and Install. (Group 0130.) 3. Remove track adjuster and recoil spring from track frame. See Track Adjuster and Recoil Spring Remove and Install. (Group 0130.) 4. Remove recoil spring from track adjuster if necessary. See Track Adjuster and Recoil Spring Disassemble and Assemble. (Group 0130.)

Continued on next page

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PN=83

Track System 5. Remove piston rod (5) from cylinder (6).

12. Apply clean multipurpose grease to inner surfaces of U-ring (3) and dust seal (2).

6. Remove holder (1) from piston rod (5) using a press. 01 0130 30

NOTE: Install U-ring (3) with lip toward inside of cylinder (6).

IMPORTANT: Remove dust seal and U-ring carefully if replacement is not necessary.

13. Install U-ring (3) and dust seal (2) into cylinder (6). 14. Press holder (1) into piston rod (5).

7. Remove dust seal (2) and U-ring (3) from cylinder (6). 8. Remove piston rod (5) from cylinder (6). 9. Inspect and replace parts as necessary.

15. Install track adjuster and recoil spring in track frame. See Track Adjuster and Recoil Spring Remove and Install. (Group 0130.) 16. Install front idler. See Front Idler Remove and Install. (Group 0130.)

10. Install piston rod (5) into cylinder (6). 11. Install spring (8), spacer (7), washer (9), fitting plug (11), nut (10), and grease valve (12) if removed. See Track Adjuster and Recoil Spring Disassemble and Assemble. (Group 0130.)

17. Connect track chain. See Track Chain Remove and Install. (Group 0130.)

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Section 02

Axles and Suspension Systems Contents Page

Group 0250—Axle Shaft, Bearings, and Reduction Gears Travel Gearbox Remove and Install . . . . . . .02-0250-1 Travel Gearbox Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-4

Group 0260—Hydraulic System Travel Motor and Park Brake Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Travel Motor and Park Brake Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . .02-0260-2 Travel Motor Cover Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-6 Travel Motor Crossover Relief Valve Disassemble and Assemble. . . . . . . . . . .02-0260-10 Travel Speed Change Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . .02-0260-11 Travel Motor and Park Brake Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . .02-0260-11

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Group 0250

Axle Shaft, Bearings, and Reduction Gears Travel Gearbox Remove and Install 1. Disconnect track chain. See Track Chain Remove and Install. (Group 0130.) AC12469,00005AD –19–21APR08–1/5

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button.

02 0250 1

2. Push pressure release button (1).

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–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

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Axle Shaft, Bearings, and Reduction Gears 3. Remove travel motor cover (2). 4. Attach vacuum pump to hydraulic tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 1—Cap Screw (4 used) 2—Travel Motor Cover

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–UN–29FEB08

02 0250 2

Travel Motor Cover

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Axle Shaft, Bearings, and Reduction Gears 5. Install identification tags and disconnect hydraulic lines (5—8). Close all openings using caps and plugs. See Travel Hydraulic System Line Connection. (Group 9025-15.) 6. Make alignment marks between travel gearbox and undercarriage to aid in installation. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

02 0250 3

TX1037679

–UN–21APR08

7. Support travel motor, gearbox, and sprocket using DF1063 Lift Bracket and DFT1130 Adapter. See DF1063 Lift Bracket. (Group 9900). See DFT1130 Adapter. (Group 9900.) Specification Travel Motor, Gearbox, and Sprocket—Weight (approximate) .................................................... 230 kg 510 lb

Travel Motor 3—Cap Screw (14 used) 4—Travel Motor and Gearbox 5—Travel Motor-to-Center Joint Hydraulic Line 6—Travel Motor-to-Center Joint Hydraulic Line 7—Travel Motor-to-Center Joint Hydraulic Line 8—Travel Motor-to-Center Joint Hydraulic Line

8. Remove travel motor and gearbox from track frame. 9. Inspect and repair parts as necessary. See Travel Gearbox Disassemble and Assemble. (Group 0250.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 10. Position travel motor, gearbox, and sprocket in track frame. Specification Travel Motor, Gearbox, and Sprocket—Weight (approximate) .................................................... 230 kg 510 lb

11. Align marks made during removal. Install cap screws and tighten to specification. Specification Travel Gearbox-to-Track Frame Cap Screw—Torque ..................................................................... 310 N•m 230 lb-ft

12. Connect hydraulic lines. See Travel Hydraulic System Line Connection. (Group 9025-15.)

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Axle Shaft, Bearings, and Reduction Gears 13. Remove vacuum pump from hydraulic tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 14. Fill travel gearbox with oil. See Check Travel Gearbox Oil Level. (Operator’s Manual.) 15. Perform Travel Motor and Park Brake Start-Up Procedure. (Group 0260.) 16. Install travel motor cover and tighten cap screws to specification. Specification Travel Motor Cover Cap Screw— Torque .......................................................................................... 175 N•m 130 lb-ft

17. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 18. Connect track chain. See Track Chain Remove and Install. (Group 0130.)

AC12469,00005AD –19–21APR08–5/5

Travel Gearbox Disassemble and Assemble 1. Remove travel gearbox. See Travel Gearbox Remove and Install. (Group 0250.) AC12469,00005AE –19–18APR08–1/11

2. Install ST5089 Repair Stand (29) on travel motor (20).

–UN–29FEB08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Position travel motor and gearbox with gearbox facing up.

TX1037705

02 0250 4

Specification Travel Motor, Gearbox, and Sprocket—Weight (approximate) .................................................... 230 kg 510 lb

ST5089 Repair Stand 20—Travel Motor 29—ST5089 Repair Stand

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Axle Shaft, Bearings, and Reduction Gears

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Axle Shaft, Bearings, and Reduction Gears

18 19

15 16

02 0250 6

5 4 1 2 3 2

1 13 28

12 26 11 10

24 22

T145869

–UN–01FEB02

T145869 Travel Gearbox Exploded View

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Axle Shaft, Bearings, and Reduction Gears 1—Thrust Plate (12 used) 2—Needle Bearing (6 used) 3—Second Planet Gear (3 used) 4—Pin (3 used) 5—Spring Pin (3 used) 6—First Planet Gear (3 used) 7—Needle Bearing (3 used)

8—Pin (3 used) 9—Spring Pin (3 used) 10—Second Planet Pinion Carrier 11—Second Planet Sun Gear 12—First Planet Pinion Carrier 13—Spacer 14—Shaft

4. Remove cap screws (18) and cover (17).

15—Ring Gear 16—Thrust Pad 17—Cover 18—Cap Screw (12 used) 19—Plug (3 used) 20—Travel Motor 21—Metal Face Seal

22—Bearing (2 used) 23—Cap Screw (16 used) 24—Drum 25—Sprocket 26—Cap Screw (16 used) 27—Bearing Nut 28—Dowel Pin

6. Remove second planet sun gear (11) and second planet pinion carrier (10).

5. Remove shaft (14) and first planet pinion carrier (12). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Specification Second Planet Pinion Carrier— Weight (approximate) ................................................................. 28 kg 62 lb

AC12469,00005AE –19–18APR08–4/11

7. Remove bearing nut (27) from travel motor using DFT1036A Travel Gearbox Nut Wrench (35) and DFT1109 Holding Bar (34). Fasten holding bar to ring gear (15). See DFT1036A Travel Gearbox Nut Wrench. (Group 9900.)

–UN–01FEB02

See DFT1109 Holding Bar. (Group 9900.)

T145906

27—Bearing Nut 34—DFT1109 Holding Bar 35—DFT1036A Travel Gearbox Nut Wrench

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02 0250 7

Axle Shaft, Bearings, and Reduction Gears

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–29FEB08

NOTE: Rotate sprocket if ring gear is difficult to remove. 8. Remove ring gear (15), drum, and sprocket (25).

TX1037717

02 0250 8

Specification Ring Gear, Drum, and Sprocket— Weight (approximate) ....................................................................... 210 lb 95 kg Travel Gearbox

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

15—Ring Gear 20—Travel Motor 25—Sprocket

9. Remove metal face seal from travel motor. See Inspect Metal Face Seals. (Group 0130.) 10. Remove sprocket from drum if necessary. See Sprocket Remove and Install. (Group 0130.) 11. Disassemble planetary drives if necessary. NOTE: Further disassembly is not necessary unless bearing replacement is required. Bearings must be replaced if removed. 12. Inspect bearings (22) and races. 13. Inspect and replace parts as necessary. CAUTION: DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 14. Heat inner bearing if removed. Install bearing tight against shoulder of travel motor.

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Axle Shaft, Bearings, and Reduction Gears IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-ring does not slip. 15. Thoroughly clean metal face seal O-rings and seat surfaces in travel motor housing, drum, and seal ring using volatile, non-petroleum base solvent and lint-free tissues. NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage the O-ring or leave an oil residue.

02 0250 9

16. Install O-ring and metal face seal on travel motor housing and drum. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore and seal ring is installed squarely. 17. Clean seal ring face. Apply a thin film of clean engine oil. 18. Apply PM38656 Rigid Form-In-Place Gasket to flange surface on drum. 19. Install ring gear on drum. Apply PM37421 Heavy-Duty Thread Lock and Sealer to drum-to-ring gear cap screws and tighten to specification. Specification Drum-to-Ring Gear Cap Screw— Torque .......................................................................................... 265 N•m 195 lb-ft

20. Install sprocket on drum if removed. See Sprocket Remove and Install. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 21. Install ring gear (15), drum (24), and sprocket (25) assembly on travel motor (20). Specification Ring Gear, Drum, and Sprocket— Weight (approximate) ....................................................................... 210 lb 95 kg

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Axle Shaft, Bearings, and Reduction Gears

CAUTION: DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 22. Heat and install outer bearing. 02 0250 10

23. Apply a thin coat of multi-purpose grease to threads of bearing nut. Install bearing nut with stepped surface towards bearing. 24. Tighten bearing nut to specification using DFT1036A Travel Gearbox Nut Wrench and DFT1109 Holding Bar. See DFT1036A Travel Gearbox Nut Wrench. (Group 9900.) See DFT1109 Holding Bar. (Group 9900.) Specification Bearing Nut—Torque.................................................................... 790 N•m 585 lb-ft

25. Repeat previous steps to ensure bearings are seated.

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Axle Shaft, Bearings, and Reduction Gears IMPORTANT: Install second planet gear (3) with marked side towards spring pin hole. 26. Assemble planetary drives if disassembled. 1—Thrust Plate (12 used) 2—Needle Bearing (6 used) 3—Second Planet Gear (3 used) 4—Pin (3 used) 5—Spring Pin (3 used) 6—First Planet Gear (3 used) 7—Needle Bearing (3 used) 8—Pin (3 used) 9—Spring Pin (3 used) 10—Second Planet Pinion Carrier 11—Second Planet Sun Gear 12—First Planet Pinion Carrier 13—Spacer 14—Shaft

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–UN–06MAR08

02 0250 11

Planetary Drives Exploded View

AC12469,00005AE –19–18APR08–9/11

27. Install spring pins in planetary drives with slit (1) towards end of pin.

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–UN–22JUN01

1—Slit

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Axle Shaft, Bearings, and Reduction Gears 28. Align center of dowel pin (28) with center of spline on travel motor shaft. If centers are not aligned, tighten bearing nut until dowel pin center meets center of the next spline. 29. Install second planet pinion carrier so dowel pin (28) enters hole (36) and engages with travel motor teeth. 30. Install first planet pinion carrier, sun gear, and shaft. –UN–01FEB02

31. Apply PM38656 Rigid Form-In-Place Gasket to mounting surface on ring gear and cover.

T145902

32. Install cover and tighten cap screws to specifications. Specification Cover-to-Ring Gear Cap Screw— Torque .......................................................................................... 110 N•m 81 lb-ft

34. Install travel gearbox. See Travel Gearbox Remove and Install. (Group 0250.) 20—Propel Motor 27—Bearing Nut 28—Dowel Pin 36—Hole

–UN–01FEB02

33. Remove ST5089 Repair Stand.

T145897

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Group 0260

Hydraulic System Travel Motor and Park Brake Remove and Install Travel motor and park brake are part of travel gearbox. To remove travel motor, see Travel Gearbox Remove and Install. (Group 0250.) To disassemble travel motor, see Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)

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Hydraulic System

Travel Motor and Park Brake Disassemble and Assemble 9

7 6 5 02 0260 2

4 10

3 2

18 17 16 15 14 13 12 28 11

29 28 29 28 29 28 27 26

–UN–01FEB02

21 22

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

9—Housing 10—Speed Change Passage 11—Pin (2 used) 12—Valve Plate 13—Rotor 14—Spring (9 used) 15—Bushing

1. Remove travel gearbox if required. See Travel Gearbox Remove and Install. (Group 0250.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. IMPORTANT: Valve plate is easily damaged. Remove travel motor cover carefully. 2. Remove travel motor cover (22) and valve plate (12). Specification Travel Motor—Weight ................................................................. 60 kg 130 lb

IMPORTANT: Remove needle bearing only if replacement is necessary. Needle bearing must be replaced if removed. 3. Remove needle bearing (23) if replacement is necessary. If needle bearing is not needing replacement, wrap with tape to protect rollers.

16—Retainer 17—Piston (9 used) 18—Swash Plate 19—Ball (2 used) 20—Piston 21—Cap Screw (9 used) 22—Travel Motor Cover

23—Needle Bearing 24—Disk Spring 25—O-Ring 26—Brake Piston 27—O-Ring 28—Plate (4 used) 29—Friction Plate (3 used)

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

02 0260 3

6. Remove parts (13—20). 7. Remove friction plates (29) and plates (28). 8. Remove swash plate (18). 9. Remove balls (19) and piston (20) using a magnet. 10. Remove retaining ring (2). 11. Remove shaft (1), roller bearing (3), and retaining ring (4). IMPORTANT: Seal is glued in and will be damaged during removal. Remove seal only if replacement is necessary. 12. Remove oil seal (5). 13. Inspect and replace parts as necessary. Park brake components must be replaced if not within specified dimensions.

NOTE: Mark orientation of disk spring (24) for assembly. 4. Remove disk spring (24). IMPORTANT: Brake piston will be damaged if pried from housing. Remove brake piston using air pressure.

Specification Disk Spring—Height ....................................................... 6.4—6.5 mm 0.252—0.256 in. Friction Plate—Thickness ........................................... 2.70—2.75 mm 0.106—0.108 in. Plate—Thickness ........................................................ 1.75—1.80 mm 0.069—0.071 in.

5. Apply 100 to 300 kPa (14 to 43 psi) air pressure to brake release passage (8) to remove brake piston (26).

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Hydraulic System 14. Apply multipurpose grease to lip of oil seal (5). Apply PM38656 Rigid Form-In-Place Gasket to outer surface of seal. 15. Install seal using D01044AA Bushing, Bearing and Seal Driver Set.

02 0260 4

18. Apply multipurpose grease onto balls (19) and install balls in housing. IMPORTANT: Shaft must be installed carefully to avoid needle bearing damage. Shaft must be installed straight to prevent damage.

NOTE: Stamped marks on roller bearing must face the outside.

19. Install retaining rings and shaft.

16. Install roller bearing (3) with stamped marks facing the outside.

20. Apply multipurpose grease to ball holes in swash plate (18) and install swash plate.

17. Install piston (20) in housing with chamfered side facing in.

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Hydraulic System IMPORTANT: Pistons must be installed into the same bores because of wear patterns. Pistons must be installed in original bores. 21. Lubricate parts (13—20) with clean hydraulic oil and install. Install bushing (15) and retainer (16) as shown.

T145938

22. Install plates and friction plates in housing, alternating between plates and friction plates.

–UN–01FEB02

23. Apply clean multipurpose grease to brake piston O-rings and install brake piston.

15—Bushing 16—Retainer

24. Install disk spring in original position. 25. Install O-rings between travel motor cover and housing. 26. Fill housing with clean hydraulic oil until top plate is covered. NOTE: Pins are installed with the large diameter in the travel motor cover. 27. Install pins into travel motor cover. NOTE: Stamped marks on needle bearing must face the outside. 28. Install needle bearing into travel motor cover if removed. IMPORTANT: Valve plate has a polished surface and will be damaged if dropped. Damage to valve plate could cause oil leakage. 29. Install clean multipurpose grease to flat surface of valve plate. Install valve plate aligned with pins in brake valve. 30. Install travel motor cover and tighten cap screws to specification. Specification Travel Motor Cover-to-Housing Cap Screws—Torque ................................................................... 177 N•m 130 lb-ft

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02 0260 5

Hydraulic System 31. Install travel gearbox if removed. See Travel Gearbox Remove and Install. (Group 0250.)

AC12469,0000597 –19–18APR08–5/5

Travel Motor Cover Disassemble and Assemble NOTE: Valves may be removed with travel motor in machine. CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. –UN–22FEB08

1. Push pressure release button (1). 1—Pressure Release Button 2—Hydraulic Oil Tank Cover

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02 0260 6

Hydraulic Pressure Release Button

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Hydraulic System 2. Remove travel motor cover (2). 3. Attach vacuum pump to hydraulic tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 1—Cap Screw (4 used) 2—Travel Motor Cover

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Travel Motor Cover

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1 2

3 7

8 02 0260 8

11 12

7 5

8 16 17

14 15

22 21 20 19

–UN–06MAR08

TX1037943

TX1037943 Travel Motor Cover Exploded View

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Hydraulic System 1—Plug (2 used) 2—O-Ring (2 used) 3—Spring (2 used) 4—Stop (2 used) 5—Cover 6—Spool

7—Plug (4 used) 8—O-Ring (4 used) 9—Plug 10—O-Ring 11—Plug 12—Ball

13—Plug 14—O-Ring (2 used) 15—Plug (2 used) 16—Poppet (2 used) 17—Spring (2 used)

18—Relief Valve (2 used) 19—Plug 20—O-Ring 21—Spring 22—Spool

4. Remove plugs (1).

16. Install relief valve and tighten to specification.

5. Using a magnet, remove springs (3), stops (4), and spool (6) from cover.

Specification Relief Valve-to-Housing— Torque.................................................................................... 310 N•m 230 lb-ft

6. Remove relief valves (18) from cover. IMPORTANT: Relief valves must be adjusted if disassembled or travel motor may be damaged. 7. Disassemble relief valves if necessary. See Travel Motor Crossover Relief Valve Disassemble and Assemble. (Group 0260.) 8. Using a magnet, remove springs (17) and poppets (16). 9. Remove plugs (15).

NOTE: Install spool with hole facing inward. 17. Install spool (22) and spring (21). 18. Install plug (19) and tighten to specification. Specification Plug-to-Housing—Torque ........................................................ 34 N•m 25 lb-ft

19. Remove vacuum pump from hydraulic tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 20. Fill travel gearbox with oil. See Check Travel Gearbox Oil Level. (Operator’s Manual.)

10. Remove other plugs if necessary. 11. Remove spring (21) and spool (22). NOTE: Covers and spools must be replaced as a set. 12. Inspect and repair or replace parts as necessary. 13. Install spool (6), springs (3), stops (4) and plugs (1) in cover.

21. Perform Travel Motor and Park Brake Start-Up Procedure. (Group 0260.) 22. Install travel motor cover and tighten cap screws to specification.

14. Tighten plugs to specification.

Specification Travel Motor Cover Cap Screw—Torque ...................................................................... 175 N•m 130 lb-ft

Specification Plug-to-Housing—Torque ...................................................... 440 N•m 325 lb-ft

23. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

15. Install springs (17) and poppets (16).

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Hydraulic System

Travel Motor Crossover Relief Valve Disassemble and Assemble 1 2 3 4 3

02 0260 10

11 12 11 –UN–11MAR08

10 9 7

TX1038085

8 TX1038085 Crossover Relief Valve Exploded View 1—Spring 2—Piston 3—Back-Up Ring (2 used)

4—O-Ring 5—O-Ring 6—Plug

7—Guide 8—Valve 9—Poppet

10—Sleeve 11—Back-Up Ring (2 used) 12—O-Ring

1. Remove crossover relief valve from travel motor. See Travel Motor Cover Disassemble and Assemble. (Group 0260.)

5. Install crossover relief valve in travel motor. See Travel Motor Cover Disassemble and Assemble. (Group 0260.)

2. Disassemble crossover relief valve.

6. Perform Travel Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.)

3. Inspect and replace parts as necessary. 4. Assemble crossover relief valve.

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Hydraulic System

Travel Speed Change Solenoid Valve Remove and Install The travel speed change solenoid valve is part of a solenoid manifold. See Travel Speed and Arm Regenerative Solenoid Valve Disassemble and Assemble. (Group 3360.)

AC12469,000059A –19–18APR08–1/1

Travel Motor and Park Brake Start-Up Procedure

TX1018694A

–UN–19MAR07

IMPORTANT: Travel motor will be damaged if not filled with oil before operating travel function. Procedure must be performed whenever a new travel motor is installed or oil has been drained from the motor. 1. Disconnect travel motor drain line (1). NOTE: Use a funnel with suitable diameter neck to allow air to escape while filling.

Travel Motor Cover and Drain 1—Travel Motor Drain Line

2. Fill motor with hydraulic oil until oil reaches top of drain port. 3. Connect travel motor drain line (1).

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Hydraulic System

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Section 04

Engine Contents Page

Page

Group 0400—Removal and Installation Engine Remove and Install . . . . . . . . . . . . . .04-0400-1 Turbocharger Remove and Install . . . . . . . . .04-0400-8 Exhaust Manifold Remove and Install . . . . .04-0400-12 Valve Cover Remove and Install . . . . . . . . .04-0400-13 Rocker Arm Assembly Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-15 Rocker Arm Assembly Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .04-0400-17 Rocker Arm Assembly Inspection . . . . . . . .04-0400-18 Intake Manifold Remove and Install. . . . . . .04-0400-20 Water Pump Remove and Install. . . . . . . . .04-0400-23 Cylinder Head Remove and Install . . . . . . .04-0400-25 Cylinder Head Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .04-0400-40 Cylinder Head Inspection . . . . . . . . . . . . . .04-0400-46 Timing Gear Case Remove and Install . . . .04-0400-53 Cylinder Block Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .04-0400-60 Cylinder Block Inspection . . . . . . . . . . . . . .04-0400-62 Rear Oil Seal Remove and Install . . . . . . . .04-0400-65 Camshafts Remove and Install . . . . . . . . . .04-0400-67 Flywheel Remove and Install. . . . . . . . . . . .04-0400-71 Flywheel Disassemble and Assemble . . . . .04-0400-73 Flywheel Housing Remove and Install. . . . .04-0400-74 Oil Pan Remove and Install. . . . . . . . . . . . .04-0400-76 Crankshaft Remove and Install . . . . . . . . . .04-0400-79 Crankshaft Disassemble and Assemble . . .04-0400-85 Crankshaft Inspection . . . . . . . . . . . . . . . . .04-0400-85 Main Bearing Inspection . . . . . . . . . . . . . . .04-0400-87 Piston and Connecting Rod Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-93 Piston and Connecting Rod Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .04-0400-95 Piston and Connecting Rod Inspection . . . .04-0400-98 Oil Pump Remove and Install . . . . . . . . . . 04-0400-105 Oil Pump Disassemble and Assemble. . . . 04-0400-109 Oil Pump Inspection . . . . . . . . . . . . . . . . . 04-0400-110 Engine Oil Cooler Remove and Install. . . . 04-0400-111 Engine Oil Cooler Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . 04-0400-114 Thermostat Housing Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . 04-0400-115 Thermostat Inspection . . . . . . . . . . . . . . . . 04-0400-118 Fuel Injection Pump Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . 04-0400-118

High Pressure Common Rail Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . 04-0400-129 Fuel Injector Remove and Install . . . . . . . . 04-0400-131 Starter Remove and Install . . . . . . . . . . . . 04-0400-133 Alternator Remove and Install . . . . . . . . . . 04-0400-133

TM10743 (09APR09)

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135D Excavator Repair 040909

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Contents

TM10743 (09APR09)

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Group 0400

Removal and Installation Engine Remove and Install 1. Disconnect batteries. See Handling, Checking, and Servicing Batteries Carefully. (Operator’s Manual.) 2. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) 3. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) 4. Drain engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.) 5. Disconnect pump 1 and 2. See Pump 1 and 2 Remove and Install. (Group 3360.)

04 0400 1 RH60123,00001B0 –19–23APR08–1/14

6. Disconnect air intake pipe (1). 7. Remove charged air pipe (4). –UN–11APR08

8. Disconnect upper radiator hose (7). 9. Disconnect lower radiator hose (8).

TX1040164A

10. Remove cooling fan, fan guard and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) Charged Air Pipe

1—Air Intake Pipe 2—Clamp 3—Clamp 4—Charged Air Pipe 5—Cap Screw (2 used) 6—Clamp 7—Upper Radiator Hose 8—Lower Radiator Hose

Continued on next page

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Removal and Installation 11. Disconnect charged air hose (9).

TX1040165A

–UN–11APR08

9—Charged Air Hose 10—Clamp

Charged Air Hose

04 0400 2 RH60123,00001B0 –19–23APR08–3/14

12. Disconnect heater hose (12).

–UN–11APR08

13. Install identification tags and disconnect fuel hoses (15 and 16). 14. Close all openings using caps and plugs.

TX1040166A

11—Clamp 12—Heater Hose 13—Cap Screw (4 used) 14—Clamp (2 used) 15—Fuel Hose 16—Fuel Hose

Heater Hose

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Removal and Installation 15. Remove clamp (17) securing wire harness (19). 16. Disconnect electrical connectors (20). –UN–15APR08

17. Remove starter. See Starter Remove and Install. (Group 0400.)

TX1040167A

NOTE: Leave air conditioning hoses connected to compressor. Discharge of air conditioning system is not necessary. 18. Disconnect compressor from engine and set aside. See Compressor Remove and Install. (Group 1830.)

Electrical Connectors 17—Clamp 18—Cap Screw 19—Wire Harness 20—Electrical Connector (5 used)

04 0400 3

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19. Disconnect breather hose (22).

TX1040168A

–UN–10APR08

21—Clamp 22—Breather Hose

Breather Hose

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Removal and Installation 20. Remove clamp (24) securing breather hose (22). 21. Disconnect heater hose (25).

–UN–10APR08

22. Install identification tags and disconnect oil cooler lines (27). 23. Close all openings using caps and plugs.

04 0400 4

TX1040169A

24. Disconnect electrical connectors on alternator. See Alternator Remove and Install. (Group 0400.) 13—Cap Screw (4 used) 22—Breather Hose 23—Cap Screw 24—Clamp 25—Heater Hose 26—Clamp 27—Oil Cooler Line (2 used)

Oil Cooler Lines

Continued on next page

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Removal and Installation

TX1041054

–UN–24APR08

04 0400 5

Engine 13—Cap Screw (4 used) 28—Nut (4 used) 29—Isolator (4 used)

30—Isolator (4 used) 31—Isolator (4 used) 32—Bracket (2 used)

33—Washer (8 used) 34—Cap Screw (8 used)

25. Support engine (36). Remove cap screws (13) and nut (28). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 26. Remove engine (36).

35—Washer (4 used) 36—Engine

28. Install engine. Specification Engine—Weight (approximate) ................................................. 426 kg 940 lb

29. Install cap screws and nuts. 30. Connect electrical connectors on alternator. See Alternator Remove and Install. (Group 0400.)

Specification Engine—Weight (approximate) ................................................. 426 kg 940 lb

27. Inspect and repair parts as necessary. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Continued on next page

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Removal and Installation 31. Connect oil cooler lines (27). 32. Connect heater hose (25).

–UN–10APR08

33. Install clamp (24) securing breather hose (22).

TX1040169A

13—Cap Screw (4 used) 22—Breather Hose 23—Cap Screw 24—Clamp 25—Heater Hose 26—Clamp 27—Oil Cooler Line (2 used) Oil Cooler Lines

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34. Connect breather hose (22). Tighten clamp (21)

–UN–10APR08

35. Connect compressor to engine. See Compressor Remove and Install. (Group 1830.) 36. Remove starter. See Starter Remove and Install. (Group 0400.)

TX1040168A

21—Clamp 22—Breather Hose

Breather Hose

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Removal and Installation 37. Connect electrical connectors (20). 38. Install clamp securing wire harness.

TX1040167A

–UN–15APR08

17—Clamp 18—Cap Screw 19—Wire Harness 20—Electrical Connector (5 used)

Electrical Connectors

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39. Connect fuel hoses (15 and 16). 40. Connect heater hose (12).

TX1040166A

–UN–11APR08

11—Clamp 12—Heater Hose 13—Cap Screw (4 used) 14—Clamp (2 used) 15—Fuel Hose 16—Fuel Hose

Heater Hose

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Removal and Installation 41. Connect charged air hose (9).

–UN–11APR08

42. Install cooling fan, fan guard, and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)

TX1040165A

9—Charged Air Hose 10—Clamp

Charged Air Hose

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43. Connect lower radiator hose (8). 44. Connect upper radiator hose (7). –UN–11APR08

45. Install charged air pipe (4). 46. Connect air intake pipe (1).

TX1040164A

47. Connect pump 1 and 2. See Pump 1 and 2 Remove and Install. (Group 3360.) 48. Fill engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.

Charged Air Pipe 1—Air Intake Pipe 2—Clamp 3—Clamp 4—Charged Air Pipe 5—Cap Screw (2 used) 6—Clamp 7—Upper Radiator Hose 8—Lower Radiator Hose

49. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.) 50. Install counterweight. See Counterweight Remove and Install. (Group 1749.) 51. Connect batteries. See Handling, Checking, and Servicing Batteries Carefully. (Operator’s Manual.)

RH60123,00001B0 –19–23APR08–14/14

Turbocharger Remove and Install 1. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) Continued on next page

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Removal and Installation 2. Disconnect charged air pipe (2). Use cap and plugs to close openings. 3. Disconnect air intake pipe (4).

TX1040145A

–UN–14APR08

1—Clamp 2—Charged Air Pipe 3—Clamp 4—Air Intake Pipe

Charged Air Pipe

RH60123,00001B1 –19–23APR08–2/5

4. Remove clamp (7). 5. Remove exhaust pipe (8).

TX1040144A

–UN–14APR08

5—Muffler 6—Cap Screw (2 used) 7—Clamp 8—Exhaust Pipe 9—Nut (3 used)

Muffler

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04 0400 9

Removal and Installation 6. Disconnect oil feed line (12). 7. Remove clamp (14) securing oil feed line (12). 8. Disconnect coolant feed hose (16).

TX1040151A

–UN–16APR08

8—Pipe 9—Nut (3 used) 10—Turbocharger 11—Cap Screw 12—Oil Feed Pipe 13—Cap Screw (4 used) 14—Clamp 15—Cap Screw 16—Coolant Feed Hose 17—Clamp 18—Coolant Feed Pipe

Turbocharger

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Removal and Installation 9. Disconnect oil return line (19). 10. Disconnect coolant return hose (22). –UN–14APR08

11. Remove turbocharger (10). 12. Inspect and replace parts as necessary.

Specification Turbocharger Cap Screws— Torque ............................................................................................ 28 N•m 21 lb-ft

14. Connect coolant return hose. 15. Connect oil return line. Tighten to specification. Specification Oil Return Pipe Cap Screw— Torque ............................................................................................ 10 N•m 87 lb-in

TX1040146A

13. Install turbocharger. Tighten to specification.

Turbocharger 10—Turbocharger 13—Cap Screw (4 used) 19—Oil Return Pipe (19) 20—Cap Screw (4 used) 21—Clamp 22—Coolant Return Hose

04 0400 11

16. Connect coolant feed hose. 17. Install clamp securing oil feed line. 18. Connect oil feed line. Tighten to specification. Specification Oil Feed Pipe Cap Screw— Torque ......................................................................................... 22.5 N•m 17 lb-ft

19. Install exhaust pipe. 20. Install clamp. 21. Connect air intake pipe. 22. Connect charged air pipe. 23. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.)

RH60123,00001B1 –19–23APR08–5/5

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Removal and Installation

Exhaust Manifold Remove and Install 1. Remove turbocharger. See Turbocharger Remove and Install. (Group 0400.) RH60123,00001B2 –19–11APR08–1/4

2. Disconnect line (7). 3. Remove cap screw (6) securing line (7).

TX1040398A

1—Turbocharger 2—Cap Screw (2 used) 3—Cap Screw (3 used) 4—Exhaust Gas Recirculation (EGR) Cooler 5—Nut (8 used) 6—Cap Screw 7—Line

Exhaust Manifold

RH60123,00001B2 –19–11APR08–2/4

5. Remove cap screw (9) securing line (12). 6. Remove nuts (5) securing exhaust manifold (10). –UN–16APR08

7. Remove exhaust manifold (10). 8. Inspect and replace as necessary.

TX1040397A

04 0400 12

–UN–16APR08

4. Disconnect exhaust gas recirculation (EGR) cooler (4).

Exhaust Manifold

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Removal and Installation 9. Install exhaust manifold. Tighten cap screws to specification. Specification Exhaust Manifold Cap Screws— Torque ............................................................................................ 28 N•m 21 lb-ft

10. Install cap screw securing line. 10 –UN–03APR08

11. Connect exhaust gas recirculation (EGR) cooler. 12. Install cap screw securing line. 13. Connect line 14. Install turbocharger. See Turbocharger Remove and Install. (Group 0400.)

TX1039756

Exhaust Manifold Torque Sequence

10—Exhaust Manifold 11—Gasket

RH60123,00001B2 –19–11APR08–4/4

Valve Cover Remove and Install

–UN–24MAR08

1. Remove charged air pipe (1). Close all opening using caps and plugs. 2. Remove cover (4).

TX1038661A

3. Disconnect fuel hose (8). 4. Disconnect hose (10). 1—Charged Air Pipe 2—Cap Screw (3 used) 3—Hose Clamp 4—Cover 5—Valve Cover 6—Cap Screw (13 used) 7—Electrical Connector (4 used) 8—Fuel Hose 9—Hose Clamp 10—Hose

TX1038662A

–UN–24MAR08

Valve Cover

Hose Continued on next page

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Removal and Installation 5. Disconnect fuel injector hose (11). 6. Disconnect electrical connectors (7). 7. Remove valve cover (5).

8. Inspect and replace as necessary. 7

TX1041134

–UN–28APR08

7—Electrical Connector (4 used) 11—Fuel Injector Hose (4 used) 12—Clamp (7 used)

04 0400 14

Fuel Injector

RH60123,00001B3 –19–30APR08–2/3

9. Install valve cover. Tighten cap screws to specification in sequence. Specification Valve Cover Cap Screws— Torque ............................................................................................ 10 N•m 87 lb-in.

10. Connect fuel injector hose. 4

11. Connect electrical connectors. 12. Connect hose.

TX1041137

13. Connect fuel hose.

–UN–28APR08

14. Install cover. Torque Sequence

15. Install charged air pipe. 5—Valve Cover

RH60123,00001B3 –19–30APR08–3/3

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Removal and Installation

Rocker Arm Assembly Remove and Install 2

3 2

TX1037391

–UN–28FEB08

04 0400 15

TX1037391 Rocker Arm Assembly 1—Exhaust Rocker Arm Assembly

2—Cap Screw (8 used)

3—Cap Screw (8 used)

4—Intake Rocker Arm Assembly

1. Remove valve cover. See Valve Cover Remove and Install. (Group 0400.)

4. Remove fuel injectors. See Fuel Injector Remove and Install. (Group 0400.)

2. Remove camshafts. See Camshafts Remove and Install. (Group 0400.)

5. Remove exhaust rocker arm shaft assembly (1). 6. Remove intake rocker arm shaft assembly (4).

IMPORTANT: Replace high pressure fuel lines after removal. Fuel leaks can occur if not replaced.

7. Inspect and replace as necessary.

3. Disconnect fuel injection line. Close all openings with caps and plugs.

Continued on next page

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Removal and Installation 8. Loosen adjusting screw (5) and apply clean engine oil over roller (6). IMPORTANT: Parts that drop in gear case can cause damage to internal components. Use care when removing parts.

9. Install intake rocker arm assembly.

–UN–28FEB08

Specification Intake Rocker Arm Cap Screws— Torque ............................................................................................ 21 N•m 15 lb-ft

04 0400 16

Specification Exhaust Rocker Arm Cap Screws—Torque ............................................................................. 21 N•m 15 lb-ft

11. Adjust engine valve lash. See Engine Valve Lash (Clearance) Check and Adjust. (Group 9010-25.)

TX1037408

10. Install exhaust rocker arm assembly.

Rocker Arm Adjusting Screw 5—Adjusting Screw 6—Roller

12. Install fuel injectors. See Fuel Injector Remove and Install. (Group 0400.) 13. Connect fuel injection line. 14. Install camshafts. See Camshafts Remove and Install. (Group 0400.) 15. Install valve cover. See Valve Cover Remove and Install. (Group 0400.)

RH60123,00001B4 –19–30APR08–2/2

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Removal and Installation

Rocker Arm Assembly Disassemble and Assemble 1. Remove snap ring (2). 1 1—Rocker Arm 2—Snap Ring 3—Rocker Arm Shaft

–UN–28FEB08

TX1037397

Snap Ring

RH60123,00001B5 –19–22APR08–1/3

2. Remove rocker arm (1). 1

3. Inspect and repair as necessary. See Rocker Arm Assembly Inspection. (Group 0400.)

1 3

TX1037398

–UN–28FEB08

1—Rocker Arm 2—Snap Ring 3—Rocker Arm Shaft

Rocker Arm

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Removal and Installation 4. Apply clean engine oil to rocker arm. 5. Install rocker arm. 6. Install snap ring. 1

TX1037407

–UN–28FEB08

1—Rocker Arm

04 0400 18

Rocker Arm

RH60123,00001B5 –19–22APR08–3/3

Rocker Arm Assembly Inspection 1. Inspect rocker arm shaft oil hole (2). 2. Inspect rocker arm shaft. 1—Rocker Arm Oil Hole 2—Rocker Arm Shaft Oil Hole

–UN–28FEB08

TX1037401

Oil Hole

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Removal and Installation 3. Measure outside diameter of rocker arm shaft (4) using a micrometer (3). If measurement falls in limit or less, replace rocker arm shaft assembly.

–UN–28FEB08

Specification Rocker Arm Shaft—Diameter (standard) ..................................................................................... 14.0 mm 0.551 in. Diameter (limit) ........................................................................... 13.85 mm 0.545 in.

Specification Rocker Arm and Rocker Arm Shaft—Clearance (standard) ......................................... 0.010—0.046 mm 0.0004—0.0018 in. Clearance (limit) ............................................................................. 0.2 mm 0.0079 in.

TX1037404

4. Measure inside diameter of rocker arm to measure a clearance between external diameter of shaft. Replace rocker arm shaft assembly if measurements exceed limit values.

Micrometer 3—Micrometer 4—Rocker Arm Shaft

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5. Inspect clearance between roller of rocker arm and rocker arm pin. Pass a string (6) into roller (5) and pull it in direction indicated with arrow. Measure gap between rocker arm and roller. Mark measuring point. 6

5 9

TX1037406

6. Pull out string and measure gap of marked area with roller pushed in. Gap between measurement taken under (8) and that under (9) will be a clearance between roller and rocker arm pin. If it exceeds limit replace rocker arm shaft assembly.

–UN–28FEB08

Specification Roller and Rocker Arm Pin— Clearance (standard) ..................................................... 0.068—0.099 mm 0.0026—0.0038 in. Clearance (limit) ............................................................................. 0.2 mm 0.0079 in.

8 Measurement 8 and 9 5—Roller 6—String 7—Rocker Arm 8—Measurement 8 9—Measurement 9

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Removal and Installation

Intake Manifold Remove and Install 1. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) RH60123,00001B7 –19–22APR08–1/5

2. Disconnect charged air pipe (1). 3. Disconnect electrical connector (3). –UN–24MAR08

4. Remove brackets (4). 5. Remove exhaust gas recirculation (EGR) valve (6). IMPORTANT: Replace high pressure fuel lines after removal. Fuel leaks can occur if not replaced.

TX1038714A

04 0400 20

Intake Manifold

6. Remove and discard fuel injection lines (11). Close all opening with caps and plugs.

1—Charged Air Pipe 2—Hose Clamp 3—Electrical Connector 4—Bracket (2 used) 5—Nut (2 used) 6—Exhaust Gas Recirculation (EGR) Valve 7—Cap Screw (2 used) 8—Nut (2 used) 9—Cap Screw (6 used) 10—Nut (2 used) 11—Fuel Line (4 used) 12—Cap Screw (2 used) 13—Electrical Connector 14—Intake Manifold

7. Remove cap screws (12) securing wire harness. 8. Disconnect electrical connector (13).

Continued on next page

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Removal and Installation 9. Remove air intake pipe (16). 14—Intake Manifold 15—Gasket 16—Air Intake Pipe 17—Cap Screw (2 used) 18—Nut (2 used)

TX1038715

–UN–18MAR08

14 Air Pipe

RH60123,00001B7 –19–22APR08–3/5

10. Remove intake manifold (14). 11. Inspect and replace as necessary.

9 9

19 14

–UN–18MAR08

TX1038716

9—Cap Screw (6 used) 10—Nut (2 used) 14—Intake Manifold 19—Gasket 20—Cylinder Head

Intake Manifold

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Removal and Installation 12. Install intake manifold. Tighten cap screws to specifications in order shown. Specification Intake Manifold—Torque ................................................................ 25 N•m 18 lb-ft

13. Install air intake pipe. Tighten cap screws to specification.

TX1038718

14. Connect electrical connector.

–UN–18MAR08

Specification Air Intake Pipe—Torque ................................................................. 10 N•m 87 lb-in

04 0400 22

15. Install cap screw securing wire harness. IMPORTANT: High-pressure fuel lines need to be replaced if removed. High-pressure fuel lines will not seal properly if reused.

Torque Sequence

16. Install new fuel lines. 17. Install exhaust gas recirculation (EGR) valve. 18. Install brackets. 19. Connect electrical connector. 20. Connect charged air pipe. 21. Install counterweight. See Counterweight Remove and Install. (Group 1749.)

RH60123,00001B7 –19–22APR08–5/5

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Removal and Installation

Water Pump Remove and Install 1. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) 2. Disconnect upper radiator hose. 3. Remove fan, fan shroud, and fan guard. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) 4. Remove belt. See Alternator Remove and Install. (Group 0400.)

04 0400 23 RH60123,00001B8 –19–29APR08–1/3

5. Remove water pump pulley. 1 2

1—Water Pump 2—Water Pump Pulley 3—Cap Screw (2 used)

TX1038732

–UN–18MAR08

Water Pump Pulley

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Removal and Installation 6. Remove water pump (1). 4

7. Inspect and replace as necessary.

8. Clean gasket surface. 5

9. Install water pump and new gasket. 10. Install water pump pulley.

12. Install fan, fan shroud, and fan guard. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)

TX1038733

04 0400 24

5 –UN–18MAR08

5 11. Install belt. See Alternator Remove and Install. (Group 0400.)

Water Pump

13. Connect upper radiator hose. 14. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.)

1—Water Pump 4—Gasket 5—Cap Screw (4 used) 6—Nut (2 used)

RH60123,00001B8 –19–29APR08–3/3

TM10743 (09APR09)

04-0400-24

135D Excavator Repair 040909

PN=136

Removal and Installation

Cylinder Head Remove and Install 1. Disconnect batteries. 2. Drain engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.) 3. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) 4. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) 5. Remove fan, fan guard, and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)

04 0400 25

6. Remove intake manifold. See Intake Manifold Remove and Install. (Group 0400.) 7. Remove turbocharger. See Turbocharger Remove and Install. (Group 0400.) 8. Remove exhaust manifold. See Exhaust Manifold Remove and Install. (Group 0400.) 9. Remove thermostat housing. See Thermostat Housing Remove and Install. (Group 0400.)

RH60123,00001B9 –19–30APR08–1/24

10. Rotate crankshaft to No. 1 position (1) on top dead center. 11. Remove upper timing chain cover. See Fuel Injection Pump Remove and Install. (Group 0400.) 12. Remove fuel injectors. See Fuel Injector Remove and Install. (Group 0400.) 1

TX1037439

–UN–28FEB08

1—Top Dead Center

Top Dead Center

Continued on next page

TM10743 (09APR09)

04-0400-25

RH60123,00001B9 –19–30APR08–2/24

135D Excavator Repair 040909

PN=137

Removal and Installation 13. Remove bypass pipe (2). 2—Bypass Pipe 3—Gasket 4—O-Ring 5—Cap Screw (2 used)

–UN–14MAR08

TX1038331

2 5

04 0400 26

Bypass Pipe

RH60123,00001B9 –19–30APR08–3/24

14. Remove glow plugs (6). 15. Remove valve cover. See Valve Cover Remove and Install. (Group 0400.) 7

16. Remove camshafts. See Camshafts Remove and Install. (Group 0400.)

–UN–14MAR08

17. Remove rocker arm assembly. See Rocker Arm Assembly Remove and Install. (Group 0400.)

TX1038332

6—Glow Plug (4 used) 7—Nut (4 used)

Glow Plugs

Continued on next page

TM10743 (09APR09)

04-0400-26

RH60123,00001B9 –19–30APR08–4/24

135D Excavator Repair 040909

PN=138

Removal and Installation 18. Remove timing chain tensioner (9).

–UN–14MAR08

8—Nut (2 used) 9—Timing Chain Tensioner 10—Gasket

TX1038333

9 8 Timing Chain Tensioner

RH60123,00001B9 –19–30APR08–5/24

19. Remove idle gear D (11). 11—Idle Gear D

TX1038334

–UN–14MAR08

Idle Gear D

Continued on next page

TM10743 (09APR09)

04-0400-27

RH60123,00001B9 –19–30APR08–6/24

135D Excavator Repair 040909

PN=139

04 0400 27

Removal and Installation 20. Remove pivot (12). 21. Remove timing chain (13).

TX1038335

–UN–14MAR08

12—Pivot 13—Timing Chain 14—Fuel Pump Sprocket

04 0400 28

Pivot

RH60123,00001B9 –19–30APR08–7/24

22. Remove socket head cap screws (15 and 16) securing chain guide. 15—Socket Head Cap Screw 16—Socket Head Cap Screw

TX1038336

–UN–14MAR08

Chain Guide

Continued on next page

TM10743 (09APR09)

04-0400-28

RH60123,00001B9 –19–30APR08–8/24

135D Excavator Repair 040909

PN=140

Removal and Installation 23. Remove nut (17) and cap screws (18) securing cylinder head to gear case.

17—Nut (2 used) 18—Cap Screw (5 used) 19—Cylinder Head 20—Timing Gear Case

TX1038337

–UN–14MAR08

20 Cylinder Head

RH60123,00001B9 –19–30APR08–9/24

24. Loosen cylinder head cap screws in order shown. 6

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

18 10

Specification Cylinder Head With Turbo Charger and Manifolds—Weight (approximate)..................................................................................... 39 kg 86 lb

27. Clean top of piston and upper surface of cylinder block.

4 8

TX1038339

26. Inspect and replace parts as necessary. See Cylinder Head Disassemble and Assemble. (Group 0400.)

–UN–13MAR08

25. Remove cylinder head.

Cylinder Head Cap Screw Sequence

19—Cylinder Head

Continued on next page

TM10743 (09APR09)

04-0400-29

RH60123,00001B9 –19–30APR08–10/24

135D Excavator Repair 040909

PN=141

04 0400 29

Removal and Installation 28. Use a dual gauge to measure protrusion amount of piston at location shown. 21—Dial Gauge 22—Cylinder Block

–UN–14MAR08

TX1038340

04 0400 30

Dial Gauge

Continued on next page

TM10743 (09APR09)

04-0400-30

RH60123,00001B9 –19–30APR08–11/24

135D Excavator Repair 040909

PN=142

Removal and Installation 29. Measure positions 1, 2, 3, and 4 for each cylinder and find differences between 1 and 2 and between 3 and 4. Specification Piston—Protrusion ........................................................................ 0.05 mm 0.0002 in.

30. Calculate average piston protrusion amount of each cylinder –UN–14MAR08

TX1038341

31. Calculate maximum amount based on average amount of each cylinder.

Dial Gauge Positions

TX1038342

–UN–14MAR08

Continued on next page

TM10743 (09APR09)

04-0400-31

RH60123,00001B9 –19–30APR08–12/24

135D Excavator Repair 040909

PN=143

04 0400 31

Removal and Installation 32. Select correct grade of gasket for maximum protrusion amount.

Piston Projection

Gasket Thickness (Reference)

0.067-0.117 (0.0026-0.0046)

0.95 (0.0630)

0.117-0.167 (0.0046-0.0066)

1.00 (0.0650)

0.167-0.217 (0.0066-0.0085)

1.05 (0.0669)

–19–10APR08

Gasket Grade Mark

TX1040171

33. Select timing gear case gasket with same grade as cylinder head gasket.

04 0400 32

TX1038345

–UN–14MAR08

Gasket Grade

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TM10743 (09APR09)

04-0400-32

RH60123,00001B9 –19–30APR08–13/24

135D Excavator Repair 040909

PN=144

Removal and Installation 34. Apply PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket to surface as shown.

Specification PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket—Height A ................................................. 2—3 mm 0.079—0.118 in. Height B ........................................................................................ 3—4 mm 0.118—0.157 in.

–UN–14MAR08

35. Position cylinder head gasket.

TX1038346

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. IMPORTANT: Take care when installing cylinder head. Cylinder head gasket may not seal properly if damaged during cylinder head installation.

Gasket Surface

IMPORTANT: Cylinder head cap screws are torque to yield. Replace with new cap screws before installing cylinder head. Internal engine damage may occur. 36. Install cylinder head. Specification Cylinder Head With Turbo Charger and Manifolds—Weight (approximate)..................................................................................... 39 kg 86 lb

Continued on next page

TM10743 (09APR09)

04-0400-33

RH60123,00001B9 –19–30APR08–14/24

135D Excavator Repair 040909

PN=145

04 0400 33

Removal and Installation 37. Tighten cylinder head cap screws as shown. Use a JT05993 Torque Turn Tool for 3rd and 4th step

19—Cylinder Head

14 10 6

7 11

04 0400 34

TX1038347

12 16

–UN–14MAR08

Specification Cylinder Head Cap Screws— Torque 1st Step .............................................................................. 70 N•m 51 lb-ft Torque 2nd Step ............................................................................ 70 N•m 51 lb-ft Torque 3rd Step .................................................................................... 60° Torque 4th Step..................................................................................... 60°

Cylinder Head Cap Screw Torque Sequence

RH60123,00001B9 –19–30APR08–15/24

38. Tighten nut (17) and cap screws (18) securing cylinder head (19) to timing gear case to specification.

Specification Cylinder Head to Timing Gear Case—Torque ................................................................................ 25 N•m 18 lb-ft

TX1038915

–UN–10APR08

17—Nut (2 used) 18—Cap Screw (5 used) 19—Cylinder Head

Cylinder Head

Continued on next page

TM10743 (09APR09)

04-0400-34

RH60123,00001B9 –19–30APR08–16/24

135D Excavator Repair 040909

PN=146

Removal and Installation 39. Install socket head cap screws (15 and 16) securing chain guide. 15—Socket Head Cap Screw 16—Socket Head Cap Screw

–UN–14MAR08

TX1038336

Chain Guide

RH60123,00001B9 –19–30APR08–17/24

40. Rotate crankshaft to No. 1 position (1) on top dead center. 1—Top Dead Center

TX1037439

–UN–28FEB08

Top Dead Center

Continued on next page

TM10743 (09APR09)

04-0400-35

RH60123,00001B9 –19–30APR08–18/24

135D Excavator Repair 040909

PN=147

04 0400 35

Removal and Installation 41. Install timing chain (13) with idle gear D (11). 11

Specification Idle Gear D—Torque ...................................................................... 59 N•m 43 lb-ft

TX1038349

–UN–13MAR08

11—Idle Gear D 13—Timing Chain

04 0400 36

Idle Gear D and Timing Chain

RH60123,00001B9 –19–30APR08–19/24

42. Align timing marks on camshaft sprocket (26) with dark chain link (25) on timing chain (13).

43. Align timing marks of fuel pump sprocket (23) with yellow chain link (24) on timing chain (13).

44. Install pivot for timing chain tensioner. Tighten to specification.

TX1038465

13—Timing Chain 23—Fuel Pump Sprocket Timing Mark 24—Yellow Chain Link 25—Dark Chain Link 26—Camshaft Sprocket Timing Mark

13 Timing Marks

Continued on next page

TM10743 (09APR09)

–UN–14MAR08

Specification Pivot—Torque ................................................................................. 27 N•m 20 lb-ft

04-0400-36

RH60123,00001B9 –19–30APR08–20/24

135D Excavator Repair 040909

PN=148

Removal and Installation 45. Push down on cam (30) of timing chain tensioner (31) and push plunger (29) into timing chain tensioner.

