John Deere 35D and 50D Excavator Repair Technical Manual TM2264 - PDF DOWNLOAD by www.heydownloads.com

35D and 50D Excavator Repair

TECHNICAL MANUAL 35D and 50D Excavator TM2264 15OCT08 (ENGLISH)

For complete service information also see: 35D and 50D Excavator Operation and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage Appraisal Manual . . . . . . . . .

TM2263 SP326

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

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

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

DX,TMIFC –19–29SEP98–1/1

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Introduction

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TX,TM,FAX –19–03JUL01–1/1

TM2264 (15OCT08)

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Introduction

TM2264 (15OCT08)

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Contents 000

SECTION 000—General Information Group 0001—Safety Group 0003—Torque Values SECTION 01—Tracks Group 0130—Track System

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

SECTION 04—Engine Group 0400—Removal and Installation 04

SECTION 05—Engine Auxiliary Systems Group 0510—Cooling System Group 0560—External Fuel Supply Systems

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

SECTION 18—Operators Station Group 1800—Removal and Installation Group 1821—Seat and Seat Belt Group 1830—Heating and Air Conditioning System

SECTION 32—Bulldozers (Blade) Group 3201—Blades Group 3260—Hydraulic System 18

SECTION 33—Excavator Group 3302—Buckets Group 3340—Frames Group 3360—Hydraulic System 32

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

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

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.

TM2264 (15OCT08)

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Contents 000

TM2264 (15OCT08)

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Contents

INDX

TM2264 (15OCT08)

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Contents

INDX

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000

Section 000

General Information Contents Page

Group 0001—Safety . . . . . . . . . . . . . . . . .000-0001-1 Group 0003—Torque Values Torque Value Metric Bolt and Cap Screw . . . . . . . . . . .000-0003-1 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . .000-0003-2 Torque Value Unified Inch Bolt and Cap Screw . . . . . . .000-0003-4 Check Oil Lines and Fittings . . . . . . . . . . . .000-0003-5 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . .000-0003-6 Service Recommendations For Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . .000-0003-8 Service Recommendations for 37° Flare and 30° Cone Seat Connectors . . . . . . . .000-0003-9 Service Recommendations For Flared Connections—Straight or Tapered Threads . . . . . . . . . . . . . . . . . . . . . . . . . 000-0003-10 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . 000-0003-11 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . 000-0003-12

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Group 0001

Safety 000 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 –UN–24AUG00

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

T133556

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

TX03679,00016F9 –19–03JAN07–1/1

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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Safety

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

–UN–23AUG88

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

000 0001 2

TX03679,00016D0 –19–03JAN07–1/1

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

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

TX03679,00016B7 –19–30OCT00–1/1

Add Cab Guarding for Special Uses Special work situations or machine attachments may create an environment with falling or flying objects. Working near an overhead bank, doing demolition work, using a hydraulic hammer, or working in a wooded area, for example, may require added guarding to protect the operator. FOPS (falling object protective structures) and special screens or guarding should be installed when falling or flying objects may enter or damage the machine. Contact your authorized dealer for information on devices intended to provide protection in special work situations.

TX14740,0001EF3 –19–25JAN07–1/1

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Safety 000 0001 3

Inspect Machine

T6607AQ

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

–UN–18OCT88

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

TX03679,0001734 –19–03JAN07–1/1

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

Avoid High-Pressure Fluids

T133509 T133840

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 fluid. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

–UN–17MAR06

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

TX03679,00016D3 –19–29JUN06–1/1

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Safety

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 –19–03JAN07–1/1

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 –19–14APR08–1/1

Prevent Battery Explosions

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

–UN–23AUG88

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

TS204

000 0001 4

TX03679,000174A –19–03JAN07–1/1

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Safety 000 0001 5

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.

TS291

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B –19–03JAN07–1/1

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Safety

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

T133468

Prevent falls by facing the machine when 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

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

–19–14SEP00

Use and Maintain Seat Belt

T133716

000 0001 6

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

TX03679,00016DD –19–20MAR07–1/1

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Safety 000 0001 7

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.

T204913

Be careful not to accidentally actuate control levers when co-workers are present. Pull pilot control shutoff lever (1) to locked position during work interruptions. Pull pilot control shutoff lever to locked position and stop engine before allowing anyone to approach machine.

–UN–03DEC04

Prevent Unintended Machine Movement

1—Pilot Control Shutoff Lever 2—Console 3—Pilot Control Levers

OUO1032,00015D1 –19–25JAN07–1/1

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

T153094 T153097

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

–UN–01APR02

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.

T153096

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

–UN–01APR02

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

–UN–01APR02

Avoid Work Site Hazards

TX14740,0001E9F –19–19JUL06–1/1

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Safety

Keep Riders Off Machine

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

T120807

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

–UN–14APR99

Only allow operator on machine.

TX14740,0001E7A –19–19MAR02–1/1

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

–UN–14APR99

Avoid Backover Accidents

T120806

000 0001 8

OUO1032,00015D0 –19–25JAN07–1/1

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Safety 000 0001 9

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

T133716 –UN–15SEP00

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

T133545

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

–UN–27SEP00

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

T133803

Use seat belt at all times.

–19–14SEP00

Avoid Machine Tip Over

TX03679,00016DF –19–03JAN07–1/1

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

T133839

Never use this machine to lift people.

–UN–27SEP00

Use Special Care When Lifting Objects

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

TX03679,00016E1 –19–03JAN07–1/1

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Safety

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

TX03679,00016F0 –19–12FEB07–1/1

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

000 0001 10

TX03679,00016E9 –19–03JAN07–1/1

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Safety 000 0001 11

Service Cooling System Safely

TS281

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

–UN–23AUG88

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

DX,RCAP –19–04JUN90–1/1

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

• 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.

TS220

Remove paint before heating:

–UN–23AUG88

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

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

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. 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.

OUO1032,00015DD –19–20MAY08–1/1

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

–UN–14SEP00

Drive Metal Pins Safely

T133738

000 0001 12

TX03679,0001745 –19–03JAN07–1/1

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Group 0003

Torque Values 000 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 –19–22MAR04–1/1

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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

000 0003 2

Continued on next page

TM2264 (15OCT08)

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04T,90,M170 –19–29SEP99–1/2

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Torque Values 000 0003 3

METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

Nominal Dia

N•m

lb-ft

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

TM2264 (15OCT08)

000-0003-3

Repair 101508

PN=23

Torque Values

–UN–27SEP99

Unified Inch Bolt and Cap Screw Torque Values

TORQ1A

000 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) b

Thread Size

Lubricated N•m (lb-ft)

Dry N•m (lb-ft)

Lubricatedb N•m (lb-ft)

Grade 5, 5.1 or 5.2

Dryc N•m (lb-ft)

Lubricatedb N•m (lb-ft)

Grade 8 or 8.2

Dryc N•m (lb-ft)

Lubricatedb N•m (lb-ft)

Dryc N•m (lb-ft)

1/4

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

305 (225)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

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

TM2264 (15OCT08)

000-0003-4

Repair 101508

PN=24

Torque Values 000 0003 5

X9811

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

–UN–23AUG88

Check Oil Lines and Fittings

T85401

Check all oil lines, hoses and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching machine parts which are moving.

–UN–24JAN89

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.

T82,FLMA,AI –19–14MAR90–1/1

TM2264 (15OCT08)

000-0003-5

Repair 101508

PN=25

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

000 0003 6

3. Tighten fitting to torque value shown on chart.

Continued on next page

TM2264 (15OCT08)

000-0003-6

04T,90,K66 –19–29SEP99–1/2

Repair 101508

PN=26

Torque Values 000 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

TM2264 (15OCT08)

000-0003-7

Repair 101508

PN=27

Torque Values 000 0003 8

Service Recommendations For Flat Face O-Ring Seal Fittings fittings, use backup wrench on straight hose couplings.

1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.

IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise.

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.

Tighten fittings to 50% of listed torque value if used in aluminum housing.

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

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

9.52

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.

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.

04T,90,K67 –19–02MAR00–1/1

TM2264 (15OCT08)

000-0003-8

Repair 101508

PN=28

Torque Values 000 0003 9

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

TM2264 (15OCT08)

000-0003-9

Repair 101508

PN=29

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

T6873AD

000 0003 10

Tapered Thread

Torque tolerance is ±10%.

With seat face.

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

04T,90,M171 –19–28JAN92–1/1

TM2264 (15OCT08)

000-0003-10

Repair 101508

PN=30

Torque Values 000 0003 11

T6890BB

–UN–01MAR90

Service Recommendations For Inch Series Four Bolt Flange Fittings

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

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

D—Single Piece Flange TORQUE CHART N•m

lb-ft

Nominal Flange Size

Cap Screw Size Min

Max

Min

Max

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

1/2

5/16-18 UNC

3/4

3/8-16 UNC

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).

3/8-16 UNC

1-1/4

7/16-14 UNC

1-1/2

1/2-13 UNC

131

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.

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

TM2264 (15OCT08)

000-0003-11

Repair 101508

PN=31

Torque Values

–UN–01MAR90

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB

000 0003 12

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

D—Single Piece Flange

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

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

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

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

TORQUE CHARTa

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

Thread

N•m

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.

Metric standard thread.

04T,90,K175 –19–29SEP99–1/1

TM2264 (15OCT08)

000-0003-12

Repair 101508

PN=32

Section 01

Tracks Contents

Page

Group 0130—Track System Track Roller Remove and Install . . . . . . . . . .01-0130-1 Track Roller Oil Leakage Test . . . . . . . . . . . .01-0130-3 Track Roller Disassemble and Assemble . . .01-0130-4 Inspect Metal Face Seals . . . . . . . . . . . . . . .01-0130-5 Measure Track Carrier Roller Wear. . . . . . . .01-0130-7 Track Carrier Roller Remove and Install . . . .01-0130-7 Measure Rubber Track Lugs . . . . . . . . . . . . .01-0130-9 Rubber Track Remove and Install . . . . . . . . .01-0130-9 Steel Track Components Inspection . . . . . .01-0130-11 Track Shoe Welded Remove and Install . . .01-0130-13 Track Shoe with Cap Screws Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-15 Steel Track Remove and Install. . . . . . . . . .01-0130-16 Sprocket Remove and Install. . . . . . . . . . . .01-0130-18 Front Idler Remove and Install . . . . . . . . . .01-0130-19 Front Idler Disassemble and Assemble . . . .01-0130-20 Measure Front Idler Wear . . . . . . . . . . . . . .01-0130-21 Track Adjuster and Recoil Spring Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .01-0130-22 Track Adjuster and Recoil Spring Disassemble and Assemble. . . . . . . . . . .01-0130-23 Track Adjuster Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-27

TM2264 (15OCT08)

01-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

01-2

Repair 101508

PN=2

Group 0130

Track System Track Roller Remove and Install

–UN–28OCT99

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.

T121510

CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing track roller. Specification Excavator—35D—Approximate Weight........................................................................................... 3543 kg 7810 lb Excavator—50D—Approximate Weight........................................................................................... 4790 kg 10,560 lb

Boom-to-Arm Angle and Bucket Position

2. Place shop stands under machine.

Continued on next page

TM2264 (15OCT08)

01-0130-1

MM61211,00008F8 –19–01MAR05–1/2

Repair 101508

PN=35

01 0130 1

Track System

CAUTION: Prevent possible injury from high pressure grease. Do not remove grease fitting (2) from valve (1).

–UN–28OCT99

IMPORTANT: If gravel or mud is packed between sprocket and track, it must be removed before loosening track.

4. Remove cap screws (4) and track roller (3).

T121512

3. Loosen track adjuster valve (1) slowly to release grease. Track Adjuster Valve

Specification 35D Track Roller Tread—New— OD ................................................................................................... 85 mm 3.35 in. 35D Track Roller Tread—Used— OD Allowable Limit .......................................................................... 77 mm 3.03 in. 50D Track Roller Tread—New— OD ................................................................................................... 95 mm 3.74 in. 50D Track Roller Tread—Used— OD Allowable Limit .......................................................................... 87 mm 3.43 in.

6. Repair or replace parts as necessary.

–UN–28OCT99

5. Measure track roller tread diameter. (See specification for new and allowable limit for wear.)

T121513

01 0130 2

Track Adjuster and Track Roller 1—Track Adjuster Valve 2—Grease Fitting 3—Track Roller 4—Cap Screw (2 used)

7. Apply T43513 Thread Lock and Sealer (high strength) to threads of cap screws (4). 8. Install track roller and tighten cap screws (4). Specification Track Roller-to-Frame Cap Screw—Torque ............................................................................. 245 N•m 180 lb-ft

9. Perform Adjusting Track Sag. (Operator’s Manual.)

MM61211,00008F8 –19–01MAR05–2/2

TM2264 (15OCT08)

01-0130-2

Repair 101508

PN=36

Track System

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

2. Remove the plug.

4. Holding plug so it is not pushed out, slowly pressurize oil cavity using regulated air. Specification Track Roller Oil Cavity Air Test— Pressure ................................................................................... 92-128 kPa 0.8-1.4 bar 12-20 psi

T109691B

3. Connect JT03001 Tee Fitting (B and A). Install parts (A—F) to track roller. Plug, barbed adapter and connector (A) are from a leak detector kit such as the D05361ST Rubber Stopper / Leak Detector Kit.

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

5. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has decreased. 6. If there is leakage, disassemble roller and replace parts as necessary. 7. Clean threads of plug. Apply TY16285 Cure Primer. 8. Apply TY9375 Thread Sealant (high temperature) to plug threads and install plug. Specification Track Roller Plug—Torque ............................................................ 9.8 N•m 87 lb-in.

MM61211,0000902 –19–08MAR05–1/1

TM2264 (15OCT08)

01-0130-3

Repair 101508

PN=37

01 0130 3

Track System

Track Roller Disassemble and Assemble

T121516

–UN–28OCT99

01 0130 4

Track Roller 1—Stopper Ring 2—Plug

3—Collar 4—Metal Face Seal (2 used)

5—Bushing (2 used) 6—Roller

7—O-Ring 8—Axle

5. Inspect metal face seals. See Inspect Metal Face Seals. (Group 0130.) For seals that will be reused, put a piece of cardboard between seal rings to protect seal face.

1. Remove plug (2) and drain oil. 2. Remove stopper ring (1). 3. Remove collar (3) using a bearing puller attachment and adapters from D01047AA puller set.

6. Remove axle (8) from roller (6).

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: If bushings (5) are worn or damaged, complete roller must be replaced.

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

8. Apply a thin film of oil to new bushings (5) and install.

7. Inspect track roller bushings (5). Replace track roller if worn or damaged.

Continued on next page

TM2264 (15OCT08)

01-0130-4

MM61211,00008EB –19–25FEB05–1/2

Repair 101508

PN=38

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. 9. Thoroughly clean O-ring and seat surfaces using volatile, non-petroleum base solvent and lint-free tissues. 10. Wipe fingerprints and foreign material off seal ring face using clean oil and lint-free tissues.

13. Install axle to roller using press. 14. Install stopper ring (1). 15. Fill roller with 35 mL (1.2 oz) of SAE 30 oil meeting API Service GL-5 (MIL-L-2105B or MIL-L-2105C).

01 0130 5

Specification Track Roller Oil—Capacity ........................................................ 35 mL 1.2 oz

16. Clean threads of plug. Apply TY16285 Cure Primer.

11. Apply a thin film of oil to each seal ring face. 12. Install metal face seals (4), collar (3), roller (6) and axle assembly (8). 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.

17. Apply TY9375 Thread Sealant (high temperature) to plug threads and install plug. Specification Track Roller Plug—Torque ..................................................... 9.8 N•m 87 lb-in.

MM61211,00008EB –19–25FEB05–2/2

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

T85079

–UN–24AUG93

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

Ring Sealing Area

Continued on next page

TM2264 (15OCT08)

01-0130-5

T47,0130,5939HQ –19–23FEB05–1/3

Repair 101508

PN=39

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

–UN–05DEC96

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

T85080

Metal Face Seals

T47,0130,5939HQ –19–23FEB05–2/3

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

T82840

01 0130 6

No Scraper on Seal Face

A—Seal Face

T47,0130,5939HQ –19–23FEB05–3/3

TM2264 (15OCT08)

01-0130-6

Repair 101508

PN=40

Track System

Measure Track Carrier Roller Wear NOTE: Track carrier roller can be measured for wear without being removed. 01 0130 7

1. Measure roller tread outer diameter using a caliper.

–UN–09MAR05

2. If not within specifications, replace roller. See Track Carrier Roller Remove and Install. (Group 0130.)

T209403A

Specification Carrier Roller Tread—OD................................................................ 70 mm 2.76 in.

1—Track Carrier Roller 2—Caliper

MM61211,0000900 –19–08MAR05–1/1

Track Carrier Roller Remove and Install 1. Swing upperstructure 90° and lower bucket to raise track off ground. –UN–28OCT99

Keep angle between boom and arm as shown, and position round side of bucket on ground.

T121510

CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing track roller.

Boom-to-Arm Angle and Bucket Position

Specification Excavator—35D—Approximate Weight............................................................................................ 3543 kg 7810 lb Excavator—50D—Approximate Weight............................................................................................ 4790 kg 10,560 lb

2. Put shop stands under machine to support machine.

Continued on next page

TM2264 (15OCT08)

01-0130-7

CED,TX08227,2889 –19–23FEB05–1/2

Repair 101508

PN=41

Track System

–UN–28OCT99 T121512

IMPORTANT: If gravel or mud is packed between sprocket and track, it must be removed before loosening track (6). 3. Loosen track adjuster valve (1) slowly to discharge grease. IMPORTANT: Place pads between track frame (3) and hydraulic jack (4) when jacking to prevent jack from slipping.

T121514

–UN–28OCT99

4. Using hydraulic jack (4), jack up track (6) until clearance between track and track carrier roller (5) is enough to allow removal. Place wooden blocks on track frame (3) to support track (6). 5. Remove cap screw (7) and track carrier roller (5). 6. Replace parts as necessary. 7. Install track carrier roller (5) and cap screw (7) and tighten.

–UN–28OCT99

Specification Track Roller-to-Frame Cap Screw—Torque ............................................................................... 88 N•m 65 lb-ft

8. Remove pads and jack.

T121515

01 0130 8

9. Perform Adjusting Track Sag. (Operator’s Manual.) 1—Track Adjuster Valve 2—Grease Fitting 3—Track Frame 4—Hydraulic Jack 5—Track Carrier Roller 6—Track 7—Cap Screw

CED,TX08227,2889 –19–23FEB05–2/2

TM2264 (15OCT08)

01-0130-8

Repair 101508

PN=42

Track System

Measure Rubber Track Lugs Measure lug height (1) where indicated.

–19–29OCT99

Replace rubber track if measurement is less than specification.

T121575

Specification Rubber Track Lug—Height............................................................... 5 mm 0.2 in.

1—Lug Height

MM61211,0000903 –19–08MAR05–1/1

Rubber Track Remove and Install 1. Swing upperstructure 90° and lower bucket to raise track off ground. –UN–28OCT99

Keep angle between boom and arm as shown and position round side of bucket on ground.

T121510

CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing track roller.

Boom-to-Arm Angle and Bucket Position

2. Put shop stands under machine to support machine.

Continued on next page

TM2264 (15OCT08)

01-0130-9

FR91424,0000012 –19–23FEB05–1/4

Repair 101508

PN=43

01 0130 9

Track System

–UN–28OCT99 T121512

IMPORTANT: If gravel or mud is packed between sprocket and track, it must be removed before loosening track. 3. Loosen track adjuster valve (1) slowly to discharge grease. Allow track to lower completely. 4. Install three steel pipes (6) into gaps between rubber track (4) and track frame (5).

–UN–28OCT99

CAUTION: Adjust engine speed to the slowest speed. Stand clear of steel pipes while moving sprocket to prevent injury.

T121514

5. Rotate sprocket in reverse direction until rubber track (4) is raised off of front idler (3) by the three steel pipes. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

–19–29OCT99

Specification Excavator—35D—Weight ................................................................ 138 kg 304 lb Excavator—50D—Weight ................................................................ 238 kg 530 lb

6. Slide rubber track (4) away from track frame (5) and remove.

T121522

01 0130 10

7. Inspect lugs and area between lugs for cracks that exceed 3 mm (0.1 in.) in depth, reach steel core, or exceed 30 mm (1.2 in.) in length. Inspect for any signs of exposed steel core. Inspect roller side of track for cracks that reach steel core. Inspect for separation of steel core anywhere on track.

1—Track Adjuster Valve 2—Grease Fitting 3—Front Idler 4—Rubber Track 5—Track Frame 6—Steel Pipe (3 used)

8. Repair or replace as necessary.

Continued on next page

TM2264 (15OCT08)

01-0130-10

FR91424,0000012 –19–23FEB05–2/4

Repair 101508

PN=44

Track System 9. Install rubber track (4) on sprocket teeth, and hand other end over front idler (3). 10. Rotate sprocket in reverse direction to sufficiently mesh rubber track onto sprocket.

01 0130 11

FR91424,0000012 –19–23FEB05–3/4

CAUTION: Adjust engine speed to the slowest speed. Stand clear of steel pipe while moving sprocket to prevent injury.

–19–29OCT99

IMPORTANT: Make sure rubber track is securely engaged on sprocket and front idler.

T121533

11. Install one steel pipe (7) into gap between rubber track (4) and track frame (5). Rotate sprocket to position rubber track completely onto front idler. 12. Perform Adjusting Track Sag. (Operator’s Manual.) 3—Front Idler 4—Rubber Track 5—Track Frame 7—Steel Pipe

FR91424,0000012 –19–23FEB05–4/4

Steel Track Components Inspection Measure Track Shoe Grouser Wear

–UN–08NOV88

1. Minimum used is the maximum allowable wear for rebuilding grouser bars with weld.

T82859

2. Measure grouser height of several track shoes to find an average using a depth gauge. Specification Grouser—New—Height ................................................................ 22.0 mm 0.87 in. Grouser—Used—Min. Height ....................................................... 16.5 mm 0.65 in.

Continued on next page

TM2264 (15OCT08)

01-0130-11

TX,01,VV2526 –19–23FEB05–1/4

Repair 101508

PN=45

Track System Measure Track Chain Link Wear NOTE: Track chain link height can be measured for wear without being removed. –UN–08NOV88

1. Measure height of several links to find an average using a depth gauge.

T82864

2. Minimum used is the maximum allowable wear for rebuilding links. Specification Track Chain Link Wear—New— Height .............................................................................................. 60 mm 2.36 in. Track Chain Link Wear—Used— Min. Height ...................................................................................... 55 mm 2.17 in.

TX,01,VV2526 –19–23FEB05–2/4

Measure Track Chain Bushing Wear NOTE: Track chain bushing wear can be measure, without being removed. –UN–08NOV88

1. Measure bushing outer diameter at the two worn places using a caliper. 2. Minimum used is the maximum allowable wear for turning pins and bushings.

T82865

01 0130 12

Specification Track Chain Bushing Wear— New—OD...................................................................................... 32.2 mm 1.27 in. Track Chain Bushing Wear— Used—OD Allowable Limit ........................................................... 29.2 mm 1.15 in.

Continued on next page

TM2264 (15OCT08)

01-0130-12

TX,01,VV2526 –19–23FEB05–3/4

Repair 101508

PN=46

Track System Measure Track Chain Pitch NOTE: Track chain pitch can measured without being removed. –UN–29JAN98

1. Remove slack by putting a wooden block between sprocket and chain, then slowly move machine in reverse to tighten chain.

T6813AL

2. Measure pitch across several four-link sections as shown, except section on either side of master pin, to find average chain wear. Maximum used is the maximum allowable wear for turning pins and bushings. Specification Track Chain—New—Pitch .......................................................... 406.4 mm 16.0 in. Track Chain—Used—Max. Pitch................................................ 412.0 mm 16.22 in.

TX,01,VV2526 –19–23FEB05–4/4

Track Shoe Welded Remove and Install 1. Swing upperstructure 90° and lower bucket to raise track off ground. –UN–28OCT99

Keep angle between boom and arm as shown and position round side of bucket on ground.

T121510

CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing track roller. Specification Excavator—35D—Approximate Weight............................................................................................ 3543 kg 7810 lb Excavator—50D—Approximate Weight............................................................................................ 4790 kg 10,560 lb

2. Put blocks or stop stands under machine to support machine.

Continued on next page

TM2264 (15OCT08)

01-0130-13

FR91424,0000026 –19–30SEP08–1/2

Repair 101508

PN=47

01 0130 13

Track System NOTE: The track shoe and track chain are a welded assembly. Removal of track shoe involves removal of track pins on either side of shoe.

–UN–28OCT99

3. Rotate sprocket to position track shoe (6) over front idler.

T121512

CAUTION: High pressure grease is in track adjuster cylinder. Do not loosen track adjuster valve (1) quickly or too much. High pressure grease may cause serious injury. Never loosen grease fitting (2) to release grease. IMPORTANT: If gravel or mud is packed between sprocket and track, it must be removed before loosening track. 4. Loosen track adjuster valve (1) slowly to discharge grease. Allow track to lower completely.

–UN–14JAN00

5. Put wooden blocks in front of front idler and under track to prevent track from falling when track pin is removed. 6. Remove one track pin (4) and lower track to ground. 7. Remove remaining track pin (3) and remove track shoe (6). 8. Check track pin bushing (5) for wear. 9. Repair or replace as necessary. 10. Place track shoe (6) in position and install track pin (3).

T126403

01 0130 14

1—Track Adjuster Valve 2—Grease Fitting 3—Track Pin 4—Track Pin 5—Track Pin Bushing 6—Track Shoe

11. Pull ends of track together and install track pin (4). 12. Perform Adjusting Track Sag. (Operator’s Manual.)

FR91424,0000026 –19–30SEP08–2/2

TM2264 (15OCT08)

01-0130-14

Repair 101508

PN=48

Track System

2. Remove track shoe. 3. Apply oil to cap screw threads. Install track shoe.

T6585TF

1. Check track shoe wear. See 50ZTS and 50C ZTS Grouser Height—Steel Track. (SP326 Undercarriage Appraisal Manual.)

–UN–25OCT88

Track Shoe with Cap Screws Remove and Install

RR71361,0000001 –19–30SEP08–1/3

4. Install all track shoe nuts (1) making sure nut is properly positioned in link so there is full contact between nut and link.

T125227

–UN–29OCT99

1—Track Shoe Nut

RR71361,0000001 –19–30SEP08–2/3

5. Starting at cap screw (A), tighten cap screws in sequence shown.

–UN–07APR98

Track Shoe—Specification Track Shoe-to-Link Cap Screw— Torque ........................................................................... 108 N•m (80 lb-ft)

T113775

A—Cap Screw (4 used)

RR71361,0000001 –19–30SEP08–3/3

TM2264 (15OCT08)

01-0130-15

Repair 101508

PN=49

01 0130 15

Track System

Steel Track Remove and Install 1. Swing upperstructure 90° and lower bucket to raise track off ground. –UN–28OCT99

Keep angle between boom and arm as shown and position round side of bucket on ground. CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing track roller.

T121510

01 0130 16

2. Put blocks or stop stands under machine to support machine.

Continued on next page

TM2264 (15OCT08)

01-0130-16

FR91424,0000027 –19–23FEB05–1/2

Repair 101508

PN=50

Track System NOTE: The track master pin (3) has drilled center holes on both sides of pin. It also has a head which is larger in diameter than the rest of pin.

–UN–28OCT99

3. Rotate sprocket to position master pin (3) over front idler.

T121512

–UN–14JAN00

5. Put wooden blocks in front of front idler and under track to prevent track from falling when master pin is removed. 6. Remove master pin (3).

8. Repair or replace as necessary. 9. Position track on ground beneath front idler and sprocket.

T126555

7. Slowly turn sprocket in reverse direction to remove track from machine. 1—Track Adjuster Valve 2—Grease Fitting 3—Track Master Pin

10. Install end of track on sprocket teeth and slowly turn sprocket in forward direction to pull track across top of track frame to front idler. 11. Pull ends of track together and install master pin (3). 12. Perform Adjusting Track Sag. (Operator’s Manual.)

FR91424,0000027 –19–23FEB05–2/2

TM2264 (15OCT08)

01-0130-17

Repair 101508

PN=51

01 0130 17

Track System

Sprocket Remove and Install 1. Remove track. To remove rubber track, see Rubber Track Remove and Install. (Group 0130.) To remove steel track, see Steel Track Remove and Install. 01 (Group 0130.) 0130 18

2. Remove cap screws (1) and lock washers (2).

–UN–14JAN00

3. Remove sprocket (3). 4. Repair or replace parts as necessary.

Specification Sprocket Cap Screw—35D— Torque .......................................................................................... 108 N•m 80 lb-ft Sprocket Cap Screw—50D— Torque .......................................................................................... 128 N•m 94 lb-ft

T126423

5. Install sprocket (3), cap screws (1), and lock washers (2). Tighten cap screws.

1—Cap Screw (9 used) 2—Lock Washer (9 used) 3—Sprocket

6. Install track. To install rubber track, see Rubber Track Remove and Install. (Group 0130.) To install steel track, see Steel Track Remove and Install. (Group 0130.)

TX,01,VV2531 –19–23FEB05–1/1

TM2264 (15OCT08)

01-0130-18

Repair 101508

PN=52

Track System

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T121683

1. Remove track. To remove rubber track, see Rubber Track Remove and Install. (Group 0130.) To remove steel track, see Steel Track Remove and Install. (Group 0130.)

–UN–28OCT99

Front Idler Remove and Install

2. Using a shop hoist, remove front idler from track frame.

T121684

CAUTION: The front idler may be under spring force from track adjuster and can be pushed out from track frame. Make sure area in front of idler is clear.

–UN–28OCT99

Specification Front Idler—35D—Approximate Weight............................................................................................. 23.0 kg 51.0 lb Front Idler—50D—Approximate Weight............................................................................................. 27.0 kg 60.0 lb

3. Repair or replace as necessary. 4. Clean and apply grease to sliding surfaces inside track frame. 5. Install front idler into track frame. 6. Install track. To install rubber track, see Rubber Track Remove and Install. (Group 0130.) To install steel track, see Steel Track Remove and Install. (Group 0130.)

MM61211,00008EC –19–25FEB05–1/1

TM2264 (15OCT08)

01-0130-19

Repair 101508

PN=53

01 0130 19

Track System

Front Idler Disassemble and Assemble

T206787

–UN–10JAN05

01 0130 20

1—Cap Screw (2 used) 2—Washer (2 used) 3—Seal (2 used)

4—O-Ring (2 used) 5—Axle 6—Bushing (2 used)

7—Idler 8—Yoke (2 used)

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 pattern on seal ring face. 1. Inspect metal face seals. See Inspect Metal Face Seals. (Group 0250.) 2. Measure axle (5) and bushings (6) for wear or damage. (See specification for new and allowable limit for wear.) Specification Front Idler Axle—New—OD .................................................. 35.0 mm 1.3 in. Front Idler Axle—Used—OD Allowable Limit ....................................................................... 34.2 mm 1.3 in.

Front Idler Bushing—New—ID .............................................. 35.0 mm 1.3 in. Front Idler Bushing—Used—ID Allowable Limit ....................................................................... 36.0 mm 1.4 in. Front Idler Bushing Flange— New—Thickness ...................................................................... 3.5 mm 0.14 in. Front Idler Flange—Used— Thickness Allowable Limit ....................................................... 2.7 mm 0.1 in.

NOTE: Remove bushings only if replacement is necessary. 3. Remove bushing using a 2-jaw puller and adapter from 17-1/2 and 30-ton puller set.

Continued on next page

TM2264 (15OCT08)

9—Cap Screw (4 used) 10—Plate

01-0130-20

MM61211,00008F7 –19–01MAR05–1/2

Repair 101508

PN=54

Track System 4. Apply a thin film of oil on bushings. If removed, install bushings with flange tight against shoulder of idler. IMPORTANT: O-rings and O-ring grooves must be clean, dry and free of oil to prevent O-rings from slipping when idler is turning. 5. Apply a thin layer of PT569 NEVER-SEEZ Anti-Seize Lubricant or equivalent to both ends of axle from O-ring grooves, bore of yokes, and spring pins.

6. Assemble and tighten cap screws. 7. Fill front idler with SAE 30 oil meeting API Service GL-5 (MIL-L-2105E). Specification Front Idler—35D—Capacity....................................................... 30 mL 1.0 oz Front Idler—50D—Capacity....................................................... 45 mL 1.5 oz Yoke Cap Screw—Torque ..................................................... 175 N•m 130 lb-ft

NEVER-SEEZ is a trademark of Emhart Chemical Group.

MM61211,00008F7 –19–01MAR05–2/2

Measure Front Idler Wear

T121638

Specification 35D Front Idler Wear—New— Diameter ........................................................................................ 300 mm 11.8 in. 35D Front Idler Wear—Used— Diameter Allowable Limit ............................................................... 291 mm 11.5 in. 50D Front Idler Wear—New— Diameter ........................................................................................ 335 mm 13.2 in. 50D Front Idler Wear—Used— Diameter ........................................................................................ 327 mm 12.9 in. 35D Front Idler Guide—Width ......................................................... 28 mm 1.1 in. 50D Front Idler Guide—Width Allowable Limit................................................................................. 39 mm 1.54 in.

–UN–28OCT99

Measure front idler diameter (1) and guide width (2).

1—Front Idler Diameter 2—Guide Width

MM61211,0000904 –19–08MAR05–1/1

TM2264 (15OCT08)

01-0130-21

Repair 101508

PN=55

01 0130 21

Track System

Track Adjuster and Recoil Spring Remove and Install

T121675

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.

IMPORTANT: When installing track adjuster (1) with recoil spring into track frame (2), make sure that flat bottom of plate faces down and top radius of plate aligns with spring guide (3).

T121676

3. Repair or replace parts as necessary.

–UN–28OCT99

2. Slide track adjuster (1) and recoil spring out of track frame (2).

5. Install front idler. See Front Idler Remove and Install. (Group 0130.) 1—Track Adjuster 2—Track Frame 3—Spring Guide 4—Plate

–UN–28OCT99

4. Install track adjuster (1) with recoil spring into track frame (2) and push into place until track adjusting valve protrudes from hole in plate (4).

T121677

0130 22

–UN–28OCT99

1. Remove front idler. See Front Idler Remove and Install. (Group 0130.) 01

TX,01,VV2537 –19–23FEB05–1/1

TM2264 (15OCT08)

01-0130-22

Repair 101508

PN=56

Track System

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

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 injury from crushing. Heavy component, use appropriate lifting device.

T6557DY

Specification Track Recoil Spring Disassembly and Assembly Tool—Approximate Weight.............................................................................................. 225 kg 496 lb

A—ST4920 Track Recoil Spring Disassembly and Assembly Tool B—Nut C—Top Plate

1. Place an 18-t (20-ton) jack on bottom of ST4920 Track Recoil Spring Disassembly and Assembly Tool (A). Remove nuts (B) and top plate (C). See ST4920 Track Recoil Spring Disassembly and Assembly Tool for instructions to make tool. (Group 9900.) NOTE: It is not necessary to remove the recoil spring to replace wear ring and U-ring packing on piston. To replace O-ring in the cylinder, remove recoil spring and rod. 2. Remove nuts (B). Remove top plate (C).

Continued on next page

TM2264 (15OCT08)

01-0130-23

MM61211,00008F0 –19–25FEB05–1/4

Repair 101508

PN=57

Track System 3. Put track adjuster (A) in disassembly and assembly tool with cylinder end on spacer (B).

–UN–28OCT99

A—Track Adjuster B—Disassembly and Assembly Spacer

T121701

01 0130 24

Installing Track Adjuster in Disassembly and Assembly Tool

Continued on next page

TM2264 (15OCT08)

01-0130-24

MM61211,00008F0 –19–25FEB05–2/4

Repair 101508

PN=58

Track System 4. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (F). See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool for instructions to make tool. (Group 9900.) 01 0130 25

5. Install top plate (A) and nuts (B) with smallest opening to allow access to nut (D). 6. Extend jack ram to provide enough travel to release spring. 7. Tighten nuts (B) so plate is tight against retainer plate. 8. Remove valve (C) and special plug (E).

T7720AG

–UN–28APR92

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

Continued on next page

TM2264 (15OCT08)

01-0130-25

MM61211,00008F0 –19–25FEB05–3/4

Repair 101508

PN=59

Track System 9. Raise upper half of guard tool (F). Tighten T-handles. 10. Operate jack to compress spring just enough so nut (D) can be removed. 11. Lower jack ram to release spring force. 12. Repair or replace parts as necessary. 13. If disassembly of track adjuster cylinder is necessary, see Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.) 14. Put track adjuster cylinder in assembly tool with cylinder end on spacer. 15. Install spacer on rod.

–UN–28APR92

16. Install retainer plate. 17. Install guard tool. 18. Install top plate (A). Install nuts (B).

T7720AH

01 0130 26

19. Raise upper half of guard tool. Tighten T-handles. 20. Operate jack to compress spring. 21. Install nut (D) so hole is aligned with hole in rod. Install and tighten plug. Specification Plug—Torque............................................................................... 14.5 N•m 128 lb-in.

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

22. Install and tighten valve.

MM61211,00008F0 –19–25FEB05–4/4

TM2264 (15OCT08)

01-0130-26

Repair 101508

PN=60

Track System

Track Adjuster Cylinder Disassemble and Assemble 2

4 01 0130 27

5 1

11 –UN–01OCT02

T159834

13 T159834 Track Adjuster Cylinder 1—Socket Head Cap Screw (3 used) 2—Dust Seal 3—Flange

4—Piston Rod 5—Wear Ring 6—U-Ring Packing 7—Retaining Ring

8—Rod 9—Cylinder 10—O-Ring 11—Plug Continued on next page

TM2264 (15OCT08)

01-0130-27

12—Valve 13—Nut 14—Retainer Plate 15—Recoil Spring TX,01,VV2539 –19–23FEB05–1/3

Repair 101508

PN=61

Track System

01 0130 28

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 of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling.

NOTE: It is not necessary to remove the recoil spring to replace wear ring (5), U-ring packing (6) and dust seal (2). To replace O-ring (10), remove recoil spring (15) and rod (8). 1. Remove recoil spring if necessary. See Track Adjuster and Recoil Spring Remove and Install. (Group 0130.)

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

Continued on next page

TM2264 (15OCT08)

01-0130-28

TX,01,VV2539 –19–23FEB05–2/3

Repair 101508

PN=62

Track System

T121703

–UN–28OCT99

01 0130 29

1—Socket Head Cap Screw (3 used) 2—Dust Seal

3—Flange 4—Piston Rod 5—Wear Ring

6—U-Ring Packing 7—Retaining Ring 8—Rod

2. If necessary, remove rod (8) from cylinder (9) using a press. 3. Repair or replace parts as necessary. 4. Apply multi-purpose grease to U-ring packing (6), dust seal (2), wear ring (5), and O-ring (10). Fill grooves inside flange (3) with grease.

9—Cylinder 10—O-Ring

6. Tighten cap screws (1). Specification Flange-to-Track Adjuster Cylinder Cap Screw—Torque .................................................. 20 N•m 177 lb-in.

5. Install U-ring packing (6) with lip toward inside of cylinder.

TX,01,VV2539 –19–23FEB05–3/3

TM2264 (15OCT08)

01-0130-29

Repair 101508

PN=63

Track System

01 0130 30

TM2264 (15OCT08)

01-0130-30

Repair 101508

PN=64

Section 02

Axles and Suspension Systems (Propel) Contents Page

Group 0250—Axle Shaft, Bearings, and Reduction Gears Propel Gearbox Remove and Install . . . . . . .02-0250-1 Propel Gearbox Disassemble and Assemble—35D . . . . . . . . . . . . . . . . . . . . .02-0250-6 Propel Gearbox Disassemble and Assemble—50D . . . . . . . . . . . . . . . . . . . .02-0250-15

Group 0260—Hydraulic System Propel Motor Disassemble and Assemble—35D . . . . . . . . . . . . . . . . . . . . .02-0260-1 Propel Motor Disassemble and Assemble—50D . . . . . . . . . . . . . . . . . . . .02-0260-10 Rotary Manifold Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0260-20

TM2264 (15OCT08)

02-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

02-2

Repair 101508

PN=2

Group 0250

Axle Shaft, Bearings, and Reduction Gears Propel Gearbox Remove and Install 1. See Rubber Track Remove and Install for removal procedure. (Group 0130.) See Steel Track Remove and Install for removal procedure. (Group 0130.) CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. SLOWLY loosen cap to relieve the air pressure in hydraulic oil tank.

02 0250 1

2. Slowly loosen cap to relieve the air pressure in hydraulic oil tank. 3. Remove the propel motor cover.

Continued on next page

TM2264 (15OCT08)

02-0250-1

MM61211,00008CB –19–15FEB05–1/5

Repair 101508

PN=67

Axle Shaft, Bearings, and Reduction Gears 4. Put identification tags on lines to aid assembly. See Propel Hydraulic System Line Identification—35D or See Propel Hydraulic System Line Identification—50D. (Group 9025-15.)