28 29

46. Swing hook (27) to secure pin (28) to hold plunger (29) in place.

27—Hook 28—Pin 29—Plunger 30—Cam 31—Timing Chain Tensioner

–UN–13MAR08

TX1038466

Timing Chain Tensioner

RH60123,00001B9 –19–30APR08–21/24

47. Install timing chain tensioner. Specification Timing Chain Tensioner—Torque .................................................. 10 N•m 87 lb-in

48. Push timing chain (13) lightly to release timing chain tensioner (31).

TX1038467

50. Install camshafts. See Camshafts Remove and Install. (Group 0400.)

–UN–13MAR08

49. Install rocker arm assembly. See Rocker Arm Assembly Remove and Install. (Group 0400.)

13—Timing Chain 31—Timing Chain Tensioner Timing Chain Tensioner

Continued on next page

TM10743 (09APR09)

04-0400-37

RH60123,00001B9 –19–30APR08–22/24

135D Excavator Repair 040909

PN=149

04 0400 37

Removal and Installation 51. Rotate crank pulley two revolutions (720°). Check alignment mark and timing mark are aligned as shown.

11—Idle Gear D 13—Timing Chain 23—Fuel Pump Sprocket 24—Yellow Plate 25—Dark Plate 26—Camshaft Sprocket 32—Exhaust Camshaft Gear 33—Intake Camshaft Gear

TX1038468

11 04 0400 38

–UN–13MAR08

52. Connect bypass pipe.

Timing Marks

–UN–14MAR08

TX1038465

23 13 Timing Marks

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TM10743 (09APR09)

04-0400-38

RH60123,00001B9 –19–30APR08–23/24

135D Excavator Repair 040909

PN=150

Removal and Installation 53. Apply PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket and install cam end seal (34).

54. Install valve cover. See Valve Cover Remove and Install. (Group 0400.) 55. Install glow plugs.

TX1038469

57. Install upper timing cover. See Fuel Injection Pump Remove and Install. (Group 0400.)

–UN–13MAR08

56. Install fuel injectors. See Fuel Injector Remove and Install. (Group 0400.)

58. Install thermostat housing. See Thermostat Housing Remove and Install. (Group 0400.) 59. Install exhaust manifold. See Exhaust Manifold Remove and Install. (Group 0400.)

Cam End Seal 19—Cylinder Head 34—Cam End Seal

60. Install turbocharger. See Turbocharger Remove and Install. (Group 0400.) 61. Install intake manifold. See Intake Manifold Remove and Install. (Group 0400.) 62. Install fan, fan guard, and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) 63. Install counterweight. See Counterweight Remove and Install. (Group 1749.) 64. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.) 65. Fill engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.) 66. Connect batteries. See Handling, Checking, and Servicing Batteries Carefully. (Operator’s Manual.)

RH60123,00001B9 –19–30APR08–24/24

TM10743 (09APR09)

04-0400-39

135D Excavator Repair 040909

PN=151

04 0400 39

Removal and Installation

Cylinder Head Disassemble and Assemble 1 1. Install 588-4028-180 valve spring replacer to compress valve spring and remove split collar. 2. Remove upper spring seat. 3. Remove 5-8840-2818-0 valve spring replacer.

1—Valve Spring Replacer

04 0400 40

TX1038552

–UN–13MAR08

4. Remove valve springs and sort by cylinder order.

Valve Spring Replacer

RH60123,00001BA –19–22APR08–1/12

TX1038554

–UN–13MAR08

5. Remove intake and exhaust valves. Attach identification tags.

Intake and Exhaust Valves

Continued on next page

TM10743 (09APR09)

04-0400-40

RH60123,00001BA –19–22APR08–2/12

135D Excavator Repair 040909

PN=152

Removal and Installation 6. Remove valve stem oil seal (2). 7. Inspect and replace parts as necessary. See Cylinder Block Inspection. (Group 0400.)

–UN–13MAR08

2—Valve Stem Oil Seal 3—Cylinder Head

TX1038543

Valve Stem Oil Seal

RH60123,00001BA –19–22APR08–3/12

8. Use a 5-8840-2816-0 valve guide remover and installer (4) to pull out valve guides. 3—Cylinder Head 4—Valve Guide Remover and Installer

–UN–13MAR08

TX1038545

Valve Guide Remover and Installer

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TM10743 (09APR09)

04-0400-41

RH60123,00001BA –19–22APR08–4/12

135D Excavator Repair 040909

PN=153

04 0400 41

Removal and Installation 9. Remove cam end seal (5).

3—Cylinder Head 5—Cam End Seal (2 used)

–UN–13MAR08

TX1038547

3 04 0400 42

Cam End Seal

RH60123,00001BA –19–22APR08–5/12

10. Remove oil seals (6).

TX1038548

–UN–13MAR08

3—Cylinder Head 6—Oil Seal (4 used)

3 Oil Seals

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TM10743 (09APR09)

04-0400-42

RH60123,00001BA –19–22APR08–6/12

135D Excavator Repair 040909

PN=154

Removal and Installation 11. Arc-weld entire diameter of valve seat insert (9). 12. Allow valve seat insert to cool for 2 or 3 minutes. 13. Take care when removing valve seat (9) insert to avoid possible damage to cylinder head (1).

–UN–25FEB08

14. Inspect and repair as necessary. See Cylinder Block Inspection. (Group 0400.)

TX1037333

1—Cylinder Head 9—Valve Seat Insert 10—Arch-Weld

Valve Seat

RH60123,00001BA –19–22APR08–7/12

NOTE: Washer contacting surface outer diameter should be smaller than valve seat. 15. Place a washer (10) smaller than valve seat (9). IMPORTANT: Do not apply too much pressure with press. Remove grinding compound completely after grinding.

–UN–25FEB08

16. Use a press (11) to apply gradual pressure on washer (10) pushing valve seat (9).

TX1037334

17. Apply grinding compound to valve seat (9) surface, rotate valve to grind it and confirm that it has even contact. 9—Valve Seat 10—Washer 11—Press

Press

Continued on next page

TM10743 (09APR09)

04-0400-43

RH60123,00001BA –19–22APR08–8/12

135D Excavator Repair 040909

PN=155

04 0400 43

Removal and Installation 18. Install oil seals using injection pipe 5-8840-2820-0 Oil Seal Installer. 19. Install cam end seal.

3 7

TX1038549

–UN–13MAR08

3—Cylinder Head 7—Injection Pipe Oil Seal Installer

04 0400 44

Injection Pipe Oil Seal Installer

RH60123,00001BA –19–22APR08–9/12

IMPORTANT: Valve guide cannot be set to specified height using valve guide remover and installer. Install valve guide while measuring height. IMPORTANT: Valve guide and valve are matched. If replacement is necessary, both will need to be replaced or internal engine damage will occur.

–UN–13MAR08

20. Install valve guides from top end of cylinder head using 5-8840-2816-0 Valve Guide Remover and Install.

TX1038550

Specification Valve Guide—Height .................................................................... 12.6 mm 0.50 in.

Valve Guide Remover and Installer

21. Install valve spring seat. 3—Cylinder Head 4—5-8840-2816-0 Valve Guide Remover and Installer

Continued on next page

TM10743 (09APR09)

04-0400-44

RH60123,00001BA –19–22APR08–10/12

135D Excavator Repair 040909

PN=156

Removal and Installation 22. Install valve stem oil seal using 5-8840-2817-0 Valve Stem Seal Installer. 23. Install intake and exhaust valves. 24. Install valve springs. 25. Install spring upper seat. –UN–13MAR08

3—Cylinder Head 8—5-8840-2817-0 Valve Stem Seal Installer

TX1038551

Valve Stem Seal Installer

RH60123,00001BA –19–22APR08–11/12

26. Install a 5-8840-2818-0 Valve Spring Replacer to compress valve spring and Install split collar.

TX1038552

–UN–13MAR08

1—5-8840-2818-0 Valve Spring Replacer 3—Cylinder Head

5-8840-2818-0 Valve Spring Replacer

RH60123,00001BA –19–22APR08–12/12

TM10743 (09APR09)

04-0400-45

135D Excavator Repair 040909

PN=157

04 0400 45

Removal and Installation

Cylinder Head Inspection IMPORTANT: Internal engine damage can occur if gasket surface is facing down on rough surface. 1. Remove valves from cylinder. See Cylinder Head Disassemble and Assemble. (Group 0400.) 2. Clean cylinder head and gasket surface. 3. Inspect for corrosion and air leak on gasket surface for leaks.

04 0400 46

4. Inspect inside combustion chamber glow plug hole for damage. 5. Inspect for cracks in valve seats and in cylinder head of exhaust port. Replace cylinder head if there is serious damage or crack.

Continued on next page

TM10743 (09APR09)

04-0400-46

RH60123,00001BB –19–22APR08–1/12

135D Excavator Repair 040909

PN=158

Removal and Installation 6. Measure out-of-flat of gasket surface of cylinder head (1). Check all four sides and diagonal line. Replace if they exceed limit. Specification Cylinder Head Surface— Out-of-Flat Standard ......................................................... 0.05 mm or less 0.002 in. or less Out-of-Flat Limit ............................................................................ 0.20 mm 0.0079 in.

–UN–25FEB08

7. Inspect gasket surface of exhaust manifold and intake manifold. 1

TX1037319

1—Cylinder Head 2—Straight Edge 3—Thickness Gauge Gasket Surface of Cylinder Head

A E

F C

TX1037320

–UN–25FEB08

Gasket Surface of Cylinder Head

Continued on next page

TM10743 (09APR09)

04-0400-47

RH60123,00001BB –19–22APR08–2/12

135D Excavator Repair 040909

PN=159

04 0400 47

Removal and Installation 8. Measure four sides (right, left, top and bottom) and diagonal lines. If measurement exceeds limit value but is less than maximum allowable grinding value, grind manifold gasket surface of cylinder head. If measurement exceeds maximum allowable grinding value it will need to be replaced.

Specification Cylinder Head—Height ............................................................... 143.4 mm 5.646 in.

–UN–25FEB08

TX1037321

1—Cylinder Head

04 0400 48

Cylinder Head Height

RH60123,00001BB –19–22APR08–3/12

9. Inspect gasket surface of exhaust manifold (4). 10. If measurement exceeds limit, replace exhaust manifold (4). Specification Exhaust Manifold Gasket Surface—Out-of-Flat (standard) ....................................... 0.05 mm or less 0.002 in. or less Out-of-Flat (limit)............................................................................. 0.2 mm 0.0079 in.

11. If there is a scratch or abnormal abrasion on valve stem and inner diameter of valve guide, replace valve and valve guide.

TX1037322

–UN–25FEB08

12. Inspect for excessive abrasion and damage on surface where cap and rocker arm adjusting cap screw contact. Repair as necessary.

Exhaust Manifold

2—Straight Edge 4—Exhaust Manifold

Continued on next page

TM10743 (09APR09)

04-0400-48

RH60123,00001BB –19–22APR08–4/12

135D Excavator Repair 040909

PN=160

Removal and Installation 13. Measure diameter of valve stem (5). If diameter of valve is smaller than limit, replace valve and valve guide.

–UN–25FEB08

Specification Valve Stem (intake valve)— Diameter (standard)....................................................... 6.955—6.970 mm 0.2738—0.2744 in. Diameter (limit) ........................................................................... 6.935 mm 0.2730 in.

TX1037323

Specification Valve Stem (exhaust valve)— Diameter (standard)....................................................... 6.939—6.949 mm 0.2732—0.2736 in. Diameter (limit) ........................................................................... 6.920 mm 0.2724 in.

5—Valve Stem 6—Micrometer

Valve Stem

RH60123,00001BB –19–22APR08–5/12

14. Measure clearance between valve stem outside diameter and valve guide inner diameter (12). If measurement exceeds limit, replace valve guide and valve together.

TX1037325

Specification Exhaust Valve—Clearance (between valve guide and valve stem) (standard) ............................................................ 0.064—0.096 mm 0.00252—0.00378 in. Clearance (between valve guide and valve stem) (limit) .................................................................. 0.25 mm 0.00984 in.

12 Valve Guide 1—Cylinder Head 12—Valve Guide

Continued on next page

TM10743 (09APR09)

–UN–25FEB08

Specification Intake Valve—Clearance (between valve guide and valve stem) (standard) ............................................................ 0.039—0.071 mm 0.00154—0.00280 in. Clearance between valve guide and valve stem) (limit) .................................................................. 0.20 mm 0.00787 in.

04-0400-49

RH60123,00001BB –19–22APR08–6/12

135D Excavator Repair 040909

PN=161

04 0400 49

Removal and Installation 15. Measure thickness of valves (7). If measurement exceeds limit, replace valve and valve guide together. Specification Valve—Thickness of Valve (standard) ..................................................................................... 1.32 mm 0.052 in. Thickness of Valve (limit) ............................................................... 1.1 mm 0.045 in.

–UN–25FEB08

16. Inspect valve seat. Clean under surface of cylinder. 17. Install valve (7) in cylinder head (1).

TX1037326

7—Valve 04 0400 50

Thickness of Valve

RH60123,00001BB –19–22APR08–7/12

18. Measure depth of valve (7) from under surface of cylinder head (1). If measurement exceeds limit, replace valve insert or cylinder head. Specification Valve Seat—Depth (standard) ....................................................... 1.8 mm 0.07 in. Depth (limit) .................................................................................... 2.5 mm 0.0984 in.

TX1037327

–UN–25FEB08

1—Cylinder Head 7—Valve

Valve Seat

Continued on next page

TM10743 (09APR09)

04-0400-50

RH60123,00001BB –19–22APR08–8/12

135D Excavator Repair 040909

PN=162

Removal and Installation 19. Measure contact width of valve seat (9). If seat contact surface has a scratch or is rough, or if abrasion of contact surface exceeds limit, modify or replace it. 1

Specification Intake Valve Seat—Contact Width (standard) ....................................................................................... 1.7 mm 0.067 in. Contact Width (limit) ....................................................................... 2.2 mm 0.087 in. Exhaust Valve Seat—Contact Width (standard) ............................................................................. 2.0 mm 0.079 in. Contact Width (limit) ....................................................................... 2.5 mm 0.098 in.

–UN–25FEB08

TX1037328

1—Cylinder Head 7—Valve 9—Valve Seat

Valve

RH60123,00001BB –19–22APR08–9/12

20. Inspect surface of valve seat. If contact surface angle of valve seat is defective, machine it or replace valve, valve guide and valve seat. Specification Contact Surface—Angle ........................................................................ 45°

TX1037329

–UN–25FEB08

7—Valve

Valve

Continued on next page

TM10743 (09APR09)

04-0400-51

RH60123,00001BB –19–22APR08–10/12

135D Excavator Repair 040909

PN=163

04 0400 51

Removal and Installation 21. Repair seat surface. Use a seat cutter (8) to minimize scratches and roughness (15/45/75°-blade). This will return contact width to standard value. IMPORTANT: Remove grinding compound completely after grinding. Internal engine damage may occur.

–UN–25FEB08

22. Apply grinding compound in valve insert seat. 23. Insert valve (7) into valve guide.

TX1037330

1—Cylinder Head 8—Seat Cutter

04 0400 52

TX1037331

–UN–25FEB08

Seat Cutter

Continued on next page

TM10743 (09APR09)

04-0400-52

RH60123,00001BB –19–22APR08–11/12

135D Excavator Repair 040909

PN=164

Removal and Installation 24. Apply grinding compound to valve seat surface. Rotate valve (7) lightly to grind valve seat surface and confirm that it has even contact all round. Inspect and repair as necessary. 25. Inspect and replace as necessary.

TX1037332

–UN–25FEB08

1—Cylinder Head 7—Valve

Cylinder Head

RH60123,00001BB –19–22APR08–12/12

Timing Gear Case Remove and Install 1. Remove engine. See Engine Remove and Install. (Group 0400.) RH60123,00001BC –19–23APR08–1/13

2. Rotate crankshaft to No. 1 position on top dead center. 3. Remove cylinder head. See Cylinder Head Remove and Install. (Group 0400.) 4. Remove alternator adjusting bracket. See Alternator Remove and Install. (Group 0400.) 5. Remove water pump. See Water Pump Remove and Install. (Group 0400.)

–UN–28FEB08

TX1037439

6. Remove fuel injection pump. See Fuel Injection Pump Remove and Install. (Group 0400.) 1—Top Dead Center

Top Dead Center

Continued on next page

TM10743 (09APR09)

04-0400-53

RH60123,00001BC –19–23APR08–2/13

135D Excavator Repair 040909

PN=165

04 0400 53

Removal and Installation 7. Remove front crankshaft pulley (12) and front oil seal. 8. Remove starter. See Starter Remove and Install. (Group 0400.) 13

12 10—Cap Screw 11—Washer 12—Crankshaft Pulley 13—Key

TX1037765

–UN–03MAR08

04 0400 54

RH60123,00001BC –19–23APR08–3/13

9. Remove cover (1). 2

1—Cover 2—Cap Screw (3 used)

TX1037762

–UN–03MAR08

Cover

Continued on next page

TM10743 (09APR09)

04-0400-54

RH60123,00001BC –19–23APR08–4/13

135D Excavator Repair 040909

PN=166

Removal and Installation 10. Remove fan shroud bracket (3) and fan shroud mount (5).

3—Fan Shroud Bracket 4—Nut 5—Fan Shroud Mount 6—Cap Screw (2 used) 7—Cap Screw (2 used)

TX1037763

–UN–03MAR08

3 Fan Shroud Brackets

RH60123,00001BC –19–23APR08–5/13

11. Remove cover (8).

TX1037764

–UN–03MAR08

8—Cover 9—Cap Screw (3 used)

9 Cover

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TM10743 (09APR09)

04-0400-55

RH60123,00001BC –19–23APR08–6/13

135D Excavator Repair 040909

PN=167

04 0400 55

Removal and Installation 12. Remove timing gear case cover (15).

14—Cap Screw (14 used) 15—Timing Gear Case Cover

TX1038735

–UN–20MAR08

04 0400 56

Timing Gear Case Cover

RH60123,00001BC –19–23APR08–7/13

13. Remove flange (18) and idle gear A (16). 14. Remove shaft (19). 16—Idle Gear A 17—Cap Screw (2 used) 18—Flange 19—Shaft

–UN–20MAR08

TX1038742

Idle Gear A

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TM10743 (09APR09)

04-0400-56

RH60123,00001BC –19–23APR08–8/13

135D Excavator Repair 040909

PN=168

Removal and Installation 15. Remove crankshaft gear (20) using 2-jaw puller. 16. Remove oil pump. See Oil Pump Remove and Install. (Group 0400.) 20

TX1038799

–UN–20MAR08

20—Crankshaft Gear

Crankshaft Gear

RH60123,00001BC –19–23APR08–9/13

17. Remove timing gear case (21). 18. Inspect and replace as necessary.

–UN–24MAR08

21—Timing Gear Case 22—Cap Screw (21 used) 23—Gasket 24—Cylinder Block

TX1038800

Timing Gear Case

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TM10743 (09APR09)

04-0400-57

RH60123,00001BC –19–23APR08–10/13

135D Excavator Repair 040909

PN=169

04 0400 57

Removal and Installation 19. Apply PM37465 Ultra Blue Silicone Form-In-Place Gasket (25) to gasket (23) and cylinder block (24) to locations shown.

Specification Timing Gear Case—Torque ........................................................... 25 N•m 18 lb-ft

21. Install crankshaft gear.

22. Install oil pump. See Oil Pump Remove and Install. (Group 0400.)

23—Gasket 24—Cylinder Block 25—PM37465 Ultra Blue Silicone Form-In-Place Gasket

RH60123,00001BC –19–23APR08–11/13

IMPORTANT: Avoid clamping idle gear A to tight in vice. Damage can occur to idle gear A.

24. Secure idle gear A (16) into a vice (26).

26 25. Install M6 cap screw in to idle gear A (16).

–UN–20MAR08

26. Rotate sub gear (27) until M6 cap screw is aligned with hole on idle gear (16). 27. Tighten M6 cap screw to prevent rotation of sub gear (23). 28. Install idle gear and flange. Align timing marks on crankshaft gear (20), idle gear (16) and fuel supply pump gear (28).

TX1038802

04 0400 58

TX1038801

23. Install shaft.

–UN–20MAR08

20. Install timing gear case.

Idle Gear A

Specification Idle Gear A—Torque ...................................................................... 32 N•m 24 lb-ft

16—Idle Gear A 26—Vice 27—Sub Gear

29. Remove M6 cap screw.

Continued on next page

TM10743 (09APR09)

04-0400-58

RH60123,00001BC –19–23APR08–12/13

135D Excavator Repair 040909

PN=170

Removal and Installation 30. Apply PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket (28) to locations shown.

31. Install timing gear case cover. Tighten cap screws to specification. Specification Timing Gear Case—Torque ........................................................... 25 N•m 18 lb-ft –UN–20MAR08

32. Install vacuum pump hole cover. 33. Install fan shroud bracket and fan shroud mount.

35. Install starter. See Starter Remove and Install. (Group 0400.)

TX1038868

34. Install power steering pump hole cover.

PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket

IMPORTANT: Crankshaft pulley cap screw is torque to yield. Replace crankshaft pulley cap screw and washer or possible engine damage will occur.

28—PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket

36. Install front crankshaft pulley and front oil seal. Specification Crankshaft Pulley Cap Screw— Torque .......................................................................................... 294 N•m 217 lb-ft

37. Install fuel injection pump. See Fuel Injection Pump Remove and Install. (Group 0400.) 38. Install water pump. See Water Pump Remove and Install. (Group 0400.) 39. Install alternator adjusting bracket. See Alternator Remove and Install. (Group 0400.) 40. Install cylinder head. See Cylinder Head Remove and Install. (Group 0400.) 41. Install engine. See Engine Remove and Install. (Group 0400.)

RH60123,00001BC –19–23APR08–13/13

TM10743 (09APR09)

04-0400-59

135D Excavator Repair 040909

PN=171

04 0400 59

Removal and Installation

Cylinder Block Disassemble and Assemble 1. Remove valve cover. See Valve Cover Remove and Install. (Group 0400.) 2. Remove camshafts. See Camshafts Remove and Install. (Group 0400.) 3. Remove rocker arm assembly. See Rocker Arm Assembly Remove and Install. (Group 0400.) 4. Remove cylinder head. See Cylinder Head Remove and Install. (Group 0400.)

6. Remove high pressure common rail. See High Pressure Common Rail Remove and Install. (Group 0400.) 7. Remove engine oil cooler. See Engine Oil Cooler Remove and Install. (Group 0400.)

RH60123,00001BD –19–30APR08–1/4

8. Remove front crankshaft pulley (12) and front oil seal. 9. Remove rear oil seal. See Rear Oil Seal Remove and Install. (Group 0400.) 12

10. Remove water pump. See Water Pump Remove and Install. (Group 0400.)

12. Remove oil pan. See Oil Pan Remove and Install. (Group 0400.)

–UN–03MAR08

11. Remove timing gear case. See Timing Gear Case Remove and Install. (Group 0400.)

13. Remove pistons and connecting rods. See Piston and Connecting Rod Remove and Install. (Group 0400.) 14. Remove crankshaft. See Crankshaft Remove and Install. (Group 0400.)

10—Cap Screw 11—Washer 12—Crankshaft Pulley 13—Key

Continued on next page

TM10743 (09APR09)

TX1037765

04 0400 60

5. Remove fuel injection pump. See Fuel Injection Pump Remove and Install. (Group 0400.)

04-0400-60

RH60123,00001BD –19–30APR08–2/4

135D Excavator Repair 040909

PN=172

Removal and Installation 15. Remove piston cooling pipe (2).

16. Inspect and repair as necessary. See Cylinder Block Inspection. (Group 0400.)

17. Install piston cooling pipe. 18. Install crankshaft. See Crankshaft Remove and Install. (Group 0400.) IMPORTANT: Oil jet or cylinder wall will be damaged if contacted by connecting rod during piston installation.

–UN–20MAR08

TX1038892

19. Install pistons and connecting rods. See Piston and Connecting Rod Remove and Install. (Group 0400.) Piston Cooling Pipe

20. Install oil pan. See Oil Pan Remove and Install. (Group 0400.)

1—Cylinder Block 2—Piston Cooling Pipe 3—Cap Screw (5 used) 4—Socket Head Cap Screw

21. Install timing gear case. See Timing Gear Case Remove and Install. (Group 0400.) 22. Install water pump. See Water Pump Remove and Install. (Group 0400.) 23. Install rear oil seal. See Rear Oil Seal Remove and Install. (Group 0400.) IMPORTANT: Crankshaft pulley cap screw is a toque to yield. Replace crankshaft pulley cap screw and washer or possible engine damage will occur. 24. Install front crankshaft pulley and front oil seal. Tighten to specification. Specification Crankshaft Pulley Cap Screw— Torque .......................................................................................... 294 N•m 217 lb-ft

25. Install engine oil cooler. See Engine Oil Cooler Remove and Install. (Group 0400.) 26. Install high pressure common rail. See High Pressure Common Rail Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-61

RH60123,00001BD –19–30APR08–3/4

135D Excavator Repair 040909

PN=173

04 0400 61

Removal and Installation 27. Install fuel injection pump. See Fuel Injection Pump Remove and Install. (Group 0400.) 28. Install cylinder head. See Cylinder Head Remove and Install. (Group 0400.) 29. Install rocker are assembly. See Rocker Arm Assembly Remove and Install. (Group 0400.) 30. Install camshafts. See Camshafts Remove and Install. (Group 0400.) 31. Install valve cover. See Valve Cover Remove and Install. (Group 0400.) 04 0400 62 RH60123,00001BD –19–30APR08–4/4

Cylinder Block Inspection 1. Clean surface of engine block. 2. Visually inspect cylinder block. Conduct a color check and hydraulic (or pneumatic) test and if you find a crack or other damage, replace cylinder block. 3. Inspect internal surface of cylinder block for scratches or damage.

RH60123,00001BF –19–11APR08–1/5

4. Measure out-of-flat of mating surface of cylinder block. Specification Cylinder Block Surface— Out-of-Flat (standard) ....................................................... 0.05 mm or less 0.002 in. or less Out-of-Flat (limit)........................................................................... 0.20 mm 0.079 in.

TX1037784

–UN–29FEB08

7—Thickness Edge 8—Straight Edge

Measure Cylinder Block

Continued on next page

TM10743 (09APR09)

04-0400-62

RH60123,00001BF –19–11APR08–2/5

135D Excavator Repair 040909

PN=174

Removal and Installation 5. Measure cylinder block height (9). If it is less than specified value replace cylinder block. Specification Cylinder Block—Height.......................................... 259.945—260.055 mm 10.2340—10.2384 in.

TX1037785

–UN–29FEB08

6. Replace cylinder block if measurements exceed limit values.

Cylinder Block

RH60123,00001BF –19–11APR08–3/5

7. Measure cylinder bore diameter both in thrust (2-2) and radial (3-3) at specified depth (1).

Specification Cylinder Bore—Depth (approximate)................................................................................... 20 mm 0.80 in.

2 Specification

Cylinder Bore—Diameter (standard) .................................................................. 95.421—95.450 mm 3.7567—3.7579 in. Diameter (limit) ........................................................................... 95.48 mm 3.7590 in.

TX1037782

1—Measuring Position 2—Trust Measurement 3—Radial Measurement 4—Cylinder Gauge

Cylinder Gauge

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TM10743 (09APR09)

–UN–29FEB08

8. Machine or replace cylinder block if wear amount exceeds limit value.

04-0400-63

RH60123,00001BF –19–11APR08–4/5

135D Excavator Repair 040909

PN=175

04 0400 63

Removal and Installation 9. Measure outside diameter of piston at a right angle to piston pin in specified position. 10. Calculate necessary amount of cylinder machining for each cylinder.

TX1037783

–UN–29FEB08

04 0400 64

Piston 5—Micrometer 6—Piston Cylinder Bore Inner Diameter =D (Piston Outside Diameter) + C (Clearance Between Piston and Cylinder) - H (Honing Allowable Amount ) + or - E (Boring Machine Error) Standard

95.330—95.359 mm 3.7531—3.7543 in.

Oversize

0.25 in.

95.580—95.609 mm 3.7629—3.7641 in.

Oversize

0.50 in.

95.830—95.859 mm 3.7728—3.7739 in.

Oversize

0.75 in.

96.080—96.109 mm 3.7826—3.7838 in.

Select a oversized piston that fits maximum cylinder bore size which is previously measured. 11. Machine or hone each cylinder as necessary. 12. Verify piston bore diameter difference is within specification. Specification Cylinder Bore Differences— Diameter ....................................................................................... 0.02 mm 0.0008 in.

RH60123,00001BF –19–11APR08–5/5

TM10743 (09APR09)

04-0400-64

135D Excavator Repair 040909

PN=176

Removal and Installation

Rear Oil Seal Remove and Install 1. Remove engine. See Engine Remove and Install. (Group 0400.) 2. Remove flywheel. See Flywheel Remove and Install. (Group 0400.) 3. Remove flywheel housing. See Flywheel Housing Remove and Install. (Group 0400.)

RH60123,00001BE –19–22APR08–1/6

4. Remove retainer (1). 04 0400 65

1—Retainer 2—Cap Screw (5 used)

TX1037706

–UN–03MAR08

Retainer

RH60123,00001BE –19–22APR08–2/6

5. Remove rear oil seal (3) from retainer (1).

–UN–03MAR08

1—Retainer 3—Oil Seal

TX1037710

3 1 Rear Oil Seal

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TM10743 (09APR09)

04-0400-65

RH60123,00001BE –19–22APR08–3/6

135D Excavator Repair 040909

PN=177

Removal and Installation IMPORTANT: When replacing rear oil seal, slinger must also be replaced. Oil leak will occur if not replaced. 6. Remove slinger using 5-8840-2360-0 Slinger Puller (4). 7. Inspect and replace as necessary.

–UN–03MAR08

4—5-8840-2360-0 Slinger Puller

TX1037707

04 0400 66

Slinger Puller

RH60123,00001BE –19–22APR08–4/6

8. Apply PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket (5) to retainer (1). 5

9. Install retainer. Torque cap screws to specification. Specification Retainer Cap Screws—Torque ...................................................... 25 N•m 18 lb-ft

TX1037708

–UN–03MAR08

2 1—Retainer 5—PM37456 Ultra Blue RTV Silicone Form-In-Place Gasket

Retainer

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TM10743 (09APR09)

04-0400-66

RH60123,00001BE –19–22APR08–5/6

135D Excavator Repair 040909

PN=178

Removal and Installation 10. Install oil seal and slinger using 5-8840-2359-0 Oil Seal Installer to specified depth. Specification Oil Seal to End of Crankshaft— Depth (approximate) ..................................................................... 12.5 mm 0.49

–UN–03MAR08

11. Install flywheel housing. See Flywheel Housing Remove and Install. (Group 0400.) 12. Install flywheel. See Flywheel Remove and Install. (Group 0400.)

TX1037709

13. Install engine. See Engine Remove and Install. (Group 0400.) 6—5-8840-2359-0 Oil Seal Installer

5-8840-2359-0 Oil Seal Installer

RH60123,00001BE –19–22APR08–6/6

Camshafts Remove and Install 1. Rotate crankshaft to No. 1 position on top dead center. 2. Remove valve cover. See Valve Cover Remove and Install. (Group 0400.) 1—Top Dead Center

TX1037439

–UN–28FEB08

Top Dead Center

Continued on next page

TM10743 (09APR09)

04-0400-67

RH60123,00001C0 –19–30APR08–1/7

135D Excavator Repair 040909

PN=179

04 0400 67

Removal and Installation 3. Install a M5 cap screw to secure cam gears.

TX1037440

–UN–28FEB08

2—M5 Cap Screw (2 used)

04 0400 68

M5 Cap Screw

RH60123,00001C0 –19–30APR08–2/7

4. Remove baffle (3). 4

3—Baffle 4—Cap Screw (4 used)

TX1037441

–UN–28FEB08

Baffle

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TM10743 (09APR09)

04-0400-68

RH60123,00001C0 –19–30APR08–3/7

135D Excavator Repair 040909

PN=180

Removal and Installation IMPORTANT: Check stamp mark on bearing cap for proper installation. Improper installation will cause internal damage.

1E 2E

5. Remove camshaft bearing caps (5).

3E 6. Remove camshafts.

7. Inspect and replace as necessary.

4l 5l

TX1037442

9. Loosen all of rocker arm adjusting nuts and screws.

–UN–28FEB08

3l 8. Rotate crankshaft to No. 1 position on top dead center.

10. Apply clean engine oil to camshaft. 11. Install camshafts. Bearing Cap Location 5—Bearing cap (10 used)

TX1037443

–UN–28FEB08

Camshafts

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TM10743 (09APR09)

04-0400-69

RH60123,00001C0 –19–30APR08–4/7

135D Excavator Repair 040909

PN=181

04 0400 69

Removal and Installation 12. Align timing marks on camshaft gear with timing marks on idle gear. 13. Apply clean engine oil to camshaft journals and bearing surfaces of bearing caps.

TX1037444

3 04 0400 70

–UN–28FEB08

A—Timing Mark (2 used) 1—Exhaust Camshaft Gear 2—Intake Camshaft Gear 3—Idle Gear

Alignment Marks

RH60123,00001C0 –19–30APR08–5/7

IMPORTANT: Check stamp mark on bearing cap for proper installation. Improper installation will cause internal damage.

1E 2E

14. Install bearing caps in there proper location.

3E 4E

2l 4l

TX1037442

–UN–28FEB08

Bearing Location

Continued on next page

TM10743 (09APR09)

04-0400-70

RH60123,00001C0 –19–30APR08–6/7

135D Excavator Repair 040909

PN=182

Removal and Installation 15. Check alignment marks on camshafts and bearing caps are aligned. 16. Torque bearing caps to specifications. 1 Specification Bearing Caps—Torque ................................................................... 18 N•m 13 lb-ft

1 2

–UN–28FEB08

17. Remove M5 lock bolt that secured cam gear. 18. Adjust valve clearance. See Rocker Arm Assembly Remove and Install. (Group 0400.)

TX1037445

19. Install baffle plate. Specification Baffle—Torque................................................................................ 10 N•m 87 lb-in

Camshaft Alignment Marks 1—Alignment Mark (camshaft) 2—Alignment Mark (Bearing Cap)

20. Install valve cover. See Valve Cover Remove and Install. (Group 0400.)

RH60123,00001C0 –19–30APR08–7/7

Flywheel Remove and Install 1. Remove engine. See Engine Remove and Install. (Group 0400.) 2. Remove starter. See Starter Remove and Install. (Group 0400.) 3. Remove dampener drive. See Dampener Drive (Flex Coupling) Remove and Install. (Group 0752.)

Continued on next page

TM10743 (09APR09)

04-0400-71

RH60123,00001C1 –19–21APR08–1/4

135D Excavator Repair 040909

PN=183

04 0400 71

Removal and Installation

TX1038130

–UN–06MAR08

4. Gradually loosen flywheel cap screws in order shown.

04 0400 72

Cap Screw Sequence

RH60123,00001C1 –19–21APR08–2/4

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

5. Remove flywheel (1) and washer (2). Specification Flywheel—Weight (approximate) ...................................................... 26 kg 58 lb

6. Inspect and replace as necessary. See Flywheel Disassemble and Assemble. (Group 0400.) 3

TX1038131

1—Flywheel 2—Washer 3—Cap Screw (8 used)

Continued on next page

TM10743 (09APR09)

–UN–06MAR08

04-0400-72

RH60123,00001C1 –19–21APR08–3/4

135D Excavator Repair 040909

PN=184

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Install flywheel and washer. Tighten cap screws to specification.

TX1038130

–UN–06MAR08

Specification Flywheel Cap Screws—Torque (1st step)......................................................................................... 59 N•m 43 lb-ft Turn Torque (2nd step) ................................................................ 60°—90° Flywheel—Weight (approximate) ...................................................... 26 kg 58 lb

8. Install dampener drive. See Dampener Drive (Flex Coupling) Remove and Install. (Group 0752.) Cap Screw Sequence

9. Install starter. See Starter Remove and Install. (Group 0400.) 10. Install engine. See Engine Remove and Install. (Group 0400.)

RH60123,00001C1 –19–21APR08–4/4

Flywheel Disassemble and Assemble 1. Remove ring gear (1) from flywheel (2). 2. Inspect and replace as necessary.

TX1038132

–UN–06MAR08

1—Ring Gear 2—Flywheel

Ring Gear

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TM10743 (09APR09)

04-0400-73

RH60123,00001C2 –19–23APR08–1/2

135D Excavator Repair 040909

PN=185

04 0400 73

Removal and Installation

CAUTION: Prevent possible burn injury. Hot equipment and fluids cause burns to unprotected skin. Wear gloves and protective cloths when working with hot equipment and fluids.

–UN–06MAR08

IMPORTANT: Avoid letting gas burner temperature exceed 200°C (390°F). Ring gear may be damaged. 3. Heat ring gear evenly.

TX1038133

4. Install ring gear on flywheel. 1—Ring Gear 04 0400 74

Ring Gear

RH60123,00001C2 –19–23APR08–2/2

Flywheel Housing Remove and Install 1. Remove engine. See Engine Remove and Install. (Group 0400.) 2. Remove starter. See Starter Remove and Install. (Group 0400.) 3. Remove flywheel. See Flywheel Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-74

RH60123,00001C3 –19–21APR08–1/2

135D Excavator Repair 040909

PN=186

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

3 3

4. Remove flywheel housing.

2 Specification Flywheel Housing—Weight (approximate)..................................................................................... 37 kg 82 lb

5. Inspect and replace as necessary. 6

6. Install flywheel housing. Tighten to specification. Specification Cap Screws—Torque (2)................................................................ 82 N•m 60 lb-ft Torque (3 and 4) ............................................................................ 51 N•m 38 lb-ft Torque (6) ....................................................................................... 97 N•m 72 lb-ft

TX1038911

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

–UN–20MAR08

Flywheel Housing 1—Flywheel Housing 2—Cap Screw (3 used) 3—Cap Screw (3 used) 4—Cap Screw 5—Nut 6—Cap Screw (4 used)

Specification Flywheel Housing—Weight (approximate)..................................................................................... 37 kg 82 lb

7. Install flywheel. See Flywheel Remove and Install. (Group 0400.) 8. Install starter. See Starter Remove and Install. (Group 0400.) 9. Install engine. See Engine Remove and Install. (Group 0400.)

RH60123,00001C3 –19–21APR08–2/2

TM10743 (09APR09)

04-0400-75

135D Excavator Repair 040909

PN=187

04 0400 75

Removal and Installation

Oil Pan Remove and Install 1. Drain engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.) 2. Remove engine. See Engine Remove and Install. (Group 0400.)

RH60123,00001C4 –19–11APR08–1/5

3. Remove dip stick (1). 1—Dip Stick

–UN–06MAR08

TX1037912

04 0400 76

Dip Stick

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TM10743 (09APR09)

04-0400-76

RH60123,00001C4 –19–11APR08–2/5

135D Excavator Repair 040909

PN=188

Removal and Installation 4. Remove oil pan (3).

5. Remove flywheel. See Flywheel Remove and Install. (Group 0400.) 6. Remove flywheel housing. See Flywheel Housing Remove and Install. (Group 0400.) 7. Remove cylinder head. See Cylinder Head Remove and Install. (Group 0400.)

–UN–06MAR08

TX1038008

8. Remove timing gear case. See Timing Gear Case Remove and Install. (Group 0400.) 9. Remove rear oil seal. See Rear Oil Seal Remove and Install. (Group 0400.) Oil Pan 2—Cap Screw (22 used) 3—Oil Pan 4—Nut (2 used) 5—Gasket

RH60123,00001C4 –19–11APR08–3/5

10. Remove crankcase (6). 11. Inspect and replace as necessary.

TX1039239

–UN–27MAR08

6—Crankcase 7—Cap Screw (19 used)

Crankcase

Continued on next page

TM10743 (09APR09)

04-0400-77

RH60123,00001C4 –19–11APR08–4/5

135D Excavator Repair 040909

PN=189

04 0400 77

Removal and Installation 12. Apply PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket to surface as shown. 13. Install crankcase. Tighten cap screws to specification. Specification Crankcase Cap Screws—Torque ................................................... 25 N•m 18 lb-ft

6 –UN–27MAR08

14. Install rear oil seal. See Rear Oil Seal Remove and Install. (Group 0400.)

16. Install cylinder head. See Cylinder Head Remove and 04 Install. (Group 0400.) 0400 78

TX1039240

15. Install timing gear case. See Timing Gear Case Remove and Install. (Group 0400.) 8 Crankcase

17. Install flywheel housing. See Flywheel Housing Remove and Install. (Group 0400.) 18. Install flywheel. See Flywheel Remove and Install. (Group 0400.)

6—Crankcase 8—PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket

19. Install oil pan. Tighten cap screws to specification. Specification Oil Pan Cap Screws—Torque ........................................................ 25 N•m 18 lb-ft

20. Install dip stick. 21. Install engine. See Engine Remove and Install. (Group 0400.) 22. Fill engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.)

RH60123,00001C4 –19–11APR08–5/5

TM10743 (09APR09)

04-0400-78

135D Excavator Repair 040909

PN=190

Removal and Installation

Crankshaft Remove and Install 1. Remove engine. See Engine Remove and Install. (Group 0400.) 2. Remove valve cover. See Valve Cover Remove and Install. (Group 0400.) 3. Remove camshafts. See Camshafts Remove and Install. (Group 0400.) 4. Remove rocker arm assembly. See Rocker Arm Assembly Remove and Install. (Group 0400.) 5. Remove cylinder head. See Cylinder Head Remove and Install. (Group 0400.)

04 0400 79

6. Remove fuel injection pump. See Fuel Injection Pump Remove and Install. (Group 0400.)

RH60123,00001C5 –19–30APR08–1/10

7. Remove front crank pulley (12). 8. Remove rear oil seal. See Rear Oil Seal Remove and Install. (Group 0400.) 12

9. Remove water pump. See Water Pump Remove and Install. (Group 0400.)

TX1037765

11. Remove timing gear case. See Timing Gear Case Remove and Install. (Group 0400.)

–UN–03MAR08

10. Remove oil pump. See Oil Pump Remove and Install. (Group 0400.)

10—Cap Screw 11—Washer 12—Crankshaft Pulley 13—Key

Continued on next page

TM10743 (09APR09)

04-0400-79

RH60123,00001C5 –19–30APR08–2/10

135D Excavator Repair 040909

PN=191

Removal and Installation 12. Remove crankshaft gear (1) using 2-jaw puller. 13. Remove oil pan. See Oil Pan Remove and Install. (Group 0400.) 1

14. Remove piston and connecting rods. See Piston and Connecting Rod Remove and Install. (Group 0400.)

TX1037446

–UN–28FEB08

1—Crankshaft Gear

04 0400 80

Crankshaft Gear

RH60123,00001C5 –19–30APR08–3/10

15. Loosen cap screws securing crankshaft bearing caps in order shown. 16. Remove bearing caps and lower bearings.

17. Remove crankshaft.

10 10

6 6 4

9 9

22 5

5 5

Specification

TX1037475

Crankshaft—Weight (approximate)..................................................................................... 26 kg 57 lb

–UN–28FEB08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

18. Remove thrust bearing. Crankshaft Bearing Cap Removal Sequence

19. Remove upper bearings. 20. Inspect and repair as necessary. See Crankshaft Disassemble and Assemble. (Group 0400.) See Crankshaft Inspection. (Group 0400.) NOTE: Upper bearings have a oil hole and an oil groove. 21. Apply clean engine oil and install upper bearings.

Continued on next page

TM10743 (09APR09)

04-0400-80

RH60123,00001C5 –19–30APR08–4/10

135D Excavator Repair 040909

PN=192

Removal and Installation 22. Install crankshaft. Apply clean engine oil to crankshaft journal. 2

TX1037478

–UN–28FEB08

2—Crankshaft

Crankshaft

RH60123,00001C5 –19–30APR08–5/10

23. Install thrust bearing (3) with oil grooves contacting crankshaft (2). 2

TX1037479

–UN–28FEB08

2—Crankshaft 3—Thrust Bearing

Thrust Bearing

Continued on next page

TM10743 (09APR09)

04-0400-81

RH60123,00001C5 –19–30APR08–6/10

135D Excavator Repair 040909

PN=193

04 0400 81

Removal and Installation IMPORTANT: Bearing caps are numbered and must be installed with arrow toward front of engine and proper order. Bearing damage will result if not installed correctly.

1—Bearing Cap 1 2—Bearing Cap 2 3—Bearing Cap 3 4—Bearing Cap 4 5—Bearing Cap 5

5 3

TX1037480

–UN–28FEB08

24. Install crankshaft bearing caps.

04 0400 82

Crankshaft Main Bearing

RH60123,00001C5 –19–30APR08–7/10

TX1037481

–UN–28FEB08

25. Apply PM37456 Ultra Blue RTV Silicone Form-In-Place Gasket to installation surfaces of no. 5 crankshaft bearing cap and cylinder block.

Surface of No. 5 Bearing Cap

Continued on next page

TM10743 (09APR09)

04-0400-82

RH60123,00001C5 –19–30APR08–8/10

135D Excavator Repair 040909

PN=194

Removal and Installation 26. Tighten cap screws to specification in sequence shown.

28. Install oil pan. See Oil Pan Remove and Install. (Group 0400.)

1 3

TX1037482

–UN–28FEB08

27. Install piston and connecting rod. See Piston and Connecting Rod Remove and Install. (Group 0400.)

Torque Sequence

Continued on next page

TM10743 (09APR09)

04-0400-83

RH60123,00001C5 –19–30APR08–9/10

135D Excavator Repair 040909

PN=195

04 0400 83

Removal and Installation 29. Install crankshaft gear (1). 30. Install timing gear case. See Timing Gear Case Remove and Install. (Group 0400.) 31. Install oil pump. See Oil Pump Remove and Install. (Group 0400.) 1 –UN–28FEB08

32. Install water pump. See Water Pump Remove and Install. (Group 0400.)

TX1037501

33. Install rear oil seal. See Rear Oil Seal Remove and Install. (Group 0400.) 34. Install front oil seal. 04 0400 84

35. Install fuel injection pump. See Fuel Injection Pump Remove and Install. (Group 0400.) 36. Install cylinder head. See Cylinder Head Remove and Install. (Group 0400.)

Crankshaft Gear 1—Crankshaft Gear

37. Install rocker arm assembly. See Rocker Arm Assembly Remove and Install. (Group 0400.) 38. Install camshafts. See Camshafts Remove and Install. (Group 0400.) 39. Install valve cover. See Valve Cover Remove and Install. (Group 0400.) 40. Install engine. See Engine Remove and Install. (Group 0400.)

RH60123,00001C5 –19–30APR08–10/10

TM10743 (09APR09)

04-0400-84

135D Excavator Repair 040909

PN=196

Removal and Installation

Crankshaft Disassemble and Assemble 1. Remove crankshaft sensor (CKP) rotor. 1 2. Inspect and replace as necessary. See Crankshaft Inspection. (Group 0400.)

2 3

3. Apply 262 to cap screws.

1—Crankshaft 2—Crankshaft Sensor Rotor 3—Cap Screw (3 used)

TX1037476

–UN–28FEB08

4. Install crankshaft rotor.

Crankshaft Sensor Rotor

RH60123,00001C6 –19–18APR08–1/1

Crankshaft Inspection IMPORTANT: Tuffriding (soft nitriding treatment) is applied to enhance strength of crankshaft. Polishing surface of crankshaft is not advised. Internal damage may occur. 1. Check main journal and connecting rod journal surfaces for wear and damage. Check oil seal contact surfaces for excessive wear and damage. 2. Check oil port for clogging.

Continued on next page

TM10743 (09APR09)

04-0400-85

RH60123,00001C7 –19–23APR08–1/3

135D Excavator Repair 040909

PN=197

04 0400 85

Removal and Installation 3. Set crankshaft on a V block. Slowly turn crankshaft to measure radial runout. If crankshaft runout exceeds limit, replace crankshaft.

–UN–22FEB08

Specification Crankshaft—Radial Runout (standard) ......................................................................... 0.05 mm or less 0.0020 in. or less Radial Runout (limit) ..................................................................... 0.08 mm 0.003 in.

TX1037297

1—Crankshaft 3—Dial Indicator 4—V Block

04 0400 86

Crankshaft Runout

RH60123,00001C7 –19–23APR08–2/3

4. Measure outer diameters of main journal and connecting rod journal and calculate differences between maximum and minimum values. Take measurements at four positions for both journal and pin.

TX1037298

Specification Crankshaft Pin—Outside Diameter Standard .................................................... 52.915—52.930 mm 2.0833—2.0839 in. Outside Diameter Limit ................................................................. 52.9 mm 2.083 in.

–UN–22FEB08

Specification Crankshaft Journal—Outside Diameter Standard .................................................... 69.917—69.932 mm 2.7526—2.7532 in. Outside Diameter Limit ............................................................... 69.91 mm 2.7524 in.

Crankshaft Outside Diameter

1—Crankshaft 5—Micrometer

RH60123,00001C7 –19–23APR08–3/3

TM10743 (09APR09)

04-0400-86

135D Excavator Repair 040909

PN=198

Removal and Installation

Main Bearing Inspection Thrust Bearing Inspection 1. Inspect crankshaft. See Crankshaft Inspection. (Group 0400.)

Continued on next page

RH60123,00001DB –19–23APR08–1/9

04 0400 87

TM10743 (09APR09)

04-0400-87

135D Excavator Repair 040909

PN=199

Removal and Installation NOTE: Measure thrust bearing clearance of crankshaft before removing from cylinder block. 1

2. Measure thrust bearing clearance of crankshaft at center journal. 3. If thrust bearing clearance exceeds limit, replace thrust bearings.

–UN–22FEB08

Specification Thrust Bearing Clearance— Clearance .......................................................................... 0.10—0.30 mm 0.004—0.012 in.

04 0400 88

TX1037293

Main Bearing Clearance CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Thrust Bearing Inspection 1—Crankshaft

1. Remove crankshaft if necessary. See Crankshaft Remove and Install. (Group 0400.) Specification Crankshaft—Weight (approximate)..................................................................................... 26 kg 57 lb

2. Remove main bearings on cylinder block. 3. Clean crankshaft journals and upper and lower main bearings. Inspect main bearings for damage and excessive wear. If any damage or excessive wear is found, replace main bearings. 4. Install main bearing in cylinder block. 5. Install crankshaft. See Crankshaft Remove and Install. (Group 0400.) 6. Turn crankshaft to seat main bearings on cylinder block.

Continued on next page

TM10743 (09APR09)

04-0400-88

RH60123,00001DB –19–23APR08–2/9

135D Excavator Repair 040909

PN=200

Removal and Installation 7. Place Plastigageon crankshaft journal as shown. 1

1—Crankshaft 2—Plastigage

TX1037294

–UN–22FEB08



Plastigage Plastigage is a trademark of Perfect Circle Corporation

RH60123,00001DB –19–23APR08–3/9

NOTE: Do not rotate crankshaft after tightening main bearing caps. Plastigage can be damaged and measurement can not be taken.

Specification Main Bearing Caps—Torque ........................................................ 166 N•m 122 lb-ft

TX1037295

9. Remove main bearing cap that has Plastigage.

–UN–25FEB08

8. Install main bearings and main bearing caps. Tighten to specification.

Torque Sequence Plastigage is a trademark of Perfect Circle Corporation

TM10743 (09APR09)

Continued on next page

04-0400-89

RH60123,00001DB –19–23APR08–4/9

135D Excavator Repair 040909

PN=201

04 0400 89

Removal and Installation 10. Measure widest part of Plastigage to determine clearance. Specification Journal Oil Clearance—Clearance (standard) ...................................................................... 0.032—0.077 mm 0.0013—0.0030 in. Clearance (limit) ........................................................................... 0.11 mm 0.0043 in.

–UN–22FEB08

11. If journal oil clearance exceeds limit, replace main bearings or crankshaft.

TX1037296

12. Repeat procedure for other bearings. 13. Remove Plastigage. Crankshaft Bearing Selection

Measure Plastigage

Plastigage is a trademark of Perfect Circle Corporation

RH60123,00001DB –19–23APR08–5/9

1. Identify grade marks in location shown.

–UN–25FEB08

1—No. 1 2—No. 2 3—No. 3 4—No. 4 5—No. 5

TX1037299

04 0400 90

Stamp

Continued on next page

TM10743 (09APR09)

04-0400-90

RH60123,00001DB –19–23APR08–6/9

135D Excavator Repair 040909

PN=202

Removal and Installation NOTE: Number of No. 4 journal diameter is stamped on either front side or rear side of No. 4 crank arm. 2. Number (1 or “-”, 2 “- -”, 3 or “- - -”) of crankshaft journal diameter is stamped on each crank arm.

TX1037300

–UN–25FEB08

1—Crankshaft Arm 1 2—Crankshaft Arm 2 3—Crankshaft Arm 3 4—Crankshaft Arm 4

Crankshaft

Continued on next page

TM10743 (09APR09)

04-0400-91

RH60123,00001DB –19–23APR08–7/9

135D Excavator Repair 040909

PN=203

04 0400 91

Removal and Installation 3. Reference bearing selection table to determine correct size of bearings.