5. Disconnect the lines. Close openings using caps and plugs.

–UN–17JAN03

T163383

1—Propel Motor Lines 2—Right Propel Motor and Gearbox 3—Left Propel Motor and Gearbox 4—Cap Screw and Lock Washer (12 used)

T163383

–UN–17JAN03

35D Shown

T163407

02 0250 2

50D Shown

Continued on next page

TM2264 (15OCT08)

02-0250-2

MM61211,00008CB –19–15FEB05–2/5

Repair 101508

PN=68

Axle Shaft, Bearings, and Reduction Gears

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T163399

–UN–17JAN03

Specification Propel Gearbox and Motor— 35D—Weight .................................................................................... 44 kg 100 lb Propel Gearbox and Motor— 50D—Weight .................................................................................... 66 kg 145 lb

6. Connect propel gearbox and motor to a hoist using a lifting strap or a JT01748 Lifting Bracket. Remove a sprocket-to-gearbox cap screw to install lifting bracket. 7. Remove cap screws and lock washers (4) to remove propel gearbox and motor. 8. Remove sprocket from gearbox. NOTE: The propel gearbox and motor are removed as an assembly because the motor housing is also the second planet carrier for the gearbox. 9. Repair or replace parts as necessary. See Propel Gearbox Disassemble and Assemble— 35D. (Group 0250.) See Propel Gearbox Disassemble and Assemble— 50D. (Group 0250.) See Propel Motor Disassemble and Assemble—35D. (Group 0260.) See Propel Motor Disassemble and Assemble—50D. (Group 0260.) 10. Install propel gearbox and motor. 11. Apply T43513 Thread Lock and Sealer (high strength) to cap screw threads. Tighten cap screws and lock washers. Specification 35D—Frame-to-Gearbox Cap Screw—Torque ............................................................................ 108 N•m 80 lb-ft

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Repair 101508

PN=69

02 0250 3

Axle Shaft, Bearings, and Reduction Gears Specification 50D—Frame-to-Gearbox Cap Screw—Torque ............................................................................ 128 N•m 94 lb-ft

12. Install sprocket to gearbox. 13. Apply T43513 Thread Lock and Sealer (high strength) to cap screw threads. Tighten cap screws and lock washers. 02 0250 4

Specification 35D—Sprocket-to-Gearbox Cap Screw—Torque ............................................................................ 108 N•m 80 lb-ft 50D—Sprocket-to-Gearbox Cap Screw—Torque ............................................................................ 128 N•m 94 lb-ft

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TM2264 (15OCT08)

02-0250-4

MM61211,00008CB –19–15FEB05–4/5

Repair 101508

PN=70

Axle Shaft, Bearings, and Reduction Gears 14.

–UN–25FEB05

IMPORTANT: Propel gearbox and motor will be damaged if not filled with oil before operating machine. Procedures must be performed whenever a new gearbox and motor are installed or oil has been drained from the gearbox and motor.

Fill motor with hydraulic oil through the fill port (5). Use a funnel with suitable diameter neck to allow air to escape. See Hydraulic Oil for correct oil. (Operator’s Manual.)

T208611A

Fill gearbox with gear oil to level port (7) on cover. See Check Propel Gearbox Oil Level. (Operator’s Manual.)

35D Shown

Connect all lines. 15. Do break-in operation to prevent propel motors from seizing:

–UN–25FEB05

a. Perform Checking Hydraulic Oil Tank Level. (Operator’s Manual.) b. Run engine at slow idle.

T208612A

c. Operate the propel motors at slow speed for 2 minutes or more. 16. Install cover. Tighten cap screws and washers. Specification Motor Cover-to-Frame Cap Screw—Torque .............................................................................. 49 N•m 36 lb-ft

5—Motor Fill Port 6—Gearbox Fill Port 7—Gearbox Level Port 8—Gearbox Drain Port

MM61211,00008CB –19–15FEB05–5/5

TM2264 (15OCT08)

02-0250-5

Repair 101508

PN=71

02 0250 5

Axle Shaft, Bearings, and Reduction Gears

Propel Gearbox Disassemble and Assemble—35D 1. See Propel Gearbox Remove and Install for gearbox and motor removal. (Group 0250.) See Propel Gearbox Operation for a cross-section of Propel Gearbox. (Group 9020-05.)

02 0250 6

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TM2264 (15OCT08)

02-0250-6

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Repair 101508

PN=72

Axle Shaft, Bearings, and Reduction Gears

02 0250 7

TM2264 (15OCT08)

02-0250-7

Repair 101508

PN=73

Axle Shaft, Bearings, and Reduction Gears

T163440

–UN–17JAN03

02 0250 8

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PN=74

Axle Shaft, Bearings, and Reduction Gears 1—Plug 2—O-Ring 3—Plug (2 used) 4—O-Ring (2 used) 5—Snap Ring 6—Cover 7—O-Ring 8—Thrust Ring 9—Input Shaft and First Planet Sun Gear

10—First Planet Carrier and Gears 11—Snap Ring 12—First Planet Carrier 13—Second Planet Sun Gear 14—Spring Pin (3 used) 15—Thrust Washer (6 used) 16—First Planet Gear (3 used) 17—Needle Roller (48 used) 18—Pin (3 used)

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Propel Gearbox and Motor— 35D—Weight.............................................................................. 44 kg 100 lb

19—Snap Ring (3 used) 20—Thrust Washer 21—Snap Ring (4 used) 22—Thrust Washer (4 used) 23—Second Planet Gear 24—Needle Roller (92 used) 25—Bushing 26—Thrust Washer (4 used) 27—Snap Ring

28—Housing and Bearings 29—Ring Gear (housing) 30—Bearing (2 used) 31—Snap Ring 32—Metal Face Seal (seal ring and O-ring) 33—Propel Motor Housing and Second Planet Carrier 34—Propel Motor

2. Remove plugs (3) and O-rings (4) to drain oil. Approximate capacity is 0.65 L (0.7 qt).

02 0250 9

3. Remove snap ring (5) to remove cover (6) and O-ring (7). Remove thrust ring (8) if replacement is necessary.

MM61211,00008CC –19–15FEB05–3/8

CAUTION: Prevent possible injury from unexpected machine movement. Planet gears can turn. Keep fingers away from gears.

–UN–19OCT88

4. Remove input shaft (9).

T6639GK

NOTE: First planet carrier and gears are serviced as an assembly. 5. Remove first planet carrier and gears (10). Disassemble for inspection and cleaning only. Spring pins (14) and pins (18) cannot be removed because they are a pressed fit in the carrier. 6. Remove snap rings (21) to remove parts (22—26) for second planet gears. Keep parts for each planet gear together.

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PN=75

Axle Shaft, Bearings, and Reduction Gears 7. Push the ring gear (29) down slightly using C-clamps or a shop press so the snap ring (26) can be removed.

–UN–17JAN03

8. Push housing (33) out of ring gear and bearings (31) using a shop press.

02 0250 10

T163448

IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 9. Remove the metal face seals (32) from ring gear and housing. Keep seal rings together as a matched set with a piece of clean cardboard between them to protect the seal ring face. See Inspect Metal Face Seals to determine if seals can be reused. (Group 0130.) NOTE: New bearings should be installed if removed. 10. Remove bearings (30) only if replacement is necessary. Bearings are a pressed fit. 11. See Propel Motor Disassemble and Assemble—35D for motor disassembly. (Group 0260.) 12. See Propel Gearbox Operation for a cross-section of Propel Gearbox. (Group 9020-05.) See Propel Motor Disassemble and Assemble—35D for motor assembly. (Group 0260.)

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Repair 101508

PN=76

Axle Shaft, Bearings, and Reduction Gears

02 0250 11

TM2264 (15OCT08)

02-0250-11

Repair 101508

PN=77

Axle Shaft, Bearings, and Reduction Gears

T163440

–UN–17JAN03

02 0250 12

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Repair 101508

PN=78

Axle Shaft, Bearings, and Reduction Gears 1—Plug 2—O-Ring 3—Plug (2 used) 4—O-Ring (2 used) 5—Snap Ring 6—Cover 7—O-Ring 8—Thrust Ring 9—Input Shaft and First Planet Sun Gear

Solvent must not damage the O-ring or leave an oil residue.

13. Install the new bearings (30) so the thicker edge of outer race is against the snap ring (31). IMPORTANT: The metal face seal O-rings and their seat surfaces must be clean, dry, and oil free so the O-rings do not slip.

16. Apply equal pressure with fingers at four equally spaced points on seal ring face. Seal must “pop” down into place so O-ring is tight against seal bore and seal ring is installed squarely.

14. Thoroughly clean O-rings, seat surfaces in housing (33), ring gear (29), and seal rings using volatile, non-petroleum base solvent and lint-free tissues.

17. Wipe fingerprints and foreign material off seal ring face using clean oil and lint-free tissues.

15. Install O-rings on seal rings. Check that O-ring is not twisted. NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant.

18. Apply a thin film of clean oil on each seal ring face. 19. Install ring gear onto housing. Tap around the top edge of ring gear using a soft-faced hammer to seat the bearings on housing.

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PN=79

02 0250 13

Axle Shaft, Bearings, and Reduction Gears

22. Install parts (26—21) for second planet gears. 02 0250 14

a. Install bushings (25) with the beveled end toward bottom of pin.

T163448

21. Check that ring gear can be turned. If not, disassemble and assemble again because the bearings or metal face seals are not installed correctly.

–UN–17JAN03

20. Push the ring gear (29) down slightly using C-clamps or a shop press so the snap ring (26) can be installed into groove.

b. Install thrust washer with the larger ID (26) over bushing and against machined surface. c. Install remaining parts. 23. Install first planet carrier and gears (10). Install input shaft (9). 24. Install O-ring (7) to groove in ring gear. Apply grease to O-ring. 25. Add approximately 0.65 L (0.7 qt) of gear oil to gearbox. See Propel Gearbox Oil for specification. (Operator’s Manual.) See Check Propel Gearbox Oil Level after plugs and O-rings (3 and 4) are installed. (Operator’s Manual.) 26. Apply grease to thrust ring (8) to hold it in cover (6). 27. Install cover so plug holes are aligned with notches in ring gear. 28. Install the snap ring (5). 29. Install plugs and O-ring. Specification Plug and O-Ring-to-Cover— Torque ................................................................................... 46—51 N•m 34—38 lb-ft Level Check Plug and O-Ring-to-Cover—Torque ..................................................... 12—13 N•m 107—113 lb-in.

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TM2264 (15OCT08)

02-0250-14

Repair 101508

PN=80

Axle Shaft, Bearings, and Reduction Gears

Propel Gearbox Disassemble and Assemble—50D 1. See Propel Gearbox Remove and Install for gearbox and motor removal. (Group 0250.) See Propel Gearbox Operation for a cross-section of Propel Gearbox. (Group 9020-05.)

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02-0250-15

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Repair 101508

PN=81

02 0250 15

Axle Shaft, Bearings, and Reduction Gears

T156462

–UN–06SEP02

02 0250 16

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PN=82

Axle Shaft, Bearings, and Reduction Gears 1—Propel Gearbox 2—Metal Face Seal 3—Bearing 4—Bearing Nut (retainer) 5—Plug 6—Ring Gear (housing) 7—Steel Ball (132 used) 8—Pipe Plug (2 used)

9—Second Planet Gear (4 used) 10—Needle Bearing (4 used) 11—Bearing Race (4 used) 12—Thrust Washer (4 used) 13—Thrust Washer 14—Cap Screw 15—Second Planet Sun Gear

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Propel Gearbox and Motor— Weight ........................................................................................ 66 kg 145 lb

16—Snap Ring 17—First Planet Carrier 18—First Planet Gear (3 used) 19—Needle Bearing (3 used) 20—Bearing Race (3 used) 22—Input Shaft and First Planet Sun Gear 23—Thrust Washer

24—Cover 25—O-Ring 26—Wire (retainer) 27—Plug (3 used) 28—O-Ring 29—Propel Motor Housing and Second Planet Carrier

2. Remove plugs (27) and O-rings (28) to drain oil. Approximate capacity is 0.7 L (0.75 qt). 02 0250 17

3. Remove pipe plug (8) located on the side of ring gear at cover end.

MM61211,00008CD –19–15FEB05–3/10

4. Install fittings (30) into holes.

–UN–16JAN03

5. Turn cover (24) until the end of wire (26) is visible through hole. Continue turning the cover, pulling the wire out through the hole. 6. Remove cover and O-ring (25).

T163455

7. Remove thrust plate (23). 24—Cover 25—O-Ring 26—Wire (retainer) 30—Fitting (2 used)

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PN=83

Axle Shaft, Bearings, and Reduction Gears

CAUTION: Prevent possible injury from unexpected machine movement. Planet gears can turn. Keep fingers away from gears.

Remove parts for first planet carrier and gears (17— 20), second planet sun gear (15), and second planet gears (9—14). Keep parts for each planet gear together.

T6639GK

02 0250 18

–UN–19OCT88

8. Remove input shaft (22).

9. Remove the sprocket. 10. Remove pipe plug (8) located on the side of ring gear adjacent to the sprocket mounting flange. Remove the 132 steel balls (7) through the hole. 11. Push the housing (29) and bearing (3) out of ring gear using a shop press or three M12 x 1.75 cap screws installed in the sprocket mounting flange and tighten against the housing. To protect the housing, use steel plates between the end of cap screws and housing. 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. 12. Remove the metal face seals (2) from ring gear and housing. Keep seal rings together as a matched set with a piece of clean cardboard between them to protect the seal ring face. See Inspect Metal Face Seals to determine if seals can be reused. (Group 0130.) 13. Remove plugs (5). Remove bearing nut (4) using a spanner wrench or ST3150 Special Tool. 14. Remove bearing (3) from housing for replacement only. Bearing is a pressed fit.

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Repair 101508

PN=84

Axle Shaft, Bearings, and Reduction Gears NOTE: A new bearing should be installed if removed. 15. See Propel Motor Disassemble and Assemble—50D for motor disassembly. (Group 0260.) 16. See Propel Gearbox Operation for a cross-section of Propel Gearbox. (Group 9020-05.) See Propel Motor Disassemble and Assemble—50D for motor assembly. (Group 0260.)

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Repair 101508

PN=85

02 0250 19

Axle Shaft, Bearings, and Reduction Gears

T156462

–UN–06SEP02

02 0250 20

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PN=86

9—Second Planet Gear (4 used) 10—Needle Bearing (4 used) 11—Bearing Race (4 used) 12—Thrust Washer (4 used) 13—Thrust Washer 14—Cap Screw 15—Second Planet Sun Gear

16—Snap Ring 17—First Planet Carrier 18—First Planet Gear (3 used) 19—Needle Bearing (3 used) 20—Bearing Race (3 used) 21—Not Used 22—Input Shaft and First Planet Sun Gear

23—Thrust Washer 24—Cover 25—O-Ring 26—Wire (retainer) 27—Plug (3 used) 28—O-Ring 29—Propel Motor Housing and Second Planet Carrier

17. Install bearing (3) so the thicker edge of outer race is towards the threaded end of housing (29).

23. Wipe finger prints and foreign material off seal ring face using clean oil and lint-free tissues.

18. Tighten bearing nut (4) to specification using spanner wrench or ST3150 Special Tool.

24. Apply a thin film of clean oil on each seal ring face.

Specification Bearing-to-Housing Bearing Nut—Torque .................................................................. 186-206 N•m 136.8-151.2 lb-ft

25. Install ring gear onto bearing and housing. Tap around the top edge of ring gear using a soft-faced hammer to seat the ring gear on bearing.

19. Tighten plug (5) to specification. Specification Bearing Nut-to-Housing Plug— Torque.................................................................................. 14.7 N•m 132 lb-in.

IMPORTANT: The metal face seal O-rings and their seat surfaces must be clean, dry, and oil free so the O-rings do not slip. 20. Thoroughly clean O-rings, seat surfaces in housing (29), ring gear (6), and seal rings using volatile, non-petroleum base solvent and lint-free tissues. 21. Install O-rings on seal rings. Check that O-ring is not twisted. 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. 22. Apply equal pressure with fingers at four equally spaced points on seal ring face. Seal must “pop” down into place so O-ring is tight against seal bore and seal ring is installed squarely.

26. Install the 132 steel balls (7) through hole and into the groove in bearing and ring gear. 27. Apply TY9375 (high temperature) Thread Sealant to threads of pipe plug (8). Tighten plug to specification. Specification Pipe Plug-to-Ring Gear— Torque.................................................................................... 7.9 N•m 70 lb-in.

28. Install thrust plates (12), races (11), needle bearings (10), and second planet gears (9) onto pins. 29. Install thrust washer (13). Apply TY24311 Thread Lock and Sealer (low strength) to threads of cap screw (14). Tighten cap screws to specifications. Specification Thrust Washer-to-Housing Cap Screw—Torque ...................................................................... 6.1 N•m 54 lb-in.

30. Install snap ring (16) on second planet sun gear (15). Install sun gear.

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TM2264 (15OCT08)

02 0250 21

02-0250-21

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Repair 101508

PN=87

Axle Shaft, Bearings, and Reduction Gears 31. Install races (20) and needle bearings (19).

34. Install thrust plate (23).

32. Install first planet gears (18) so the flat side is against machined surface of first planet carrier (17).

35. Install O-ring (25) on cover (24). Apply grease to O-ring.

33. Install input shaft (22).

02 0250 22

MM61211,00008CD –19–15FEB05–9/10

36. Install cover. Install fittings (30). 37. Bend end of wire (26) to 90° approximately 6 mm (0.24 in.) from end. –UN–16JAN03

38. Push wire through hole and into groove in cover and ring gear.

T163455

39. Turn cover to pull remaining wire into the groove. 40. Apply TY9375 (high temperature) Thread Sealant to threads of pipe plug (8). Tighten plug to specification. Specification Pipe Plug-to-Ring Gear—Torque ................................................. 7.9 N•m 70 lb-in.

24—Cover 25—O-Ring 26—Wire (retainer) 30—Fitting (2 used)

41. Remove fittings. 42. Add approximately 0.7 L (0.75 qt) of gear oil to gearbox. See Propel Gearbox Oil for specification. (Operator’s Manual.) See Check Propel Gearbox Oil Level after plugs and O-rings (27 and 28) are installed. (Operator’s Manual.) 43. Tighten plugs to specification. Specification Plug to Cover—Torque ................................................................. 34 N•m 25 lb-ft

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TM2264 (15OCT08)

02-0250-22

Repair 101508

PN=88

Group 0260

Hydraulic System Propel Motor Disassemble and Assemble— 35D CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Propel Gearbox and Motor— Weight................................................................................................ 44 kg 97 lb

02 0260 1

1. See Propel Gearbox Remove and Install for gearbox and motor removal. (Group 0250.) See Propel Gearbox Disassemble and Assemble—35D for gearbox disassembly. (Group 0250.) See Propel Motor and Brake Valve Housing Operation for a cross-section of Propel Motor and Brake Valve Housing. (Group 9025-05.)

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TM2264 (15OCT08)

02-0260-1

MM61211,00008CE –19–15FEB05–1/9

Repair 101508

PN=89

Hydraulic System

T163627

–UN–21FEB03

02 0260 2

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TM2264 (15OCT08)

02-0260-2

MM61211,00008CE –19–15FEB05–2/9

Repair 101508

PN=90

Hydraulic System 1—Housing Kit 2—Propel Motor Housing and Second Planet Carrier 3—Control Piston 4—Oil Seal 5—Ball Bearing 6—Drive Shaft 7—Pivot Ball (2 used) 8—Swash Plate 9—Rotary Group Kit

10—Piston and Shoe (9 used) 11—Retainer (holder) 12—Ball Guide (holder) 13—Pin (3 used) 14—Cylinder Block 15—Retainer (2 used) 16—Spring 17—Snap Ring 18—Valve Plate

19—Spacer 20—Plate (2 used) 21—Disk 22—Backup Ring 23—O-Ring 24—Park Brake Piston 25—O-Ring 26—Backup Ring 27—O-Ring

28—Brake Valve Housing Kit 29—Ball Bearing 30—Spring Pin 31—Brake Valve Housing 32—Dowel Pin 33—O-Ring (2 used) 34—Park Brake Spring (8 used) 35—Cap Screw (7 used)

5. Remove ball bearing (29) from brake valve housing only if replacement is necessary. Bearing is a pressed fit. If removed, install new bearings.

CAUTION: Brake valve housing contains springs under load. Prevent injury from sudden release by loosen cap screws evenly.

6. Remove park brake piston (24).

2. Loosen cap screws (35) evenly to release force of park brake springs (34). 3. Before removing the brake valve housing (31), measure and record the distance between it and motor housings as a reference for assembly. IMPORTANT: Valve plate can stick to the brake valve housing. Dropping the valve plate can damage the highly machined surfaces. Use care when removing the brake valve housing. 4. Remove brake valve housing being careful not to drop the valve plate (18).

7. Hold the housing in a horizontal position and then slid the rotary group (10—17) out of housing and off the drive shaft. CAUTION: Cylinder block contains a springs under load. Prevent injury from sudden release by using a press to compress the spring before removing snap ring. 8. Disassemble rotary group for inspection and cleaning only. Rotary group is serviced as an assembly. Compress spring (16) using a press before removing the snap ring (21).

Protect machined surfaces of valve plate from damage.

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02-0260-3

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Repair 101508

PN=91

02 0260 3

Hydraulic System 9. Check the clearance between piston and shoe. Specification Piston-to-Shoe—Clearance ............................................................ 0.4 mm 0.0157 in.

–UN–03FEB03

T164706

Specification Piston-to-Cylinder Block Bore— Clearance ....................................................................................... 0.4 mm 0.0157 in.

T164714

02 0260 4

–UN–03FEB03

10. Substract piston diameter from cylinder block bore diameter to check for wear.

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TM2264 (15OCT08)

02-0260-4

MM61211,00008CE –19–15FEB05–4/9

Repair 101508

PN=92

Hydraulic System

T163669

–UN–21FEB03

02 0260 5

Brake Valve Housing Exploded View—35D 31—Brake Valve Housing 38—Plug (2 used) 39—O-Ring (2 used) 40—Spring (2 used) 41—Washer (2 used) 42—Guide (2 used)

43—O-Ring (2 used) 44—Spring (2 used) 45—Check Valve (2 used) 46—Counterbalance Valve Spool

11. Brake valve housing (31) is serviced as an assembly except the O-rings (39, 43, 48, and 52) and springs (8 and 9). Disassemble for inspection and cleaning only. 12. Apply clean hydraulic oil to all machined surfaces after cleaning.

47—Plug (2 used) 48—O-Ring (2 used) 49—Spring 50—Propel Speed Change Valve Spool

13. See Propel Motor and Brake Valve Housing Operation for a cross-section of Propel Motor and Brake Valve Housing. (Group 9025-05.) See Propel Gearbox Disassemble and Assemble—35D for gearbox assembly. (Group 0250.)

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TM2264 (15OCT08)

51—Plug (2 used) 52—O-Ring (2 used) 53—Shuttle Valve Spool 54—Counterbalance Valve Orifice (4 used)

02-0260-5

MM61211,00008CE –19–15FEB05–5/9

Repair 101508

PN=93

Hydraulic System

T163669

–UN–21FEB03

02 0260 6

Brake Valve Housing Exploded View—35D 31—Brake Valve Housing 38—Plug (2 used) 39—O-Ring (2 used) 40—Spring (2 used) 41—Washer (2 used) 42—Guide (2 used)

43—O-Ring (2 used) 44—Spring (2 used) 45—Check Valve (2 used) 46—Counterbalance Valve Spool

47—Plug (2 used) 48—O-Ring (2 used) 49—Spring 50—Propel Speed Change Valve Spool

51—Plug (2 used) 52—O-Ring (2 used) 53—Shuttle Valve Spool 54—Counterbalance Valve Orifice (4 used)

14. Apply clean hydraulic oil to all parts before installing. 15. Tighten plugs (38, 47, and 51) to specification. Specification Shuttle Valve-to-Housing Plug—Torque .............................................................. 11.8—21.5 N•m 104—190 lb-in.

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Repair 101508

PN=94

Hydraulic System

02 0260 7

TM2264 (15OCT08)

02-0260-7

Repair 101508

PN=95

Hydraulic System

T163627

–UN–21FEB03

02 0260 8

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02-0260-8

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Repair 101508

PN=96

10—Piston and Shoe (9 used) 11—Retainer (holder) 12—Ball Guide (holder) 13—Pin (3 used) 14—Cylinder Block 15—Retainer (2 used) 16—Spring 17—Snap Ring 18—Valve Plate

19—Spacer 20—Plate (2 used) 21—Disk 22—Backup Ring 23—O-Ring 24—Park Brake Piston 25—O-Ring 26—Backup Ring 27—O-Ring

28—Brake Valve Housing Kit 29—Ball Bearing 30—Spring Pin 31—Brake Valve Housing 32—Dowel Pin 33—O-Ring (2 used) 34—Park Brake Spring (8 used) 35—Cap Screw (7 used)

16. Apply petroleum jelly to lip of oil seal. Install oil seal (4) so the sealing lip (spring side) is toward ball bearing (5). Push to the bottom of bore.

24. Install O-rings (23 and 25) and backup rings (22 and 26) into grooves of park brake piston (24) making sure the backup rings are to outer edges.

17. Apply clean hydraulic oil to components before installing.

25. Push park brake piston into housing against the plate.

As needed, apply petroleum jelly to help hold components in place.

26. Add approximately 0.2 L (0.2 qt) of hydraulic oil to housing.

18. Install a new ball bearing tight against shoulder on drive shaft (6).

27. Push the new ball bearing (29) to bottom of bore in brake valve housing (31).

Install shaft into housing so bearing is to the bottom of bore.

28. Install valve plate (18), springs (34), and O-rings (27 and 33) to brake valve housing. Use petroleum jelly to hold parts in place while installing brake valve housing.

19. Install control piston (3) so large diameter end is to the bottom of piston bore. 20. Install swash plate (8) making sure the pivot balls (7) are seated in the holes in housing and swash plate. 21. Assemble the rotary group (10—17). 22. Hold the propel motor housing (2) in a horizontal position. Carefully install the rotary group aligning the splines in ball guide (12) and cylinder block (14) with the splines on drive shaft. NOTE: The valve plate (18) is installed on the brake valve housing. 23. Install spacer (19).

29. Install brake valve housing (2) being careful that the valve plate does not drop off. 30. Measure the distance between the two housings and compare to measurement made at disassembly. If not the same, disassemble and check for correct assembly. 31. Tighten cap screws (35) in steps to pull housing down evenly against the springs. Tighten cap screws to specification in a diagonal pattern. Specification Brake Valve Housing-to-Housing Cap Screw—Torque ................................................................. 51—65 N•m 38—48 lb-ft

Starting with a plate (20), alternately install two plates and one disk (21).

Continued on next page

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Repair 101508

PN=97

02 0260 9

Hydraulic System 32. See Propel Gearbox Remove and Install for gearbox and motor installation. (Group 0250.)

MM61211,00008CE –19–15FEB05–9/9

Propel Motor Disassemble and Assemble— 50D 02 0260 10

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Propel Gearbox and Motor— Weight............................................................................................... 66 kg 145 lb

1. See Propel Gearbox Remove and Install for gearbox and motor removal. (Group 0250.) See Propel Gearbox Disassemble and Assemble—50D for gearbox disassembly. (Group 0250.) See Propel Motor and Brake Valve Housing Operation for a cross-section of Propel Motor and Brake Valve Housing. (Group 9025-05.)

Continued on next page

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MM61211,00008CF –19–15FEB05–1/10

Repair 101508

PN=98

Hydraulic System

69 70

02 0260 11

T163830

–UN–17JAN03

T163830 Propel Motor Flow Control Valve—50D 43—Plug (2 used) 44—O-Ring (2 used)

69—Spring (2 used) 70—Spring Seat (2 used)

71—Flow Control Valve Spool 72—Housing

73—Cap Screw (3 used) 74—O-Ring (3 used)

2. Check the flow control valve spool (71) moves freely in housing bore. Continued on next page

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02-0260-11

MM61211,00008CF –19–15FEB05–2/10

Repair 101508

PN=99

Hydraulic System

T156461

–UN–06SEP02

02 0260 12

Propel Motor and Park Brake Exploded View—50D

Continued on next page

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Repair 101508

PN=100

Hydraulic System 0—Propel Motor and Brake Valve Housing 2—Drive Shaft 3—Ball Bearing 4—Oil Seal 5—Swash Plate 6—Pivot Ball (2 used) 7—Cylinder Block 8—Washer 9—Spring 10—Washer 11—Snap Ring 12—Pin (3 used) 13—Ball Guide (holder) 14—Retainer (plate) 15—Piston and Shoe (9 used) 16—Park Brake Disk

17—Park Brake Piston 18—Park Brake Spring (8 used) 19—Control Piston (2 used) 20—Spring (2 used) 21—O-Ring 23—O-Ring 25—Valve Plate 26—Dowel Pin 27—Ball Bearing 28—O-Ring 29—Packing (4 used) 30—Brake Valve Housing 31—Counterbalance Valve 31A—Counterbalance Valve Spool

CAUTION: Brake valve housing contains springs under load. Prevent injury from sudden release by loosing cap screws evenly. 3. Loosen cap screws (48) evenly to release force of park brake springs (18). 4. Before removing the brake valve housing (30), measure and record the distance between it and motor housings as a reference for assembly.

31B—Check Valve (2 used) 31C—Spring (2 used) 31D—Plug (2 used) 31E—O-Ring (2 used) 36—Spring Seat (2 used) 37—Spring (2 used) 38—Plug (2 used) 39—O-Ring (2 used) 40—Orifice (4 used) 41—Propel Speed Change Valve Spool 42—Spring 43—Pipe Plug 44—O-Ring (2 used) 45—Pipe Plug (3 used) 46—Dowel Pin (2 used)

47—Orifice (4 used) 48—Cap Screw (6 used) 49—Dowel Pin (2 used) 53—Plug (2 used) 55—Plug (2 used) 56—Packing (2 used) 58—Plug (2 used) 59—Plug (2 used) 60—O-Ring (2 used) 61—Plug 62—Adapter 63—Cap 64—Orifice (2 used) 65—Seal Kit 66—Brake Valve Housing Kit 67—Cylinder Block Kit

02 0260 13

plate can damage the highly machined surfaces. Use care when removing the brake valve housing. 5. Remove brake valve housing being careful not to drop the valve plate (14). Protect machined surfaces of valve plate from damage. 6. Remove ball bearings (3 and 27) from drive shaft (2) and brake valve housing only if replacement is necessary. Bearings are a pressed fit. New bearings should be installed if removed.

IMPORTANT: Valve plate can stick to the brake valve housing. Dropping the valve

Continued on next page

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Repair 101508

PN=101

Hydraulic System 7. Before removing park brake piston (17), take notice of its position with respect to motor housing. Piston must be installed so dowel pin holes and springs align with dowel pins and holes in brake valve housing.

T163857

02 0260 14

–UN–16JAN03

8. Hold the housing in a horizontal position, then slide the rotary group (7—15) out of housing and off the drive shaft. CAUTION: Cylinder block contains a spring under load. Prevent injury from sudden release by using a press to compress the spring before removing snap ring.

17—Park Brake Piston 28—O-Ring 29—Oil Passage 68—Park Brake Oil Passage

9. Disassemble rotary group for inspection and cleaning only. Rotary group is serviced as an assembly. Compress spring (9) using a press before removing the snap ring (11).

Continued on next page

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Repair 101508

PN=102

Hydraulic System 10. Check the clearance between piston and shoe. Specification Piston to Shoe—Clearance ............................................................ 0.4 mm 0.0157 in. –UN–03FEB03

11. Substract piston diameter from cylinder block bore diameter to check for wear.

T164706

Specification Piston to Cylinder Block Bore— Clearance ....................................................................................... 0.4 mm 0.0157 in.

12. Check that spools (31, 41, and 71) move freely in their bores.

–UN–03FEB03

13. Disassemble counterbalance valve (31) for cleaning and inspection only. Valve is serviced as an assembly except for the O-rings (31E) and plugs (31D).

T164714

14. Apply clean hydraulic oil to all machined surfaces after cleaning. 15. See Propel Gearbox Disassemble and Assemble— 50D for gearbox assembly. (Group 0250.) See Propel Motor and Brake Valve Housing Operation for a cross-section of Propel Motor and Brake Valve Housing. (Group 9025-05.)

Continued on next page

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Repair 101508

PN=103

02 0260 15

Hydraulic System

T156461

–UN–06SEP02

02 0260 16

Continued on next page

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Repair 101508

PN=104

16. Install new O-rings (21, 23, 39, 44, and 60) and packing (29 and 56) as needed. 17. Apply clean hydraulic oil to all parts before installing.

31B—Check Valve (2 used) 31C—Spring (2 used) 31D—Plug (2 used) 31E—O-Ring (2 used) 36—Spring Seat (2 used) 37—Spring (2 used) 38—Plug (2 used) 39—O-Ring (2 used) 40—Orifice (4 used) 41—Propel Speed Change Valve Spool 42—Spring 43—Plug 44—O-Ring (2 used) 45—Pipe Plug (3 used) 46—Dowel Pin (2 used)

02 0260 17

22. Install swash plate (5) making sure the pivot balls (6) are seated in the holes in housing and swash plate. 23. Install park brake disk (16).

18. Tighten plugs (38 and 43) and adapter (62) to specification. Specification Counterbalance Valve-to-Housing Plug—Torque ............................................ 240 N•m 177 lb-ft Propel Speed Change Valve-to-Housing Plug—Torque .............................................. 54 N•m 40 lb-ft Propel Speed Change Valve-to-Housing Adapter— Torque...................................................................................... 54 N•m 40 lb-ft

19. Install oil seal (4) to the bottom of bore with the sealing lip (spring side) toward ball bearing (3). Apply petroleum jelly to lip of oil seal. 20. Install a new ball bearing (3) tight against shoulder on drive shaft (2). Install shaft into housing so bearing is to the bottom of bore.

24. Assemble the rotary group (7—15). 25. Hold the propel motor housing in a horizontal position. Carefully install the rotary group aligning the splines for ball guide (13) and cylinder block (7) with the spline on drive shaft and park brake disk. NOTE: The valve plate (25) is installed on the brake valve housing. 26. Install park brake piston (17) to position noted at disassembly. Dowel pin holes and springs (18) in brake piston must align with dowel pins and holes in brake valve housing. 27. Add approximately 0.2 L (0.2 qt) of hydraulic oil to housing. 28. Push the new ball bearing (27) to bottom of bore in brake valve housing.

21. Install springs (20) into the control pistons (19) and then into propel motor housing so spring is to the bottom of piston bore.

Continued on next page

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Repair 101508

PN=105

Hydraulic System 29. Install valve plate (25) so notch engages dowel pin (26). Use petroleum jelly to help hold valve plate in place while installing brake valve housing.

02 0260 18

disassembly. If not the same, disassemble and check for correct assembly.

30. Install brake valve housing (30) being careful that the valve plate does not drop off.

33. Tighten cap screws (48) in steps to pull housing down evenly against the spring force. Tighten cap screws to specification in a diagonal pattern.

31. Check that dowel pin holes and springs in brake piston are aligned with dowel pins and holes in brake valve housing.

Specification Brake Valve Housing-to-Motor Housing Cap Screw—Torque .................................................. 64 N•m 47 lb-ft

32. Measure the distance between the two housings and compare to measurement made at

Continued on next page

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Hydraulic System

69 70

02 0260 19

T163830

–UN–17JAN03

T163830 Propel Motor Flow Control Valve—50D 43—Plug (2 used) 44—O-Ring (2 used)

69—Spring (2 used) 70—Spring Seat (2 used)

71—Flow Control Valve Spool 72—Housing

34. Tighten plugs (43) and cap screws (73) to specification. Specification Flow Control Valve-to-Housing Plug—Torque ........................................................................... 54 N•m 40 lb-ft

73—Cap Screw (3 used) 74—O-Ring (3 used)

Flow Control Valve Housing-to-Brake Valve Housing Cap Screw—Torque .................................................. 37 N•m 27 lb-ft

35. See Propel Gearbox Remove and Install for gearbox and motor installation. (Group 0250.)

MM61211,00008CF –19–15FEB05–10/10

TM2264 (15OCT08)

02-0260-19

Repair 101508

PN=107

Hydraulic System

Rotary Manifold Disassemble and Assemble 1. Take notice of the position of ports in spindle and flange (13) with respect to the boss on side of body (6) to aid assembly. 2. Secure rotary manifold in upright position. 3. Remove socket head cap screws (1) and remove cover (2). 4. Remove retaining ring (4) and thrust washer (5).

–UN–01MAR05

1—Socket Head Cap Screw (4 used) 2—Cover 3—O-Ring 4—Retaining Ring 5—Thrust Washer (ring) 6—Body 7—Plug Assembly (5 used) 8—Plug Assembly (1 used) 9—Oil Seal (7 used) 10—O-Ring 11—Backup Ring 12—Dust Seal 13—Spindle and Flange 14—Plug (3 used) 15—Plug (4 used) 16—Puller Tool

T208758

02 0260 20

Continued on next page

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Repair 101508

PN=108

Hydraulic System 5. Remove spindle and flange (13) from body (6) using a puller tool (16). 6. Remove and replace parts (9—12) as necessary.

–UN–01MAR05

7. Apply petroleum jelly or hydraulic oil to seals (9) before installing into grooves. Check that seals are seated in the groove.

T208757

8. Install O-ring (10) into groove of the body so it is toward the seals and backup ring (11) is toward the dust seal end of body. 9. Install dust seal (12) so lip is toward the bottom end of body. Apply petroleum jelly to seal lip. 10. Put the spindle (13) on a workbench in a vertical position. IMPORTANT: Seals can be damaged by pushing the body onto the spindle too rapidly. Push body onto the spindle slowly. 11. Install body (6) on the spindle (13) so the boss on the side of the body is aligned with the spindle ports as noted at disassembly. Slowly push body (6) down onto the spindle (13) by tapping on end of body using a soft-face hammer. 12. Install the thrust washer (5).

T208756

–UN–01MAR05

Continued on next page

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Repair 101508

PN=109

02 0260 21

Hydraulic System 13. Install retaining ring (4) with the flat side toward the thrust washer (5) and the chamfered side toward the cover (2). Check that retaining ring (4) is seated in the groove. 14. Install oil ring (3) and cover (2). Tighten socket head cap screws to specification.

02 0260 22

Specification Cover-to-Housing Cap Screw— Torque ............................................................................................ 20 N•m 177 lb-in.

MM61211,00008D1 –19–15FEB05–3/3

TM2264 (15OCT08)

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Repair 101508

PN=110

Section 04

Engine Contents Page

Page

Group 0400—Removal and Installation Engine Remove and Install—35D . . . . . . . . .04-0400-1 Engine Remove and Install—50D . . . . . . . . .04-0400-6 Exhaust Manifold Remove and Install— 35D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-11 Muffler Remove and Install—35D . . . . . . . .04-0400-12 Exhaust Manifold Remove and Install— 50D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-13 Muffler Remove and Install—50D . . . . . . . .04-0400-15 Thermostat Remove and Install. . . . . . . . . .04-0400-16 Water Pump Remove and Install. . . . . . . . .04-0400-17 Intake Manifold Remove and Install. . . . . . .04-0400-19 Fuel Injection Pump Remove and Install . . .04-0400-20 Fuel Injection Nozzles Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-29 Fuel Injection Nozzles Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .04-0400-32 Rocker Arm Cover Remove and Install . . . .04-0400-35 Rocker Arm Shaft Assembly Repair . . . . . .04-0400-36 Cylinder Head Remove and Install . . . . . . .04-0400-39 Cylinder Head and Valves Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .04-0400-45 Piston and Connecting Rod Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-53 Preliminary Piston and Rod Checks . . . . . .04-0400-60 Piston and Connecting Rod Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .04-0400-61 Cylinder Block Repair . . . . . . . . . . . . . . . . .04-0400-72 Check Engine Rotation for Excessive Tightness . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-77 Crankshaft and Main Bearing Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-78 Replace Crankshaft Front Oil Seal . . . . . . .04-0400-78 Measure Crankshaft End Play. . . . . . . . . . .04-0400-79 Flywheel Remove and Install. . . . . . . . . . . .04-0400-80 Crankshaft Rear Oil Seal Replace. . . . . . . .04-0400-80 Crankcase Extension Housing Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .04-0400-81 Flywheel Housing Remove and Install. . . . .04-0400-82 Crankshaft and Main Bearings Repair . . . . .04-0400-82 Measure Valve Lift . . . . . . . . . . . . . . . . . . .04-0400-91 Timing Gear Cover Remove and Install. . . .04-0400-92 Camshaft End Play Check . . . . . . . . . . . . .04-0400-93 Timing Gear Backlash Check . . . . . . . . . . .04-0400-94 Camshaft Remove and Install . . . . . . . . . . .04-0400-95 Idler Gear Remove and Install. . . . . . . . . . 04-0400-102

Timing Gear Cover Mounting Plate Remove and Install . . . . . . . . . . . . . . . . . . . . . . . 04-0400-104 Oil Pan and Strainer Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . 04-0400-105 Oil Pump Remove and Install . . . . . . . . . . 04-0400-106 Oil Pump Disassemble, Inspect, and Assemble. . . . . . . . . . . . . . . . . . . . . . . . 04-0400-107 Oil Pressure Regulating Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . 04-0400-109 Oil Filter Adapter Remove and Install . . . . 04-0400-110

TM2264 (15OCT08)

04-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

04-2

Repair 101508

PN=2

Group 0400

Removal and Installation Engine Remove and Install—35D 1. Disconnect negative battery cable.

–UN–23AUG88

2. Remove counterweight. See Counterweight Remove and Install—35D. (Group 1749.)

TS281

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to first stop to relieve pressure, then remove. 3. Drain coolant. Approximate capacity is 3.75 L (4.0 qt).

04 0400 1

4. Drain hydraulic oil. See Changing Hydraulic Tank Oil and Cleaning Suction Screen. (Operator’s Manual.)

Continued on next page

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Removal and Installation 5. Remove two cap screws (1) holding air cleaner housing. NOTE: Note any shims that may accompany frame brackets for installation. 6. Remove frame brackets (2-4) and frame cover (5). –UN–14JAN05

7. Remove right-side frame bracket (7). 8. Remove air cleaner assembly.

10. Remove radiator. See Radiator Remove and Install— 35D. (Group 0510.) 11. Remove fan belt and fan. 12. Disconnect the inlet (10) and return (11) fuel lines. 13. Disconnect speed control cable (12) from engine.

–UN–14JAN05

14. Disconnect ground strap (13). 1—Cap Screw (2 used) 2—Left-Side Frame Bracket 3—Left-Rear Frame Bracket 4—Right-Rear Frame Bracket 5—Frame Cover 6—Frame Cover 7—Right-Side Frame Bracket 8—Fan Guard 9—Coolant Hoses 10—Inlet Fuel Line 11—Return Fuel Line 12—Speed Control Cable 13—Ground Strap

T207063A

04 0400 2

T207062A

9. Remove coolant fan guard (8) and coolant hoses (9).

Continued on next page

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Repair 101508

PN=114

Removal and Installation 15. Disconnect hydraulic pump hose (14) and inlet flange (15). 16. Remove two cap screws (16) and pull hydraulic pump (17) away from engine until drive coupler is disengaged from flywheel and housing.

–UN–14JAN05

17. Disconnect wire harnesses from alternator (18) and starter motor (19). 18. Remove starter motor.

T207064A

19. Remove two cap screws (20) and fasteners under starter motor securing wiring harness to engine block. 20. Disconnect wiring harnesses from fuel shut-off solenoid, switches, and sensors. Attach identification tags to wiring to aid installation. See Engine Harness (W10) Component Location. (Group 9015.)

04 0400 3

–UN–17JAN05

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T207070A

Specification Engine—Weight ............................................................................... 199 kg 440 lb

IMPORTANT: The recommended method for lifting the engine is using the JDG23 Lifting Sling. The lifting force must be at 90° to the lifting points. 21. Attach engine to a hoist using the JDG23 Lifting Sling (21). 22. Remove engine mount cap screws and washers (22).

T207122A

–UN–17JAN05

14—Hydraulic Pump Hose 15—Inlet Flange 16—Cap Screw (2 used) 17—Hydraulic Pump 18—Wire Harness-to-Alternator 19—Wire Harness-to-Starter Motor 20—Wire Harness Cap Screw (2 used) 21—JDG23 Lifting Sling 22—Engine Mount Cap Screw and Washer (4 used)

Continued on next page

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Repair 101508

PN=115

Removal and Installation 23. Repair or replace parts as necessary. 24. Install engine using JDG23 Lifting Sling (21). 25. Install four engine mounts and cap screws (22). Tighten to specifications. Specification Engine Mount-to-Isolator Cap Screw—Torque ............................................................................... 88 N•m 65 lb-ft

26. Align hydraulic pump splines to engine coupler. Tighten to specifications.

04 0400 4

Specification Hydraulic Pump-to-Flywheel Housing Cover Cap Screws— Torque ............................................................................................ 88 N•m 65 lb-ft

27. Connect inlet flange and hydraulic hose to pump. Tighten to specifications. Specification Inlet Flange-to-Hydraulic Pump— Torque ............................................................................................ 48 N•m 36 lb-ft

28. Fill hydraulic system. 29. Bleed hydraulic system. See Bleed Hydraulic System. (Operator’s Manual.) NOTE: Before installing starter motor, install two cap screws and fasteners under starter, securing wiring harness to engine block. 30. Install starter motor. 31. Connect engine wire harness. See Engine Harness (W10) Component Location. (Group 9015.) 32. Connect speed control cable to engine. 33. Install ground strap to frame. 34. Install fan and fan belt.

Continued on next page

TM2264 (15OCT08)

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Repair 101508

PN=116

Removal and Installation 35. Adjust fan belt tension. See Inspect Fan Belt, Check and Adjust Tension. (Operator’s Manual.) 36. Install radiator. See Radiator Remove and Install— 35D. (Group 0510.) 37. Fill radiator and reservoir with coolant. See Cooling System Fill and Deaeration. (Operator’s Manual.) 38. Install air cleaner assembly. NOTE: Make note of any shims that were removed in the disassembly process, and place in same location of removal. 39. Attach frame brackets to frame.

04 0400 5

40. Attach two cap screws from the upper frame bracket-to-air cleaner. 41. Bleed fuel system. See Bleed Fuel System. (Group 0560.) 42. Install counterweight. See Counterweight Remove and Install—35D. (Group 1749.) 43. Connect the negative battery cable.

MM61211,000087F –19–09FEB05–5/5

TM2264 (15OCT08)

04-0400-5

Repair 101508

PN=117

Removal and Installation

Engine Remove and Install—50D 1. Disconnect negative battery cable.

–UN–23AUG88

2. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 3. Remove counterweight. See Counterweight Remove and Install—50D. (Group 1749.)

TS281

4. Remove air cleaner assembly (1). 5. Remove tail pipe clamp (2). 6. Remove top frame bracket (3). 7. Safely support rear of cab using rear lift bracket (4).

–UN–08FEB05

T207930A

–UN–08FEB05

1—Air Cleaner Assembly 2—Tail Pipe Clamp 3—Top Frame Bracket 4—Rear Lift Bracket

T207931A

04 0400 6

Continued on next page

TM2264 (15OCT08)

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MM61211,0000880 –19–09FEB05–1/5

Repair 101508

PN=118

Removal and Installation 8. Remove tilt unit (5) and tilt unit bracket (6). 9. Remove both frame brackets (7).

–UN–08FEB05

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

T207929A

Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to first stop to relieve pressure, then remove. 10. Drain coolant. Approximate capacity is 5.2 L (5.5 qt). 11. Drain hydraulic oil. See Changing Hydraulic Tank Oil and Cleaning Suction Screen. (Operator’s Manual.)

04 0400 7

12. Remove coolant fan guard (8) and radiator hoses (9). 13. Remove radiator. See Radiator Remove and Install— 50D. (Group 0510.)

–UN–08FEB05

14. Remove fan belt and fan.

T207965A

5—Tilt Unit 6—Tilt Unit Bracket 7—Frame Bracket (2 used) 8—Fan Guard 9—Radiator Hoses

Continued on next page

TM2264 (15OCT08)

04-0400-7

MM61211,0000880 –19–09FEB05–2/5

Repair 101508

PN=119

Removal and Installation 15. Disconnect the inlet (10) and return (11) fuel lines. 16. Disconnect speed control cable (12) from engine. 17. Disconnect ground strap (13).

–UN–08FEB05

18. Disconnect hydraulic pump hose (14) and inlet flange (15).

T207963A

19. Remove two cap screws (16) and pull hydraulic pump (17) away from engine until drive coupler is disengaged from flywheel and housing. 20. Disconnect wire harnesses from alternator (18) and starter motor (19). 21. Remove starter motor. 22. Remove two cap screws (20) and fasteners under starter motor securing wiring harness to engine block.

–UN–08FEB05

23. Disconnect wiring harnesses from fuel shut-off solenoid, switches, and sensors. Attach identification tags to wiring to aid installation. See Engine Harness (W10) Component Location. (Group 9015.)

–UN–17JAN05

T207966A

10—Inlet Fuel Line 11—Return Fuel Line 12—Speed Control Cable 13—Ground Strap 14—Hydraulic Pump Hose 15—Inlet Flange 16—Cap Screw (2 used) 17—Hydraulic Pump 18—Wire Harness-to-Alternator 19—Wire Harness-to Starter Motor 20—Wire Harness Cap Screw (2 used)

T207070A

04 0400 8

Continued on next page

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04-0400-8

MM61211,0000880 –19–09FEB05–3/5

Repair 101508

PN=120

Removal and Installation

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Engine—Weight ............................................................................... 199 kg 440 lb

T207122A

–UN–17JAN05

IMPORTANT: The recommended method for lifting the engine is using the JDG23 Lifting Sling. The lifting force must be at 90° to the lifting points. 24. Attach engine to a hoist using the JDG23 Lifting Sling (21).

04 0400 9

21—JDG23 Lifting Sling 22—Engine Mount Cap Screw and Washer (4 used)

25. Remove engine mount cap screws and washers (22). 26. Repair or replace parts as necessary. 27. Install engine using JDG23 Lifting Sling (21). 28. Install four engine mounts and cap screws (22). Tighten to specifications. Specification Engine Mount-to-Isolator Cap Screw—Torque ............................................................................... 88 N•m 65 lb-ft

29. Align hydraulic pump splines to engine coupler. Tighten to specifications. Specification Hydraulic Pump-to-Flywheel Housing Cover Cap Screws— Torque ............................................................................................ 88 N•m 65 lb-ft

30. Connect inlet flange and hydraulic hose to pump. Tighten to specifications. Specification Inlet Flange-to-Hydraulic Pump— Torque ............................................................................................ 48 N•m 36 lb-ft

31. Fill hydraulic system.

Continued on next page

TM2264 (15OCT08)

04-0400-9

MM61211,0000880 –19–09FEB05–4/5

Repair 101508

PN=121

Removal and Installation 32. Bleed hydraulic system. See Bleed Hydraulic System. (Operator’s Manual.) NOTE: Before installing starter motor, install two cap screws and fasteners under starter, securing wiring harness to engine block. 33. Install starter motor. 34. Connect engine wire harness. See Engine Harness (W10) Component Location. (Group 9015.) 35. Connect speed control cable to engine. 36. Install ground strap to frame. 04 0400 10

37. Install fan and fan belt. 38. Adjust fan belt tension. See Inspect Fan Belt, Check and Adjust Tension. (Operator’s Manual.) 39. Install radiator. See Radiator Remove and Install— 50D. (Group 0510.) 40. Fill radiator and reservoir with coolant. See Cooling System Fill and Deaeration. (Operator’s Manual.) 41. Install air cleaner assembly. NOTE: Make note of any shims that were removed in the disassembly process, and place in same location of removal. 42. Attach frame brackets to frame. 43. Attach two cap screws from the upper frame bracket to air cleaner. 44. Bleed fuel system. See Bleed Fuel System. (Group 0560.) 45. Install counterweight. See Counterweight Remove and Install—50D. (Group 1749.) 46. Connect the negative battery cable.

MM61211,0000880 –19–09FEB05–5/5

TM2264 (15OCT08)

04-0400-10

Repair 101508

PN=122

Removal and Installation

Exhaust Manifold Remove and Install—35D 1. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

3. Remove four muffler-to-manifold nuts (3) and washers. 4. Loosen muffler bracket cap screw (4).

T207342A

5. Remove four exhaust manifold cap screws (5).

–UN–21JAN05

2. Remove cap screws (1 and 2) and washers. Remove both heat shields.

6. Remove two exhaust manifold nuts (6).

04 0400 11

7. Clean all gasket material from exhaust manifold (7) and cylinder head mating surfaces (8). 8. Install muffler gasket (9) and exhaust manifold gasket (10).

T207343A

Specification Exhaust Manifold-to-Cylinder Head Cap Screw and Nut— Torque ........................................................................................... 26 N•m 19 lb-ft

–UN–21JAN05

9. Install exhaust manifold cap screws and nuts. Tighten to specifications.

10. Install muffler-to-exhaust manifold nuts and muffler bracket cap screw.

T207362A

1—Muffler Heat Shield Cap Screw (3 used) 2—Exhaust Manifold Heat Shield Cap Screw (3 used) 3—Muffler-to-Exhaust Manifold Nut (4 used) 4—Muffler Bracket Cap Screw (1 used) 5—Exhaust Manifold Cap Screw (4 used) 6—Exhaust Manifold Nut (2 used) 7—Exhaust Manifold 8—Cylinder Head Mating Surface 9—Muffler Gasket 10—Exhaust Manifold Gasket

–UN–24JAN05

11. Install exhaust manifold heat shield and muffler heat shield.

MM61211,0000881 –19–09FEB05–1/1

TM2264 (15OCT08)

04-0400-11

Repair 101508

PN=123

Removal and Installation

Muffler Remove and Install—35D 1. Park machine on level surface. 2. Remove counterweight. See Counterweight Remove and Install—35D. (Group 1749.)

–UN–24JAN05

3. Remove left-side frame bracket (1). 4. Remove exhaust pipe clamp (2).

6. Remove four muffler-to-exhaust manifold nuts (5) and washers. 7. Remove muffler bracket cap screw (6) and remove muffler. 8. Install muffler gasket and muffler.

–UN–24JAN05

9. Install muffler bracket cap screw (6). 10. Install muffler-to-exhaust manifold nuts (5) and tighten. 11. Install heat shields to exhaust manifold (4) and muffler (3).

T207372A

04 0400 12

T207371A

5. Remove heat shields to muffler (3) and exhaust manifold (4).

12. Install exhaust pipe clamp (2). 13. Install counterweight. And install left-side panels. See Counterweight Remove and Install—35D. (Group 1749.)

1—Frame Bracket 2—Exhaust Pipe Clamp 3—Muffler Heat Shield 4—Exhaust Manifold Heat Shield 5—Muffler-to-Exhaust Manifold Nut (4 used) 6—Muffler Bracket Cap Screw

MM61211,0000882 –19–09FEB05–1/1

TM2264 (15OCT08)

04-0400-12

Repair 101508

PN=124

Removal and Installation

Exhaust Manifold Remove and Install—50D 1. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 2. Remove counterweight. See Counterweight Remove and Install—50D. (Group 1749.) –UN–08FEB05

3. Remove air cleaner assembly (1). 4. Remove exhaust pipe clamp (2).

T207930A

5. Remove top frame bracket (3). 6. Safely support rear of cab using rear lift bracket (4).

04 0400 13

7. Remove tilt unit (5) and tilt unit bracket (6). 8. Remove both frame brackets (7).

T207929A

–UN–08FEB05

T207931A

–UN–08FEB05

1—Air Cleaner Assembly 2—Exhaust Pipe Clamp 3—Top Frame Bracket 4—Rear Lift Bracket 5—Tilt Unit 6—Tilt Unit Bracket 7—Frame Bracket (2 used)

Continued on next page

TM2264 (15OCT08)

04-0400-13

MM61211,0000883 –19–09FEB05–1/3

Repair 101508

PN=125

Removal and Installation 9. Remove exhaust manifold heat shield (8). 10. Remove muffler heat shield (9). 11. Loosen two muffler bracket cap screws (10). 12. Remove four muffler-to exhaust nuts (11). –UN–25FEB05

13. Remove muffler. 14. Remove six exhaust manifold cap screws (12).

16. Clean all gasket material from exhaust manifold (14) and cylinder head mating surfaces (15). 17. Install muffler-to-exhaust gasket (16) and exhaust manifold gasket (17). 18. Install exhaust manifold caps screws and nuts.

–UN–08FEB05

19. Install muffler-to-exhaust manifold. 20. Install muffler-to-exhaust manifold nuts. Tighten muffler bracket cap screw to specifications.

T207927A

Specification Exhaust Manifold-to-Cylinder Head Cap Screw and Nut— Torque ........................................................................................... 26 N•m 19 lb-ft

21. Install exhaust manifold heat shield and muffler heat shield. 22. Install both frame brackets (7). 23. Install top frame bracket (3). –UN–08FEB05

8—Exhaust Manifold Heat Shield 9—Muffler Heat Shield 10—Muffler Bracket Cap Screw (2 used) 11—Muffler-to-Exhaust Nut (4 used) 12—Exhaust Manifold Cap Screw (6 used) 13—Exhaust Manifold Nut (2 used) 14—Exhaust Manifold Mating Surface 15—Cylinder Head Mating Surface 16—Muffler-to-Exhaust Gasket 17—Exhaust Manifold Gasket

T207926A

04 0400 14

T207928A

15. Remove two exhaust manifold nuts (13).

Continued on next page

TM2264 (15OCT08)

04-0400-14

MM61211,0000883 –19–09FEB05–2/3

Repair 101508

PN=126

Removal and Installation 24. Install exhaust pipe clamp (2). 25. Install air cleaner assembly (1). 26. Install tilt unit bracket (6) and tilt unit (5).

MM61211,0000883 –19–09FEB05–3/3

Muffler Remove and Install—50D 04 0400 15

1. Park machine on level surface. 2. Remove exhaust pipe clamp (1). 3. Remove muffler heat shield (2). –UN–16FEB05

4. Remove four muffler-to-exhaust manifold nuts (3) and washers.

T207935A

5. Remove muffler bracket cap screws (4) and remove muffler. 6. Install muffler gasket and muffler. 7. Install muffler bracket cap screws (4). 8. Install muffler-to-exhaust manifold nuts (3) and tighten.

–UN–25FEB05

9. Install muffler heat shield (2). 10. Install exhaust pipe clamp (1).

T207936A

11. Install counterweight. And install left-side panels. See Counterweight Remove and Install—50D. (Group 1749.) 1—Exhaust Pipe Clamp 2—Muffler Heat Shield 3—Muffler-to-Exhaust Manifold Nut (4 used) 4—Muffler Bracket Cap Screw (2 used)

MM61211,0000884 –19–09FEB05–1/1

TM2264 (15OCT08)

04-0400-15

Repair 101508

PN=127

Removal and Installation

Thermostat Remove and Install 1. Drain engine coolant. See Draining Cooling System. (Operator’s Manual.) 2. Remove cap screws (A). 3. Remove cover (B), cover gasket (C), thermostat (D), and gasket (E). 4. Test thermostat. See Engine Thermostat Test. (Group 9010-25.)

Specification Thermostat Cover Cap Screw— Torque ........................................................................................... 20 N•m 15 lb-ft

M82315A

04 0400 16

–UN–12JUN00

5. At installation, replace gaskets.

A—Cap Screw B—Cover C—Cover Gasket D—Thermostat E—Gasket

OUO1030,00000BC –19–05JAN06–1/1

TM2264 (15OCT08)

04-0400-16

Repair 101508

PN=128

Removal and Installation

Water Pump Remove and Install

RG8583A

–UN–25APR00

04 0400 17

A—Water Pump B—Fan-to-Water Pump Cap Screw C—Fan

D—Spacer E—Pulley F—Fan Belt G—Water Pump-to-Cylinder Head Cap Screw

1. Remove radiator. See Radiator Remove and Install—35D or See Radiator Remove and Install— 50D. (Group 0510.) 2. Remove thermostat and cover. See Thermostat Remove and Install. (Group 0400.)

H—Gasket I—O-Ring J—Gasket

K—Ball Joint L—Cap Screw

6. Remove cap screws (B), fan (C), spacer (D), and pulley (E). 7. Remove mounting cap screws (G), water pump (A), and gasket (H).

3. Disconnect coolant temperature sensor leads.

8. Remove cap screws (L), ball joint (K), gasket (J) and O-ring (I).

4. Disconnect upper and lower radiator hoses.

9. Installation is done in the reverse order of removal.

5. Remove fan belt (F).

Continued on next page

TM2264 (15OCT08)

04-0400-17

OUO1030,00000BB –19–13JAN05–1/2

Repair 101508

PN=129

Removal and Installation IMPORTANT: At installation, replace all O-rings and copper washers. Specification Water Pump Mounting Cap Screws—Torque ..................................................................... 26 N•m 230 lb-in. Water Pump-to-Fan Mounting Cap Screws—Torque ............................................................. 11 N•m 97 lb-in. Water Pump Plug—Torque .................................................... 15 N•m 132 lb-in.

10. Adjust fan belt tension. See Inspect Fan Belt, Check and Adjust Tension. (Operator’s Manual.)

IMPORTANT: Air must be expelled from cooling system when system is filled. Loosen coolant temperature sender or plug in thermostat housing to allow air to escape when filling system. Retighten sender or plug when all the air has been expelled. 11. Close drain valve and remove coolant temperature sender from engine. Fill radiator with proper coolant until coolant is present at temperature sender hole. Install temperature sender and continue to fill radiator to top of filler neck.

04 0400 18 OUO1030,00000BB –19–13JAN05–2/2

TM2264 (15OCT08)

04-0400-18

Repair 101508

PN=130

Removal and Installation

Intake Manifold Remove and Install NOTE: 50D shown; 35D repair is similar. 1. Remove counterweight. See Counterweight Remove and Install—35D or see Counterweight Remove and Install—50D. (Group 1749.) 2. Disconnect crankcase breather tube (1).

–UN–02FEB05

IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump.

T207764A

3. Clean the injection pump lines and area around the nozzles using a parts cleaning solvent or steam cleaner. 4. Loosen fuel injection line (2) connectors-to-nozzles slightly to release pressure in the fuel system.

1—Breather Tube 2—Fuel Injection Lines 3—Intake Manifold Cap Screw (35D-4 used) (50D-6 used) 4—Fuel Filter Bracket 5—Final Fuel Filter Housing 6—Terminal Connection

5. Remove fuel injection lines. 6. Disconnect fuel filter bracket (4) from intake manifold. 7. Disconnect final fuel filter housing (5) from intake manifold. 8. Disconnect air intake heater terminal (6). 9. Remove intake manifold cap screws (3). 10. Remove intake manifold. 11. Clean cylinder head and intake manifold mounting surfaces. 12. Install intake manifold using new gasket. 13. Tighten cap screws to specification. Specification Intake Manifold Cap Screws— Torque ........................................................................................... 11 N•m 97 lb-in.

14. Connect air intake heater terminal.

Continued on next page

TM2264 (15OCT08)

04-0400-19

OUO1030,00000CD –19–01FEB05–1/2

Repair 101508

PN=131

04 0400 19

Removal and Installation 15. Connect both fuel filters to intake manifold. 16. Install fuel injection lines. 17. Connect crankcase breather tube.

OUO1030,00000CD –19–01FEB05–2/2

Fuel Injection Pump Remove and Install 04 0400 20

Fuel Injection Pump Remove IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean injection lines and area around the injection pump with cleaning solvent or a steam cleaner. 2. Remove radiator, fan, and belt. See Radiator Remove and Install—35D or see Radiator Remove and Install— 50D. (Group 0510.) 3. Remove intake manifold. See Intake Manifold Remove and Install. (Group 0400.) 4. Lower air conditioning compressor.

Continued on next page

TM2264 (15OCT08)

04-0400-20

OUO1030,00000CA –19–17SEP08–1/10

Repair 101508

PN=132

Removal and Installation 5. Disconnect fuel inlet line (A), fuel return line (B), and injector return line (C). 6. Disconnect coolant lines (D and E). 7. Disconnect fuel shutoff solenoid wire connector (F).

9. Remove cap screws (H) and remove injection pump gear access cover.

–UN–13APR04

NOTE: For all the timing marks to become aligned, engine may need to be rotated up to fifty-two times.

RG13396A

8. Remove foam spacer (G).

04 0400 21

Alignment marks (I and J) are both identified with a stamped letter “B”.

–UN–13APR04

10. Rotate engine in the direction of rotation until mark (I) on pump gear aligns with mark on idler gear (J) (both identified by a stamped letter B). Use chalk or paint to mark injection pump gear to idler gear.

RG13398A

–UN–13APR04

RG13397A

A—Fuel Inlet Line B—Fuel Return Line C—Injector Return Line D—Coolant Line E—Coolant Line F—Fuel Shutoff Solenoid Wire Connector G—Foam Spacer H—Cap Screw (4 used) I—Pump Gear Timing Mark J—Idler Gear Timing Mark

Continued on next page

TM2264 (15OCT08)

04-0400-21

OUO1030,00000CA –19–17SEP08–2/10

Repair 101508

PN=133

Removal and Installation 11. Remove gear retaining nut and washer (A).

–UN–13APR04

IMPORTANT: Do not loosen or disturb cap screws (B) securing gear to the hub. Gear to hub adjustment is pre-set to comply with strict EPA emissions requirements and is not adjustable. This procedure is done at the pump manufacturer and cannot be duplicated in the field.

RG13399A

12. Install puller (E) into threaded holes (C) on gear using cap screws (D). IMPORTANT: Engine must not be rotated when timing gear is removed from injection pump shaft. Engine should only be rotated 04 when timing gear is securely fastened 0400 to pump or engine damage could result. 22 13. Remove gear and hub assembly from injection pump shaft. Gear will stay inside timing cover.

RG13400A

–UN–13APR04

IMPORTANT: Marks must be made on the injection pump and the gear cover mounting plate to correctly install the pump. If marks are not made, there will be no way to properly time the injection pump. 14. Note position of timing marks on gear cover mounting plate (G) and injection pump (F). Pump must be installed at the exact same timing mark as when removed. Scribe a line as accurately and straight as possible at the pump flange mark (F) onto the gear cover mounting plate.

RG13401A

–UN–13APR04

A—Timing Gear Nut and Washer B—Cap Screw (4 used) C—Threaded Puller Holes D—Puller Cap Screw (2 used) E—Gear Puller F—Injection Pump Timing Mark G—Gear Cover Mounting Plate Timing Mark

Continued on next page

TM2264 (15OCT08)

04-0400-22

OUO1030,00000CA –19–17SEP08–3/10

Repair 101508

PN=134

Removal and Installation 15. Remove external lube line (A) from pump. 16. Remove cap screw (B).

RG13402A

–UN–13APR04

IMPORTANT: Marks must be made on the injection pump and the gear cover mounting plate to properly install pump. You must also record the injection pump timing number marked on the pump to correctly install the pump. If marks are not made and the timing number not recorded, there will be no way to properly time the injection pump. 17. Remove pump flange mounting nuts (C) and remove pump.

04 0400 23

A—External Lube Line B—Cap Screw C—Nut (3 used)

NOTE: The injection pump timing number is stamped on the engine side of the fuel injection pump housing. Treat this number as though there is a decimal point between the two digits. (Example 68 = 6.8). 18. Find and record pump timing number stamped on pump. This number will be needed if pump is being replaced or recalibrated. IMPORTANT: DO NOT attempt to service the injection pump or governor. If unit is in need of repair, it must be serviced by a qualified EPA/CARB certified fuel injection repair shop. If replacement is necessary, replace entire unit. Do not rotate engine while injection pump is removed. If engine is rotated, the timing gear cover must be removed to ensure correct timing.

Continued on next page

TM2264 (15OCT08)

04-0400-23

OUO1030,00000CA –19–17SEP08–4/10

Repair 101508

PN=135

Removal and Installation Pump Installation 1. Install new O-ring on injection pump.

–UN–13APR04

2. Put injection pump onto back of gear cover mounting plate. Install three mounting nuts. Do not tighten. Align key on shaft with keyway in gear hub. Ensure gear is still aligned to idler gear. 3. Install nut and washer (A) on pump shaft. Tighten nut to specification.

04 0400 24

RG13399A

Specification Fuel Injection Pump Drive Gear Hub-to-Shaft Retaining Nut— Torque ................................................................................... 78—88 N•m 58—65 lb-ft

A—Timing Gear Nut and Washer B—Cap Screw (4 used) C—Threaded Puller Holes

Continued on next page

TM2264 (15OCT08)

04-0400-24

OUO1030,00000CA –19–17SEP08–5/10

Repair 101508

PN=136

Removal and Installation 4. Align timing mark on injection pump (A) with correct mark on gear cover mounting plate (B). 5. Tighten three pump mounting nuts (C) to specification.

–UN–13APR04

Specification Injection Pump Mounting Nuts— Torque ........................................................................................... 26 N•m 228 lb-in.

6. Install cap screw (D). Tighten to specification.

RG13403A

Specification Injection Pump Mounting Cap Screw—Torque .............................................................................. 26 N•m 228 lb-in.

04 0400 25

7. Fill pump with engine oil through external lube line port until oil runs out. Install external lube line. Tighten lube line fitting (E) to specification. Specification Injection Pump External Lube Line Fitting—Torque ...................................................................... 15 N•m 133 lb-in. –UN–13APR04

8. Install cover for injection pump timing gear.

RG13415A

A—Injection Pump Timing Mark B—Gear Cover Mounting Plate Timing Mark C—Pump Mounting Nut (3 used) D—Cap Screw E—External Lube Line

Continued on next page

TM2264 (15OCT08)

04-0400-25

OUO1030,00000CA –19–17SEP08–6/10

Repair 101508

PN=137

Removal and Installation 9. Install spacer (G) between pump and engine block. 10. Connect fuel shutoff solenoid wire connector (F). 11. Connect fuel lines (A, B, and C). 12. Connect coolant lines (D and E). –UN–13APR04

13. Install intake manifold. See Intake Manifold Remove and Install. (Group 0400.)

04 0400 26

RG13396A

14. Install radiator, fan, and belt. See Radiator Remove and Install—35D or see Radiator Remove and Install—50D. (Group 0510.) Install Fuel and Coolant Lines

A—Fuel Inlet Line B—Fuel Return Line C—Injectors Return Line D—Coolant Line E—Coolant Line F—Fuel Shutoff Solenoid Wire Connector G—Foam Spacer

Continued on next page

TM2264 (15OCT08)

04-0400-26

OUO1030,00000CA –19–17SEP08–7/10

Repair 101508

PN=138

Removal and Installation New, Rebuilt, or Recalibrated Pump Timing 1. Install timing mark sticker supplied with pump so that the (A) line is exactly in-line with the mark that was made on the gear cover mounting plate when the pump was removed.

–UN–05MAY04

IMPORTANT: Injection pump timing can not be performed without injection pump timing numbers from original and replacement pumps. There is no way to properly install the injection pump without these numbers.

04 0400 27

RG13614

2. Calculate the difference between the timing numbers, recorded earlier, from the original and replacement/recalibrated pumps. This calculated number will be needed to correctly time the pump. Example: If the timing number on the replacement/recalibrated pump was 6.0, and the timing number on the original pump is 4.0 (fuel injection angle of replacement/recalibrated pump) - (fuel injection angle of original pump), the replacement pump should be timed at the +2.0° (advanced) mark (C) on the new timing mark sticker.

Injection Pump Sticker A—Middle 0° Line B—1° Line C—2° Line D—0.5° Line

NOTE: Rotating the injection pump away from the cylinder block will advance the timing and rotating the injection pump toward the cylinder block will delay the timing. 3. Set the pump to the correct timing mark using the calculated number difference between the original and replacement pumps. Adjust timing accordingly using the new timing mark sticker. 4. Hold the pump at the correct timing mark and tighten three pump mounting nuts and cap screw to specification. Specification Injection Pump Mounting Nuts— Torque ........................................................................................... 26 N•m 228 lb-in. Injection Pump Mounting Cap Screw—Torque .............................................................................. 26 N•m 228 lb-in.

Continued on next page

TM2264 (15OCT08)

04-0400-27

OUO1030,00000CA –19–17SEP08–8/10

Repair 101508

PN=139

Removal and Installation 5. If removed, install timing cover. See Timing Gear Cover Remove and Install. (Group 0400.)

OUO1030,00000CA –19–17SEP08–9/10

6. Install spacer (G) between pump and engine block. 7. Connect fuel shutoff solenoid wire connector (F). 8. Connect fuel lines (A, B, and C).

10. Install intake manifold. See Intake Manifold Remove and Install. (Group 0400.) 11. Install radiator, fan, and belt. See Radiator Remove and Install—35D or see Radiator Remove and Install—50D. (Group 0510.)

RG13396A

04 0400 28

–UN–13APR04

9. Connect coolant lines (D and E).

A—Fuel Inlet Line B—Fuel Return Line C—Injectors Return Line D—Coolant Line E—Coolant Line F—Fuel Shutoff Solenoid Wire Connector G—Foam Spacer

OUO1030,00000CA –19–17SEP08–10/10

TM2264 (15OCT08)

04-0400-28

Repair 101508

PN=140

Removal and Installation

Fuel Injection Nozzles Remove and Install General Nozzle Service Precautions Before removal, thoroughly remove all dirt from the cylinder head around fuel injection nozzles. Clean with compressed air to prevent dirt from entering the cylinders. Plug the bore in the cylinder head after each nozzle has been removed. Cap fuel line openings as soon as they are disconnected. Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage and getting debris in fuel system. Do not bend the fuel delivery lines, as this may affect their durability. When loosening the fuel pressure lines, hold male union of nozzle line stationary with a backup wrench.

04 0400 29

IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump lines and area around the nozzles using a parts cleaning solvent or steam cleaner. NOTE: Nozzles are matched to the cylinders. If removing more than one nozzle, tag each nozzle, according to the cylinder from which it was removed.

Continued on next page

TM2264 (15OCT08)

04-0400-29

OUO1030,00000CB –19–28NOV05–1/3

Repair 101508

PN=141

Removal and Installation 2. Loosen fuel injection line connectors-to-nozzles slightly to release pressure in the fuel system. 3. Loosen line clamp(s) and remove fuel injection lines. 4. Remove clamps (C) and leak-off hoses (D). 5. Remove cap screw and washer (A) and retaining plate (B). 6. Remove injection nozzle (E), ring (F), and TEFLON heat protector (G). If ring and protector stay in cylinder head, thread a cap screw into protector and pull from cylinder head.

–UN–16APR04

A—Cap Screw and Washer B—Retaining Plate C—Hose Clamp D—Leak-Off Hose E—Injection Nozzle F—Ring G—Heat Protector

RG13407

04 0400 30

TEFLON is a trademark of Du Pont Co.

TM2264 (15OCT08)

Continued on next page

04-0400-30

OUO1030,00000CB –19–28NOV05–2/3

Repair 101508

PN=142

Removal and Installation 7. If nozzles are stuck in cylinder head: Grind the head of a cap screw (C) so it fits inside a nut from an old injection line (D).

–UN–09JUN00

Use two nuts (B) to attach a large flat washer (A) to the cap screw.

M82126A

Install assembly onto nozzle and use a puller and slide hammer to pull nozzle from cylinder head. 8. Test injection nozzles. Perform Fuel Injection Nozzle Check. (Group 9010-25.) 9. Installation is done in the reverse order of removal. 10. Tighten retaining plate nuts.

A—Large Flat Washer B—Nut (2 used) C—Cap Screw D—Old Injection Line Nut E—Injection Nozzle

04 0400 31

Specification Fuel Injection Retaining Plate Cap Screw—Torque .............................................................. 24—28 N•m 212—248 lb-in

OUO1030,00000CB –19–28NOV05–3/3

TM2264 (15OCT08)

04-0400-31

Repair 101508

PN=143

Removal and Installation

Fuel Injection Nozzles Disassemble and Assemble Fuel Injection Nozzles Disassemble NOTE: If servicing more than one nozzle, keep parts for each nozzle separate from one another. 1. Disassemble fuel injection nozzles. IMPORTANT: If injection nozzles are disassembled to be cleaned, the same number and thickness of shims must be installed. 2. Clean and inspect nozzle components.

–UN–12JUN00

A—Injector Body B—Shims C—Spring D—Spring Seat E—Separator Plate F—Nozzle Valve G—Nozzle Body H—Retaining Nut I—Index Pin (2 used)

RG11097A

04 0400 32

Continued on next page

TM2264 (15OCT08)

04-0400-32

OUO1030,00000CC –19–28NOV05–1/4

Repair 101508

PN=144

Removal and Installation Fuel Injection Nozzles Clean and Inspect NOTE: To clean nozzles properly, JDF13B Nozzle Cleaning Kit is recommended. The cleaning kit is available through the John Deere SERVICEGARD Catalog. 1. Remove anti-corrosive grease from new or reconditioned nozzles by washing them thoroughly in diesel fuel. IMPORTANT: Never use a steel brush to clean nozzles as this will distort the spray hole. 2. Remove carbon from used nozzles, and clean by washing in diesel fuel. If parts are coated with hardened carbon or lacquer, it may be necessary to use a brass wire brush (supplied in nozzle cleaning kit).

04 0400 33

3. After removing carbon or lacquer from the exterior of nozzle, inspect sealing surfaces between separator plate and nozzle body for nicks or scratches. 4. Inspect condition of separator plate and nozzle body. Contact area of separator plate (both parts) must not be scored or pitted. Use an inspection magnifier to aid in making the inspection.

–UN–08JUN00

5. Check nozzle contact surface on separator plate for wear. If contact surface is more than specification, replace nozzle assembly.

M82326B

–UN–12JUN00

M37684A

A—Injector Body B—Fuel Return Pipe C—Shims D—Spring E—Index Pin F—Separator Plate G—Nozzle Body H—Nozzle Valve I—Retaining Nut J—Spring Seat K—Nozzle Contact Surfaces L—Sealing Surfaces

SERVICEGARD is a trademark of Deere & Company.

TM2264 (15OCT08)

Continued on next page

04-0400-33

OUO1030,00000CC –19–28NOV05–2/4

Repair 101508

PN=145

Removal and Installation Specification Fuel Injection Nozzle Contact Surface—Size .............................................................................. 0.10 mm 0.0039 in.

6. Inspect the piston (large) part of nozzle valve to see that it is not scratched or scored and that lower (tip) end of valve is not broken. If any of these conditions are present, replace the nozzle assembly.

OUO1030,00000CC –19–28NOV05–3/4

7. Further inspect the nozzle assembly by performing a slide test. Use the following procedure:

–UN–26AUG88

a. Dip the nozzle valve in clean diesel fuel. Insert valve (A) in nozzle body (B). b. Hold nozzle vertical, and pull valve out about 1/3 of its engaged length as shown. c. Release valve. Valve should slide down to its seat by its own weight. Replace nozzle assembly if the valve does not slide freely to its seat.

M35919

04 0400 34

A—Nozzle Valve B—Nozzle Body

Fuel Injection Nozzles Assemble 1. Assembly is done in the reverse order of disassembly. 2. Tighten retaining nut (H) to specification. Specification Fuel Injection Nozzle Retaining Nut—Torque .................................................................................. 43 N•m 31 lb-ft

3. After assembly is complete, test injection nozzle. Perform Fuel Injection Nozzle Check. (Group 9010-25.)

OUO1030,00000CC –19–28NOV05–4/4

TM2264 (15OCT08)

04-0400-34

Repair 101508

PN=146

Removal and Installation

Rocker Arm Cover Remove and Install 1. Remove the special nuts (A). 2. Disconnect crankcase breather tube (K). 3. Remove rocker arm cover (J) from cylinder head. 4. Remove diaphragm cover (B). 5. Remove and inspect spring (C) and diaphragm (D). Replace if damaged or deteriorated. 6. Remove baffle plate (H) and baffle (G). 7. Wash baffle in solvent and blow dry with compressed air. Replace baffle if it is damaged or deteriorated.

04 0400 35

–UN–05APR04

8. Install baffle and baffle plate. 9. Install diaphragm, spring plate (M), spring, and diaphragm cover.

11. Clean cylinder head surface and install rocker arm cover on cylinder head. Install special nuts and tighten to specification. Specification Rocker Arm Cover Special Nuts—Torque ................................................................................ 18 N•m 156 lb-in.

RG13393

10. Inspect gasket (I) and O-rings (L) before reinstalling rocker arm cover. Replace if damaged.

A—Special Nut (3 used) B—Diaphragm Cover C—Spring D—Diaphragm E—Oil Filler Cap F—Gasket G—Baffle H—Baffle Plate I—Gasket J—Rocker Arm Cover K—Crankcase Breather Tube L—O-Ring M—Spring Plate

OUO1030,000006C –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-35

Repair 101508

PN=147

Removal and Installation

Rocker Arm Shaft Assembly Repair

RG13416

–UN–13APR04

04 0400 36

A—Nut B—Adjusting Screw C—Mounting Cap Screw D—Nut

E—Stud F—Rocker Arm End Support G—Rocker Arm Shaft H—Push Rod

Rocker Arm Shaft Disassemble 1. Remove rocker arm cover. See Rocker Arm Cover Remove and Install. (Group 0400.)

I—Valve Cap J—Intake Valve Rocker Arm K—Exhaust Valve Rocker Arm L—Mounting Cap Screw

M—Rocker Arm Shaft Spring N—Rocker Arm Center Support

NOTE: When disassembling the rocker arm assembly, replace components in same location on rocker arm shaft they were removed from. 5. Slide rocker arm assembly components off rocker arm shaft while noting positions for reassembly.

2. Remove rocker arm end support mounting cap screws (C). 3. Remove rocker arm center support mounting cap screws (L).

6. Lift push rods (H) from cylinder head and note order of removal for reassembly in same positions in head.

4. Lift rocker arm assembly from cylinder head and set on bench.

Continued on next page

TM2264 (15OCT08)

04-0400-36

OUO1030,000006F –19–05JAN06–1/3

Repair 101508

PN=148

Removal and Installation Rocker Arm Shaft Inspect 1. Measure outer diameter of rocker arm shaft (A) at each rocker arm location.

M35262A

–UN–09JUN00

Specification Rocker Arm Shaft—OD ................................................. 15.97—15.98 mm 0.6286—0.6293 in. Wear Limit ................................................................................. 15.95 mm 0.6280 in.

Replace rocker arm shaft if less than wear limit. 2. Measure inner diameters of rocker arms (B) and supports. Specification Rocker Arm Shaft Support—ID ..................................... 16.00—16.02 mm 0.630—0.631 in. Wear Limit ................................................................................. 16.09 mm 0.633 in. Rocker Arm Shaft-to-Rocker Arm and Shaft Support Clearance— Wear Limit ................................................................................... 0.14 mm 0.006 in.

–UN–12JUN00

04 0400 37

M82022A

Replace rocker arms or supports if ID is more than wear limit.

A—Rocker Arm Shaft B—Rocker Arm

Continued on next page

TM2264 (15OCT08)

04-0400-37

OUO1030,000006F –19–05JAN06–2/3

Repair 101508

PN=149

Removal and Installation 3. Measure length (A) and bending (B) of push rod. Specification Push Rod—Length ..................................................... 178.2—178.75 mm 7.018—7.037 in. Push Rod Bend—Wear Limit ...................................................... 0.03 mm 0.001 in. –UN–25APR00

Replace push rod if not within specifications. Rocker Arm Shaft Assemble

1. Install push rods in cylinder head with ball-shaped end down in head. Push rods should be in same locations they were removed from. 04 0400 38

M82023A

NOTE: Lubricate all parts with clean oil during assembly.