–UN–22FEB08

TX1037301

04 0400 92

Bearing 6—Lot Number 7—Size Code 8—Bearing Combination of Grades

Oil Clearance

Cylinder Block Grade

Crank Journal Grade

Bearing Grade Mark

1 or “-”

0.030—0.049 mm (0.00118—0.00193 in.)

2 or “- - “

0.035—0.054 mm (0.00138—0.00213 in.)

3 or “- - - “

0.034—0.053 mm (0.00134—0.00209 in.)

1 or “-”

0.033—0.052 mm (0.00130—0.00205 in.)

2 or “- - “

0.032—0.051 mm (0.00126—0.00201 in.

3 or “- - - “

0.031—0.050 mm 0.00122—0.00197 in.

1 or “-”

0.031—0.049 mm 0.00122—0.00193 in.

2 or “- - “

0.030—0.048 mm 0.00118—0.00189 in.

3 or “- - -”

0.035—0.053 mm 0.00138—0.00209 in.

4. Install selected bearings in journals.

Continued on next page

TM10743 (09APR09)

04-0400-92

RH60123,00001DB –19–23APR08–8/9

135D Excavator Repair 040909

PN=204

Removal and Installation IMPORTANT: Install bearings with care. Internal damage may occur if bearings are damaged. 5. When installing new crankshaft bearings make reference to bearing selection table.

RH60123,00001DB –19–23APR08–9/9

Piston and Connecting Rod Remove and Install

04 0400 93

1. Remove engine. See Engine Remove and Install. (Group 0400.) 2. Remove cylinder head. See Cylinder Head Remove and Install. (Group 0400.) 3. Remove timing gear case. See Timing Gear Case Remove and Install. (Group 0400.) 4. Remove oil pan. See Oil Pan Remove and Install. (Group 0400.)

RH60123,00001C8 –19–11APR08–1/5

5. Remove carbon on upper side of cylinder block (5).

TX1037882

–UN–05MAR08

5—Cylinder Block

5 Cylinder Block

Continued on next page

TM10743 (09APR09)

04-0400-93

RH60123,00001C8 –19–11APR08–2/5

135D Excavator Repair 040909

PN=205

Removal and Installation IMPORTANT: Label position of connecting rod cap and bearing. If connecting rod caps and bearings are installed in wrong position, internal engine damage can occur. 6. Remove connecting rod cap (6). 7. Remove piston and connecting rod. –UN–05MAR08

8. Remove connecting rod bearing (7).

10. Install connecting rod bearing. Connecting Rod Bearing Cap

11. Apply clean engine oil on piston rings, ring groove and piston side surface.

6—Connecting Rod Cap 7—Connecting Rod Cap Bearing

RH60123,00001C8 –19–11APR08–3/5

12. Position each end gap of piston rings in following positions. (1) for top ring, (2) for second ring, (3) for oil ring and (4) for coil expander.

IMPORTANT: Oil jet or cylinder wall will be damaged if contacted by connecting rod during piston installation. 13. Install piston with arrow facing front of engine.

–UN–05MAR08

14. Install bearing then apply oil to friction surface. 15. Install connecting rod cap. Match numbers (1, 2, 3, and 4) of caps and connecting rods.

TX1037885

04 0400 94

TX1037884

9. Inspect and replace as necessary. See Piston and Connecting Rod Disassemble and Assemble. (Group 0400.)

1—Position For Top Ring 2—Position For Second Ring 3—Position For Oil Ring 4—Position For Coil Expander 8—Piston Ring Compressor

Piston Ring End Gap Position

Continued on next page

TM10743 (09APR09)

04-0400-94

RH60123,00001C8 –19–11APR08–4/5

135D Excavator Repair 040909

PN=206

Removal and Installation 16. Align mark (9) on cap forward so that cylinder number indication come to left side. 9

Specification Connecting Rod Cap—Torque First Step ..................................................................................... 29.4 N•m 22 lb-ft Torque Second Step ............................................................................. 45°

9 –UN–05MAR08

17. Apply clean engine oil to threads and seating surface of cap screw and tighten to specification.

TX1037887

18. After connecting rods are torqued, make sure engine rotates smoothly. 19. Install oil pan. See Oil Pan Remove and Install. (Group 0400.) Mark on Connecting Rod Cap

20. Install timing gear case. See Timing Gear Case Remove and Install. (Group 0400.)

9—Mark on Connecting Rod

21. Install cylinder head. See Cylinder Head Remove and Install. (Group 0400.) 22. Install engine. See Engine Remove and Install. (Group 0400.)

RH60123,00001C8 –19–11APR08–5/5

Piston and Connecting Rod Disassemble and Assemble 1. Remove piston rings (1).

TX1037893

–UN–06MAR08

1—Piston Ring (4 used) 2—Piston

Piston Rings

Continued on next page

TM10743 (09APR09)

04-0400-95

RH60123,00001C9 –19–23APR08–1/7

135D Excavator Repair 040909

PN=207

04 0400 95

Removal and Installation 2. Remove snap ring (3).

3 04 0400 96

TX1037894

–UN–05MAR08

2—Piston 3—Snap Ring

Snap Ring

RH60123,00001C9 –19–23APR08–2/7

3. Remove piston pin (4) from piston (2). 4. Remove connecting rod from piston. 5. Inspect and replace as necessary.

TX1037895

–UN–06MAR08

2—Piston 4—Piston Pin

Piston

Continued on next page

TM10743 (09APR09)

04-0400-96

RH60123,00001C9 –19–23APR08–3/7

135D Excavator Repair 040909

PN=208

Removal and Installation IMPORTANT: Align marks on piston with marks on connecting rod. Internal damage may occur. 6. Install connecting rod (5) to piston (2). 7. Apply clean engine oil to piston pin and push it in piston and connecting rod.

TX1037900

–UN–05MAR08

2—Piston 3—Snap Ring 5—Connecting Rod 6—Mark on Piston

Piston and Connecting Rod

RH60123,00001C9 –19–23APR08–4/7

8. Install snap ring (3). 2

2—Piston 3—Snap Ring 5—Connecting Rod

TX1037896

–UN–05MAR08

Snap Ring

Continued on next page

TM10743 (09APR09)

04-0400-97

RH60123,00001C9 –19–23APR08–5/7

135D Excavator Repair 040909

PN=209

04 0400 97

Removal and Installation IMPORTANT: Shapes are different for each piston ring. Rings must be installed in proper order or internal engine damage may occur.

9. Install piston rings in order shown. Install top piston ring (7) with “N” mark facing upwards. Install second ring (8) so yellow comes to right side of end gap.

10 04 0400 98

TX1037897

2—Piston 7—Top Ring 8—Second Ring 9—Oil Ring 10—Coil Expander

–UN–05MAR08

Piston Rings

RH60123,00001C9 –19–23APR08–6/7

10. Install coil expander (10). Check gap (11) on coil expander. There should be no gap in coil expander when installed. 11. Install oil ring (9).

TX1037898

–UN–05MAR08

10—Coil Expander 11—Gap

Coil Expander

RH60123,00001C9 –19–23APR08–7/7

Piston and Connecting Rod Inspection 1. Clean piston and inspect for cracks, burns, and other excessive wear. Replace if damage is observed. Continued on next page

TM10743 (09APR09)

04-0400-98

RH60123,00001CA –19–23APR08–1/13

135D Excavator Repair 040909

PN=210

Removal and Installation 2. Measure cylinder blocks inner diameter both in thrust (2-2) and radial (3-3) directions in specified position (1).

3. Measure from top surface of cylinder about 20 mm (0.79 in).

2 3

1—Measuring Position 2—Thrust Measurement 3—Radial Measurement 4—Cylinder Gauge

TX1037782

–UN–29FEB08

Specification Cylinder Block Bore—Diameter................................. 95.421—95.450 mm 3.7567—3.7579 in.

Cylinder Gauge

RH60123,00001CA –19–23APR08–2/13

4. Measure outside diameter of piston (6) in right angle to piston pin in specified position. Piston Diameter (supply parts) Standard

95.330—95.339 mm 3.75314—3.75350 in.

95.340—95.349 mm 3.75354—3.75389 in.

95.350—95.359 mm 3.75393—3.75428 in.

–UN–06MAR08

Grade

TX1037899

5. If gap between cylinder block diameter and piston exceeds standard value, replace piston or cylinder block. Specification Gap Between Cylinder Wall and Piston—Clearance ......................................................... 0.082—0.100 mm 0.0032—0.0039 in.

Piston 5—Micrometer 6—Piston

Continued on next page

TM10743 (09APR09)

04-0400-99

RH60123,00001CA –19–23APR08–3/13

135D Excavator Repair 040909

PN=211

04 0400 99

Removal and Installation 6. Measure gap of piston ring. Insert piston ring (8) into cylinder block (7). Use a piston (6) to push ring into cylinder block.

TX1037901

–UN–06MAR08

6—Piston 7—Cylinder Block 8—Piston Ring

04 0400 ,100

Piston Ring

RH60123,00001CA –19–23APR08–4/13

7. Measure gap of piston ring (8) at specified depth (A). Specification Ring Gap Measurement at Position A—Depth (approximate) .................................................... 10 mm 0.4 in.

A—Ring Gap Measurement Position 8—Piston Ring 9—Thickness Gauge

–UN–06MAR08

9 A

TX1037902

Position A

Continued on next page

TM10743 (09APR09)

04-0400-100

RH60123,00001CA –19–23APR08–5/13

135D Excavator Repair 040909

PN=212

Removal and Installation 8. Measure gap of piston ring (8) at specified depth (B). Specification Ring Gap Measurement at Position B—Depth ......................................................................... 120 mm 4.7 in.

9. If measurement exceeds limit, replace piston ring. B

Limit

0.3—0.5 mm 0.0018—0.0197 in.

1.5 mm 0.059 in.

Second Ring

0.3—0.5 mm 0.0118—0.0197 in.

1.5 mm 0.059 in.

Oil Ring

0.25—0.45 mm 0.0098—0.0177 in.

1.5 mm 0.059 in.

TX1037903

Standard Top Ring

–UN–06MAR08

Piston Ring Gap

Position B

B—Ring Gap Measurement Position

RH60123,00001CA –19–23APR08–6/13

10. Measure clearance between piston ring groove and piston ring.

Standard

Limit

Top Ring

Measurement is Impossible

Second Ring

0.05—0.09 mm 0.0020—0.0035 in.

0.15 mm 0.0059 in.

Oil Ring

0.03—0.07 mm 0.0012—0.0028 in.

0.15 mm 0.0059 in.

–UN–06MAR08

Piston Ring Groove and Piston Ring Clearance Piston Ring

TX1037904

11. If measurement exceeds limit, replace piston ring and piston. 12. Inspect piston pin for cracks, scratches and other damage. Replace piston pin if necessary.

Piston Groove Gap

6—Piston 8—Piston Ring 9—Thickness Gauge

Continued on next page

TM10743 (09APR09)

04-0400-101

RH60123,00001CA –19–23APR08–7/13

135D Excavator Repair 040909

PN=213

04 0400 ,101

Removal and Installation 13. Measure outer diameter of piston pin. If measured value exceeds limit, replace piston pin. Specification Piston Pin—Outer Diameter (standard) .................................................................. 33.995—34.000 mm 1.33838—1.33858 in. Outside Diameter (limit)............................................................ 33.970 mm 1.33740 in.

TX1037905

–UN–06MAR08

5—Micrometer 10—Piston Pin

04 0400 ,102

Piston Pin

RH60123,00001CA –19–23APR08–8/13

14. Install piston pin into piston. If piston pin is loose or rattles in piston under normal temperatures, replace piston or piston pin.

TX1037906

–UN–06MAR08

6—Piston 10—Piston Pin

Piston Pin

Continued on next page

TM10743 (09APR09)

04-0400-102

RH60123,00001CA –19–23APR08–9/13

135D Excavator Repair 040909

PN=214

Removal and Installation 15. Measure bushing (12) in small end of connecting rod (11). 16. If clearance between bushing inner diameter and pin diameter exceeds limit, replace connecting rod assembly and pin.

–UN–06MAR08

Specification Piston Pin and Connecting Rod— Clearance (standard) ..................................................... 0.008—0.020 mm 0.0003—0.0008 in. Clearance (limit) ........................................................................... 0.05 mm 0.0020 in.

TX1037908

17. Measure clearance between piston and piston pin. 18. Apply clean engine oil on piston pin. Push piston pin into piston and check that it rotates smoothly and with out rattling. 19. If there is rattling, measure clearance. If clearance exceeds limit, replace piston and piston. Specification Piston and Piston Pin—Clearance (standard) ...................................................................... 0.004—0.017 mm 0.0002—0.0007 in. Clearance (limit) ........................................................................... 0.04 mm 0.0016 in.

Connecting Rod Bushing 5—Micrometer 10—Piston Pin 11—Connecting Rod 12—Bushing 13—Cylinder Gauge

Continued on next page

TM10743 (09APR09)

04-0400-103

RH60123,00001CA –19–23APR08–10/13

135D Excavator Repair 040909

PN=215

04 0400 ,103

Removal and Installation 20. Measure connecting rod alignment using a connecting rod aligner. 21. Measure torsion and parallelism of bearing hole and bushing hole. 22. If measured value exceeds limit, replace connecting rod.

0.20 mm 0.008 in.

Limit

0.05 mm or less 0.003 in. or less

0.015 mm 0.006 in.

23. Measure oil clearance between connecting rod bearing and crank pin. 24. Remove connecting rod cap. Check bearing for damage. Replace as necessary.

TX1037909

Limit

0.08 mm or less 0.003 in. or less

Connecting Rod Aligner 9—Thickness Gauge 11—Connecting Rod 14—Connecting Rod Aligner

RH60123,00001CA –19–23APR08–11/13

IMPORTANT: Do not rotate crankshaft. Plastigage will be damaged and measurement can not be taken. 25. Place Plastigage on crankshaft pin.

26. Install bearing cap. Tighten to specification.

–UN–06MAR08

Specification Connecting Rod Bearing Cap Screw—Torque 1st. Step ............................................................ 29.4 N•m 22 lb-ft Torque 2nd. Step .................................................................................. 45°

15—Crankshaft 16—Plastigage

TX1037910

04 0400 ,104

Standard Torsion

–UN–06MAR08

Connecting Rod Alignment (per length of 100 mm (3.94 in.)

Plastigage

Plastigage is a trademark of Perfect Circle Corporation

TM10743 (09APR09)

Continued on next page

04-0400-104

RH60123,00001CA –19–23APR08–12/13

135D Excavator Repair 040909

PN=216

Removal and Installation 27. Remove bearing cap and measure largest width of Plastigage to calculate oil clearance. 15 17

28. If clearance exceeds limit, replace bearing or crankshaft.

–UN–06MAR08

Specification Crankshaft Pin Bearing— Clearance (standard) ..................................................... 0.029—0.083 mm 0.0011—0.0026 in. Clearance (limit) ........................................................................... 0.10 mm 0.0039 in.

TX1037911

29. Remove Plastigage from bearing and crankshaft. 15—Crankshaft 16—Plastigage 17—Plastigage Measuring Tool



Plastigage

Plastigage is a trademark of Perfect Circle Corporation

RH60123,00001CA –19–23APR08–13/13

Oil Pump Remove and Install 1. Drain engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.) 2. Disconnect upper radiator hose. 3. Remove fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) 4. Remove belt. See Water Pump Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-105

RH60123,00001CB –19–23APR08–1/7

135D Excavator Repair 040909

PN=217

04 0400 ,105

Removal and Installation 5. Remove cover (1). 2

1—Cover 2—Cap Screw (3 used)

–UN–03MAR08

TX1037762

2 04 0400 ,106

Cover

RH60123,00001CB –19–23APR08–2/7

6. Remove fan shroud bracket (3) and fan shroud mount (5).

3—Fan Shroud Bracket 4—Nut 5—Fan Shroud Mount 6—Cap Screw (2 used) 7—Cap Screw (2 used)

TX1037763

–UN–03MAR08

3 Fan Shroud Brackets

Continued on next page

TM10743 (09APR09)

04-0400-106

RH60123,00001CB –19–23APR08–3/7

135D Excavator Repair 040909

PN=218

Removal and Installation 7. Remove cover. 8. Remove starter. See Starter Remove and Install. (Group 0400.)

TX1037764

–UN–03MAR08

8—Cover 9—Cap Screw (3 used)

9 Cover

RH60123,00001CB –19–23APR08–4/7

9. Remove front crankshaft pulley (12). 10. Remove timing gear case cover. See Timing Gear Case Remove and Install. (Group 0400.) 12 10—Cap Screw 11—Washer 12—Crankshaft Pulley 13—Key

TX1037765

–UN–03MAR08

Continued on next page

TM10743 (09APR09)

04-0400-107

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135D Excavator Repair 040909

PN=219

04 0400 ,107

Removal and Installation 11. Remove oil pump (14).

12. Inspect and replace as necessary. Oil Pump Disassemble and Assemble. (Group 0400.)

13. Apply clean engine oil to pump case. 15

Specification Engine Oil Pump—Torque ............................................................. 25 N•m 18 lb-ft 04 0400 ,108

15. Install timing gear case cover. See Timing Gear Case Remove and Install. (Group 0400.)

TX1037766

15 14. Install oil pump. Tighten cap screws to specification.

–UN–03MAR08

IMPORTANT: Make sure that oil pump turns after it is installed. If oil pump doesn’t turn, internal engine damage can occur.

14—Oil Pump 15—Cap Screw (7 used)

IMPORTANT: Replace crankshaft pulley cap screw and washer. 16. Install crankshaft pulley. Specification Crankshaft Pulley Cap Screw— Torque .......................................................................................... 294 N•m 217 lb-ft

17. Install starter. See Starter Remove and Install. (Group 0400.) 18. Install cover. Specification Vacuum Pump Hole Cover Cap Screws—Torque ............................................................................. 25 N•m 18 lb-ft

19. Install fan shroud brackets. 20. Install cover. Specification Power Steering Hole Cover Cap Screws—Torque ............................................................................. 25 N•m 18 lb-ft

21. Install belt. See Water Pump Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-108

RH60123,00001CB –19–23APR08–6/7

135D Excavator Repair 040909

PN=220

Removal and Installation 22. Install fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) 23. Connect upper radiator hose. 24. Fill engine oil. See Change Engine Oil and Replace Filter. (Operator’s Manual.)

RH60123,00001CB –19–23APR08–7/7

Oil Pump Disassemble and Assemble 04 0400 ,109

1. Remove spring pin (1). 2. Remove spring seat (2). 2 3. Remove spring (3).

–UN–03APR08

4. Remove valve (4). 5. Inspect and replace as necessary. Oil Pump Inspection. (Group 0400.)

TX1039754

6. Install valve. 7. Install spring. Oil Pump

8. Install spring seat. 9. Install spring pin.

1—Spring Pin 2—Spring Seat 3—Spring 4—Valve

RH60123,00001DA –19–11APR08–1/1

TM10743 (09APR09)

04-0400-109

135D Excavator Repair 040909

PN=221

Removal and Installation

Oil Pump Inspection 1. Measure outside diameters of drive gear shaft (2) and driven gear shaft (1).

0400 ,110

–UN–03APR08

2. Measure inside diameters of bushing (3) of oil pump body and pump case hole (4). If clearance between driven gear and bushing, or between drive gear shaft/driven gear shaft and pump case hole exceeds 04 limit, replace oil pump assembly.

TX1039753

Specification Drive Gear Shaft and Driven Gear Shaft—Outside Diameter (standard) .................................................................. 15.989—16.000 mm 0.62949—0.62992 in. Outside Diameter (limit)............................................................ 15.900 mm 0.62598 in.

Oil Pump Specification Bushing of Oil Pump Body and Pump Case Hole—Clearance (standard) ............................................................................. 0.04—0.7 mm 0.0016—0.0028 in. Clearance (limit) ........................................................................... 0.20 mm 0.0079 in.

3. Measure width of driven gear / drive gear.

A—Driven Gear Shaft Measurement B—Drive Gear Shaft Measurement C—Driven Gear Hole Measurement D—Drive Gear Hole Measurement 1—Driven Gear Shaft 2—Drive Gear Shaft 3—Bushing 4—Pump Case Hole

Specification Driven Gear / Drive Gear—Width ................................................ 14.5 mm 0.5709 in.

Continued on next page

TM10743 (09APR09)

04-0400-110

RH60123,00001CD –19–11APR08–1/2

135D Excavator Repair 040909

PN=222

Removal and Installation 4. Measure depth (E) between gear case housing surface and oil pump housing gear case side.

Specification Gear Case Housing Surface and Oil Pump Housing Gear Case Side—Depth .............................................................. 14.500—14.527 mm 0.5709—0.5719 in.

–UN–03APR08

5. Measure oil pump gear side surface and oil pump housing gear side surface. 6. Determine clearance and replace parts if necessary.

TX1039752

Specification Oil Pump Gear Side Surface and Oil Pump Housing Gear Side Surface—Clearance (Standard) .................................... 0.063—0.027 mm 0.0025—0.0011 in. Clearance (limit) ........................................................................... 0.20 mm 0.0079 in.

Depth Measurement

E—Depth Measurement

RH60123,00001CD –19–11APR08–2/2

Engine Oil Cooler Remove and Install 1. Remove engine. See Engine Remove and Install. (Group 0400.) 2. Remove exhaust manifold. See Exhaust Manifold Remove and Install. (Group 0400.) 3. Remove alternator. See Alternator Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-111

RH60123,00001CE –19–23APR08–1/6

135D Excavator Repair 040909

PN=223

04 0400 ,111

Removal and Installation 4. Remove bypass pipe. 1—Bypass Pipe 2—Gasket 3—O-ring 4—Cap Screw (2 used)

–UN–06MAR08

3 2

TX1037913

4 1 04 0400 ,112

Bypass Pipe

RH60123,00001CE –19–23APR08–2/6

5. Remove intake pipe (5). 6. Support engine. Remove right hand engine mount (6).

TX1038014

–UN–06MAR08

5—Intake Pipe 6—Right Hand Engine Mount

Intake Pipe

Continued on next page

TM10743 (09APR09)

04-0400-112

RH60123,00001CE –19–23APR08–3/6

135D Excavator Repair 040909

PN=224

Removal and Installation 7. Remove engine oil cooler. 8. Inspect and replace as necessary. See Engine Oil Cooler Disassemble and Assemble. (Group 0400.) 8

8 7—Engine Oil Cooler 8—Cap Screw (16 used)

TX1038013

–UN–06MAR08

Engine Oil Cooler

RH60123,00001CE –19–23APR08–4/6

9. Apply PM37465 Ultra Blue RTV Silicone Form-In-Place Gasket to flange surface groove (9). 10. Install O-rings to engine oil cooler passages.

TX1038012

–UN–06MAR08

9—PM37465 Blue Silicone 10—Flange Surface Groove (2 used)

Engine Oil Cooler

Continued on next page

TM10743 (09APR09)

04-0400-113

RH60123,00001CE –19–23APR08–5/6

135D Excavator Repair 040909

PN=225

04 0400 ,113

Removal and Installation 11. Install engine oil cooler. Tighten cap screws to specification. Specification Engine Oil Cooler—Torque ............................................................ 25 N•m 18 lb-ft

11 17

12. Install right hand engine mount. 20 16 14

14. Install bypass pipe.

15 10

04 0400 ,114

TX1038011

15. Install alternator. See Alternator Remove and Install. (Group 0400.)

–UN–06MAR08

13. Install intake pipe.

16. Install exhaust manifold. See Exhaust Manifold Remove and Install. (Group 0400.)

Torque Sequence

17. Install engine. See Engine Remove and Install. (Group 0400.)

RH60123,00001CE –19–23APR08–6/6

Engine Oil Cooler Disassemble and Assemble 1. Remove engine oil cooler. See Engine Oil Cooler Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-114

RH60123,00001CF –19–11APR08–1/3

135D Excavator Repair 040909

PN=226

Removal and Installation 2. Remove nuts (1).

1 1

TX1038721

–UN–18MAR08

1—Nut (4 used) 2—Engine Oil Cooler

Engine Oil Cooler

RH60123,00001CF –19–11APR08–2/3

3. Remove element (3). 4. Remove gasket (4). 5. Inspect and replace as necessary.

6. Install gasket.

8. Install nuts. 4

Specification Element—Torque............................................................................ 25 N•m 18 lb-ft

TX1038722

–UN–18MAR08

7. Install element.

3—Element 4—Gasket

Element

RH60123,00001CF –19–11APR08–3/3

Thermostat Housing Remove and Install 1. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) Continued on next page

TM10743 (09APR09)

04-0400-115

RH60123,00001D0 –19–11APR08–1/4

135D Excavator Repair 040909

PN=227

04 0400 ,115

Removal and Installation 2. Disconnect charged air hose (6).

–UN–05MAR08

3. Disconnect charged air pipe (3) from bracket (1) and set aside. 4. Remove bracket (1).

TX1038006A

1—Bracket 2—Cap Screw (2 used) 3—Charged Air Pipe 4—Hose Clamp 5—Cap Screw (2 used) 6—Charged Air Hose

Charged Air Pipe

04 0400 ,116 RH60123,00001D0 –19–11APR08–2/4

5. Disconnect upper radiator hose (7). 6. Remove cap screw (9) securing wire harness clamp. –UN–05MAR08

7. Remove wire harness from clamp (13). 8. Disconnect electrical connector (12).

TX1038007A

9. Remove thermostat housing (11). 7—Upper Radiator Hose 8—Hose Clamp 9—Cap Screw 10—Cap Screw (2 used) 11—Thermostat Housing 12—Electrical Connector 13—Wire Harness Clamp

Thermostat Housing

Continued on next page

TM10743 (09APR09)

04-0400-116

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135D Excavator Repair 040909

PN=228

Removal and Installation 10. Remove thermostat (14). 11. Inspect and replace as necessary. See Thermostat Inspection. (Group 0400.)

12. Install thermostat. 13. Install thermostat housing.

15. Install wire harness in clamp.

TX1038009

16. Install cap screw securing wire harness clamp.

–UN–06MAR08

14. Connect electrical connector.

17. Connect upper radiator hose. Thermostat

18. Install bracket.

11—Thermostat Housing 14—Thermostat 15—Check Valve

19. Connect charged air pipe to bracket. 20. Connect charged air hose. 21. Fill cooling system.See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.)

RH60123,00001D0 –19–11APR08–4/4

TM10743 (09APR09)

04-0400-117

135D Excavator Repair 040909

PN=229

04 0400 ,117

Removal and Installation

Thermostat Inspection 1. Place thermostat in water and increase temperature while stirring it.

2. Measure temperature when valve is just open and when its fully open. 2

TX1038010

04 0400 ,118

–UN–06MAR08

Specification Thermostat—Temperature (valve opening) ............................................................................................. 85 °C 185 °F Temperature (full open) ................................................................... 100 °C 212 °F Valve Lift Amount at Full—Open .................................................... 10 mm 0.39 in.

1—Thermometer 2—Thermostat

Thermostat

RH60123,00001D2 –19–11APR08–1/1

Fuel Injection Pump Remove and Install 1. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) 2. Disconnect upper radiator hose. 3. Remove fan, fan guard, and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) 4. Remove high pressure common rail. See High Pressure Common Rail Remove and Install. (Group 0400.) 5. Remove valve cover. See Valve Cover Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-118

RH60123,00001D3 –19–21APR08–1/21

135D Excavator Repair 040909

PN=230

Removal and Installation 6. Disconnect electrical connector (43).

TX1039317A

–UN–01APR08

43—Electrical Connector

Electrical Connector

04 0400 ,119 RH60123,00001D3 –19–21APR08–2/21

7. Disconnect electrical connectors (44 and 45).

TX1039318A

–UN–01APR08

44—Electrical Connector 45—Electrical Connector

Electrical Connectors

Continued on next page

TM10743 (09APR09)

04-0400-119

RH60123,00001D3 –19–21APR08–3/21

135D Excavator Repair 040909

PN=231

Removal and Installation 8. Remove upper fan shroud bracket (4). 3 2—Upper Timing Chain Cover 3—Bracket 4—Upper Fan Shroud Bracket 5—Nut (4 used) 6—Cap Screw (2 used) 7—Cap Screw 8—Cap Screw

2 5 6

5 4 04 0400 ,120

TX1039299

–UN–27MAR08

Upper Timing Chain Cover

RH60123,00001D3 –19–21APR08–4/21

9. Remove lower timing chain cover (9). 9—Lower Timing Chain Cover 10—Nut (2 used) 11—Cap Screw (3 used)

11 10

TX1039300

–UN–27MAR08

Lower Timing Chain Cover

Continued on next page

TM10743 (09APR09)

04-0400-120

RH60123,00001D3 –19–21APR08–5/21

135D Excavator Repair 040909

PN=232

Removal and Installation 10. Rotate crankshaft to No. 1 position on top dead center. 11. Remove starter. See Starter Remove and Install. (Group 0400.) 1—Top Dead Center 12—Camshaft Alignment Mark (2 used) 13—Bearing Cap Alignment Mark (2 used)

TX1037439

–UN–28FEB08

Top Dead Center

12 13

TX1039301

–UN–27MAR08

Timing Marks

Continued on next page

TM10743 (09APR09)

04-0400-121

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135D Excavator Repair 040909

PN=233

04 0400 ,121

Removal and Installation 12. Loosen nut (14).

–UN–27MAR08

14—Nut

TX1039302

04 0400 ,122

Nut

RH60123,00001D3 –19–21APR08–7/21

13. Remove timing chain tensioner (16).

–UN–27MAR08

15—Nut (2 used) 16—Timing Chain Tensioner 17—Gasket

TX1039303

17 16 15 Timing Chain Tensioner

Continued on next page

TM10743 (09APR09)

04-0400-122

RH60123,00001D3 –19–21APR08–8/21

135D Excavator Repair 040909

PN=234

Removal and Installation 14. Remove timing chain tension lever pivot (18). 15. Remove nut (20) and sprocket (19). 19 18 8

TX1039304

–UN–27MAR08

18—Timing Chain Tension Lever Pivot 19—Sprocket 20—Nut

Timing Chain Tension Lever Pivot

RH60123,00001D3 –19–21APR08–9/21

16. Pull timing chain (21) upward. 21

TX1039305

–UN–27MAR08

21—Timing Chain

Timing Chain

Continued on next page

TM10743 (09APR09)

04-0400-123

RH60123,00001D3 –19–21APR08–10/21

135D Excavator Repair 040909

PN=235

04 0400 ,123

Removal and Installation 17. Align timing marks on idle gear A (22) and fuel injection pump gear (23) 22—Idle Gear A 23—Fuel Injection Pump Gear

–UN–27MAR08

TX1039306

04 0400 ,124

Idle Gear A

RH60123,00001D3 –19–21APR08–11/21

18. Use a gear puller (24) to remove fuel injection pump gear (23).

TX1039307

–UN–27MAR08

24 Fuel Injection Supply Pump

Continued on next page

TM10743 (09APR09)

04-0400-124

RH60123,00001D3 –19–21APR08–12/21

135D Excavator Repair 040909

PN=236

Removal and Installation 19. Remove fuel injection pump (25). 26 25—Fuel Injection Pump 26—Cap Screw (3 used) 27—Nut (2 used) 29—Fuel Injection Pump Bracket

26 27

TX1039308

–UN–27MAR08

26 Fuel Injection Pump

RH60123,00001D3 –19–21APR08–13/21

20. Remove O-ring (28). 21. Inspect and replace as necessary.

22. Install O-ring. 23. Install fuel injection pump. Tighten to specification.

25—Fuel Injection Pump 28—O-Ring

TX1039309

–UN–27MAR08

Specification Fuel Injection Pump Cap Screws and Nuts—Torque .......................................................................... 25 N•m 18 lb-ft

O-Ring

Continued on next page

TM10743 (09APR09)

04-0400-125

RH60123,00001D3 –19–21APR08–14/21

135D Excavator Repair 040909

PN=237

04 0400 ,125

Removal and Installation 24. Turn fuel injection pump shaft (29) to position shown. 29—Fuel Injection Pump Shaft 30—Key

TX1039310

–UN–27MAR08

04 0400 ,126

Fuel Injection Pump Shaft

RH60123,00001D3 –19–21APR08–15/21

IMPORTANT: Align timing marks when installing fuel injection pump gear. Internal damage will occur if timing marks are not properly aligned. 25. Align timing marks and install fuel injection pump gear.

27. Install fuel injection pump sprocket.

22—Idle Gear A 23—Fuel Injection Pump Gear 31—Idle Gear A Timing Marks 32—Fuel Injection Pump Gear Timing Marks

Timing Marks

Continued on next page

TM10743 (09APR09)

TX1039311

NOTE: Leave fuel injection pump sprocket loose at this point. Timing of gears needs to be adjusted.

–UN–27MAR08

26. Install timing chain on each sprocket.

04-0400-126

RH60123,00001D3 –19–21APR08–16/21

135D Excavator Repair 040909

PN=238

Removal and Installation 28. Align timing marks on camshaft sprocket (34) with dark plate (33) on timing chain.

29. Align timing marks on fuel injection pump sprocket (23) with yellow plate (36).

NOTE: Leave torque timing chain tension lever pivot loose at this point.

23—Fuel Injection Pump Sprocket 33—Dark Plate 34—Camshaft Sprocket 35—Camshaft Sprocket Timing Mark 36—Yellow Plate 37—Timing Chain

TX1039312

–UN–27MAR08

30. Install timing chain tension lever pivot.

37 36

Timing Chain

RH60123,00001D3 –19–21APR08–17/21

31. Push down cam (41) on timing chain tensioner (16) and push in plunger (40).

39 40

32. Secure plunger by moving hook (38) onto pin (39). 33. Install timing chain tensioner. Tighten to specification.

Specification Timing Chain Tensioner Cap Screws—Torque ............................................................................. 10 N•m 87 lb-in

38 –UN–27MAR08

TX1039313

16—Timing Chain Tensioner 38—Hook 39—Pin 40—Plunger 41—Cam Timing Chain Tensioner

Continued on next page

TM10743 (09APR09)

04-0400-127

RH60123,00001D3 –19–21APR08–18/21

135D Excavator Repair 040909

PN=239

04 0400 ,127

Removal and Installation 34. Push timing chain to release timing chain plunger. 35. Tighten fuel injection pump sprocket to specification. Specification Fuel Injection Pump Sprocket Nut—Torque ................................................................................. 130 N•m 96 lb-ft

36. Tighten timing chain tension lever pivot bolt to specification. Specification Timing Chain Tension Lever Pivot Bolt—Torque................................................................................... 27 N•m 20 lb-ft

TX1039314

37. Rotate crankshaft 2 revolutions. Timing Chain Tensioner

38. Check alignment of timing marks. 39. Check alignment marks on camshafts are aligned. 40. Install starter. See Starter Remove and Install. (Group 0400.) 41. Install valve cover. See Valve Cover Remove and Install. (Group 0400.)

RH60123,00001D3 –19–21APR08–19/21

42. Apply PM37465 Ultra Blue RTV Silicon Form-In-Place Gasket (42) to upper timing chain cover (2). 42

43. Install upper timing chain cover. Tighten cap screws to specification.

–UN–27MAR08

Specification Upper Timing Chain Cover Cap Screws—Torque ............................................................................. 25 N•m 18 lb-ft

44. Install upper fan shroud bracket. 2—Upper Timing Chain Cover 42—PM37465 Ultra Blue RTV Silicon Form-In-Place Gasket

TX1039315

04 0400 ,128

–UN–27MAR08

Upper Timing Chain Cover

Continued on next page

TM10743 (09APR09)

04-0400-128

RH60123,00001D3 –19–21APR08–20/21

135D Excavator Repair 040909

PN=240

Removal and Installation 45. Apply PM37465 Ultra Blue RTV Silicon Form-In-Place Gasket (42) to lower timing chain cover (9).

46. Install lower timing chain cover. Specification Lower Timing Chain Cover Cap Screws—Torque ............................................................................. 10 N•m 88 lb-in

–UN–27MAR08

47. Connect electrical connector. 48. Install high pressure common rail. See High Pressure Common Rail Remove and Install. (Group 0400.)

50. Install fan, fan guard, and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)

TX1039316

49. Connect electrical connectors.

Lower Timing Chain Cover 9—Lower Timing Cover 42—Lower Timing Chain Cover

51. Connect upper radiator hose. 52. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.)

RH60123,00001D3 –19–21APR08–21/21

High Pressure Common Rail Remove and Install 1. Remove starter. See Starter Remove and Install. (Group 0400.)

Continued on next page

TM10743 (09APR09)

04-0400-129

RH60123,00001D9 –19–14APR08–1/2

135D Excavator Repair 040909

PN=241

04 0400 ,129

Removal and Installation IMPORTANT: Replace high pressure fuel lines after removal. Fuel leaks can occur if not replaced. –UN–02APR08

2. Remove and discard fuel line (3) and fuel hose (9). Cap and plug openings.

TX1039323A

3. Remove and discard fuel line (4). Cap and plug openings. 4. Remove and discard fuel injector lines (5). Cap and plug openings. 5. Disconnect electrical connector (6). 04 0400 ,130

6. Remove cap screws (1) securing wire harness (10). 7. Remove high pressure common rail (8). 8. Inspect and replace as necessary. 9. Install high pressure common rail.

1—Cap Screw (2 used) 2—Cap Screw (4 used) 3—Fuel Line 4—Fuel Line 5—Fuel Injector Nozzle Line (4 used) 6—Electrical Connector 7—Bracket 8—High Pressure Common Rail 9—Fuel Hose 10—Wire Harness

Specification High Pressure Common Rail Cap Screws—Torque ............................................................................. 25 N•m 18 lb-ft

10. Install cap screws securing wire harness. 11. Connect electrical connector. IMPORTANT: Replace high pressure fuel lines after removal. Fuel leaks can occur if not replaced. 12. Install new fuel injector lines. 13. Install new fuel line. 14. Install new fuel line and connect fuel hose. 15. Install starter. See Starter Remove and Install. (Group 0400.)

RH60123,00001D9 –19–14APR08–2/2

TM10743 (09APR09)

04-0400-130

135D Excavator Repair 040909

PN=242

Removal and Installation

Fuel Injector Remove and Install 1. Remove valve cover. See Valve Cover Remove and Install. (Group 0400.) RH60123,00001D4 –19–23APR08–1/4

2. Remove brackets (2). IMPORTANT: Replace high pressure fuel lines after removal. Fuel leaks can occur if not replaced.

1 2

2 3. Remove and discard fuel injection lines (1).

TX1039320

1—Fuel Injection Line (4 used) 2—Bracket (4 used) 3—Nut (2 used) 4—Stud (2 used)

–UN–28MAR08

4. Record fuel injectors cylinder position before removal.

Fuel Injection Lines

RH60123,00001D4 –19–23APR08–2/4

5. Remove fuel injectors (1). 6. Inspect and replace as necessary. 5 6

TX1039321

–UN–28MAR08

5—Fuel Injector (4 used) 6—Cap Screw (4 used) 7—Bracket (4 used)

Fuel Injectors

Continued on next page

TM10743 (09APR09)

04-0400-131

RH60123,00001D4 –19–23APR08–3/4

135D Excavator Repair 040909

PN=243

04 0400 ,131

Removal and Installation 7. Record ID code label information of all replaced fuel injectors. 8. If replacing fuel injector nozzles, remove fuel injector nozzle ID code label on cylinder head cover. If replacing one or more injectors, black out the replaced cylinder of fuel injector nozzle ID code on the fuel injector nozzle ID code label with a marking pen or equivalent.

5F 16 1A 25 1A 24 17 17 00 14 00 52

–UN–28MAR08

NOTE: Install each fuel injector nozzle in its original position.

04 0400 ,132

TX1039322

9. Install fuel injectors. Specification Fuel Injector Cap Screws— Torque ............................................................................................ 26 N•m 20 lb-ft

IMPORTANT: Replace high pressure fuel lines after removal. Fuel leaks can occur if not replaced.

ID Label 5—Fuel Injector 6—ID Code Label

10. Install new fuel injection lines. 11. Install brackets. Specification Bracket Nuts—Torque ...................................................................... 7 N•m 69 lb-in

12. Install valve cover. See Valve Cover Remove and Install. (Group 0400.) 13. Program electronic control module (ECU). See Engine Control Module (ECM) Special Function Using Dr. ZX. (Group 9015-20.)

RH60123,00001D4 –19–23APR08–4/4

TM10743 (09APR09)

04-0400-132

135D Excavator Repair 040909

PN=244

Removal and Installation

Starter Remove and Install

–UN–05MAR08

1. Disconnect batteries. See Handling, Checking, and Servicing Batteries Carefully. (Operator’s Manual.) 2. Remove counterweight. See Counterweight Remove and Install. (Group 1749.)

TX1037793A

3. Disconnect electrical connectors (1 and 3). 4. Disconnect battery connector (2). Starter

5. Remove cap screw (4) securing ground (5).

1—Electrical Connector 2—Battery Connector 3—Electrical Connector 4—Cap Screw (2 used) 5—Ground 6—Starter

6. Remove starter (6). 7. Inspect and replace as necessary. 8. Install starter.

04 0400 ,133

9. Connect ground. 10. Connect battery connector. 11. Connect electrical connectors. 12. Install counterweight. See Counterweight Remove and Install. (Group 1749.) 13. Connect batteries. See Handling, Checking, and Servicing Batteries Carefully. (Operator’s Manual.)

RH60123,00001D6 –19–23APR08–1/1

Alternator Remove and Install 1. Disconnect batteries. See Handling, Checking, and Servicing Batteries Carefully. (Operator’s Manual.) Continued on next page

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Removal and Installation 2. Disconnect electrical connectors (6 and 7). 3. Loosen cap screw (4) and adjuster nut (3). –UN–01APR08

4. Loosen adjuster (8) to loosen belt (2). 5. Remove belt (2) from alternator (1).

TX1039319A

6. Remove cap screw (3 and 4) securing alternator (1). 7. Remove alternator (1). Alternator

8. Inspect and replace necessary. 9. Install alternator. 04 0400 ,134

10. Install cap screw and nut securing alternator. Leave cap screw and nut loose. 11. Install belt on alternator.

1—Alternator 2—Belt 3—Adjuster Nut 4—Cap Screw 5—Cap Screw 6—Electrical Connector 7—Electrical Connector 8—Adjuster

12. Tighten adjuster to adjust belt tension. See Serpentine Belt Check and Adjust. (Group 9010-25.) 13. Tighten adjuster nut to specification. Specification Alternator Adjuster Nut—Torque .................................................... 25 N•m 18 lb-ft

14. Tighten cap screw to specification. Specification Alternator Cap Screw—Torque ...................................................... 51 N•m 38 lb-ft

15. Connect electrical connectors. 16. Connect batteries. See Handling, Checking, and Servicing Batteries Carefully. (Operator’s Manual.)

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Section 05

Engine Auxiliary Systems Contents Page

Group 0510—Cooling System Radiator Remove and Install . . . . . . . . . . . . .05-0510-1 Hydraulic Oil Cooler Remove and Install . . . .05-0510-3 Intercooler Remove and Install . . . . . . . . . . .05-0510-5 Fuel Cooler Remove and Install . . . . . . . . . .05-0510-7 Fan, Fan Guard, and Fan Shroud Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-7 Group 0520—Intake System Air Cleaner Remove and Install. . . . . . . . . . .05-0520-1 Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-1 Primary Fuel Filter (Water Separator) Remove and Install . . . . . . . . . . . . . . . . . .05-0560-4 Final Fuel Filter Remove and Install . . . . . . .05-0560-4

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Group 0510

Cooling System Radiator Remove and Install CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) 2. Remove covers above and below cooling package. 3. Disconnect upper and lower radiator hoses.

05 0510 1

AC12469,000057F –19–14APR08–1/3

4. Remove shrouds (1 and 4).

TX1040348A

–UN–18APR08

1—Cooling Package Shroud 2—Cap Screw (4 used) 3—Cap Screw (4 used) 4—Radiator and Intercooler Shroud

Radiator and Intercooler Shrouds

Continued on next page

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Cooling System 5. Remove debris screen (5). 6. Disconnect radiator overflow hose (10). 7. Remove insulating foam (9). 8. Remove radiator cap screws (6). Record position of rubber isolators and washers for installation. IMPORTANT: Remove radiator carefully to prevent damage to drain valve (7). –UN–18APR08

9. Remove radiator (11). 10. Inspect and replace radiator as necessary.

Radiator and Intercooler

11. Position radiator in machine. 12. Install radiator cap screws, washers, and isolators. 13. Position insulating foam on top of radiator.

–UN–18APR08

14. Connect radiator overflow hose. 15. Install debris screen. 16. Install shrouds over cooling package.

TX1040430A

05 0510 2

TX1040429A

IMPORTANT: Insulating foam on sides of radiator must be intact or cooling system performance will be reduced.

17. Connect upper and lower radiator hoses. 18. Install covers above and below cooling package. 19. Fill and deaerate cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.)

Debris Screen 5—Debris Screen 6—Radiator Cap Screw (4 used) 7—Drain Valve 8—Intercooler Cap Screw (2 used) 9—Insulating Foam 10—Radiator Overflow Hose 11—Radiator 12—Intercooler

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Cooling System

Hydraulic Oil Cooler Remove and Install CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) 2. Drain hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.) 3. Remove radiator. See Radiator Remove and Install. (Group 0510.) 05 0510 3

AC12469,0000581 –19–14APR08–1/3

4. Remove cover (3).

TX1040450A

–UN–18APR08

1—Cap Screw (4 used) 2—Hydraulic Oil Cooler 3—Cover

Hydraulic Oil Cooler

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Cooling System 5. Remove clamps and separate pipes at upper connection (5) and lower connection (6). Close all openings with caps and plugs. 6. Remove cap screws (1). IMPORTANT: Remove hydraulic oil cooler carefully to prevent damage to insulating foam. 7. Remove hydraulic oil cooler.

–UN–18APR08

8. Inspect and replace hydraulic oil cooler as necessary. 9. Inspect restriction valve. See Restriction Valve Remove and Install. (Group 3360.)

Hydraulic Oil Cooler Upper Connection

10. Position hydraulic oil cooler in machine. 11. Install cap screws. 12. Align oil cooler connections and install clamps. 13. Install cover. 14. Install radiator. See Radiator Remove and Install. (Group 0510.) 15. Fill hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

–UN–18APR08

16. Fill and deaerate cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.) 17. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 18. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

TX1040492A

05 0510 4

TX1040493A

IMPORTANT: Insulating foam on sides of hydraulic oil cooler must be intact or cooling system performance will be reduced.

Hydraulic Oil Cooler Lower Connection 1—Cap Screw (4 used) 2—Hydraulic Oil Cooler 3—Cover 4—Insulating Foam 5—Upper Connection 6—Lower Connection.

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Cooling System

Intercooler Remove and Install CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) 2. Remove radiator. See Radiator Remove and Install. (Group 0510.) 3. Disconnect upper and lower charged air pipes from intercooler. 05 0510 5

Continued on next page

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Cooling System 4. Remove intercooler cap screws (8). Record position of rubber isolators and washers for installation. 5. Remove intercooler. Inspect and replace as necessary. IMPORTANT: Insulating foam on sides of intercooler must be intact or cooling system performance will be reduced. 6. Position intercooler in machine.

–UN–18APR08

7. Install intercooler cap screws, washers, and isolators. 8. Connect upper and lower charged air pipes to intercooler.

10. Fill and deaerate cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.)

Radiator and Intercooler

–UN–18APR08

5—Debris Screen 6—Radiator Cap Screw (4 used) 7—Drain Valve 8—Intercooler Cap Screw (2 used) 9—Insulating Foam 10—Radiator Overflow Hose 11—Radiator 12—Intercooler

TX1040430A

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TX1040429A

9. Install radiator. See Radiator Remove and Install. (Group 0510.)

Debris Screen

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Cooling System

Fuel Cooler Remove and Install 1. Disconnect fuel hoses (1). –UN–21FEB08

2. Remove cap screws (3) securing fuel cooler (4). 3. Remove fuel cooler.

TX1037022A

4. Inspect and replace as necessary. 5. Install fuel cooler. Fuel Cooler

NOTE: It is not necessary to bleed fuel system when replacing fuel cooler.

1—Fuel Hose (2 used) 2—Hose Clamp (2 used) 3—Cap Screw (4 used) 4—Fuel Cooler

6. Start engine and check for leaks. 7. Connect fuel hoses.

05 0510 7

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Fan, Fan Guard, and Fan Shroud Remove and Install 1. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) 2. Remove covers over engine and cooling package. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 3. Drain engine coolant until coolant level is below upper radiator hose. See Drain Cooling System. (Operator’s Manual.)

Continued on next page

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Cooling System 4. Disconnect upper radiator hose (1) from radiator. 5. Remove upper charged air pipe (4). 6. Remove upper fan shroud bracket (2). Record position of isolators and washers for installation. 7. Remove fan guard (3). 8. Disconnect lower charged air pipe from engine.

–UN–21APR08

9. Remove tie bands securing air conditioner compressor hoses to cooling package.

TX1040674A

NOTE: Air conditioner hoses do not need to be disconnected from compressor. 10. Disconnect air conditioner compressor (5) from engine and set aside.

05 0510 8

Cooling Package Connections

1—Upper Radiator Hose 2—Upper Fan Shroud Bracket 3—Fan Guard 4—Upper Charged Air Pipe 5—Air Conditioner Compressor

Continued on next page

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Cooling System 11. Remove lower fan shroud brackets (8). Record position of isolators and washers for installation. 12. Remove fan (6) and fan spacer (7) from engine.

TX1040698A

–UN–21APR08

6—Fan 7—Fan Spacer 8—Lower Fan Shroud Bracket (2 used) 9—Fan Shroud

Fan and Fan Shroud Brackets 05 0510 9

Continued on next page

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Cooling System 13. Separate fan shroud (9) from isolator (11) and remove fan shroud. 14. Remove tie band (10) and isolator if necessary. 15. Inspect and replace fan, fan guard, and fan shroud if necessary. 16. Position isolator on cooling package and install tie band if removed.

–UN–21APR08

17. Position fan shroud in isolator. 18. Install fan and fan spacer.

TX1040699A

19. Install lower fan shroud brackets between engine and fan shroud. 20. Install air conditioner compressor on engine.

05 0510 10

21. Install belt for air conditioner compressor. See Check and Adjust A/C Belt. (Operator’s Manual.) 22. Install tie bands securing air conditioner hoses to cooling package.

Fan Shroud and Isolator 9—Fan Shroud 10—Tie Band 11—Isolator

23. Connect lower charged air pipe to engine. 24. Install fan guard. 25. Install upper fan shroud bracket. 26. Install upper charged air pipe. 27. Connect upper radiator hose to radiator. 28. Fill and deaerate cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.) 29. Install covers over engine and cooling package. 30. Install counterweight. See Counterweight Remove and Install. (Group 1749.)

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Group 0520

Intake System Air Cleaner Remove and Install 1. Disconnect air cleaner (1) from bracket (3). –UN–25FEB08

2. Disconnect air cleaner from air duct. 3. Inspect and replace parts as necessary.

TX1037224A

4. Connect air cleaner to air duct. 5. Connect air cleaner to bracket. Air Cleaner

1—Air Cleaner 2—Cap Screws (4 used) 3—Bracket

RH60123,00001D8 –19–29APR08–1/1

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Intake System

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Group 0560

External Fuel Supply Systems Fuel Tank Remove and Install 1. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) 2. Drain fuel tank. Specification Fuel Tank—Capacity ......................................................................... 220 L 58 gal

RH60123,00001AD –19–29APR08–1/4

3. Disconnect return fuel hose (3) and close all openings with caps and plugs. 4. Disconnect fuel supply hose (4) and close all openings with caps and plugs. 5. Remove bracket (1) holding fuel filter housings.

05 0560 1

6. Remove cap screws (5) holding hoses to fuel tank (8). 7. Open control valve access door.

TX1040494A

–UN–17APR08

1—Bracket 2—Cap Screw (4 used) 3—Return Fuel Hose 4—Fuel Supply Hose 5—Cap Screw (2 used) 6—Cap Screw (2 used) 8—Fuel Tank

Rear of Fuel Tank Continued on next page

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External Fuel Supply Systems 8. Disconnect electrical connector (7).

TX1040495A

–UN–17APR08

7—Electrical Connector

Front of Fuel Tank 05 0560 2

Continued on next page

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External Fuel Supply Systems 9. Remove cap screw (5) holding wire harness to fuel tank. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 10. Support fuel tank.