A—Push Rod Length B—Push Rod Bend

2. Assemble rocker arm assembly components in the reverse order of removal. 3. Place rocker arm assembly on cylinder head. Align rocker arms with valves and push rods. Align rocker arm end supports and center supports with corresponding holes in head. 4. Install rocker arm support mounting cap screws and torque to specification. Specification Rocker Arm Support Cap Screws—Torque ............................................................................. 26 N•m 230 lb-in.

5. Adjust valve clearance. See Engine Valve Lash (Clearance) Check and Adjustment. (Group 9010-25.)

OUO1030,000006F –19–05JAN06–3/3

TM2264 (15OCT08)

04-0400-38

Repair 101508

PN=150

Removal and Installation

Cylinder Head Remove and Install Cylinder Head Remove 1. Remove rocker arm cover, rocker arm assembly, push rods, and valve caps. See Rocker Arm Cover Remove and Install. (Group 0400.) 2. Remove exhaust and intake manifolds. See Exhaust Manifold Remove and Install—35D or see Exhaust Manifold Remove and Install—50Dand see Intake Manifold Remove and Install. (Group 0400.) –UN–01FEB05

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

T207557

4. Remove fuel injection nozzles. See Fuel Injection Nozzles Remove and Install. (Group 0400.) NOTE: Loosen cap screws in two steps. First, loosen all cap screws to 54 N•m (40 lb-ft). Then, loosen again to remove. 5. Remove all mounting cap screws.

–UN–05APR04

IMPORTANT: DO NOT use screwdrivers or pry bars between cylinder block and head to loosen head gasket seal. Screwdrivers or pry bars can damage cylinder head and block gasket surfaces.

RG13395

6. Lift cylinder head from the block. 7. Remove cylinder head gasket. Inspect for possible oil, coolant, or combustion chamber leaks. Cylinder Head Cap Screw Loosening Sequence—35D

8. Clean gasket sealing surface on cylinder head and engine block. 9. If repair to cylinder head is necessary, see Cylinder Head and Valve Disassemble and Assemble. (Group 0400.)

RG8574A

–UN–25APR00

A—Mounting Cap Screw B—Cylinder Head C—Gasket D—Fan End of Engine

Cylinder Head Cap Screw Loosening Sequence—50D

Continued on next page

TM2264 (15OCT08)

04-0400-39

OUO1030,000006D –19–16JUN08–1/7

Repair 101508

PN=151

04 0400 39

Removal and Installation

–UN–21JAN05

Cylinder Head Flatness Check Before inspection, thoroughly clean all components of carbon or dirt.

T207255

Measure cylinder head distortion. Place D05012ST Precision “Beveled Edge” Straightedge (A) along each of the four sides and each diagonal. Measure clearance between straightedge and combustion surface with a feeler gauge (B).

–UN–12JUN00 M82028A

04 0400 40

Specification Cylinder Head—Out-of-Flat Maximum ..................................................................................... 0.05 mm 0.002 in. Wear Limit ................................................................................... 0.15 mm 0.006 in.

If distortion exceeds the wear limit, resurface or replace cylinder head. Remove only enough metal to make cylinder head flat, but do not remove more than 0.20 mm (0.008 in.).

Measuring Cylinder Head Flatness A—Straightedge B—Feeler Gauge

Specification Maximum Material Removal for Flattening Head—Quantity .......................................................... 0.20 mm 0.008 in.

Continued on next page

TM2264 (15OCT08)

04-0400-40

OUO1030,000006D –19–16JUN08–2/7

Repair 101508

PN=152

Removal and Installation Measure Piston-to-Cylinder Head Clearance 1. Remove cylinder head. See Cylinder Head Remove and Install. (Group 0400.)

–UN–25APR00

2. Place three 10 mm (0.400 in.) long pieces of 1.50 mm (0.060 in.) diameter soft wire in three positions on the flat part of the piston head.

M82042A

3. Install cylinder head and old gasket. Install cylinder head cap screws and tighten in proper sequence to specified torque. See Cylinder Head Remove and Install. (Group 0400.) 4. Slowly turn crankshaft one complete revolution.

04 0400 41

5. Remove cylinder head and gasket. 6. Measure thickness of flattened section of each piece of wire. Calculate average thickness of wires to obtain piston-to-cylinder head clearance specification. Specification Piston-to-Cylinder Head— Clearance ......................................................................... 0.66—0.78 mm 0.026—0.031 in.

If clearance is less than specifications, replace cylinder head. Preliminary Cylinder Head and Valve Checks Make preliminary inspection of cylinder head and valve assembly during disassembly. Look for the following conditions: Sticking Valves: • Carbon deposits on valve stem. • Worn valve guides. • Scored valve stems. • Warped valve stems. • Misaligned or broken valve springs. • Worn or distorted valve seats. • Insufficient lubrication. Warped, Worn, or Distorted Valve Guides:

Continued on next page

TM2264 (15OCT08)

04-0400-41

OUO1030,000006D –19–16JUN08–3/7

Repair 101508

PN=153

Removal and Installation • Lack of lubrication. • Cylinder head distortion. • Excessive heat. • Unevenly tightened cylinder head cap screws. Distorted Cylinder Head and Gasket Leakage: • Loss of cylinder head cap screw torque. • Broken cylinder head cap screw(s). • Overheating from low coolant level operation. • Insufficient liner standout. • Coolant leakage into cylinder causing hydraulic failure of gasket. • Leaking aftercooler. • Cracked cylinder head. • Cracked cylinder liner. 04 0400 • Damaged or incorrect gasket. 42 • Overpowering or overfueling. • Damaged cylinder head or block surfaces. • Improper surface finish on cylinder head. • Improperly tightened cylinder head cap screws. • Faulty gasket installation (misaligned). Worn or Broken Valve Seats: • Misaligned valves. • Distorted cylinder head. • Carbon deposits on seats due to incomplete combustion. • Valve spring tension too weak. • Excessive heat. • Improper valve clearance. • Improper valve timing. • Incorrect valve or seat installed. Burned, Pitted, Worn, or Broken Valves: • Worn or distorted valve seats. • Loose valve seats. • Worn valve guides. • Insufficient cooling. • Cocked or broken valve springs. • Improper engine operation. • Improper valve train timing. • Faulty valve rotators. • Warped or distorted valve stems. • “Stretched” valves due to excessive spring tension.

Continued on next page

TM2264 (15OCT08)

04-0400-42

OUO1030,000006D –19–16JUN08–4/7

Repair 101508

PN=154

Removal and Installation • Warped cylinder head. • Bent push rods. • Carbon buildup on valve seats. • Rocker arm failure. • Incorrect valve or seat installed. • Incorrect piston-to-valve clearance. Improper Valve Clearance: • Inefficient use of fuel. • Engine starts harder. • Maximum engine power will not be achieved. • Shorter service life of valve train. • Greater chance for engine to overheat. Excessive Recession:

04 0400 43

• Worn valve guides. • Bent valves. • Debris passed through valve train.

OUO1030,000006D –19–16JUN08–5/7

Cylinder Head Install IMPORTANT: Oil passage in gasket must be located over oil passage in cylinder block. 1. Place cylinder head gasket (C) on engine block. Dowels in engine block will assist in aligning gasket. 2. Place cylinder head (B) on engine block. Dowels in engine block will again assist in alignment.

T207557

–UN–01FEB05

A—Mounting Cap Screw B—Cylinder Head C—Gasket

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TM2264 (15OCT08)

04-0400-43

OUO1030,000006D –19–16JUN08–6/7

Repair 101508

PN=155

Removal and Installation

–UN–12JUN00

IMPORTANT: Cylinder head mounting cap screws must be checked for proper torque after 50 hours of engine operation.

4. Install water pump. See Water Pump Remove and Install. (Group 0400.) 5. Install exhaust and intake manifolds. See Exhaust Manifold Remove and Install—35D or see Exhaust Manifold Remove and Install—50D and see Intake Manifold Remove and Install. (Group 0400.) 6. Install rocker arm assembly, push rods, and valve caps. See Rocker Arm Cover Remove and Install. (Group 0400.)

M82025A

04 0400 44

Cylinder Head Torque Sequence—35D

–UN–25APR00

Specification Cap Screw—First—Torque ............................................................ 24 N•m 212 lb-in. Cap Screw—Second—Torque ...................................................... 48 N•m 36 lb-ft Cap Screw—Final—Torque........................................................... 88 N•m 65 lb-ft

M82260A

3. Dip mounting cap screws in oil. Install and tighten cap screws in the sequence shown, in stages of gradually-increasing torque. See torque specifications below.

Cylinder Head Torque Sequence—50D A—Exhaust Manifold Side B—Timing Gear Case Side C—Intake Manifold Side D—Flywheel Side

7. Install fuel injectors. See Fuel Injection Nozzles Remove and Install. (Group 0400.)

OUO1030,000006D –19–16JUN08–7/7

TM2264 (15OCT08)

04-0400-44

Repair 101508

PN=156

Removal and Installation

Cylinder Head and Valves Disassemble and Assemble Cylinder Head and Valves Disassemble 1. Remove valve caps from valves. Valve caps should be installed on the valves they were removed from. 2. Compress valve spring using a valve spring compressor; remove the collet halves, retainer, valve spring, and valve stem seal for each valve.

–UN–01FEB05

3. Intake and exhaust valve guides are press fit. Replace guides only if necessary.

T207558

4. Intake and exhaust valve seat inserts are not replaceable. If inspection of cylinder head reveals worn or damaged valve seats that grinding will not repair, cylinder head must be replaced. A—Collet Halves B—Retainer C—Valve Spring D—Stem Seal E—Intake Valve Guide F—Exhaust Valve Guide G—Exhaust Valve H—Intake Valve

OUO1030,000007B –19–28NOV05–1/12

Valve Seats Inspect Measure valve seat width (A). If necessary, grind valve seats to meet specifications.

M82029A

–UN–12JUN00

Specification Intake Valve Seat—Width ............................................................ 1.77 mm 0.070 in. Wear Limit .................................................................................... 2.27 mm 0.089 in. Exhaust Valve Seat—Width ......................................................... 1.34 mm 0.053 in. Wear Limit .................................................................................... 1.84 mm 0.072 in.

A—Valve Seat Width

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TM2264 (15OCT08)

04-0400-45

OUO1030,000007B –19–28NOV05–2/12

Repair 101508

PN=157

04 0400 45

Removal and Installation Grind Valve Seats IMPORTANT: Valve seats should never be cut. Cutting a valve seat can damage its sealing surface, which may result in leaks or valve seat failure. Valve seats should be ground and lapped. –UN–09FEB03

NOTE: Lightly grind valve seats for a few seconds only to avoid excessive valve seat width.

2. Measure valve seat width (D) after grinding.

–UN–09FEB03

3. If seat is too wide after grinding, grind lower seat surface (B) using a 70° seat grinder until seat width is close to specifications. Specification Lower Valve Seat Surface—Angle ........................................................ 70°

4. Grind upper seat surface (E) using a 15° seat grinder until seat width is narrowed to specifications.

M82040A

04 0400 46

M82039A

1. Grind valve seats (C) using a seat grinder (A). For intake valve seats, use a 30° seat grinder. For exhaust valve seats use a 45° grinder. Follow tool manufacturer’s instructions.

Specification Upper Seat Surface—Angle .................................................................. 15°

A—Seat Grinder B—Lower Seat Surface (70°) C—Valve Seat Surface (45°) D—Seat Width E—Upper Seat Surface (15°)

5. If valve seats are ground, measure valve recession and check contact pattern between the seat and valve with bluing dye. 6. Lap valves. If valve recession exceeds maximum specifications or seats cannot be reconditioned, replace valves and/or cylinder head. Clean Valves 1. Hold each valve firmly against a soft wire wheel on a bench grinder.

Continued on next page

TM2264 (15OCT08)

04-0400-46

OUO1030,000007B –19–28NOV05–3/12

Repair 101508

PN=158

Removal and Installation IMPORTANT: Any carbon left on the stem will affect alignment in valve refacer. DO NOT use a wire wheel on plated portion of valve stem. Polish the valve stem with steel wool or crocus cloth to remove any scratch marks left by the wire brush. 2. Make sure all carbon is removed from valve head, face, and unplated portion of stem.

OUO1030,000007B –19–28NOV05–4/12

Inspect and Measure Valves 04 0400 47

–UN–29AUG88

1. Check valve for out-of-round, bent, or warped condition using a valve inspection center. Replace valve if necessary.

M35307

2. If valve faces are worn, burned, or pitted, grind valves to proper face angle. If valve face margin (A) is less than 0.51 mm (0.020 in.) after grinding, replace valve. Specification Intake Valve Face Margin—Width..................................... 1.24—1.44 mm 0.049—0.057 in. Wear Limit Minimum..................................................................... 0.50 mm 0.020 in. Exhaust Valve Face Margin— Width ................................................................................. 1.35—1.55 mm 0.053—0.061 in. Wear Limit Minimum..................................................................... 0.50 mm 0.020 in.

Measuring Valve for Bend

–UN–25APR00

3. Measure valve face angles (B).

M82030A

Specification Intake Valve Face—Angle ..................................................................... 30° Exhaust Valve Face—Angle ................................................................. 45°

A—Valve Face Margin B—Valve Face Angle

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TM2264 (15OCT08)

04-0400-47

OUO1030,000007B –19–28NOV05–5/12

Repair 101508

PN=159

Removal and Installation 4. Measure valve stem diameter at the two locations (C) and (D) at the points shown as (A) and (B). Replace valve if measurement exceeds wear limit.

–UN–25APR00

Lap Valves

M82031A

NOTE: Use a rubber suction-cup type lapping tool for valves without a lapping tool groove slit. If seat does not make proper contact, lap the valve into the seat:

Measure Valve Stem Diameter

1. Apply small amount of fine lapping compound to face of valve.

A—Distance from Valve Face to Measure Point C B—Distance from Measure Point C to Measure Point D C—First Valve Stem Diameter Measure Point D—Second Valve Stem Diameter Measure Point

OUO1030,000007B –19–28NOV05–6/12

2. Turn valve lapping tool (A) to lap valve to seat. 3. Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the surface of the valve face.

–UN–12JUN00

4. Wash all parts in solvent to remove lapping compound. Dry parts. 5. Check position of lap mark on valve face. Lap mark must be on or near center of valve face. If not, grind valve seat to relocate contact area.

M82041A

04 0400 48

Specification First Valve Stem Measure Point— Distance .......................................................................................... 43 mm 1.693 in. Second Valve Stem Measure Point—Distance .............................................................................. 60 mm 2.360 in. Intake Valve Stem—OD ................................................... 7.96—7.98 mm 0.3134—0.3142 in. Wear Limit ................................................................................... 7.90 mm 0.3110 in. Exhaust Valve Stem—OD ................................................ 7.96—7.97 mm 0.3134—0.3138 in. Wear Limit ................................................................................... 7.90 mm 0.3110 in.

A—Valve Lapping Tool

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TM2264 (15OCT08)

04-0400-48

OUO1030,000007B –19–28NOV05–7/12

Repair 101508

PN=160

Removal and Installation Check Valve Recess in Cylinder Head Measure valve recession (A) using a depth gauge (C). Replace valve or cylinder head (B) if measurement exceeds specification. Specification Intake and Exhaust Valve Recession—Depth ............................................................ 0.30—0.50 mm 0.012—0.020 in. Wear Limit ................................................................................... 0.80 mm 0.031 in.

Inspect and Measure Valve Guides 1. Clean valve guides with a plastic brush before inspection or repair. –UN–09FEB03

NOTE: A few drops of light oil or kerosene will help clean the guides.

M82032A

2. Measure valve guide inside diameter. Specification Valve Guide—ID-Intake ................................................ 8.010—8.025 mm 0.3154—0.3159 in. Wear Limit ................................................................................... 8.10 mm 0.319 in. Valve Guide—ID-Exhaust............................................. 8.015—8.030 mm 0.3156—0.3161 in. Wear Limit ................................................................................... 8.10 mm 0.319 in. Valve Stem-to-Valve Guide— Clearance-Intake .......................................................... 0.035—0.070 mm 0.0014—0.0028 in. Clearance-Exhaust ....................................................... 0.045—0.075 mm 0.0018—0.0030 in. Wear Limit-Intake and Exhaust ................................................... 0.18 mm 0.279 in.

A—Valve Recession B—Cylinder Head C—Depth Gauge

If diameter exceeds wear limit, knurl or replace guide. If diameter is less than wear limit, determine guide-to-stem clearance (guide diameter minus stem diameter). If clearance exceeds 0.15 mm (0.006 in.) but is less than 0.20 mm (0.008 in.), knurl valve guides. If clearance exceeds 0.20 mm (0.008 in.), replace valve guides.

Continued on next page

TM2264 (15OCT08)

04-0400-49

OUO1030,000007B –19–28NOV05–8/12

Repair 101508

PN=161

04 0400 49

Removal and Installation Knurl valve guides using: • D20019WI Valve Guide Knurler Ream inside diameter of valve guides using: • D20021WI Valve Guide Reamer Replace Valve Guides Replace valve guides using: • JDE118 Valve Guide Driver • Knurl and ream guides. 04 0400 50 OUO1030,000007B –19–28NOV05–9/12

–UN–12JUN00

Intake and exhaust valve guides are different. The exhaust valve guide has one groove and the intake valve guide has none. Install valve guides with tapered ends down. Push valve guides down until top of valve guides are a specified distance (A) from top of cylinder head.

M82193A

Specification Valve Guide—Height ........................................................ 14.7—15.0 mm 0.578—0.590 in.

A—Distance from Top of Cylinder Head

Continued on next page

TM2264 (15OCT08)

04-0400-50

OUO1030,000007B –19–28NOV05–10/12

Repair 101508

PN=162

Removal and Installation Inspect Valve Springs NOTE: Free length may vary slightly between valve springs. 1. Measure spring free length (C). Replace spring if measurement is less than specification. –UN–25APR00

Specification Valve Spring—Free Length ......................................................... 44.4 mm 1.870 in.

M82034A

2. Measure spring inclination (B). Replace spring if measurement exceeds specification. Specification Valve Spring—Inclination .............................................................. 1.2 mm 0.047 in.

04 0400 51

M82035A

–UN–25APR00

A—Square Gauge B—Spring Inclination C—Free Length

Continued on next page

TM2264 (15OCT08)

04-0400-51

OUO1030,000007B –19–28NOV05–11/12

Repair 101508

PN=163

Removal and Installation Cylinder Head and Valves Assemble IMPORTANT: Do not reuse stem seals if removed. Used seals will leak. 1. Install new valve stem seals over valve guides. 2. Apply clean engine oil on intake and exhaust valve stems during assembly. 3. Install springs with smaller pitch end or paint mark toward cylinder head.

5. Carefully release tension on spring compressor.

T207558

04 0400 52

–UN–01FEB05

4. Compress valve springs and retainer until collet halves are able to be installed in grooves of valve stem.

6. Tap on end of valve with a plastic hammer to ensure collet halves have seated properly on valve stem. 7. Repeat for remaining valves. 8. Measure valve recession if new valves were installed.

A—Collet Halves B—Retainer C—Valve Spring D—Stem Seal E—Intake Valve Guide F—Exhaust Valve Guide G—Exhaust Valve H—Intake Valve

OUO1030,000007B –19–28NOV05–12/12

TM2264 (15OCT08)

04-0400-52

Repair 101508

PN=164

Removal and Installation

Piston and Connecting Rod Remove and Install Measure Connecting Rod Side Play Use a feeler gauge (A) to measure clearance between connecting rod and crankshaft. If side play exceeds wear limit, replace connecting rod and connecting rod cap.

–UN–12JUN00

Specification Connecting Rod Side Play— Clearance ......................................................................... 0.20—0.40 mm 0.0079—0.0157 in. Wear Limit ................................................................................... 0.55 mm 0.022 in.

M82116A

Measure Connecting Rod Bearing Clearance IMPORTANT: Connecting rod caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage.

A—Feeler Gauge

1. Remove connecting rod cap. 2. Wipe oil from bearing insert and crankshaft journal.

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TM2264 (15OCT08)

04-0400-53

OUO1030,0000097 –19–28NOV05–1/8

Repair 101508

PN=165

04 0400 53

Removal and Installation 3. Put a piece of PLASTIGAGE (A), or an equivalent, along the full width of the bearing insert approximately 6 mm (0.250 in.) off center.

–UN–29AUG88

4. Turn crankshaft approximately 30° from bottom dead center.

M35351

IMPORTANT: Do not rotate crankshaft while PLASTIGAGE is installed. Doing so will result in a false reading. 5. Install connecting rod end cap and original cap screws. Tighten cap screws to specifications.

04 0400 54

A—PLASTIGAGE

Specification Connecting Rod Cap Screw— Torque ............................................................................................ 47 N•m 35 lb-ft

PLASTIGAGE is a trademark of the DANA Corporation.

TM2264 (15OCT08)

Continued on next page

04-0400-54

OUO1030,0000097 –19–28NOV05–2/8

Repair 101508

PN=166

Removal and Installation 6. Remove cap screws and connecting rod cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or the crankshaft journal.

M82117A

–UN–12JUN00

7. Use the graduation marks on the envelope (B) to compare the width of the flattened PLASTIGAGE (A) at its widest point. 8. Determine bearing clearance. The number within the graduation marks indicates the bearing clearance in millimeters or inches, depending on which side of the envelope is used.

A—PLASTIGAGE B—Envelope

9. Remove PLASTIGAGE. 04 0400 55

Specification Connecting Rod Bearing-to-Crankshaft—Oil Clearance ..................................................................... 0.038—0.074 mm 0.0015—0.0029 in. Wear Limit ................................................................................... 0.15 mm 0.0059 in.

If clearance is not within specification, replace bearing inserts, repair crankshaft, or both. Piston and Connecting Rod Remove CAUTION: Do not drain engine coolant until it cools below operating temperature. Then slowly loosen cylinder block drain valve to relieve any pressure. 1. Drain coolant and engine oil. 2. Remove cylinder head. See Cylinder Head Remove and Install. (Group 0400.) 3. Remove camshaft followers and keep in order for reassembly in the same position. 4. Clean all foreign material from cylinder block top deck.

Continued on next page

TM2264 (15OCT08)

04-0400-55

OUO1030,0000097 –19–28NOV05–3/8

Repair 101508

PN=167

Removal and Installation NOTE: Always follow manufacturer’s directions provided with ridge reamer.

–UN–04NOV97

5. Remove carbon from cylinder bore with a scraper or ridge reamer (A). Use compressed air to remove loose material from cylinders.

RG7455

A—Ridge Reamer

OUO1030,0000097 –19–28NOV05–4/8

6. Remove oil pan and strainer tube. 7. Measure connecting rod side play. 8. Measure crankshaft end play. 9. Measure connecting rod bearing clearance. IMPORTANT: Pistons and rings, connecting rods, and bearings must be installed in the cylinders from which they were removed. 10. Mark rods, pistons, and caps to ensure correct assembly in the same location. IMPORTANT: Keep inserts with their respective caps for rod and main bearings. 11. Remove all rod caps (C) with bearing inserts (B).

–UN–12JUN00

IMPORTANT: Hold onto piston to prevent piston from dropping. Piston will drop once piston rings have cleared cylinder bore. 12. Push piston and connecting rod out of cylinder bore using a wooden dowel.

M82196AB

04 0400 56

A—Piston and Connecting Rod B—Bearing Inserts C—Connecting Rod Cap D—Connecting Rod Cap Screws

Continued on next page

TM2264 (15OCT08)

04-0400-56

OUO1030,0000097 –19–28NOV05–5/8

Repair 101508

PN=168

Removal and Installation Measure Crankshaft Connecting Rod Journals

–UN–25APR00

Measure crankshaft connecting rod journals. Measure at several places around journal.

M82062A

NOTE: If engine has had a previous major overhaul, journals may have been ground and undersized bearing inserts installed. If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine shop. A—Main Bearing Journal B—Connecting Rod Journal

If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.) undersize.

04 0400 57

Specification Crankshaft Connecting Rod Journal—OD ............................................................. 47.952—47.962 mm 1.8879—1.8883 in. Wear Limit ................................................................................ 47.902 mm 1.8859 in. Connecting Rod Bearing-to-Crankshaft Journal— Oil Clearance ................................................................ 0.038—0.074 mm 0.0015—0.0029 in. Wear Limit ................................................................................... 0.15 mm 0.0059 in.

Continued on next page

TM2264 (15OCT08)

04-0400-57

OUO1030,0000097 –19–28NOV05–6/8

Repair 101508

PN=169

Removal and Installation Piston and Connecting Rod Install IMPORTANT: Pistons must be installed in cylinders from which they were removed and in the same direction. Be careful not to damage crankshaft rod journal while installing piston. NOTE: Apply clean engine oil to all parts during installation. Never reuse connecting rod cap screws; replace with new.

2. Rotate crankshaft so that connecting rod journal for the cylinder you working on is at bottom dead center. IMPORTANT: Ensure rings are correctly staggered before installing ring compressor. –UN–12JUN00

3. Install piston ring compressor over piston and rings, and tighten. 4. Install piston and connecting rod into the cylinder from which it was removed, with alignment mark (D) on connecting rod and/or with piston size mark (A) on top of piston toward fuel injection pump side of engine.

M82196C

04 0400 58

1. Coat piston, cylinder bore, and piston ring compressor with clean engine oil.

A—Piston Mark “M” B—Fuel Injection Pump Side C—Flywheel Side D—Connecting Rod Alignment Mark E—Connecting Rod Cap Screw F—Groove G—Tangs

IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 5. Install bearing insert on connecting rod and rod cap, aligning tangs with grooves. 6. Apply clean engine oil to both bearing inserts and crankshaft journal. Carefully pull rod against crankshaft journal. IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. 7. Install cap on connecting rod with match marks on same side.

Continued on next page

TM2264 (15OCT08)

04-0400-58

OUO1030,0000097 –19–28NOV05–7/8

Repair 101508

PN=170

Removal and Installation 8. Dip new connecting rod cap screws in clean engine oil. Install cap screws and tighten to specifications. 9. Repeat with remaining cylinders. Specification Connecting Rod Cap Screw— Torque ........................................................................................... 47 N•m 35 lb-ft

10. If a new piston and connecting rod were installed, stamp a number corresponding to the cylinder number on the connecting rod cap and connecting rod. 11. Install cylinder head. See Cylinder Head Remove and Install. (Group 0400.)

04 0400 59

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

OUO1030,0000097 –19–28NOV05–8/8

TM2264 (15OCT08)

04-0400-59

Repair 101508

PN=171

Removal and Installation

Preliminary Piston and Rod Checks Stuck Rings:

Scuffed or Scored Pistons:

• Improper oil classification. • Improper periodic service. • Poor operating conditions. • Coolant leakage in crankcase. • Excessive cylinder bore taper.

• Insufficient lubrication. • Insufficient cooling. • Improper piston-to-cylinder bore clearance. • Coolant leakage in crankcase. • Misaligned or bent connecting rod. • Improperly installed piston. • Low oil level. • Improper operation. • Incorrect connecting rod bearing clearance. • Carbon build-up in ring groove. • Improper break-in. • Worn piston. 04 0400 • Contaminated oil.

Cylinder Wear and Distortion: • Incorrectly installed compression rings. • Insufficient lubrication. • Uneven cooling around cylinder bore. • Improper piston-to-cylinder bore clearance. • Cylinder bore damage.

Worn or Broken Compression Rings:

Warped Cylinder Block:

• Insufficient lubrication. • Insufficient cooling. • Improper ring installation. • Improper combustion. • Improper timing. • Abrasives in combustion chamber.

• Insufficient cooling. Broken Connecting Rod: • Inadequate piston-to-cylinder bore clearance. • Worn connecting rod bearing. • Distorted cylinder bore. • Piston pin failure.

Clogged Oil Control Ring: • Improper oil. • Excessive blow-by. • Contaminated oil. • Improper periodic service. • Low operating temperature.

Piston Pin and Snap Ring Failure:

Dull Satin Finish and Fine Vertical Scratches on Rings:

Mottled, Grayish, or Pitted Compression Rings:

• Dirt and abrasives in air intake system.

• Misaligned connecting rod. • Excessive crankshaft end play. • Incorrect snap rings.

• Internal coolant leaks.

OUO1030,0000094 –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-60

Repair 101508

PN=172

Removal and Installation

Piston and Connecting Rod Disassemble and Assemble Piston and Connecting Rod Disassemble 1. Remove piston rings. IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. 2. Put a mark on each piston and connecting rod to aid in assembly. 3. Remove and discard piston pin snap rings and separate piston from connecting rod.

04 0400 61

4. Piston pin bushing is press fit in connecting rod. Remove bushing only if replacement is necessary.

Continued on next page

TM2264 (15OCT08)

04-0400-61

OUO1030,0000093 –19–28NOV05–1/13

Repair 101508

PN=173

Removal and Installation Clean Pistons CAUTION: Always follow manufacturer’s instructions and safety steps exactly. –UN–23NOV97

1. Clean piston ring grooves using a piston ring groove cleaning tool.

RG7465

IMPORTANT: When washing pistons, always use a stiff bristle brush—NOT A WIRE BRUSH—to loosen carbon residue. DO NOT bead blast ring groove areas. 2. Clean pistons by any of the following methods: 04 0400 62

• Immersion-Solvent “D-Part”. • Hydra-Jet Rinse Gun. • Hot water with liquid detergent soap. If cleaning with hot water and liquid detergent, soak pistons in a 50 percent solution of liquid household detergent and hot water for 30 to 60 minutes. Use a stiff bristle brush—NOT A WIRE BRUSH—to loosen carbon residue. Dry with compressed air.

Continued on next page

TM2264 (15OCT08)

04-0400-62

OUO1030,0000093 –19–28NOV05–2/13

Repair 101508

PN=174

Removal and Installation Visually Inspect Pistons Carefully inspect pistons under magnification. Check for: • Signs of fatigue. • Fine cracks in the piston head (A). • Bent or broken ring lands (B). • Cracks in the skirt (C) at inner and outer ends of piston pin bore. • Excessive piston skirt wear (original machining marks must be visible). If any imperfections are found, replace the piston. A—Fine Cracks in Piston Head B—Bent or Broken Ring Lands C—Cracks in the Skirt

RG3326

–UN–04DEC97

04 0400 63

(Defects Exaggerated)

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TM2264 (15OCT08)

04-0400-63

OUO1030,0000093 –19–28NOV05–3/13

Repair 101508

PN=175

Removal and Installation Check Piston Ring Groove Wear With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston.

–UN–29AUG88 M35360

OUO1030,0000093 –19–28NOV05–4/13

Measure Piston Ring End Gap Push loose piston ring (C) into cylinder bore, using a piston, until ring is approximately 30 mm (1.181 in.) from bottom of cylinder bore. Measure piston ring end gap (A) and compare to specifications. If end gap exceeds wear limit, replace piston rings. Specification All Piston Rings—Gap ...................................................... 0.20—0.40 mm 0.008—0.016 in. Wear Limit ................................................................................. 0.490 mm 0.019 in.

–UN–08JUN00

A—End Gap B—Cylinder Bore C—Piston Ring D—Approx. 30 mm (1.181 in.)

M82049B

04 0400 64

Specification Top Compression Ring— Clearance ....................................................................... 0.70—0.105 mm 0.0028—0.0041 in. Wear Limit ............................................ Can not be accurately measured due to design Second Compression Ring— Clearance ..................................................................... 0.035—0.070 mm 0.0014—0.0028 in. Wear Limit ................................................................................ 0.190 mm 0.0075 in. Oil Ring—Clearance ..................................................... 0.030—0.060 mm 0.0012—0.0024 in. Wear Limit ................................................................................ 0.180 mm 0.0071 in.

Continued on next page

TM2264 (15OCT08)

04-0400-64

OUO1030,0000093 –19–28NOV05–5/13

Repair 101508

PN=176

Removal and Installation Measure Piston Pin Bore Measure piston pin bore diameter in piston.

–UN–06SEP88

If piston pin bore is not within specification, replace piston. If bore clearance (bore ID minus pin OD) exceeds specification, replace piston, piston pin, or both.

M37683

Specification Piston Pin Bore—Diameter ........................................ 26.00—26.009 mm 1.0236—1.0240 in. Wear Limit .............................................................................. 26.039 mm 1.0252 in. Piston Pin-to-Piston Pin Bore— Wear Limit ................................................................................. 0.120 mm 0.0047 in. Oil Clearance ............................................................... 0.000—0.014 mm 0.0000—0.0006 in. Wear Limit ................................................................................. 0.074 mm 0.0029 in.

04 0400 65

Continued on next page

TM2264 (15OCT08)

04-0400-65

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Repair 101508

PN=177

Removal and Installation Measure Piston Diameter 1. Measure piston diameter perpendicular (90°) to piston pin bore at distance (A).

–UN–25APR00

M82200A

Specification Measurement Location (A)— Distance .......................................................................................... 24 mm 0.945 in. Standard Piston—Diameter ...................................... 87.945—87.975 mm 3.4624—3.4636 in. Wear Limit ............................................................................... 87.900 mm 3.4606 in. 0.25 mm (0.010 in.) Oversize Piston—Diameter...................................................... 88.195—88.225 mm 3.4722—3.4734 in. Wear Limit ............................................................................... 88.150 mm 3.4705 in. Piston-to-Cylinder Bore— Clearance ..................................................................... 0.040—0.070 mm 0.0016—0.0028 in.

NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines.

M82052A

04 0400 66

–UN–12JUN00

If piston diameter is less than wear limit, install a new piston.

A—Piston Measure Point

2. Measure cylinder bore diameter and compare with piston diameter to determine piston-to-cylinder bore clearance. If clearance exceeds wear limit, cylinders must be bored oversize.

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TM2264 (15OCT08)

04-0400-66

OUO1030,0000093 –19–28NOV05–7/13

Repair 101508

PN=178

Removal and Installation Inspect Piston Pins and Bushings 1. Visually inspect piston pin. Pin must be in good condition with no visible wear. –UN–04NOV97

IMPORTANT: Do not attempt to polish or refinish piston pin. Pin has a highly polished surface.

RG7466

2. Dip piston pin in clean engine oil. 3. Install pin (A) through piston. Pin should pass through piston using only light thumb pressure. A—Pin

4. Insert pin from both sides. If pin enters freely, but binds in the center, the bore could be tapered. Pin should not “click” or need to be forced into bore on opposite side.

04 0400 67 OUO1030,0000093 –19–28NOV05–8/13

Measure Piston Pins Measure piston pin diameter. Measure diameter at six places. If pin diameter is less than wear limit, replace pin. If bore clearance (bore ID minus pin OD) exceeds specification, replace piston pin, piston, or both.

M82050A

–UN–25APR00

Specification Piston Pin—Diameter ............................................... 25.995—26.000 mm 1.0234—1.0236 in. Wear Limit ............................................................................... 25.965 mm 1.0222 in. Piston Pin-to-Piston Pin Bore—Oil Clearance ..................................................................... 0.000—0.014 mm 0.0000—0.0006 in. Wear Limit ................................................................................. 0.074 mm 0.0029 in.

Measure Piston Pins

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TM2264 (15OCT08)

04-0400-67

OUO1030,0000093 –19–28NOV05–9/13

Repair 101508

PN=179

Removal and Installation Measure Piston Pin Bushings Measure piston pin bushing diameter in connecting rod. If bushing diameter exceeds specification, replace bushing.

–UN–12JUN00

NOTE: When pressing in new bushings in connecting rod end, be sure oil holes are aligned. If bushing clearance (bushing ID minus pin OD) exceeds specification, replace bushing, piston pin, or both.

M82051A

04 0400 68

Specification Piston Pin Bushing In Connecting Rod—ID ..................................................................... 25.025—26.038 mm 0.9852—1.0251 in. Wear Limit ............................................................................... 26.068 mm 0.9082 in. Piston Pin-to-Piston Pin Bushing—Oil Clearance ................................................ 0.025—0.043 mm 0.0010—0.0017 in.

Continued on next page

TM2264 (15OCT08)

04-0400-68

OUO1030,0000093 –19–28NOV05–10/13

Repair 101508

PN=180

Removal and Installation Measure Connecting Rod Bearings Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap screws and tighten to specifications. Specification Connecting Rod Cap Screw— Torque ........................................................................................... 47 N•m 35 lb-ft

–UN–12JUN00

Measure inside diameter of bearing at three places as shown.

M82048A

If bearing diameter exceeds wear limit, replace bearing inserts. If bearing clearance with new bearing inserts (bearing ID minus crankshaft journal OD) exceeds specification, grind crankshaft connecting rod journals and install undersized bearing inserts, or replace bearing inserts and crankshaft. Specification Connecting Rod Bearing—ID ....................................... 48.00—48.028 mm 1.888—1.891 in. Wear Limit ................................................................................. 48.07 mm 1.893 in.

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TM2264 (15OCT08)

04-0400-69

OUO1030,0000093 –19–28NOV05–11/13

Repair 101508

PN=181

04 0400 69

Removal and Installation Piston and Connecting Rod Assemble IMPORTANT: Pistons must be installed on the same connecting rod they were removed from, and new piston pin snap rings must be used. NOTE: Apply clean engine oil to all parts during assembly.

–UN–12JUN00

1. Assemble piston to connecting rod with piston identification mark “M” (A) on same side as connecting rod stamped mark (F). If a new connecting rod is used, assemble piston to connecting rod with piston mark “M” opposite connecting rod bearing insert groove (G). Be sure oil hole in piston pin bushing is aligned with hole 04 in connecting rod. 0400 70

M82198AB

2. Install piston pin and new snap rings. A—Piston Mark “M” B—Piston C—Piston Pin D—Snap Ring E—Connecting Rod F—Stamped Mark G—Bearing Insert Groove

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TM2264 (15OCT08)

04-0400-70

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Repair 101508

PN=182

Removal and Installation Piston Rings Install

3. Install second compression ring, with manufacturer’s mark (near ring gap) toward top of piston, in middle groove. Turn ring until gap is 120° away from oil ring gap.

M82046A

2. Install oil ring over expander with ring gap (D) opposite (180°) of expander ends (B).

–UN–25APR00

1. Install oil ring expander (A) in bottom ring groove of piston with ends above either end of piston pin (E).

4. Install first compression ring (chrome plated), with manufacturer’s mark “R”, “T”, or “RN” (near ring gap) toward top of piston, in top groove. Turn ring until gap is 120° away from second ring gap and oil ring gap.

04 0400 71

M82199A

–UN–25APR00

A—Oil Ring Expander B—Oil Ring Expander Ends C—Oil Ring D—Oil Ring Gap E—Piston Pin F—Second Compression Ring G—First Compression Ring

OUO1030,0000093 –19–28NOV05–13/13

TM2264 (15OCT08)

04-0400-71

Repair 101508

PN=183

Removal and Installation

Cylinder Block Repair Cylinder Block Clean and Inspect Before inspecting and cleaning cylinder block, remove all of the following: • Soft plugs. • Oil galley plugs. • All internal and external mounted components. IMPORTANT: If block is cleaned in a hot tank, remove any aluminum parts (such as galley plugs) that can be damaged by hot tank solutions. 04 0400 72

1. Clean block thoroughly using cleaning solvent, pressure steam, or a hot tank. 2. All passages and crevices must be clear of sludge and grease. 3. All coolant passages must be free of lime deposits and scale. Measure Camshaft Follower Bores in Block Measure camshaft follower bores at all bore locations in block. If any one camshaft follower bore ID or cam follower-to-follower bore clearance exceeds specification, install a new cylinder block. Inspect and measure cam followers. Specification Camshaft Follower Bore—ID........................................ 12.00—12.025 mm 0.4724—0.4734 in. Wear Limit ................................................................................ 12.045 mm 0.4742 in. Camshaft Follower-to-Bore—Oil Clearance ...................................................................... 0.010—0.050 mm 0.0004—0.0019 in. Wear Limit .................................................................................. 0.090 mm 0.0035 in.

Continued on next page

TM2264 (15OCT08)

04-0400-72

OUO1030,0000088 –19–28NOV05–1/6

Repair 101508

PN=184

Removal and Installation Measure Camshaft Bushing and Bores in Block NOTE: Replaceable bushing (A) is installed in front camshaft bore only. Remaining bores in cylinder block act as camshaft bushings. –UN–25APR00

1. Measure camshaft bushing diameter at gear housing end.

M82072

If bushing diameter is not within specification, replace bushing. 2. To replace bushing: A—Camshaft Bushing B—Oil Hole

a. Remove bushing using a chisel. Be careful not to push bushing inside of engine.

04 0400 73

b. Align oil holes in new bushing and cylinder block. Install bushing using a driver set.

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TM2264 (15OCT08)

04-0400-73

OUO1030,0000088 –19–28NOV05–2/6

Repair 101508

PN=185

Removal and Installation 3. Remove flywheel housing. See Flywheel Housing Remove and Install. (Group 0400.)

–UN–08JUN00

4. Remove plug (A) using a long wooden dowel. Insert wooden dowel through gear housing side.

M35287A

5. Measure intermediate (B) and flywheel end (C) camshaft bore diameters. If bore diameter exceeds specification, replace cylinder block. 6. Apply TY6304 Flexible Form-In-Place Gasket on outer edge of plug. Install plug until it bottoms in bore. 7. Install flywheel housing. See Flywheel Housing Remove and Install. (Group 0400.)

–UN–25APR00

Specification Gear Housing End (Bushing)—ID ............................. 44.990—45.055 mm 1.771—1.774 in. Wear Limit .................................................................................. 45.13 mm 1.777 in. Intermediate and Flywheel-End Bores—ID ..................................................................... 45.00—45.025 mm 1.772—1.773 in. Wear Limit ................................................................................. 45.10 mm 1.776 in. Camshaft Journal-to-Bushing— Gear Housing End—Oil Clearance ...................................................................... 0.040—0.130 mm 0.0016—0.0051 in. Wear Limit ................................................................................. 0.240 mm 0.0094 in. Camshaft Journal-to-Block— Intermediate—Oil Clearance ......................................... 0.065—0.115 mm 0.0026—0.0045 in. Wear Limit ................................................................................. 0.225 mm 0.0089 in. Camshaft Journal-to-Block— Flywheel End—Oil Clearance ....................................... 0.050—0.100 mm 0.0020—0.0039 in. Wear Limit ................................................................................. 0.210 mm 0.0083 in.

M82073

04 0400 74

A—Plug B—Intermediate Bores C—Flywheel-End Bore

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TM2264 (15OCT08)

04-0400-74

OUO1030,0000088 –19–28NOV05–3/6

Repair 101508

PN=186

Removal and Installation Inspect and Measure Cylinder Bore Measure cylinder bore diameter at three positions: top, middle, and bottom. At these three positions, measure in both directions: along crankshaft centerline and in direction of crankshaft rotation. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Slight uneven wear, flaws, or minor damage may be corrected by deglazing. If cylinder bore exceeds wear limit, replace cylinder block or have cylinder rebored.

04 0400 75 –UN–25APR00

If cylinder is rebored, oversize pistons and rings must be installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize.

M82053A

If clearance (cylinder bore ID minus piston OD) exceeds specification, replace cylinder block, piston, or both; or rebore cylinder and install oversize piston and rings. Specification Standard Bore—Diameter ............................................. 88.00—88.03 mm 3.4646—3.4657 in. Wear Limit .................................................................................. 88.20 mm 3.472 in. 0.25 mm (0.010 in.) Oversize Bore—Diameter ............................................................. 88.25—88.28 mm 3.4744—3.4756 in. Wear Limit .................................................................................. 88.45 mm 3.482 in. Piston-to-Cylinder Bore— Clearance ...................................................................... 0.040—0.070 mm 0.0016—0.0028 in. Cylinder Bore—Out-of-Round ..................................................... 0.01 mm 0.0004 in. Wear Limit ................................................................................... 0.03 mm 0.0012 in. Cylinder Bore—Taper .................................................................. 0.01 mm 0.0004 in. Wear Limit ................................................................................... 0.03 mm 0.0012 in.

A—Top Position B—Middle Position C—Bottom Position D—Direction of Crankshaft Rotation E—Direction of Crankshaft Centerline

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TM2264 (15OCT08)

04-0400-75

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Repair 101508

PN=187

Removal and Installation Deglaze Cylinder Bores If cylinder bores have slight uneven wear, minor flaws, or damage, they can possibly be corrected by deglazing.

M82054A

–UN–12JUN00

IMPORTANT: If cylinder bores are to be deglazed with crankshaft installed in engine, put clean shop towels over crankshaft to protect journal and bearing surfaces from any abrasives. 1. Deglaze cylinder bores using a flex-hone with 300 grit stones.

04 0400 76

30°—40° Crosshatch Pattern

2. Use flex-hone as instructed by manufacturer to obtain a 30°—40° crosshatch pattern as shown. IMPORTANT: Do not use gasoline, kerosene, or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls. 3. Remove excess abrasive residue from cylinder walls using a clean, dry rag. Clean cylinder walls using clean white rags and warm, soapy water. Continue to clean cylinder until white rags show no discoloration. Rebore Cylinder Bores NOTE: The cylinder block can be rebored to use oversize pistons and rings. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines. 1. Align center of bore to drill press center. IMPORTANT: Check stone for wear or damage. Use a rigid hone with 180 grit stones. 2. Adjust hone so lower end is even with lower end of cylinder bore. 3. Adjust rigid hone stones until they contact narrowest point of cylinder. 4. Coat cylinder with honing oil. Hone should turn by hand. Adjust if too tight.

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TM2264 (15OCT08)

04-0400-76

OUO1030,0000088 –19–28NOV05–5/6

Repair 101508

PN=188

Removal and Installation 5. Run drill press at about 250 rpm. Move hone up and down in order to obtain a 30°—40° crosshatch pattern. NOTE: Measure bore when cylinder is cool. 6. Stop press and check cylinder diameter. NOTE: Finish should not be smooth. It should have a 30°—40° crosshatch pattern. 7. Remove rigid hone when cylinder is within 0.03 mm (0.001 in.) of desired size. 8. Use a flex hone with 300 grit stones for honing to final size.

04 0400 77

9. Check bore for size, taper, and out-of-round.

–UN–05APR89

IMPORTANT: Do not use solvents to clean cylinder bore. Solvents will not remove all metal particles and abrasives produced during honing.

M52959

10. Clean cylinder thoroughly using warm, soapy water until clean white rags show no discoloration. Using Rigid Hone

11. Dry cylinder and apply engine oil.

OUO1030,0000088 –19–28NOV05–6/6

Check Engine Rotation for Excessive Tightness 1. Rotate crankshaft several revolutions to be sure engine rotates without excessive tightness. 2. Check cylinder bores for deep scratches caused by an improperly installed or broken piston ring. 3. Check side clearance of connecting rods.

OUO1030,000007F –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-77

Repair 101508

PN=189

Removal and Installation

Crankshaft and Main Bearing Failure Analysis Scored Main Bearing: (Diagnosis also applies to connecting rod bearing.) • Oil starvation. • Contaminated oil. • Engine parts failure. • Excessive heat. • Poor periodic service.

• Misaligned or bent connecting rod. • Warped or bowed crankshaft. • Distorted cylinder block. Broken Main Bearing Caps: • Improper installation. • Dirt between bearing and crankshaft journal. • Low oil pressure. • Oil pump failure.

Galled or “Wiped” Bearings: • Fuel in lubricating oil (incomplete combustion). • Coolant in lubrication system (cracked block). • Leaking water pump (Seal with plugged hole). 04 0400 • Insufficient bearing oil clearance. 78 • Parts not lubricated prior to engine operation. • Wrong bearing size.

Cracked, Chipped or Broken Bearings: • Overspeeding. • Excessive idling. • Lugging. • Excessive oil clearance. • Improper installation.

Inconsistent Wear Pattern

OUO1030,00000B4 –19–28NOV05–1/1

Replace Crankshaft Front Oil Seal 1. Remove timing gear cover (A). See Timing Gear Cover Remove and Install. (Group 0400.)

–UN–12JUN00

2. Replace oil seal (B) using a driver set. Install seal with lip toward inside of gear housing cover. Install seal flush with surface of cover.

M82203A

A—Timing Gear Cover B—Oil Seal

OUO1030,00000B3 –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-78

Repair 101508

PN=190

Removal and Installation

Measure Crankshaft End Play NOTE: Crankshaft end play can be measured at front end or rear end of crankshaft. Procedure shown is performed from the rear end. The flywheel is removed to show detail. 1. Fasten dial indicator (A) to engine, and position indicator tip on end of crankshaft. –UN–12JUN00

IMPORTANT: Do not use excessive force when moving crankshaft to avoid damaging bearings.

M82118A

2. Push crankshaft (B) toward rear as far as possible. 3. Zero the dial indicator. 4. Using a bar, gently pry the crankshaft as far forward as possible.

A—Dial Indicator B—Crankshaft

Specification Crankshaft—End Play ...................................................... 0.13—0.23 mm 0.005—0.009 in. Wear Limit ................................................................................... 0.28 mm 0.011 in.

If end play exceeds wear limit, replace thrust bearings.

OUO1030,00000B2 –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-79

Repair 101508

PN=191

04 0400 79

Removal and Installation

Flywheel Remove and Install 1. Remove dampener drive (flex coupler). See Dampener Drive (Flex Coupling) Remove and Install. (Group 3360.) 2. Remove mounting cap screws (1) and flywheel (2). –UN–20JAN05

3. Examine flywheel ring gear for worn or broken teeth. 4. Replace flywheel if defective.

5. Apply clean engine oil to flywheel mounting cap screws.

1—Cap Screw (6 used) 2—Flywheel

6. Tighten to specification. Specification Flywheel Cap Screw—Torque....................................................... 83 N•m 61 lb-ft

OUO1030,00000AF –19–05JAN06–1/1

Crankshaft Rear Oil Seal Replace 1. Remove flywheel. See Flywheel Remove and Install. (Group 0400.) 2. Remove rear oil seal case (C).

–UN–12JUN00

3. Replace oil seal (A) using a driver set. Install seal, with lip toward cylinder block. Install seal flush with surface of oil seal case. NOTE: If crankshaft is grooved at oil seal contact point, seal can be installed 3 mm (0.120 in.) farther into oil seal case.

M82349A

04 0400 80

T207259A

IMPORTANT: Never reuse flywheel mounting cap screws. Always install new cap screws.

4. Apply TY6304 Flexible Form-In-Place Gasket to oil seal case mounting surface. 5. Install rear oil seal case and tighten cap screws securely.

A—Rear Oil Seal B—Oil Seal Case-to-Cylinder Block Cap Screw C—Oil Seal Case D—Flexible Form-In-Place Gasket E—Oil Seal Case-to-Crankcase Extension Cap Screw

OUO1030,00000AE –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-80

Repair 101508

PN=192

Removal and Installation

Crankcase Extension Housing Remove and Install 1. Remove flywheel. See Flywheel Remove and Install. (Group 0400.) 2. Remove oil pan. See Oil Pan and Strainer Remove and Install. (Group 0400.)

–UN–25APR00

3. Remove rear oil seal case-to-crankcase extension housing cap screws (D) and flywheel housing-to-crankcase extension housing cap screws. (C). 4. Remove crankcase extension housing cap screws (F and H) and crankcase extension housing (G).

M82056

5. Inspect crankcase extension housing for cracks. 6. Apply PM38657 Flexible Form-In-Place Gasket in a continuous 2—4 mm (0.080—0.157 in.) bead to crankcase extension housing.

RG10855A

Specification Rear Oil Seal Case-to-Crankcase Extension Housing Cap Screws— Torque ........................................................................................... 21 N•m 186 lb-in. Flywheel Housing-to-Crankcase Extension Housing Cap Screws— Torque ........................................................................................... 49 N•m 36 lb-ft Crankcase Extension Housing-to-Cylinder Block Cap Screws—Torque ............................................................................ 27 N•m 20 lb-ft Crankcase Extension Housing-to-Timing Gear Cover Cap Screws—Torque .................................................................... 22 N•m 195 lb-in.

–UN–25APR00

7. Install extension housing and tighten cap screws to specification.

A—Flywheel Housing B—Rear Oil Seal Case C—Cap Screw (Flywheel Housing-to-Crankcase Extension Housing) D—Cap Screw (Rear Oil Seal Case-to-Crankcase Extension Housing) E—Flexible Form-In-Place Gasket F—Cap Screw (Crankcase Extension Housing-to-Timing Gear Cover) G—Crankcase Extension Housing H—Cap Screw (Crankcase Extension Housing-to-Cylinder Block)

OUO1030,00000AD –19–30NOV05–1/1

TM2264 (15OCT08)

04-0400-81

Repair 101508

PN=193

04 0400 81

Removal and Installation

Flywheel Housing Remove and Install 1. Remove flywheel. See Flywheel Remove and Install. (Group 0400.)

–UN–25APR00

2. Remove starting motor. 3. Remove cap screws (A and E) and remove flywheel housing.

M82288A

4. When installing, apply a bead of TY6304 Flexible Form-In-Place Gasket to mounting flange of flywheel housing. 5. Tighten cap screws (A and E) to specification. 04 0400 82

A—Flywheel Housing-to-Cylinder Block Cap Screw B—Flywheel Housing C—Flexible Form-In-Place Gasket D—Plug E—Flywheel Housing-to-Crankcase Extension Cap Screw

Specification Flywheel Housing-to-Cylinder Block Cap Screw—Torque ............................................................ 49 N•m 36 lb-ft Flywheel Housing-to-Crankcase Extension Cap Screw—Torque ..................................................... 49 N•m 36 lb-ft

OUO1030,00000AC –19–28NOV05–1/1

Crankshaft and Main Bearings Repair Crankshaft and Main Bearings Remove

7. Check crankshaft main bearing clearance.

1. Drain oil from crankcase.

IMPORTANT: Connecting rod caps must be installed on the same connecting rods from which they were removed. Note alignment marks on caps and rods.

2. Check crankshaft end play. See Measure Crankshaft End Play. (Group 0400.) 3. Remove rear oil seal. See Crankshaft Rear Oil Seal Replace. (Group 0400.) 4. Remove flywheel housing. See Flywheel Housing Remove and Install. (Group 0400.)

8. Remove connecting rod cap screws and caps. See Piston and Connecting Rod Remove and Install. (Group 0400.) 9. Push pistons and connecting rods away from crankshaft.

5. Remove oil pan and crankcase extension housing.See Crankcase Extension Housing Remove and Install . (Group 0400.) 6. Remove timing gear cover and mounting plate or housing. See Timing Gear Cover Remove and Install. (Group 0400.)

Continued on next page

TM2264 (15OCT08)

04-0400-82

OUO1030,00000AA –19–28NOV05–1/9

Repair 101508

PN=194

Removal and Installation

T207254

–UN–21JAN05

04 0400 83

A—Crankshaft B—Smooth Bearing Inserts C—Main Bearing Cap Screw

D—Main Bearing Cap E—Tangs F—Bearing Cap Thrust Bearing

G—Cylinder Block Thrust Bearing

IMPORTANT: Main bearing caps must be installed on the same main bearings from which they were removed. 10. Remove main bearing cap screws (C), caps (D), and cap thrust bearings (F and G). Visually inspect condition of bearing inserts and crankshaft journals as bearing caps are removed.

11. Remove crankshaft (A). 12. Remove cylinder block thrust bearing (G) and main bearing inserts (B and H). 13. Inspect all parts for wear or damage.

Continued on next page

TM2264 (15OCT08)

H—Grooved Bearing Inserts I—Flywheel End of Crankshaft

04-0400-83

OUO1030,00000AA –19–28NOV05–2/9

Repair 101508

PN=195

M82284A

–UN–25APR00

Removal and Installation

Inspect Crankshaft and Main Bearings 1. Inspect crankshaft gear for chipped or broken teeth. Replace if necessary.

–UN–25APR00

2. If necessary, remove crankshaft gear from crankshaft using a knife-edge puller and a press. 3. To install crankshaft gear, heat new gear to approximately 150°C (300°F). Install gear (D) with timing mark “A” (E) toward end of crankshaft. Align slot in gear with key (C) in shaft. Press crankshaft into gear until gear is tight against crankshaft shoulder.

M82060A

04 0400 84

4. Inspect crankshaft for bend using V-blocks (B) and a dial indicator (A). Turn crankshaft slowly and read runout on indicator. If runout is greater than specification, replace crankshaft.

A—Dial Indicator B—V-Blocks C—Key D—Crankshaft Gear E—Timing Mark “A”

Specification Crankshaft—Radial Runout Maximum ..................................................................................... 0.02 mm 0.0007 in.

Continued on next page

TM2264 (15OCT08)

04-0400-84

OUO1030,00000AA –19–28NOV05–3/9

Repair 101508

PN=196

Removal and Installation 5. Measure crankshaft connecting rod journal (B) and main bearing journal (A) diameters. Measure several places around each journal.

–UN–25APR00

NOTE: If engine has had a previous major overhaul, journals may have been ground and undersized bearing inserts installed.

M82062A

Specification Connecting Rod Journal—OD .................................. 47.952—47.962 mm 1.8879—1.8883 in. Wear Limit ............................................................................... 47.902 mm 1.8859 in. Main Bearing Journal—OD .............................................. 53.952—53.962 2.1241—2.1245 in. Wear Limit ...................................................................................... 53.902 2.1221 in.

A—Main Bearing Journal B—Crankshaft Connecting Rod Journal

04 0400 85

If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine shop. If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.) undersize.

Continued on next page

TM2264 (15OCT08)

04-0400-85

OUO1030,00000AA –19–28NOV05–4/9

Repair 101508

PN=197

Removal and Installation 6. Install bearing inserts and main bearing cap on main bearing. Tighten main bearing cap screws to specifications.

–UN–25APR00

Specification Main Bearing Cap Screw— Torque ........................................................................................... 98 N•m 72 lb-ft

M82063

7. Measure main bearing inner diameter as shown. Specification Main Bearing Insert—ID ........................................... 54.000—54.020 mm 2.1260—2.1268 in.

04 0400 86

If bearing diameter exceeds wear limit, replace bearing inserts. If bearing clearance (bearing ID minus crankshaft main bearing journal OD) exceeds specification, replace bearing inserts and crankshaft or have crankshaft journals ground undersize by a qualified machine shop and install undersized bearing inserts. Specification Main Bearing-to-Crankshaft— Clearance ..................................................................... 0.038—0.068 mm 0.0015—0.0027 in. Wear Limit ................................................................................. 0.150 mm 0.0059 in.

Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 8. Clean and inspect oil passages in main bearing journals, connecting rod journals, and main bearing bores in cylinder block. 9. Inspect crankshaft for cracks or damage. Replace if necessary.

Continued on next page

TM2264 (15OCT08)

04-0400-86

OUO1030,00000AA –19–28NOV05–5/9

Repair 101508

PN=198

Removal and Installation Measure Crankshaft Main Bearing Clearance

–UN–06SEP88

IMPORTANT: Main bearing caps must be installed on the same main bearing and in the same direction to prevent crankshaft and main bearing damage. 1. Remove main bearing cap.

M35382

2. Wipe oil from bearing insert and crankshaft journal. 3. Put a piece of PLASTIGAGE (A), or an equivalent, along the full width of the bearing insert approximately 6 mm (0.250 in.) off center.

A—PLASTIGAGE

IMPORTANT: Do not rotate crankshaft while PLASTIGAGE is installed. Doing so will result in a false reading.

04 0400 87

4. Install main bearing cap and cap screws. Tighten cap screws to specifications. Specification Main Bearing Cap Screw— Torque ........................................................................................... 98 N•m 72 lb-ft

5. Remove cap screws and main bearing cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal.

PLASTIGAGE is a trademark of DANA Corp.

TM2264 (15OCT08)

Continued on next page

04-0400-87

OUO1030,00000AA –19–28NOV05–6/9

Repair 101508

PN=199

Removal and Installation 6. Use the graduation marks (A) on the envelope to compare the width of the flattened PLASTIGAGE (B) at its widest point.

M82117B

–UN–12JUN00

7. Determine main bearing clearance. The number within the graduation marks indicates the bearing clearance in millimeters or inches, depending on which side of the envelope is used. 8. Remove PLASTIGAGE. Specification Main Bearing—Clearance ............................................ 0.038—0.068 mm 0.0015—0.0027 in. Wear Limit ................................................................................. 0.150 mm 0.0059 in.

04 0400 88

A—Graduation Marks B—PLASTIGAGE

If clearance exceeds specification, replace bearing inserts.

Continued on next page

TM2264 (15OCT08)

04-0400-88

OUO1030,00000AA –19–28NOV05–7/9

Repair 101508

PN=200

Removal and Installation

T207254

–UN–21JAN05

04 0400 89

A—Crankshaft B—Smooth Bearing Inserts C—Main Bearing Cap Screw

D—Main Bearing Cap E—Tangs F—Bearing Cap Thrust Bearing

G—Cylinder Block Thrust Bearing

H—Grooved Bearing Insert I—Flywheel End of Crankshaft

Crankshaft and Main Bearings Install

4. Install crankshaft.

1. Apply clean engine oil to all parts during installation.

5. Install smooth bearing inserts (B) in main bearing caps, aligning tangs with slots in caps.

IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 2. Install grooved bearing inserts (H) in crankshaft bearing bores, aligning tangs with slots in bores. Ensure oil holes align with oil passages in cylinder block.

NOTE: Main bearing caps have “raised arrows” that are stamped with numbers. Both correspond to their location on the engine block. Install all bearing caps with the “arrow” toward the flywheel end. Install bearing caps beginning with thrust bearing cap (no number), number 1, then 2, etc. The main bearing cap at gear train end does not have a number.

3. Install cylinder block thrust bearings with oil grooves facing away from engine block.

6. Install bearing cap thrust bearings, with oil grooves facing away from cap.

Continued on next page

TM2264 (15OCT08)

04-0400-89

OUO1030,00000AA –19–28NOV05–8/9

Repair 101508

PN=201

Removal and Installation IMPORTANT: DO NOT use high-speed power tools or air wrenches to tighten main bearing cap screws.

IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from.

7. Install main bearing caps (D) in their original locations with arrows pointing toward flywheel side of engine.

Never reuse connecting rod cap screws, replace with new.

8. Dip entire main bearing cap screws in clean engine oil. Install cap screws and tighten. DO NOT tighten to specifications. 9. Using a soft-faced hammer, tap the front end of the crankshaft, then the rear end of the crankshaft, to align the thrust bearings. 04 0400 90

10. Tighten main bearing cap screws to specifications. When tightening, start at center main bearing cap and work your way out, alternating to the ends. Turn crankshaft by hand. If it does not turn easily, disassemble the parts and find the cause.

11. Match the connecting rod caps to the rods, using alignment marks. Install caps. 12. Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to specifications. Specification Connecting Rod Cap Screw— Torque..................................................................................... 47 N•m 35 lb-ft

Specification Main Bearing Cap Screw— Torque..................................................................................... 98 N•m 72 lb-ft

OUO1030,00000AA –19–28NOV05–9/9

TM2264 (15OCT08)

04-0400-90

Repair 101508

PN=202

Removal and Installation

Measure Valve Lift 1. Remove rocker arm cover.

–UN–12JUN00

2. Adjust valve clearance. See Engine Valve Lash (Clearance) Check and Adjustment. (Group 9010-25.)

T6333DTA

3. Fasten dial indicator (A) to engine, and position indicator tip on valve spring retainer (B). Valve must be fully closed and rocker arm must move freely. 4. Zero the dial indicator. 5. Manually turn crankshaft pulley clockwise (from fan end).

A—Dial Indicator B—Valve Spring Retainer

04 0400 91

6. Observe dial indicator as valve is moved to the full open position. Specification Intake and Exhaust Valve—Lift Minimum ........................................................................................ 5.1 mm 0.201 in.

7. Repeat for each valve.

OUO1030,00000A5 –19–05JAN06–1/1

TM2264 (15OCT08)

04-0400-91

Repair 101508

PN=203

Removal and Installation

Timing Gear Cover Remove and Install

T207257

–UN–21JAN05

04 0400 92

A—Oil Fill Cap B—O-Ring C—O-Ring D—Cover E—Gasket

F—Auxiliary Drive Cover G—Front Crankshaft Oil Seal H—Injection Pump Gear Cover I—Crankshaft Pulley

1. Remove engine. See Engine Remove and Install— 35D or see Engine Remove and Install—50D. (Group 0400.)

J—Washer K—Cap Screw, Crankshaft Pulley L—Form-in-Place Gasket

M—Timing Gear Cover N—Pipe Plug O—Pipe Plug P—Form-in-Place Gasket

NOTE: When removing timing gear cover, it is not necessary to remove auxiliary drive cover and gasket, end cover and O-ring, or fuel injection pump gear cover.

2. Remove alternator and belt. 3. Remove fan, spacer, and pulley.

6. Remove mounting cap screws and timing gear cover.

4. Remove cap screw and washer securing crankshaft pulley.

7. Apply TY6304 Flexible Form-In-Place Gasket where indicated on illustrations.

5. Remove crankshaft pulley using puller.

8. Install timing gear cover.

Continued on next page

TM2264 (15OCT08)

04-0400-92

OUO1030,00000A4 –19–28NOV05–1/2

Repair 101508

PN=204

Removal and Installation 9. Tighten cap screws to specification. 10. Install crankshaft pulley and tighten to specification. 11. Install fan, spacer, fan pulley, alternator, and belt. 12. Install engine. See Engine Remove and Install— 35D or see Engine Remove and Install—50D. (Group 0400.)

End Cover-to-Timing Gear Cover—Torque ....................................................................... 26 N•m 229 lb-in. Injection Pump Gear Cover-to-Timing Gear Cover— Torque..................................................................................... 26 N•m 229 lb-in. Oil Pan-to-Timing Gear Cover—Torque ....................................................................... 22 N•m 192 lb-in. Crankshaft Pulley-to-Crankshaft—Torque .............................................. 115 N•m 85 lb-ft

Specification Timing Gear Cover-to-Front Plate—Torque ......................................................................... 26 N•m 229 lb-in.

04 0400 93 OUO1030,00000A4 –19–28NOV05–2/2

Camshaft End Play Check

2. Fasten dial indicator to engine, and position indicator tip on end of camshaft.

M37512

3. Push camshaft toward the rear as far as possible.

–UN–06SEP88

1. Remove timing gear cover. See Timing Gear Cover Remove and Install. (Group 0400.)

4. Zero the dial indicator. 5. Pull camshaft forward as far as possible. If end play exceeds wear limit, remove camshaft and replace thrust plate. See Camshaft Remove and Install. (Group 0400.) Specification Camshaft—End Play ......................................................... 0.05—0.20 mm 0.002—0.008 in. Wear Limit ................................................................................... 0.30 mm 0.012 in.

OUO1030,00000A3 –19–05JAN06–1/1

TM2264 (15OCT08)

04-0400-93

Repair 101508

PN=205

Removal and Installation

Timing Gear Backlash Check

Specification Timing Gear Backlash—Backlash .................................... 0.07—0.15 mm 0.002—0.006 in. Wear Limit ................................................................................... 0.17 mm 0.007 in.

T207256

A—Fuel Injection Pump Gear-to-Idler Gear B—Camshaft Gear-to-Idler Gear C—Idler Gear-to-Crankshaft Gear

–UN–21JAN05

Measure backlash between meshing gears at points (A— D and G). If backlash exceeds wear limit, replace meshing gears as a set.

04 0400 94 OUO1030,00000A2 –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-94

Repair 101508

PN=206

Removal and Installation

Camshaft Remove and Install Camshaft Remove 1. Drain engine oil and coolant if not done previously.

–UN–16FEB05

2. Remove rocker arm assembly and push rods. See Rocker Arm Cover Remove and Install. (Group 0400.) 3. Remove timing gear cover. See Timing Gear Cover Remove and Install. (Group 0400.)

T207559A

4. Check camshaft end play. See Camshaft End Play Check. (Group 0400.) 5. Check backlash of timing gears. See Timing Gear Backlash Check. (Group 0400.)

04 0400 95

A—Timing Marks B—Camshaft Mounting Cap Screws C—Camshaft and Gear

NOTE: If a magnetic follower holder kit is not available, turn engine until oil pan is upward, to hold cam followers away from camshaft. 6. Hold cam followers away from camshaft using a magnetic follower holder kit such as D15001NU. NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. 7. Rotate crankshaft and align timing marks (A). IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces can be damaged. 8. Remove two cap screws (B) and remove camshaft with gear. 9. Inspect camshaft for wear or damage. 10. Inspect camshaft followers. 11. Inspect camshaft follower bores in block and inspect camshaft bushing and bores in block.

Continued on next page

TM2264 (15OCT08)

04-0400-95

OUO1030,00000A1 –19–28NOV05–1/8

Repair 101508

PN=207

Removal and Installation Inspect Camshaft 1. If camshaft end play was not checked before removing camshaft, check clearance (side gap) between camshaft and camshaft thrust plate using a feeler gauge. If side gap exceeds wear limit, remove camshaft gear and replace thrust plate.

M82067A

04 0400 96

–UN–12JUN00

Specification Camshaft-to-Thrust Plate— Clearance ......................................................................... 0.05—0.20 mm 0.002—0.008 in. Wear Limit ................................................................................... 0.30 mm 0.012 in.

A—Camshaft Gear B—Thrust Plate C—Camshaft D—Side Gap

Continued on next page

TM2264 (15OCT08)

04-0400-96

OUO1030,00000A1 –19–28NOV05–2/8

Repair 101508

PN=208

Removal and Installation 2. Inspect gear (A) for chipped or broken teeth. Replace if necessary.

–UN–12JUN00

3. If necessary, remove gear (A) and thrust plate (B) from camshaft (C) using a knife-edge puller and a press.

M82068A

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.

A—Camshaft Gear B—Thrust Plate C—Camshaft D—Key

4. Heat gear in oil to approximately 150°C (300°F). IMPORTANT: Be sure thrust plate is not between camshaft gear and camshaft shoulder while installing gear. Thrust plate must spin freely on camshaft after installation of gear.

04 0400 97

5. Install thrust plate (B) if removed. Install gear with timing mark “C” facing away from end of camshaft. Align slot in gear with key (D) in shaft. Press camshaft into gear until gear is tight against camshaft shoulder.

OUO1030,00000A1 –19–28NOV05–3/8

6. Measure camshaft bend using V-blocks and a dial indicator (A). Turn camshaft slowly and read variation on indicator. If variation exceeds wear limit, replace camshaft.

–UN–12JUN00

Specification Camshaft Bend—Radial Runout maximum .................................................................................... 0.02 mm 0.0008 in. Wear Limit ................................................................................... 0.05 mm 0.0020 in.

M82291A

A—Dial Indicator B—Camshaft Central Bearing Areas C—V-Block

Continued on next page

TM2264 (15OCT08)

04-0400-97

OUO1030,00000A1 –19–28NOV05–4/8

Repair 101508

PN=209

Removal and Installation 7. Measure camshaft lobe height (A). If lobe height is less than wear limit, replace camshaft.

–UN–08JUN00

Specification Camshaft Lobe—Height ........................................... 38.600—38.800 mm 1.5197—1.5276 in. Wear Limit ................................................................................. 38.35 mm 1.5098 in.

RG11086A

A—Camshaft Lobe Height

04 0400 98 Continued on next page

TM2264 (15OCT08)

04-0400-98

OUO1030,00000A1 –19–28NOV05–5/8

Repair 101508

PN=210

Removal and Installation 8. Measure camshaft journal OD at both flywheel- and gear-end journals (A and C), and at intermediate journals (B).

–UN–12JUN00

If journal diameter is less than wear limit, replace camshaft.

M82292A

Specification Camshaft End Journals—OD ................................... 44.925—44.950 mm 1.7687—1.7697 in. Wear Limit .............................................................................. 44.890 mm 1.7673 in. Camshaft Intermediate Journal— OD ............................................................................ 44.910—44.935 mm 1.7681—1.7691 in. Wear Limit ............................................................................... 44.875 mm 1.7667 in.

A—Flywheel-End Journal B—Intermediate Journals C—Gear-End Journal

04 0400 99

9. Measure camshaft bushing and camshaft bores in cylinder block. 10. Inspect cam followers. 11. Inspect cam follower bores in cylinder block. Inspect Cam Followers IMPORTANT: Cam followers must be installed in the same bores from which they were removed. 1. Put a mark on each cam follower and cylinder block bore to aid in installation. 2. Remove cam followers. 3. Inspect all parts for wear or damage.

Continued on next page

TM2264 (15OCT08)

04-0400-99

OUO1030,00000A1 –19–28NOV05–6/8

Repair 101508

PN=211

Removal and Installation 4. Inspect cam follower contact surface for abnormal wear (A). Replace if necessary. A normal contact surface is shown in (B).

–UN–01FEB05

5. Measure cam follower diameter.

T207560

Specification Cam Follower—OD .................................................. 11.975—11.990 mm 0.471—0.472 in. Wear Limit .............................................................................. 11.955 mm 0.4707 in.

If diameter is less than wear limit, replace cam follower. 6. Measure cam follower bore diameter in cylinder block and determine if clearance is within specification.

–UN–01FEB05

If cam follower bore diameter exceeds wear limit, replace cylinder block. If bore clearance (bore ID minus follower OD) exceeds specification, replace cam follower, cylinder block, or both.

T207561

04 0400 ,100

A—Abnormal Wear Surface B—Normal Contact Surface

Continued on next page

TM2264 (15OCT08)

04-0400-100

OUO1030,00000A1 –19–28NOV05–7/8

Repair 101508

PN=212

Removal and Installation Camshaft Install NOTE: Apply clean engine oil to all parts during installation. Due to the odd number of teeth on the idler gear, timing marks will only align periodically. –UN–16FEB05

1. Rotate crankshaft to align timing marks (A).

2. Install camshaft (C). 3. Install and tighten cap screws (B) to specification.

T207559A

IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Machined surfaces can be damaged.

04 0400 ,101

A—Timing Marks B—Camshaft Mounting Cap Screws C—Camshaft and Gear

Specification Camshaft Mounting Cap Screw— Torque ........................................................................................... 26 N•m 228 lb-in.

4. Install timing gear cover. See Timing Gear Cover Remove and Install. (Group 0400.) 5. Install push rods and rocker arm assembly. See Rocker Arm Cover Remove and Install. (Group 0400.)

OUO1030,00000A1 –19–28NOV05–8/8

TM2264 (15OCT08)

04-0400-101

Repair 101508

PN=213

Removal and Installation

Idler Gear Remove and Install Idler Gear Remove 1. Remove timing gear cover. See Timing Gear Cover Remove and Install. (Group 0400.)

–UN–22APR04

2. Check backlash of timing gears. See Timing Gear Backlash Check. (Group 0400.)

04 0400 ,102

3. Rotate crankshaft and align timing marks. 4. Remove three cap screws (D), shaft (E), and gear (C).

RG13595A

NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. When all timing marks on gears align, the piston closest to the coolant pump is at TDC on compression stroke. No. 1 cylinder is closest to the flywheel. C—Idler Gear D—Cap Screw E—Idler Gear Shaft

5. Inspect all parts for wear or damage.

Continued on next page

TM2264 (15OCT08)

04-0400-102

OUO1030,000009D –19–28NOV05–1/2

Repair 101508

PN=214

Removal and Installation Inspect Idler Gear

–UN–12JUN00

1. Inspect gear (C) for chipped or broken teeth. Replace if necessary. 2. Measure outside diameter of idler gear shaft (A).

Specification Idler Gear Shaft—OD ............................................... 45.950—45.975 mm 1.809—1.810 in. Wear Limit ................................................................................. 45.93 mm 1.808 in.

RG10849A

If shaft diameter is less than wear limit, replace idler gear shaft.

A—Idler Gear Shaft B—Idler Gear Bushing C—Idler Gear

3. Measure idler gear bushing (B) inside diameter.

04 0400 ,103

If bushing diameter exceeds wear limit, replace bushing. Specification Idler Gear Bushing—ID .............................................. 46.00—46.025 mm 1.811—1.812 in. Wear Limit ................................................................................. 46.08 mm 1.814 in. Oil Clearance ................................................................ 0.025—0.075 mm 0.001—0.003 in. Wear Limit ................................................................................... 0.18 mm 0.007 in.

If bushing oil clearance (bushing ID minus shaft OD) exceeds specification, replace bushing, shaft, or both. Replace bushing using a universal driver set. Align oil holes in bushing and idler gear. Install bushing flush with surface of idler gear. Idler Gear Install 1. Install idler gear and ensure all timing marks are aligned. 2. Install cap screws. 3. Install timing gear cover and crankshaft pulley. See Timing Gear Cover Remove and Install. (Group 0400.)

OUO1030,000009D –19–28NOV05–2/2

TM2264 (15OCT08)

04-0400-103

Repair 101508

PN=215

Removal and Installation

Timing Gear Cover Mounting Plate Remove and Install

RG8578A

–UN–25APR00

04 0400 ,104

A—Timing Gear Cover Mounting Plate

B—Cap Screw C—O-Rings

D—Stud

E—Form-in-Place Gasket

1. Remove camshaft. See Camshaft Remove and Install. (Group 0400.)

7. Install plate (A) and tighten cap screws (B) to specification.

2. Remove idler gear. See Idler Gear Remove and Install. (Group 0400.)

Specification Timing Gear Cover Mounting Plate Cap Screws—Torque .................................................... 25 N•m 221 lb-in.

3. Remove fuel injection pump. See Fuel Injection Pump Remove and Install. (Group 0400.) 4. Remove mounting cap screws (B) and plate (A).

8. Install camshaft, idler gear, oil pump, fuel injection pump, fuel supply pump, and coolant pump.

5. Install new O-rings (C). 6. Apply a bead of TY6304 Flexible Form-In-Place Gasket to the cylinder block and plate mating surfaces.

OUO1030,000009B –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-104

Repair 101508

PN=216

Removal and Installation

Oil Pan and Strainer Remove and Install 1. Drain engine oil from crankcase. 2. Remove cap screws (F) and oil pan (E). 3. Remove oil strainer (B). 4. Replace gasket on oil strainer. 5. Install oil strainer and tighten cap screws (C) to specification. Specification Oil Strainer Cap Screw—Torque................................................... 26 N•m 230 lb-in.

04 0400 ,105 –UN–25APR00

6. Apply TY6304 Flexible Form-In-Place Gasket to oil pan rail.

M82362A1

7. Install oil pan (E) and spacer plate (I) (if equipped), and tighten cap screws to specification. Specification Oil Pan Cap Screw—Torque ......................................................... 26 N•m 230 lb-in.

8. Replace drain washer as necessary. NOTE: Install washer with raised center against plug. 9. Fill engine crankcase with correct grade and viscosity of engine oil. See Diesel Engine Oil. (Operator’s Manual.)

A—Gasket B—Oil Strainer C—Cap Screw D—Form-in-Place Gasket E—Oil Pan F—Cap Screw G—Drain Plug H—Washer I—Spacer Plate (if equipped)

OUO1030,00000BA –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-105

Repair 101508

PN=217

Removal and Installation

Oil Pump Remove and Install 1. Remove timing gear cover. See Timing Gear Cover Remove and Install. (Group 0400.)

4. Inspect all parts for wear or damage. See Oil Pump Disassemble, Inspect and Assemble. (Group 0400.) 04 0400 ,106

RG13414A

3. Remove oil pump cover mounting cap screws (C) and remove oil pump cover (B).

–UN–12APR04

2. Remove oil pressure regulating valve. See Oil Pressure Regulating Valve Remove and Install. (Group 0400.)

5. Install timing gear cover. See Timing Gear Cover Remove and Install. (Group 0400.) A—Timing Gear Cover B—Oil Pump Cover C—Screw (7 used)

OUO1030,00000B9 –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-106

Repair 101508

PN=218

Removal and Installation

Oil Pump Disassemble, Inspect, and Assemble 1. Check rotor recess. If rotors are below face of pump housing more than specification, replace rotor assembly.

RG13408A

–UN–12APR04

Specification Oil Pump Rotor—Recess ................................................. 0.02—0.07 mm 0.001—0.003 in. Wear Limit ................................................................................... 0.12 mm 0.005 in.

2. Check inner-to-outer rotor clearance. If clearance is more than specification, replace rotor assembly. Rotor Recess

Specification Oil Pump Inner-to-Outer Rotor— Clearance Maximum.................................................................... 0.16 mm 0.006 in.

04 0400 ,107

3. Check outer rotor-to-pump body clearance. If clearance is more than wear limit, replace entire assembly.

RG13409A

–UN–12APR04

Specification Oil Pump Outer Rotor-to-Housing—Clearance .......................................... 0.12—0.21 mm 0.005—0.008 in. Wear Limit ................................................................................... 0.30 mm 0.012 in.

A—Outer Rotor B—Inner Rotor C—Pump Housing

RG13410A

–UN–12APR04

Rotor-to-Rotor Clearance

Rotor-to-Housing Clearance

Continued on next page

TM2264 (15OCT08)

04-0400-107

OUO1030,00000B7 –19–28NOV05–1/3

Repair 101508

PN=219

Removal and Installation 4. Measure inner rotor diameter (A). If measurement is less than specification, replace rotor assembly. Specification Oil Pump Inner Rotor Inner— Diameter ....................................................................... 53.05—53.15 mm 2.088—2.093 in.

–UN–12APR04

5. Measure distance between flats (B) of inner rotor. If measurement is less than specification, replace rotor assembly.

RG13411A

Specification Oil Pump Inner Rotor Flat-to-Flat—Distance ................................................... 49.95—50.05 mm 1.967—1.974 in. Inner Rotor Flats

6. Measure crankshaft gear outer diameter (C). If measurement is less than specification, replace crankshaft gear. Specification Crankshaft Gear Outer—Diameter ............................... 53.45—53.55 mm 2.104—2.108 in.

–UN–16APR04

7. Measure distance between flats (D) of crankshaft gear. If measurement is less than specification, replace crankshaft gear. Specification Crankshaft Gear Flat-to-Flat— Distance ........................................................................ 49.45—49.75 mm 1.947—1.959 in.

RG13412A

04 0400 ,108

Crankshaft Gear A—Inner Rotor Diameter B—Inner Rotor Flat-to-Flat C—Crankshaft Gear Diameter D—Crankshaft Gear Flat-to-Flat

Continued on next page

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04-0400-108

OUO1030,00000B7 –19–28NOV05–2/3

Repair 101508

PN=220

Removal and Installation 8. Install rotors with alignment marks (A) facing out. 9. Apply T43512 Thread Lock and Sealer (medium strength) to pump cover mounting cap screws. Install cap screws and tighten to specification.

–UN–12APR04

Specification Oil Pump Cover Mounting Cap Screw—Torque ................................................................................ 7 N•m 61 lb-in.

RG13413A

10. Install oil pump. See Oil Pump Remove and Install. (Group 0400.) A—Alignment Marks Oil Pump Rotor Installation

04 0400 ,109 OUO1030,00000B7 –19–28NOV05–3/3

Oil Pressure Regulating Valve Remove and Install Remove parts as follows:

–UN–08APR04

1. Remove cap (A) and add shims. Each 1 mm (0.039 in.) of shim thickness increases oil pressure 10.9 kPa (1.6 psi).

RG13404A

NOTE: Valve components are not serviced individually. Replace complete regulating valve if any components are defective. 2. Inspect all parts for wear or damage and replace parts or complete valve as needed. 3. Installation is done in the reverse order of removal. 4. Stake valve cap to valve body.