–UN–17APR08

Specification Fuel Tank—Weight (approximate) .................................................... 91 kg 200 lb

11. Remove cap screws (6) from front and rear of fuel tank.

TX1040496A

12. Remove fuel tank. 13. Inspect and replace parts as necessary. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Front of Fuel Tank 05 0560 3

5—Cap Screw 6—Cap Screw (2 used)

14. Install fuel tank. Specification Fuel Tank—Weight (approximate) .................................................... 91 kg 200 lb

15. Install cap screws holding fuel tank. 16. Connect electrical connector. 17. Install bracket holding fuel filter housings. 18. Connect return fuel and supply fuel hoses. 19. Install clamps holding fuel hoses to fuel tank. 20. Install Counterweight. See Counterweight Remove and Install. (Group 1749.) 21. Fill fuel tank. 22. Bleed air from fuel hoses. See Bleed Fuel System Electric Priming Pump. (Operators Manual.)

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External Fuel Supply Systems

Primary Fuel Filter (Water Separator) Remove and Install 1. Disconnect fuel hoses (2). 2. Remove cap screws (4) securing primary fuel filter (1). 3. Remove primary fuel filter. 4. Inspect and repair parts as necessary. 5. Install primary fuel filter. 6. Connect fuel hoses.

–UN–21FEB08

1—Primary Fuel Filter (Water Separator) 2—Fuel hose (2 used) 3—Hose Clamp (2 used) 4—Cap Screw (2 used)

TX1037043A

05 0560 4 Primary Fuel Filter (Water Separator)

RH60123,00001AE –19–29APR08–1/1

Final Fuel Filter Remove and Install 1. Disconnect fuel hoses (3). 2. Disconnect electrical connector (5). 3. Remove cap screws (2) securing final fuel filter (1). 4. Remove final fuel filter. 5. Inspect and repair parts as necessary. 6. Install final fuel filter. 7. Connect electrical connector.

–UN–21FEB08

8. Connect fuel hoses.

TX1037044A

1—Final Fuel Filter 2—Cap Screw (3 used) 3—Fuel Hose (2 used) 4—Clamp (2 used) 5—Electrical Connector

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Section 07

Dampener Drive (Flex Coupling) Contents Page

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

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Group 0752

Elements Dampener Drive (Flex Coupling) Remove and Install

10 1. Remove hydraulic pump. See Pump 1 and 2 Remove and Install. (Group 3360.)

NOTE: Flex coupling may come off with pump or stay on engine flywheel. 17

2. Remove parts (8 and 10—17).

IMPORTANT: Do not use a steel hammer to install guide pins damage will occur. Use a plastic or rubber hammer to install guide pins.

TX1036387

–UN–07FEB08

3. Inspect and replace parts as necessary.

4. Install new guide pins. Dampener Drive 8—Guide Pins (4 used) 10—Flex Coupling 11—Cap Screw (4 used) 12—Insert (4 used) 14—Insert (4 used) 15—Set Screw (2 used) 16—Cap Screw (4 used) 17—Hub

07 0752 1

JW00603,000010D –19–30APR08–1/3

5. Install each insert (12) so index hole is aligned with guide pin, installed in previous step. 6. Apply PM37418 Medium-Strength Thread Lock and Sealer to cap screws (11). Tighten to specification.

–UN–08JAN08

Specification Flex Coupling-to-Flywheel Cap Screw—Torque ............................................................................. 137 N•m 101 lb-ft

7. Install flex coupling (10) onto inserts (12) as shown.

TX1032788A

9—Engine Flywheel 10—Flex Coupling 11—Cap Screw (4 used) 12—Insert (4 used) Flywheel with Dampener Drive

Continued on next page

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Elements 8. Clean mounting surface of hydraulic pump housing (13).

–UN–08JAN08

9. Apply PM37418 Medium-Strength Thread Lock and Sealer to threads of cap screws (16).

Specification Pump Insert Cap Screws— Torque .......................................................................................... 137 N•m 101 lb-ft

IMPORTANT: Install hub assembly so surface is flush with end of pump shaft. Damage to pump and shaft seal will occur if installed incorrectly. 11. Install hub (17) onto splines of pump shaft (18). Position hub so face is flush with pump shaft end.

TX1032856A

10. Install inserts (14) onto hub (17) using cap screws (16) and tighten to specification.

Hydraulic Pump Dampener Drive 13—Hydraulic Pump Housing 14—Insert (4 used) 15—Set Screw (2 used) 16—Cap Screw (4 used) 17—Hub 18—Pump Shaft

12. Apply PM37418 Medium-Strength Thread Lock and Sealer to set screws (15). 13. Tighten set screws (15) to specification. 07 0752 2

Specification Hub-to-Pump Shaft Set Screw— Torque .......................................................................................... 108 N•m 80 lb-ft

14. Install hydraulic pump. See Pump 1 and 2 Remove and Install. (Group 3360.)

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Section 17

Frame or Supporting Structure Contents Page

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

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Group 1740

Frame Installation Welding On Machine IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, engine control unit, and pump and valve controller. Disconnect battery ground cable, engine control unit, and pump and valve controller electrical connectors before welding on the machine. Before welding on the machine, perform the steps listed below to protect the machine electrical system. 1. Disconnect the battery ground and positive cables. 2. Disconnect electrical connectors to engine control unit (ECU). See Engine Control Module (ECM) Remove and Install. (Group 9015-20.) 3. Disconnect electrical connectors to main controller (MCF). See Main Controller (MCF) Remove and Install. (Group 9015-20.) 4. Disconnect electrical connectors to information controller (ICF). See Information Controller (ICF) Remove and Install. (Group 9015-20.)

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17 1740 1

Frame Installation

Welding Repair of Major Structure CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 1. Remove paint before welding or heating. IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, machine information center, and pump and valve controller. Disconnect battery ground cable, machine information center, and pump and valve controller electrical connectors before welding on the machine. 17 1740 2

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

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

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

2. Use one of the following weld processes: • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.

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Group 1749

Chassis Weights Counterweight Remove and Install 1. Park machine on level ground.

GD61784,000029A –19–24APR08–1/4

2. Remove engine door (3). 3. Remove caps from top of counterweight.

TX1037753A

–UN–29FEB08

3—Engine Door 4—Cap Screw (4 used) 5—Pin 6—Support Rod

Engine Door

GD61784,000029A –19–24APR08–2/4

4. Install M36-4.0 lifting eyebolts (9) in top of counterweight.

–UN–17MAR08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1038558

The capacity of a lifting eyebolt decreases as the lift angle increases from vertical. A spreader bar should be used to obtain a vertical lift from eyebolts. Spreader Bar

5. Attach counterweight (8) to an appropriate lifting device using a spreader bar (7).

7—Spreader Bar 8—Counterweight 9—Lifting Eyebolt (2 used)

Specification Counterweight—Weight (approximate)................................................................................. 3680 kg 8120 lb

Continued on next page

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17 1749 1

Chassis Weights 6. Remove cap screws (10) and washers (11). 7. Remove counterweight (8) from upperstructure (12). 8. Repair or replace parts as necessary. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

–UN–25APR08

The capacity of a lifting eyebolt decreases as the lift angle increases from vertical. A spreader bar should be used to obtain a vertical lift from eyebolts.

Specification Counterweight—Weight (approximate)................................................................................. 3680 kg 8120 lb

TX1041221A

9. Install counterweight onto machine using appropriate lifting device.

Counterweight Cap Screws 8—Counterweight 10—Cap Screw (4 used) 11—Washer (4 used) 12—Upperstructure

10. Install cap screws and washers and tighten to specification. Specification Frame-to-Counterweight Cap Screw—Torque ............................................................................. 2250 Nm 1660 lb-ft

11. Install engine door. 17 1749 2

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Section 18

Operator’s Station Contents Page

Group 1800—Removal and Installation Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1 Group 1810—Operator Enclosure Sliding Window Remove and Install . . . . . . .18-1810-1 Windowpane Remove and Install . . . . . . . . .18-1810-2 Windowpanes Dimensions . . . . . . . . . . . . . .18-1810-3 Group 1821—Seat and Seat Belt Seat Remove and Install . . . . . . . . . . . . . . . .18-1821-1 Seat Belt Remove and Install . . . . . . . . . . . .18-1821-4 Mechanical Suspension Seat Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-5 Air Suspension Seat Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-7 Left and Right Console Covers Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-8 Group 1830—Heating and Air Conditioning Refrigerant Cautions and Proper Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Flush and Purge Air Conditioner System. . . .18-1830-3 R134a Refrigerant Oil Information . . . . . . . . .18-1830-6 R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-8 Evacuate R134a System . . . . . . . . . . . . . . . .18-1830-9 Charge R134a System . . . . . . . . . . . . . . . .18-1830-10 Compressor Remove and Install . . . . . . . . .18-1830-11 Condenser Remove and Install . . . . . . . . . .18-1830-12 Heater and Air Conditioner Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 Receiver-Dryer Remove and Install . . . . . . .18-1830-20

TM10743 (09APR09)

18-1

135D Excavator Repair 040909

PN=1

Contents

TM10743 (09APR09)

18-2

135D Excavator Repair 040909

PN=2

Group 1800

Removal and Installation Cab Remove and Install 1. Remove air cleaner. See Air Cleaner Remove and Install. (Group 0520.) 2. Remove fresh air filter cover. See Check Cab Fresh Air Filter. (Operator’s Manual.) 3. Disconnect hose from windshield washer reservoir.

GD61784,00002BD –19–26MAR08–1/18

4. Disconnect electrical connectors (3). See Machine Harness (W2) Component Location. (Group 9015-10.) 5. Disconnect cab harness ground (6). 6. Remove cover (4). –UN–13MAR08

7. Remove fresh air filter housing (1).

TX1038375A

1—Fresh Air Filter Housing 2—Cap Screw (4 used) 3—Electrical Connector (3 used) 4—Cover 5—Cap Screw (2 used) 6—Cab Harness Ground Cab Harness

Continued on next page

GD61784,00002BD –19–26MAR08–2/18

18 1800 1

TM10743 (09APR09)

18-1800-1

135D Excavator Repair 040909

PN=277

Removal and Installation 8. Remove air duct (7). 9. Remove monitor controller. See Monitor Controller Remove and Install. (Group 9015-20.) 10. Remove floor mat.

TX1038453A

–UN–13MAR08

7—Air Duct 8—Cap Screw (4 used)

Air Duct

GD61784,00002BD –19–26MAR08–3/18

11. Remove cup holder (9) and panel (10). 12. Remove air duct (11).

TX1038352A

9—Cup Holder 10—Panel 11—Air Duct 12—Cap Screw

–UN–13MAR08

Cup Holder and Panel

TX1038351A

18 1800 2

–UN–13MAR08

13. Remove seat. See Seat Remove and Install. (Group 1821.)

Duct Continued on next page

TM10743 (09APR09)

18-1800-2

GD61784,00002BD –19–26MAR08–4/18

135D Excavator Repair 040909

PN=278

Removal and Installation 14. Remove cover (15).

–UN–13MAR08

15. Remove screws attaching fuse block (16) to cover (14). 16. Remove cover (14).

TX1038474A

13—Cap Screws (4 used) 14—Cover 15—Cover 16—Fuse Block

TX1038475A

–UN–13MAR08

Access Cover

Fuse Block GD61784,00002BD –19–26MAR08–5/18

17. Remove air duct (17). 18. Disconnect air hose (20).

TX1038477A

–UN–13MAR08

17—Duct 18—Cap Screw 19—Hose Clamp 20—Air Hose 21—Screws

Duct

Continued on next page

TM10743 (09APR09)

18-1800-3

GD61784,00002BD –19–26MAR08–6/18

135D Excavator Repair 040909

PN=279

18 1800 3

Removal and Installation 19. Disconnect cab wiring harness (22) from left and right consoles and air conditioning module. See Cab Harness (W1) Component Location. (Group 9015-10.) –UN–13MAR08

20. Remove any clamps or tie bands securing cab harness to floor, consoles or air conditioning module.

TX1038476A

22—Cab Wiring Harness

Cab Wiring Harness

GD61784,00002BD –19–26MAR08–7/18

21. Remove hand railing (32).

TX1038574A

–UN–14MAR08

32—Hand Railing 33—Cap Screw (2 used)

Hand Railing 18 1800 4 Continued on next page

TM10743 (09APR09)

18-1800-4

GD61784,00002BD –19–26MAR08–8/18

135D Excavator Repair 040909

PN=280

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–13MAR08

22. Attach lifting device to cab.

TX1038323A

Specification Cab—Weight (approximate) ............................................................ 310 kg 680 lb

Lifting Brackets

GD61784,00002BD –19–26MAR08–9/18

23. Remove isolator lock nuts (25) and washers (26). Discard lock nuts. 24. Remove cap screws (23) and washers (24). 25. Remove socket head cap screws and washers (27— 30).

23 24 25 –UN–11MAR08

26. Remove access covers from bottom of cab.

26 23—Cap Screw (5 used) 24—Washer (5 used) 25—Lock Nut (2 used) 26—Washer (2 used) 27—Socket Head Cap Screw 28—Washer 29—Socket Head Cap Screw (4 used) 30—Washer (4 used)

27 28

TX1038482

18 1800 5

Cab Mounting Hardware

Continued on next page

TM10743 (09APR09)

18-1800-5

GD61784,00002BD –19–26MAR08–10/18

135D Excavator Repair 040909

PN=281

Removal and Installation 27. Remove anchor bolt (31), spacer, and washer.

–UN–13MAR08

IMPORTANT: Before lifting cab, ensure all wiring harness connectors and ducts have been disconnected. 28. Remove cab.

TX1038483A

29. Inspect and replace parts as necessary. 31—Anchor Bolt Anchor Bolt

GD61784,00002BD –19–26MAR08–11/18

IMPORTANT: Ensure all wiring harnesses and other components are out of the way before installing cab. 30. Install cab and tighten cab mounting hardware to specification.

24 25 26 27

Specification

Cab-to-Floor Cap Screws— Torque ............................................................................................ 50 N•m 37 lb-ft

18 1800 6

TX1038482

Specification Cab Isolator Lock Nuts—Torque .................................................. 210 N•m 155 lb-ft

Cab Mounting Hardware 23—Cap Screw (5 used) 24—Washer (5 used) 25—Lock Nut (2 used) 26—Washer (2 used) 27—Socket Head Cap Screw 28—Washer 29—Socket Head Cap Screw (4 used) 30—Washer (4 used)

Specification Cab Anchor Bolt—Torque ............................................................ 550 N•m 406 lb-ft

31. Install access covers on bottom of cab.

Continued on next page

TM10743 (09APR09)

–UN–11MAR08

Specification Cab-to-Floor Socket Head Cap Screws—Torque ............................................................................. 50 N•m 37 lb-ft

18-1800-6

GD61784,00002BD –19–26MAR08–12/18

135D Excavator Repair 040909

PN=282

Removal and Installation 32. Install hand railing. 33. Connect cab wiring harness connectors. See Cab Harness (W1) Component Location. (Group 9015-10.)

TX1038574A

–UN–14MAR08

32—Hand Railing 33—Cap Screw (2 used)

Hand Railing

GD61784,00002BD –19–26MAR08–13/18

34. Connect air hose (20). 35. Install air duct (17).

TX1038477A

–UN–13MAR08

17—Duct 18—Cap Screw 19—Hose Clamp 20—Air Hose 21—Screws

Duct

18 1800 7 Continued on next page

TM10743 (09APR09)

18-1800-7

GD61784,00002BD –19–26MAR08–14/18

135D Excavator Repair 040909

PN=283

Removal and Installation 36. Install cover (14). 37. Attach fuse block (16) to cover (14). –UN–13MAR08

38. Install cover (15).

TX1038474A

39. Install seat. See Seat Remove and Install. (Group 1821.) 13—Cap Screws (4 used) 14—Cover 15—Cover 16—Fuse Block

TX1038475A

–UN–13MAR08

Access Cover

Fuse Block GD61784,00002BD –19–26MAR08–15/18

40. Install air duct (11). 41. Install cup holder (9) and panel (10). –UN–13MAR08

42. Install floor mat.

9—Cup Holder 10—Panel 11—Air Duct 12—Cap Screw

–UN–13MAR08

Cup Holder and Panel

TX1038351A

18 1800 8

TX1038352A

43. Install monitor controller. See Monitor Controller Remove and Install. (Group 9015-20.)

Duct Continued on next page

TM10743 (09APR09)

18-1800-8

GD61784,00002BD –19–26MAR08–16/18

135D Excavator Repair 040909

PN=284

Removal and Installation 44. Install air duct (7).

TX1038453A

–UN–13MAR08

7—Air Duct 8—Cap Screw (4 used)

Air Duct

GD61784,00002BD –19–26MAR08–17/18

45. Install fresh air filter housing (1). 46. Install cover (4). 47. Connect cab harness ground (6).

–UN–13MAR08

48. Connect electrical connectors (3). See Machine Harness (W2) Component Location. (Group 9015-10.) 49. Connect hose from windshield washer reservoir.

51. Install air cleaner. See Air Cleaner Remove and Install. (Group 0520.)

TX1038375A

50. Install fresh air filter cover. See Check Cab Fresh Air Filter. (Operator’s Manual.)

Cab Harness 1—Fresh Air Filter Housing 2—Cap Screw (4 used) 3—Electrical Connector (3 used) 4—Cover 5—Cap Screw (2 used) 6—Cab Harness Ground

GD61784,00002BD –19–26MAR08–18/18

TM10743 (09APR09)

18-1800-9

135D Excavator Repair 040909

PN=285

18 1800 9

Removal and Installation

18 1800 10

TM10743 (09APR09)

18-1800-10

135D Excavator Repair 040909

PN=286

Group 1810

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

T140968

–UN–30APR01

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

Sliding Window

GD61784,000029B –19–25FEB08–1/3

4. Remove molding (5) from inside and outside of upper windowpane (6). Remove upper windowpane.

18 1810 1

T189001B

–UN–26MAR03

5—Molding 6—Upper Windowpane 7—Upper Sliding Window Support

Upper Windowpane

Continued on next page

TM10743 (09APR09)

18-1810-1

GD61784,000029B –19–25FEB08–2/3

135D Excavator Repair 040909

PN=287

Operator Enclosure 5. Remove screws (8) and upper sliding window support (7). 6. Repair or replace parts as necessary. –UN–26MAR03

7. Install upper sliding window support and screws. 8. Install upper windowpane and molding.

T189002B

9. Apply PM37391 Instant Gel Adhesive to cab flange. 10. Install windows and frame with spacers at bottom. Upper Sliding Window Support

11. Install molding around window and cab flange.

7—Upper Sliding Window Support 8—Screw (4 used)

GD61784,000029B –19–25FEB08–3/3

Windowpane Remove and Install Adhesive used to secure windowpanes is urethane adhesive used on automobile windshields. Urethane adhesive, manufactured by Loctite Corporation or equivalent, is recommended. DO NOT use any other type of adhesive. It is recommended that auto glass dealer install windowpanes.

IMPORTANT: Adhesive will not stick to bare metal. 3. If existing adhesive is removed and paint is scraped, paint window frame. Paint must be fully cured before installing windowpane. 4. Trim existing adhesive to form smooth surface.

IMPORTANT: Windowpanes must include an ultra-violet barrier around edge so adhesive will not deteriorate. Windowpanes ordered through John Deere Parts have this ultra-violet barrier. If windowpane is purchased through glass dealer, the dealer 18 must incorporate an ultra-violet 1810 barrier on the glass. DO NOT paint 2 border of glass.

IMPORTANT: Follow manufacturer’s instructions for using adhesive. 5. Apply 6 mm (1/4 in.) bead of adhesive over existing adhesive. 6. Position windowpane in cab frame. Use hand pressure to force windowpane down until edges are even with metal frame. 7. Secure windowpane with duct tape until adhesive cures. Allow adhesive to cure for 24 hours before operating machine.

If auto glass dealer does not install windowpanes, proceed as follows: 1. Remove windowpane frame from cab. 2. Scrape any broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab.

GD61784,000029C –19–25FEB08–1/1

TM10743 (09APR09)

18-1810-2

135D Excavator Repair 040909

PN=288

Operator Enclosure

Windowpanes Dimensions

TX1018570

–UN–23FEB07

18 1810 3

Cab Front Glass Continued on next page

TM10743 (09APR09)

18-1810-3

GD61784,000029D –19–25FEB08–1/5

135D Excavator Repair 040909

PN=289

Operator Enclosure

TX1018571

–UN–20FEB07

18 1810 4

Cab Door Glass

Continued on next page

TM10743 (09APR09)

18-1810-4

GD61784,000029D –19–25FEB08–2/5

135D Excavator Repair 040909

PN=290

Operator Enclosure

TX1018573

–UN–23FEB07

18 1810 5

Cab Right-Hand Glass

Continued on next page

TM10743 (09APR09)

18-1810-5

GD61784,000029D –19–25FEB08–3/5

135D Excavator Repair 040909

PN=291

Operator Enclosure

TX1018576

–UN–23FEB07

18 1810 6

Cab Rear and Left-Hand Rear Glass

Continued on next page

TM10743 (09APR09)

18-1810-6

GD61784,000029D –19–25FEB08–4/5

135D Excavator Repair 040909

PN=292

Operator Enclosure 1—Black Ceramic Coating Range

2—Black Ceramic Coating Surface

NOTE: Dimensions shown are in millimeters. GD61784,000029D –19–25FEB08–5/5

18 1810 7

TM10743 (09APR09)

18-1810-7

135D Excavator Repair 040909

PN=293

Operator Enclosure

18 1810 8

TM10743 (09APR09)

18-1810-8

135D Excavator Repair 040909

PN=294

Group 1821

Seat and Seat Belt Seat Remove and Install 1. Disconnect tethers (1).

TX1018443A

–UN–09FEB07

1—Tether (2 used) 2—Cap Screw (2 used)

Tether

GD61784,00002C3 –19–11MAR08–1/5

2. Slide seat forward and remove cap screws (3) and nuts (4).

TX1038434A

–UN–14MAR08

3—Cap Screw (2 used) 4—Nut (2 used)

Seat Cap Screws

18 1821 1 Continued on next page

TM10743 (09APR09)

18-1821-1

GD61784,00002C3 –19–11MAR08–2/5

135D Excavator Repair 040909

PN=295

Seat and Seat Belt 3. Slide seat back and remove front socket head cap screws (5).

TX1038441A

–UN–14MAR08

5—Socket Head Cap Screw (2 used)

Front Socket Head Cap Screws

GD61784,00002C3 –19–11MAR08–3/5

4. Slide seat forward and install cap screws (3) and nuts (4).

TX1038434A

–UN–14MAR08

3—Cap Screw (2 used) 4—Nut (2 used)

Seat Cap Screws

18 1821 2 Continued on next page

TM10743 (09APR09)

18-1821-2

GD61784,00002C3 –19–11MAR08–4/5

135D Excavator Repair 040909

PN=296

Seat and Seat Belt 5. Disconnect electrical connectors (6). 6. Remove rear socket head cap screws (7). –UN–14MAR08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Specification Mechanical Suspension Seat— Weight (approximate) ....................................................................... 40 kg 90 lb Air Suspension Seat—Weight (approximate)..................................................................................... 60 kg 131 lb

TX1038445A

7. Remove seat.

Rear Socket Head Cap Screws 6—Electrical Connector (2 used) 7—Socket Head Cap Screw (2 used)

8. Inspect and repair parts as necessary. 9. Install seat and tighten socket head cap screws to specification. Specification Seat Mount Socket Head Cap Screws—Torque ............................................................................. 20 N•m 177 lb-in.

10. Connect tethers and tighten to specification. Specification Lower Seat Belt Mount Cap Screws—Torque ............................................................................. 50 N•m 37 lb-ft

11. Connect electrical connectors.

18 1821 3 GD61784,00002C3 –19–11MAR08–5/5

TM10743 (09APR09)

18-1821-3

135D Excavator Repair 040909

PN=297

Seat and Seat Belt

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

3. Repair or replace parts as necessary. 4. Install seat belts and cap screws (4). 5. Install lower seat belt to lower mount on each side of seat using cap screw (4), lock washer and cap screw. Tighten cap screw to specification.

TX1018443A

–UN–09FEB07

2. Remove cap screw (4) and upper seat belt (3) from each side of seat.

Specification Lower Seat Belt Mount Cap Screws—Torque ............................................................................. 50 N•m 37 lb-ft

T188988B

–UN–26MAR03

1—Lower Seat Belt 2—Cap Screw 3—Upper Seat Belt 4—Cap Screw

GD61784,00002C6 –19–10MAR08–1/1

18 1821 4

TM10743 (09APR09)

18-1821-4

135D Excavator Repair 040909

PN=298

Seat and Seat Belt

TX1031411

–UN–05NOV07

Mechanical Suspension Seat Disassemble and Assemble

Mechanical Suspension Seat 2—Cushion Cover 3—Support 4—Cushion 5—Pad 6—Frame

7—Cable 8—Stand 10—Spring 11—Torsional Damper 12—Adjuster

1. Remove seat. See Seat Remove and Install. (Group 1821.)

13—Lever 14—Seat Suspension 15—Seat Slide Track 16—Handle 17—Cover

2. Disassemble seat as shown.

Continued on next page

TM10743 (09APR09)

20—Bushing 21—Link 24—Heater 25—Head Restraint

18-1821-5

GD61784,00002C0 –19–26MAR08–1/2

135D Excavator Repair 040909

PN=299

18 1821 5

Seat and Seat Belt 3. Inspect and repair parts as necessary.

5. Install seat. See Seat Remove and Install. (Group 1821.)

4. Assemble seat as shown.

GD61784,00002C0 –19–26MAR08–2/2

18 1821 6

TM10743 (09APR09)

18-1821-6

135D Excavator Repair 040909

PN=300

Seat and Seat Belt

TX1004009

–UN–21FEB06

Air Suspension Seat Disassemble and Assemble

0—Seat Assembly 2—Cushion Cover 3—Pad 4—Cushion 5—Pad 6—Frame 7—Cable

8—Handle 9—Stand 10—Spring 11—Seat Slide Track Kit 14—Lever Kit 15—Bearing Kit

16—Compressor 17—Lever 18—Torsional Damper 19—Air Spring Seat Kit 20—Valve 21—Kit

22—Seat Suspension 23—Seat Suspension Boot Kit 24—Seat Adjustment Cable Kit 25—Wiring Lead 26—Head Restraint 27—Heater

GD61784,00002C1 –19–21APR08–1/1

TM10743 (09APR09)

18-1821-7

135D Excavator Repair 040909

PN=301

18 1821 7

Seat and Seat Belt

Left and Right Console Covers Remove and Install

–UN–10MAR08

1. Remove cap (1) and cover (2).

TX1038023A

1—Cap 2—Cover 3—Left Outer Cover

Pilot Shutoff Lever Cover

JW00603,000012D –19–23APR08–1/9

2. Remove socket head cap screws (4), and pilot shutoff lever (5).

TX1038024A

–UN–10MAR08

4—Socket Head Cap Screw (2 used) 5—Pilot Shutoff Lever

Pilot Shutoff Lever

18 1821 8 Continued on next page

TM10743 (09APR09)

18-1821-8

JW00603,000012D –19–23APR08–2/9

135D Excavator Repair 040909

PN=302

Seat and Seat Belt 3. Remove screws (8) to remove boot. 4. Remove screw (6).

TX1038025A

–UN–10MAR08

6—Screw 7—Left Bezel 8—Screw (4 used)

TX1038026A

–UN–10MAR08

Pilot Lever Boot

Pilot Lever Boot JW00603,000012D –19–23APR08–3/9

5. Remove bezel (7).

TX1038027A

–UN–10MAR08

6—Screw 7—Left Bezel

Left Bezel

Continued on next page

TM10743 (09APR09)

18-1821-9

JW00603,000012D –19–23APR08–4/9

135D Excavator Repair 040909

PN=303

18 1821 9

Seat and Seat Belt 6. Remove screws (6) from bottom of left inner (17) and left outer (3) covers.

–UN–10MAR08

7. Remove left outer cover (3) and left inner cover (17). 8. Install left outer cover.

TX1038028A

9. Install left bezel. 10. Install left pilot lever boot. 11. Install pilot shutoff lever and cover. Bottom of Left Inner and Left Outer Cover 3—Left Outer Cover 6—Screw (2 used) 17—Left Inner Cover

JW00603,000012D –19–23APR08–5/9

12. Remove caps (1). 13. Remove screws (6) and right bezel (14).

TX1038035A

–UN–10MAR08

1—Cap 6—Screw 14—Right Bezel

Right Bezel

TX1038034A

–UN–10MAR08

18 1821 10

Right Bezel Continued on next page

TM10743 (09APR09)

18-1821-10

JW00603,000012D –19–23APR08–6/9

135D Excavator Repair 040909

PN=304

Seat and Seat Belt 14. Remove screws (6 and 8) and right pilot lever boot. 15. Remove right pilot lever bezel (13).

TX1038031A

–UN–10MAR08

6—Screw 8—Screw (4 used) 13—Right Pilot Lever Bezel

TX1038032A

–UN–10MAR08

Right Pilot Lever Boot

Left Pilot Lever Boot JW00603,000012D –19–23APR08–7/9

16. Remove screws (6) and right outer cover (18) and right inner cover (19).

TX1038036A

–UN–10MAR08

6—Screw (4 used) 18—Right Outer Cover 19—Right Inner Cover

Right Cover

Continued on next page

TM10743 (09APR09)

18-1821-11

JW00603,000012D –19–23APR08–8/9

135D Excavator Repair 040909

PN=305

18 1821 11

Seat and Seat Belt 17. Remove cap screws (16) and control panel (15). 18. Install control panel. –UN–10MAR08

19. Install right inner and right outer covers. 20. Install right pilot lever bezel.

TX1038037A

21. Install right pilot lever boot. 22. Install right bezel. Control Panel

10—Cap Screw With Pin 11—Cap Screw 15—Control Panel 16—Cap Screw 20—Right Pilot Lever

JW00603,000012D –19–23APR08–9/9

18 1821 12

TM10743 (09APR09)

18-1821-12

135D Excavator Repair 040909

PN=306

Group 1830

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

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

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

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

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

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

18 1830 1

Continued on next page

TM10743 (09APR09)

18-1830-1

JH38101,000075C –19–17MAR08–1/2

135D Excavator Repair 040909

PN=307

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

JH38101,000075C –19–17MAR08–2/2

18 1830 2

TM10743 (09APR09)

18-1830-2

135D Excavator Repair 040909

PN=308

Heating and Air Conditioning

Flush and Purge Air Conditioner System CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (Group 1830.) NOTE: Flushing can be performed on machine. 1. Perform Recover R134a Refrigerant. (Group 1830.) Add flushing solvent to system with JT02075 Flusher and JT02098 Flusher Fitting Kit. 2. Remove and discard receiver/dryer. 3. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. 4. Fill flusher tank with solvent and fasten all connections. Dispose of solvent properly.

a. Remove compressor and measure oil drained from both manifold ports. b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. c. Pour flushing solvent into suction port and discharge port. Plug both ports in compressor manifold, using JT02099 and JT03194 Caps. Specification Flushing Solvent in Suction Port—Volume........................................................................... 240 mL 8 fl oz Flushing Solvent in Discharge Port—Volume........................................................................... 120 mL 4 fl oz

d. Turn compressor end for end and roll it side to side.

Specification Flusher Tank—Capacity ................................................................. 4 L 1 gal

NOTE: Air pressure must be at least at specification for flushing and purging. Specification Air Pressure—Minimum Pressure........................................................ 620 kPa for flushing and purging 90 psi for flushing and purging 6.2 bar for flushing and purging

5. Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve. 6. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

e. Remove both plugs from manifold ports and drain solvent from compressor. f. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders. g. Invert compressor. Roll end for end and side to side. Drain thoroughly. h. Repeat previous two steps at least three times. 8. Divide system into two circuits:

18 1830 3

• Condenser circuit, including inlet and outlet hoses. • Evaporator circuit, including inlet and outlet hoses. 9. Condenser:

7. Clean compressor as follows:

Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=309

Heating and Air Conditioning IMPORTANT: DO NOT attempt to flush through compressor or receiver/dryer. Flushing through expansion valve is acceptable if refrigerant oil has a normal odor and appearance. a. Flush/Purge condenser.

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

b. Remove and discard receiver/dryer. c. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

10. See flush evaporator, if evaporator requires flushing.

d. Fill flusher tank with solvent and fasten all connections. Specification Flusher Tank—Capacity ................................................................. 4 L 1 gal

NOTE: Air pressure must be at least to specification for flushing and purging. Specification Air Pressure—Minimum Pressure........................................................ 620 kPa for flushing and purging. 90 psi for flushing and purging. 6.2 bar for flushing and purging.

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

18 1830 4

Put nozzle in container to collect flushing solvent.

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

If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. See following steps to flush evaporator through expansion valve, if oil appears normal. 11. Flush evaporator: a. Remove evaporator and expansion valve. See Heater and Air Conditioner Remove and Install. (Group 1830.) b. Force flushing solvent through evaporator inlet with compressed air. c. Purge system until dry. d. Install evaporator and then go to step 13. 12. Flush evaporator through expansion valve: a. Connect flusher outlet hose to connection of receiver/dryer outlet hose using JT03188 adapter. b. Fill flusher tank and fasten all connections. Specification Flusher Tank—Capacity ................................................................. 4 L 1 gal

Continued on next page

TM10743 (09APR09)

18-1830-4

GD61784,00002A4 –19–17MAR08–2/3

135D Excavator Repair 040909

PN=310

Heating and Air Conditioning NOTE: Air pressure must be at least to specification for flushing and purging. Specification Air Pressure—Minimum Pressure........................................................ 620 kpa for flushing and purging. 90 psi for flushing and purging. 6.2 bar for flushing and purging.

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

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

NOTE: Purging evaporator circuit takes 12—15 minutes to thoroughly remove solvent.

GD61784,00002A4 –19–17MAR08–3/3

18 1830 5

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=311

Heating and Air Conditioning

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

If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz per ft ) to determine correct amount of oil to be added. Drain compressor oil into graduated container while rotating compressor shaft and record amount. If oil drained from compressor is very black or amount of oil is less than 6 mL (0.2 fl oz), perform the following and discard oil properly: ❒ Determine if R134a leakage was detected, remove component and repair or replace component. ❒ Remove and discard receiver/dryer. ❒ Flush complete system with TY16134 Air Conditioning Flushing Solvent. If component is serviceable, pour flushing solvent in ports and internally wash out old oil and discard oil properly. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) Install required amount of TY22025 Refrigerant Oil in compressor.

• New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent 18 1830 6

Specification Oil—Volume ............................................................................. 210 mL 7.10 fl oz R134a—Weight.................................................................. 800—900 g 1.76—1.99 lb

Connect all components. Perform Evacuate R134a System and Perform Charge R134a System. (Group 1830.)

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

GD61784,00002A5 –19–05MAR08–1/1

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=312

Heating and Air Conditioning

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (Group 1830.) IMPORTANT: Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment.

1. Follow procedures. See Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (E).

T8118AG

IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

–UN–06DEC93

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

R134a and Charging Station Installation A—High Pressure Hose Charge Port Cap B—Red Hose C—Blue Hose D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging Station

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

18 1830 7

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

GD61784,00002A8 –19–11MAR08–1/1

TM10743 (09APR09)

18-1830-7

135D Excavator Repair 040909

PN=313

Heating and Air Conditioning

Recover R134a Refrigerant CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (Group 1830.) CAUTION: Do not remove high pressure relief valve. Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Run air conditioning system for three minutes to help in recovery process. Turn air conditioning system off before proceeding with recovery steps. 2. With engine OFF identify refrigerant type using JT02167A Refrigerant Identification Instrument. 3. Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.) 4. Follow manufacturers’ instructions when using refrigerant recovery/recycling and charging station.

18 1830 8 GD61784,00002A9 –19–11MAR08–1/1

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=314

Heating and Air Conditioning

Evacuate R134a System CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

4. Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.

See Refrigerant Cautions and Proper Handling. (Group 1830.)

Specification Evacuate System—Vacuum ..................................................... 98 kPa 980 kPa 29 in. Hg

Do not remove high pressure relief valve. Air conditioning system will discharge rapidly causing possible injury.

If above specification vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Test. (Group 9031-25.)

1. Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.)

5. When vacuum reaches above specification, close low-side and high-side valves. Turn vacuum pump off.

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

6. If vacuum decreases more than specification in 5 minutes, there is a leak in system.

3. Follow manufacturers’ instructions and evacuate system.

Specification Evacuate System—Vacuum .................................................... 3.4 kPa 34 mbar 1 in. Hg

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

7. Repair leak. 8. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 9. Close low-side and high-side valves. Stop evacuation. 10. Perform Charge R134a System. (Group 1830.)

18 1830 9

GD61784,00002AA –19–11MAR08–1/1

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=315

Heating and Air Conditioning

Charge R134a System CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (Group 1830.) IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Identify refrigerant type using JT02167A Refrigerant Identification Instrument. 2. Connect R134a Refrigerant Recovery/Recycling and Charging Station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.) 3. Perform Evacuate R134a System. (Group 1830.) NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

18 1830 10

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

4. Follow manufacturer’s instructions and charge system.

Continued on next page

TM10743 (09APR09)

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GD61784,00002AB –19–11MAR08–1/2

135D Excavator Repair 040909

PN=316

Heating and Air Conditioning 5. Add refrigerant to system. Specification Air Conditioning System Refrigerant—Refrigerant Quantity .................................................. 0.85 kg 1.87 lb

6. Check air conditioning for proper function. See Diagnose Air Conditioning System Malfunctions. (Group 9031-15.)

GD61784,00002AB –19–11MAR08–2/2

Compressor Remove and Install 1. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) 2. Perform Recover R134a Refrigerant. (Group 1830.)

Continued on next page

GD61784,00002BB –19–29APR08–1/2

18 1830 11

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=317

Heating and Air Conditioning 3. Disconnect electrical connector (3).

–UN–29APR08

4. Loosen and remove compressor belt. See Check and Adjust A/C Belt. (Operator’s Manual.) 5. Remove high and low pressure lines.

TX1037640A

6. Remove compressor (1). 7. Inspect and replace parts as necessary. 8. Install compressor (1). Compressor

9. Install high and low pressure lines.

1—Compressor 2—Cap Screw (4 used) 3—Electrical Connector

10. Connect electrical connector. 11. Install and adjust compressor belt tension. See Check and Adjust A/C Belt. (Operator’s Manual.) 12. Perform Evacuate R134a System. (Group 1830.) 13. Perform Charge R134a System. (Group 1830.) 14. Install counterweight. See Counterweight Remove and Install. (Group 1749.)

GD61784,00002BB –19–29APR08–2/2

Condenser Remove and Install 18 1830 12

1. Perform Recover R134a Refrigerant. (Group 1830.)

Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=318

Heating and Air Conditioning 2. Open cooler door (3).

TX1037410A

–UN–28FEB08

3—Cooler Door

Cooler Door

GD61784,00002AD –19–26MAR08–2/6

3. Remove upper cover (4).

TX1037467A

–UN–29FEB08

4—Cover 5—Cap Screw (8 used)

Upper Cover

18 1830 13 Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=319

Heating and Air Conditioning 4. Disconnect electrical connectors (9). 5. Remove cover (8).

TX1037468A

–UN–05MAR08

6—Cap Screw (2 used) 7—Cap Screw 8—Cover 9—Electrical Connector (2 used)

Cover

GD61784,00002AD –19–26MAR08–4/6

6. Disconnect clip (11).

–UN–05MAR08

7. Remove windshield washer tank (10) from bracket and set aside.

TX1037500A

10—Windshield Washer Tank 11—Clip 12—Door Support 13—Cap Screw 14—Cap Screw (2 used) 15—Main Controller (MCF) Harness Connector (4 used) 16—Engine Control Module (ECM) Harness Connector (2 used) 17—Cap Screw

Windshield Washer Tank

TX1037466A

–UN–03MAR08

18 1830 14

Door Support

Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=320

Heating and Air Conditioning 8. Remove receiver-dryer (21). See Receiver-Dryer Remove and Install. (Group 1830.)

–UN–03MAR08

9. Disconnect air conditioner line (19) from condenser (18). 10. Remove condenser.

TX1037469A

11. Inspect and replace as necessary. 12. Install condenser. Condenser

13. Connect air conditioner line.

18—Condenser 19—Air Conditioner Line 20—Cap Screw 21—Receiver-Dryer 22—Cap Screw

14. Install receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 15. Install windshield washer tank. 16. Connect clip. 17. Install cover. 18. Connect electrical connector. 19. Install upper cover. 20. Close cooler door. 21. Perform Evacuate R134a System. (Group 1830.) 22. Perform Charge R134a System. (Group 1830.)

18 1830 15 GD61784,00002AD –19–26MAR08–6/6

Heater and Air Conditioner Remove and Install 1. Disconnect battery ground (-) cable. 2. Perform Recover R134a Refrigerant. (Group 1830.) 3. Remove seat. See Seat Remove and Install. (Group 1821.)

Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=321

Heating and Air Conditioning 4. Remove cap screw (2), screws (3) and duct (1). 5. Disconnect duct (4) from heater and air conditioning module.

TX1018414A

–UN–01FEB07

1—Duct 2—Cap Screw 3—Screws 4—Duct

Continued on next page

GD61784,00002AE –19–26MAR08–2/6

18 1830 16

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=322

TX1018351A

–UN–01FEB07

Heating and Air Conditioning

1—Cap Screw (4 used) 2—Cover 3—Cover

4—Fuse Block 5—Nut and Lock Washer 6—Cap Screw

7—Cap Screw and Washer (6 used)

6. Remove screws and cover (3). 7. Remove screws and disconnect fuse block (4) from cover (2).

8—Engine Stop Switch 9—Console Mount

18 1830 17

NOTE: Support consoles to aid in the removal of the seat base, air conditioner cover and air conditioner. 11. Support left and right consoles.

8. Remove cap screws (1) and cover (2). 9. Remove cap screw (6) attaching wiring harness to seat base.

12. Remove cap screws (7) and consoles from console mount. 13. Remove console mount (9).

10. Remove retaining nut and engine stop switch (8) from mounting bracket.

Continued on next page

TM10743 (09APR09)

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GD61784,00002AE –19–26MAR08–3/6

135D Excavator Repair 040909

PN=323

TX1018350A

–UN–01FEB07

Heating and Air Conditioning

1—Seat Base 2—Cap Screws 3—Cab Air Temperature Sensor Connector 18 1830 18

4—Recirculating Air Filter Screen 5—Screw

14. Remove floor mat.

6—Cap Screw (3 used) 7—Cap Screw 8—Floor Vent

9—Screw 10—Cap Screw 11—Cap Screws

17. Remove cap screws (2, 6, and 11) from seat base (1).

15. Remove cap screws (7 and 10) and floor vent (8). 16. Remove screw (5) and recirculating air filter screen (4).

18. Lift up seat base (1) and disconnect cab air temperature sensor connector (3). Remove seat base (1).

Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=324

TX1018352A

–UN–01FEB07

Heating and Air Conditioning

1—Cap Screw (3 used) 2—Engine Coolant Hoses

3—Cap Screw (2 used) 4—Cap Screw

5—Cap Screw (3 used) 6—Air Conditioner Refrigerant Lines

7—Air Conditioner

19. Clamp off engine coolant hoses (2). Disconnect engine coolant hoses from air conditioner (7). Plug engine coolant lines to minimize coolant loss.

24. Install air conditioner and cap screws.

20. Remove air conditioner refrigerant lines (6) from air conditioner (7).

26. Connect engine coolant hoses and refrigerant lines.

21. Remove cap screws (1, 3, 4 and 5).

27. Install seat base.

22. Disconnect electrical harness and remove air conditioner (7).

28. Install console mount.

18 1830 19

25. Connect wiring harness.

29. Install left and right console. 23. Repair or replace parts as necessary.

Continued on next page

TM10743 (09APR09)

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PN=325

Heating and Air Conditioning 30. Install floor mat.

33. Perform Charge R134a System. (Group 1830.)

31. Install seat. See Seat Remove and Install. (Group 1821.)

34. Check engine coolant level. Add coolant as necessary.

32. Perform Evacuate R134a System. (Group 1830.)

GD61784,00002AE –19–26MAR08–6/6

Receiver-Dryer Remove and Install 1. Perform Recover R134a Refrigerant. (Group 1830.)

GD61784,00002AC –19–26MAR08–1/3

2. Open cooler door (3).

TX1037410A

–UN–28FEB08

3—Cooler Door

Cooler Door

18 1830 20 Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=326

Heating and Air Conditioning 3. Disconnect electrical connector (5). 4. Remove cap screws (6). 5. Disconnect air conditioning hose (7) and condenser pipe (4). Close all openings using caps and plugs. 6. Loosen cap screw (8) and remove receiver-dryer (9). –UN–28FEB08

7. Inspect and replace parts as necessary. 8. Install receiver-dryer.

TX1037411A

9. Connect condenser pipe. 10. Connect air conditioning hose. Receiver-Dryer

11. Connect electrical connector. 12. Perform Evacuate R134a System. (Group 1830.) 13. Perform Charge R134a System. (Group 1830.)

4—Condenser Pipe 5—Electrical Connector 6—Cap Screw (2 used) 7—Air Conditioning Hose 8—Cap Screw 9—Receiver-Dryer 10—Bracket

GD61784,00002AC –19–26MAR08–3/3

18 1830 21

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=327

Heating and Air Conditioning

18 1830 22

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=328

Section 32

Bulldozers (Blades) Contents Page

Group 3201—Blades Blade Remove and Install . . . . . . . . . . . . . . .32-3201-2 Group 3260—Hydraulic System Blade Pump Remove and Install . . . . . . . . . .32-3260-1 Blade Pump Disassemble and Assemble . . .32-3260-3 Blade Pump Pressure Relief Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-6 Blade Control Valve Remove and Install . . . .32-3260-7 Blade Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .32-3260-10 Blade Pilot Controller Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-11 Blade Pilot Controller Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .32-3260-13 Blade Cylinder Remove and Install . . . . . . .32-3260-15 Blade Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .32-3260-20

TM10743 (09APR09)

32-1

135D Excavator Repair 040909

PN=1

Contents

TM10743 (09APR09)

32-2

135D Excavator Repair 040909

PN=2

Group 3201

Blades

32 3201 1

TM10743 (09APR09)

32-3201-1

135D Excavator Repair 040909

PN=331

Blades

Blade Remove and Install

TX1039297

–UN–27MAR08

32 3201 2

Blade Remove and Install Continued on next page

TM10743 (09APR09)

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JW00603,000010A –19–07APR08–1/2

135D Excavator Repair 040909

PN=332

Blades 1—Blade

9—Pin (2 used)

13—Cap Screw (2 used)

1. Lower blade to ground.

15—Shim (4 used)

8. Install shims (15) as required for minimum clearance.

2. Remove blade cylinders. See Blade Cylinder Remove and Install. (Group 3260.)

IMPORTANT: Align pin bores so shims are not damaged as pin is installed.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Support blade. Specification Blade—Weight (approximate)................................................... 557 kg 1228 lb.

9. Install pins (9) and cap screws (13). 10. Tighten nuts against each other allowing cap screws to be free to turn in hole. Specification Blade-to-Frame Pin Retainer Nut (tighten nut against nut)— Torque.................................................................................... 270 N•m 200 lb-ft

4. Remove pins (9). 11. Install blade cylinders.See Blade Cylinder Remove and Install. (Group 3260.)

5. Remove blade. 6. Inspect and replace blade as necessary.

12. Grease all pins. See Grease Front End Pin Joints. (Operator’s Manual.)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Install blade. Specification Blade—Weight (Approximate) .................................................. 557 kg 1228 lb.

JW00603,000010A –19–07APR08–2/2

32 3201 3

TM10743 (09APR09)

32-3201-3

135D Excavator Repair 040909

PN=333

Blades

32 3201 4

TM10743 (09APR09)

32-3201-4

135D Excavator Repair 040909

PN=334

Group 3260

Hydraulic System Blade Pump Remove and Install 1. Lower blade to ground.

JW00603,000010E –19–30APR08–1/3

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 2. Push pressure release button (1). 3. Apply vacuum to hydraulic system. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

–UN–22FEB08

4. Open hydraulic pump door.

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

Continued on next page

JW00603,000010E –19–30APR08–2/3

32 3260 1

TM10743 (09APR09)

32-3260-1

135D Excavator Repair 040909

PN=335

Hydraulic System 5. Install identification tags on hydraulic hoses to blade pump and pilot pump. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.) See Blade Hydraulic System Component Location. (Group 9025-15.)

15 16

6. Disconnect hydraulic hoses and close all openings with caps and plugs.

135

NOTE: Blade pump and pilot pump are assembled together and must be removed as a unit. –UN–10APR08

7. Remove blade pump (135) and pilot pump (28) together.

TX1040214

8. Inspect and repair as necessary. See Blade Pump Disassemble and Assemble. (Group 3260.) 9. Install blade pump and pilot pump together. 10. Connect hydraulic hoses. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.) See Blade Hydraulic System Component Location. (Group 9025-15.)

Blade Pump 15—Pump 1 16—Pump 2 28—Pilot Pump 135—Blade Pump

11. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 12. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 13. Adjust pilot pump pressure. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.) 14. Adjust blade pump pressure. Perform Blade Main Relief Valve Test and Adjustment. (Group 9025-25.)

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Hydraulic System

Blade Pump Disassemble and Assemble NOTE: Blade pump and pilot pump are assembled together and must be removed together. 1. Remove blade and pilot pump assembly. See Blade Pump Remove and Install. (Group 3260.)

Continued on next page

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Hydraulic System

26 13 25

34 34 2

8 25 15

8 16

25 34 34 25 15 31

26 8 9 10 3

32 3260 4

10 –UN–11APR08

2 9

TX1040221

28 TX1040221

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PN=338

Hydraulic System 1—Flange 2—Housing (2 used) 3—Flange 5—End Plate 6—Snap Ring

7—Seal 8—Seal (4 used) 9—Back-Up Ring (4 used) 10—O-Ring (4 used) 13—Gear

15—Gear (2 used) 16—Gear 25—Bushing (4 used) 26—Bushing (4 used) 27—Coupler

28—Dowel Pin (6 used) 29—Washer (4 used) 30—Stud (4 used) 31—Nut (4 used)

14. Remove bushings (25 and 26) with gears (13 and 15) from housing (2).

2. Remove nuts (31). 3. Remove end plate (5).

IMPORTANT: Keys are loose and can fall out of position during pump disassembly. Pump will not function with out keys.

4. Remove seal (8) and back-up ring (9). 5. Remove housing (2) from flange (3).

15. Remove bushings (25 and 26) from gears (13 and 15) and keys (34).

6. Remove seal (8) and back-up ring (9). IMPORTANT: Note location of gears and bushings, They must be installed in the original location due to wear patterns. Damage to pump and housing will occur if assembled incorrectly.

16. Remove seal (7) from Flange (1).

7. Remove bushings (25 and 26) with gears (15 and 16) from housing (2).

18. Inspect Gears (13, 15 and 16) and housings (2). If gear teeth, shaft, and inside of housing is rough or worn, replace pump.

IMPORTANT: Keys are loose and can fall out of position during pump disassembly. Pump will not function with out keys. 8. Remove bushings (25 and 26) from gears (15 and 16) and keys (34).

17. Inspect bushings (25 and 26). If inside diameter and surface toward gear are rough or worn, replace the pump.

IMPORTANT: Pump damage will occur if pump is assembled dry. 19. Apply clean hydraulic oil to all parts. 20. Apply multipurpose grease to lip of seal (7). Install seal with lip (spring side) towards inside of flange (1).

9. Remove Flange (3) and coupler (27). 10. Remove Snap ring (6).

21. Install new O-ring (10). 11. Remove seal (8) and back-up ring (9). 22. Assemble bushings (25 and 26), keys (34) and gears (13 and 15) in original location and install in housing (2).

12. Remove housing (2). 13. Remove seal (8) and back-up ring (9).

23. Install seal (8) and back-up ring (9). IMPORTANT: Note location of gears and bushings, They must be installed in the original location due to wear patterns. Damage to pump and housing will occur if assembled incorrectly.

24. Install assembled pump to flange (1). 25. Install snap ring (6).

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Hydraulic System 26. Install new O-ring (10) to flange (3) and install to assembled housing (2).

32. Install end plate (5). 33. Install washers (29) and nuts (31) and tighten to specification.

27. Install coupler (27) and O-ring (10). 28. Assemble bushings (25 and 26), keys (34) and gears (15 and 16) in original location and install in housing (2).

Specification Blade pump End Flange-to-Pilot pump Mounting Flange— Torque...................................................................................... 40 N•m 30 lb-ft

29. Install seal (8) and back-up ring (9). 34. Install blade and pilot pump assembly. See Blade Pump Remove and Install. (Group 3260.)

30. Install assembled pump to flange (3). 31. Install O-ring (10) to end plate (5).

JW00603,0000110 –19–10APR08–4/4

Blade Pump Pressure Relief Valve Remove and Install 1. Lower blade to the ground. JW00603,0000128 –19–16APR08–1/3

–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

TX1037206A

32 3260 6

Hydraulic Pressure Release Button

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Hydraulic System 4. Install identification tags on hydraulic hoses. 5. Disconnect hydraulic hoses (4) and close all openings with caps and plugs. 6. Remove blade pump pressure relief valve (3). 7. Inspect and replace as necessary. 8. Install blade pump pressure relief valve.

–UN–28MAR08

9. Connect hydraulic hoses. 10. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

TX1039501A

11. Set blade pump pressure relief valve. See Blade Main Relief Valve Test and Adjustment. (Group 9025-25.) 3—Blade Pump Pressure Relief Valve 4—Hydraulic Hose (3 used) 5—Cap Screw (2 used)

Blade Pump Pressure Relief Valve

JW00603,0000128 –19–16APR08–3/3

Blade Control Valve Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Apply vacuum to hydraulic system. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

Continued on next page

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32 3260 7

Hydraulic System 3. Remove cover (4).

TX1040470A

–UN–17APR08

3—Cap Screw (3 used) 4—Cover

Center Joint Cover

Continued on next page

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Hydraulic System

7 7

TX1040471

–UN–29APR08

TX1040471 Blade Control Valve 5—Blade Control Valve

6—Cap Screw (4 used)

7—Hydraulic Hose (5 used)

4. Install identification tags on hydraulic hoses (7).

9. Connect hydraulic hoses.

5. Disconnect hydraulic hoses (7). Close all openings with caps and plugs.

10. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

6. Remove blade control valve (5).

11. Adjust blade relief valve. Perform Blade Main Relief Valve Test and Adjustment. (Group 9025-25.)

7. Inspect and repair as necessary. See Blade Control Valve Disassemble and Assemble. (Group 3260.) 8. Install blade control valve.

JW00603,000010F –19–30APR08–3/3

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Hydraulic System

Blade Control Valve Disassemble and Assemble 19 23 20

24 10

26 10

1 31 29

28 30

31 –UN–31MAR08

TX1039412

Blade Control Valve 1—Relief Valve 10—O-Ring (2 used) 19—Fitting 20—O-Ring (2 used) 21—Plunger 22—Spring

23—Body 24—Plunger 25—Relief Valve 26—Cap Screw (4 used) 27—Spool End

28—Spring Seat (2 used) 29—Spring 30—Spring 31—O-Ring (2 used) 32—End Cap

1. Remove blade control valve. See Blade Control Valve Remove and Install. (Group 3260.)

33—Spool 34—O-Ring 35—Plug 36—Housing 37—End Cap

5. Disassemble parts (27—28). 6. Remove plug (35) from spool (33).

IMPORTANT: Relief valves are not adjustable. Disassembly will change relief settings and will result in machine damage. 32 3260 10

IMPORTANT: Relief valves are not interchangeable. Mark location to aid in assembly. 2. Remove relief valves (1 and 25). 3. Remove end caps (32 and 37).

7. Remove parts (19—24). 8. Inspect and replace parts as necessary. 9. Install plunger (24), spring (22), O-ring (20), and body (23). 10. Install spring (22), plunger (21), O-ring (20), and fitting (19). 11. Install O-ring (34), and plug (35) to spool (33) and install to housing (36).

4. Remove parts (27—35).

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Hydraulic System 12. Assemble parts (27—30) as shown and install to housing (36). 13. Install end caps (32 and 37) with new O-rings (31). IMPORTANT: Install Relief valves in locations marked in removal. Damage to hydraulic system will occur if they are interchanged.

14. Install relief valves 15. Install blade control valve. See Blade Control Valve Remove and Install. (Group 3260.) 16. If relief valves were replaced set blade main relief valve. See Blade Main Relief Valve Test and Adjustment. (Group 9025-25.)

JW00603,0000129 –19–16APR08–2/2

Blade Pilot Controller Remove and Install 1. Lower Blade to ground.

Continued on next page

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Hydraulic System

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 2. Push pressure release button (1). 3. Swing machine 90 degrees to gain access to bottom of cab.

–UN–22FEB08

4. Remove cover under cab. 5. Apply vacuum to hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

7. Disconnect hydraulic hoses and close all openings with caps and plugs.

TX1037206A

6. Install identification tags on hydraulic hoses. See Blade Hydraulic System Component Location. (Group 9025-15.) Hydraulic Pressure Release Button 1—Pressure Release Button 2—Hydraulic Oil Tank Cover

8. Disconnect blade lever control cable. 9. Remove blade pilot controller. 10. Inspect and repair as necessary. See Blade Pilot Controller Disassemble and Assemble. (Group 3260.) 11. Install blade pilot controller. 12. Connect hydraulic hoses. 13. Connect blade lever control cable. 14. Install access cover under cab. 15. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

32 3260 12

NOTE: Blade hydraulic system will bleed automatically when operating. 16. Start machine and operate blade controls.

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Hydraulic System

Blade Pilot Controller Disassemble and Assemble 1. Remove blade pilot controller. See Blade Pilot Controller Disassemble and Assemble. (Group 3260.) IMPORTANT: Spools are select fitted to bores in housing. If damage is observed blade pilot controller must be replaced. 2. Remove boot (10). 3. Scribe alignment marks on housing (1) and housing cover (6) to aid in assembly. 4. Remove set screw (12) to remove pin (13).

–UN–02APR08

5. Remove cam (11). 6. Record number of threads on set screw (9) beyond nut (8) to aid in assembly.

TX1039427A

7. Remove nuts (8) and set screws (9). CAUTION: Slowly remove cap screws to relieve spring force.

Blade Pilot Controller 1—Housing 2—Return Spring (2 used) 3—Spool Assembly (2 used) 4—Plunger (2 used) 5—Plunger (2 used) 6—Housing Cover 7—Cap Screw (2 used) 8—Nut (2 used) 9—Set Screw (2 used) 10—Boot 11—Cam 12—Set Screw 13—Pin 14—O-Ring (2 used)

8. Remove housing cover (6). IMPORTANT: Spools must be installed in the same bores of the housing because of wear patterns. Mark location of spools with respect to bores to aid in assembly. 9. Remove parts (2—5) from housing (1).

32 3260 13

Continued on next page

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Hydraulic System 10. Push spring guide (16) inward to release spring force and remove retainers (15). 11. Remove parts (17—20). 12. Inspect and replace parts as necessary. 13. Apply clean hydraulic oil to all machined surfaces.

TX1039428A

–UN–02APR08

15—Retainer (4 used) 16—Spring Guide (2 used) 17—Spring (2 used) 18—Spring Seat (2 used) 19—Shim (2 used) 20—Spool (2 used)

Spool Assembly Disassemble

JW00603,000012B –19–16APR08–2/4

NOTE: When assembling spools install retainers so concave side is against spring guide. 14. Assemble parts (15—20).

–UN–02APR08

15—Retainer (4 used) 16—Spring Guide (2 used) 17—Spring (2 used) 18—Spring Seat (2 used) 19—Shim (2 used) 20—Spool (2 used)

TX1039428A

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Spool Assembly Assemble

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Hydraulic System 15. Install new O-rings (14) to plungers (5). NOTE: Install parts into the same bores from which they were removed. 16. Install parts (2—5) to housing (1). IMPORTANT: Tighten cap screws evenly to prevent binding and damage to housing and spools. 17. Install housing cover (6) 18. Install set screws (9) nuts (8) to cam (11). Use measurement recorded in disassembly procedure. 19. Install assembled cam (11) to housing cover (6). –UN–02APR08

20. Install pin (13) and set screw (12). 21. Apply multi purpose grease to ends of set screws (9).

TX1039427A

22. Install boot (10). 23. Install blade pilot controller. See Blade Pilot Controller Disassemble and Assemble. (Group 3260.) Blade Pilot Controller 1—Housing 2—Return Spring (2 used) 3—Spool Assembly (2 used) 4—Plunger (2 used) 5—Plunger (2 used) 6—Housing Cover 7—Cap Screw (2 used) 8—Nut (2 used) 9—Set Screw (2 used) 10—Boot 11—Cam 12—Set Screw 13—Pin 14—O-Ring (2 used)

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Blade Cylinder Remove and Install 1. Lower blade to ground.

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Hydraulic System

TX1037206A

–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

JW00603,000010B –19–16APR08–2/5

NOTE: Procedure is the same for both left and right blade cylinders.

–UN–03APR08

3. Remove cover (3). 4. Apply vacuum to hydraulic system. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1039778A

3—Cover 4—Cap Screw (2 used)

Blade Cylinder

32 3260 16

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Hydraulic System 5. Install identification tags on hydraulic hoses (6). 6. Disconnect hydraulic hoses and close all openings with caps and plugs.

–UN–04APR08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Support blade cylinder (5).

TX1039780A

Specification Blade Cylinder—Weight (approximate)..................................................................................... 52 kg 115 lb. Blade Cylinder

8. Remove cap screws (7) and pins (9). 5—Blade Cylinder 6—Hydraulic Hose (2 used) 7—Cap Screw (2 used) 8—Nut (4 used) 9—Pin (2 used)

9. Remove blade cylinder. 10. Inspect and repair as necessary. See Blade Cylinder Disassemble and Assemble. (Group 3260.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Install blade cylinder. Specification Blade Cylinder—Weight (approximate)..................................................................................... 52 kg 115 lb.

12. Install pins. 13. Install cap screws and nuts and tighten nuts to specification against each other allowing cap screw to be free to turn in hole. Specification Blade Cylinder-to-Blade Pin Retainer Nut (tighten nut against nut)—Torque................................................................................. 270 N•m 200 lb-ft

32 3260 17

14. Connect hydraulic hoses. 15. Install cover.

Continued on next page

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Hydraulic System 16. Bleed blade cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 17. Grease blade pins. See Grease Front End Pin Joints. (Operator’s Manual.) 18. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

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Hydraulic System

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Hydraulic System

Blade Cylinder Disassemble and Assemble

T113632

–UN–22APR98

32 3260 20

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Hydraulic System 1—Wiper Seal (2 used) 2—Bushing 3—Cylinder Tube 4—Grease Fitting 5—Cap Screw (4 used) 6—Joint 7—O-Ring 8—Piston Nut 9—Shim (as required)

10—Wear Ring 11—Slide Ring 12—Backup Ring 13—Seal Ring 14—Piston 15—Backup Ring 16—Slide Ring 17—Wear Ring

18—Steel Ball 19—Set Screw 20—Wiper Seal (2 used) 21—Bushing 22—Piston Rod 23—Grease Fitting 24—Wiper Ring 25—Backup Ring

1. Remove blade cylinder. See Blade Cylinder Remove and Install. (Group 3260.)

26—U-Ring 27—Seal 28—Rod Guide 29—O-Ring 30—Bushing 31—Retaining Ring 32—Backup Ring 33—O-Ring

IMPORTANT: Remove components carefully during disassembly to prevent damage to sliding surfaces.

NOTE: Procedure is the same for both blade cylinders.

4. Loosen rod guide (28) using ST3223 Spanner Wrench.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Support cylinder and fasten cylinder head (28) to JT30043 cylinder service stand. Specification Cylinder—Weight (approximate)................................................. 52 kg 114 lb.

5. Pull piston rod (22) out so piston (14) is against rod guide. 6. Support piston rod. 7. Remove piston rod, rod guide and piston from cylinder head.

3. Drain hydraulic oil from cylinder head.

Continued on next page

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Hydraulic System 8. Install piston rod eye in sliding housing and install housing in the JT30043 Cylinder Service Stand. 9. Remove the staked material from set screw hole using a small air grinder or a drill and bit. 10. Remove set screw (19). –UN–31MAY05

NOTE: Mark mating surfaces of piston rod and nut.

T211651A

11. Remove nut (8) using JT30043 Cylinder Service Stand. 12. Remove piston from piston rod. 13. Remove rod guide from piston rod.

34—Sliding Housing

IMPORTANT: Take care not to damage other parts when removing seals. IMPORTANT: Do not reuse slide rings, seal ring, backup ring, or O-ring. 14. Remove parts (15—17). 15. Remove Retaining ring (31), and bushing (30) using ST2685 Rod Bushing Driver. 16. Remove parts (24—27). 17. Remove parts (29—33). 18. Inspect and repair parts as necessary. 19. Apply clean hydraulic oil to all sealing parts and machined surfaces. 20. Install bushing using ST2685 Rod Bushing Driver. 21. Install snap ring. 22. Install snap ring, U-ring, and seal. 32 3260 22

23. Install dust seal using ST2689 Dust Seal Driver. 24. Install O-ring on to rod guide. 25. Install backup ring and O-ring.

Continued on next page

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Hydraulic System 26. Install rod guide. IMPORTANT: O-rings must not be twisted when installed in grove. 27. Install backup rings, O-ring and seal ring. IMPORTANT: When installing slide rings splits must be offset to prevent leaking. 28. Install slide rings to piston. 29. Install piston to piston rod. 30. Install nut to piston rod and tighten to specification using ST3334 Spanner Wrench. Specification Nut-to Piston Rod—Torque ........................................................ 2640 N•m 1950 lb-ft

31. Install steel ball. 32. Apply PM37418 Medium-Strength Thread Lock and Sealer to set screw. IMPORTANT: After installation of steel ball and set screw stake the set screw head in two places, to prevent loosening. 33. Install set screw and tighten to specification. Specification Blade Cylinder Piston Nut Set Screw—Torque ............................................................................... 32 N•m 23 lb-ft

34. Install piston, piston rod, and rod guide into cylinder head. 35. Tighten rod guide to specification using ST3223 Spanner Wrench. Specification Rod Guide—Torque ..................................................................... 850 N•m 480 lb-ft

32 3260 23

36. Install blade cylinder. See Blade Cylinder Remove and Install. (Group 3260.)

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Hydraulic System

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Section 33

Excavator Contents Page

Page

Group 3302—Buckets Bucket Remove and Install . . . . . . . . . . . . . .33-3302-1 Bucket Pin-Up Data. . . . . . . . . . . . . . . . . . . .33-3302-2

Travel Pilot Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-56 Pilot Signal Manifold Remove and Install. . .33-3360-58 Pilot Signal Manifold Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-62 Control Valve Remove and Install . . . . . . . .33-3360-69 Control Valve Separation. . . . . . . . . . . . . . .33-3360-76 Control Valve (5-Spool) Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-77 Control Valve (4-Spool) Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-88 Hydraulic Oil Tank Remove and Install . . . 33-3360-100 Hydraulic Oil Tank Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-104 Restriction Valve Remove and Install . . . . 33-3360-108 Hydraulic Oil Cooler Bypass Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . 33-3360-110 Boom Cylinder Remove and Install . . . . . . 33-3360-111 Boom Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-116 Arm Cylinder Remove and Install . . . . . . . 33-3360-118 Arm Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-124 Bucket Cylinder Remove and Install . . . . . 33-3360-126 Bucket Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-130 Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-132

Group 3340—Frames Bucket Links Remove and Install . . . . . . . . .33-3340-1 Arm Remove and Install . . . . . . . . . . . . . . . .33-3340-2 Boom Remove and Install . . . . . . . . . . . . . . .33-3340-7 Inspect Pins, Bushings and Bosses—Front Attachment . . . . . . . . . . . . . . . . . . . . . . .33-3340-10 Bushings and Seal Remove and Install . . . .33-3340-13 Group 3360—Hydraulic System Apply Vacuum to Hydraulic Oil Tank . . . . . . .33-3360-1 Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-3 Pump 1 and 2 Remove and Install . . . . . . . .33-3360-4 Pump 1 and 2 Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-9 Pump 1 and 2 Inspection . . . . . . . . . . . . . .33-3360-23 Pump 1 and 2 Start-Up Procedure . . . . . . .33-3360-25 Pump 1 and 2 Regulator Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-27 Pump 1 and 2 Regulator Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-29 Pilot Pump Remove and Install . . . . . . . . . .33-3360-34 Pilot Pump Disassemble and Assemble . . .33-3360-35 Pilot Pressure Regulating Valve and Filter Remove and Install . . . . . . . . . . . . . . . . .33-3360-38 Pilot Pressure Regulating Valve and Filter Disassemble and Assemble. . . . . . . . . . .33-3360-39 Pilot Shutoff Solenoid Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-39 Pilot Shutoff Solenoid Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-42 Solenoid Valve Manifold Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-43 Travel Speed and Arm Regenerative Solenoid Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-46 Pilot Valve (Left and Right) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-48 Pilot Valve (Left and Right) Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-52 Travel Pilot Valve Remove and Install . . . . .33-3360-54 TM10743 (09APR09)

33-1

135D Excavator Repair 040909

PN=1

Contents

TM10743 (09APR09)

33-2

135D Excavator Repair 040909

PN=2

Group 3302

Buckets Bucket Remove and Install

6 3 3 5 7

4 3 2

1 8

–UN–24JUL01

5 1

T142450

3 T142450

1—Bushing (2 used) 2—Seal (2 used)

3—O-Ring (4 used) 4—Ring (2 used)

5—Pin (2 used) 6—Pin

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

7—Pin 8—Bucket

3. Remove bucket. 4. Repair or replace parts as necessary. 5. Align pin bores and install pins (6 and 7).

1. Position bucket (8) on level surface. Specification Bucket—Weight (approximate) ................................................. 420 kg 928 lb

6. Adjust bucket to arm joint.

2. Remove parts (5—7).

JW00603,0000085 –19–22APR08–1/1

33 3302 1

TM10743 (09APR09)

33-3302-1

135D Excavator Repair 040909

PN=361

Buckets

Bucket Pin-Up Data

2 1 10

8 7 17 Section A

14 13 12 Section B

TX1003797

–UN–07MAR06

Continued on next page

JW00603,00000E4 –19–24MAR08–1/2

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=362

Buckets IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine. Item 1

325 mm 12.8 in.

5 mm 0.2 in.

505 mm 19.9 in.

460 mm 18.1 in.

—

1230 mm 48.4 in.

377 mm 14.8 in.

254 mm 10 in.

65 mm 2.6 in.

355.2 mm 14 in.

70 mm 2.8 in.

377 mm 14.8 in.

255 mm 10 in.

650 mm 25.5 in.

90°

30°

391 mm 15.4 in.

JW00603,00000E4 –19–24MAR08–2/2

33 3302 3

TM10743 (09APR09)

33-3302-3

135D Excavator Repair 040909

PN=363

Buckets

33 3302 4

TM10743 (09APR09)

33-3302-4

135D Excavator Repair 040909

PN=364

Group 3340

Frames Bucket Links Remove and Install

27 27

1 1 2 29

2 4

19 18 24

5 21 19 11 20 21

T166094

–UN–13MAR03

T166094 Bucket Links 1—Bushing (2 used) 2—Seal (4 used) 3—Bushing (2 used) 4—Link 5—Link

10—Pin 11—Pin 12—Pin 13—Pin

18—Cap Screw (2 used) 19—Nut (4 used) 20—Retainer (2 used) 21—Pin (2 used)

Continued on next page

TM10743 (09APR09)

33-3340-1

24—O-Ring (4 used) 27—Shim (as required) 29—Shim (as required) 40—Center Link

33 3340 1

JW00603,00000DD –19–16APR08–1/2

135D Excavator Repair 040909

PN=365

Frames NOTE: It is not necessary to remove bucket to remove bucket links.

7. Repair or replace parts as necessary. 8. Install center link (40) and pin (12).

1. Connect center link (40) to a hoist using a lifting strap. Put a wood block between bucket cylinder and arm to hold cylinder up when cylinder pin (10) is removed. 2. Remove cap screws (18) and nuts (19). NOTE: Mark location of shims (27 and 29) to aid in assembly.

9. Install pins (21) and retainers (20). 10. Install shims (27 and 29) equally on each side of joint to get a minimal amount of clearance in the joint. There must be some clearance in the joint. 11. Align pin bores and install pins (10 and 13). 12. Install cap screws (18) and nuts (19).

3. Remove pins (10 and 13) and shims (27 and 29). Tighten nuts (19) against each other. Cap screws (18) need to be free to turn.

4. Remove retainers (20) and pins (21).

13. Apply multipurpose grease to pivot joints. See Grease Front End Pin Joints. (Operator’s Manual.)

5. Remove pin (12) and center link (40). 6. Inspect bushings and seals. See Inspect Pins, Bushings and Bosses—Front Attachment. (Group 3340.)

JW00603,00000DD –19–16APR08–2/2

Arm Remove and Install 1. Remove bucket. See Bucket Remove and Install. (Group 3302.) 2. Retract arm cylinder. 3. Put floor stand under end of boom, so load is on boom, not on arm cylinder. Extend arm cylinder just enough to put end of arm on ground.

Continued on next page

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=366

Frames

TX1037206A

–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

JW00603,00000DE –19–16APR08–2/7

–UN–08DEC08

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 5. Loosen bucket cylinder hydraulic hoses to release any residual pressure.

X9811

NOTE: Remove bucket cylinder and linkage only if necessary to repair arm. 7. Remove bucket links and bucket cylinder. See Bucket Links Remove and Install. (Group 3340.) See Bucket Cylinder Remove and Install. (Group 3360.)

Continued on next page

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=367

Frames

CAUTION: Prevent crushing injury ; use appropriate lifting device. Weight of boom, arm and bucket assembly and components will vary depending on machine configuration. Specification Boom, Arm and Bucket Assembly—Approximate Weight ................................................... 3100 kg 6840 lb Bucket Cylinder—Weight................................................................. 110 kg 243 lb Arm Cylinder—Weight ..................................................................... 110 kg 243 lb

T6626JC

–UN–31OCT88

8. Attach appropriate lifting device to arm.

Arm With Bucket Cylinder

JW00603,00000DE –19–16APR08–4/7

9. Put wooden block between arm cylinder (5) and boom to hold cylinder up when cylinder pin (2) is removed.

–UN–19APR06

10. Remove nuts (1), cap screw (3) and pin (2).

TX1003794A

1—Nut (2 used) 2—Pin 3—Cap Screw 4—Arm 5—Arm Cylinder

Continued on next page

JW00603,00000DE –19–16APR08–5/7

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TM10743 (09APR09)

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135D Excavator Repair 040909

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Frames 11. Install identification tags and disconnect hydraulic hoses (3). Close all openings with caps and plugs.

–UN–15MAR06

12. Remove cap screw (1) and boom-to-arm pin (2). 13. Remove arm and lower to floor.

TX1003793A

14. Inspect bushings and dust seals. See Inspect Pins, Bushings and Bosses—Front Attachment. (Group 3340.) 15. Repair or replace parts as necessary. See Bushings and Seal Remove and Install. (Group 3340.) 1—Cap Screw 2—Pin 3—Hydraulic Hose

Continued on next page

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33 3340 5

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=369

Frames 16. Install thrust plates (4 and 12) equally on each side of arm to get minimal amount of clearance between boom and arm.

17. Install boom-to-arm pin (11), block (10), plate (9), washer (8) and cap screw (7). 18. Connect arm cylinder by inserting cylinder pin (6), cap screw (3) and nuts (1).

19. Connect hoses.

2 20. Apply multipurpose grease to all lubrication fittings. See Grease Front End Pin Joints. (Operator’s Manual.) 21. Install bucket. See Bucket Remove and Install. (Group 3302.)

T142652

–UN–27SEP01

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

10 7 8

T142653

–UN–24JUL01

JW00603,00000DE –19–16APR08–7/7

33 3340 6

TM10743 (09APR09)

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135D Excavator Repair 040909

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Frames

Boom Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Remove bucket and arm. See Bucket Remove and Install. (Group 3302.) See Arm Remove and Install. (Group 3340.) 3. Lower boom to ground.

TX1037206A

4. Install identification tags on hydraulic lines and hoses and electrical wire connectors. 5. Disconnect hydraulic hoses and lines close all openings with caps and plugs.

Hydraulic Pressure Release Button 1—Pressure Release Button 2—Hydraulic Oil Tank Cover

6. Disconnect electrical connectors. 7. Disconnect lubrication hoses at rod end of boom cylinders. 8. Remove arm cylinder only if necessary to repair boom. See Arm Cylinder Remove and Install. (Group 3360.) 9. Disconnect boom cylinder rod ends. See Boom Cylinder Remove and Install. (Group 3360.)

Continued on next page

JW00603,00000E3 –19–16APR08–1/4

33 3340 7

TM10743 (09APR09)

33-3340-7

135D Excavator Repair 040909

PN=371

Frames 10. Open door (3). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

–UN–19MAR08

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

TX1038495A

11. Support boom. Specification Boom—Weight Approximate ........................................................... 759 kg 1673 lb Access Door 3—Access Door

Continued on next page

JW00603,00000E3 –19–16APR08–2/4

33 3340 8

TM10743 (09APR09)

33-3340-8

135D Excavator Repair 040909

PN=372

Frames 12. Remove cap screw (8) and washer (9). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 13. Remove boom pin (10). –UN–26MAR08

14. Remove boom.

TX1038695A

Specification Boom Pin—Weight ............................................................................ 23 kg 51 lb

15. Inspect and replace as necessary. See Inspect Pins, Bushings and Bosses—Front Attachment. (Group 3340.) See Bushings and Seal Remove and Install. (Group 3340.)

Boom Pin 8—Cap Screw 9—Washer 10—Boom Pin

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. NOTE: Arm end of boom is heavy end with arm cylinder installed. Frame end is heavy end when arm cylinder is removed. 16. Install boom. Specification Boom—Weight Approximate ........................................................... 759 kg 1673 lb

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 17. Install boom pin, washer, and cap screw and tighten to specification. Specification Boom Pin—Weight ............................................................................ 23 kg 51 lb Boom Pin-to-Frame Cap Screw— Torque .......................................................................................... 400 N•m 295 lb-ft

33 3340 9

Continued on next page

TM10743 (09APR09)

33-3340-9

JW00603,00000E3 –19–16APR08–3/4

135D Excavator Repair 040909

PN=373

Frames 18. Install boom cylinder rod ends. See Boom Cylinder Remove and Install. (Group 3360.) 19. Connect hydraulic hoses and lines. 20. Connect electrical connectors. 21. Connect lubrication hoses. 22. Install arm. See Arm Remove and Install. (Group 3340.) 23. Install bucket. See Bucket Remove and Install. (Group 3302.) 24. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 25. Perform cylinder bleed procedure. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 26. Grease all pins and bosses. See Grease Front End Pin Joints. (Operator’s Manual.)

JW00603,00000E3 –19–16APR08–4/4

4 9 2 TX1004442

Continued on next page

TX1004442

1—Boom-to-Frame Joint 2—Boom Cylinder Head End-to-Frame Joint 3—Boom Cylinder Rod End-to-Boom Joint 4—Boom-to-Arm Joint 5—Arm Cylinder Rod End-to-Arm Joint 6—Arm Cylinder Head End-to-Boom Joint 7—Bucket Cylinder Head End-to-Arm Joint 8—Bucket Cylinder Rod End-to-Side and Bucket Links Joint 9—Side Links-to-Arm Joint 10—Bucket Link-to-Bucket Joint 11—Bucket-to-Arm Joint

–UN–06MAR06

Inspect Pins, Bushings and Bosses—Front Attachment

JW00603,00000DF –19–17MAR08–1/3

33 3340 10

TM10743 (09APR09)

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135D Excavator Repair 040909

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Frames Pins, Bushings, and Bosses

Item

Standard

Allowable Limit

Remedy

71 mm 2.79 in.

70.0 mm 2.75 in.

Replace

Bushing

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

71 mm 2.79 in.

70.0 mm 2.75 in.

Replace

Boss (Main Frame)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

Bushing (Boom Cylinder)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

71 mm 2.79 in.

70.0 mm 2.75 in.

Replace

Bushing (Boom Cylinder)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

Boss (Boom)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

71 mm 2.79 in.

70.0 mm 2.75 in.

Replace

Bushing

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

71 mm 2.79 in.

70.0 mm 2.75 in.

Replace

Boss (Arm)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

Bushing (Arm Cylinder)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

71 mm 2.79 in.

70.0 mm 2.75 in.

Replace

Boss (Boom)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

Bushing (Arm Cylinder)

71 mm 2.79 in.

72.5 mm 2.85 in.

Replace

60 mm 2.36 in.

59 mm 2.32 in.

Replace

Boss (Arm)

60 mm 2.36 in.

61.5 mm 2.42 in.

Replace

Bushing (Bucket Cylinder)

60 mm 2.36 in.

61.5 mm 2.42 in.

Replace

65 mm 2.55 in.

64 mm 2.52 in.

Replace

Bushing

65 mm 2.55 in.

66.5 mm 2.61 in.

Replace

Bushing (Bucket Cylinder)

65 mm 2.55 in.

66.5 mm 2.61 in.

Replace

33 3340 11

Continued on next page

TM10743 (09APR09)

33-3340-11

JW00603,00000DF –19–17MAR08–2/3

135D Excavator Repair 040909

PN=375

Frames Pins, Bushings, and Bosses

Item

Standard

Allowable Limit

Remedy

65 mm 2.55 in.

64 mm 2.52 in.

Replace

Bushing

65 mm 2.55 in.

66.5 mm 2.61 in.

Replace

65 mm 2.55 in.

64 mm 2.52 in.

Replace

Bushing

65 mm 2.55 in.

66.5 mm 2.61 in.

Replace

65 mm 2.55 in.

64 mm 2.52 in.

Replace

Bushing

65 mm 2.55 in.

66.5 mm 2.61 in.

Replace

JW00603,00000DF –19–17MAR08–3/3

33 3340 12

TM10743 (09APR09)

33-3340-12

135D Excavator Repair 040909

PN=376

Frames

Bushings and Seal Remove and Install

IMPORTANT: Only install bushings using press as shown. Bushings will be damaged if installed with driver.

NOTE: Bushing can also be removed by welding three to five weld beads on the inside of bushing. Bushing will shrink enough to permit removal using a hammer.

1. Remove bushing (5) using D01045AA Bushing, Bearing, and Seal Driver Set and 17-1/2 and 30 Ton Puller Set.

9 8

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

–UN–20MAY05

3. Install bushing to a depth equal to thickness of dust seal (10).

T211543

–UN–20MAY05

T211542

T211543

1—Hydraulic Ram 2—Pipe—Minimum ID to Clear Bushing OD 3—Pipe—Maximum OD 4—Pipe—Length of Bushing 5—Bushing 6—Disks 7—Bushing Stop (disk) 8—Pilot (disk) 9—Ram Stop (disk) 10—Thickness of Dust Seal

T211542

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

JW00603,00000E0 –19–16APR08–1/1

33 3340 13

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=377

Frames

33 3340 14

TM10743 (09APR09)

33-3340-14

135D Excavator Repair 040909

PN=378

Group 3360

Hydraulic System Apply Vacuum to Hydraulic Oil Tank Applying vacuum to hydraulic oil tank eliminates the need to drain tank prior to servicing of hydraulic system components.

JW00603,0000084 –19–22APR08–1/5

TX1037206A

–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

Continued on next page

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33 3360 1

TM10743 (09APR09)

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PN=379

Hydraulic System 2. Remove cap screws (3) and hydraulic oil tank cover (2).

TX1037207A

–UN–22FEB08

2—Hydraulic Oil Tank Cover 3—Cap Screws (6 used)

Hydraulic Oil Tank Cover

JW00603,0000084 –19–22APR08–3/5

3. Remove socket head cap screws (4) and pressure release button housing (5).

TX1037208A

–UN–22FEB08

4—Socket Head Cap Screw (4 used) 5—Pressure Release Button Housing

Pressure Release Button Housing

Continued on next page

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33 3360 2

TM10743 (09APR09)

33-3360-2

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PN=380

Hydraulic System 4. Assemble fittings and hydraulic oil tank adapter from D15032NU Vacuum Pump Kit, and JT07085A Vacuum Pump Set. Install in hydraulic tank opening as shown. Refer to pump instructions for operating information. 5. Perform hydraulic system service.

–UN–22FEB08

6. Remove vacuum pump from hydraulic system when finished servicing hydraulic system.

TX1037209A

7. Install pressure release button housing.

Vacuum Pump Installation

JW00603,0000084 –19–22APR08–5/5

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy See General Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy. (Group 9025-25.)

JW00603,0000108 –19–30APR08–1/1

33 3360 3

TM10743 (09APR09)

33-3360-3

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PN=381

Hydraulic System

Pump 1 and 2 Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1). 2. Disconnect negative (-) battery cable. –UN–22FEB08

3. Remove counterweight. See Counterweight Remove and Install. (Group 1749.)

TX1037206A

4. Remove covers above engine. 5. Remove covers under hydraulic oil tank and pump 1 and 2. Hydraulic Pressure Release Button

6. Drain hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

JW00603,00000C5 –19–22APR08–1/7

NOTE: It is not necessary to disconnect the engine oil hoses from the filter housing. 7. Remove engine oil filter housing (5) and set to the side.

TX1038696A

–UN–19MAR08

3—Cap Screw (2 used) 4—Cap Screw (2 used) 5—Engine Oil Filter Housing

Engine Oil Filter Housing and Filter

Continued on next page

JW00603,00000C5 –19–22APR08–2/7

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TM10743 (09APR09)

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PN=382

Hydraulic System 8. Remove muffler heat shields (7—9).

–UN–19MAR08

9. Remove pilot pump. See Pilot Pump Remove and Install. (Group 3360.) NOTE: It is not necessary to disconnect hydraulic hoses from the pilot pressure regulating valve.

TX1038687A

10. Remove pilot pressure regulating valve and filter from heat shield support (10). 6—Cap Screw (5 used) 7—Muffler Heat Shield 8—Muffler Heat Shield 9—Muffler Heat Shield 10—Heat Shield Support

TX1038688A

–UN–19MAR08

Muffler Heat Shield

TX1038689A

–UN–19MAR08

Muffler Heat Shield

TX1038690A

–UN–19MAR08

Muffler Heat Shield

Muffler Heat Shield Continued on next page

TM10743 (09APR09)

33-3360-5

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PN=383

33 3360 5

Hydraulic System 11. Remove heat shield support (10).

TX1038691A

–UN–19MAR08

6—Cap Screw (2 used) 10—Heat Shield Support

TX1038692A

–UN–19MAR08

Heat Shield Support

Heat Shield Support Continued on next page

JW00603,00000C5 –19–22APR08–4/7

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PN=384

Hydraulic System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–19MAR08

12. Remove muffler and bracket.

TX1038694A

Specification Muffler and Bracket—Weight ............................................................ 25 kg 55 lb

13. Install identification tags on hydraulic hoses. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.)

Muffler Flange to Turbo

14. Install identification tags on electrical connectors and harness. See Pump Harness (W8) Component Location. (Group 9015-10.) –UN–19MAR08

15. Disconnect hydraulic hoses and close all openings using caps and plugs.

TX1038693A

16. Disconnect electrical connectors and harness. 17. Install lifting eyebolts JT05550. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Muffler Bracket 6—Cap Screw (3 used) 11—Muffler Bracket 12—Nut (3 used) 13—Muffler Pipe

18. Support pump 1 and 2 (Main Pump). Specification Pump 1 and 2 (Main Pump)— Weight.............................................................................................. 118 kg 260 lb

19. Remove main pump. 20. Inspect and repair as necessary. See Pump 1 and 2 Disassemble and Assemble. (Group 3360.) 21. Inspect dampener drive and repair as necessary. See Dampener Drive (Flex Coupling) Remove and Install. (Group 0752.)

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Hydraulic System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 22. Install main pump. Specification Pump 1 and 2 (Main Pump)— Weight.............................................................................................. 118 kg 260 lb

23. Connect electrical connectors. See Pump Harness (W8) Component Location. (Group 9015-10.) 24. Connect hydraulic hoses. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 25. Install muffler and bracket. Specification Muffler and Bracket—Weight ............................................................ 25 kg 55 lb

26. Install heat shield support and all heat shields. 27. Install pilot pressure regulating valve and filter. See Pilot Pressure Regulating Valve and Filter Remove and Install. (Group 3360.) 28. Install pilot pump. See Pilot Pump Remove and Install. (Group 3360.) 29. Install engine oil filter housing and filter. 30. Install covers under hydraulic oil tank and main pump. 31. Fill hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.) 32. Install counterweight. See Counterweight Remove and Install. (Group 1749.) 33. Connect negative (-) battery cable. 33 3360 8

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PN=386

Hydraulic System 34. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 35. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 36. Install top covers.

JW00603,00000C5 –19–22APR08–7/7

Pump 1 and 2 Disassemble and Assemble 1. Remove pilot pump. See Pilot Pump Remove and Install. (Group 3360.) 2. Remove pump. See Pump 1 and 2 Remove and Install. (Group 3360.) 3. Remove flex coupler. See Dampener Drive (Flex Coupling) Remove and Install. (Group 0752.) 4. Remove regulators. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.)

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Hydraulic System

10 9

27 28

5 4

1 23

12 14

13 34

22 20

19 18 36

17 16

35 1

15 38

39 41

4 45

44 48

16 17 51 19

38 18 33 3360 10

–UN–01FEB02

T146708

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PN=388

Hydraulic System 1—Cap Screw (12 used) 2—Lock Washer (12 used) 3—Cover 4—Knock Pin (2 used) 5—Pin (4 used) 6—O-Ring 7—Retaining Ring (2 used) 8—Roller Bearing 9—O-Ring (4 used) 10—Cap Screw (8 used) 11—Cradle Plate (2 used) 12—O-Ring (4 used) 13—Backup Ring (4 used) 14—Orifice Pin (2 used)

15—Pump 2 (Rear) Swash Plate 16—Servo Piston (6 used) 17—Spring (6 used) 18—Piston (18 used) 19—Retainer (2 used) 20—Bushing (2 used) 21—Disk Spring (8 used) 22—Knock Pin (4 used) 23—Spring Pin (2 used) 24—Pin (2 used) 25—Pin (2 used) 26—Spring Pin (2 used) 27—O-Ring (2 used)

NOTE: Pump 1 and 2 share a common housing. Parts are similar but are not interchangeable. 5. Disassemble pump 1 (front).

28—O-Ring (10 used) 29—O-Ring (4 used) 30—Pin (2 used) 31—Feedback Link (2 used) 32—Spring Pin (4 used) 33—Pump 1 (Front) Valve Plate 34—Needle Bearing 35—Pump Housing 36—Needle Bearing 37—Pump 2 (Rear) Valve Plate 38—Cylinder Block (2 used) 39—Shaft

40—Plate (2 used) 41—Pin (2 used) 42—Pump 1 (Front) Swash Plate 43—Inner Race 44—Retaining Ring (2 used) 45—Roller Bearing 46—Seal 47—Retaining Ring 48—Cover 49—O-Ring 50—Shaft 51—Retaining Ring

assembly. Place cylinder block assembly with swash plate side up. IMPORTANT: Pistons (18) must be installed into the same bores of cylinder block (38) because of wear patterns. Mark location of pistons with respect to bores for proper assembly.

Remove cap screws (1), lock washers (2) from cover (48). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. IMPORTANT: Cylinder block (38) assembly may slide off shaft during removal. When removing cover (48), incline opposite end of shaft (50) so cylinder block does not slide. NOTE: Do not remove orifice pin (14) unless replacement is necessary.

9. While holding retainer (19), remove retainer and pistons (18). 10. Remove bushing (20) and disk springs (21). 11. Remove plate (40) from pump 1 (front) swash plate (42). 12. Remove cap screws (10) and cradle plate (11) from cover (48). 13. Remove shaft (50) assembly.

6. Remove cover (48) assembly, cylinder block (38) assembly, and shaft (50) assembly from pump housing (35). Specification Cover—Weight............................................................................ 27 kg 60 lb

7. Place cover (48) assembly on blocks with engine side down.

IMPORTANT: Use care not to scratch end of shaft (50) when removing retaining rings (44). Pump could leak if sealing surface is damaged. 14. Remove retaining rings (44) and roller bearing (45). If necessary, remove inner race (43). 15. Remove servo pistons (16) and springs (17).

8. While holding pump 1 (front) swash plate (42), remove swash plate and cylinder block (38)

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Hydraulic System IMPORTANT: Valve plate has a polished surface and may be damaged if dropped.

on retaining ring (7). Retaining ring and shaft (39) can be damaged if puller is incorrectly positioned.

16. Remove pump 1 (front) valve plate (33). NOTE: Do not disassemble parts (23—26 and 30) from feedback link (31) unless replacement is necessary. 17. Remove feedback link (31) assembly from pump 1 (front) side of pump housing. NOTE: Do not remove needle bearing (34) unless replacement is necessary.

27. Remove inner race of roller bearing (8) using a 2-jaw puller. 28. Remove retaining ring (7). 29. Remove pump 2 (rear) swash plate (15). 30. Remove plate (40) from pump 2 (rear) swash plate (15).

19. Disassemble pump 2 (rear).

IMPORTANT: Pistons (18) must be installed into the same bores of cylinder block (38) because of wear patterns. Mark location of pistons with respect to bores for proper assembly.

20. Remove cap screws (1) and lock washers (2) from cover (3).

31. While holding retainer (19), remove retainer and pistons (18).

21. Remove cover (3), cylinder block (38), and shaft (39) assemblies from pump housing (35).

32. Remove bushing (20), disk springs (21) and cylinder block (38).

22. Place assembly on blocks with cylinder block (38) side down.

IMPORTANT: Use care when removing valve plate, it is easily damaged.

23. Remove retaining ring (7) and inner ring plate of roller bearing (8) from shaft (39).

33. Remove pump 2 (rear) valve plate (37).

18. If necessary, tap needle bearing (34) out of pump housing (35) towards pump 1 (front) side.

34. Remove servo pistons (16) and springs (17). NOTE: Do not remove orifice pin (14) from cover (3) unless replacement is necessary. 24. Remove cover (3) from shaft (39). Outer race of roller bearing (8) will remain in cover. 25. Remove cap screws (10) and cradle plate (11) from cover.

NOTE: Do not disassemble parts (23—26 and 30) from feedback link (31) unless replacement is necessary. 35. Remove feedback link (31) assembly from pump 2 (rear) side of pump housing. NOTE: Do not remove needle bearing (36) unless replacement is necessary.

26. Remove outer race of roller bearing (8) from cover. IMPORTANT: When using puller to remove inner race of roller bearing (8) be sure to position jaws of puller on race, not

36. If necessary, tap needle bearing (36) out of pump housing (35) towards pump 2 (rear) side. 37. Inspect and repair as necessary.

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Hydraulic System

25 30

24 31

–UN–24MAR08

22 17

TX1039123

1 36 TX1039123 Needle Bearing and Feed back Links 1—Cap Screw (12 used) 2—Lock Washer (12 used) 16—Servo Piston (6 used) 17—Spring (6 used) 22—Knock Pin (4 used)

23—Spring Pin (2 used) 24—Pin (2 used) 25—Pin (2 used) 26—Spring Pin (2 used) 27—O-Ring (2 used)

28—O-Ring (10 used) 29—O-Ring (4 used) 30—Pin (2 used) 31—Feedback Link (2 used) 32—Spring Pin (4 used)

38. Install needle bearings (34 and 36) with stamping on outer race facing outward. 39. Install knock pins (22). Apply clean petroleum jelly to pump 2 (rear) valve plate (37) and install with

34—Needle Bearing 35—Pump Housing 36—Needle Bearing 37—Pump 2 (Rear) Valve Plate

inlet port facing inlet port side of pump housing (35). 40. Install springs (17) and servo pistons (16).

JW00603,0000111 –19–23APR08–5/16

41. Install feedback link (31) assembly with link facing outwards from pump housing (35). 31

35 –UN–01FEB02

42. Pin (30) should be installed with parallel sides in cavity as shown.

T149630

30—Pin 31—Feedback Link 35—Pump Housing

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33 3360 13

Hydraulic System 43. Install disk springs (21) into cylinder block (38) as shown. Install bushing (20), retainers and pistons .

T149631

–UN–01FEB02

20—Bushing 21—Disk Springs (4 used) 38—Cylinder Block

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PN=392

Hydraulic System

19 20 35

18 21

15 11 8

10 39

9 41

7 –UN–24MAR08

2 1 12

TX1039124

13 14 TX1039124

Pump 2 (Rear) 1—Cap Screw (12 used) 2—Lock Washer (12 used) 3—Cover 4—Knock Pin (2 used) 5—Pin (4 used) 6—O-Ring

7—Retaining Ring (2 used) 8—Roller Bearing 9—O-Ring (4 used) 10—Cap Screw (8 used) 11—Cradle Plate (2 used) 12—O-Ring (4 used)

44. Install shaft (39) to cylinder block (38) assembly. 45. Apply petroleum jelly to pin (41) side of plate (40). Assemble pin and plate to pump 2 (rear) swash plate (15). 46. Install pump 2 (rear) swash plate (15) to shaft (39). 47. Install retaining ring (7) into inner groove of shaft (39). 48. Install inner race of roller bearing (8) to shaft with flange side toward retaining ring.

13—Backup Ring (4 used) 14—Orifice Pin (2 used) 15—Pump 2 (rear) Swash Plate 18—Piston (18 used) 19—Retainer (2 used) 20—Bushing (2 used)

21—Disk Spring (8 used) 35—Pump Housing 38—Cylinder Block (2 used) 39—Shaft 40—Plate (2 used) 41—Pin (2 used)

49. Install retaining ring (7) into outer groove of shaft (39). 50. Install outer race of roller bearing (8) into cover (3) with stamped face towards pilot pump side of cover. 51. Install O-rings (9), pins (5), cradle plate (11), and tighten cap screws (10) to specification. Specification Cradle Plate-to-Cover Cap Screw—Torque ........................................................................ 10 N•m 87 lb-in

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Hydraulic System 52. Install orifice pin (14) with orifice side towards cover (3) If removed. 53. Assemble pump 2 (rear) swash plate (15) to cradle plate (11), aligning cylindrical surfaces and orienting feedback link connection upwards. Install assembly onto shaft (39) assembly. 54. Install inner ring plate of roller bearing (8) with stamped side opposite rollers. Install retaining ring (7).

T149655

–UN–01FEB02

12—O-Ring (2 used) 13—Backup Ring (2 used) 14—Orifice Pin

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Hydraulic System

2 1 5

TX1039125

–UN–24MAR08

TX1039125 Pump 2 (Rear) 1—Cap Screw (12 used) 2—Lock Washer (12 used)

3—Cover 4—Knock Pin (2 used)

5—Pin (4 used) 6—O-Ring

55. Install cover (3) assembly into pump housing (35) while aligning feedback link pin with connection on swash plate.

15—Pump 2 35—Pump Housing

Specification Cover-to-Pump Housing Cap Screw—Torque ...................................................................... 108 N•m 79 lb-ft

56. Install washers (2) and cap screws (1) and tighten to specification.

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PN=395

Hydraulic System

27 28 26 29

25 30

23 22 17

–UN–24MAR08

35 2

TX1039126

1 TX1039126 Pump 1 (Front) 1—Cap Screw (12 used) 2—Lock Washer (12 used) 16—Servo Piston (6 used) 17—Spring (6 used) 22—Knock Pin (4 used)

23—Spring Pin (2 used) 24—Pin (2 used) 25—Pin (2 used) 26—Spring Pin (2 used) 27—O-Ring (2 used)

28—O-Ring (10 used) 29—O-Ring (4 used) 30—Pin (2 used) 31—Feedback Link (2 used)

57. Install knock pins (22).

32—Spring Pin (4 used) 33—Pump 1 (Front) Valve Plate 35—Pump Housing

59. Install springs (17) and servo pistons (16).

58. Apply petroleum jelly to pump 1 (front) valve plate (33) and install with inlet port facing inlet port side of pump housing (35).

JW00603,0000111 –19–23APR08–11/16

60. Install feedback link (31) assembly with link facing outwards from pump housing (35). 31

30—Pin 31—Feedback Link 35—Pump Housing

T149630

33 3360 18

–UN–01FEB02

61. Pin (30) should be installed with parallel sides in cavity as shown.

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Hydraulic System 62. Install disk springs (21) into cylinder block (38) as shown. Install bushing (20), retainer and pistons.

T149631

–UN–01FEB02

20—Bushing 21—Disk Springs (4 used) 38—Cylinder Block

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PN=397

Hydraulic System

47 49 46

4 44 44 50

9 43

12 35

–UN–24MAR08

TX1039127

2 TX1039127

1 Pump 2 (Front)

1—Cap Screw (12 used) 2—Lock Washer (12 used) 4—Knock Pin (2 used) 5—Pin (4 used) 9—O-Ring (4 used)

10—Cap Screw (8 used) 11—Cradle Plate (2 used) 12—O-Ring (4 used) 13—Back-Up Ring (4 used) 14—Orifice Pin (2 used)

63. Install inner race (43) if removed. Install retaining ring (51).

35—Pump Housing 43—Inner Race 44—Retaining Ring (2 used) 45—Roller Bearing 46—Seal

47—Retaining Ring 48—Cover 49—O-Ring 50—Shaft 51—Retaining Ring

66. Install retaining ring (47). 67. Install shaft (50) assembly into cover (48).

NOTE: Stamped side of roller bearing should face out from pump, toward engine.

68. Install O-rings (9), pins (5), cradle plate (11), and tighten cap screws (10) to specification.

64. Install retaining rings (44) and roller bearing (45). NOTE: Install oil seals with lip (spring side) toward inside of housing.

Specification Cradle Plate-to-Cover Cap Screw—Torque .......................................................................... 9 N•m 87 lb-in.

65. Apply clean multipurpose grease to lip of seal (46) and install.

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Hydraulic System 69. If necessary, install orifice pin (14) with orifice side towards cover (48) as shown.

13 Continued on next page

–UN–01FEB02

T149693

12—O-Ring (2 used) 13—Backup Ring (2 used) 14—Orifice Pin 48—Cover

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PN=399

Hydraulic System

20 38

40 18

TX1039136

–UN–24MAR08

2 TX1039136 1—Cap Screw (12 used) 2—Lock Washer (12 used) 18—Piston (18 used) 19—Retainer (2 used)

1 20—Bushing (2 used) 21—Disk Spring (8 used) 35—Pump Housing

38—Cylinder Block (2 used) 40—Plate (2 used) 41—Pin (2 used)

70. Apply clean petroleum jelly to pin (41) side of plate (40). Assemble pin and plate to pump 1 (front) swash plate (42). 71. Assemble pump 1 (front) swash plate (42) to cradle plate (11), aligning cylindrical surfaces and orientating feedback link connection upwards.

42—Pump 1 (Front) Swash Plate 48—Cover

75. Install regulators. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.) 76. Install flex coupler. See Dampener Drive (Flex Coupling) Remove and Install. (Group 0752.) 77. Install pump 1 and 2. See Pump 1 and 2 Remove and Install. (Group 3360.)

72. Install assembly onto shaft (39) assembly. 78. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)

73. Install cylinder block (38) assembly to shaft. 74. Install O-ring (49), cover (48) assembly, washers (2) and cap screws (1). Specification Cover-to-Pump Housing Cap Screw—Torque ...................................................................... 108 N•m 79 lb-ft

79. Set pump 1 and 2 regulators.Perform Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.) Perform Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)

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PN=400

Hydraulic System

Pump 1 and 2 Inspection 1. Measure outer diameter of shaft (1).

1—Shaft Diameter

T149477

–UN–01FEB02

Specification Shaft—Diameter (new) .................................................................... 35 mm 1.38 in. Diameter (minimum) ..................................................................... 34.8 mm 1.37 in.

JW00603,0000112 –19–30APR08–1/5

2. Measure thickness (2) of piston slipper. 2

Specification Piston Slipper—Thickness (new) ................................................... 5.5 mm 0.22 in. Thickness (minimum) ..................................................................... 5.2 mm 0.20 in.

–UN–01FEB02

T149481

2—Piston Slipper Thickness 3—Play

JW00603,0000112 –19–30APR08–2/5

3. Measure play (3) between slipper and piston. 2

Specification Piston-to-Slipper—Play (new) ...................................................... 0.15 mm 0.006 in. Play (maximum).............................................................................. 0.4 mm 0.016 in.

–UN–01FEB02

T149481

2—Piston Slipper Thickness 3—Play

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Hydraulic System 4. Measure cylinder block bore (5). Subtract piston diameter (4) for clearance.

Specification Piston-to-Cylinder Block Bore— Clearance (new) ......................................................................... 0.033 mm 0.0013 in. Clearance (maximum) .................................................................. 0.07 mm 0.0028 in.

T149483

–UN–01FEB02

4—Piston Diameter 5—Cylinder Block Bore

JW00603,0000112 –19–30APR08–4/5

5. Measure servo piston bore (7). Subtract servo piston diameter (6) for clearance.

–UN–01FEB02

T149484

Specification Servo Piston-to-Bore—Clearance (new) ............................................................................................ 0.06 mm 0.002 in. Clearance (maximum) .................................................................. 0.12 mm 0.005 in.