A—Valve Cap C—Spring D—Valve

Specification Oil Pressure Regulating Valve Filter Housing Cap Screws— Torque ............................................................................................ 27 N•m 20 lb-ft Oil Pressure Regulating Valve Body Retaining Nut—Torque ........................................................ 30 N•m 22 lb-ft

OUO1030,00000B6 –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-109

Repair 101508

PN=221

Removal and Installation

Oil Filter Adapter Remove and Install 1. Remove oil filter (A). 2. Remove three cap screws (D), oil filter adapter (B), and gasket (C).

Specification Oil Filter Adapter Cap Screws— Torque ........................................................................................... 27 N•m 20 lb-ft

04 0400 ,110

T207258

4. Tighten cap screws to specification.

–UN–21JAN05

3. Installation is done in the reverse order of removal.

A—Oil Filter B—Adapter C—Gasket D—Cap Screw (3 used)

OUO1030,00000B5 –19–28NOV05–1/1

TM2264 (15OCT08)

04-0400-110

Repair 101508

PN=222

Section 05

Engine Auxiliary Systems Contents Page

Group 0510—Cooling System Radiator Remove and Install—35D . . . . . . . .05-0510-1 Radiator Remove and Install—50D . . . . . . . .05-0510-4 Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install—35D . . . . . . .05-0560-1 Fuel Tank Remove and Install—50D . . . . . . .05-0560-4 Bleed Fuel System . . . . . . . . . . . . . . . . . . . .05-0560-6

TM2264 (15OCT08)

05-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

05-2

Repair 101508

PN=2

Group 0510

Cooling System Radiator Remove and Install—35D

–UN–23AUG88

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

TS281

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 2. Remove counterweight. See Counterweight Remove and Install—35D. (Group 1749.) 3. Remove two cap screws (1) holding air cleaner housing.

–UN–14JAN05

NOTE: Note any shims that may accompany frame brackets for installation.

T207062A

4. Remove frame brackets (2-4) and frame cover (5). 5. Remove right-side frame bracket (7). 6. Remove air cleaner assembly. 7. Drain coolant from radiator. Approximate capacity is 3.75 L (4.0 qt). 8. Remove fan guard (8). Remove upper radiator hose (9) and lower radiator hose (10).

–UN–21JAN05

9. Remove four cap screws (11) securing fan shroud. Carefully move away from radiator.

T207277A

1—Cap Screw (2 used) 2—Left-Side Frame Bracket 3—Left-Rear Frame Bracket 4—Right-Rear Frame Bracket 5—Frame Cover 6—Frame Cover 7—Right-Side Frame Bracket 8—Fan Guard 9—Upper Radiator Hose 10—Lower Radiator Hose 11—Cap Screw (4 used)

Continued on next page

TM2264 (15OCT08)

05-0510-1

MM61211,0000844 –19–07FEB05–1/3

Repair 101508

PN=225

05 0510 1

Cooling System 10. Remove lower drain hose. 11. Remove cap screws (12 and 13). 12. Disconnect overflow hose (14). 13. Remove cap screws (15) and remove bracket. –UN–21JAN05

14. Remove radiator. Carefully move oil cooler and lines away from radiator when removing radiator.

T207273A

15. Remove fan shroud. 16. Remove two lower bushings from the bottom of the radiator. 17. Replace parts as necessary. 18. Install two lower bushings. 19. Temporarily position fan shroud over fan.

–UN–21JAN05

20. Install radiator (16). 21. Install fan shroud (17) to radiator with four cap screws.

T207274A

22. Install drain hose (18) to bottom of radiator. 23. Position fan guard (19) and install cap screws. 24. Install upper radiator hose (20) and lower radiator hose (21) and tighten clamps.

–UN–21JAN05

12—Cap Screw (2 used) 13—Cap Screw (2 used) 14—Overflow Hose 15—Cap Screw (2 used) 16—Radiator 17—Fan Shroud 18—Drain Hose 19—Fan Guard 20—Upper Radiator Hose 21—Lower Radiator Hose

T207275A

05 0510 2

Continued on next page

TM2264 (15OCT08)

05-0510-2

MM61211,0000844 –19–07FEB05–2/3

Repair 101508

PN=226

Cooling System 25. Install four cap screw (22) connecting oil cooler to radiator. 26. Connect overflow hose (23).

29. Install air cleaner assembly. 30. Install frame brackets. 31. Install counterweight. See Counterweight Remove and Install—35D. (Group 1749.)

T207278A

28. Fill radiator with coolant. See Cooling System Fill and Deaeration. (Operator’s Manual.)

–UN–21JAN05

27. Install bracket and two cap screws (24).

32. Install engine covers. 22—Cap Screw (4 used) 23—Overflow Hose 24—Bracket

05 0510 3

MM61211,0000844 –19–07FEB05–3/3

TM2264 (15OCT08)

05-0510-3

Repair 101508

PN=227

Cooling System

Radiator Remove and Install—50D

–UN–23AUG88

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

TS271

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. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 2. Remove counterweight. See Counterweight Remove and Install—50D. (Group 1749.) 3. Remove two cap screws (1) securing tool box.

5. Remove cap screws (3) and remove cover plate (4) under alternator.

–UN–04FEB05

T207696A

1—Tool Box Cap Screw (2 used) 2—Cover 3—Cap Screw (5 used) 4—Cover Plate

T207697A

05 0510 4

–UN–04FEB05

4. Remove cover (2).

Continued on next page

TM2264 (15OCT08)

05-0510-4

MM61211,0000846 –19–07FEB05–1/5

Repair 101508

PN=228

Cooling System 6. Remove air cleaner hoses (5). 7. Remove two cap screws (6) and remove air cleaner assembly. 8. Remove two cap screws (7) and remove first half of fan guard. –UN–04FEB05

9. Remove second half of fan guard (8).

T207698A

10. Remove cap screws (9) securing radiator frame bracket, and frame bracket (10). 5—Air Cleaner Hoses 6—Cap Screw (2 used) 7—Fan Guard Cap Screw (4 used) 8—Fan Guard 9—Radiator Frame Bracket Cap Screw (3 used) 10—Frame Bracket

T207776A

–UN–04FEB05

T207699A

–UN–04FEB05

05 0510 5

Continued on next page

TM2264 (15OCT08)

05-0510-5

MM61211,0000846 –19–07FEB05–2/5

Repair 101508

PN=229

Cooling System 11. Remove three cap screws (11) securing undercarriage inspection cover (12). 12. Drain coolant from radiator. Approximate capacity is 5.2 L (5.5 qt).

–UN–04FEB05

13. Disconnect upper radiator hose (13) and lower radiator hose (14). 14. Disconnect overflow hose (15).

T207774A

15. Disconnect drain hose. 16. Remove upper radiator support bracket (16). 17. Remove two upper bushings from the top of the radiator. 18. Remove fan shroud from radiator (17). 19. Remove cap screws (18) securing receiver-dryer (19) and vapor condenser (20) from radiator.

–UN–04FEB05

20. Remove two cap screws (21) securing hydraulic tube to radiator bracket.

T207772A

21. Remove four cap screws (22) securing hydraulic oil cooler to radiator bracket. 22. Remove radiator. Carefully move oil cooler and lines away from radiator when removing radiator. 23. Remove upper and lower support brackets (23) from radiator.

–UN–04FEB05

11—Cap Screw (3 used) 12—Undercarriage Inspection Cover 13—Upper Radiator Hose 14—Lower Radiator Hose 15—Overflow Tube 16—Upper Radiator Support Bracket 17—Fan Shroud 18—Support Bracket Cap Screw (4 used) 19—Receiver-Dryer 20—Vapor Condenser 21—Hydraulic Tube Cap Screw (2 used) 22—Oil Cooler Cap Screw (4 used) 23—Upper and Lower Support Brackets 24—Vapor Condenser Support Bracket

T207770A

05 0510 6

Continued on next page

TM2264 (15OCT08)

05-0510-6

MM61211,0000846 –19–07FEB05–3/5

Repair 101508

PN=230

Cooling System 24. Remove two lower bushings from the bottom of the radiator. 25. Remove vapor condenser support bracket (24) from radiator. 26. Replace parts as necessary. 27. Install two lower bushings. 28. Install upper and lower support brackets (23) to radiator. 29. Install vapor condenser support bracket (24) to radiator. 30. Install drain hose to bottom of radiator. 31. Temporarily position lower section of fan shroud under fan. 32. Install radiator.

05 0510 7

33. Install remaining sections of fan shroud to radiator using four cap screws. 34. Position fan guard (8) and install cap screws (7). 35. Install upper radiator hose (13) and lower radiator hose (14) and tighten clamps. 36. Install four cap screws (22) connecting oil cooler and hydraulic tube (21) to radiator. 37. Install receiver-dryer (19) and vapor condenser (20) to radiator. 38. Install upper radiator support bracket (16) with two cap screws. 39. Install radiator frame bracket (10). 40. Connect overflow hose (15). 41. Install three cap screws (11) securing undercarriage inspection cover (12). 42. Install air cleaner assembly.

Continued on next page

TM2264 (15OCT08)

05-0510-7

MM61211,0000846 –19–07FEB05–4/5

Repair 101508

PN=231

Cooling System 43. Install cover plate (4) and cap screws (3) under alternator. 44. Install cover (2) and cap screws (1) securing tool box to frame. 45. Fill radiator with coolant. See Cooling System Fill and Deaeration. (Operator’s Manual.) 46. Install counterweight. See Counterweight Remove and Install—50D. (Group 1749.) 47. Install engine covers.

MM61211,0000846 –19–07FEB05–5/5

05 0510 8

TM2264 (15OCT08)

05-0510-8

Repair 101508

PN=232

Group 0560

External Fuel Supply Systems Fuel Tank Remove and Install—35D 1. Remove right-side covers. 2. Lift maintenance cover.

–UN–04FEB05

3. Disconnect negative battery cable (2) and positive battery cable (1). 4. Remove battery securing bracket (3) and rods.

T207591A

5. Disconnect fuel level sender harness (4). 6. Disconnect fuel sender harness fastener clip (5) from battery box outer side plate (6). 7. Remove outer side plate (6) of battery box. 8. Carefully remove battery from battery box. 9. Remove clip, washer, and cable (7) to maintenance cover.

05 0560 1 –UN–04FEB05

10. Remove five cap screws (8) and remove battery box (9).

T207592A

11. Remove fuel tank strap. 1—Positive Battery Cable 2—Negative Battery Cable 3—Battery Securing Bracket 4—Fuel Level Sender Harness 5—Fuel Level Sender Harness Fastener Clip 6—Battery Box Outer Side Plate 7—Maintenance Cover Clip, Washer, and Cable 8—Battery Box Cap Screw (5 used) 9—Battery Box

Continued on next page

TM2264 (15OCT08)

05-0560-1

MM61211,0000848 –19–07FEB05–1/3

Repair 101508

PN=233

External Fuel Supply Systems 12. Remove inspection plate (10) under fuel tank. NOTE: Residual fuel may drain from tank when removing hoses. Place drain on track prior to disconnecting fuel hoses to tank.

–UN–04FEB05

13. Drain fuel using valve (11). Approximate capacity is 40 L (10.6 gal). 14. Disconnect pick-up hoses (12).

T207594A

15. Remove fuel tank (13). 16. Replace parts as necessary. 17. Position fuel tank (13) and tank strap (14). 18. Connect pick-up hoses (12). 19. Install inspection plate (10) under fuel tank. 20. Install battery box (9).

–UN–04FEB05

21. Install five cap screws (8) securing battery box. 22. Install clip, washer, and cable (7) to maintenance cover.

T207593A

05 0560 2

23. Carefully install battery in battery box. 24. Install outer side plate (6) to battery box. 10—Inspection Plate 11—Fuel Drain Valve 12—Pick-Up Hoses 13—Fuel Tank 14—Fuel Tank Strap

25. Connect fuel level harness (4) and harness fastener clip (5). 26. Install battery securing bracket (3) to battery. 27. Connect positive battery cable (1) and negative battery cable (2). 28. Install right-side covers. 29. Fill fuel tank. 30. Bleed fuel system by turning fuel shut-off valve to the ON position. 31. Turn the key switch to ON for 10—15 seconds to engage automatic bleeding. Do not start engine.

Continued on next page

TM2264 (15OCT08)

05-0560-2

MM61211,0000848 –19–07FEB05–2/3

Repair 101508

PN=234

External Fuel Supply Systems 32. Start engine. Stop engine. Check for fuel leakage.

MM61211,0000848 –19–07FEB05–3/3

05 0560 3

TM2264 (15OCT08)

05-0560-3

Repair 101508

PN=235

External Fuel Supply Systems

Fuel Tank Remove and Install—50D 1. Lift maintenance cover. 2. Remove right-side covers.

–UN–08FEB05

3. Disconnect negative battery cable (1) then positive battery cable (2). 4. Remove battery securing bracket (3) and rods.

T207907A

5. Carefully remove battery (4) from battery box (5). 6. Disconnect fuel level sender harness (6). 7. Remove outer side plate (7) from side of battery box (5). 8. Remove fuel tank strap (8). 9. Remove four cap screws (9) and remove battery box (5).

–UN–08FEB05

10. Remove inspection cover under fuel tank.

T207908A

NOTE: Residual fuel may drain from tank when removing hoses. Place drain on track prior to disconnecting fuel hoses to tank. 11. Drain fuel using valve (10). Approximate capacity is 70 L (18.5 gal). 12. Disconnect pick-up hoses (11 and 12). 13. Remove fuel tank. 14. Replace parts as necessary.

–UN–08FEB05

1—Negative Battery Cable 2—Positive Battery Cable 3—Battery Securing Bracket 4—Battery 5—Battery Box 6—Fuel Level Sender Harness 7—Outer Side Plate 8—Fuel Tank Strap 9—Battery Box Cap Screw (4 used) 10—Fuel Drain Valve 11—Pick-Up Hoses 12—Pick-Up Hoses

T207909A

05 0560 4

Continued on next page

TM2264 (15OCT08)

05-0560-4

MM61211,0000849 –19–07FEB05–1/2

Repair 101508

PN=236

External Fuel Supply Systems 15. Position fuel tank. 16. Connect pick-up hoses (11 and 12). 17. Install inspection cover under fuel tank. 18. Install battery box (5). 19. Install fuel level sender harness (6). 20. Install four cap screws (9) securing battery box (5). 21. Install fuel tank strap (8). 22. Install outer side plate (7) to side of battery box (5). 23. Carefully install battery (4) in battery box. 24. Install battery securing bracket (3) to battery. 25. Connect positive battery cable (2) and negative battery cable (1).

05 0560 5

26. Install right-side covers. 27. Fill fuel tank. 28. Bleed fuel system by turning fuel shut-off valve to ON. 29. Turn the key switch to ON for 10—15 seconds to engage automatic bleeding. Do not start engine. 30. Start engine. Stop engine. Check for fuel leakage.

MM61211,0000849 –19–07FEB05–2/2

TM2264 (15OCT08)

05-0560-5

Repair 101508

PN=237

External Fuel Supply Systems

Bleed Fuel System IMPORTANT: Air in the fuel system will cause the engine to start hard and/or run rough. Be sure to bleed air from system after replacing fuel filter or draining fuel tank. Bleeding Procedure (Automatic Bleeding Device) 1. Confirm that fuel level is more than one half of tank capacity. If lower, automatic bleeding cannot be accomplished. Add fuel. 2. Loosen plug in the final fuel filter head to bleed air. Tighten plug when fuel flows from the hole. 3. Turn key switch to ON and hold for 10—15 seconds to engage automatic bleeding. 4. Start engine and check for fuel leakage. 05 0560 6

CED,OUOE003,30019 –19–14FEB03–1/1

TM2264 (15OCT08)

05-0560-6

Repair 101508

PN=238

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—35D . . .17-1749-1 Counterweight Remove and Install—50D . . .17-1749-3

TM2264 (15OCT08)

17-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

17-2

Repair 101508

PN=2

Group 1740

Frame Installation Welding on Machine IMPORTANT: Electrical current traveling from the welder through the machine electrical system can damage the machine electrical system, including the battery, and any electronic control units. Before welding on the machine, disconnect the battery ground cable and wiring harness connectors to any electronic control units. Electrical current traveling from the welder through a bearing can arc inside the bearing causing damage. The welder ground clamp must be connected as close to each weld area as possible so electrical current does not pass through any bearings. Disconnect the battery ground cable. Disconnect wiring harness connectors to any electronic control units. Connect the welder ground clamp as close to the weld area as possible.

17 1740 1

OUO1030,00000D4 –19–03MAR05–1/1

TM2264 (15OCT08)

17-1740-1

Repair 101508

PN=241

Frame Installation

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

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. 2. Use one of the following weld processes: • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. • AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process. Specification Weld Metal—Tensile Strength................................................. 482.6 mPa 70,000 psi Yield Strength ............................................................................ 413.7 mPa 60,000 psi Elongation ............................................................................................ 22%

Continued on next page

TM2264 (15OCT08)

17-1740-2

OUT1738,0000074 –19–10MAR05–1/2

Repair 101508

PN=242

Frame Installation 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). Specification Structural Assembly—Preheat Temperature ...................................................................................... 38°C 100°F Ground Engaging Tool—Preheat Temperature ..................................................................................... 177°C 350°F

OUT1738,0000074 –19–10MAR05–2/2

TM2264 (15OCT08)

17-1740-3

Repair 101508

PN=243

17 1740 3

Frame Installation

17 1740 4

TM2264 (15OCT08)

17-1740-4

Repair 101508

PN=244

Group 1749

Chassis Weights Counterweight Remove and Install—35D CAUTION: Prevent possible injury. Heavy component, ensure side cover is properly supported before removing.

–UN–14JAN05

1. Park machine on a level surface. 2. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

T206931A

3. Remove left-side panels (1, 2 and 3) from main frame. 4. Open maintenance cover (4). 5. Remove right-side panels (5 and 6) from main frame. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T206930A

–UN–14JAN05

The lifting capacity of a lifting eyebolt decreases as the lift angle increases from vertical. A load positioning sling should be used to obtain, as close as possible, a vertical lift from lifting eyebolts. 6. Remove plastic plugs. Install M20 x 2.5 lifting eyebolts (6) such as JT05552 Metric Lifting Eyebolts to counterweight. 1—Left-Side Upper Panel 2—Left-Side Middle Panel 3—Left-Side Lower Panel 4—Maintenance Cover 5—Right-Side Middle Panel 6—Right-Side Lower Panel 7—Lifting Eyebolts

Specification Counterweight—35D—Weight...................................................... 550 N•m 1220 lb

Continued on next page

TM2264 (15OCT08)

17-1749-1

MM61211,00008D7 –19–16FEB05–1/2

Repair 101508

PN=245

17 1749 1

Chassis Weights 7. Attach D01043AA Load Positioning Sling (8) to eyebolts. 8. Attach load positioning sling to crane or hoist.

11. Replace parts as necessary. 12. Install counterweight using a crane or hoist. Place counterweight into main frame (10) and slide forward.

T206932A

10. Lift counterweight a little and slide backward. Hoist and remove counterweight from main frame.

–UN–14JAN05

9. Remove three cap screws (9) from bottom side of counterweight.

13. Install three cap screws to bottom side of counterweight. Tighten to specification.

15. Remove eyebolts. 16. Install plastic plugs into the top of counterweight. 17. Install outer access panels. 18. Close maintenance cover. 19. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

–UN–14JAN05

8—D01043AA Load Positioning Sling 9—Counterweight Cap Screws (3 used) 10—Main Frame

T206934A

17 1749 2

T206933A

14. Remove crane or hoist and load positioning sling.

–UN–14JAN05

Specification Counterweight-to-Frame Cap Screw—35D—Torque................................................................... 550 N•m 410 lb-ft

MM61211,00008D7 –19–16FEB05–2/2

TM2264 (15OCT08)

17-1749-2

Repair 101508

PN=246

Chassis Weights

Counterweight Remove and Install—50D 1. Park machine on a level surface. 2. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

–UN–25JAN05

3. Remove left-side panels (1 and 2). 4. Open maintenance cover (3).

T206859A

5. Remove right side panel (4). 6. Remove top covers (5). CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

–UN–25FEB05

T206860A

7. Remove plastic plugs. Install M20 x 2.5 lifting eyebolts (6) such as JT05552 Metric Lifting Eyebolts to counterweight. 8. Attach D01043AA Load Positioning Sling (7) to eyebolts. Specification Counterweight—Weight ................................................................ 675 N•m 1490 lb

T206886A

–UN–26JAN05

1—Left-Side Upper Panel 2—Left-Side Middle Panel 3—Maintenance Cover 4—Right-Side Middle Panel 5—Top Covers 6—JT05552 Eyebolts 7—D01043AA Load Positioning Sling

Continued on next page

TM2264 (15OCT08)

17-1749-3

MM61211,00008D6 –19–16FEB05–1/2

Repair 101508

PN=247

17 1749 3

Chassis Weights 9. Attach load positioning sling to a crane or hoist. 10. Remove three cap screws (8) from bottom side of counterweight. 11. Lift counterweight a little and slide backward. Hoist and remove counterweight from main frame. –UN–12JAN05

12. Replace parts as necessary.

T206861A

13. Install counterweight using a crane or hoist. Place counterweight into main frame and slide forward. 14. Install three cap screws to bottom side of counterweight. Tighten to specification. 8—Counterweight Cap Screws (3 used)

Specification Counterweight-to-Frame Cap Screw—50D—Torque................................................................... 700 N•m 520 lb-ft

15. Remove crane or hoist and load positioning sling. 16. Remove eyebolts. 17. Install plastic plugs into the top of counterweight. 17 1749 4

18. Install outer access panels. 19. Install top covers. 20. Close maintenance cover. 21. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

MM61211,00008D6 –19–16FEB05–2/2

TM2264 (15OCT08)

17-1749-4

Repair 101508

PN=248

Section 18

Operators Station Contents Page

Group 1800—Removal and Installation Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1 Canopy Remove and Install . . . . . . . . . . . . .18-1800-3 Platform Remove and Install . . . . . . . . . . . . .18-1800-5 Group 1821—Seat and Seat Belt Seat Remove and Install . . . . . . . . . . . . . . . .18-1821-1 Seat Base Remove and Install . . . . . . . . . . .18-1821-2 Seat Belt Remove and Install . . . . . . . . . . . .18-1821-4

Group 1830—Heating and Air Conditioning System 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 Air Conditioner Compressor Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Receiver-Dryer Remove and Install . . . . . . .18-1830-12 Condenser Remove and Install . . . . . . . . . .18-1830-13 Air Conditioner / Heater Module Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .18-1830-14 Heater Control Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-17

TM2264 (15OCT08)

18-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

18-2

Repair 101508

PN=2

Group 1800

Removal and Installation Cab Remove and Install 1. Disconnect negative battery (-) cable.

Continued on next page

OUO1030,0000124 –19–21FEB05–1/3

18 1800 1

TM2264 (15OCT08)

18-1800-1

Repair 101508

PN=251

18 1800 2

T208922

–UN–08MAR05

Removal and Installation

1—Air Duct Cover 2—Air Duct

3—Front Cap Screw (3 used) 4—Side Cap Screw (4 used)

5—Cap Screw Cover (2 used) 6—Cap Screw (2 used)

2. Remove air duct cover (1) and disconnect wires to accessory outlet. 3. Remove air duct (2). Disconnect wires and hose to windshield pump motor. 4. Disconnect wires to monitor. 5. Below right control lever, disconnect cab harness to floor harness connector.

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Cab—Weight approximate........................................................ 120 kg 265 lb.

8. Attach hoist to cab lifting points using lifting straps. 9. Slowly lift cab from platform. Cab must be moved forward while being raised to allow front of cab to clear front of propel pedals.

6. Remove front (3) and side (4) cap screws. 7. Remove cap screw covers (5) and cap screws (6 and 7).

10. Repair or replace parts as necessary.

Continued on next page

TM2264 (15OCT08)

7—Cap Screw (3 used) 8—Lifting Point (3 used)

18-1800-2

OUO1030,0000124 –19–21FEB05–2/3

Repair 101508

PN=252

Removal and Installation NOTE: When installing cab, check that all lines and wiring harness have not been pinched when cab is lowered.

13. Connect cab harness to floor harness connector.

11. Lower cab into position.

15. Connect wires and hose to windshield pump motor. Install air duct (2).

12. Install and tighten cap screws (3, 4, 6, and 7). Install cap screw covers (5).

14. Connect wires to monitor.

16. Connect wires to accessory outlet and install air duct cover (1).

Specification Front and Side Cab Cap Screw—Torque ........................................................................ 50 N•m 37 lb-ft Rear Cab Cap Screw—Torque ............................................... 90 N•m 66 lb-ft

17. Connect negative battery (-) cable.

OUO1030,0000124 –19–21FEB05–3/3

Canopy Remove and Install CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Canopy—Weight approximate........................................................... 72 kg 160 lb.

1. Attach chain (1) to canopy lifting points (2).

18 1800 3 –UN–25FEB05

2. Remove side panel (3), front cover (4), and side cover (5).

T208894

1—Chain 2—Canopy Lifting Point (4 used) 3—Side Panel 4—Front Cover 5—Side Cover 6—Canopy

Continued on next page

TM2264 (15OCT08)

18-1800-3

OUO1030,0000123 –19–21FEB05–1/2

Repair 101508

PN=253

Removal and Installation 3. Remove front (7) and side (8) cap screws. 4. Remove rear cap screws (9). 5. Remove canopy (6).

7. Lower canopy (6) into position. 8. Install front (7), side (8), and rear (9) cap screws.

T208895A

NOTE: When installing canopy, check that all lines and wiring harness have not been pinched when canopy is lowered.

–UN–25FEB05

6. Repair or replace parts as necessary.

9. Install side panel (3), front cover (4), and side cover (5).

T208896A

7—Front Cap Screw (5 used) 8—Side Cap Screw (2 used) 9—Rear Cap Screw (5 used)

–UN–25FEB05

Specification Front and Side Canopy Mount Cap Screw—Torque ...................................................................... 50 N•m 37 lb-ft Rear Canopy Mount Cap Screw—Torque .............................................................................. 90 N•m 66 lb-ft

18 1800 4

OUO1030,0000123 –19–21FEB05–2/2

TM2264 (15OCT08)

18-1800-4

Repair 101508

PN=254

Removal and Installation

Platform Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 1. Loosen cap to release air pressure in hydraulic oil tank. 2. Disconnect negative battery (-) cable. 3. Remove canopy or cab. See Cab Remove and Install or See Canopy Remove and Install. (Group 1800.) 4. Tilt the operator station. See Tilting the Operator Station (Operator’s Manual.)

OUO1030,00000D5 –19–04MAR05–1/4

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. 18 1800 5 –UN–23AUG88

Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

TS281

5. If equipped with a heater, close the shut-off valve for heater hoses at the engine or drain the coolant. See Drain Cooling System for procedure. (Operator’s Manual)

Continued on next page

TM2264 (15OCT08)

18-1800-5

OUO1030,00000D5 –19–04MAR05–2/4

Repair 101508

PN=255

Removal and Installation 6. Disconnect the heater hoses, at the bracket (1). 7. If equipped with air conditioning system, purge system. See R134a Refrigerant Recovery / Recycling and Charging Station Installation Procedure. (Group 1830.)

–UN–28FEB05

8. Disconnect air conditioning lines (2) and wire to compressor at the bracket. Install caps and plugs. 9. Cut tie band to air conditioning drain hose (3).

T209043A

10. Disconnect wire harness and horn (4). 11. Disconnect quick coupler for hydraulic lines (5) at the bracket. Label lines to aid in assembly. Install caps and plugs.

Platform—50D Shown 1—Heater Hose (2 used) 2—Air Conditioning Line (2 used) 3—Drain Hose (2 used) 4—Wire Harness and Horn 5—Quick Coupler Hydraulic Line

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Platform, Seat Base, Heater, Pilot Controls and Seat Weight— Weight approximate........................................................................... 95 kg 210 lb

NOTE: Four JT01748 Lifting Bracket are required to lift platform. 12. Using JT01748 lifting brackets, fasten rear platform to a hoist using lifting straps. 18 1800 6

13. Disconnect tilt assembly and lower operator station.

Continued on next page

TM2264 (15OCT08)

18-1800-6

OUO1030,00000D5 –19–04MAR05–3/4

Repair 101508

PN=256

Removal and Installation 14. Loosen cap screws (1), lift front cover (2), and remove hinge cap screws (3). IMPORTANT: Carefully lift platform. Check to be sure all lines and wiring harnesses are disconnected.

–UN–28FEB05

15. Using a hoist, lift the platform. 16. Repair of replace parts as necessary.

17. Install platform and hinge cap screws (3), and secure front cover (2). Specification Platform Hinge Cap Screws.— Torque .......................................................................................... 140 N•m 103 lb-ft

T209044A

IMPORTANT: When installing platform, check that all lines and wiring harness have not been pinched when platform is lowered. Platform Mounts—50D Shown 1—Cap Screw (2 used) 2—Front Cover 3—Hinge Cap Screw (3 used)

18. Raise operator station and install tilt assembly. 19. Connect hydraulic lines, wire harness, and horn. Install tie bands where needed. 20. If equipped connect heater hose, air conditioning lines, and wire to compressor. 21. Lower operator station and install cab or canopy. 18 1800 7

22. Connect negative battery (-) cable. NOTE: If equipped with heater, open shut-off valve for heater hoses at the engine. 23. Fill radiator with coolant. See Cooling System Fill and Deaeration. (Operator’s Manual.) 24. Service air conditioning. 25. Check level in hydraulic oil tank.

OUO1030,00000D5 –19–04MAR05–4/4

TM2264 (15OCT08)

18-1800-7

Repair 101508

PN=257

Removal and Installation

18 1800 8

TM2264 (15OCT08)

18-1800-8

Repair 101508

PN=258

Group 1821

Seat and Seat Belt Seat Remove and Install 1. Park machine on a flat level surface.

4. Tilt operator station back to normal position. 5. Remove seat bracket nuts (2) from front of seat base. 6. Remove seat.

T208367A

3. Remove rear seat bracket nuts (1) from rear of seat base.

–UN–11FEB05

2. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

7. Replace parts as necessary. 8. Install seat.

T208368A

–UN–11FEB05

1—Rear Seat Bracket Nut (2 used) 2—Front Seat Bracket Nut (2 used)

MM61211,00008E3 –19–18FEB05–1/1

TM2264 (15OCT08)

18-1821-1

Repair 101508

PN=259

18 1821 1

Seat and Seat Belt

Seat Base Remove and Install 1. Disconnect battery negative (-) cable. 2. Remove seat. See Seat Remove and Install. (Group 1821.)

–UN–14FEB05

3. Remove floor mat. 4. Remove floor plate (1).

T208439A

5. Remove access panel (2). 6. Remove air vent cover (3). 7. Remove and disconnect power outlet wire harness (4). 8. Remove heater control valve cap screws (5). 9. Remove four cap screws (6) to pilot control shut-off lever.

–UN–14FEB05

10. Remove cap screw (7) on upper structure of seat base (8).

T208437A

1—Floor Plate 2—Access Panel 3—Air Vent Cover 4—Power Outlet Wire Harness 5—Cap Screw (2 used) Heater Control Valve 6—Cap Screw (4 used) Pilot Control Shut-Off Lever 7—Cap Screw (1 used) Upper Structure Seat Base 8—Seat Base

T208435A

–UN–14FEB05

18 1821 2

Continued on next page

TM2264 (15OCT08)

18-1821-2

MM61211,00008E4 –19–18FEB05–1/2

Repair 101508

PN=260

Seat and Seat Belt 11. Remove cap screws (9) to air conditioner relay panel. 12. Remove cap screws (10) on lower structure of seat base. 13. Remove seat base from platform.

–UN–14FEB05

14. Replace parts as necessary. 15. Install seat base

T208438A

16. Install air conditioner relay panel 17. Connect electrical harnesses. 18. Install air vent cover 19. Install seat. 20. Install access cover and floor plate. 21. Connect battery negative (-) cable.

T208449A

–UN–14FEB05

9—Cap Screw (5 used) Air Conditioner Relay Panel 10—Cap Screw (4 used) Lower Structure Seat Base

MM61211,00008E4 –19–18FEB05–2/2

TM2264 (15OCT08)

18-1821-3

Repair 101508

PN=261

18 1821 3

Seat and Seat Belt

Seat Belt Remove and Install 1. Remove seat. See Seat Remove and Install. (Group 1821.)

3. Remove cap screw (3) and spacer. Remove seat belt (4).

T208369A

4. Replace as needed.

–UN–11FEB05

2. Remove cap screw (1) and spacer. Remove seat belt latch (2).

5. Install seat belt and seat belt latch. 6. Install seat.

T208370A

–UN–11FEB05

1—Cap Screw (1 used) 2—Seat Belt Latch 3—Cap Screw (1 used) 4—Seat Belt

18 1821 4

MM61211,00008E5 –19–18FEB05–1/1

TM2264 (15OCT08)

18-1821-4

Repair 101508

PN=262

Group 1830

Heating and Air Conditioning System 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 18 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.

1830 1

IMPORTANT: To meet government standards relating to the use of refrigerants,

Continued on next page

TM2264 (15OCT08)

18-1830-1

TX,9031,DY5073 –19–19NOV01–1/2

Repair 101508

PN=263

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

TX,9031,DY5073 –19–19NOV01–2/2

18 1830 2

TM2264 (15OCT08)

18-1830-2

Repair 101508

PN=264

Heating and Air Conditioning System

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 A/C Flushing Solvent in Suction Port—Volume........................................................................... 240 mL 8 fl oz A/C Flushing Solvent in Discharge Port—Volume ......................................................... 120 mL 4 fl oz

d. Turn compressor end for end and roll it side to side.

Specification A/C Flusher Tank—Capacity .......................................................... 4 L 1 gal

NOTE: Air pressure must be at least at specification for flushing and purging. Specification A/C Flusher Tank Air Pressure—Minimum Pressure ...................... 620 kPa for flushing and purging 6.2 bar for flushing and purging 90 psi 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: • 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

TM2264 (15OCT08)

18-1830-3

TX,18,DU2461 –19–31JAN06–1/3

Repair 101508

PN=265

18 1830 3

Heating and Air Conditioning System 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 A/C Flusher Tank—Capacity .......................................................... 4 L 1 gal

NOTE: Air pressure must be at least to specification for flushing and purging. Specification A/C Flusher Tank Air Pressure—Minimum Pressure ...................... 620 kPa for flushing and purging. 6.2 bar for flushing and purging. 90 psi for flushing and purging.

18 1830 4

Put nozzle in container to collect flushing solvent.

e. Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve. f. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. g. Attach return hose and aerator nozzle to end of receiver-dryer inlet hose using JT03197 Adapter.

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 Air Conditioner / Heater Module 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 A/C Flusher Tank—Capacity .......................................................... 4 L 1 gal

Continued on next page

TM2264 (15OCT08)

18-1830-4

TX,18,DU2461 –19–31JAN06–2/3

Repair 101508

PN=266

Heating and Air Conditioning System NOTE: Air pressure must be at least to specification for flushing and purging. Specification A/C Flusher Tank Air Pressure—Minimum Pressure ...................... 620 kPa for flushing and purging. 6.2 bar for flushing and purging. 90 psi 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.

TX,18,DU2461 –19–31JAN06–3/3

18 1830 5

TM2264 (15OCT08)

18-1830-5

Repair 101508

PN=267

Heating and Air Conditioning System

R134a Refrigerant Oil Information CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22101 (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. 18 1830 6

Compressors can be divided into three categories when determining correct oil charge for system. • New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent Determining amount of system oil charge prior to installation of compressor on machine.

Specification Refrigerant Oil—Total System Volume ....................................................................................... 59 mL 2.0 fl oz R134a Refrigerant—Weight........................................................ 794 g 1.75 lb

If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz per ft) to determine correct amount of oil to be added. Drain compressor oil into graduated container while rotating compressor shaft and record amount. If oil drained from compressor removed from operation is very black or amount of oil is less than 6 mL (0.2 fl oz), perform the following and discard oil properly: ❒ Determine if R134a leakage was detected, remove component and repair or replace component. ❒ Remove and discard receiver-dryer. ❒ Flush complete system with TY25601 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 TY22101 Refrigerant Oil in compressor. Connect all components. Perform Evacuate R134a System and Perform Charge R134a System. (Group 1830.)

When complete system, lines, and components are flushed add correct amount of oil as described.

KV70328,00001FE –19–03JUL07–1/1

TM2264 (15OCT08)

18-1830-6

Repair 101508

PN=268

Heating and Air Conditioning System

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.

3 2 4

1 2

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. Use only John Deere approved R134a refrigerant products. Mixing of non-compatible products will cause system damage and contaminate recovery / recycling and charging station equipment.

–UN–26OCT04 T204413

1. Follow procedures. See Refrigerant Cautions and Proper Handling. (Group 1830.)

5 2

T204413

2. Close both high-side and low-side valves on refrigerant recovery / recycling and charging station (5). 3. Remove caps from low pressure and high pressure test ports (1 and 2).

1—Low Pressure Test Port 2—High Pressure Test Port 3—Blue Hose 4—Red Hose 5—Refrigerant Recovery / Recycling and Charging Station

18 1830 7

4. Connect blue hose (3) from refrigerant recovery / recycling and charging station to low pressure test port (1). 5. Connect red hose (4) from refrigerant recovery / recycling and charging station to high pressure test port (2). 6. Follow the manufacturer’s instructions when using refrigerant recovery / recycling and charging station.

OUO1010,00006B3 –19–22OCT04–1/1

TM2264 (15OCT08)

18-1830-7

Repair 101508

PN=269

Heating and Air Conditioning System

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.) 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 manufacturer’s instructions when using refrigerant recovery / recycling and charging station.

18 1830 8

OUO1010,00006C6 –19–29OCT04–1/1

TM2264 (15OCT08)

18-1830-8

Repair 101508

PN=270

Heating and Air Conditioning System

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 mbar 29 in. Hg

1. Connect refrigerant recovery system. See R134a Refrigerant Recovery / Recycling and Charging Station Installation Procedure. (Group 1830.)

If above specification vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Test. (Group 9031-25.)

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

5. When vacuum reaches above specification, close low-side and high-side valves. Turn vacuum pump off.

3. Follow manufacturer’s instructions and evacuate system. NOTE: Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. Specification Evacuate 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 sea level Subtract 1 in. Hg from 29 in. Hg for each 1000 ft elevation above sea level

6. If vacuum decreases more than specification in 5 minutes, there is a leak in system. Specification Evacuate System—Vacuum .................................................... 3.4 kPa 34 mbar 1 in. Hg

7. Repair leak. 8. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 9. Close low-side and high-side valves. Stop evacuation. 18 1830 9

10. Perform Charge R134a System. (Group 1830.)

OUO1010,00006C7 –19–29OCT04–1/1

TM2264 (15OCT08)

18-1830-9

Repair 101508

PN=271

Heating and Air Conditioning System

Charge R134a System • Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

IMPORTANT: Use only John Deere approved refrigerant recovery / recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

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

1. Identify refrigerant type using JT02167A Refrigerant Identification Instrument.

4. Follow manufacturer’s instructions and charge system.

2. Connect R134a Refrigerant Recovery / Recycling and Charging Station. See R134a Refrigerant Recovery / Recycling and Charging Station Installation Procedure. (Group 1830.)

5. Add refrigerant to system.

See Refrigerant Cautions and Proper Handling. (Group 1830.)

3. Perform Evacuate R134a System. (Group 1830.) NOTE: Before beginning to charge air conditioning system, the following conditions must exist:

Specification R134a Air Conditioning System Refrigerant—Refrigerant Quantity....................................................................................... 794 g 1.75 lb

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

• Engine STOPPED • Pump used must be capable of pulling at least 28.6 in. Hg vacuum (sea level) 18 1830 10

AC12469,00005D7 –19–23MAY08–1/1

TM2264 (15OCT08)

18-1830-10

Repair 101508

PN=272

Heating and Air Conditioning System

Air Conditioner Compressor Remove and Install 1. Park machine on a flat level surface. 2. Recover refrigerant. Perform Recover R134a Refrigerant. (Group 1830.)

T208185A

–UN–11FEB05

IMPORTANT: Close A/C lines with caps or plugs immediately after disconnecting to prevent contamination of system. If system is left open, receiver-dryer must be replaced before charging system. 3. Disconnect high and low pressure lines (2 and 3). 1—Wire Harness Connector 2—Low Pressure Input Line 3—High Pressure Output Line 4—Cap Screw (3 used) 5—A/C Compressor

4. Remove compressor belt. 5. Disconnect wire harness connector (1). 6. Remove cap screws (4) washers, and lock nuts to remove A/C compressor (5). Repair or replace parts as necessary. 7. Install A/C compressor. 8. Install compressor belt and connect wire harness connector. 9. Connect high and low pressure lines to A/C compressor.

18 1830 11

Specification A/C Compressor High and Low Pressure Output Line Cap Screw—Torque ............................................................................... 29 N•m 21 lb-ft

10. Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

MM61211,00008BD –19–31JAN06–1/1

TM2264 (15OCT08)

18-1830-11

Repair 101508

PN=273

Heating and Air Conditioning System

Receiver-Dryer Remove and Install 1. Park machine on a flat level surface. 2. Recover refrigerant. Perform Recover R134a Refrigerant. (Group 1830.)

–UN–11FEB05

3. Disconnect refrigerant lines (1). 4. Disconnect wire harness connector (5).

6. Remove retainer cap screws (3) and remove receiver-dryer (2).

T208210A

5. Remove high / low pressure switch (4) if receiver-dryer is to be replaced.

1—A/C Refrigerant Lines 2—Receiver-Dryer 3—Cap Screws and Retainer 4—High / Low Pressure Switch 5—Wire Harness Connector

7. Repair or replace parts as necessary. 8. Install receiver-dryer. 9. Install high / low pressure switch, if removed. 10. Connect refrigerant lines. Specification Receiver-Dryer Refrigerant Lines—Torque ................................................................................ 16 N•m 144 lb-in.

18 1830 12

11. Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

MM61211,00008BE –19–10FEB05–1/1

TM2264 (15OCT08)

18-1830-12

Repair 101508

PN=274

Heating and Air Conditioning System

Condenser Remove and Install 1. Park machine on a flat level surface. 2. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

–UN–11FEB05

3. Remove counterweight. See Counterweight Remove and Install—35D or see Counterweight Remove and Install—50D. (Group 1749.)

T208212A

4. Remove right-side frame bracket. 5. Recover refrigerant. Perform Recover R134a Refrigerant. (Group 1830.) IMPORTANT: Close A/C lines with caps or plugs immediately after disconnecting to prevent contamination of system. If system is left open, receiver-dryer must be replaced before charging system.

1—High Pressure Gas Input Line 2—High Pressure Liquid Output Line 3—Cap Screws (5 used) 4—Air Conditioner Condenser

6. Disconnect refrigerant lines (1 and 2). 7. Remove cap screws (3) washers, and lock nuts to remove condenser (4). 8. Repair or replace parts as necessary. 9. Install condenser. 10. Connect refrigerant lines. 18 1830 13

Specification Refrigerant Lines—Torque ............................................................. 16 N•m 144 lb-in.

11. Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

MM61211,00008BF –19–10FEB05–1/1

TM2264 (15OCT08)

18-1830-13

Repair 101508

PN=275

Heating and Air Conditioning System

Air Conditioner / Heater Module Remove and Install 1. Park machine on a flat level surface.

–UN–11FEB05

2. Recover refrigerant. Perform Recover R134a Refrigerant. (Group 1830.)

T208297A

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. NOTE: Heater core and heater hoses contain coolant. Properly dispose of coolant. 3. Drain coolant from system and to heater hoses. See Draining Cooling System. (Operator’s Manual.)

–UN–11FEB05

4. Disconnect heater hoses.

T208298A

5. Remove screws (3). And cap screw (2) from air duct cover (1). 6. Disconnect wire harness from power outlet (4). 7. Remove floor plate (5). 18 1830 14

1—Air Vent Cover 2—Cap Screw (1 used) 3—Screw (4 used) 4—Power Outlet Wire Harness 5—Floor Plate 6—Rubber Mat 7—Pedal Covers 8—Auxiliary Control Pedals 9—Bracket 10—Screw (2 used)

8. Remove rubber pad (6) and remove auxiliary control pedals (8) and pedal covers (7). 9. Remove bracket (9) under auxiliary pedals. 10. Remove two air duct cover screws (10).

Continued on next page

TM2264 (15OCT08)

18-1830-14

MM61211,00008C0 –19–05JAN06–1/3

Repair 101508

PN=276

Heating and Air Conditioning System 11. Remove air vent screws (11). 12. Remove access panel (12). 13. Remove cap screw (13).

–UN–11FEB05

IMPORTANT: Close A/C lines with caps or plugs immediately after disconnecting to prevent contamination of system. If system is left open, receiver-dryer must be replaced before charging system.

T208299A

NOTE: Refrigerant lines-to-expansion valve connections are located under the cab floor, just to the rear of the brake valve. 14. Disconnect refrigerant lines (14) from module (15). 15. Disconnect heater hoses (16) from module (15). 16. Remove cap screws (17) from module.

–UN–11FEB05

17. Remove blower motor cover (18). 18. Remove cap screws (19) under blower motor cover.

T208300A

19. Disconnect A/C thermostat / blower harness connector (20). 20. Carefully remove A/C-heater module (15). 21. Repair or replace parts as necessary.

11—Screw (3 used) 12—Access Panel 13—Cap Screw (1 used) 14—Refrigerant Lines 15—Module 16—Heater Hoses 17—Cap Screw (2 used) 18—Blower Motor Cover 19—Cap Screw (2 used) 20—Wire Harness Connector

22. Install A/C-heater module. Add insulation as necessary around module and refrigerant lines. 23. Connect heater hoses (16). 24. Install air vent, and air duct.

18 1830 15

25. Connect all wire harness connectors. 26. Install air duct cover (1). 27. Connect refrigerant lines to module using new O-rings.

Continued on next page

TM2264 (15OCT08)

18-1830-15

MM61211,00008C0 –19–05JAN06–2/3

Repair 101508

PN=277

Heating and Air Conditioning System Specification Refrigerant Lines—Torque ............................................................. 16 N•m 144 lb-in.

28. Evacuate air conditioning system and charge. See Evacuate R134a System and see Charge R134a System. (Group 1830.) 29. Fill cooling system to proper level. See Diesel Engine Coolant. (Operator’s Manual.) 30. Start engine and check heater hoses for leaks. 31. Check air conditioning system for leaks. See Refrigerant Leak Test. (Group 9031-25.) 32. Install access panel (12). 33. Install floor plate (5) and auxiliary control pedal assembly (8). 34. Install rubber floor mat (6).

MM61211,00008C0 –19–05JAN06–3/3

18 1830 16

TM2264 (15OCT08)

18-1830-16

Repair 101508

PN=278

Heating and Air Conditioning System

Heater Control Valve Remove and Install 1. Drain cooling system. For approximate capacity of 50D excavator cooling system, see Miscellaneous—Specifications. (Operator’s Manual.) –UN–11FEB05

2. Remove three cap screws (1). 3. Disconnect wire harnesses (2).

T208344A

4. Disconnect both heater hoses (3) from control valve (4). 5. Remove control lever pattern conversion cap screws (5). 6. Remove control lever pattern conversion bracket cap screw (6). 7. Remove bracket nuts (7) on back side of cab.

–UN–11FEB05

8. Remove heater control valve (4). Replace if necessary.

T208345A

9. Connect hoses to control valve using new hose clamps. 10. Install cap screws (1). 11. Install nuts (7) on back side of cab, but do not tighten. 12. Install control lever pattern conversion bracket cap screw (6).

18 1830 17

13. Install control lever pattern conversion cap screws (5). 14. Tighten all cap screws and nuts.

T208346A

–UN–11FEB05

1—Cap Screw (3 used) 2—Wire Harness (2 used) 3—Heater Hoses (2 used) 4—Heater Control Valve 5—Control Lever Pattern Conversion Cap Screw (2 used) 6—Control Lever Pattern Conversion Bracket Cap Screw (2 used) 7—Bracket Nuts (2 used)

Continued on next page

TM2264 (15OCT08)

18-1830-17

MM61211,00008C1 –19–10FEB05–1/2

Repair 101508

PN=279

Heating and Air Conditioning System 15. Fill cooling system to proper level. See Diesel Engine Coolant. (Operator’s Manual.) 16. Start engine and check for leaks. 17. Stop engine.

MM61211,00008C1 –19–10FEB05–2/2

18 1830 18

TM2264 (15OCT08)

18-1830-18

Repair 101508

PN=280

Section 32

Bulldozers (Blade) Contents Page

Group 3201—Blades Blade Remove and Install . . . . . . . . . . . . . . .32-3201-1 Blade Disassemble and Assemble . . . . . . . .32-3201-4 Group 3260—Hydraulic System Blade Cylinder Remove and Install . . . . . . . .32-3260-1 Blade Pilot Controller Remove and Install . . .32-3260-3 Blade Pilot Controller Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-6

TM2264 (15OCT08)

32-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

32-2

Repair 101508

PN=2

Group 3201

Blades Blade Remove and Install 1. Lower all equipment to ground. 2. Stop the engine.

–UN–20JAN99

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T119390

Specification Blade—35D—Weight approximate ..................................................................................... 205 kg 450 lb Blade—50D—Weight approximate ..................................................................................... 218 kg 480 lb

3. Attach blade (3) to a hoist (1) by the lifting holes (2) using chains or lifting straps.

1—Hoist 2—Lifting Holes (2 used) 3—Blade

Continued on next page

OUO1030,0000110 –19–18MAR05–1/3

32 3201 1

TM2264 (15OCT08)

32-3201-1

Repair 101508

PN=283

T208280

–UN–01MAR05

Blades

32 3201 2

1—Blade 2—Hydraulic Cylinder 3—Cap Screw (2 used) 4—Washer (2 used)

5—Locking Plate 6—Cylinder Pin 7—Cylinder Shim—50D only (4 used)

8—Cap Screw (4 used) 9—Washer (4 used) 10—Locking Plate (2 used)

11—Arm Pin (2 used) 12—Arm Shim—50D only (4 used)

4. Put support stands under the rear arms of blade (1) and front of hydraulic cylinder (2).

7. Remove cap screws (8), washers (9), and locking plates (10).

5. Remove cap screws (3), washers (4), and locking plate (5).

NOTE: Arm shims (12) may fall out as blade (1) is removed.

NOTE: Cylinder shims (7) may fall out as cylinder pin (6) is removed.

8. Remove arm pins (11) using a brass punch and hammer. Remove remaining arm shims (12).

6. Remove cylinder pin (6) using a brass punch and hammer. Remove remaining cylinder shims (7).

9. Remove blade and replace parts as necessary.

Continued on next page

TM2264 (15OCT08)

32-3201-2

OUO1030,0000110 –19–18MAR05–2/3

Repair 101508

PN=284

Blades 10. Clean and apply grease to all pins (6 and 11).

13. Line up hydraulic cylinder (2) with the blade (1).

NOTE: On 50D machine, arm shims (12) are used with arm pins (11).

NOTE: On 50D machine, cylinder shims (7) are used with cylinder pin (6).

11. Line up blade (1) mounts and install arms pins (11), with one arm shim (12) on each side.

14. Install cylinder pin (6) with two cylinder shims (7) on each side.

IMPORTANT: You must rotate the arm pins (11) to properly align the keyway with the locking plates (10).

15. Install locking plate (5), washer (4), and cap screw (3). Tighten cap screw to specification.

12. Install locking plate (10), washers (9), and cap screws (8). Tighten cap screws to specification. Specification Arm Cap Screw Torque— Torque.................................................................................... 137 N•m 101 lb-ft

Specification Lock Plate Cap Screw—Torque ............................................ 137 N•m 101 lb-ft

16. Check oil level. See Check Hydraulic Oil Tank Level. (Operator’s Manual.) Add oil as necessary. See Hydraulic Oil. (Operator’s Manual.)

OUO1030,0000110 –19–18MAR05–3/3

32 3201 3

TM2264 (15OCT08)

32-3201-3

Repair 101508

PN=285

Blades

T125452

–UN–14JAN00

Blade Disassemble and Assemble

1—Blade

Repair or replace parts as needed.

2—Dust Seal (4 used)

3—Bushing (2 used)

See Welding Repair of Major Structure before welding on the blade. (Group 1740.)

See Welding on Machine. (Group 1740.)

32 3201 4 OUO1030,0000122 –19–18FEB05–1/1

TM2264 (15OCT08)

32-3201-4

Repair 101508

PN=286

Group 3260

Hydraulic System Blade Cylinder Remove and Install 1. Lower blade to ground. 2. Turn off engine. CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. SLOWLY loosen cap to relieve the air pressure in hydraulic oil tank. 3. SLOWLY loosen cap to release air pressure in hydraulic oil tank.

Continued on next page

OUO1030,0000114 –19–10FEB05–1/3

32 3260 1

TM2264 (15OCT08)

32-3260-1

Repair 101508

PN=287

Hydraulic System 4. Remove cap screws (1), washers (2), and cylinder guard (3). 5. Disconnect hydraulic lines (4). Install caps and plugs.

–UN–10FEB05

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T208279A

Specification Blade Cylinder—35D—Weight approximate ...................................................................................... 24 kg 53 lb Blade Cylinder—50D—Weight approximate ....................................................................................... 36 kg 80 lb

Blade Cylinder Removal (35D Shown)

6. Attach blade cylinder (10) to a hoist using lifting straps.

1—Cap Screw (2 used—35D) (3 used—50D) 2—Washer (3 used—50D) 3—Cylinder Guard 4—Hydraulic Line 5—Cap Screw (4 used) 6—Washer (4 used) 7—Locking Plate (2 used) 8—Cylinder Pin (2 used) 9—Cylinder Shim—50D only (4 used) 10—Blade Cylinder

7. Remove cap screws (5), washers (6), and locking plates (7). NOTE: On 50D machine, cylinder shims (9) are used on the front cylinder pin (8). Cylinder shims (9) may fall out as blade cylinder (10) is removed. 8. Remove cylinder pins (8) using a brass punch and hammer. Remove remaining cylinder shims. 9. Remove blade cylinder (10). 10. Repair or replace blade cylinder as necessary. See Blade and Boom Swing Cylinder Disassemble and Assemble. (Group 3360.) 11. Apply grease to cylinder pins (8). 12. Line up blade cylinder (10) mounts and install cylinder pins (8). 32 3260 2

IMPORTANT: You must rotate the cylinder pins (8) to properly align the keyway with the locking plates (7). 13. Install locking plates (7), washers (6), and cap screws (5). Tighten cap screws to specification.

Continued on next page

TM2264 (15OCT08)

32-3260-2

OUO1030,0000114 –19–10FEB05–2/3

Repair 101508

PN=288

Hydraulic System Specification Arm Cap Screw—Torque ............................................................. 137 N•m 101 lb-ft

14. Connect and tighten hydraulic lines (4) to blade cylinder (10). 15. Install cylinder guard (3), washers (2), and cap screws (1). Tighten cap screws (1). 16. Check oil level. See Check Hydraulic Oil Tank Level. (Operator’s Manual.) Add oil as necessary. See Hydraulic Oil. (Operator’s Manual.)

OUO1030,0000114 –19–10FEB05–3/3

Blade Pilot Controller Remove and Install 1. Lower blade to ground. CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. SLOWLY loosen cap to relieve the air pressure in hydraulic oil tank. 2. SLOWLY loosen cap to release air pressure in hydraulic oil tank.

32 3260 3 Continued on next page

TM2264 (15OCT08)

32-3260-3

OUO1030,0000113 –19–10FEB05–1/3

Repair 101508

PN=289

Hydraulic System NOTE: Open access panel (26) to ease the removal of the cover (25). 3. Remove screws (23), and cap screw (24) to remove cover (25). Disconnect wiring leads to 12-volt power outlet.

T208342A

–UN–14FEB05

22—Control Lever 23—Screw (4 used) 24—Cap Screw 25—Cover 26—Access Panel

OUO1030,0000113 –19–10FEB05–2/3

4. Remove cap screws (27) and lever (22). 5. Identify hydraulic lines (28) for assembly. See Blade Hydraulic System Line Identification. (Group 9025-15.) Disconnect hydraulic lines and install caps and plugs.

6. Remove cap screws (29) to remove blade pilot controller (30). 28

7. Replace parts as necessary.

8. Install blade pilot controller (30) using cap screws (29).

10. Install lever (22) using cap screws (27). 32 3260 4

11. Connect wire leads to 12-volt power outlet.. 12. Install cover (25), cap screw (24), and screws (23).

T208341

–UN–14FEB05

9. Connect hydraulic lines (28).

22—Lever 27—Cap Screws (2 used) 28—Hydraulic Line (4 used) 29—Cap Screw (2 used) 30—Blade Pilot Controller

OUO1030,0000113 –19–10FEB05–3/3

TM2264 (15OCT08)

32-3260-4

Repair 101508

PN=290

Hydraulic System

32 3260 5

TM2264 (15OCT08)

32-3260-5

Repair 101508

PN=291

Hydraulic System

Blade Pilot Controller Disassemble and Assemble

12 2

13 13

14 5

15 16

14 15 16

6 7

17 17

18 19

18 20

8 9 9 10 32 3260 6

21 10

T160028

–UN–07OCT02

T160028

Blade Pilot Controller

Continued on next page

TM2264 (15OCT08)

32-3260-6

OUO1030,0000121 –19–18FEB05–1/2

Repair 101508

PN=292

Hydraulic System 1—Boot 2—Set Screw 3—Cam 4—Steel Ball (2 used) 5—Cap Screw (2 used) 6—Bushing (2 used)

7—Shaft 8—Bracket 9—Packing (2 used) 10—Plug (2 used) 11—O-Ring (2 used)

12—Push Rod (2 used) 13—Spring Seat (2 used) 14—Inner Spring (2 used) 15—Shim (2 used) 16—Washer (2 used)

17—Spool (2 used) 18—Outer Spring (2 used) 19—Plug 20—O-Ring 21—Housing

Compress the spring just enough to install spring seats (13) onto spools through the larger diameter hole.

IMPORTANT: If damage to cam (3), bracket (8), push rods (12), spools (17), or housing (21) is noticed, the pilot controller must be replaced.

8. Install the outer spring (18). 1. Take notice of part location with respect to its mating part for assembly.

9. Carefully install spool assemblies into the same ports from which they were removed.

2. Remove set screw (2). PM37616 Thread Lock and Sealer (medium strength) is used on the threads of set screws. Remove shaft (7) to remove cam (3) from bracket (8). Steel balls (4) cannot be removed. 3. Loosen the cap screws (5) to relieve the slight spring force. Remove bracket (8) from housing (21). 4. Remove packing (9), plugs (10), O-rings (11), and push rods (12). IMPORTANT: The spool assemblies are adjusted for equal pressure using shims. The shims and washers must be kept with their respective spools. The spools must be installed into the same ports from which they were removed. 5. Remove spool assemblies (13—17) and outer springs (18). Keep parts for each spool together.

10. Install O-rings (11) on plugs (10). 11. Apply grease to packing (9). Install packing in plugs with lip toward O-ring end of plug. 12. Apply hydraulic oil to push rods (12) before pushing rod through the packing in plugs (10). Install plug and push rod into housing. 13. Install bracket (8). Tighten cap screws (5). Specification Cover-to-Housing Cap Screw— Torque................................................................................... 23.5 N•m 208 lb-in.

14. Install cam (3). Install the shaft (7) through cover and cam so hole in shaft aligns with tapped hole in cam. 15. Apply PM37616 Thread Lock and Sealer (medium strength) to threads of set screw (2). Tighten set screw. Specification

6. Clean and repair or replace parts as necessary. 7. Install washer (16), shim (15), and inner spring (14) onto their original spool (17).

Cam-to-Shaft Set Screw— Torque.................................................................................... 5.0 N•m 44 lb-in.

OUO1030,0000121 –19–18FEB05–2/2

TM2264 (15OCT08)

32-3260-7

Repair 101508

PN=293

32 3260 7

Hydraulic System

32 3260 8

TM2264 (15OCT08)

32-3260-8

Repair 101508

PN=294

Section 33

Excavator Contents Page

Page

Group 3302—Buckets Tooth Shank Remove and Install—35D. . . . .33-3302-2 Tooth Shank Remove and Install—50D. . . . .33-3302-3

Hydraulic Oil Tank Remove and Install— 50D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-59 Hydraulic Oil Cooler Remove and Install— 35D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 Hydraulic Oil Cooler Remove and Install— 50D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-66 Boom Cylinder Remove and Install . . . . . . .33-3360-69 Arm Cylinder Remove and Install . . . . . . . .33-3360-72 Bucket Cylinder Remove and Install— 35D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-75 Bucket Cylinder Remove and Install— 50D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-78 Boom Swing Cylinder Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-81 Boom Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-85 Arm Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Bucket Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-93 Blade and Boom Swing Cylinder Disassemble and Assemble. . . . . . . . . . .33-3360-97 Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-100

Group 3340—Frames Bucket Link Remove and Install . . . . . . . . . .33-3340-1 Arm Remove and Install . . . . . . . . . . . . . . . .33-3340-4 Boom Remove and Install . . . . . . . . . . . . . . .33-3340-8 Boom Swing Remove and Install. . . . . . . . .33-3340-13 Inspect Arm, Boom, Bucket, and Boom Swing Pins and Bushings . . . . . . . . . . . .33-3340-16 Bushing and Seal Remove and Install. . . . .33-3340-20

Group 3360—Hydraulic System Hydraulic Pump Remove and Install . . . . . . .33-3360-1 Hydraulic Pump Remove and Install— 50D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3 Hydraulic Pump Disassemble—35D . . . . . . .33-3360-6 Hydraulic Pump Assemble—35D. . . . . . . . .33-3360-14 Hydraulic Pump Disassemble—50D . . . . . .33-3360-20 Hydraulic Pump Assemble—50D. . . . . . . . .33-3360-23 Hydraulic Pump Start-Up Procedure . . . . . .33-3360-26 Dampener Drive (Flex Coupling) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-26 Solenoid Valve Manifold Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-28 Pilot Controller Remove and Install . . . . . . .33-3360-29 Pilot Controller Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-31 Propel Pilot Controller Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-33 Propel Pilot Controller Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-36 Boom Swing or Auxiliary Pilot Controller Remove and Install . . . . . . . . . . . . . . . . .33-3360-38 Boom Swing or Auxiliary Pilot Controller Disassemble and Assemble. . . . . . . . . . .33-3360-40 Control Valve Remove and Install . . . . . . . .33-3360-42 Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-44 Pilot Controller Pattern Conversion Valve Remove and Install . . . . . . . . . . . . . . . . .33-3360-53 Pilot Controller Pattern Conversion Valve Disassemble and Assemble. . . . . . . . . . .33-3360-56 Hydraulic Oil Tank Remove and Install— 35D . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-58 TM2264 (15OCT08)

33-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

33-2

Repair 101508

PN=2

Group 3302

Buckets

33 3302 1

TM2264 (15OCT08)

33-3302-1

Repair 101508

PN=297

Buckets

Tooth Shank Remove and Install—35D

T197606

–UN–03FEB04

33 3302 2

Continued on next page

TM2264 (15OCT08)

33-3302-2

OUO1030,000011B –19–10FEB05–1/2

Repair 101508

PN=298

Buckets 0—Bucket Assembly

1—Tooth

2—Cap Screw

3—Nut

IMPORTANT: Take all precautions and move vehicle into safe work area.

4. Install tooth (1), cap screw (2), and nut (3). Tighten nut (3) to specification.

1. Adjust the bucket to comfortable working height and turn off engine.

Specification Tooth Shank—35D—Torque ................................................. 150 N•m 115 lb-ft

2. Remove nut (3), cap screw (2), and tooth (1). 3. Replace as necessary. OUO1030,000011B –19–10FEB05–2/2

Tooth Shank Remove and Install—50D IMPORTANT: Electrical current traveling from the welder through the machine’s electrical system can damage the electrical system, including the battery, and any electronic control units. Before welding on the machine, the battery ground cable and wiring harness connectors to any electronic control units must be disconnected to protect the machine’s electrical system. 1. Disconnect the battery ground strap and the wiring harness connectors to any electronic control units.

Continued on next page

OUO1030,000011A –19–10FEB05–1/5

33 3302 3

TM2264 (15OCT08)

33-3302-3

Repair 101508

PN=299

Buckets 2. Being careful not to cut into cutting edge, remove weld using a cutting torch or air arc equipment to remove shank. See Welding on Machine. (Group 1740.)

T92510

–UN–31OCT88

T92509

–UN–31OCT88

3. Grind all surfaces smooth.

Continued on next page

OUO1030,000011A –19–10FEB05–2/5

33 3302 4

TM2264 (15OCT08)

33-3302-4

Repair 101508

PN=300

T5985AQ

–UN–31OCT89

Buckets

IMPORTANT: Good welds are important. Have only a qualified welder do the welding. Before welding, clean all dirt and paint from weld area. Connect the welder ground clamp as close to each weld area as possible so electrical current does not pass through any bearings or bushings.

5. Install shank into corner so it is tight against the bevel edge and side of bucket. Install center shanks so they are tight against bevel edge and spaced equally across width of bucket. 6. Tack weld at the top rear center to hold it in position.

4. Before welding shank, remove the tooth tip so rubber pin lock is not damaged by the heat.

Continued on next page

TM2264 (15OCT08)

33-3302-5

OUO1030,000011A –19–10FEB05–3/5

Repair 101508

PN=301

33 3302 5

Buckets Use E7018 electrodes or Lincoln Electric Co. gas less flux core process electrode type NS3M. Either 3/32 or 1/8 in. rod may be used.

OUO1030,000011A –19–10FEB05–4/5

7. Preheat shank and cutting edge to 204°—316°C (400°—600°F). Check temperature using a temperature stick to be sure correct temperature is obtained.

–UN–31OCT88

Specification Tooth Shank—Preheat Temperature .......................................................................... 204°—316°C 400°—600°F

T82798

IMPORTANT: All weld beads must be continuous, starting at rear center and going around the corner and along the side, for a good strong weld joint. DO NOT start or stop welding at a corner. 8. Weld shank to cutting edge using 12.7 mm (0.5 in.) fillet weld (1).

T82799

Specification Tooth Shank-to-Cutting Edge Fillet Weld—Size ......................................................................... 12.7 mm 0.5 in. Distance From Edge Of Cutting Edge ......................................................................................... 19—31 mm 0.74—1.22 in.

–UN–31OCT88

Starting at the rear center of shank, weld a continuous bead across end, around the corner, and along the side, stopping 24.4—25.6 mm (0.96—1.01 in.) from edge of cutting edge. Alternating from side to side, make as many passes as necessary to get the specified bead size.

1—Fillet Weld

9. Allow the weld area to cool slowly at room temperature.

33 3302 6

OUO1030,000011A –19–10FEB05–5/5

TM2264 (15OCT08)

33-3302-6

Repair 101508

PN=302

Group 3340

Frames Bucket Link Remove and Install 9 3

6 3

4 4 1

11 10

2 4

–UN–04OCT02

T159968

Bucket Links 1—Retainer (2 used) 2—Left Side Link 3—O-Ring (2 used)

4—Plate (washer) (6 used) 5—Plate (washer) (6 used) 6—Center Link

NOTE: Removal of bucket is not necessary for the removal of just the bucket links. Remove the bucket if the arm is also being removed. See Installing Bucket with Quick Coupler. (Operator’s Manual.) 1. Connect center link (6) to a hoist using a lifting strap. Put a wood block between bucket cylinder

7—Pin (2 used) 8—Links-to-Arm Pin 9—Lubrication Fitting (2 used)

10—Cylinder Pin 11—Right Side Link

and arm to hold cylinder up when links-to-bucket cylinder pin (8) is removed. 2. Remove retainers (1) and pins (7). As links-to-bucket cylinder pin (8) is removed, lower left (2) and right (11) side links to ground.

33 3340 1

Continued on next page

TM2264 (15OCT08)

33-3340-1

OUO1030,000011C –19–11FEB05–1/2

Repair 101508

PN=303

Frames 3. Inspect bushings (4 and 7) and dust seals (5 and 6). See Inspect Arm, Boom, Bucket, and Boom Swing Pins and Bushings. (Group 3340.) Replace parts as necessary.

–UN–09MAR05

4. Install plates (washers) (2) equally on each side of joint to get a minimal amount of clearance in the joints. There must be some clearance in the joints.

T208458

5. Before installing pins, align pin bores so as not to damage dust seal when pins are installed. 6. Install pins and retainers. 7. Apply multi-purpose grease to pivot joints.

1—O-Ring (2 used) 2—Plate (washer) (4 used) 3—Center Link 4—Bushing (2 used) 5—Dust Seal (2 used) 6—Dust Seal (4 used) 7—Bushing (2 used)

OUO1030,000011C –19–11FEB05–2/2

33 3340 2

TM2264 (15OCT08)

33-3340-2

Repair 101508

PN=304

Frames

33 3340 3

TM2264 (15OCT08)

33-3340-3

Repair 101508

PN=305

Frames

Arm Remove and Install 21 11 21 22 12 22 5

16 31 30

31 31

6 17

30 30

30 31

30 39

37 40

5 16

33 3340 4

T159754

–UN–30SEP02

T159754 Continued on next page

TM2264 (15OCT08)

33-3340-4

OUO1030,000011D –19–14FEB05–1/4

Repair 101508

PN=306

Frames 1—Bushing 2—Cap Screw 3—Washer 4—Arm-to-Boom Pin 5—Link 6—Stop (2 used) 7—Link 8—Shim (4 used) 9—Arm-to-Arm Cylinder Pin

10—Arm-to-Bucket Cylinder Pin 11—Pin 12—Pin 13—Bucket-to-Arm Pin 14—Bucket-to-Center Link Pin 15—Plug (6 used) 16—Pin (4 used)

17—Retainer (4 used) 21—Lubrication Fitting (4 used) 22—O-Ring (4 used) 24—Cap Screw 25—Bushing 26—Cap Screw 27—Bushing

1. Remove bucket. See Installing Bucket with Quick Coupler. (Operator’s Manual.)

2. Retract arm cylinder. 3. Place a floor stand under boom so load is on boom, not on arm cylinder. 4. Stop engine.

29—Shim (3 used) 30—Shim (8 used) 31—Shim (8 used) 35—Adapter (2 used) 36—O-Ring (2 used) 37—Hydraulic Hose (2 used) 39—Plug (4 used) 40—Plug (2 used)

5. Slowly loosen cap to relieve the air pressure in hydraulic oil tank.

Continued on next page

OUO1030,000011D –19–14FEB05–2/4

33 3340 5

TM2264 (15OCT08)

33-3340-5

Repair 101508

PN=307

Frames

–UN–23AUG88

X9811

6. Loosen bucket cylinder hydraulic lines to release any residual pressure. Disconnect lines, install caps and plugs. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Arm—35D—Weight approximate .................................................... 118 kg 260 lb Arm—50D—Weight approximate .................................................... 181 kg 400 lb

NOTE: Remove bucket cylinder and linkage only if necessary to repair arm. 7. Attach arm to hoist. 8. Place a wood block between arm cylinder and boom to keep cylinder off lines.

Continued on next page

OUO1030,000011D –19–14FEB05–3/4

33 3340 6

TM2264 (15OCT08)

33-3340-6

Repair 101508

PN=308

T124955

–UN–03NOV99

Frames

1—Cap Screw 2—Bushing

3—Arm-to-Arm Cylinder Pin 4—Cap Screw

5—Bushing

6—Boom-to-Arm Pin

Boom-to-Arm Pin Cap Screw— 50D—Torque ......................................................................... 300 N•m 221 lb-ft

9. Remove parts (1—6). Remove arm. 10. Repair or replace parts as necessary.

13. Remove wood block.

11. Install arm. Install shims equally on each side of joint to get a minimal amount of clearance in the joints. There must be some clearance in the joints.

14. Remove hoist. 15. If removed, install bucket cylinder. 16. Connect bucket cylinder hydraulic lines.

Specification Arm and Cylinder Joints— Clearance..................................................................... 0.5 mm or less 0.020 in. or less

12. Install parts (1—6). Apply T43513 Thread Lock and Sealer (high strength) to threads of cap screws. Tighten cap screws (1 and 4). Specification Arm-to-Arm Cylinder Pin Cap Screw—35D—Torque ............................................................ 137 N•m 101 lb-ft Boom-to-Arm Pin Cap Screw— 35D—Torque ......................................................................... 210 N•m 154 lb-ft Arm-to-Arm Cylinder Pin Cap Screw—50D—Torque ............................................................ 137 N•m 101 lb-ft

17. If removed, install bucket links. 18. Install bucket. See Installing Bucket with Quick Coupler. (Operator’s Manual.) 19. Check oil level and add oil if necessary. See Hydraulic Oil. (Operator’s Manual.) 20. Apply multi-purpose grease to all joints. 21. Perform Hydraulic Cylinder Bleed Procedure. (Group 3360.)

33 3340 7

OUO1030,000011D –19–14FEB05–4/4

TM2264 (15OCT08)

33-3340-7

Repair 101508

PN=309

Frames

Boom Remove and Install

5 1

10 15

11 6

3 4

17 14

33 3340 8

T159763

–UN–01OCT02

T159763

Boom 1—Boom-to-Arm Cylinder Pin 2—Arm-to-Boom Pin 3—Shim (2 used) 4—Shim (2 used) 5—Shim (8 used)

6—Boom-to-Boom Cylinder Pin 7—Bushing 8—Cap Screw 9—Bushing

10—Cap Screw 11—Bushing 12—Cap Screw 13—Lock Washer

Continued on next page

TM2264 (15OCT08)

33-3340-8

14—Lubrication Fitting 15—Plug (5 used) 16—Bushing (2 used) 17—Seal (2 used)

OUO1030,000011E –19–14FEB05–1/6

Repair 101508

PN=310

Frames

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 1. Slowly loosen cap to relieve the air pressure in hydraulic oil tank. 2. Remove bucket. See Installing Bucket with Quick Coupler. (Operator’s Manual.) 3. Remove arm. See Arm Remove and Install. (Group 3340.)

4. Lower boom so the end is on a support stand. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Boom Cylinder—35D—Weight approximate ................................................................................ 35 kg 77 lb Boom Cylinder—50D—Weight approximate ................................................................................ 55 kg 121 lb

5. Attach a hoist to boom cylinder.

OUO1030,000011E –19–14FEB05–2/6

6. Remove cap screw (6), bushing (7), pin (5), and shims (3 and 4). Lower end of boom cylinder to a support stand. Remove cover (1) if cylinder is being removed for repair. –UN–29OCT99

7. Remove arm cylinder only if necessary to repair boom.

T124958

1—Cover 2—Cap Screw and Washer 3—Shim (2 used) 4—Shim (2 used) 5—Boom-to-Boom Cylinder Pin 6—Cap Screw 7—Bushing

Continued on next page

OUO1030,000011E –19–14FEB05–3/6

33 3340 9

TM2264 (15OCT08)

33-3340-9

Repair 101508

PN=311

Frames

–UN–23AUG88

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. 8. Remove cover (1).

X9811

9. Attach identification tags to hydraulic lines to aid in assembly. See Main Hydraulic Working System Line Identification—35D or See Main Hydraulic Working System Line Identification—50D. Disconnect lines (2). Insert caps and plugs. 10. Disconnect wires for boom light. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

–UN–18FEB05

Specification Boom Weight—35D—Weight approximate ..................................................................................... 236 kg 520 lb Boom Weight—50D—Weight approximate ..................................................................................... 363 kg 800 lb

T208656A

11. Attach boom to a hoist. 12. Remove cap screw and nuts (3). Remove the pin (4) and shims (5).

35D Shown

13. Remove boom.

1—Cover 2—Hydraulic Lines 3—Cap Screw and Nuts 4—Boom-to-Frame Pin 5—Shims (2 used)

14. Repair or replace parts as necessary. 15. Install boom. Install parts (3—5). Install shims (5) equally on each side of joint to get a minimal amount of clearance in the joint. There must be some clearance in the joint. 33 3340 10

Specification Boom, Arm, and Cylinder Joints— Clearance ....................................................................................... 0.5 mm 0.020 in.

Continued on next page

TM2264 (15OCT08)

33-3340-10

OUO1030,000011E –19–14FEB05–4/6

Repair 101508

PN=312

Frames 16. Apply T43513 Thread Lock and Sealer (high strength) to threads of nuts. Tighten the nuts against each other, not the boss. There must be clearance between nuts and boss. Cap screw must be free to turn in hole. Specification Boom-to-Frame Pin Cap Screw and Nuts—35D—Torque ................................................................ 90 N•m 66 lb-ft Boom Cylinder-to-Frame Pin Cap Screw and Nuts—35D—Torque ..................................................... 50N•m 37 lb-ft Boom-to-Frame Pin Cap Screw and Nuts—50D—Torque .............................................................. 140 N•m 103 lb-ft Boom Cylinder-to-Frame Pin Cap Screw and Nuts—50D—Torque ..................................................... 90 N•m 66 lb-ft Nut-to-Boss—Clearance ............................................................... 3—5 mm 0.12—0.20 in.

Continued on next page

OUO1030,000011E –19–14FEB05–5/6

33 3340 11

TM2264 (15OCT08)

33-3340-11

Repair 101508

PN=313

Frames 17. Raise boom cylinder.

–UN–29OCT99

Install shims (3 and 4) equally on each side of joint to get a minimal amount of clearance in the joint. There must be some clearance in the joint. Install pin (5).

T124958

18. Apply T43513 Thread Lock and Sealer (high strength) to threads of cap screw (6). Install bushing (7) and cap screw. Tighten cap screw. Specification Boom-to-Cylinder Pin Cap Screw—Torque ............................................................................... 88 N•m 65 lb-ft Cover-to-Boom Cylinder Cap Screw—35D—Torque..................................................................... 50 N•m 37 lb-ft Cover-to-Boom Cylinder Cap Screw—50D—Torque..................................................................... 90 N•m 66 lb-ft

1—Cover 2—Cap Screw and Washer 3—Shim (2 used) 4—Shim (2 used) 5—Boom Cylinder-to-Boom Pin 6—Cap Screw 7—Bushing

19. Install arm cylinder. 20. Connect hydraulic lines. 21. Install cover. 22. Install arm. See Arm Remove and Install. (Group 3340.) 23. Install bucket. See Installing Bucket with Quick Coupler. (Operator’s Manual.) 24. Check oil level and add oil if necessary. See Hydraulic Oil. (Operator’s Manual.) 25. Apply multi-purpose grease to all joints. 26. Perform Hydraulic Cylinder Bleed Procedure. (Group 3360.) 33 3340 12

OUO1030,000011E –19–14FEB05–6/6

TM2264 (15OCT08)

33-3340-12

Repair 101508

PN=314

Frames

Boom Swing Remove and Install

–UN–23AUG88

X9811

1. Slowly loosen cap to relieve the air pressure in hydraulic oil tank. 2. Remove boom. See See Boom Remove and Install. (Group 3340.)

Continued on next page

OUO1030,000011F –19–16FEB05–1/3

33 3340 13

TM2264 (15OCT08)

33-3340-13

Repair 101508

PN=315

Frames

18 17

19 18

12 10

13 14

2 4

21 22

6 5

8 26

–UN–01MAR05

T208655

Swing Post—50D Shown 1—Cap Screw (4 used) 2—Cover 3—Cap Screw (2 used) 4—Cover 5—Cap Screw (2 used) 6—Cover 7—Nut (2 used)

33 3340 14

8—Cap Screw 9—Pin 10—Nut (2 used) 11—Cap Screw 12—Pin 13—Shim (2 used) 14—Shim

15—Nut (2 used) 16—Cap Screw 17—Pin 18—Shim (2 used) 19—Shim 20—Screw (3 used) 21—Guide

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

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

4. Remove cap screws (3) and cover (4). 5. Remove cap screws (5) and cover (6). (50D only) 6. Remove nuts (7), cap screw (8), and pin (9) to disconnect boom swing cylinder.

7. Attach a hoist to boom swing frame (27) using a lifting strap.

Continued on next page

TM2264 (15OCT08)

22—Nut (2 used) 23—Cap Screw 24—Pin 25—Bushing 26—Thrust Washer 27—Swing Frame

33-3340-14

OUO1030,000011F –19–16FEB05–2/3

Repair 101508

PN=316

Frames 8. Remove nuts (22), cap screw (23), and pin (24). 9. Remove thrust washer (26) and bushings (25). NOTE: Remove and reinstall guide (21) if replacing swing frame (27).

Specification Nut-to-Boss—Clearance ........................................................ 3—5 mm 0.12—0.20 in. Specification Swing Frame Cap Screw and Nuts—Torque........................................................................... 88 N•m 65 lb-ft

10. Remove swing frame (27). 15. Install guide (21) and screws (20). 11. Make repairs or replace parts as necessary. 12. Install swing frame (27). 13. Install thrust washer (26), bushings (25), and pin (24). 14. Apply T43513 Thread Lock and Sealer (high strength) to the threads of nuts (22). Install cap screw (23) and tighten nuts (22) against each other, not the boss. There must be clearance between nuts and boss. Cap screw must be free to turn in hole.

16. Apply T43513 Thread Lock and Sealer (high strength) to the threads of nuts (7). Connect swing boom cylinder using pin (9), cap screw (8), and nuts (7). 17. Install boom. See Boom Remove and Install. (Group 3340.) 18. Check oil level and add oil if necessary. See Hydraulic Oil. (Operator’s Manual.) 19. Apply multi-purpose grease to all joints.

OUO1030,000011F –19–16FEB05–3/3

33 3340 15

TM2264 (15OCT08)

33-3340-15

Repair 101508

PN=317

Frames

T124959

–UN–04NOV99

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

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

E—Arm Cylinder Rod End-to-Arm Joint F—Boom-to-Arm Joint G—Bucket Cylinder Head End-to-Arm Joint H—Side Links-to-Arm Joint

NOTE: Specifications listed are for both the 35D and 50D unless otherwise noted.

33 3340 16

Specification Boom Cylinder Head End-to-Frame Joint Pin—35D— OD (nominal) ......................................................................... 40.0 mm 1.58 in. OD (limit of use) .................................................................... 39.0 mm 1.54 in. Boom Cylinder Head End-to-Frame Joint Bushing— 35D—ID (nominal) ................................................................. 40.0 mm 1.58 in. ID (limit of use) ..................................................................... 41.5 mm 1.63 in.

I—Bucket Cylinder Rod End-to-Boom Joint J—Center Link-to-Bucket Joint K—Bucket-to-Arm Joint L—Boom Swing-to-Frame Joint

Boom Cylinder Rod End-to-Boom Joint Pin—35D— OD (nominal) ......................................................................... 40.0 mm 1.58 in. OD (limit of use) .................................................................... 39.0 mm 1.54 in. Boom Cylinder Rod End-to-Boom Joint Bushing— 35D—ID (nominal) ................................................................. 40.0 mm 1.58 in. ID (limit of use) ...................................................................... 41.5 mm 1.63 in.