6—Servo Piston Diameter 7—Bore

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PN=402

Hydraulic System

Pump 1 and 2 Start-Up Procedure IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank. Procedure is to ensure the pumps and gearbox are filled with oil and air is bled from suction side of pumps to prevent cavitation. 1. Fill hydraulic tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

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PN=403

Hydraulic System 2. Remove air bleed plugs (1) to allow housing to fill with oil from the hydraulic oil tank and to let air escape. 3. Install plugs when pumps 1 and 2 housing are full of oil. 4. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) –UN–29FEB08

5. Start engine and run at slow idle. 6. Slowly raise boom to full height.

TX1037712A

7. Lower boom to pressurize hydraulic oil tank. NOTE: Air in pilot circuits are purged automatically. Pump 1 and 2 Air Bleed Plugs

8. Purge air from the hydraulic system by slowly operating each function through three cycles.

1—Air Bleed Plug (2 used)

9. Perform cylinder bleed procedure. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 10. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,0000113 –19–22APR08–2/2

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PN=404

Hydraulic System

Pump 1 and 2 Regulator Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1). 2. Open hydraulic pump door. –UN–22FEB08

3. Drain hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

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PN=405

Hydraulic System 4. Install identification tags on hydraulic hoses and electrical connectors. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.) See Pump Harness (W8) Component Location. (Group 9015-10.) 5. Disconnect hydraulic hoses and close all openings with caps and plugs. 6. Disconnect electrical connectors (5).

–UN–20MAR08

7. Remove pump 1 regulator (3) and pump 2 regulator (6). 8. Inspect and repair as necessary. See Pump 1 and 2 Regulator Disassemble and Assemble. (Group 3360.)

TX1037973A

9. Install pump 2 regulator. 10. Install pump 1 regulator. Pump 1 Regulator

11. Connect electrical connectors. 12. Connect hydraulic hoses. 13. Fill hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

–UN–20MAR08

IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank.

TX1037972A

Procedure is to ensure the pumps and gearbox are filled with oil and air is bled from suction side of pumps to prevent cavitation. 14. Perform pump 1 and 2 start up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)

Pump 2 Regulator

15. Set pump 1 and 2 regulators. Perform Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.) Perform Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)

3—Pump 1 Regulator 4—Cap Screw (8 used) 5—Electrical Connectors (4 used) 6—Pump 2 Regulator

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PN=406

Hydraulic System 16. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,0000114 –19–22APR08–3/3

Pump 1 and 2 Regulator Disassemble and Assemble 1. Remove pump 1 regulator. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.)

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PN=407

Hydraulic System

5 7

2 3 47

50 60 61

55 46 15 37

12 22 14

16 12

29 34

15 –UN–10MAR08

49 28

TX1038038

33 3360 30

TX1038038 Pump 1 Regulator Disassemble and Assemble

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PN=408

Hydraulic System 1—Pump 1 Regulator Housing 2—Sleeve 3—Spool 5—Cylinder 6—Piston 7—O-Ring 8—Backup Ring 9—O-Ring 10—Stop 12—Stop (2 used)

14—O-Ring (3 used) 15—O-Ring (2 used) 16—Nut (2 used) 17—Nut (2 used) 20—Piston 22—Piston 24—Stop 25—Sleeve 26—Piston 28—Spool

29—Set Screw 34—Nut 35—Cover 37—M8 Cap Screw (8 used) 38—Cover 43—M10 Cap Screw (2 used) 46—Spring 47—Spring 49—Spring 50—Solenoid Valve

51—Cap Screw (2 used) 52—Screw 55—Sensor 56—Fitting 57—Line 58—Fitting 59—Elbow Fitting 60—O-Ring 61—O-Ring 62—O-Ring

14. Apply clean hydraulic oil to all seals and machined parts.

2. Remove line (57). 3. Remove solenoid valve (50).

15. Install spring (47), spool (3), sleeve (2), piston (6), O-ring (7), backup ring (8), cylinder (5), O-ring (9), and piston (26).

4. Remove nuts (16, 17, and 34). 5. Remove set screw (29). 6. Remove stop (12).

16. Install sleeve (25), spool (28), spring (49), O-ring (15), stop (24), O-ring (14), and stop (12).

7. Remove cover (38).

17. Install cover (35), and nuts (16 and 17).

8. Remove parts (10, 14, 15, 20, 22, and 46)

18. Install piston (20), piston (22), O-ring (14).

9. Remove nuts (16 and 17).

19. Install spring (46), O-ring (15), stop (10), O-ring (14), and stop (12).

10. Remove stop (12) 20. Install cover (38), and set screw (29). 11. Remove cover (35). 21. Install nuts (16, 17 and 34). 12. Remove parts (2, 3, 5-9, 14, 15, 25, 26, 28, 47, 49) NOTE: If damage to pump 1 regulator housing is observed, the entire pump 1 regulator valve assembly must be replaced. 13. Inspect and repair parts as necessary.

22. Install O-rings (60—62), and solenoid valve (50). 23. Install line (57). 24. Install pump 1 regulator to pump 1. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.)

Continued on next page

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9 5 8 7 6

2 55

3 43

56 52

15 16

14 20

12 22 14

17 16

38 12

24 37

15 49

–UN–10MAR08

33 3360 32

TX1038039

TX1038039 Pump 2 Regulator Disassemble and Assemble

Continued on next page

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PN=410

Hydraulic System 1—Pump 2 Regulator Housing 2—Sleeve 3—Spool 5—Cylinder 6—Piston 7—O-Ring 8—Backup Ring 9—O-Ring

10—Stop 12—Stop (2 used) 14—O-Ring (3 used) 15—O-Ring (2 used) 16—Nut 17—Nut 20—Piston 22—Piston

24—Stop 25—Sleeve 28—Spool 29—Set Screw 34—Nut 35—Cover 37—M8 Screw (8 used) 38—Cover

39—Plug 43—M10 Screw (4 used) 46—Spring 47—Spring 49—Spring 52—Sensor 55—Plug 56—O-Ring

25. Remove pump 2 regulator. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.)

36. Install sleeve (25), spool (28), spring (49), stop (24), O-ring (14) and cover (35).

26. Remove plug (55).

37. Install stop (12) and nuts (16 and 17).

27. Remove nuts (16, 17, and 34).

38. Install piston (20), Piston (22), and O-ring (14).

28. Remove cover (38).

39. Install spring (46), stop (10), O-rings (14 and 15), and cover (38).

29. Remove parts (10, 14, 15, 20, 22, and 46) 40. Install stop (12) and set screw (29). 30. Remove cover (35). 41. Install nuts (16, 17, and 34). 31. Remove parts (2, 3, 5-9, 12, 14, 15, 20, 24, 25, 47, 49) 32. Remove sensor (52).

42. Install sensor (52) and plugs (39 and 55). 43. Install pump 2 regulator to pump 2. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.)

NOTE: If damage to pump 2 regulator housing is observed, the entire pump 2 regulator assembly must be replaced.

44. Adjust pump 1 and 2 regulators. Perform Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.) Perform Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)

33. Inspect and repair as necessary. 34. Apply clean hydraulic oil to all seals and machined parts. 35. Install spring (47), spool (3), sleeve (2), piston (6) O-ring (7), backup ring (8), cylinder (5), and O-ring (9).

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Hydraulic System

Pilot Pump Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1). 2. Open pump access door. –UN–22FEB08

3. Apply vacuum to hydraulic system. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

JW00603,00000EA –19–22APR08–1/2

4. Disconnect hydraulic hoses (6) from pilot pump (4) and close all openings with caps and plugs. 5. Remove pilot pump (4). 6. Inspect and repair as necessary. See Pilot Pump Disassemble and Assemble. (Group 3360.) 7. Install pilot pump. 8. Connect hydraulic hoses. 9. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

4—Pilot Pump 5—Cap Screw (2 used) 6—Hydraulic hose (2 used)

TX1038508A

33 3360 34

–UN–20MAR08

10. Check pilot pump pressure settings. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

Pilot Pump JW00603,00000EA –19–22APR08–2/2

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Hydraulic System

Pilot Pump Disassemble and Assemble 1. Remove pilot pump. See Pilot Pump Remove and Install. (Group 3360.) Continued on next page

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Hydraulic System

27 13 1

9 28

6 26 14

27 6 9

3 5

15 16 12 –UN–03MAR08

TX1037750

33 3360 36 Pilot Pump

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PN=414

Hydraulic System 1—Pilot Pump Housing 2—Flange 3—Oil Seal 5—Snap Ring

6—Seal (2 used) 7—End Cover 9—Backup Retainer (2 used) 10—Key (2 used)

12—O-Ring (2 used) 13—Driven Gear 14—Drive Gear 15—Washer (4 used)

IMPORTANT: Keys are loose and can fall out of position during pump disassembly. Pump will not function without keys.

16—Cap Screw (4 used) 26—Bushing (2 used) 27—Bushing (2 used) 28—Pin (4 used)

2. Disassemble pilot pump as shown.

JW00603,0000116 –19–22APR08–3/4

3. Inspect bushings (26 and 27). If inside diameter and surface toward gear are rough or worn, replace pump.

–UN–03MAR08

4. Check gears (13 and 14) and housing (1). If gear teeth, shaft, and inside of housing is rough or worn, replace pump.

TX1037751A

IMPORTANT: Pump damage can result if pump is assembled dry. 5. Apply clean hydraulic oil to all parts. 6. Apply multi-purpose grease to lip of oil seal. Install oil seal with lip (spring side) towards inside of housing. 7. Assemble pump housing and tighten cap screws to specification. Specification Pilot Pump Flange-to-End Cover Cap Screws—Torque ..................................................................... 41 N•m 30 lb-ft

Pilot Pump 1—Pilot Pump Housing 10—Key (2 used) 13—Driven Gear 14—Drive Gear 26—Bushing (2 used) 27—Bushing (2 used)

8. Install pilot pump. See Pilot Pump Remove and Install. (Group 3360.) 9. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

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Hydraulic System

Pilot Pressure Regulating Valve and Filter Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Apply vacuum to hydraulic system. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

JW00603,00000C7 –19–22APR08–1/2

3. Install identification tags on hydraulic hoses (6).

–UN–20MAR08

4. Disconnect hydraulic hoses and close all openings with caps and plugs. 5. Remove pilot pressure regulating valve (4) and filter (7).

Pilot Pressure Regulating Valve and Filter

7. Install pilot pressure regulating valve and filter. 8. Connect hydraulic hoses. 9. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

33 3360 38

TX1038657A

6. Inspect and repair as necessary. See Pilot Pressure Regulating Valve and Filter Disassemble and Assemble. (Group 3360.)

4—Pilot Pressure Regulating Valve 5—Cap Screw (2 used) 6—Hydraulic hose (3 used) 7—Pilot Pressure Regulating Valve Filter

10. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

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Hydraulic System

Pilot Pressure Regulating Valve and Filter Disassemble and Assemble

1 2

1. Remove plug (6) with O-ring (5).

4 5

2. Remove parts (2—4).

–UN–07FEB06

3. Inspect and replace parts as necessary.

TX1003402

4. Inspect poppet (2) for smooth operation in pilot pressure regulating valve housing. 5. Tighten plug (6). Specification Plug-to-Housing—Torque ............................................................... 50 N•m 37 lb-ft

1—Pilot Pressure Regulating Valve Housing 2—Poppet 3—Shim (as required) 4—Spring 5—O-Ring 6—Plug

JW00603,0000117 –19–22APR08–1/1

Pilot Shutoff Solenoid Valve Remove and Install 1. Turn upperstructure 90° to tracks. Continued on next page

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Hydraulic System

TX1037206A

–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

Continued on next page

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Hydraulic System 3. Install identification tags and disconnect hoses and lines. Close all openings using caps and plugs.

6. Inspect and repair parts as necessary. See Pilot Shutoff Solenoid Valve Disassemble and Assemble. (Group 3360.) 7. Install valve. Tighten cap screws.

TX1003407A

5. Remove cap screws (1) and valve.

–UN–07FEB06

4. Disconnect solenoid connector (2).

9. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 1—Cap Screw (2 used) 2—Connector

TX1003406A

8. Connect hydraulic lines.

–UN–07FEB06

Specification Pilot Shutoff Valve Housing-to-Cab Platform Cap Screw—Torque .............................................................................. 50 N•m 37 lb-ft

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Hydraulic System

–UN–16NOV05

Pilot Shutoff Solenoid Valve Disassemble and Assemble

TX1000413

33 3360 42

Continued on next page

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PN=420

Hydraulic System 1—Spring 2—Plate 3—Housing 4—Spool

5—Screen 6—Solenoid 8—Plug (2 used)

9—Screw (2 used) 10—Screw (2 used) 11—O-Ring

12—O-Ring (2 used) 13—Valve, Pilot Shutoff Solenoid

Specification Shutoff Solenoid Valve Housing Plug—Torque ........................................................................... 28 N•m 246 lb-in

1. Clamp housing (3) in a vise. 2. Scribe a line on housing (3) and solenoid (6). 3. Remove screws (9), solenoid (6), and O-ring (11).

8. Install screen (5).

4. Remove plug (8), O-rings (12), spring (1), and spool (4), from housing.

9. Install O-ring (11) to solenoid (6).

5. Remove screen (5).

10. Align scribe marks and install solenoid (6) to housing (3), using screws (9). Tighten screws to specification.

NOTE: Use new O-rings when assembling. 6. Inspect and replace parts as necessary. 7. Install spool (4), spring (1), plug (8), and O-rings (12). Tighten plug to specification.

Specification Solenoid-to-Housing Screws— Torque........................................................................................ 4 N•m 36 lb-in

JW00603,0000118 –19–22APR08–2/2

Solenoid Valve Manifold Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Apply vacuum to hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

33 3360 43

Hydraulic Pressure Release Button

Continued on next page

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PN=421

Hydraulic System 3. Remove cap screw (4) on back of control valve access door (3).

TX1038495A

–UN–19MAR08

3—Control Valve Access Door 4—Cap Screw (2 used)

TX1038496A

–UN–20MAR08

Control Valve Access Door

Cap Screw on Back of Control Valve Access Door

Continued on next page

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Hydraulic System 4. Open door (5) to access cap screw (4) to open control valve access door (3).

TX1038497A

–UN–20MAR08

3—Control Valve Access Door 4—Cap Screw 5—Door 6—Cover 9—Guard Rail Support

TX1038498A

–UN–20MAR08

Door

Hidden Cap Screw

Continued on next page

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Hydraulic System 5. Install identification tags on hydraulic hoses and electrical connectors.

–UN–14MAR08

6. Disconnect hydraulic hoses and close all openings with caps and plugs. 7. Disconnect electrical connectors.

TX1038507A

8. Remove solenoid valve manifold. 9. Inspect and repair as necessary. See Travel Speed and Arm Regenerative Solenoid Valve Disassemble and Assemble. (Group 3360.)

Solenoid Valve Manifold 9—Solenoid Valve Manifold 10—Socket Head Cap Screw (2 used)

10. Install solenoid valve manifold. 11. Connect electrical connectors. 12. Connect hydraulic hoses. 13. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,00000C8 –19–22APR08–4/4

Travel Speed and Arm Regenerative Solenoid Valve Disassemble and Assemble CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Remove solenoid manifold from control valve. See Solenoid Valve Manifold Remove and Install. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

33 3360 46

Hydraulic Pressure Release Button

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Hydraulic System

3 2 3

4 5

8 9

10 6

–UN–10MAR08

TX1038458

1 TX1038458 Travel Speed and Arm Regenerative Solenoids 1—Solenoid Manifold Housing 2—Solenoid Coil (2 used) 3—Cap Screw (4 used)

4—O-Ring (2 used) 5—Spool (2 used) 6—Valve (2 used)

7—O-Ring (2 used) 8—O-Ring (2 used) 9—O-Ring (2 used)

10—Plate (2 used) 11—Washer (2 used)

3. Remove cap screws (3).

9. Install spool (5), O-ring (4), and solenoid coil (2).

4. Remove parts (4—11). 5. Inspect and replace parts as necessary.

10. Install solenoid manifold to control valve. See Solenoid Valve Manifold Remove and Install. (Group 3360.)

6. Apply clean hydraulic oil to all seals and machined surfaces.

11. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

7. Install O-rings (7—9) to valve (6). 8. Install washer (11), plate (10), and assembled valve (6).

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Hydraulic System

Pilot Valve (Left and Right) Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Apply vacuum to hydraulic system. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

3. Remove left console covers. See Left and Right Console Covers Remove and Install. (Group 1821.) 1—Pressure Release Button 2—Hydraulic Oil Tank Cover Hydraulic Pressure Release Button

JW00603,000011A –19–22APR08–1/4

4. Install identification tags on hydraulic hoses.

–UN–10MAR08

5. Disconnect hydraulic hoses and close all openings with caps and plugs.

TX1038029A

12—Left Pilot Valve

Left Pilot Valve

Continued on next page

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Hydraulic System NOTE: Cap screw with pin must be installed in original location.

–UN–10MAR08

6. Remove pilot lever (9) and cap screws (10 and 11).

TX1038030A

7. Inspect and repair left pilot valve as necessary. See Pilot Valve (Left and Right) Disassemble and Assemble. (Group 3360.) 8. Install left pilot valve. 9. Connect hydraulic hoses. Left Pilot Lever

10. Install left pilot lever.

9—Left Pilot Lever 10—Cap Screw With Pin 11—Cap Screw (3 used)

11. Install left console covers. See Left and Right Console Covers Remove and Install. (Group 1821.) 12. Remove right console covers. See Left and Right Console Covers Remove and Install. (Group 1821.)

Continued on next page

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Hydraulic System 13. Remove cap screws (16) and control panel (15). 14. Remove right pilot lever (20). –UN–10MAR08

NOTE: Cap screw with pin must be installed in original location.

TX1038037A

15. Remove cap screws (10 and 11). 16. Install identification tags on hydraulic hoses. 17. Disconnect hydraulic hoses and close all openings using caps and plugs. 18. Inspect and repair right pilot valve as necessary. See Pilot Valve (Left and Right) Disassemble and Assemble. (Group 3360.)

Control Panel 10—Cap Screw With Pin 11—Cap Screw 15—Control Panel 16—Cap Screw 20—Right Pilot Lever

19. Connect hydraulic hoses. 20. Install right pilot valve. 21. Install right pilot lever. 22. Install control panel. 23. Install right console covers. See Left and Right Console Covers Remove and Install. (Group 1821.) 24. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 25. Start machine and check that all pilot functions operate normally.

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Hydraulic System

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Hydraulic System

–UN–16NOV05

Pilot Valve (Left and Right) Disassemble and Assemble

TX1000262

33 3360 52

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PN=430

Hydraulic System 0—Housing and Spools 3—Shim (4 used) 4—Spacer (4 used) 6—Balance Spring (2 used) 8—Balance Spring (2 used) 10—Guide (4 used)

11—Snap Ring (4 used) 14—Pusher B (2 used) 15—Pusher A (2 used) 17—Sleeve (4 used) 19—O-Ring (4 used)

21—Plate 22—Universal Joint 23—Cam 24—Coupling 26—Plug

IMPORTANT: The housing and spools (0) are replaced as an assembly because the spools are select fitted to bores in housing. NOTE: Some parts from ports 1 and 3 are different than parts from ports 2 and 4. Parts for each port must be kept together and installed into the same port from which it was removed. The port numbers are stamped on the housing.

27—O-Ring 28—Snap Ring 33—Return Spring (2 used) 34—Return Spring (2 used) 35—Pilot Valve

IMPORTANT: Ports 1 and 3 use short balance springs. Ports 2 and 4 use long balance springs. 8. Install spacers (4), shims (3), and balance springs (6 and 8). IMPORTANT: Ports 1 and 3 use short return springs. Ports 2 and 4 use long return springs.

NOTE: Remove universal joint (22) only if necessary.

9. Install return springs (33 and 34).

1. Remove parts coupling (24), cam (23), universal joint (22), plate (21).

10. Install guides (10) with protrusion facing upward. 11. Install snap rings (11).

NOTE: Sleeves (17) cannot be disassembled. Do not attempt to remove oil seal from sleeve. 2. Remove sleeves (17).

IMPORTANT: Ports 1 and 3 use pushers with 1 outer groove. Ports 2 and 4 use pushers with 2 outer grooves.

IMPORTANT: Note port location and quantity of shims (3) when removing. Same number of shims must be used when installing.

12. Install pushers A (15) and pushers B (14).

3. Remove pusher (14 and 15), snap ring (11), guide (10), springs (6, 8, 33 and 34), shim (3), spacer (4), spools (0), snap ring (28), O-ring (27), and plug (26).

14. Apply clean multipurpose grease to joint of universal joint (22) and to inner surface of sleeve (17) seals.

13. Apply clean multipurpose grease to ball at ends of pushers A and pushers B.

15. Install O-rings (19) and sleeves (17). 4. Inspect and replace parts as necessary. 16. Apply PM37479 Thread Lock (high strength) to threads of universal joint (22).

5. Install O-ring (27) onto plug (26).

IMPORTANT: Align cap screw hole in plate (21) with cap screw hole in housing (0).

6. Install plug (26) and snap ring (28). IMPORTANT: Components are select fit to bores. Install components in the same bore that they were removed from.

17. Install plate (21) and universal joint (22). Tighten universal joint to specification.

7. Install spools (0). 33 3360 53

Continued on next page

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PN=431

Hydraulic System Specification Universal Joint—Torque ....................................................... 24.5 N•m 217 lb-in.

18. Install cam (23) on universal joint (22). Adjust clearance between pushers A (15) and pushers B (14) and cam.

19. Hold cam (23) and tighten coupling (24) to specification. Specification Coupling-to-Cam and Universal Joint—Torque .......................................................................... 69 N•m 51 lb-ft

Specification Cam-to-Pusher A and Pusher B—Clearance................................................................... 0—0.20 mm 0—0.008 in.

JW00603,000011B –19–15APR08–3/3

Travel Pilot Valve Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Apply vacuum to hydraulic system. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

Continued on next page

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PN=432

Hydraulic System 3. Install identification tags and disconnect hoses underneath of cab.

–UN–16FEB06

4. Close all openings using caps and plugs. 5. Remove cap screws (1) and remove pedals and levers.

TX1003510A

6. Remove cap screws (2) and remove travel pilot valve (3). 7. Inspect and repair as necessary. See Travel Pilot Valve Disassemble and Assemble. (Group 3360.) 8. Install travel pilot valve and tighten cap screws (2) to specification.

1—Cap Screw (4 used) 2—Cap Screw (2 used) 3—Travel Pilot Valve

Specification Valve-to-Cab Platform Cap Screw—Torque ............................................................................... 50 N•m 37 lb-ft

9. Install travel pedal and lever and tighten cap screws (1) to specification. Specification Travel Pedal-to-Lever Cap Screw—Torque ............................................................................... 50 N•m 37 lb-ft

10. Connect hydraulic hoses. 11. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 12. After travel pilot valve is installed, check the operation of all functions to be sure they operate correctly.

JW00603,000011C –19–22APR08–2/2

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PN=433

Hydraulic System

Travel Pilot Valve Disassemble and Assemble 1 35

4 5

8 29 27

9 11 10

13 18 17

24 31 22

15 –UN–31JAN07

TX1018305

33 3360 56

1—Cap Screw (2 used) 2—Cover 3—Pin (2 used) 4—O-Ring (2 used) 5—O-Ring (2 used) 6—Dampener (2 used) 7—Rubber Seat (2 used) 8—Cap Screw (2 used) 9—Lock Washer (2 used)

10—Holder 11—Oil Seal (4 used) 12—O-Ring (4 used) 13—Bushing (4 used) 14—Casing 15—O-Ring 16—Plug 17—Plug 18—O-Ring

19—Spool (4 used) 20—Spring (4 used) 21—Spacer (4 used) 22—Shim (As required) 23—Balance Spring (4 used) 24—Spring Guide (4 used) 25—Pusher (4 used) 26—Bracket (2 used) 27—Spring Pin (2 used)

Continued on next page

TM10743 (09APR09)

33-3360-56

28—Cap Screw (4 used) 29—Lock Washer (4 used) 30—Spring Pin (2 used) 31—Spring Pin (2 used) 32—Bushing (4 used) 33—Cam (2 used) 34—Spring Pin (2 used) 35—Spring Pin (2 used)

JW00603,000011D –19–22APR08–1/3

135D Excavator Repair 040909

PN=434

Hydraulic System IMPORTANT: The casing (14) and spools (19) are replaced as an assembly because the spools are select fitted to bores in housing. Parts for each port must be kept together and installed into the same port from which it was removed. The port numbers are stamped on the housing. Note port location and quantity of shims (22) when removing. Same number of shims must be used when installing. 1. Remove parts from casing. Remember to keep parts removed from each port together. Identify each group of parts by port numbers stamped on casing. NOTE: Spring pins (30 and 31) are stepped and can only be removed from one direction. Remove spring pin (27) and bushings (32) only if necessary.

7. Lock pins (34 and 35) in position by displacing the bore above spring pin using a punch and hammer. 8. Install holder (10) to casing (14) with cap screws (8), lock washers (9) and tighten. Specification Holder-to-Casing Cap Screw— Torque...................................................................................... 49 N•m 36 lb-ft

9. Apply multipurpose grease to O-rings (4 and 5) and install on pin (3). 10. Position rubber seat (7) and dampener (6) on pin (3) with lever facing upward. 11. Install cap screws (28), lock washers (29) and tighten. Specification Dampener-to-Holder Cap Screw—Torque .......................................................................... 7 N•m 62 lb-in.

IMPORTANT: Note direction of insertion for spring pins (30 and 31). Spring pins must be positioned with slits 90° apart.

2. Repair or replace parts as necessary. NOTE: Use same number of shims (22) as were removed.

Align brackets with marks made during disassembly.

3. Install spools (19), springs (20), spacers (21), shims (22) and balance springs (23) into casing (14).

12. Install brackets (26) and spring pins (30 and 31).

4. Install spring guides (24) with stepped end facing down.

13. Lock pins (30 and 31) in position by displacing the bore above spring pin using a punch and hammer.

5. Apply multipurpose grease to the end of each pusher (25) and to oil seals (11).

14. Install cover (2) and cap screws (1) and tighten.

IMPORTANT: Note direction of insertion of spring pins (34 and 35) to prevent spring pins from shearing.

Specification Cover-to-Holder Cap Screw— Torque........................................................................................ 5 N•m 44.3 lb-in.

15. Apply multipurpose grease to spring pin (27). 6. Assemble cam (33) in holder (10) with spring pins (34 and 35), and pin (3). Install spring pins with slits 90° apart.

16. Install O-ring (18) and plug (17). Tighten plug to specification. 33 3360 57

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JW00603,000011D –19–22APR08–2/3

135D Excavator Repair 040909

PN=435

Hydraulic System Specification Plug—Torque ........................................................................... 10 N•m 89 lb-in.

Specification Plug—Torque ........................................................................... 20 N•m 177 lb-in.

17. Install O-ring (15) and plug (16). Tighten plug to specification.

JW00603,000011D –19–22APR08–3/3

Pilot Signal Manifold Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Apply vacuum to hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

Continued on next page

JW00603,00000C9 –19–22APR08–1/5

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=436

Hydraulic System 3. Remove cap screw (4) on back of control valve access door (3).

TX1038495A

–UN–19MAR08

3—Control Valve Access Door 4—Cap Screw (2 used)

TX1038496A

–UN–20MAR08

Control Valve Access Door

Cap Screw on Back of Control Valve Access Door

Continued on next page

JW00603,00000C9 –19–22APR08–2/5

33 3360 59

TM10743 (09APR09)

33-3360-59

135D Excavator Repair 040909

PN=437

Hydraulic System 4. Open door (5) to access cap screw (4) to open control valve access door (3). 5. Remove guard rail support (9). 6. Disconnect electrical connector for work light.

TX1038497A

–UN–20MAR08

3—Control Valve Access Door 4—Cap Screw 5—Door 6—Cover 9—Guard Rail Support

TX1038498A

–UN–20MAR08

Door

Hidden Cap Screw

Continued on next page

JW00603,00000C9 –19–22APR08–3/5

33 3360 60

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=438

Hydraulic System 7. Remove cover (6)

TX1038499A

–UN–20MAR08

4—Cap Screw (6 used) 6—Cover

TX1038500A

–UN–20MAR08

Cover

Top of Cover

Continued on next page

JW00603,00000C9 –19–22APR08–4/5

33 3360 61

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=439

Hydraulic System 8. Install identification tags on hydraulic hoses. See Pilot Signal Manifold-to-Control Valve Line Connection. (Group 9025-15.) See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern. (Group 9025-15.)

–UN–17MAR08

9. Disconnect hydraulic hoses and close all openings with caps and plugs. 10. Install identification tags on electrical connectors.

TX1038506A

11. Disconnect electrical connectors. 12. Remove pilot signal manifold. Pilot Signal Manifold

13. Inspect and repair as necessary. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.)

9—Pilot Signal Manifold 10—Socket Head Cap Screw (4 used)

14. Install pilot signal manifold. 15. Connect hydraulic hoses. See Pilot Signal Manifold-to-Control Valve Line Connection. (Group 9025-15.) See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern. (Group 9025-15.) 16. Connect electrical connectors. 17. Install all covers. 18. Close the control valve access door and install cap screws. 19. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,00000C9 –19–22APR08–5/5

Pilot Signal Manifold Disassemble and Assemble 1. Remove pilot signal manifold. See Pilot Signal Manifold Remove and Install. (Group 3360.) 33 3360 62

Continued on next page

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JW00603,000011E –19–22APR08–1/7

135D Excavator Repair 040909

PN=440

Hydraulic System

33 3360 63

TM10743 (09APR09)

33-3360-63

135D Excavator Repair 040909

PN=441

TX1037515

6 21

TM10743 (09APR09)

TX1037515 –UN–29FEB08

Continued on next page

Pilot Signal Manifold

33-3360-64

Hydraulic System

PN=442

040909

135D Excavator Repair

JW00603,000011E –19–22APR08–2/7

Hydraulic System 1—Pilot Signal Manifold Housing 2—Pilot Signal Manifold Valve Housing 3—Pilot Signal Manifold Port Housing

4—Pilot Signal Manifold Port Housing 5—Pilot Signal Manifold End Housing

IMPORTANT: Pilot signal manifold housings must be assembled in the same order as disassembled or pilot functions will not operate properly.

6—Gasket 7—Gasket 8—Gasket 9—Gasket

10—Cap Screw (12 used) 21—Sleeve (21 used) 22—Spring (4 used) 23—Filter (15 used)

2. Put alignment marks on pilot signal manifold housings. 3. Disassemble pilot signal manifold as shown.

Continued on next page

JW00603,000011E –19–22APR08–3/7

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TM10743 (09APR09)

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PN=443

Hydraulic System

14 17

18 19

34 13 17

19 11

14 18

17 19

11 20 24

A B 15 C

12 17

16 19

11 17 2

14 19

11 17

13 19

–UN–29FEB08

18 17 14 19

TX1037516

33 3360 66

TX1037516 Pilot Signal Manifold Valve Housing

Continued on next page

TM10743 (09APR09)

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JW00603,000011E –19–22APR08–4/7

135D Excavator Repair 040909

PN=444

Hydraulic System A—Spool Valve Location B—Spool Valve Location C—Spool Valve Location 2—Pilot Signal Manifold Valve Housing

11—Spool Valve (6 used) 12—Spool Valve 13—Spring (2 used) 14—Spring (4 used) 15—Spring

4. Disassemble pilot signal manifold valve housing (2) as shown. NOTE: If damage to pilot signal manifold housings is found, complete pilot signal manifold must be replaced

16—Spring 17—Valve Seat (7 used) 18—Plug (7 used) 19—O-Ring (7 used) 20—Flow Control Valve

24—O-Ring (2 used) 33—Plate 34—Plate 35—Plate 36—Cap Screw (11 used)

5. Inspect and replace parts as necessary. 6. Apply clean hydraulic oil to all seals and machined surfaces.

Continued on next page

JW00603,000011E –19–22APR08–5/7

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PN=445

Hydraulic System

14 17

18 19

34 13 17

19 11

14 18

17 19

11 20 24

A B 15 C

12 17

16 19

11 17 2

14 19

11 17

13 19

–UN–29FEB08

18 17 14 19

TX1037516

33 3360 68

TX1037516 Pilot Signal Manifold Valve Housing

Continued on next page

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JW00603,000011E –19–22APR08–6/7

135D Excavator Repair 040909

PN=446

Hydraulic System A—Spool Valve Location B—Spool Valve Location C—Spool Valve Location 2—Pilot Signal Manifold Valve Housing

11—Spool Valve (6 used) 12—Spool Valve 13—Spring (2 used) 14—Spring (4 used) 15—Spring

16—Spring 17—Valve Seat (7 used) 18—Plug (7 used) 19—O-Ring (7 used) 20—Flow Control Valve

7. Assemble pilot signal manifold valve housing as shown.

24—O-Ring (2 used) 33—Plate 34—Plate 35—Plate 36—Cap Screw (11 used)

9. Install pilot signal manifold. See Pilot Signal Manifold Remove and Install. (Group 3360.)

8. Assemble pilot signal manifold as shown.

JW00603,000011E –19–22APR08–7/7

Control Valve Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Drain hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

Continued on next page

JW00603,00000CF –19–22APR08–1/8

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=447

Hydraulic System 3. Remove cap screw (4) on back of control valve access door (3).

TX1038495A

–UN–19MAR08

3—Control Valve Access Door 4—Cap Screw (2 used)

TX1038496A

–UN–20MAR08

Control Valve Access Door

Cap Screw on Back of Control Valve Access Door

Continued on next page

JW00603,00000CF –19–22APR08–2/8

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=448

Hydraulic System 4. Open door (5) to access cap screw (4) to open control valve access door (3). 5. Remove guard rail support (9). 6. Disconnect electrical connector for work light.

TX1038497A

–UN–20MAR08

3—Control Valve Access Door 4—Cap Screw 5—Door 6—Cover 9—Guard Rail Support

TX1038498A

–UN–20MAR08

Door

Hidden Cap Screw

Continued on next page

JW00603,00000CF –19–22APR08–3/8

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=449

Hydraulic System 7. Remove cover (6)

TX1038499A

–UN–20MAR08

4—Cap Screw (6 used) 6—Cover

TX1038500A

–UN–20MAR08

Cover

Top of Cover

JW00603,00000CF –19–22APR08–4/8

8. Remove cover (7).

TX1038501A

–UN–20MAR08

4—Cap Screw (3 used) 7—Cover

Cover 33 3360 72

Continued on next page

TM10743 (09APR09)

33-3360-72

JW00603,00000CF –19–22APR08–5/8

135D Excavator Repair 040909

PN=450

Hydraulic System 9. Remove cover support (8).

TX1038503A

–UN–20MAR08

4—Cap Screw (2 used) 8—Cover Support

TX1038504A

–UN–20MAR08

Cover Support

Cover Support Continued on next page

JW00603,00000CF –19–22APR08–6/8

33 3360 73

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=451

Hydraulic System 10. Install identification tags on hydraulic hoses and lines. See Control Valve Line Identification. (Group 9025-15.) –UN–20MAR08

11. Disconnect hydraulic hoses and lines from control valve and close all openings with caps and plugs.

TX1038505A

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Support control valve.

Control Valve

Specification —Weight Approximate..................................................................... 150 kg 330 lb

10—Control Valve

13. Remove control valve. 14. Inspect and repair as necessary. See Control Valve Separation. (Group 3360.) See Control Valve (5-Spool) Disassemble and Assemble. (Group 3360.)See Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 15. Install control valve. Specification —Weight Approximate..................................................................... 150 kg 330 lb

16. Connect all hydraulic hoses and lines. See Control Valve Line Identification. (Group 9025-15.) 17. Install cover support. 18. Install all covers. 19. Fill hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.) 20. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 33 3360 74

Continued on next page

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JW00603,00000CF –19–22APR08–7/8

135D Excavator Repair 040909

PN=452

Hydraulic System 21. Close control valve access door and install cap screws. 22. Install guard rail support. 23. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,00000CF –19–22APR08–8/8

33 3360 75

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=453

Hydraulic System

–UN–25FEB08

Control Valve Separation

TX1037353

33 3360 76

Control Valve Separation Continued on next page

TM10743 (09APR09)

33-3360-76

JW00603,000011F –19–22APR08–1/2

135D Excavator Repair 040909

PN=454

Hydraulic System 1—Control Valve Housing (4-Spool Side) 2—Control Valve Housing (5-Spool Side)

4—O-Ring (5 used) 5—O-Ring (3 used) 6—Backup Ring (3 used) 7—Packing

8—Backup Ring 9—O-Ring 10—Backup Ring (7 used) 11—O-Ring (5 used)

12—O-Ring 13—Packing 15—Cap Screw (9 used)

1. Separate control valve as shown. 2. Inspect and replace parts as necessary. 3. Assemble control valve as shown. 4. Tighten cap screws to specification. Specification 4-Spool Side-to-5-Spool Side Cap Screw—Torque .............................................................. 110 N•m 81 lb-ft

JW00603,000011F –19–22APR08–2/2

Control Valve (5-Spool) Disassemble and Assemble 1. Remove control valve. See Control Valve Remove and Install. (Group 3360.)

Continued on next page

JW00603,0000120 –19–30APR08–1/14

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=455

Hydraulic System 2. Remove pilot housing (5)

A—Pilot Housing Alignment Point 1—Control Valve (5-Spool) Housing 3—Cap Screw (10 used) 5—Pilot Housing 14—Pilot Housing Plug

A A

TX1037365

–UN–27FEB08

Control Valve

JW00603,0000120 –19–30APR08–2/14

3. Remove spools (76, 80—83). 81

TX1037366

–UN–27FEB08

A—Pilot Housing Alignment Point 1—Control Valve (5-Spool) Housing 76—Spool Valve 80—Spool Valve 81—Spool Valve 82—Spool Valve 83—Spool Valve

Spool Valves

33 3360 78

Continued on next page

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33-3360-78

JW00603,0000120 –19–30APR08–3/14

135D Excavator Repair 040909

PN=456

Hydraulic System 4. Disassemble valves as shown. 84

87 86

86 80

85 87

89 90

4 2

–UN–27FEB08

TX1037367

2—Plug 4—O-Ring 9—O-Ring (5 used) 76—Spool Valve 80—Spool Valve 81—Spool Valve 82—Spool Valve 83—Spool Valve 84—Cap Screw (5 used) 85—Seat (5 used) 86—Seat (5 used) 87—Spring (5 used) 89—Flow Control Valve 90—Spring

Control Valves

Continued on next page

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=457

Hydraulic System NOTE: Control valve spools are not serviceable. If spools are damaged, the control valve must be replaced.

5. Remove pressure relief valves (7 and 8).

7. Remove plug (12), snap ring (15), packing (6) and O-ring (16).

1—Control Valve (5-Spool) Housing 4—O-Ring 6—Packing 7—Pressure Relief Valve 8—Pressure Relief Valve 10—Valve 11—O-Ring 12—Plug 13—O-Ring 15—Snap Ring 16—O-Ring 17—O-Ring 18—Stop 19—O-Ring 20—Packing 21—Backup Ring (2 used) 22—O-Ring (2 used) 23—Housing 24—Washer 25—Spring 26—Backup Ring 27—O-Ring 28—Plug 31—Spring 32—Backup Ring

8 32

12 16 15 6

10 17

TX1037368

–UN–27FEB08

6. Remove parts (10, 18—28, and 31).

Control Valve Circuit Relief Valves

Continued on next page

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=458

Hydraulic System 8. Remove plugs (38 and 95).

77 91

9. Remove flow control valve (11). 78

10. Remove parts (66—69).

76 72

77 74

12. Disassemble spools (74 and 91) as shown. 70 71

8 11 95

73 66

68 –UN–27FEB08

11. Remove housing (73) and spools (74 and 91).

9 95

TX1037394

1—Control Valve (5-Spool) Housing 8—O-Ring (2 used) 9—O-Ring (5 used) 11—Flow Control Valve 38—Plug 66—Plug 67—O-Ring 68—Snap Ring 69—Packing 70—Cap Screw 71—Spring 72—Seat 73—Pilot Housing 74—Spool 75—Check Valve (2 used) 76—Spring (2 used 77—Plug (2 used) 78—Cap Screw 79—Spring 91—Spool 95—Plug

3 Control Valve Bottom

Continued on next page

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=459

Hydraulic System

14. Remove parts (56—59).

3 3 62

58 56

36 53

49 65

15. Remove parts (43—45, 63 and 64).

16. Remove parts (38—41, and 52). 17. Inspect and replace parts as necessary.

63 33

37 47

3—M8 Cap Screw (11 used) 33—M10 Cap Screw (10 used) 35—O-Ring (3 used) 36—O-Ring (2 used) 37—Valve 38—O-Ring 39—Spring 40—Plug 41—Check Valve 42—Check Valve 43—Check Valve 44—Spring 45—Seat 46—Spring (2 used) 47—Plug 48—Flange 49—Plug 51—Spring 52—Bushing 53—Backup Ring 54—Seat 56—Spool 57—Washer 58—Spring 59—Plug 60—O-Ring 62—Cap 63—O-Ring (4 used) 64—Backup Ring (4 used) 65—Cap

63 64

44 43

63 64 46 42

–UN–31MAR08

TX1037369

13. Remove control valve caps (62 and 65) and flange (48).

Control Valve End Caps

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=460

Hydraulic System

18. Install seat (54).

3 3 62

58 56

36 53

49 65

19. Install check valve (41), spring (39), O-ring (38), and plug (40).

20. Install spring (51), O-ring (36), backup ring (53), bushing (52), backup ring (53), and O-ring (36).

63 33

37 47

21. Install check valve (43), spring (44), seat (45), backup ring (64), and O-ring (63).

63 64

44 43

22. Install check valve (42), spring (46), backup ring (64), and O-ring (63).

63 64 46 42

23. Install valve (37), spring (46), backup ring (64), and O-ring (63).

–UN–31MAR08

TX1037369

NOTE: Apply clean hydraulic oil to all sealing and machined surfaces.

Control Valve End Caps

24. Install O-rings (35) and pilot plate (62) and tighten cap screws to specification.

Specification Pilot Plate-to-Control Valve (5-Spool) Housing M8 Cap Screw—Torque ............................................................................... 25 N•m 216 lb-in. Pilot Plate-to-Control Valve (5-Spool) Housing M10 Cap Screw—Torque ............................................................................... 50 N•m 37 lb-ft

25. Install O-ring (35) and flange (48) and tighten cap screws to specification. Specification Flange-to-Control Valve (5-Spool) Housing M10 Cap Screw— Torque ............................................................................................ 50 N•m 37 lb-ft

26. Install cap (65) and tighten cap screws to specification. Specification Cap-to-Control Valve (5-Spool) Housing M8 Cap Screw—Torque .................................................. 25 N•m 216 lb-in.

33 3360 83

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JW00603,0000120 –19–30APR08–8/14

135D Excavator Repair 040909

PN=461

Hydraulic System 27. Install spool (56), washer (57), spring (58), O-ring (60), and plug (59) and tighten to specification. Specification Pilot Plate Plug—Torque .............................................................. 200 N•m 150 lb-ft

28. Install plug (49).

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JW00603,0000120 –19–30APR08–9/14

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=462

Hydraulic System 29. Assemble spools (91 and 74) as shown and tighten to specification.

91 78

79 76 8

77 74

Specification Flow Control Valve-to-Control Valve (5-Spool) Housing—Torque ................................................. 78 N•m 58 ft-lb

31. Install O-rings (9) and pilot housing (73) and tighten to specification.

70 71

8 11 95

73 66

68 –UN–27FEB08

30. Install flow control valve (11) and tighten to specification.

9 95

Specification Pilot Housing-to-Control Valve (5-Spool) Housing M8 Cap Screw—Torque ............................................................................... 25 N•m 216 lb-in.

TX1037394

Specification Spool Cap Screw—Torque............................................................. 12 N•m 108 lb-in.

77 75

3 Control Valve Bottom

1—Control Valve (5-Spool) Housing 3—M8 Cap Screw (11 used) 8—O-Ring (2 used) 9—O-Ring (9 used) 11—Flow Control Valve 38—Plug 66—Plug 67—O-Ring 68—Snap Ring 69—Packing 70—Cap Screw 71—Spring 72—Seat 73—Pilot Housing 74—Spool 75—Check Valve (2 used) 76—Spring (2 used) 77—Plug (2 used) 78—Cap Screw 79—Spring 91—Spool 95—Plug

32. Install plugs (38 and 95).

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JW00603,0000120 –19–30APR08–10/14

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=463

Hydraulic System 33. Install valve (10) and spring (31). 34. Assemble housing (23) as shown. 35. Install assembled housing (23) to control valve (5-spool) housing (1).

22 25

16 15

Specification Pressure Relief Valves-to-Control Valve (5-Spool) Housing—Torque ................................................. 78 N•m 58 ft-lb

10 17

37. Install O-ring (16), snap ring (15) and packing (6) to plug (12).

TX1037368

–UN–27FEB08

36. Install pressure relief valves (7 and 8) and tighten to specification.

38. Install plug (12) and tighten to specification. Specification Control Valve (5-Spool) Housing Plug—Torque................................................................................ 200 N•m 150 lb-ft

Control Valve Circuit Relief Valves 1—Control Valve (5-Spool) Housing 4—O-Ring 6—Packing 7—Pressure Relief Valve 8—Pressure Relief Valve 10—Valve 11—O-Ring 12—Plug 13—O-Ring 15—Snap Ring 16—O-Ring 17—O-Ring 18—Stop 19—O-Ring 20—Packing 21—Backup Ring (2 used) 22—O-Ring (2 used) 23—Housing 24—Washer 25—Spring 26—Backup Ring 27—O-Ring 28—Plug 31—Spring 32—Backup Ring

39. Install O-rings (4 and 17) and backup ring (32).

Continued on next page

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PN=464

Hydraulic System 40. Assemble spool valves as shown and tighten cap screws (84) to specification.

Specification Spool Valve Cap Screw—Torque .................................................. 25 N•m 216 lb-in.

9 9

87 84

85 81

87 86 80

89 90

4 2

TX1037367

–UN–27FEB08

84 A—Pilot Housing Alignment Point 2—Plug 4—O-Ring 9—O-Ring (5 used) 76—Spool Valve 80—Spool Valve 81—Spool Valve 82—Spool Valve 83—Spool Valve 84—Cap Screw (5 used) 85—Seat (5 used) 86—Seat (5 used) 87—Spring (5 used) 89—Flow Control Valve 90—Spring

Control Valves

JW00603,0000120 –19–30APR08–12/14

41. Install assembled spool valves (76—83) to control valve (5-spool) housing (1).

TX1037366

–UN–27FEB08

1—Control Valve (5-Spool) Housing 76—Spool Valve 80—Spool Valve 81—Spool Valve 82—Spool Valve 83—Spool Valve

Spool Valves

Continued on next page

TM10743 (09APR09)

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PN=465

Hydraulic System 42. Install pilot housing (5) and tighten cap screws to specification.

Specification Pilot Housing-to-Control Valve (5-Spool) Housing M8 Cap Screw—Torque ............................................................................... 25 N•m 216 lb-in.

A 1

43. Install pilot housing plug (14).

–UN–27FEB08

44. Install control valve. See Control Valve Remove and Install. (Group 3360.)

TX1037365

A—Pilot Housing Alignment Point 1—Control Valve (5-Spool) Housing 3—Cap Screw (10 used) 5—Pilot Housing 14—Pilot Housing Plug

Control Valve

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Control Valve (4-Spool) Disassemble and Assemble 1. Remove control valve. See Control Valve Remove and Install. (Group 3360.)

Continued on next page

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PN=466

Hydraulic System 2. Remove pilot housing (94)

1—Control Valve (4-Spool) Housing 3—M8 Cap Screw (6 used) 40—Plug 44—Nut (2 used) 45—Cap 46—Cap 48—Ring 49—Washer 94—Pilot Housing

94 3

–UN–27FEB08

TX1037451

Control Valve (4-Spool) Housing

JW00603,0000121 –19–22APR08–2/14

NOTE: Spools are not serviceable. If spools are damaged, control valve must be replaced.

43 47 79

3. Remove spool valves (76—79).

77 78 76

TX1037452

–UN–27FEB08

1—Control Valve (4-Spool) Housing 43—Plunger 47—O-Ring 76—Spool Valve 77—Spool Valve 78—Spool Valve 79—Spool Valve

Control Valve Spools

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PN=467

Hydraulic System 4. Disassemble spool valves as shown.

47 9

43 9

84 9

89 79

4 91

–UN–27FEB08

TX1037453

4—O-Ring (2 used) 9—O-Ring (4 used) 43—Plunger 47—O-Ring 76—Spool 77—Spool 78—Spool 79—Spool 84—Cap Screw (4 used) 85—Seat (4 used) 86—Seat (4 used) 87—Spring (4 used) 89—Valve (2 used) 90—Spring (2 used) 91—Plug (2 used)

Spool Valves

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PN=468

Hydraulic System

6. Remove parts (10 and 95—103).

47 42

74 19

14 97

7. Remove parts (22 and 26—29).

4 73

1—Control Valve (4-Spool) Housing 4—O-Ring 8—O-Ring 10—Valve 11—O-Ring 13—Backup Ring 14—Backup Ring 19—Pressure Regulator 22—Check Valve 26—Spring 27—Plug 28—O-Ring 29—Backup Ring 41—Valve Housing 42—Plunger 47—O-Ring 68—Washer 73—Spool 74—Spring 95—O-Ring 96—O-Ring (2 used) 97—Ring (2 used) 98—Washer 99—Spring 100—Ring 101—O-Ring 102—Plug 103—Spring 105—Pressure Relief Valve

13 95 96 41

101

102

100 10

103

105

27 28 26

TX1037454

–UN–27FEB08

5. Remove pressure regulator (19) and pressure relief valve (105).

Circuit Relief Valves

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PN=469

Hydraulic System 8. Remove pilot housing (55). 16

20 52

30 9

108 105

16 18

47 107

53 9

63 64

–UN–27FEB08

106 57

60 61

104

56 58

TX1037455

1—Control Valve (4-Spool) Housing 3—M8 Cap Screw (3 used) 9—O-Ring (2 used) 16—Plug (2 used) 18—Plug (2 used) 20—Plug 24—Bushing 26—Spring 28—O-Ring 30—Plunger 36—Spring 42—Check Valve 46—Check Valve 47—Seat 51—Spring 52—Bushing 53—Ring (2 used) 55—Pilot Housing 56—Spool 57—Washer 58—Spring 60—O-Ring 61—Plug 63—O-Ring (4 used) 64—Ring 67—Spool 68—Washer 69—Spring 71—Plug 72—O-Ring 104—M10 Cap Screw (7 used) 105—Plunger 106—O-Ring 107—Spring 108—Check Valve

9. Disassemble as shown.

Control Valve End Caps

Continued on next page

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PN=470

Hydraulic System 10. Remove pilot housing (6). 1 11. Remove parts (23 and 26—29). 26

12. Remove parts (26 and 50—52).

28 29

13. Inspect and replace parts as necessary. 14. Apply clean hydraulic oil to seal and machined surfaces.

51 26

27 52

1—Control Valve (4-Spool) Housing 3—M8 Cap Screw 6—Pilot Housing 9—O-Ring (4 used) 12—Pressure Regulator (2 used) 23—Check Valve 26—Spring 27—Plug 28—O-Ring 29—Backup Ring 50—O-Ring 51—Check Valve 52—Plug

12 –UN–27FEB08

TX1037456

3 Control Valve Bottom

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PN=471

Hydraulic System 15. Install check valve (51), spring (26), O-ring (50), and plug (52).

16. Install check valve (23), spring (26), O-ring (28), backup ring (29), and plug (27).

28 29

17. Install pressure regulators (12) and tighten to specification.

Specification Pressure Regulator-to-Control Valve (4-Spool) Housing—Torque ................................................. 78 N•m 58 lb-ft

27 52

12 –UN–27FEB08

9 18. Install pilot housing (6) and tighten cap screws to specification. Specification Pilot Housing-to-Control Valve (4-Spool) Housing M8 Cap Screw—Torque ............................................................................... 25 N•m 216 lb-in.

TX1037456

3 Control Valve Bottom

1—Control Valve (4-Spool) Housing 3—M8 Cap Screw 6—Pilot Housing 9—O-Ring (4 used) 12—Pressure Regulator (2 used) 23—Check Valve 26—Spring (2 used) 27—Plug 28—O-Ring 29—Backup Ring 50—O-Ring 51—Check Valve 52—Plug

Continued on next page

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PN=472

Hydraulic System 19. Install check valve (42), spring (26), ring (64), and O-ring (63).

18 20. Install bushing (24), check valve (46) spring (36), plunger (30), ring (64), and O-ring (63).

24 36

63 64

23. Install spring (51) O-ring (9), ring (53), bushing (52), ring (53), and O-ring (9).

30 9

108 105

16 18

47 107

53 24. Install ring (64) and O-rings (28 and 63).

63 64

–UN–27FEB08

22. Install seat (47), check valve (108), spring (107), O-ring (106), and plunger (105).

106 57

60 61

104

56 58

TX1037455

21. Install spool (67), washer (68), spring (69), O-ring (72), and plug (71).

Control Valve End Caps

33 3360 95

Continued on next page

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PN=473

Hydraulic System 25. Install pilot housing (55) and tighten cap screws to specification. Specification Pilot Housing-to-Control Valve (4-Spool) Housing M8 Cap Screw—Torque ............................................................................... 25 N•m 216 lb-in. Pilot Housing-to-Control Valve (4-Spool) Housing M10 Cap Screw—Torque ............................................................................... 50 N•m 37 lb-ft

26. Install plugs (16, 18, and 20). 27. Install spool (56), washer (57), spring (58), O-ring (60), and plug (61) and tighten to specification. Specification Pilot Housing Plug—Torque ......................................................... 200 N•m 150 lb-ft

Continued on next page

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PN=474

Hydraulic System

Specification Pressure Relief Valves-to-Control Valve (4-Spool) Housing—Torque ................................................. 78 N•m 58 ft-lb

47 42

74 19

14 97 4

29. Install spool (73), washer (68), and spring (74), and O-ring (8). 30. Install check valve (10) and spring (103).

13 95 96 41

101

102

100 10

103

31. Install plug (102), O-ring (101), ring (100), spring (99), and washer (98) to valve housing (41).

105

27 28 26

32. Install assembled valve housing (41), rings (97), O-rings (11, 95, 96), ring (13), plunger (42), and O-ring (47).

TX1037454

–UN–27FEB08

28. Install pressure relief valves (105) and pressure regulator (19) and tighten to specification.

33. Install check valve (22), spring (26), O-ring (28), backup ring (29), and plug (27).

Circuit Relief Valves 1—Control Valve (4-Spool) Housing 4—O-Ring 8—O-Ring 10—Check Valve 11—O-Ring 13—Backup Ring 14—Backup Ring 19—Pressure Regulator 22—Check Valve 26—Spring 27—Plug 28—O-Ring 29—Backup Ring 41—Valve Housing 42—Plunger 47—O-Ring 68—Washer 73—Spool 74—Spring 95—O-Ring 96—O-Ring (2 used) 97—Ring (2 used) 98—Washer 99—Spring 100—Ring 101—O-Ring 102—Plug 103—Spring 105—Pressure Relief Valve

33 3360 97

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PN=475

Hydraulic System 34. Assemble spools as shown and tighten cap screws to specification.

47 9

Specification Spool Valve Cap Screw—Torque .................................................. 25 N•m 216 lb-in.

84 85

85 87

87 78

89 89

TX1037453

–UN–27FEB08

Spool Valves

JW00603,0000121 –19–22APR08–12/14

35. Install assembled spool valves (76—79).

43 47

36. Install plunger (43) and O-rings (9 and 47). 79

77 78

1—Control Valve (4-Spool) Housing 43—Plunger 47—O-Ring 76—Spool Valve 77—Spool Valve 78—Spool Valve 79—Spool Valve

TX1037452

–UN–27FEB08

Control Valve Spools

33 3360 98

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PN=476

Hydraulic System 37. Install pilot housing (94) and tighten cap screws to specification.

46 40

Specification Pilot Housing-to-Control Valve (4-Spool) Housing M8 Cap Screw—Torque ............................................................................... 25 N•m 216 lb-in.

45 44

48 49 44

94 3

38. Install nuts (44), washer (49), ring (48), and caps (45 and 46).

40. Install control valve. See Control Valve Remove and Install. (Group 3360.)

TX1037451

1—Control Valve (4-Spool) Housing 3—M8 Cap Screw (6 used) 40—Plug 44—Nut (2 used) 45—Cap 46—Cap 48—Ring 49—Washer 94—Pilot Housing

–UN–27FEB08

39. Install plug (40).

Control Valve (4-Spool) Housing

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PN=477

Hydraulic System

Hydraulic Oil Tank Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Drain hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

TX1037206A

Specification Hydraulic Oil Tank—Capacity Approximate......................................................................................... 66 L 17 gal

1—Pressure Release Button 2—Hydraulic Oil Tank Cover Hydraulic Pressure Release Button

Continued on next page

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PN=478

Hydraulic System 3. Install identification tags on hydraulic hoses (6) and lines (5). 4. Disconnect hydraulic oil lines and hoses and close all openings with caps and plugs.

TX1038792A

–UN–19MAR08

5—Hydraulic Line (4 used) 6—Hydraulic Hose (9 used) 7—Hydraulic Oil Tank

TX1038793A

–UN–25MAR08

Front of Hydraulic Oil Tank

TX1038794A

–UN–25MAR08

Rear of Hydraulic Oil Tank

Side of Hydraulic Oil Tank Continued on next page

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PN=479

33 3360 ,101

Hydraulic System 5. Remove bracket (40).

TX1038795A

–UN–25MAR08

3—Fuel Tank 7—Hydraulic Oil Tank 40—Bracket 42—Cap Screw (4 used)

Top of Hydraulic Oil Tank

Continued on next page

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PN=480

Hydraulic System 6. Disconnect electrical connector (15). 7. Remove cap screws (11) and spacers (41). –UN–25MAR08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1038796A

8. Support hydraulic oil tank. Specification Hydraulic Oil Tank—Weight Approximate..................................................................................... 150 kg 330 lb

Rear of Hydraulic Oil Tank

9. Remove hydraulic oil tank.

–UN–25MAR08

10. Inspect and repair as necessary. See Hydraulic Oil Tank Disassemble and Assemble. (Group 3360.)

TX1038797A

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Install hydraulic oil tank. Front of Hydraulic Oil Tank Specification Hydraulic Oil Tank—Weight Approximate..................................................................................... 150 kg 330 lb

7—Hydraulic Oil Tank 11—Cap Screw (4 used) 15—Electrical Connector 41—Spacer (4 used)

12. Install spacers and caps crews and tighten to specification. Specification Hydraulic Oil Tank-to-Frame Cap Screws—Torque ........................................................................... 210 N•m 155 lb-ft

13. Connect electrical connector. 14. Connect hydraulic hoses and lines. 15. Install bracket to fuel tank. 16. Fill hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

33 3360 ,103

Continued on next page

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PN=481

Hydraulic System 17. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 18. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,00000CA –19–22APR08–5/5

Hydraulic Oil Tank Disassemble and Assemble NOTE: Removal of hydraulic oil tank is not necessary to disassemble. Remove hydraulic oil tank only if replacement is necessary. 1. Remove hydraulic oil tank if necessary. See Hydraulic Oil Tank Remove and Install. (Group 3360.)

Continued on next page

JW00603,00000CB –19–22APR08–1/3

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PN=482

Hydraulic System

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PN=483

Hydraulic System 38 37 36 35

34 33

2 31 4

29 28

5 42 42 40

6 24 23 11 13

33 3360 ,106

13 17

TX1038755

20 20

TX1038755

–UN–20MAR08

41 15

Hydraulic Oil Tank Continued on next page

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PN=484

Hydraulic System 1—Cap Screw (6 used) 2—Cover 3—O-Ring 4—Spring 5—Filter Element 6—Fitting (6 used) 7—Hydraulic Tank 11—Cap Screw (4 used) 12—Lock Washer (4 used) 13—Washer (4 used)

14—Gasket 15—Sensor 17—Plug 18—Fitting 19—Plug 20—Seal (4 used) 21—Cap Screw (2 used) 22—Level Gauge 23—Suction Strainer 24—Nut (3 used)

25—Rod 26—O-Ring 27—Cap Screw 28—Lock Washer 29—Washer 30—Bracket 31—Cover 32—Cap Screw (6 used) 33—O-Ring

34—Body 35—Element 36—Cover 37—Nut 38—Button 39—Cap Screw (4 used) 40—Bracket 41—Spacer (4 used) 42—Cap Screw (4 used)

2. Disassemble parts as shown.

7. Tighten nuts (24) to specification.

3. Inspect and replace parts as necessary.

Specification Rod-to-Suction Strainer Nut— Torque...................................................................................... 17 N•m 153 lb-in.

4. Install filter element (5), spring (4), O-ring (3), cover (2), and cap screws (1) and tighten to specification. Specification Cover-to-Hydraulic Oil Tank Cap Screws—Torque .............................................................. 49 N•m 36 lb-ft

5. Install seals (20), level gauge (22), and cap screws (21).

8. Install O-ring (26), assembled suction strainer, cover (31), and cap screws (32) and tighten to specification. Specification Cover-to-Hydraulic Oil Tank Cap Screws—Torque .............................................................. 49 N•m 36 lb-ft

IMPORTANT: To ensure suction strainer (23) is held in position on suction tube, the rod and suction strainer must be adjusted to the correct length.

9. Install O-ring (33), body (34) and cap screws (39).

6. Adjust rod (25) so length from end of rod to bottom of suction strainer (23) is 869 mm (34.2 in.).

11. Install sensor (15).

Specification End of Rod-to-Bottom of Suction Strainer—Length........................................................ 869 mm 34.2 in.

10. Install element (35), cover (36), nut (37), button (38).

12. Install hydraulic oil tank if removed. See Hydraulic Oil Tank Remove and Install. (Group 3360.)

JW00603,00000CB –19–22APR08–3/3

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PN=485

Hydraulic System

Restriction Valve Remove and Install

12 11 –UN–20MAR08

TX1038812

TX1038812 Restriction Valve Location 10—Hydraulic Pipe 11—Snap Ring

12—Restriction Valve 13—Coupler

14—Coupler 15—Hydraulic Oil Tank

Continued on next page

16—Hydraulic Oil Cooler

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PN=486

Hydraulic System

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1). 2. Drain hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

–UN–22FEB08

3. Remove pipe (10) and close all openings with caps and plugs. 4. Remove snap ring (11) and restriction valve (12).

TX1037206A

5. Inspect and replace parts as necessary. 6. Install restriction valve and snap ring. Hydraulic Pressure Release Button

7. Install pipe and clamps. 8. Fill hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

9. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 10. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,00000CC –19–22APR08–2/2

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PN=487

Hydraulic System

Hydraulic Oil Cooler Bypass Valve Remove and Install

7 –UN–20MAR08

6 4 15

TX1038811

3 TX1038811 Hydraulic Oil Cooler Bypass Valve Location 3—Cap Screw (2 used) 4—Pipe

5—Coupler 6—Hydraulic Oil Cooler Bypass Valve

7—Snap Ring 15—Hydraulic Oil Tank

Continued on next page

16—Control Valve

JW00603,00000CD –19–22APR08–1/2

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PN=488

Hydraulic System

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1). 2. Drain hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.)

–UN–22FEB08

3. Remove pipe (4). 4. Remove snap ring (7) and hydraulic oil cooler bypass valve (6).

TX1037206A

5. Inspect and replace as necessary. 6. Install hydraulic oil cooler bypass valve. Hydraulic Pressure Release Button

7. Install snap ring.

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

8. Install pipe and coupler. 9. Fill hydraulic oil tank. See Change Hydraulic Tank Oil, Clean Suction Screen. (Operator’s Manual.) 10. Perform pump startup procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 11. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,00000CD –19–22APR08–2/2

Boom Cylinder Remove and Install NOTE: Procedure is the same for both boom cylinders.

–UN–10JAN97

1. Park machine on firm, level surface.

T106031

2. Retract arm and bucket cylinders and lower bucket to ground.

Continued on next page

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PN=489

33 3360 ,111

Hydraulic System

TX1037206A

–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

JW00603,0000122 –19–22APR08–2/6

4. Disconnect lubrication line (10).

–UN–20DEC07

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1033302A

5. Support boom cylinder using an appropriate lifting device. Specification Boom Cylinder—Weight (approximate)................................................................................... 110 kg 243 lb

6. Remove parts (11—14). 7. Push pin into boom. 8. Lower boom cylinder on floor stand.

Boom Cylinder 10—Lubrication Line 11—Cap Screw 12—Retainer 13—Nut (2 used) 14—Shim (2 used) 15—Cylinder Rod End

33 3360 ,112

Continued on next page

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PN=490

Hydraulic System

–UN–08DEC08

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

–UN–17DEC07

X9811

TX1033295A

10. Disconnect hydraulic lines (4). Close all open lines and fittings using caps and plugs. 11. Record location of shims (6) to aid in assembly. 12. Remove parts (5—8) and remove boom cylinder (3). 13. Inspect and repair parts as necessary. See Boom Cylinder Disassemble and Assemble. (Group 3360.)

Boom Cylinder 3—Boom Cylinder 4—Hydraulic Line (2 used) 5—Boom Cylinder-to-Boom Pin 6—Shim (2 used) 7—Cap Screw 8—Nut (2 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 14. Support boom cylinder using an appropriate lifting device. Specification Boom Cylinder—Weight (approximate)................................................................................... 110 kg 243 lb

15. Install shims.

33 3360 ,113

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PN=491

Hydraulic System IMPORTANT: Align pin bores so shims are not damaged as pin is installed. 16. Connect boom cylinder head end to frame. 17. Tighten nuts against each other allowing cap screws to be free to turn in hole. Specification Boom Cylinder-to-Frame Pin Retainer Nut (tighten nut against nut)—Torque................................................................................. 270 N•m 200 lb-ft

18. Connect hydraulic lines. 19. Tighten boom cylinder hoses to specification. Specification Boom Cylinder Hose Fitting— Torque ............................................................................................ 78 N•m 58 lb-ft

20. Align pin bores so shims are not damaged as pin is installed. 21. Install shims to get the minimum amount of clearance between boom and boom cylinder rod end. 22. Connect boom cylinder rod end to boom. 23. Tighten nuts against each other allowing cap screw to be free to turn in hole. Specification Boom Cylinder-to-Frame Pin Retainer Nut (tighten nut against nut)—Torque................................................................................. 550 N•m 405 lb-ft

24. Connect lubrication line and tighten to specification. Specification Boom Cylinder Pivot Lubrication Line—Torque .................................................................................. 25 N•m 18 lb-ft

25. Lubricate all pivot joints. See Grease Front End Pin Joints. (Operator’s Manual.)

33 3360 ,114

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Hydraulic System 26. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 27. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

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Hydraulic System

TX1004546

–UN–14MAR06

Boom Cylinder Disassemble and Assemble

Boom Cylinder Exploded View

14 15 14

13 18 –UN–14MAR06

10 11

16 17

TX1004547

19 TX1004547

Seal Identification 1—Rod 2—Dust Wiper 3—Backup Ring 4—U-Ring 5—Buffer Ring 6—Cap Screw (12 used)

7—Cylinder Head 8—Bushing 9—Snap Ring 10—Backup Ring 11—O-Ring 12—Barrel

13—Slide Ring (2 used) 14—Wear Ring (2 used) 15—Backup Ring (2 used) 16—O-Ring 17—Seal Ring

18—Set Screw 19—Ball 20—Piston Nut 21—Cushion Bearing 22—Cushion Seal

4. Support rod (1).

1. Remove boom cylinder. See Boom Cylinder Remove and Install. (Group 3360.)

5. Remove cap screws (6) from cylinder head (7). 2. Fasten head end of cylinder to JT30043 Cylinder Service Stand. 33 3360 ,116

6. Remove rod (1), cylinder head (7), and piston nut (20) from barrel (12).

3. Pull rod (1) out so piston nut is against cylinder head.

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Hydraulic System 7. Install rod eye in sliding housing and install housing in JT30043 Cylinder Service Stand.

17. Remove bushing (8) using ST8017 Bushing Driver.

8. Remove staked material from set screw (18) hole using a small air grinder or a drill and bit.

18. Inspect and repair parts as necessary. See Inspect Pins, Bushings and Bosses—Front Attachment. (Group 3340.)

9. Remove set screw (18) and ball (19). IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the ST3262 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole.

19. Apply clean hydraulic oil to all sealing parts and machined surfaces. 20. Install bushing (8) into cylinder head (7) using ST8017 Bushing Driver. 21. Install snap ring (9).

To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw.

22. Install backup ring (10) and O-ring (11). 23. Install buffer ring (5).

10. Install ST3262 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) without tapped hole.

24. Install U-ring (4) with lip towards bushing. 25. Install backup ring (3).

11. Install a piece of steel flat stock between piston nut and cap screw. Tighten cap screw of piston nut wrench.

26. Install dust wiper (2). 27. Install cylinder head (7) on rod (1).

12. Remove piston nut (20). 28. Install O-ring (16) and seal ring (17). 13. Remove cushion bearing (21) and cushion seal (22).

29. Install slide rings (13) wear rings (14), and backup rings (15).

14. Remove components (13—17) from piston nut (20).

30. Install cushion bearing (21) and cushion seal (22).

15. Remove cylinder head (7) from rod (1).

31. Install piston nut (20).

16. Remove components (2—5) and (9—11) from cylinder head (7).

32. Install ST3262 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) without tapped hole.

IMPORTANT: Use of hammer and punch to remove bushing will cause damage to rod guide. Use only ST8017 Bushing Driver.

33. Install a piece of steel flat stock between piston nut (20) and cap screw. Tighten cap screw of Hex Piston Nut Wrench.

33 3360 ,117

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Hydraulic System 34. Tighten piston nut (20) to specification.

38. Install piston nut (20), rod (1), and cylinder head (7) into barrel (12).

Specification Boom Cylinder Piston Nut— Torque.................................................................................. 3140 N•m 2320 lb-ft

35. Install ball (19) and set screw (18). 36. Stake set screw (18) in two places 90° from previous stake marks.

39. Tighten cap screws to specification. Specification Boom Cylinder Head-to-Barrel Cap Screw—Torque .............................................................. 171 N•m 126 lb-ft

40. Install boom cylinder. See Boom Cylinder Remove and Install. (Group 3360.)

37. Attach appropriate lifting device to rod (1).

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Arm Cylinder Remove and Install 1. Park machine on firm, level surface.

T106031

–UN–10JAN97

2. Retract arm and bucket cylinders and lower bucket to ground.

Machine Position

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Hydraulic System

–UN–22FEB08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Support arm cylinder.

TX1037206A

Specification Arm Cylinder—Weight (approximate)................................................................................... 160 kg 353 lb

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

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NOTE: Record position of shims to aid in assembly. 5. Remove parts (4—7).

TX1033315A

–UN–09JAN08

3—Arm Cylinder 4—Cap Screw 5—Shim (2 used) 6—Nut (2 used) 7—Arm Cylinder Pin

Arm Cylinder Rod

Continued on next page

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Hydraulic System 6. Disconnect lubrication line (9).

TX1033307A

–UN–09JAN08

3—Arm Cylinder 8—Hydraulic Line (2 used) 9—Lubrication Line 10—Cap Screw 11—Arm Cylinder Pin 12—Nut (2 used) 13—Shim (2 used)

Arm Cylinder

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Hydraulic System

–UN–08DEC08

X9811

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 7. Loosen arm cylinder hydraulic lines at frame end of arm to release any residual pressure. 8. Install identification tags and disconnect hydraulic lines (8). Close all open lines and fittings using caps and plugs. 9. Remove parts (10—13). 10. Remove arm cylinder (3). 11. Inspect and repair parts as necessary. See Arm Cylinder Disassemble and Assemble. (Group 3360.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Support arm cylinder. Specification Arm Cylinder—Weight (approximate)................................................................................... 160 kg 353 lb

13. Install shims equally on each side of cylinder head end to get the minimum amount of clearance in joint.

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Hydraulic System 14. Align pin bores so shims are not damaged as pin is installed. 15. Connect arm cylinder head end to frame. 16. Tighten nuts against each other allowing cap screws to be free to turn in hole. Specification Arm Cylinder-to-Frame Pin Retainer Nut (tighten nut against nut)—Torque................................................................................. 270 N•m 200 lb-ft

17. Connect hydraulic lines and tighten to specifications. Specification Arm Cylinder Hose—Torque ........................................................ 175 N•m 130 lb-ft

NOTE: Align pin bores so shims are not damaged as pin is installed. 18. Install shims to get the minimum amount of clearance between arm and arm cylinder rod end. 19. Connect arm cylinder rod end to arm. 20. Tighten nuts against each other allowing cap screw to be free to turn in hole. Specification Arm Cylinder-to-Frame Pin Retainer Nut (tighten nut against nut)—Torque................................................................................. 550 N•m 405 lb-ft

21. Connect lubrication line and tighten to specification. Specification Arm Cylinder Pivot Lubrication Line—Torque .................................................................................. 25 N•m 18 lb-ft

22. Lubricate all pivot joints. See Grease Front End Pin Joints. (Operator’s Manual.) 23. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.)

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Hydraulic System 24. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

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Hydraulic System

TX1004548

–UN–14MAR06

Arm Cylinder Disassemble and Assemble

Arm Cylinder Exploded View

6 4

18 25

18 19 18

14 –UN–14MAR06

26 24

10 11

20 21

TX1004549

13 23 16 15 TX1004549

Seal Identification 1—Rod 2—Dust Wiper 3—Backup Ring 4—U-Ring 5—Buffer Ring 6—Cap Screw (12 used) 7—Cylinder Head

8—Bushing 9—Snap Ring 10—Backup Ring 11—O-Ring 12—Barrel 13—Stopper (2 used) 14—Cushion Bearing

15—Cushion Seal 16—Snap Ring 17—Slide Ring (2 used) 18—Wear Ring (2 used) 19—Backup Ring (2 used) 20—O-Ring

1. Remove arm cylinder. See Arm Cylinder Remove and Install. (Group 3360.) 2. Fasten head end of cylinder to JT30043 Cylinder Service Stand. 3. Pull rod out so piston nut (24) is against cylinder head. 33 3360 ,124

4. Support rod (1).

5. Remove cap screws (6) from cylinder head (7). 6. Remove rod, cylinder head and piston nut from barrel (12). 7. Remove stopper (13), cushion bearing (14), cushion seal (15), and snap ring (16). 8. Install rod eye in sliding housing and install housing in JT30043 Cylinder Service Stand.

Continued on next page

TM10743 (09APR09)

21—Seal Ring 22—Set Screw 23—Ball 24—Piston Nut 25—Cushion Bearing 26—Cushion Seal

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Hydraulic System 9. Remove staked material from set screw (22) hole using a small air grinder or a drill and bit.

21. Install bushing (8) into cylinder head (7) using ST8019 Bushing Driver.

10. Remove set screw (22) and steel ball (23).

22. Install snap ring (9).

IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the ST3304 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole.

23. Install backup ring (10) and O-ring (11).

To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 11. Install ST3304 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (24) without tapped hole.

24. Install buffer ring (5). 25. Install U-ring (4) with lip towards bushing (8). 26. Install backup ring (3). 27. Install dust wiper (2) with lip towards outside of cylinder. 28. Install cylinder head (7) on rod (1). 29. Install cushion bearing (25) and cushion seal (26).

12. Install a piece of steel flat stock between piston nut (24) and cap screw. Tighten cap screw of piston nut wrench.

30. Install parts (17—21) on piston nut (24). 31. Install piston nut (24).

13. Remove piston nut (24). 14. Remove cushion bearing (25) and cushion seal (26) from rod (1). 15. Remove components (17—21) from piston nut (24).

32. Install ST3304 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (24) without tapped hole. 33. Install a piece of steel flat stock between piston nut (24) and cap screw. Tighten cap screw of ST3304 Hex Piston Nut Wrench.

16. Remove cylinder head (7) from rod (1). 34. Tighten piston nut (24) to specification. 17. Remove components (2—5) and (9—11) from cylinder head (7). 18. Remove bushing (8) using ST8019 Bushing Driver. 19. Inspect and replace as necessary. See Inspect Pins, Bushings and Bosses—Front Attachment. (Group 3340.)

Specification Arm Cylinder Piston Nut— Torque.................................................................................. 6180 N•m 4560 lb-ft

35. Install ball (23) and set screw (22). 36. Stake set screw (22) in two places 90° from previous stake marks.

20. Apply clean hydraulic oil to all sealing parts and machined surfaces.

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Hydraulic System NOTE: Install cushion seal so that notch is towards piston. IMPORTANT: Note direction of oil groove in cushion bearing during installation to prevent leaking. 37. Install stopper (13), cushion bearing (14), cushion seal (15), and snap ring (16).

40. Tighten cap screws to specification. Specification Arm Cylinder Head-to-Barrel Cap Screw—Torque .............................................................. 267 N•m 197 lb-ft

41. Install arm cylinder. See Arm Cylinder Remove and Install. (Group 3360.)

38. Attach appropriate lifting device to rod (1). 39. Install piston nut (24), rod (1) and cylinder head (7) into barrel (12).

JW00603,0000125 –19–22APR08–3/3

Bucket Cylinder Remove and Install 1. Park machine on firm, level surface.

–UN–14DEC07

2. Retract arm cylinder and bucket cylinder (3) and lower bucket to ground. Position end of arm (4) on wood block (5).

TX1033323

3—Bucket Cylinder 4—End of Arm 5—Wood Block Bucket Position

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Hydraulic System

TX1037206A

–UN–22FEB08

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

JW00603,0000126 –19–22APR08–2/5

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–08JAN08

4. Support center link (12).

TX1033338A

5. Place a wood block between bucket cylinder and arm to support cylinder when pin is removed. 6. Remove parts (8—11). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Support bucket cylinder. Specification Bucket Cylinder—Weight (approximate).................................................................................. 110 kg 243 lb

Arm Cylinder Rod End 6—Arm Cylinder Rod End 7—Arm Cylinder 8—Pin 9—Nut (2 used) 10—Cap Screw 11—Shim (4 used) 12—Center Link 33 3360 ,127

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Hydraulic System 8. Install identification tags and disconnect hydraulic lines (16). Close all open lines and fittings using caps and plugs. 9. Remove parts (13—15). 10. Remove bucket cylinder (7).

–UN–08JAN08

11. Inspect and repair parts as necessary. See Bucket Cylinder Disassemble and Assemble. (Group 3360.) 12. Install shims.

TX1033337A

IMPORTANT: Align pin bores so shims are not damaged as pin is installed. 13. Connect bucket cylinder head end to arm.

Bucket Cylinder

14. Tighten nut against nut allowing cap screw to be free to turn in hole. Specification Bucket Cylinder-to-Arm Pin Retainer Nut (tighten nut against nut)—Torque................................................................................. 270 N•m 200 lb-ft

7—Bucket Cylinder 13—Shim (2 used) 14—Cap Screw 15—Nut (2 used) 16—Hydraulic Line

15. Connect hydraulic lines. 16. Tighten bucket cylinder hoses. Specification Bucket Cylinder Hose—Torque ...................................................... 78 N•m 58 lb-ft

17. Align pin bores so shims are not damaged as pin is installed. 18. Install shims equally on each side of cylinder rod end and side links to get minimum amount of clearance in joint. 19. Connect bucket cylinder head end to arm. 20. Tighten nuts against each other allowing cap screw to be free to turn in hole.

33 3360 ,128

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Hydraulic System Specification Bucket Cylinder-to-Pin Retainer Nut (tighten nut against nut)— Torque .......................................................................................... 550 N•m 405 lb-ft

21. Lubricate all pivot joints. See Grease Front End Pin Joints. (Operator’s Manual.) 22. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 23. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

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Hydraulic System

Bucket Cylinder Disassemble and Assemble 7

8 10

13 14

TX1004550

–UN–09MAR06

TX1004550

15 17 16 15 13 Bucket Cylinder Exploded View

7 12

14 13

20 18

–UN–09MAR06

10 11 16 17

TX1004551

13 14

TX1004551 Seal Identification 1—Rod 2—Dust Wiper 3—Backup Ring 4—U-Ring 5—Buffer Ring

33 3360 ,130

6—Cap Screw (12 used) 7—Cylinder Head 8—Bushing 9—Snap Ring 10—Backup Ring

11—O-Ring 12—Barrel 13—Slide Ring (2 used) 14—Wear Ring (2 used) 15—Backup Ring (2 used)

16—O-Ring 17—Seal Ring 18—Set Screw 19—Ball 20—Piston Nut

1. Remove bucket cylinder. See Bucket Cylinder Remove and Install. (Group 3360.)

6. Remove rod (1), cylinder head (7) and piston nut (20) from barrel (12).

2. Fasten head end of cylinder to JT30043 Cylinder Service Stand.

7. Install rod eye in sliding housing and install housing in JT30043 Cylinder Service Stand.

3. Pull rod (1) out so piston nut (20) is against cylinder head (7).

8. Remove staked material from set screw (18) hole using a small air grinder or a drill and bit.

4. Support rod (1) with an appropriate lifting device.

9. Remove set screw (18) and ball (19).

5. Remove cap screws (6) from cylinder head (7).

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Hydraulic System IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the ST3271 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole. To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 10. Install ST3271 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) without tapped hole. 11. Install a piece of steel flat stock between nut and cap screw. Tighten cap screw of piston nut wrench.

13. Remove components (13—17) from piston nut (20). 14. Remove cylinder head (7) from rod (1). 15. Remove components (2—5) and (9—11) from cylinder head (7).

17. Inspect and replace as necessary. See Inspect Pins, Bushings and Bosses—Front Attachment. (Group 3340.) 18. Apply clean hydraulic oil to all sealing parts and machined surfaces. 19. Install bushing (8) into cylinder head (7) using ST8017 Bushing Driver.

22. Install buffer ring (5).

26. Install cylinder head (7) on rod (1). 27. Install O-ring (16) and seal ring (17). 28. Install slide rings (13) wear rings (14), and backup rings (15). 29. Install piston nut (20). 30. Install ST3271 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) without tapped hole.

32. Tighten piston nut (20) to specification. Specification Bucket Cylinder Piston Nut— Torque.................................................................................. 3970 N•m 2930 lb-ft

33. Install ball (19) and set screw (18).

16. Remove bushing (8) using ST8017 Bushing Driver.

21. Install backup ring (10) and O-ring (11).

25. Install dust wiper (2).

31. Install a piece of steel flat stock between piston nut (20) and cap screw. Tighten cap screw of ST3271 Hex Piston Nut Wrench.

12. Remove piston nut (20).

20. Install snap ring (9).

24. Install backup ring (3).

34. Stake set screw (18) in two places 90° from previous stake marks. 35. Attach appropriate lifting device to rod (1). 36. Install piston nut (20), rod (1), and cylinder head (7) into barrel (12). 37. Tighten cap screws to specification. Specification Bucket Cylinder Head-to-Barrel Cap Screw—Torque .............................................................. 171 N•m 126 lb-ft

38. Install bucket cylinder. See Bucket Cylinder Remove and Install. (Group 3360.)

23. Install U-ring (4) with lip towards bushing. 33 3360 ,131

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Hydraulic System

Hydraulic Cylinder Bleed Procedure IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retracted and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. NOTE: Bleed air at initial start-up, whenever major repairs or maintenance (oil change) is done on hydraulic system, or when machine has been in storage for a period of time. 1. Run engine at slow idle. 2. Slowly operate function to move cylinder to the most horizontal position possible. 3. Slowly extend and retract cylinder several times to approximately 100 mm (4 in.) from end of stroke. 4. Operate cylinder several times to full stroke. 5. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

JW00603,0000088 –19–22APR08–1/1

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PN=510

Section 43

Swing or Pivoting System Contents Page

Group 4350—Mechanical Drive Elements Swing Gearbox Remove and Install . . . . . . .43-4350-1 Swing Gearbox Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-4 Swing Gearbox Start-Up Procedure . . . . . . .43-4350-9 Upperstructure Remove and Install . . . . . . .43-4350-10 Swing Bearing Remove and Install . . . . . . .43-4350-13 Swing Bearing Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .43-4350-17 Swing Bearing Upper Seal Install . . . . . . . .43-4350-21 Swing Bearing Lower Seal Install . . . . . . . .43-4350-22 Group 4360—Hydraulic System Center Joint Remove and Install . . . . . . . . . .43-4360-1 Center Joint Disassemble and Assemble . . .43-4360-5 Center Joint Air Test . . . . . . . . . . . . . . . . . . .43-4360-6 Swing Motor and Park Brake Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-7 Swing Motor and Park Brake Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . .43-4360-10 Swing Motor and Park Brake Inspection . . .43-4360-12 Swing Motor and Park Brake Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . .43-4360-17 Crossover Relief Valve and Make-Up Check Valve Remove and Install . . . . . . .43-4360-17 Swing Park Brake Release Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .43-4360-20

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PN=1

Contents

TM10743 (09APR09)

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PN=2

Group 4350

Mechanical Drive Elements Swing Gearbox Remove and Install 43 4350 1

–UN–22FEB08

2. Attach vacuum pump to hydraulic tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

AC12469,000059C –19–21APR08–1/4

3. Remove cover over swing gearbox.

TX1040989A

–UN–25APR08

3—Swing Gearbox Cover 4—Cap Screw (3 used)

Swing Gearbox Cover

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PN=513

Mechanical Drive Elements 4. Disconnect front attachment pressure sensor (9). 5. Install identification tags on hydraulic lines (5, 6, 10— 12). See Swing Motor Line Identification. (Group 9025-15.) 6. Disconnect hydraulic lines. Close all openings using caps and plugs. 7. Make alignment marks on swing gearbox (8) and upperstructure to assist installation. –UN–25APR08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 8. Support swing motor and gearbox and remove cap screws (7).

TX1040990A

43 4350 2

Specification Swing Motor and Gearbox— Weight (approximate) ...................................................................... 135 kg 300 lb

Swing Gearbox 5—Swing Motor Return-to-Control Valve (port T3) 6—Swing Motor-to-Return Manifold 7—Cap Screw (10 used) 8—Swing Motor and Gearbox 9—Front Attachment Pressure Sensor 10—Pilot Signal Manifold (port SH)-to-Swing Motor 11—Swing Motor-to-Control Valve Swing Right (port A) 12—Swing Motor-to-Control Valve Swing Left (port B)

9. Remove swing motor and gearbox from upperstructure. 10. Inspect and replace parts as necessary. See Swing Gearbox Disassemble and Assemble. (Group 4350.) 11. Clean mounting surfaces of swing gearbox and upperstructure. 12. Apply PM38656 Rigid Form-In-Place Gasket to swing gearbox mounting surface. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 13. Install swing gearbox and align marks made during removal. Specification Swing Motor and Gearbox— Weight (approximate) ...................................................................... 135 kg 300 lb

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PN=514

Mechanical Drive Elements 14. Install cap screws and tighten to specification. 43 4350 3

Specification Swing Gearbox Cap Screw— Torque .......................................................................................... 500 N•m 370 lb-ft

15. Connect hydraulic lines. See Swing Motor Line Identification. (Group 9025-15.) 16. Connect front attachment pressure sensor. 17. Remove vacuum pump from hydraulic tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 18. Perform Swing Gearbox Start-Up Procedure. (Group 4350.) 19. Perform Swing Motor and Park Brake Start-Up Procedure. (Group 4360.) 20. Install cover over swing gearbox. 21. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

AC12469,000059C –19–21APR08–4/4

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PN=515

Mechanical Drive Elements

Swing Gearbox Disassemble and Assemble 43 4350 4

24 12

9 32 15

18 19

7 20

6 21 4 22

26 27

5 28 2

19 29

30 31 –UN–24APR08

TX1038654

TX1038654 Swing Gearbox Exploded View 1—Shaft 2—O-Ring 3—Sleeve 4—Oil Seal 5—Roller Bearing 6—Drain Plug 7—Pipe 8—Housing

9—Roller Bearing 10—Bearing Nut 11—Lock Plate 12—Cap Screw (2 used) 15—First Planet Sun Gear 16—Thrust Plate 17—Pin (3 used) 18—First Planet Carrier

19—Spring Pin (6 used) 20—Needle Bearing (3 used) 21—Planetary Gear (3 used) 22—Thrust Plate (3 used) 23—Ring Gear 24—Cap Screw (12 used) 25—Second Planet Sun Gear

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TM10743 (09APR09)

43-4350-4

26—Thrust Plate 27—Pin (3 used) 28—Second Planet Carrier 29—Thrust Plate (6 used) 30—Needle Bearing (3 used) 31—Planetary Gear (3 used) 32—Plug

AC12469,000059D –19–18APR08–1/8

135D Excavator Repair 040909

PN=516

Mechanical Drive Elements 7. Disassemble first planet carrier (18) assembly.

1. Remove swing gearbox. See Swing Gearbox Remove and Install. (Group 4350.)

43 4350 5

8. Tap spring pin (19) into pin (17). 2. Remove swing motor from swing gearbox. See Swing Motor and Park Brake Remove and Install. (Group 4360.) 3. Make alignment marks between ring gear (23) and housing (8) to aid in assembly. 4. Remove first planet carrier (18) assembly from ring gear (23). NOTE: First planet sun gear may be removed separately or along with carrier.

NOTE: Procedure for the disassembly of first and second planetary carriers is the same. 9. Remove pin (17), planetary gear (21), needle bearing (20), and thrust plate (22) from first planet carrier (18). 10. Inspect needle bearing (20) for wear. 11. Remove thrust plate (16) from carrier.

NOTE: Ring gear is attached to housing with silicone form-in-place gasket. Pry ring gear loose from housing at notches provided. 5. Remove cap screws (24) and ring gear (23).

IMPORTANT: Damaging the surface of pin (17) can damage bearing. Be careful when handling pin to avoid scratches or gouges. 12. Using wood blocks, clamp pin (17) with vise. Tap spring pin (19) out.

6. Remove second planet carrier (28). 13. Remove cap screws (12) and lock plate (11). NOTE: Second planet sun gear may be removed separately or with carrier.

AC12469,000059D –19–18APR08–2/8

14. Remove bearing nut (10) from shaft using DFT1237 Swing Gearbox Nut Spanner Wrench (35). See DFT1237 Swing Gearbox Nut Spanner Wrench. (Group 9900.)

–UN–18MAR08

TX1038678

8—Housing 35—DFT1237 Swing Gearbox Nut Spanner Wrench

Bearing Nut Removal

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PN=517

Mechanical Drive Elements NOTE: Bearing and sleeve are pressed onto shaft.

–UN–18MAR08

15. Using a press, push upper end of shaft (1) and remove from housing (8). Inner race of roller bearing (5) and sleeve (3) are removed with shaft. 16. Remove oil seal from bottom of housing.

TX1038680

1—Shaft 8—Housing

Shaft and Housing

AC12469,000059D –19–18APR08–4/8

17. Remove outer race of bearing (5) from housing (8) by inserting bar through oil passage (36) in housing and tapping it out. 18. Inspect sleeve, roller bearing (5), and shaft for wear.

19. If disassembly is necessary, use press to push at upper end of shaft and remove ball bearing and sleeve.

–UN–18MAR08

TX1038684

43 4350 6

20. Inspect and replace parts as necessary. 21. Apply PM38656 Rigid Form-In-Place Gasket to outside of oil seal.

Housing Oil Passages 5—Roller Bearing 8—Housing 36—Oil Passage

22. Install bottom oil seal so lip (spring side) is toward bottom of bore. Push seal to bottom of bore. 23. Apply clean multi-purpose grease to O-ring and lip of bottom oil seal. 24. Apply clean hydraulic oil to all internal parts. 25. Install new bearings if removed.

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135D Excavator Repair 040909

PN=518

Mechanical Drive Elements 26. Apply clean, multipurpose grease on threaded surface of bearing nut (10). 27. Install bearing nut on shaft (1) with stepped side of bearing nut toward top roller bearing.

43 4350 7

12 10

28. Tighten bearing nut to specification. Continue tightening until splines of lock plate (11) and shaft (1) are aligned using DFT1237 Swing Gearbox Nut Spanner Wrench. See DFT1237 Swing Gearbox Nut Spanner Wrench. (Group 9900.)

1—Shaft 8—Housing 10—Bearing Nut 11—Lock Plate 12—Cap Screw (2 used)

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TM10743 (09APR09)

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TX1038701

–UN–25MAR08

Specification Bearing Nut—Torque.................................................................... 390 N•m 290 lb-ft

AC12469,000059D –19–18APR08–6/8

135D Excavator Repair 040909

PN=519

Mechanical Drive Elements 29. Install thrust plate (16) with oil grooves towards second planet sun gear (25).

15 16

30. Install second planet carrier (28) so notch is aligned with lock plate (11). 31. Install second planet sun gear (25) into second planet carrier (28) assembly with small diameter part of second planet sun gear facing up.

27 18 25

32. Install first planet sun gear (15) into first planet carrier (18) assembly with stepped side of sun gear facing down.

20 28 21 19 22

33. Install spring pins (19) with slit (37) towards end of pin.

31 35. Apply PM37477 Thread Lock and Sealer (medium strength) to ring gear-to-housing cap screws.

36. Align marks made on ring gear and housing during disassembly. Install cap screws and tighten to specification.

TX1038789

–UN–20MAR08

29 34. Clean mating surfaces and apply PM38656 Rigid Form-In-Place Gasket to ring gear and housing mating surfaces.

Planetary Gear Sets

–UN–18MAR08

Specification Ring Gear-to-Housing Cap Screw—Torque ............................................................................. 140 N•m 109 lb-ft 15—First Planet Sun Gear 16—Thrust Plate 17—Spring Pin (3 used) 18—First Planet Carrier 19—Spring Pin (6 used) 20—Needle Bearing (3 used) 21—Planetary Gear (3 used) 22—Thrust Plate (3 used) 25—Second Planet Sun Gear 26—Thrust Plate 27—Pin (3 used) 28—Second Planet Carrier 29—Thrust Plate (6 used) 30—Needle Bearing (3 used) 31—Planetary Gear (3 used) 37—Slit

TX1038798

43 4350 8

Spring Pin Installation

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135D Excavator Repair 040909

PN=520

Mechanical Drive Elements 37. Install swing motor on swing gearbox. See Swing Motor and Park Brake Remove and Install. (Group 4360.)

43 4350 9

38. Install swing gearbox. See Swing Gearbox Remove and Install. (Group 4350.) 39. Perform Swing Gearbox Start-Up Procedure. (Group 4350.)

AC12469,000059D –19–18APR08–8/8

Swing Gearbox Start-Up Procedure IMPORTANT: Swing gearbox will be damaged if not filled with oil before operating swing function. Procedure must be performed whenever a new swing gearbox is installed or oil has been drained from the gearbox. 1. Check for properly installed oil level plug (1).

–UN–25APR08

2. Check swing gearbox oil level using dipstick (2). See Check Swing Gearbox Oil Level. (Operator’s Manual.)

TX1040996A

3. Add oil through filler tube (3) if necessary. See Swing Gearbox and Travel Gearbox Oils. (Operator’s Manual.) 4. Install filler cap. Check oil level on dipstick. Swing Gearbox 1—Oil Level Plug 2—Dipstick 3—Filler Tube 4—Swing Gearbox

AC12469,000059E –19–21APR08–1/1

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=521

Mechanical Drive Elements

Upperstructure Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Attach vacuum pump to hydraulic tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

3. Remove cab. See Cab Remove and Install. (Group 1800.) 4. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) Hydraulic Pressure Release Button

5. Remove boom. See Boom Remove and Install. (Group 3340.)

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

AC12469,000059F –19–22APR08–1/5

NOTE: Center joint stays attached to undercarriage. 6. Install identification tags on hydraulic lines. See Travel Hydraulic System Line Connection. (Group 9025-15.) For machines equipped with a blade, also see Blade Hydraulic System Component Location. (Group 9025-15.) 7. Disconnect hydraulic lines. Close all openings using caps and plugs. –UN–25APR08

3—Hydraulic Line (6 used) 4—Center Joint

TX1041030A

43 4350 10

Center Joint and Lines (without blade shown)

Continued on next page

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PN=522

Mechanical Drive Elements 8. Remove cap screws (7), washers (6), and stop bar (8). 43 4350 11

9. Scribe alignment marks between upperstructure and swing bearing for installation. 5

–UN–24APR08

TX1041033

4—Center Joint 5—Cover 6—Washer (2 used) 7—Cap Screw (2 used) 8—Stop Bar 9—Cap Screw (3 used)

Center Joint Stop Bar

Continued on next page

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135D Excavator Repair 040909

PN=523

Mechanical Drive Elements

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–18MAR08

10. Support upperstructure (7) and remove cap screws securing upperstructure to swing bearing (8). Specification Upperstructure—Weight (approximate)................................................................................. 2970 kg 6550 lb

TX1038565

43 4350 12

11. Remove upperstructure from undercarriage.

Upperstructure Removal 7—Upperstructure 8—Swing Bearing 9—Undercarriage

12. Inspect and replace parts as necessary. See Swing Bearing Remove and Install. (Group 4350.) 13. Install three DFT1304 Guide Pins in swing bearing. See DFT1304 Guide Pin. (Group 9900.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 14. Align marks made during removal and install upperstructure. Specification Upperstructure—Weight (approximate)................................................................................. 2970 kg 6550 lb

15. Remove DFT1304 Guide Pin. Install cap screws and tighten to specification. Specification Upperstructure-to-Swing Bearing Cap Screw—Torque ..................................................................... 270 N•m 200 lb-ft

16. Install center joint stop bar and tighten cap screws to specification. Specification Stop Bar Cap Screw—Torque ....................................................... 90 N•m 67 lb-ft

17. Connect hydraulic lines to center joint.

Continued on next page

TM10743 (09APR09)

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AC12469,000059F –19–22APR08–4/5

135D Excavator Repair 040909

PN=524

Mechanical Drive Elements 18. Install cab. See Cab Remove and Install. (Group 1800.) 43 4350 13

19. Install counterweight. See Counterweight Remove and Install. (Group 1749.) 20. Install boom. See Boom Remove and Install. (Group 3340.) 21. Remove vacuum pump. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 22. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

AC12469,000059F –19–22APR08–5/5

Swing Bearing Remove and Install 1. Remove upperstructure. See Upperstructure Remove and Install. (Group 4350.) AC12469,00005A0 –19–18APR08–1/6

2. Scribe alignment mark (3) on swing bearing inner race (1) and undercarriage (2) to aid in installation.

TX1032008

–UN–12DEC07

1—Swing Bearing Inner Race 2—Undercarriage 3—Alignment Mark

Alignment Mark

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TM10743 (09APR09)

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PN=525

Mechanical Drive Elements 3. Remove dowel pin (4) from swing bearing outer race (5).

TX1038326

–UN–11MAR08

1—Swing Bearing Inner Race 2—Undercarriage 4—Dowel Pin 5—Swing Bearing Outer Race

Dowel Pin

AC12469,00005A0 –19–18APR08–3/6

4. Remove cap screws (6).

–UN–11MAR08

6—Cap Screw (36 used)

TX1038338

43 4350 14

Swing Bearing Cap Screws

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PN=526

Mechanical Drive Elements

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

43 4350 15 –UN–11MAR08

5. Attach JT01748 Lifting Brackets (7) to swing bearing and remove swing bearing.

TX1038343

Specification Swing Bearing—Weight (approximate)................................................................................... 171 kg 378 lb.

6. Check and replace swing bearing upper and lower seals if necessary. See Swing Bearing Upper Seal Install. (Group 4350.)

Swing Bearing Removal 7— JT01748 Lifting Bracket (3 used)

See Swing Bearing Lower Seal Install. (Group 4350.) 7. Replace bearing races, steel balls, and spacers as necessary. See Swing Bearing Disassemble and Assemble. (Group 4350.) 8. Clean mating surfaces of swing bearing, upperstructure, and undercarriage. 9. Apply PM38656 Rigid Form-In-Place Gasket to swing bearing mounting surface on undercarriage.

Continued on next page

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=527

Mechanical Drive Elements

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

–UN–11MAR08

IMPORTANT: The tooth marked with the letter “G” or “S” or equivalent is the starting and stopping point for the hardening process. The tooth and the bearing loading plug must be installed on the right side of the machine as shown so the use of that part of the swing bearing is minimized. 10. Install swing bearing. Align swing bearing with marks made during removal and position swing bearing races as shown. Specification Swing Bearing—Weight (approximate)................................................................................... 160 kg 355 lb

11. Install cap screws and lock washers and tighten to specification. Specification Undercarriage-to-Swing Bearing Cap Screw—Torque ..................................................................... 270 N•m 200 lb-ft

TX1038325

43 4350 16

Swing Bearing Position A—Front of Machine B—Lubrication Fitting C—Knock Pin D—Soft Zone Tooth E—Plug

IMPORTANT: Dowel pins will be damaged if installed with a steel hammer. Use only a plastic or rubber mallet during installation. 12. Install dowel pin in swing bearing outer race. 13. Install upperstructure. See Upperstructure Remove and Install. (Group 4350.) 14. Grease swing bearing gear. See Grease Swing Bearing Gear. (Operator’s Manual.)

AC12469,00005A0 –19–18APR08–6/6

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=528

Mechanical Drive Elements

Swing Bearing Disassemble and Assemble 43 4350 17

3 4 5

TX1032130

–UN–14DEC07

TX1032130 Swing Bearing Exploded View 1—Outer Bearing Race 2—Upper Seal

3—Spacer (99 used) 4—Steel Ball (99 used)

5—Inner Bearing Race

6—Lower Seal

1. Remove swing bearing. See Swing Bearing Remove and Install. (Group 4350.)

Continued on next page

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135D Excavator Repair 040909

PN=529

Mechanical Drive Elements 2. Check and replace swing bearing upper (2) and lower (6) seals if necessary. See Swing Bearing

Upper Seal Install. (Group 4350.) See Swing Bearing Lower Seal Install. (Group 4350.)

43 4350 18 AC12469,00005A1 –19–18APR08–2/5

NOTE: Pin is peened after installation. Grind off peened area before removal.

3. Grind peened area of pin (7). 4. Drive pin out from bottom side of bearing. 1—Outer Bearing Race 7—Pin 8—Loading Plug

TX1032164

–UN–10DEC07

8 Swing Bearing Plug and Pin

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PN=530

Mechanical Drive Elements 5. Remove loading plug (8) using an M10-1.5 cap screw. 1

43 4350 19

1—Outer Bearing Race 8—Loading Plug 9—M10-1.5 Cap Screw

TX1032165

–UN–10DEC07

9 Loading Plug Removal

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135D Excavator Repair 040909

PN=531

Mechanical Drive Elements 6. Remove steel balls (4) and spacers (3). 7. Rotate inner race to remove remaining steel balls and spacers. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 8. Lift outer race off inner race.

–UN–10DEC07

Specification Swing Bearing Inner Race— Weight (approximate) ........................................................................ 86 kg 190 lb.

TX1032167

9. Inspect and replace parts as necessary. 10. Install spacers (3) and steel balls (4). Turn inner race as needed to install spacers and steel balls. 11. Install loading plug (8). 12. Install pin (7) even with top of swing bearing and peen head of pin using a punch. 13. Lubricate swing bearing. See Grease Swing Bearing. (Operator’s Manual.) 14. Install swing bearing. See Swing Bearing Remove and Install. (Group 4350.) 3

–UN–10DEC07

3—Spacer (99 used) 4—Steel Ball (99 used)

TX1032168

43 4350 20

Spacer Removal

AC12469,00005A1 –19–18APR08–5/5

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=532

Mechanical Drive Elements

Swing Bearing Upper Seal Install 43 4350 21

1. Remove upperstructure. See Upperstructure Remove and Install. (Group 4350.) –UN–11APR90

2. Remove and discard old seal (A).

T5925AM

3. Scrape old adhesive from seal groove. Thoroughly clean seal groove and new seal using PM37509 Cure Primer. 4. Apply PM37391 Gel Super Glue sparingly to seal groove. A—Seal

5. Install seal with lip against inner bearing race. Start about 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 6. Before bringing ends of seal together, cut off excess length. 7. Apply PM37391 Gel Super Glue to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 8. Install upperstructure. See Upperstructure Remove and Install. (Group 4350.)

AC12469,00005A2 –19–18APR08–1/1

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=533

Mechanical Drive Elements

Swing Bearing Lower Seal Install NOTE: Part of swing bearing shown cut away to show lower seal in groove. –UN–17MAY89

1. Remove and discard old seal (A). 2. Scrape old adhesive from seal groove (B). Thoroughly clean seal groove and new seal using PM37509 Cure Primer.

T5936BA

43 4350 22

3. Apply PM37391 Gel Super Glue sparingly to seal groove. 4. Install seal with seal lip against outer race. Start about 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal.

A—Seal B—Seal Groove

5. Before bringing ends of seal together, cut off excess length. 6. Apply PM37391 Gel Super Glue to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function.

AC12469,00005A3 –19–18APR08–1/1

TM10743 (09APR09)

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135D Excavator Repair 040909

PN=534

Group 4360

Hydraulic System Center Joint Remove and Install 43 4360 1

–UN–22FEB08

2. Attach vacuum pump to hydraulic tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

AC12469,00005A4 –19–22APR08–1/6

3. Remove cap screws (4) and center joint cover (3).

TX1040989A

–UN–25APR08

3—Center Joint Cover 4—Cap Screw (3 used)

Center Joint Cover

Continued on next page

TM10743 (09APR09)

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AC12469,00005A4 –19–22APR08–2/6

135D Excavator Repair 040909

PN=535

Hydraulic System 4. Install identification tags on hydraulic lines (5). See Travel Hydraulic System Line Connection. (Group 43 9025-15.) For machines equipped with a blade, also see Blade Hydraulic System Component Location. (Group 9025-15.) 5. Disconnect hydraulic lines. Close all openings using caps and plugs.

TX1041047A

–UN–25APR08

5—Hydraulic Line (6 used) 6—Center Joint

Center Joint (without blade shown)

AC12469,00005A4 –19–22APR08–3/6

6. Remove cap screws (9), washers (8), and stop bar (10). 6—Center Joint 7—Cover 8—Washer (2 used) 9—Cap Screw (2 used) 10—Stop Bar 11—Cap Screw (3 used)

–UN–24APR08

TX1041049

4360 2

Center Joint and Stop Bar

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135D Excavator Repair 040909

PN=536

Hydraulic System 7. From underneath machine, install identification tags on hydraulic lines on center joint. 43 4360 3

8. Disconnect hydraulic lines and close all openings using caps and plugs. 9. Install two DFT1303 Center Joint (Rotary Manifold) Lifting Tools on top of center joint. See DFT1303 Center Joint (Rotary Manifold) Lifting Tool. (Group 9900.)

–UN–25APR08

10. Thread two JT05548 Lifting Eyebolts into DFT1303 Center Joint (Rotary Manifold) Lifting Tools.

TX1041050A

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Support center joint and remove cap screws (11). Center Joint (without blade shown)

12. Remove center joint through bottom of machine.

6—Center Joint 11—Cap Screw (3 used)

13. Inspect and replace as necessary. See Center Joint Air Test. (Group 4360.) See Center Joint Disassemble and Assemble. (Group 4360.) 14. Position rotary manifold in undercarriage. 15. Install cap screws (11) and tighten to specification. Specification Center Joint-to-Undercarriage Cap Screw—Torque ....................................................................... 50 N•m 37 lb-ft

16. Remove DFT1303 Center Joint (Rotary Manifold) Lifting Tools. 17. Install stop bar and tighten cap screws to specification. Specification Stop Bar Cap Screw—Torque ....................................................... 90 N•m 67 lb-ft

18. Connect hydraulic lines.

Continued on next page

TM10743 (09APR09)

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AC12469,00005A4 –19–22APR08–5/6

135D Excavator Repair 040909

PN=537

Hydraulic System 19. Install covers over center joint. 43 4360 4

20. Remove vacuum pump. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 21. Perform Travel Motor and Park Brake Start-Up Procedure. (Group 0260.) 22. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

AC12469,00005A4 –19–22APR08–6/6

TM10743 (09APR09)

43-4360-4

135D Excavator Repair 040909

PN=538

Hydraulic System

Center Joint Disassemble and Assemble 1. Remove center joint. See Center Joint Remove and Install. (Group 4360.)

2. Perform center joint air test to determine location of leaks. See Center Joint Air Test. (Group 4360.)

43 4360 5

3. Make alignment marks between spindle assembly (1) and housing (6) to aid in assembly.

4 4. Remove parts (7—11). Remove spindle assembly (1— 5) from housing (6).

NOTE: Remove bushing (4) only if replacement is necessary. 6 5. Remove O-ring (3), oil seal (2), oil seal rings (5) and bushing (4) from housing (6).

7 –UN–01FEB02

6. Inspect and repair as necessary.

9 7. Install bushing (4) if removed.

T145903

10 NOTE: Quantity of oil seal rings differs depending on machine options.

11 Rotary Manifold Exploded View (without blade)

8. Install O-ring (3), oil seal (2), and oil seal rings (5) in housing.

9. Apply clean hydraulic oil to spindle assembly (1) and install in housing. 1—Spindle Assembly 2—Oil Seal 3—O-Ring 4—Bushing 5—Oil Seal Rings (6 used without blade, 8 used with blade) 6—Housing 7—Ring 8—Snap Ring 9—O-Ring 10—Cover 11—Cap Screw (4 used)

6 2 3 7 8

10 11

TX1038187

–UN–11MAR08

Rotary Manifold Exploded View (with blade) Continued on next page

TM10743 (09APR09)

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AC12469,00005A5 –19–18APR08–1/2

135D Excavator Repair 040909

PN=539

Hydraulic System IMPORTANT: Install ring (7) with chamfered face toward spindle assembly (1). 10. Install parts (7—11). Tighten cap screws to specification. Specification Cover-to-Housing Cap Screw— Torque ............................................................................................ 49 N•m 36 lb-ft

11. Install center joint. See Center Joint Remove and Install. (Group 4360.)

AC12469,00005A5 –19–18APR08–2/2

Center Joint Air Test

2. Apply air pressure using JDG185 Air Test Plug and shop air pressure through the other port in that passage. 3. Listen for air leaks at ports on either side of pressurized port. 4. Repair center joint as required. See Center Joint Disassemble and Assemble. (Group 4360.)

–UN–01NOV88

1. Install a plug in one port.

T6557JB

43 4360 6

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Hydraulic System

Swing Motor and Park Brake Remove and Install 43 4360 7

–UN–22FEB08

2. Attach vacuum pump to hydraulic tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

1—Pressure Release Button 2—Hydraulic Oil Tank Cover

Hydraulic Pressure Release Button

AC12469,00005A7 –19–22APR08–1/4

3. Remove cap screws (4) and cover (3) over swing gearbox.

TX1040989A

–UN–25APR08

3—Swing Motor Cover 4—Cap Screw (3 used)

Swing Motor Cover

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Hydraulic System 4. Disconnect front attachment pressure sensor (9). 5. Install identification tags on hydraulic lines (5, 6, 10— 12). See Swing Motor Line Identification. (Group 9025-15.) 6. Disconnect hydraulic lines. Close all openings using caps and plugs. 7. Make alignment marks between swing motor (8) and swing gearbox to assist installation. –UN–25APR08

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 8. Remove cap screws securing swing motor to swing gearbox and remove swing motor.

TX1041061A

43 4360 8

Specification Swing Motor—Weight (approximate)..................................................................................... 34 kg 75 lb

Swing Motor 5—Swing Motor Return-to-Control Valve (port T3) 6—Swing Motor-to-Return Manifold 8—Swing Motor 9—Front Attachment Pressure Sensor 10—Pilot Signal Manifold (port SH)-to-Swing Motor 11—Swing Motor-to-Control Valve Swing Right (port A) 12—Swing Motor-to-Control Valve Swing Left (port B)

9. Inspect and repair swing motor and park brake as necessary. See Swing Motor and Park Brake Disassemble and Assemble. (Group 4360.) See Swing Motor and Park Brake Inspection. (Group 4360.) 10. Clean mating surfaces of swing motor and swing gearbox. 11. Apply PM38656 Rigid Form-In-Place Gasket to swing motor mating surface. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Install swing motor and align marks made during removal.

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Hydraulic System Specification Swing Motor—Weight (approximate)..................................................................................... 34 kg 75 lb

43 4360 9

13. Install cap screws and tighten to specification. Specification Swing Motor-to-Swing Gearbox Cap Screw—Torque ....................................................................... 64 N•m 47 lb-ft

14. Connect hydraulic lines. See Swing Motor Line Identification. (Group 9025-15.) 15. Connect front attachment pressure sensor. 16. Remove vacuum pump from hydraulic tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 17. Perform Swing Motor and Park Brake Start-Up Procedure. (Group 4360.) 18. Install cover over swing motor. 19. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

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Hydraulic System

Swing Motor and Park Brake Disassemble and Assemble 43 4360 10

1 14 2 15 3 16 4 17 5 18 6 7

8 20 9 10 21 11 22

26 13 27 28

12 13

31 13

34 33

T148208

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T148208

–UN–01FEB02

AC12469,00005A8 –19–18APR08–1/3

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PN=544

Hydraulic System 1—Cap Screw (4 used) 2—Washer (4 used) 3—Swing Motor and Park Brake Cover 4—O-Ring 5—Needle Bearing 6—Disk Spring 7—Pin (2 used) 8—Valve Plate

9—O-Ring 10—Brake Piston 11—O-Ring 12—Plate (4 used) 13—Friction Plate (4 used) 14—Cylinder Block 15—Disc Spring (4 used) 16—Bushing 17—Retainer

1. Remove swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.)

2. Scribe alignment marks between swing motor and park brake cover (3) and housing (33). Loosen cap screws (1) evenly to release spring force. IMPORTANT: Valve plate may remain on housing or stay with cylinder block when swing motor is disassembled. Valve plate has a polished surface and may be damaged if dropped. 3. Remove swing motor and park brake cover.

5. Remove disk spring (6), valve plate (8), and pins (7). 6. Remove brake piston (10). IMPORTANT: Mark location of pistons during disassembly. Pistons must be installed in same bores as removed due to wear patterns.

9. Remove snap ring (21) from shaft (20).

10. Push out oil seal (24), remove snap ring (23), and remove outer race of roller bearing (22).

NOTE: Do not disassemble park brake release valve block unless internal screen is clogged or deformed. Parts must be replaced as an assembly. 12. Remove parts (25—32) from park brake release valve block if necessary. 13. Inspect and replace parts as necessary. See Swing Motor and Park Brake Inspection. (Group 4360.) 14. Clean oil seal bore in housing (33).

NOTE: Install roller bearing with markings on inner race toward splines on shaft. 16. Install roller bearing (22) on shaft. 17. Apply clean multipurpose grease to inside of oil seal and install shaft in housing. IMPORTANT: Swash plate must be installed with chamfered side down. 18. Apply clean multipurpose grease and install swash plate (19) into housing. 19. Rotate swash plate in housing. If swash plate does not move freely, remove and reinstall.

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TM10743 (09APR09)

43 4360 11

15. Apply PM38655 Flexible Form-In-Place Gasket to oil seal and install oil seal in housing.

4. Remove needle bearing (5) if replacement is necessary.

8. Remove plates (12) and friction plates (13).

27—Spring 28—Plunger 29—Poppet 30—Spring 31—O-Ring 32—Plug 33—Housing 34—Drain Plug

11. Remove inner racer of roller bearing (22) from shaft (20).

CAUTION: Swing motor and park brake cover and housing are under spring pressure. Remove cap screws evenly to release spring force.

7. Remove parts (14—18) from shaft (20).

18—Piston (9 used) 19—Swash Plate 20—Shaft 21—Snap Ring 22—Roller Bearing 23—Snap Ring 24—Oil Seal 25—Plug 26—O-Ring

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Hydraulic System IMPORTANT: Swing motor will not function properly if pistons are mismatched. 43 Pistons must be installed in same 4360 bores as removed due to wear 12 patterns. 20. Apply clean hydraulic oil to pistons (18) and bores of cylinder block (14). Install pistons in same bores as removed.

bearing must align with center of groove in swing motor and park brake cover. 29. Apply clean multipurpose grease to valve plate and position valve plate in swing motor and park brake cover. 30. Align marks on housing and swing motor and park brake cover. 31. Install cap screws and tighten to specification.

21. Install disk springs (15) with outer collars and inner collars contacting.

Specification Swing Motor and Park Brake Cover Cap Screw—Torque ................................................... 265 N•m 195 lb-ft

22. Install bushing (16). 23. Install retainer (17) on bushing (16) with chamfered side down. 24. Apply clean hydraulic oil to plates (12) and friction plates (13). 25. Starting with a friction plate, install friction plates and plates in housing. Align splines on friction plates with cylinder block and outer tabs on plates with housing. 26. Apply clean hydraulic oil to O-rings and install brake piston (10) on housing. 27. Install disk spring (6) in housing with concave side facing brake piston.

32. Assemble park release valve block if disassembled. 33. Apply PM37477 Medium Strength Thread Lock and Sealer to park brake release valve plugs and tighten to specification. Specification Park Brake Release Valve Plug—Torque .......................................................................... 5.9 N•m 52 lb-in.

34. Install swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.)

28. Install needle bearing (5) in swing motor and park brake cover if removed. Hole on outside of needle

AC12469,00005A8 –19–18APR08–3/3

Swing Motor and Park Brake Inspection 1. Disassemble swing motor and park brake. See Swing Motor and Park Brake Disassemble and Assemble. (Group 4360.)

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Hydraulic System 2. Measure clearance between piston outside diameter (A) and cylinder block bore (B). 43 4360 13

Specification Piston-to-Cylinder Block Bore— Clearance (new) ............................................................................. 0.0 mm 0.0 in. Piston-to-Cylinder Block Bore— Clearance (maximum) .................................................................. 0.05 mm 0.0020 in.

A—Piston Outside Diameter B—Cylinder Block Bore

TX1040877

–UN–24APR08

Piston and Bore Measurement

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Hydraulic System 3. Measure piston-to-piston slipper clearance (C). Specification Piston-to-Piston Slipper— Clearance (new) ............................................................................. 0.0 mm 0.0 in. Piston-to-Piston Slipper— Clearance (maximum) .................................................................... 0.2 mm 0.0079 in.

C—Piston-to-Piston Slipper Clearance

–UN–24APR08

TX1040879

43 4360 14

Piston and Piston Slipper Measurement

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Hydraulic System 4. Measure piston slipper thickness (D). 43 4360 15

Specification Piston Slipper—Thickness (new) ................................................... 5.5 mm 0.217 in. Piston Slipper—Thickness (minimum) ....................................................................................... 5.3 mm 0.209 in.

D—Piston Slipper Thickness

TX1040881

–UN–24APR08

Piston Slipper Thickness Measurement

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Hydraulic System 5. Measure friction plate thickness (E). Specification Friction Plate—Thickness (new)................................................... 2.40 mm 0.094 in. Friction Plate—Thickness (minimum) ..................................................................................... 2.35 mm 0.093 in.

–UN–29APR08

6. Measure plate thickness (E). Specification Plate—Thickness (new)................................................................ 1.40 mm 0.055 in. Plate—Thickness (minimum)........................................................ 1.35 mm 0.053 in.

TX1040883

43 4360 16

Friction Plate and Plate Thickness Measurement E—Friction Plate and Plate Thickness

7. Measure overall height of disk spring. Specification Disk Spring—Height (new) ............................................................. 6.8 mm 0.268 in. Disk Spring—Height (minimum) ..................................................... 6.7 mm 0.263 in.

NOTE: Brake piston must be replaced if any wear or damage is observed. 8. Measure thickness of brake piston between disk spring top surface and brake piston bottom surface. Specification Brake Piston—Thickness (new) ................................................... 41.0 mm 1.614 in.

9. Replace parts that do not meet specifications. 10. Assemble swing motor and park brake. See Swing Motor and Park Brake Disassemble and Assemble. (Group 4360.)

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Hydraulic System

Swing Motor and Park Brake Start-Up Procedure 43 4360 17

IMPORTANT: Swing motor will be damaged if not filled with oil before operating swing function. Start-up procedure must be performed whenever a new swing motor is installed or oil has been drained from the motor.

–UN–25APR08

1. Disconnect swing motor-to-control valve (port T3) hose (5). NOTE: Air must be allowed to escape from the swing motor while filling.

TX1041065A

2. Fill motor with clean hydraulic oil through drain port until oil reaches level of port. See Hydraulic Oil. (Operator’s Manual.) Swing Motor

3. Connect swing motor-to-control valve (port T3) hose (5).

5—Swing Motor Return-to-Control Valve (port T3) 8—Swing Motor

AC12469,00005AA –19–22APR08–1/1

Crossover Relief Valve and Make-Up Check Valve Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 1. Push pressure release button (1).

–UN–22FEB08

2. Attach vacuum pump to hydraulic tank to minimize oil loss. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

TX1037206A

3. Remove covers over swing motor and gearbox. 1—Pressure Release Button 2—Hydraulic Oil Tank Cover Hydraulic Pressure Release Button

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Hydraulic System

43 4360 18

2 3 17

4 5

18 12

14 7

8 9

TX1039210

–UN–03APR08

TX1039210 Swing Motor Valves

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Hydraulic System 1—Crossover Relief Valve (2 used) 2—O-Ring 3—O-Ring 4—Back-Up Ring 5—O-Ring

6—Back-Up Ring 7—Swing Motor and Park Brake Cover 8—Counterbalance Valve Spool 9—Spring Seat (2 used)

4. Remove crossover relief valves (1).

10—Spring (2 used) 11—O-Ring (2 used) 12—Counterbalance Valve Plug (2 used) 13—Make-Up Check Valve Plug (2 used)

14—O-Ring (2 used) 15—Spring (2 used) 16—Poppet (2 used) 17—Plug (2 used) 18—O-Ring (2 used)

43 4360 19

11. Install spring seat (9) on counterbalance valve spool (8). Install counterbalance valve spool in swing motor and park brake cover.

5. Remove plugs (12) and springs (11). IMPORTANT: Remove counterbalance valve spool carefully. If counterbalance valve spool or cover bore is damaged, the cover and spool must be replaced. 6. Remove counterbalance valve spool (8) and spring seats (9). 7. Remove make-up check valve plugs (13), springs (15) and poppets (16). 8. Inspect and replace parts as necessary.

12. Ensure spool is centered in swing motor and park brake cover and install other spring seat (9) and springs (10). 13. Install counterbalance valve plugs (12) and tighten to specification. Specification Counterbalance Valve Plug— Torque...................................................................................... 69 N•m 51 lb-ft

14. Remove vacuum pump from hydraulic tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)

9. Install crossover relief valves and tighten to specification. Specification Crossover Relief Valve— Torque.................................................................................... 235 N•m 175 lb-ft

10. Install poppets (16), springs (15) and make-up check valve plugs (13). Tighten plugs to specification.

15. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 16. Adjust crossover relief valves. See Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.) 17. Install covers over swing motor and gearbox.

Specification Make-Up Check Valve Plug— Torque.................................................................................... 235 N•m 175 lb-ft

AC12469,00005AB –19–22APR08–3/3

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Hydraulic System

Swing Park Brake Release Valve Remove and Install 43 4360 20

The swing park brake release valve is removed during swing motor and park brake disassembly. See Swing Motor and Park Brake Disassemble and Assemble. (Group 4360.)

AC12469,00005AC –19–18APR08–1/1

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Section 99

Dealer Fabricated Tools Contents Page

Group 9900—Dealer Fabricated Tools DF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-1 ST4920 Track Recoil Spring Disassembly and Assembly Tool . . . . . . . . . . . . . . . . . .99-9900-3 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. . .99-9900-7 DFT1112A Spacer. . . . . . . . . . . . . . . . . . . . .99-9900-8 DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .99-9900-9 DFT1036A Travel Gearbox Nut Wrench . . .99-9900-10 DFT1109 Holding Bar . . . . . . . . . . . . . . . . .99-9900-11 DFT1303 Center Joint (Rotary Manifold) Lifting Tool. . . . . . . . . . . . . . . . . . . . . . . .99-9900-12 DFT1304 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-12 DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-13 DFT1237 Swing Gearbox Nut Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-14

TM10743 (09APR09)

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PN=1

Contents

TM10743 (09APR09)

99-2

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PN=2

Group 9900

Dealer Fabricated Tools DF1063 Lift Bracket Tool is the same as used on other machines. Only the lift bracket of the tool is used for this machine with adapter DFT1130. Lift Bracket is used to remove and install travel motor. 99 9900 1

Material required:

T8318AC

–UN–20SEP94

• 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16 in.) Square Tube • 1.3 mm (1/2 in.) 1020 Steel Plate • 1 mm x 38.1 mm (3/8 in. x 1-1/2 in.) Cap Screw with Nut (4 used)

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TM10743 (09APR09)

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135D Excavator Repair 040909

PN=557

Dealer Fabricated Tools

T7247BW

–19–25APR90

99 9900 2

AC12469,0000573 –19–09APR08–2/2

TM10743 (09APR09)

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PN=558

Dealer Fabricated Tools

ST4920 Track Recoil Spring Disassembly and Assembly Tool NOTE: It is recommended that DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool be used with track recoil spring disassembly and assembly tool. See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. (Group 9900.)

99 9900 3

Dimensions given are metric. Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size hole for the nut on that track adjuster.

–UN–24MAR98

Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring in track adjuster repair. Material required:

T6585UY

• 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G). • “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H). • “F” Grade (SAE Grade 8) for Studs (B). A—Nut (12 used) B—Stud (4 used) C—Holder D—Eyebolt (2 used) E—Supporting Plate F—Base Plate G—Base (4 used) H—Cap Screw (4 used) I—Lock Washer (8 used)

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

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Dealer Fabricated Tools

T7029CI

–UN–06JUL89

99 9900 4

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Dealer Fabricated Tools

T7029CH

–UN–06JUL89

99 9900 5

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135D Excavator Repair 040909

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Dealer Fabricated Tools

T7029CG

–UN–06JUL89

99 9900 6

AC12469,0000574 –19–09APR08–4/4

TM10743 (09APR09)

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PN=562

Dealer Fabricated Tools

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

T7162AF

–UN–17OCT89

99 9900 7

A—3/16 in. 1020 CR Steel Plate B—9/16 in. Hole (2 places)

C—1/2 in. Nut (2 used)

D—1/2 x 2 in. Cap Screw (2 used)

Track Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.)

E—1/2 x 3 in. Steel Round Stock (2 used)

• 3/16 in. 1020 CR Steel Plate (A) • 9/16 in. Hole (2 places) (B) • 1/2 in. Nut (2 used) (C) • 1/2 x 2 in. Cap Screw (D) (2 used) • 1/2 x 3 in. Steel Round Stock (E) (2 used)

Material required:

AC12469,0000575 –19–09APR08–1/1

TM10743 (09APR09)

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PN=563

Dealer Fabricated Tools

DFT1112A Spacer

T7969AB

–UN–30MAR93

99 9900 8

Spacer is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. See ST4920 Track Recoil Spring Disassembly and Assembly Tool . (Group 9900.) Spacer is installed on the bottom plate so force is applied to spring flange on cylinder and not to the piston.

Material Required: • 133 x 108 x 114 mm (5.25 x 4.25 x 4.50 in.) Heavy Wall Steel Pipe

Cut the ends of spacer so they are parallel to each other.

AC12469,000057E –19–09APR08–1/1

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PN=564

Dealer Fabricated Tools

DFT1130 Adapter

T8319BN

–UN–20SEP94

99 9900 9

A—Adapter Plate

B—Tube

C—Stop Plate

Adapter is used with DF1063 Lift Bracket to remove and install travel motor. Material required:

• 1.3 mm (1/2 in.) 1020 Steel Plate (A) • 38.1 mm x 38.1 mm x .48 mm (1-1/2 in. x 1-1/2 in. x 3/16 in.) Square Tube (B) • .6 mm (1/4 in.) 1020 Steel Plate (C)

AC12469,0000577 –19–09APR08–1/1

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PN=565

Dealer Fabricated Tools

DFT1036A Travel Gearbox Nut Wrench

T7681FZ

–UN–28FEB92

99 9900 10

Travel Gearbox Nut Wrench is used to remove and install the hub-to-housing nut in the travel gearbox. Material required:

• 16 mm (5/8 in.) Flat Bar Stock • M24 (1 in.) Nut • M10-1.5 x 60 mm Cap Screw (2 used) • M10-1.5 Nut (2 used)

AC12469,0000578 –19–09APR08–1/1

TM10743 (09APR09)

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PN=566

Dealer Fabricated Tools

DFT1109 Holding Bar

T7690AA

–UN–27FEB92

99 9900 11

Holding Bar is used with the DFT1036A Travel Gearbox Nut Wrench as a guide when loosening the hub-to-housing nut in the travel gearbox. See DFT1036A Travel Gearbox Nut Wrench. (Group 9900.))

Material required: • 16 mm (5/8 in.) Flat Bar Stock

AC12469,0000579 –19–09APR08–1/1

TM10743 (09APR09)

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PN=567

Dealer Fabricated Tools

DFT1303 Center Joint (Rotary Manifold) Lifting Tool Tool is used to remove and install center joint. Drill and tap disk in fitting cap to M8-1.25 mm threads (A). Material required: • 38H1416 Cap (—12) • M8-1.25 Lifting Eyebolt such as JT05548 Metric Lifting Eyebolt

T6641DO

–UN–24OCT88

A—Threads

AC12469,000057A –19–09APR08–1/1

DFT1304 Guide Pin

Remove threads for a distance (B) and then grind a taper on same end. Material Required:

–UN–24OCT88

Guide pin is used to align cap screw holes in swing bearing and upperstructure.

T6641EK

99 9900 12

• M16-2.0 x 230 mm (9 in.) Threaded Rod A—230 mm (9 in.) B—100 mm (4 in.)

AC12469,000057B –19–09APR08–1/1

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PN=568

Dealer Fabricated Tools

DFT1119 Pump Support Ø38 mm (1.5 in.) 13 mm (0.5 in.)

9.5 mm (0.375 in.) Ø11 mm (0.438 in.)

19 mm (0.750 in.)

89 mm (3.5 in.) 102 mm (4 in.) 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.)

38 mm (1.5 in.) 76 mm (3 in.) 114 mm (4.5 in.)

457 mm (18 in.)

Ø12 mm (0.472 in.) 5 Places

Ø11 mm (0.438 in.) 12 PLACES

38 mm (1.5 in.) 76 mm (3 in.) 152 mm (6 in.) 229 mm (9 in.) 305 mm (12 in.) 380 mm (15 in.) 457 mm (18 in.) 533 mm (21 in.) 610 mm (24 in.)

9.5 mm (0.375 in.)

1524 mm (60 in.)

104.8 mm (4.125 in.) 165 mm (6.5 in.) 376 mm (14.8 in.)

–UN–11JAN08

9.5 mm (0.375 in.)

99 9900 13

76 mm (3 in.)

13 mm (0.5 in.) 76.2 x 76.2 x 6.35 mm 610 mm (3 x 3 x 0.250 in.) (24 in.) 9.5 mm 76 mm (0.375 in.) (3 in.)

88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.)

TX1022920

335 mm (13.2 in.)

Pump support is used with a hand hoist to support a pump(s) when an engine is removed. Two end stands are needed. Drill the holes through the square steel tubing so they are centered. Material required: • C3 x 5 Steel Channel

TX1022920

233 mm (9.2 in.)

• 88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.) Square Steel Tubing • 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) Square Steel Tubing • 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) Square Steel Tubing • 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)

AC12469,000057C –19–09APR08–1/1

TM10743 (09APR09)

99-9900-13

135D Excavator Repair 040909

PN=569

Dealer Fabricated Tools

DFT1237 Swing Gearbox Nut Spanner Wrench

124 mm (4.9 in.)

19 mm (.75 in.)

99 9900 14

138 mm (5.43 in.)

14 mm (.55 in.)

9.525 mm ( 0.375 in.)

82.55 mm (3.25 in.)

138 mm (5.43 in.)

38.1 mm (1.5 in.) 19 mm (.75 in.)

19 mm (.75 in.)

6.35 mm (.25 in.)

TX1057816

–UN–03APR09

TX1057816 DFT1237 Swing Gearbox Nut Spanner Wrench Continued on next page

TM10743 (09APR09)

99-9900-14

AC12469,000057D –19–08APR09–1/2

135D Excavator Repair 040909

PN=570

Dealer Fabricated Tools 1—Weld (4 places)

Material required:

• 138 x 38.1 x 6.35 mm (5.43 x 1.5 x .25 in.)

• 138 x 82.5 mm (5.43 x 3.25 in.) Steel Tubing

99 9900 15

AC12469,000057D –19–08APR09–2/2

TM10743 (09APR09)

99-9900-15

135D Excavator Repair 040909

PN=571

Dealer Fabricated Tools

99 9900 16

TM10743 (09APR09)

99-9900-16

135D Excavator Repair 040909

PN=572

Index Page

A Adjuster, track Cylinder, disassemble and assemble . .01-0130-29 Disassemble and assemble . . . . . . . . .01-0130-22 Remove and install . . . . . . . . . . . . . . . .01-0130-20 Air cleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-1 Air conditioner and heater Remove and install . . . . . . . . . . . . . . . .18-1830-15 Air conditioner compressor Remove and install . . . . . . . . . . . . . . . .18-1830-11 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-10 Evacuate R134a system . . . . . . . . . . . . .18-1830-9 Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3 Receiver-dryer remove and install . . . . .18-1830-20 Recover R134a refrigerant . . . . . . . . . . .18-1830-8 Refrigerant handling and cautions. . . . . .18-1830-1 R134a refrigerant oil information . . . . . . .18-1830-6 R134a station installation . . . . . . . . . . . .18-1830-7 Air suspension seat Disassemble and assemble . . . . . . . . . .18-1821-7 Alternator Remove and install . . . . . . . . . . . . . . . 04-0400-133 Arm Remove and install . . . . . . . . . . . . . . . . .33-3340-2 Arm cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-132 Disassemble and assemble . . . . . . . . 33-3360-124 Inspect pins and bushings. . . . . . . . . . .33-3340-10 Remove and install . . . . . . . . . . . . . . . 33-3360-118 Arm pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-10 Arm regenerative Solenoid valve, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-46 Attachments Adding safely . . . . . . . . . . . . . . . . . . . .00-0001-11 Operating safely . . . . . . . . . . . . . . . . . .00-0001-11

B Backover accidents Avoiding . . . . . . . . . . . . . . . . . . . . . . . .00-0001-10 Battery explosions Prevent . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Bearing Swing, disassemble and assemble . . . .43-4350-17 Swing, lower seal install . . . . . . . . . . . .43-4350-22 Swing, remove and install . . . . . . . . . . .43-4350-13 TM10743 (09APR09)

Page

Swing, upper seal install . . . . . . . . . . . .43-4350-21 Blade Control valve, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .32-3260-10 Control valve, remove and install . . . . . .32-3260-7 Cylinder, disassemble and assemble . .32-3260-20 Cylinder, remove and install . . . . . . . . .32-3260-15 Pilot controller, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .32-3260-13 Pilot controller, remove and install . . . .32-3260-11 Pump pressure relief valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-6 Pump, remove and install . . . . . . . . . . . .32-3260-1 Remove and Install . . . . . . . . . . . . . . . . .32-3201-2 Blade control valve Disassemble and assemble . . . . . . . . .32-3260-10 Remove and install . . . . . . . . . . . . . . . . .32-3260-7 Blade cylinder Disassemble and assemble . . . . . . . . .32-3260-20 Remove and install . . . . . . . . . . . . . . . .32-3260-15 Blade pilot controller Disassemble and assemble . . . . . . . . .32-3260-13 Remove and install . . . . . . . . . . . . . . . .32-3260-11 Blade pump Disassemble and assemble . . . . . . . . . .32-3260-3 Remove and install . . . . . . . . . . . . . . . . .32-3260-1 Blade pump pressure relief valve Remove and install . . . . . . . . . . . . . . . . .32-3260-6 Bleed procedure Hydraulic cylinder . . . . . . . . . . . . . . . . 33-3360-132 Boom Remove and install . . . . . . . . . . . . . . . . .33-3340-7 Boom cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-132 Dissassemble and assemble. . . . . . . . 33-3360-116 Inspect pins and bushings. . . . . . . . . . .33-3340-10 Remove and install . . . . . . . . . . . . . . . 33-3360-111 Boom pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-10 Boom, arm, and bucket bushings and bosses Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-10 Boom, arm, and bucket pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-10 Bucket Remove and install . . . . . . . . . . . . . . . . .33-3302-1 Bucket cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-132 Disassemble and assemble . . . . . . . . 33-3360-130 Inspect pins and bushings. . . . . . . . . . .33-3340-10 Remove and install . . . . . . . . . . . . . . . 33-3360-126 Bucket links Remove and install . . . . . . . . . . . . . . . . .33-3340-1

Index-1

135D Excavator Repair 040909

PN=1

Indx 1

Index

Page

Bucket pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-10 Bushings Remove and install . . . . . . . . . . . . . . . .33-3340-13

Arm, remove and install . . . . . . . . . . . 33-3360-118 Blade, disassemble and assemble . . . .32-3260-20 Blade, Remove and install . . . . . . . . . .32-3260-15 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-132 Boom, disassemble and assemble . . . 33-3360-116 Boom, remove and install . . . . . . . . . . 33-3360-111 Bucket, disassemble and asemble . . . 33-3360-130 Bucket, remove and install . . . . . . . . . 33-3360-126 Cylinder block Disassemble and assemble . . . . . . . . .04-0400-60 Inspection . . . . . . . . . . . . . . . . . . . . . . .04-0400-62 Cylinder head Disassemble and assemble . . . . . . . . .04-0400-40 Inspection . . . . . . . . . . . . . . . . . . . . . . .04-0400-46 Remove and install . . . . . . . . . . . . . . . .04-0400-25

C Cab Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Cab guarding . . . . . . . . . . . . . . . . . . . . . . .00-0001-3 Indx Camshafts 2 Remove and install . . . . . . . . . . . . . . . .04-0400-67 Center joint Air test . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-6 Disassemble and assemble . . . . . . . . . .43-4360-5 Remove and install . . . . . . . . . . . . . . . . .43-4360-1 Chain Track, disassemble and assemble . . . .01-0130-12 Track, remove and install . . . . . . . . . . .01-0130-10 Track, repair . . . . . . . . . . . . . . . . . . . . .01-0130-14 Check valve Travel motor, remove and install . . . . . . .02-0260-6 Chemical products Handling . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-6 Compressor Air conditioner, remove and install . . . .18-1830-11 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-12 Control valve Remove and install . . . . . . . . . . . . . . . .33-3360-69 Separation . . . . . . . . . . . . . . . . . . . . . .33-3360-76 Control valve (4-spool) Disassemble and assemble . . . . . . . . .33-3360-88 Control valve (5-spool) Disassemble and assemble . . . . . . . . .33-3360-77 Cooling system Servicing . . . . . . . . . . . . . . . . . . . . . . . .00-0001-13 Counterbalance valve Travel motor, remove and install . . . . . . .02-0260-6 Counterweight Remove and install . . . . . . . . . . . . . . . . .17-1749-1 Crankshaft Disassemble and assemble . . . . . . . . .04-0400-85 Inspection . . . . . . . . . . . . . . . . . . . . . . .04-0400-85 Remove and install . . . . . . . . . . . . . . . .04-0400-79 Crossover relief valve Travel motor, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .02-0260-10 Travel motor, remove and install . . . . . . .02-0260-6 Cylinder Arm, disassemble and assemble. . . . . 33-3360-124 TM10743 (09APR09)

D Dampener drive (flex coupling) Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Dealer fabricated tool DFT1036A travel gearbox nut wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10 DFT1087 track recoil spring disassembly and assembly guard tool . . . . . . . . . . . . . .99-9900-7 DFT1109 holding bar . . . . . . . . . . . . . .99-9900-11 DFT1112A spacer . . . . . . . . . . . . . . . . . .99-9900-8 DFT1119 pump support . . . . . . . . . . . .99-9900-13 DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9 DFT1144 guide pin . . . . . . . . . . . . . . . .99-9900-12 DFT1237 swing gearbox nut spanner wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-14 DFT1303 center joint (rotary manifold) lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-12 DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1 ST4920 track recoil spring disassembly and assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3 Driving metal pins. . . . . . . . . . . . . . . . . . .00-0001-15

E Emergency preparation . . . . . . . . . . . . . . .00-0001-6 Engine Remove and install . . . . . . . . . . . . . . . . .04-0400-1 Engine cooling fan Remove and install . . . . . . . . . . . . . . . . .05-0510-7 Engine oil cooler Disassemble and assemble . . . . . . . . 04-0400-114 Remove and install . . . . . . . . . . . . . . . 04-0400-111 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . .00-0001-5

Index-2

135D Excavator Repair 040909

PN=2

Index

Page

Exhaust manifold Remove and install . . . . . . . . . . . . . . . .04-0400-12 Explosion Battery . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5

Hazards Avoiding . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-9 Heater and air conditioner Remove and install . . . . . . . . . . . . . . . .18-1830-15 High pressure common rail Remove and install . . . . . . . . . . . . . . . 04-0400-129 High-pressure oils Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-4 Hydraulic Blade pump, disassemble ans assemble . . . . . . . . . . . . . . . . . . . . . . .32-3260-3 Blade pump, remove and install . . . . . . .32-3260-1 Fittings, 30&deg; cone seat. . . . . . . . . . .00-0003-5 Fittings, 37&deg; flare . . . . . . . . . . . . . . .00-0003-5 Oil cleanup procedure using portable filter caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3 Oil cooler bypass valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-110 Pump regulator 1 and 2, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-29 Pump start-up procedure . . . . . . . . . . .33-3360-25 Pump 1 and 2, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .33-3360-9 Pump 1 and 2, inspection . . . . . . . . . . .33-3360-23 Pump 1 and 2, remove and install . . . . .33-3360-4 Hydraulic cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-132 Hydraulic fitting Flared connections . . . . . . . . . . . . . . . .00-0003-10 Non-restricted banjo (adjustable). . . . . .00-0003-22 O-ring boss with shoulder . . . . . . . . . . .00-0003-24 Hydraulic oil cleanup Using portable filter caddy. . . . . . . . . . . .33-3360-3 Hydraulic oil cooler Remove and install . . . . . . . . . . . . . . . . .05-0510-3 Hydraulic oil cooler bypass valve Remove and install . . . . . . . . . . . . . . . 33-3360-110 Hydraulic oil tank Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1 Hydraulic pump Pilot, remove and install . . . . . . . . . . . .33-3360-34 Hydraulic tank Remove and install . . . . . . . . . . . . . . . 33-3360-100 Hydrtaulic oil tank Disassemble and assemble . . . . . . . . 33-3360-104

F Fan Engine cooling, remove and install . . . . .05-0510-7 Guard, remove and install . . . . . . . . . . . .05-0510-7 Shroud, remove and install . . . . . . . . . . .05-0510-7 Filter Pilot pressure regulating valve . . . . . . .33-3360-38 Final fuel filter Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Fire prevention . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Flex coupling Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Flywheel Disassemble and assemble . . . . . . . . .04-0400-73 Remove and install . . . . . . . . . . . . . . . .04-0400-71 Flywheel housing Remove and install . . . . . . . . . . . . . . . .04-0400-74 Front idler Disassemble and assemble . . . . . . . . .01-0130-19 Remove and install . . . . . . . . . . . . . . . .01-0130-18 Fuel Tank, remove and install . . . . . . . . . . . . .05-0560-1 Fuel cooler Remove and install . . . . . . . . . . . . . . . . .05-0510-7 Fuel injection nozzle Remove and install . . . . . . . . . . . . . . . 04-0400-131 Fuel injection pump Remove and install . . . . . . . . . . . . . . . 04-0400-118 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-1

G Gearbox, swing Disassemble and assemble . . . . . . . . . .43-4350-4 Remove and install . . . . . . . . . . . . . . . . .43-4350-1 Start-up procedure . . . . . . . . . . . . . . . . .43-4350-9 Gearbox, travel Disassemble and assemble . . . . . . . . . .02-0250-4 Remove and install . . . . . . . . . . . . . . . . .02-0250-1

I H Handhold use . . . . . . . . . . . . . . . . . . . . . . .00-0001-7 TM10743 (09APR09)

Inch bolt and cap screw Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-4

Index-3

135D Excavator Repair 040909

PN=3

Indx 3

Index

Page

Inch series four bolt flange fitting Service recommendation, torque value for high pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-21 Inspect machine . . . . . . . . . . . . . . . . . . . . .00-0001-3 Intake manifold Remove and install . . . . . . . . . . . . . . . .04-0400-20 Intercooler Remove and install . . . . . . . . . . . . . . . . .05-0510-5

O-ring face seal fitting Inch hex nut and stud end for high pressure torque values . . . . . . . . . . . . . . . . . . . . . . . .00-0003-13 Metric hex nut and stud end for high pressure torque values. . . . . . . . . . . . . . . . . . .00-0003-17 Metric hex nut and stud end for standard pressure torque values. . . . . . . . . . . . . . . . . . .00-0003-15 O-ring seal, metric 24 Service recommendation. . . . . . . . . . . .00-0003-27 Oil information R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6 Oil pan Remove and install . . . . . . . . . . . . . . . .04-0400-76 Oil pump Disassemble and assemble . . . . . . . . 04-0400-109 Inspection . . . . . . . . . . . . . . . . . . . . . . 04-0400-110 Remove and install . . . . . . . . . . . . . . . 04-0400-105 Operation qualification . . . . . . . . . . . . . . . .00-0001-1

L Indx 4

Left console cover Remove and install . . . . . . . . . . . . . . . . .18-1821-8 Lifting objects Special care . . . . . . . . . . . . . . . . . . . . .00-0001-11

M P Machine inspection. . . . . . . . . . . . . . . . . . .00-0001-3 Machine modifications Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-2 Machine movement Unintended . . . . . . . . . . . . . . . . . . . . . . .00-0001-8 Machine tip over Avoiding . . . . . . . . . . . . . . . . . . . . . . . .00-0001-10 Manifold Pilot signal, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-62 Pilot signal, remove and install . . . . . . .33-3360-58 Solenoid valve, remove and install . . . .33-3360-43 Mechanical suspension seat Disassemble and assemble . . . . . . . . . .18-1821-5 Metal face seals Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . .00-0001-15 Metric bolt and cap screw Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-1 Moving parts Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-3

O O-ring boss fitting in aluminum housingexcavators Torque value, service recommendation . . . . . . . . . . . . . . . . .00-0003-8 O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6 TM10743 (09APR09)

Park brake, travel Disassemble and assemble . . . . . . . . . .02-0260-2 Remove and install . . . . . . . . . . . . . . . . .02-0260-1 Start-up procedure . . . . . . . . . . . . . . . .02-0260-11 Pilot control shutoff lever . . . . . . . . . . . . . .00-0001-8 Pilot pressure regulating valve and filter Disassemble and assemble . . . . . . . . 33-3360-38, 33-3360-39 Pilot pump Disassemble and assemble . . . . . . . . .33-3360-35 Remove and install . . . . . . . . . . . . . . . .33-3360-34 Pilot shutoff solenoid valve Disassemble and assemble . . . . . . . . .33-3360-42 Remove and install . . . . . . . . . . . . . . . .33-3360-39 Pilot signal manifold Disassemble and assemble . . . . . . . . .33-3360-62 Remove and install . . . . . . . . . . . . . . . .33-3360-58 Pilot valve (left and right) Disassemble and assemble . . . . . . . . .33-3360-52 Remove and install . . . . . . . . . . . . . . . .33-3360-48 Piston and connecting rod Disassemble and assemble . . . . . . . . .04-0400-95 Inspection . . . . . . . . . . . . . . . . . . . . . . .04-0400-98 Remove and install . . . . . . . . . . . . . . . .04-0400-93 Pressure test Track roller . . . . . . . . . . . . . . . . . . . . . . .01-0130-5 Prevent unintended detonation of explosive devices . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-11 Primary fuel filter (water separator) Remove and install . . . . . . . . . . . . . . . . .05-0560-4

Index-4

135D Excavator Repair 040909

PN=4

Index

Page

Protective equipment . . . . . . . . . . . . . . . . .00-0001-2 Pump Blade, disassemble and assemble . . . . .32-3260-3 Hydraulic start-up procedure . . . . . . . . .33-3360-25 Pilot, disassemble and assemble . . . . .33-3360-35 1 and 2 regulator, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-29 1 and 2 regulator, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-27 1 and 2, remove and install. . . . . . . . . . .33-3360-4 Pump 1 and 2 Disassemble and assemble . . . . . . . . . .33-3360-9 Inspection . . . . . . . . . . . . . . . . . . . . . . .33-3360-23 Remove and install . . . . . . . . . . . . . . . . .33-3360-4 Pump 1 and 2 Regulator Remove and install . . . . . . . . . . . . . . . .33-3360-27

R134a system evacuate . . . . . . . . . . . . . . .18-1830-9

R Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Rear oil seal Remove and install . . . . . . . . . . . . . . . .04-0400-65 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-20 Recoil spring Disassemble and assemble . . . . . . . . .01-0130-22 Remove and install . . . . . . . . . . . . . . . .01-0130-20 Refrigerant Cautions and proper handling . . . . . . . . .18-1830-1 Charging station installation procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Recover R134a, air conditioning . . . . . . .18-1830-8 Refrigerant oil information R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Restriction valve Remove and install . . . . . . . . . . . . . . . 33-3360-108 Riding machine. . . . . . . . . . . . . . . . . . . . . .00-0001-9 Right console cover Remove and install . . . . . . . . . . . . . . . . .18-1821-8 Rocker arm assembly Disassemble and assemble . . . . . . . . .04-0400-17 Inspection . . . . . . . . . . . . . . . . . . . . . . .04-0400-18 Remove and install . . . . . . . . . . . . . . . .04-0400-15 Roller Track carrier, remove and install . . . . . . .01-0130-6 Track, disassemble and assemble . . . . .01-0130-2 Track, pressure test . . . . . . . . . . . . . . . .01-0130-5 Track, remove and install . . . . . . . . . . . .01-0130-1 R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8 R134a system charge. . . . . . . . . . . . . . . .18-1830-10 TM10743 (09APR09)

S Safety Operator’s seat . . . . . . . . . . . . . . . . . . . .00-0001-7 Safety equipment . . . . . . . . . . . . . . . . . . . .00-0001-2 Safety information Recognizing . . . . . . . . . . . . . . . . . . . . . .00-0001-1 Safety instructions . . . . . . . . . . . . . . . . . . .00-0001-1 Safety symbols . . . . . . . . . . . . . . . . . . . . . .00-0001-1 Seals Remove and install . . . . . . . . . . . . . . . .33-3340-13 Seat Air suspension disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-7 Mechanical suspension disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-5 Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Seat belt Remove and install . . . . . . . . . . . . . . . . .18-1821-4 Use and maintenance . . . . . . . . . . . . . . .00-0001-7 Service recommendation Inch series four bolt flange fitting for high pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-21 O-ring boss fitting in aluminum housingexcavators. . . . . . . . . . . . . . . .00-0003-8 O-ring face seal fittings with inch hex nut and stud end for high pressure. . . . . . . . .00-0003-13 O-ring face seal fittings with metric hex nut and stud end for high pressure. . . . . . . . .00-0003-17 O-ring face seal fittings with metric hex nut and stud end for standard pressure . . . . .00-0003-15 O-ring seal, metric 24 . . . . . . . . . . . . . .00-0003-27 Servicing cooling system . . . . . . . . . . . . .00-0001-13 Servicing machine safely . . . . . . . . . . . . .00-0001-12 Shoe Track, remove and install . . . . . . . . . . . .01-0130-9 Shuttle valve Travel motor, remove and install . . . . . . .02-0260-6 Sliding window Remove and install . . . . . . . . . . . . . . . . .18-1810-1 Solenoid valve manifold Remove and install . . . . . . . . . . . . . . . .33-3360-43 Sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-16 Start-up procedure Drive gearbox . . . . . . . . . . . . . . . . . . . .33-3360-25 Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-25 Swing gearbox . . . . . . . . . . . . . . . . . . . .43-4350-9 Swing motor and park brake . . . . . . . . .43-4360-17

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Page

Travel motor . . . . . . . . . . . . . . . . . . . . .02-0260-11 Starter Remove and install . . . . . . . . . . . . . . . 04-0400-133 Steps use . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-7 Swing bearing Disassemble and assemble . . . . . . . . .43-4350-17 Lower seal install . . . . . . . . . . . . . . . . .43-4350-22 Remove and install . . . . . . . . . . . . . . . .43-4350-13 Upper seal install . . . . . . . . . . . . . . . . .43-4350-21 Swing gearbox Disassemble and assemble . . . . . . . . . .43-4350-4 Remove and install . . . . . . . . . . . . . . . . .43-4350-1 Indx Start-up procedure . . . . . . . . . . . . . . . . .43-4350-9 6 Swing motor Crossover relief valve remove and install. . . . . . . . . . . . . . . . . . . . . . . . .43-4360-17 Disassemble and assemble . . . . . . . . .43-4360-10 Inspection . . . . . . . . . . . . . . . . . . . . . . .43-4360-12 Make-up check valve remove and install. . . . . . . . . . . . . . . . . . . . . . . . .43-4360-17 Remove and install . . . . . . . . . . . . . . . . .43-4360-7 Start-up procedure . . . . . . . . . . . . . . . .43-4360-17 Swing park brake Disassemble and assemble . . . . . . . . .43-4360-10 Inspection . . . . . . . . . . . . . . . . . . . . . . .43-4360-12 Release valve remove and install . . . . .43-4360-20 Remove and install . . . . . . . . . . . . . . . . .43-4360-7 Start-up procedure . . . . . . . . . . . . . . . .43-4360-17

Metric bolt and cap screw . . . . . . . . . . . .00-0003-1 Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-2 Metric four bolt flange fitting . . . . . . . . .00-0003-19 Non-restricted banjo fittings. . . . . . . . . .00-0003-22 O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6 O-ring boss fitting in aluminum housingexcavators. . . . . . . . . . . . . . . .00-0003-8 O-ring boss fittings with shoulder . . . . .00-0003-24 O-ring face seal fittings with inch hex nut and stud end for high pressure. . . . . . . . .00-0003-13 O-ring face seal fittings with metric hex nut and stud end for high pressure. . . . . . . . .00-0003-17 O-ring face seal fittings with metric hex nut and stud end for standard pressure . . . . .00-0003-15 O-ring seal, metric 24 . . . . . . . . . . . . . .00-0003-27 Unified inch bolt and cap screw . . . . . . .00-0003-4 30&deg; cone seat hydraulic fittings . . . .00-0003-5 37&deg; flare hydraulic fittings . . . . . . . .00-0003-5 Track Adjuster and recoil spring, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-22 Adjuster and recoil spring, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-20 Adjuster cylinder, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-29 Carrier roller, remove and install . . . . . . .01-0130-6 Chain, disassemble and assemble . . . .01-0130-12 Chain, remove and install . . . . . . . . . . .01-0130-10 Chain, repair . . . . . . . . . . . . . . . . . . . . .01-0130-14 Front idler, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-19 Front idler, remove and install. . . . . . . .01-0130-18 Roller, disassemble and assemble . . . . .01-0130-2 Roller, pressure test . . . . . . . . . . . . . . . .01-0130-5 Roller, remove and install . . . . . . . . . . . .01-0130-1 Shoe, remove and install . . . . . . . . . . . .01-0130-9 Sprocket, remove and install . . . . . . . . .01-0130-16 Travel gearbox Disassemble and assemble . . . . . . . . . .02-0250-4 Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Travel motor Cover, disassemble and assemble . . . . .02-0260-6 Crossover relief valve, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .02-0260-10 Disassemble and assemble . . . . . . . . . .02-0260-2 Remove and install . . . . . . . . . . . . . . . . .02-0260-1 Start-up procedure . . . . . . . . . . . . . . . .02-0260-11 Travel pilot valve Disassemble and assemble . . . . . . . . .33-3360-56 Remove and install . . . . . . . . . . . . . . . .33-3360-54 Travel speed Solenoid valve, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-46

T Tank Hydraulic oil, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-104 Hydraulic oil, remove and install . . . . . 33-3360-100 Tank, hydraulic oil Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1 Thermostat Inspection . . . . . . . . . . . . . . . . . . . . . . 04-0400-118 Thermostat housing Remove and install . . . . . . . . . . . . . . . 04-0400-115 Timing gear case Remove and install . . . . . . . . . . . . . . . .04-0400-53 Tip over Avoiding . . . . . . . . . . . . . . . . . . . . . . . .00-0001-10 Torque value Flared connections . . . . . . . . . . . . . . . .00-0003-10 Flat face O-ring seal fitting . . . . . . . . . .00-0003-11 Inch SAE four bolt flange fitting. . . . . . .00-0003-20 Inch series four bolt flange fitting for high pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-21 TM10743 (09APR09)

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Page

Travel speed change valve Remove and install . . . . . . . . . . . . . . . . .02-0260-6 Turbocharger Remove and install . . . . . . . . . . . . . . . . .04-0400-8

U Upperstructure Remove and install . . . . . . . . . . . . . . . .43-4350-10

Page

W Waste disposal . . . . . . . . . . . . . . . . . . . . . .00-0001-6 Water pump Remove and install . . . . . . . . . . . . . . . .04-0400-23 Welding on machine . . . . . . . . . . . . . . . . . .17-1740-1 Welding repairs . . . . . . . . . . . . . . . . . . . .00-0001-15 Window Sliding, remove and install . . . . . . . . . . .18-1810-1 Windowpane Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Windowpanes Dimensions . . . . . . . . . . . . . . . . . . . . . . .18-1810-3 Work site hazards Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-9

Valve Arm regenerative solenoid, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-46 Blade control, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .32-3260-10 Blade control, remove and install . . . . . .32-3260-7 Blade pump pressure relief, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-6 Control valve, remove and install . . . . .33-3360-69 Control (4-spool), disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-88 Control (5-spool), disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-77 Control, separation . . . . . . . . . . . . . . . .33-3360-76 Hydraulic oil cooler bypassvalve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-110 Pilot (left and right), disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-52 Pilot (left and right), remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-48 Pilot pressure regulating valve and filter, disassemble and assemble . . . . . . . .33-3360-39 Pilot pressure regulating, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-38 Pilot shutoff solenoid valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-39 Pilot shutoff solenoid, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-42 Restriction, remove and install . . . . . . 33-3360-108 Travel pilot valve, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-56 Travel pilot, remove and install . . . . . . .33-3360-54 Travel speed solenoid, disassmble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-46 Valve cover Remove and install . . . . . . . . . . . . . . . .04-0400-13 TM10743 (09APR09)

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Indx 8

TM10743 (09APR09)

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