Continued on next page

TM2264 (15OCT08)

M—Boom Swing Cylinder Rod End-to-Boom Swing Joint N—Frame-to-Boom Swing Cylinder Head End Joint

33-3340-16

OUO1030,0000120 –19–17FEB05–1/4

Repair 101508

PN=318

Frames Specification Boom Cylinder Head End-to-Frame Joint Pin—50D— OD (nominal) ......................................................................... 50.0 mm 1.97 in. OD (limit of use) .................................................................... 49.0 mm 1.93 in. Boom Cylinder Head End-to-Frame Joint Bushing— 50D—ID (nominal) ................................................................. 50.0 mm 1.97 in. ID (limit of use) ...................................................................... 51.5 mm 2.03 in. Boom Cylinder Rod End-to-Boom Joint Pin—50D— OD (nominal) ......................................................................... 50.0 mm 1.97 in. OD (limit of use) .................................................................... 49.0 mm 1.93 in. Boom Cylinder Rod End-to-Boom Joint Bushing— 50D—ID (nominal) ................................................................. 50.0 mm 1.97 in. ID (limit of use) ...................................................................... 51.5 mm 2.03 in. Boom-to-Frame Joint Pin— 35D—OD (nominal) ............................................................... 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Boom-to-Frame Joint Bushing—35D—ID (nominal) ................................................ 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in. Boom-to-Arm Joint Pin—35D— OD (nominal) ......................................................................... 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Boom-to-Arm Joint Bushing— 35D—ID (nominal) ................................................................. 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in. Boom-to-Frame Joint Pin— 50D—OD (nominal) ............................................................... 50.0 mm 1.97 in. OD (limit of use) .................................................................... 49.0 mm 1.93 in.

Boom-to-Frame Joint Bushing—50D—ID (nominal) ................................................ 50.0 mm 1.97 in. ID (limit of use) ...................................................................... 51.5 mm 2.03 in. Boom-to-Arm Joint Pin—50D— OD (nominal) ......................................................................... 50.0 mm 1.97 in. OD (limit of use) .................................................................... 49.0 mm 1.93 in. Boom-to-Arm Joint Bushing— 50D—ID (nominal) ................................................................. 50.0 mm 1.97 in. ID (limit of use) ...................................................................... 51.5 mm 2.03 in. Boom Swing-to-Frame Pin— 35D—OD (nominal) .............................................................. 80.0 mm 3.15 in. OD (limit of use) .................................................................... 79.0 mm 3.11 in. Boom Swing-to-Frame Bushing—35D—ID (nominal) ................................................ 80.0 mm 3.15 in. ID (limit of use) ...................................................................... 81.5 mm 3.21 in. Boom Swing-to-Frame Pin— 50D—OD (nominal) ............................................................... 95.0 mm 3.74 in. OD (limit of use) ................................................................... 94.0 mm 3.70 in. Boom Swing-to-Frame Bushing—50D—ID (nominal) ............................................... 95.0 mm 3.74 in. ID (limit of use) ...................................................................... 96.5 mm 3.80 in. Boom Swing Cylinder-to-Boom Swing Pin—35D—OD (nominal) ........................................... 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Boom Swing Cylinder-to-Boom Swing Bushing—35D—ID (nominal) ............................................................................... 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in. Boom Swing Cylinder-to-Boom Swing Pin—50D—OD (nominal) ........................................... 50.0 mm 1.97 in. OD (limit of use) .................................................................... 49.0 mm 1.93 in.

33 3340 17

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TM2264 (15OCT08)

33-3340-17

OUO1030,0000120 –19–17FEB05–2/4

Repair 101508

PN=319

Frames Specification Boom Swing Cylinder-to-Boom Swing Bushing—50D—ID (nominal) ................................................................................ 50.0 mm 1.97 in. ID (limit of use) ...................................................................... 51.5 mm 2.03 in. Frame-to-Boom Swing Cylinder Pin—35D—OD (nominal) ...................................................... 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Frame-to-Boom Swing Cylinder Bushing—35D—ID (nominal) ............................................... 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in. Frame-to-Boom Swing Cylinder Pin—50D—OD (nominal) ...................................................... 50.0 mm 1.97 in. OD (limit of use) .................................................................... 49.0 mm 1.93 in. Frame-to-Boom Swing Cylinder Bushing—50D—ID (nominal) ................................................ 50.0 mm 1.97 in. ID (limit of use) ...................................................................... 51.5 mm 2.03 in. Arm Cylinder Head End-to-Boom Joint Pin—OD (nominal) ................................................................................ 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Arm Cylinder Head End-to-Boom Joint Bushing—ID (nominal) ................................................................................ 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in. Arm Cylinder Rod End-to-Arm Joint Pin—OD (nominal) ........................................................ 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Arm Cylinder Rod End-to-Arm Joint Bushing—ID (nominal) .................................................. 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in.

Bucket Cylinder Head End-to-Arm Joint Pin—35D— OD (nominal) ......................................................................... 40.0 mm 1.58 in. OD (limit of use) .................................................................... 39.0 mm 1.54 in. Bucket Cylinder Head End-to-Arm Joint Bushing— 35D—ID (nominal) ................................................................. 40.0 mm 1.58 in. ID (limit of use) ...................................................................... 41.5 mm 1.63 in. Bucket Cylinder Head End-to-Arm Joint Pin—50D— OD (nominal) ......................................................................... 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Bucket Cylinder Head End-to-Arm Joint Bushing— 50D—ID (nominal) ................................................................. 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in. Bucket Cylinder Rod End-to-Side and Center Links Joint Pin—35D—OD (nominal) .............................................. 40.0 mm 1.58 in. OD (limit of use) .................................................................... 39.0 mm 1.54 in. Bucket Cylinder Rod End-to-Side and Center Links Joint Bushing—35D—ID (nominal) ................................................................................ 40.0 mm 1.58 in. ID (limit of use) ...................................................................... 41.5 mm 1.63 in. Bucket Cylinder Rod End-to-Side and Center Links Joint Pin—50D—OD (nominal) .............................................. 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Bucket Cylinder Rod End-to-Side and Center Links Joint Bushing—50D—ID (nominal) ................................................................................ 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in.

33 3340 18

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TM2264 (15OCT08)

33-3340-18

OUO1030,0000120 –19–17FEB05–3/4

Repair 101508

PN=320

Frames Specification Side Links-to-Arm Joint Pin— 35D—OD (nominal) ............................................................... 40.0 mm 1.58 in. OD (limit of use) .................................................................... 39.0 mm 1.54 in. Side Links-to-Arm Joint Bushing—35D—ID (nominal) ................................................ 40.0 mm 1.58 in. ID (limit of use) ...................................................................... 41.5 mm 1.63 in. Side Links-to-Arm Joint Pin— 50D—OD (nominal) ............................................................... 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Side Links-to-Arm Joint Bushing—50D—ID (nominal) ................................................ 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in. Center Link-to-Bucket Joint Pin—35D—OD (nominal) ...................................................... 40.0 mm 1.58 in. OD (limit of use) .................................................................... 39.0 mm 1.54 in. Center Link-to-Bucket Joint Bushing—35D—ID (nominal) ................................................ 40.0 mm 1.58 in. ID (limit of use) ...................................................................... 41.5 mm 1.63 in.

Center Link-to-Bucket Joint Pin—50D—OD (nominal) ...................................................... 45.0 mm 1.77 in. OD (limit of use) .................................................................... 44.0 mm 1.73 in. Center Link-to-Bucket Joint Bushing—50D—ID (nominal) ................................................ 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.73 in. Bucket-to-Arm Joint Pin— 35D—OD (nominal) ............................................................... 40.0 mm 1.58 in. OD (limit of use) .................................................................... 39.0 mm 1.54 in. Bucket-to-Arm Joint Bushing— 35D—ID (nominal) ................................................................. 40.0 mm 1.58 in. ID (limit of use) ...................................................................... 41.5 mm 1.63 in. Bucket-to-Arm Joint Pin— 50D—OD (nominal) ............................................................... 45.0 mm 1.77 in. OD (limit of use) ...................................................................... 4.0 mm 1.73 in. Bucket-to-Arm Joint Bushing— 50D—ID (nominal) ................................................................. 45.0 mm 1.77 in. ID (limit of use) ...................................................................... 46.5 mm 1.83 in.

OUO1030,0000120 –19–17FEB05–4/4

33 3340 19

TM2264 (15OCT08)

33-3340-19

Repair 101508

PN=321

Frames

Bushing and Seal Remove and Install NOTE: Bushing can also be removed by welding three to five weld beads on the inside of bushing. Bushing will shrink enough to permit removal using a hammer. 1. Remove bushings (C) and dust seals using bushing, bearing, and seal driver set. 2. Install bushings with lubrication hole aligned with lubrication passage in pivot. 3. Install bushing to a depth equal to thickness of dust seal (H). 4. Install dust seals with lip toward outside of component.

T6641CW

–UN–31OCT88

T95237

–UN–01NOV88

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

CED,OUOE023,2178 –19–27JAN03–1/1

33 3340 20

TM2264 (15OCT08)

33-3340-20

Repair 101508

PN=322

Group 3360

Hydraulic System Hydraulic Pump Remove and Install CAUTION: Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank. 1. Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank. 2. Drain hydraulic tank. Approximate capacity is 42.0 L (11.0 gal). 3. Remove left side covers to access hydraulic pump.

Continued on next page

MH66O88,000004E –19–31JAN06–1/3

33 3360 1

TM2264 (15OCT08)

33-3360-1

Repair 101508

PN=323

Hydraulic System

–UN–23AUG88

CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 4. Disconnect lines (1—4) and (7) if equipped. Close openings using caps and plugs.

X9811

5. Loosen clamp and disconnect line (9). CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device. Hydraulic Pump—Specification Hydraulic Pump—Weight approximate ...................................................................................... 21 kg 46 lb

–UN–08DEC05

6. Attach hoist and lifting strap to hydraulic pump. Remove cap screws (6) and lock washers (5). Remove hydraulic pump (8).

T217404A

7. See Hydraulic Pump Disassemble (Group 3360.) See Hydraulic Pump Assemble for procedure. (Group 3360.) 1—Hydraulic Line 2—Hydraulic Line 3—Hydraulic Line 4—Hydraulic Line 5—Washer (2 used) 6—Cap Screw (2 used) 7—Hydraulic Line (air conditioning only) 8—Hydraulic Pump 9—Hose

8. Install hydraulic pump (8), lock washers (5) and cap screws (6). Tighten cap screws to specification. Specification Hydraulic Pump-to-Flywheel Housing Cover Cap Screw— Torque ........................................................................................... 90 N•m 67 lb-ft

9. Connect hose (9) and tighten clamp. 10. Connect lines (1—4) and (7) if equipped.

33 3360 2

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TM2264 (15OCT08)

33-3360-2

MH66O88,000004E –19–31JAN06–2/3

Repair 101508

PN=324

Hydraulic System IMPORTANT: Hydraulic pump will be damaged if not filled with fluid before starting engine. Procedure must be performed whenever the pump is installed or fluid has been drained from the pump or hydraulic tank. 11. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

MH66O88,000004E –19–31JAN06–3/3

Hydraulic Pump Remove and Install—50D CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 1. Slowly loosen cap to relieve the air pressure in hydraulic oil tank. 2. Drain hydraulic oil tank. Approximate capacity is 65.0 L (17.0 gal). 3. Remove left side covers to access hydraulic pump.

Continued on next page

OUO1030,00000CE –19–07FEB05–1/3

33 3360 3

TM2264 (15OCT08)

33-3360-3

Repair 101508

PN=325

Hydraulic System

–UN–23AUG88

X9811

5. Loosen clamp and disconnect hose (7). CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Hydraulic Pump—Specification Hydraulic Pump—Weight approximate ...................................................................................... 19 kg 42 lb

6. Attach shop hoist to hydraulic pump. Remove cap screws (1) and washers (2). Remove hydraulic pump (4).

–UN–12JAN05

7. See Hydraulic Pump Disassemble—50D to procedure. (Group 3360.)

T206862A

See Hydraulic Pump Assemble—50D for procedure. (Group 3360.) 8. Install hydraulic pump (4), washers (2) and cap screws (1). Tighten cap screws to specification. Hydraulic Pump Specification

1—Cap Screw (2 used) 2—Washer (2 used) 3—Hydraulic Line 4—Hydraulic Pump 5—Hydraulic Line 6—Hydraulic Line 7—Hose 8—Hydraulic Line 9—Hydraulic Line

Hydraulic Pump-to-Flywheel Housing Cover Cap Screw— Torque ......................................................................................... 108 N•m 80 lb-ft

9. Connect hose (7) and tighten clamp. 10. Connect lines (3) and (5—9). 33 3360 4

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TM2264 (15OCT08)

33-3360-4

OUO1030,00000CE –19–07FEB05–2/3

Repair 101508

PN=326

Hydraulic System IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed whenever the pump is installed or oil has been drained from the pump or hydraulic oil tank. 11. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

OUO1030,00000CE –19–07FEB05–3/3

33 3360 5

TM2264 (15OCT08)

33-3360-5

Repair 101508

PN=327

Hydraulic System

Hydraulic Pump Disassemble—35D

T207937

–UN–11FEB05

33 3360 6

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TM2264 (15OCT08)

33-3360-6

OUO1030,000010F –19–14OCT08–1/14

Repair 101508

PN=328

Hydraulic System 1—Snap Ring 2—Seal 3—Shaft 4—Bearing 5—Snap Ring 6—O-Ring (2 used) 7—Plug (2 used) 8—Pin 9—Pump Housing 10—Gasket 11—Disk Spring (4 used) 12—Pin (stop, short) 13—Rod

14—Swash Plate 15—Hose Fitting 16—Pin (stop, long) 17—Ceramic Ball (2 used) 18—Piston (10 used) 19—Retainer 20—Bushing 21—Pin (3 used) 22—Cylinder Block 23—Washer (2 used) 24—Spring 25—Snap Ring 26—Valve Plate

27—Spring Pin 28—Bearing 29—Spring Seat 30—Spring 31—Spring Seat 32—Pin 33—O-Ring (2 used) 34—Pump Housing 35—Sealing Washer 36—Adjusting Screw 37—Nut 38—Lock Washer (5 used) 39—Cap Screw (5 used)

40—O-Ring 41—O-Ring 42—O-Ring 43—Bushing 44—Coupling 45—Hydraulic Pump 3 46—Washer (2 used) 47—Cap Screw (2 used) 48—Cap Screw (4 used) 49—O-Ring 50—Rod (air conditioning only)

OUO1030,000010F –19–14OCT08–2/14

1. Remove cap screws (48), hose fitting (15), and O-ring (49).

T125691

–UN–14JAN00

15—Hose Fitting 48—Cap Screw (4 used) 49—O-Ring

Continued on next page

OUO1030,000010F –19–14OCT08–3/14

33 3360 7

TM2264 (15OCT08)

33-3360-7

Repair 101508

PN=329

Hydraulic System NOTE: Bushing (43) and coupling (44) may come off with hydraulic pump 3 (45) or remain on hydraulic pump.

–UN–14JAN00

2. Remove cap screws (47) and washers (46) to remove hydraulic pump 3 (45). 3. Remove bushing (43) and coupling (44).

T125692

4. Remove O-rings (40—42). NOTE: Adjusting screw controls the maximum pump flow rate. Removal will require a test and adjustment to get the correct setting for maximum pump flow rate.

–UN–14JAN00

5. Remove nut (37), sealing washer (35), and adjusting screw (36) for inspection or replacement only. Measure length of adjusting screw from pump housing to end of screw to aid assembly.

T125693

6. Remove cap screws (39) and lock washers (38).

35—Sealing Washer 36—Adjusting Screw 37—Nut 38—Lock Washer (5 used) 39—Cap Screw (5 used) 40—O-Ring 41—O-Ring 42—O-Ring 43—Bushing 44—Coupling 45—Hydraulic Pump 3 46—Washer (2 used) 47—Cap Screw (2 used)

Continued on next page

OUO1030,000010F –19–14OCT08–4/14

33 3360 8

TM2264 (15OCT08)

33-3360-8

Repair 101508

PN=330

Hydraulic System IMPORTANT: When separating pump housing, use care not to drop the valve plate. 7. Separate pump housing (9 and 34). –UN–14JAN00

8. Remove gasket (10) and valve plate (26).

T125694

9—Pump Housing 10—Gasket 26—Valve Plate 34—Pump Housing

OUO1030,000010F –19–14OCT08–5/14

9. Remove spring pin (27), spring seat (31), and O-ring (33).

–UN–14JAN00

10. Remove bearing (28) for replacement only. Bearing is press fit.

T125695

27—Spring Pin 28—Bearing 31—Spring Seat 33—O-Ring (2 used)

OUO1030,000010F –19–14OCT08–6/14

11. Remove spring (30), spring seat (29), and O-ring (33).

T125696

–UN–14JAN00

29—Spring Seat 30—Spring 33—O-Ring (2 used)

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TM2264 (15OCT08)

33-3360-9

OUO1030,000010F –19–14OCT08–7/14

Repair 101508

PN=331

33 3360 9

Hydraulic System IMPORTANT: When removing rotary group, use care not to damage cylinder block and piston assembly.

–UN–14JAN00

The original pistons must be installed into the same bores of original cylinder block because of wear patterns.

T125697

12. Mark pistons (18) with respect to cylinder block (22) bores for assembly. Remove parts (18—22).

18—Piston (10 used) 19—Retainer 20—Bushing 21—Pin (3 used) 22—Cylinder Block

OUO1030,000010F –19–14OCT08–8/14

CAUTION: Prevent possible injury. Spring is under load. Spring must be compressed before removing snap ring.

–UN–14JAN00

13. Remove snap ring (25), washers (23), and spring (24) for inspection or replacement only. Apply force to outer washer using a press. Remove snap ring.

T125698

23—Washer (2 used) 24—Spring 25—Snap Ring

Continued on next page

OUO1030,000010F –19–14OCT08–9/14

33 3360 10

TM2264 (15OCT08)

33-3360-10

Repair 101508

PN=332

Hydraulic System 14. Check the clearance between piston and shoe. Specification Piston-to-Shoe—Clearance ................................................ 0.2 mm or less 0.00787 in. or less –UN–03FEB03

Substract piston diameter from cylinder block bore diameter to check for wear.

T164714

–UN–03FEB03

T164706

Specification Piston-to-Cylinder Block Bore— Clearance ....................................................................... 0.050 mm or less 0.00197 in. or less

OUO1030,000010F –19–14OCT08–10/14

15. Remove swash plate (14) and ceramic balls (17). NOTE: Pin (16) has two cavities and is longer than pin (12). Note location of pins to aid in assembly. –UN–07FEB05

16. Remove parts (11—13, 16 and 50).

T207939A

17. Remove plugs (7) and O-rings (6). 6—O-Ring (2 used) 7—Plug (2 used) 11—Disk Spring (4 used) 12—Pin (stop, short) 13—Rod 14—Swash Plate 16—Pin (stop, long) 17—Ceramic Ball (2 used) 50—Rod (air conditioning only)

33 3360 11

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TM2264 (15OCT08)

33-3360-11

OUO1030,000010F –19–14OCT08–11/14

Repair 101508

PN=333

Hydraulic System 18. Remove snap ring (5).

T125700

–UN–14JAN00

5—Snap Ring

OUO1030,000010F –19–14OCT08–12/14

19. Remove shaft (3) using a press.

T125701

–UN–14JAN00

3—Shaft

OUO1030,000010F –19–14OCT08–13/14

20. Remove snap ring (1). Remove seal (2).

22. Remove pins (8 and 32) for replacement only.

T125702

23. See Hydraulic Pump Assemble—35D.

–UN–14JAN00

21. Remove bearing (4) for replacement only. Bearing is press fit in pump housing.

1—Snap Ring 2—Seal 4—Bearing 8—Pin 32—Pin

T125703

–UN–14JAN00

33 3360 12

OUO1030,000010F –19–14OCT08–14/14

TM2264 (15OCT08)

33-3360-12

Repair 101508

PN=334

Hydraulic System

33 3360 13

TM2264 (15OCT08)

33-3360-13

Repair 101508

PN=335

Hydraulic System

Hydraulic Pump Assemble—35D

T207938

–UN–11FEB05

33 3360 14

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TM2264 (15OCT08)

33-3360-14

OUO1030,000012B –19–17MAR05–1/12

Repair 101508

PN=336

40—O-Ring 41—O-Ring 42—O-Ring 43—Bushing 44—Coupling 45—Hydraulic Pump 3 46—Washer (2 used) 47—Cap Screw (2 used) 48—Cap Screw (4 used) 49—O-Ring 50—Rod (air conditioning only)

OUO1030,000012B –19–17MAR05–2/12

1. Install pins (8 and 32). 2. Install bearing (4) using a press.

–UN–14JAN00

3. Install seal (2). 4. Install snap ring (1).

T125703

–UN–14JAN00

T125702

1—Snap Ring 2—Seal 4—Bearing 8—Pin 32—Pin

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TM2264 (15OCT08)

33-3360-15

OUO1030,000012B –19–17MAR05–3/12

Repair 101508

PN=337

33 3360 15

Hydraulic System 5. Install shaft (3) using a press.

T125701

–UN–14JAN00

3—Shaft

OUO1030,000012B –19–17MAR05–4/12

6. Install snap ring (5).

T125700

–UN–14JAN00

5—Snap Ring

OUO1030,000012B –19–17MAR05–5/12

7. Install O-rings (6) and plugs (7). 8. Install disk springs (11) so convex side is against head of pins (12 and 16). –UN–07FEB05

9. Install pins (12 and 16) into their original bores.

T207939A

NOTE: Rod (50) is only installed in the machine if equipped with air conditioning. 10. Install rods (13 and 50) so the larger diameter end is toward the swash plate (14). 6—O-Ring (2 used) 7—Plug (2 used) 11—Disk Spring (4 used) 12—Pin (stop, short) 13—Rod 14—Swash Plate 16—Pin (stop, long) 17—Ceramic Ball (2 used) 50—Rod (air conditioning only)

11. Install ceramic balls (17) and swash plate (14). 33 3360 16

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TM2264 (15OCT08)

33-3360-16

OUO1030,000012B –19–17MAR05–6/12

Repair 101508

PN=338

Hydraulic System 12. Install washers (23) and spring (24). 13. Apply force to outer washer to compress spring. Install snap ring (25).

T125698

–UN–14JAN00

23—Washer (2 used) 24—Spring 25—Snap Ring

OUO1030,000012B –19–17MAR05–7/12

14. Install pins (21), bushing (20), retainer (19), and pistons (18) into cylinder block (22) so marks on pistons and cylinder block are aligned.

–UN–14JAN00

15. Install cylinder block (22).

T125697

18—Piston (10 used) 19—Retainer 20—Bushing 21—Pin (3 used) 22—Cylinder Block

OUO1030,000012B –19–17MAR05–8/12

16. Install O-ring (33), spring seat (29), and spring (30).

T125696

–UN–14JAN00

29—Spring Seat 30—Spring 33—O-Ring (2 used)

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TM2264 (15OCT08)

33-3360-17

OUO1030,000012B –19–17MAR05–9/12

Repair 101508

PN=339

33 3360 17

Hydraulic System 17. Install bearing (28) using a press.

–UN–14JAN00

18. Install O-ring (33), spring seat (31), and spring pin (27).

T125695

27—Spring Pin 28—Bearing 31—Spring Seat 33—O-Ring

OUO1030,000012B –19–17MAR05–10/12

IMPORTANT: Valve plate has highly machined surfaces and can be damaged. Do not drop valve plate.

–UN–14JAN00

19. Apply petroleum jelly to valve plate (26) to help hold it in place on pump housing (34). 20. Install gasket (10).

T125694

21. Join pump housing (9 and 34). Pull the housing together against the spring using M10 x 65 mm cap screw. 9—Pump Housing 10—Gasket 26—Valve Plate 34—Pump Housing

Continued on next page

OUO1030,000012B –19–17MAR05–11/12

33 3360 18

TM2264 (15OCT08)

33-3360-18

Repair 101508

PN=340

Hydraulic System 22. Install lock washers (38) and cap screws (39). Tighten cap screws.

–UN–14JAN00

Specification Housing-to-Housing Cap Screw— Torque ............................................................................................ 59 N•m 44 lb-ft

T125693

23. Install adjusting screw (36), sealing washer (35), and nut (37) so screw is to the measurement taken at disassembly. See Hydraulic Pump 1 and 2 Regulator Test and Adjustment—Engine Pulldown—35D to check maximum pump flow rate after pump is installed. (Group 9025-25.) 24. Install O-rings (40—42).

–UN–14JAN00

25. Install bushing (43) and coupling (44). 26. Install hydraulic pump 3 (45), washers (46), and cap screws (47). Tighten cap screws.

T125692

Specification Hydraulic Pump 3-to-Pump Housing Cap Screw—Torque......................................................... 12 N•m 108 lb-in. 35—Sealing Washer 36—Adjusting Screw 37—Nut 38—Lock Washer (5 used) 39—Cap Screw (5 used) 40—O-Ring 41—O-Ring 42—O-Ring 43—Bushing 44—Coupling 45—Hydraulic Pump 3 46—Washer (2 used) 47—Cap Screw (2 used)

27. Install O-ring, hose fitting, and cap screws.

OUO1030,000012B –19–17MAR05–12/12

33 3360 19

TM2264 (15OCT08)

33-3360-19

Repair 101508

PN=341

Hydraulic System

Hydraulic Pump Disassemble—50D

T164108

–UN–22JAN03

33 3360 20

Hydraulic Pump—50D Continued on next page

TM2264 (15OCT08)

33-3360-20

OUO1030,000012C –19–17MAR05–1/3

Repair 101508

PN=342

Hydraulic System 1—Snap Ring 2—O-Ring 3—Seal Holder 4—Seal 5—Shaft 6—Ball Bearing 7—Snap Ring 8—Plug 9—O-Ring 10—Pump Half 11—Gasket 12—Pin (2 used) 13—Spring

14—Stopper 15—Ceramic Ball (2 used) 16—Swash Plate 17—Piston (11 used) 18—Retainer 19—Holder 20—Retainer 21—Pin (3 used) 22—Cylinder Block 23—Retainer 24—Spring 25—Retainer 26—Snap Ring

27—Valve Plate 28—Needle Bearing 29—Spring Seat 30—Spring 31—Spring Seat 32—Control Piston 33—Sleeve 34—O-Ring 35—Spring Pin 36—Pump Delivery Flow Rate Valve 37—Pump Half

38—Washer 39—Screw 40—Nut 41—Orifice 42—O-Ring 43—Plug 44—Cap Screw (7 used) 45—Coupling 46—Collar (2 used) 47—Pilot Pump 48—Washer (4 used) 49—Cap Screw (4 used)

1. Remove cap screws (49), and washers (48) to remove pilot pump (47).

7. Remove spring seat (31), spring (30), and spring seat (29).

2. Remove pump delivery flow rate valve (36).

8. Remove control piston (32), sleeve (33), and O-ring (34).

CAUTION: Prevent possible injury. Compressed spring in pump. Use temporary cap screws to remove pump half. Alternate loosening the cap screws to prevent spring from pushing out. IMPORTANT: Do not loosen nut (40) and screw (39). If loosened, pump flow rate setting will be changed. 3. Remove two cap screws (44) closest to the spring (30). Install two M10 x 60 mm temporary cap screws.

9. Remove parts (41—43) from pump half (37). CAUTION: Prevent possible injury. Cylinder block contains a spring under load. Compress spring using a press. 10. Compress spring using a press. Remove snap ring (26) to remove retainer (25), spring (24), and retainer (23). IMPORTANT: When removing rotary group, use care not to damage cylinder block and piston assembly.

4. Remove remaining cap screws (44). The original pistons must be installed into the same bores of the original cylinder block because of wear patterns.

Alternate loosening M10 x 60 mm temporary cap screws to release spring force. IMPORTANT: When separating pump halves, use care not to drop and damage valve plate (27) and spring pin (35). Needle bearing (28) should not be removed unless it is being replaced.

11. Mark pistons (17) with respect to cylinder block (22) bores for assembly. Remove parts (17—21) from cylinder block (22). 12. Remove swash plate (16), ceramic balls (15), stopper (14), and spring (13).

5. Separate pump halves (37 and 10). 6. Remove gasket (11), pins (12), and valve plate (27).

13. Remove plug (8) and O-ring (9).

Continued on next page

TM2264 (15OCT08)

33 3360 21

33-3360-21

OUO1030,000012C –19–17MAR05–2/3

Repair 101508

PN=343

Hydraulic System 16. Remove snap ring (7) and seal holder (3) with O-ring (2).

14. Remove snap ring (1). 15. Remove shaft (5) from pump half (10) using a soft face hammer.

17. Remove ball bearing (6) for replacement only. OUO1030,000012C –19–17MAR05–3/3

33 3360 22

TM2264 (15OCT08)

33-3360-22

Repair 101508

PN=344

Hydraulic System

Hydraulic Pump Assemble—50D

T164108

–UN–22JAN03

33 3360 23

Hydraulic Pump Continued on next page

TM2264 (15OCT08)

33-3360-23

OUO1030,0000115 –19–10FEB05–1/3

Repair 101508

PN=345

T164105

–UN–22JAN03

Hydraulic System

33 3360 24

1—Snap Ring 2—O-Ring 3—Seal Holder 4—Seal 5—Shaft 6—Bearing 7—Snap Ring 8—Plug 9—O-Ring 10—Pump Half 11—Gasket 12—Pin (2 used) 13—Spring

1. Install bearing (6) using a press. Install shaft (5) into pump half (10). 2. Apply grease to O-ring (2), to the outer diameter of seal holder (3), and to lip part of seal (4).

27—Valve Plate 28—Bearing 29—Spring Seat 30—Spring 31—Spring Seat 32—Control Piston 33—Sleeve 34—O-Ring 35—Pin 36—Pump Delivery Flow Rate Valve 37—Pump Half

3. Install seal (4) and O-ring (2) to seal holder (3). 4. Install seal holder (3) and snap ring (1) to shaft (5) in pump half (10).

Continued on next page

TM2264 (15OCT08)

38—Washer 39—Screw 40—Nut 41—Orifice 42—O-Ring 43—Plug 44—Cap Screw (7 used) 45—Coupling 46—Collar (2 used) 47—Pilot Pump 48—Washer (4 used) 49—Cap Screw (4 used)

33-3360-24

OUO1030,0000115 –19–10FEB05–2/3

Repair 101508

PN=346

Hydraulic System 5. Apply hydraulic oil to ceramic balls (15) and swash plate (16) slide surface.

16. Install gasket (11) and join pump halves (10 and 37).

6. Install spring (13), stopper (14), ceramic balls (15) and swash plate (16).

17. Install two M10 x 60 mm temporary cap screws in cap screw (44) holes on spring side of pump half (37). Connect pump half (37) with pump half (10).

7. Install retainer (23), spring (24), and retainer (25) into cylinder block (22). 8. Hold spring (24) and retainer (25) using a press. Install snap ring (26).

18. Install cap screws (44) in remaining cap screw (44) holes. 19. Remove M10 x 60 mm temporary cap screws and replace with cap screws (44).

9. Install parts (17—21) into cylinder block (22). 20. Tighten cap screws. 10. Align hole in swash plate (16) with spherical part of spring seat (29). Install spring seat and spring (30). 11. Install cylinder block (22) on shaft (5).

Specification Hydraulic Pump Half-to-Pump Half Cap Screw—Torque.................................................. 51—65 N•m 38—48 lb-ft

21. Install pump delivery flow rate valve (36).

12. Install coupling (45) to end of shaft. 13. Install parts (41—43) in pump half (37). Specification Hydraulic Pump Orifice— Torque................................................................................... 6—9 N•m 53—80 lb-in. Hydraulic Pump Plug—Torque ......................................... 15—20 N•m 133—177 lb-in.

14. Install parts (32—34) in pump half (37). Specification Hydraulic Pump Sleeve— Torque............................................................................... 50—60 N•m 37—44 lb-ft

Specification Hydraulic Pump Delivery Flow Rate Valve—Torque ......................................................... 59—69 N•m 43.5—51 lb-ft

22. Install pilot pump (47). Tighten cap screws (49). Specification Hydraulic Pilot Pump-to-Pump Half Cap Screws—Torque .......................................... 24.5—27.5 N•m 217 —243 lb-in.

23. Install hydraulic pump. See Hydraulic Pump Remove and Install—50D. (Group 3360.)

15. Install pin (35), valve plate (27), spring seat (31), pins (12), and gasket (11) into pump half (37).

33 3360 25

OUO1030,0000115 –19–10FEB05–3/3

TM2264 (15OCT08)

33-3360-25

Repair 101508

PN=347

Hydraulic System

Hydraulic Pump Start-Up Procedure IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new hydraulic pump is installed or oil has been drained from the pump or hydraulic oil tank. Procedure is to ensure pump is filled with oil and air is bled from suction side of pump to prevent cavitation. –UN–17DEC02

1. Add oil until it is between marks on hydraulic oil tank sight glass.

T162991B

2. Remove air bleed plug (1) from the top of pump housing. Fill pump housing with hydraulic oil. 3. Install plug after pump housing is full of oil. 35D Hydraulic Pump

4. Check oil level in hydraulic oil tank. Add oil as necessary. Tighten hydraulic oil tank cap. 5. Start engine and run at slow idle. Slowly raise boom to full height and then lower to pressurize hydraulic oil tank.

T208658A

–UN–18FEB05

6. Purge air from the hydraulic system by starting engine and run at slow idle. Slowly loosen air bleed plug (1) allowing air to escape. Tighten plug when hydraulic oil appears.

50D Hydraulic Pump 1—Air Bleed Plug

OUO1030,00000D3 –19–16FEB05–1/1

33 3360 26

Dampener Drive (Flex Coupling) Remove and Install 1. Remove engine. See Engine Remove and Install—35D or see Engine Remove and Install—50D. (Group 0400.)

Continued on next page

TM2264 (15OCT08)

33-3360-26

OUO1030,00000CF –19–07FEB05–1/2

Repair 101508

PN=348

Hydraulic System 2. Remove eight cap screws (2). 3. Remove flywheel cover (1). 4. Remove three socket head cap screws (3).

7. Apply T43512 Thread Lock and Sealer (medium strength) to socket head cap screws (3). Install cap screws and tighten to specification. Specification Flex Coupling-to-Flywheel Cap Screw—Torque ...................................................................... 83—92 N•m 61—68 lb-ft

T207302A

6. Install dampener (4).

–UN–20JAN05

5. Remove dampener (4).

8. Install flywheel cover (1), and cap screws (2).

T207260A

9. Install engine. See Engine Remove and Install—35D or see Engine Remove and Install—50D. (Group 0400.)

–UN–20JAN05

Specification Cover-to-Flywheel Housing Cap Screw—Torque .............................................................................. 49 N•m 36 lb-ft

1—Flywheel Cover 2—Cap Screw (used) 3—Socket Head Cap Screw (3 used) 4—Dampener

OUO1030,00000CF –19–07FEB05–2/2

33 3360 27

TM2264 (15OCT08)

33-3360-27

Repair 101508

PN=349

Hydraulic System

Solenoid Valve Manifold Disassemble and Assemble Remove and replace parts as necessary. Specification Pilot Pressure Regulating Valve-to-Manifold Guide—Torque ......................................... 74—88 N•m 55—65 lb-ft Solenoid-to-Manifold Tube— Torque ................................................................................... 47—74 N•m 35—55 lb-ft Solenoid-to-Tube Nut—Torque .................................................... 4.9 N•m 3.6 lb-ft

T164374

–UN–27JAN03

1—Guide 2—O-Ring 3—Washer 4—Spring 5—Washer 6—Spool 7—Nut 8—Solenoid 9—Tube 10—O-Ring 11—Spool 12—Spring 13—Manifold

MM61211,0000905 –19–18MAR05–1/1

33 3360 28

TM2264 (15OCT08)

33-3360-28

Repair 101508

PN=350

Hydraulic System

Pilot Controller Remove and Install 1

4 5

6 13

16 7

8 14 3

10 7

6—Cap (4 used per side) 7—Screw (5 used per side) 8—Gasket (2 used per side) 9—Pilot Controller 10—Insulator

11—Tie Strap 12—Lower Cover 13—Cap Screw (4 used per side)

Continued on next page

TM2264 (15OCT08)

33-3360-29

T208557

T208557 1—Grip 2—Boot 3—Jam Nut (2 used per side) 4—Rod 5—Upper Cover

–UN–25FEB05

14—Grip 15—Bracket (2 used per side) 16—Gasket 17—Cap Screw (4 used)

OUO1017,0000B57 –19–18MAR05–1/2

Repair 101508

PN=351

33 3360 29

Hydraulic System which is used to route the wire harness for the horn switch so it will not interfere with the movement of the pilot controller. The cap screw with the pin must be installed in the same location it was removed from, and harness must be routed around the pin.

6. Remove cap screws (17) and pilot controller (9). 7. Repair or replace parts as necessary.

2. Remove screws (7) and remove brackets (15). 3. Lift up boot (2), loosen lower jam nut (3) and remove rod (4) with boot and grip (1). If removing right-side controller, disconnect wire connector for horn. 4. Remove upper and lower covers (5 and 12).

8. Install valve using cap screws (17). Tighten cap screws to specification. Specification Pilot Controller Cap Screws— Torque...................................................................................... 20 N•m 177 lb-in.

5. Tag and disconnect hydraulic lines from pilot controller (9). See Pilot Controller to Pattern Conversion Valve Line Connection and see Main Hydraulic Pilot System Line Identification—35D or see Main Hydraulic Pilot System Line Identification—50D. (Group 9025-15.) Install plugs and caps.

9. Install hydraulic hoses on pilot controller. See Pilot Controller to Pattern Conversion Valve Line Connection and see Main Hydraulic Pilot System Line Identification—35D or see Main Hydraulic Pilot System Line Identification—50D. (Group 9025-15.)

NOTE: Right-side pilot controller has a pin inserted in the center of one of the cap screws (17),

11. Install rod, jam nut, boot, and grip.

10. Install upper and lower covers.

OUO1017,0000B57 –19–18MAR05–2/2

33 3360 30

TM2264 (15OCT08)

33-3360-30

Repair 101508

PN=352

Hydraulic System

Pilot Controller Disassemble and Assemble 1 2

4 5 22

21 20

19 18 17

16 13

8 9

T208558

T208558 1—Coupling 2—Cam 3—Threaded Universal Joint 4—Plate 5—O-Ring (4 used) 6—Pusher A (2 used)

7—Housing 8—O-Ring 9—Plug 10—Retaining Ring 11—Spool (4 used) 12—Return Spring A (2 used)

13—Balance Spring A (2 used) 14—Spacer (4 used) 15—Shim 16—Balance Spring B (2 used) 17—Return Spring B (2 used)

Continued on next page

TM2264 (15OCT08)

–UN–25FEB05

33-3360-31

33 3360 31

18—Spring Guide (4 used) 19—Retaining Ring (4 used) 20—Pusher B (2 used) 21—Seal (4 used) 22—Sleeve (4 used)

OUO1017,0000B58 –19–18MAR05–1/2

Repair 101508

PN=353

Hydraulic System IMPORTANT: The housing (7) and spools (11) are replaced as an assembly because the spools are select fitted to bores in housing. Some parts from ports 1 and 3 are different than parts from ports 2 and 4. Parts for each port must be kept together and installed into the same port from which they were removed. The port numbers are stamped on the housing. Note port location and quantity of shims (15) when removing. The quantity of shims has been determined for each port during testing at factory. When shim(s) are removed, they must be installed in the bore they were removed from.

6. Repair or replace parts as necessary. 7. Install parts. Install spring guides (18) with protrusion facing up. 8. Apply multi-purpose grease to seals (21). 9. Install pushers (6 and 20). Pushers with three outer grooves go into ports 1 and 3. Pushers without grooves go into ports 2 and 4. 10. Apply multi-purpose grease to the end of each pusher. 11. Install seals (21), sleeves (22), and O-rings (5). 12. Apply T43512 Thread Lock and Sealer (medium strength) to the threads of universal joint (3) on the end that will be installed in housing (7). 13. Place plate (4) on housing and install universal joint. Tighten to specification.

1. Using two wrenches, hold cam (2) and remove coupling (1). 2. Remove cam (2). IMPORTANT: There are flats on the threaded universal joint for a wrench to fit on. Use these flats to remove universal joint with a wrench. Do not use a pliers, or damage to joint could result. 3. Using a wrench, remove universal joint (3) from housing (7).

Specification Pilot Controller Universal Joint—Torque ....................................................................... 24.5 N•m 217 lb-in.

14. Install cam (2) on universal joint (3). Adjust clearance between pushers (6 and 20) and cam. Hold cam (2) in place and tighten coupling (1). Specification Cam-to-Pusher—Clearance............................................. 0—0.20 mm 0—0.008 in. Specification Coupling-to-Cam and Universal Joint—Torque ....................................................................... 68.4 N•m 50 lb-ft

4. Remove plate (4). 5. Remove parts from housing. Remember to keep parts removed from each port together. Identify each group of parts by port numbers stamped on housing. 33 3360 32

OUO1017,0000B58 –19–18MAR05–2/2

TM2264 (15OCT08)

33-3360-32

Repair 101508

PN=354

Hydraulic System

Propel Pilot Controller Remove and Install

–UN–25FEB05

T208785A

2. Remove front section of floor mat. 3. Remove pedal / lever assemblies from pilot controller. 4. Tilt operator station. See Tilting the Operator Station . (Operator’s Manual.)

–UN–25FEB05

5. Disconnect wire connector (1) and remove pressure switch (2).

T208786A

6. Tag and disconnect lines. See Propel Hydraulic System Line Identification—35D or see Propel Hydraulic System Line Identification—50D. (Group 9025-15.) Install plugs and caps. 7. Remove fittings (3 and 4). 1—Wire Connector 2—Pressure Switch 3—Fitting 4—Fitting 5—Socket Head Cap Screw (2 used)

8. Remove socket head cap screws (5) and remove controller. 9. Repair or replace parts as necessary. 10. Install controller using two socket head cap screws (5). Tighten to specification. Specification Propel Pilot Controller Socket Head Cap Screws—Torque ........................................................... 50 N•m 37 lb-ft

11. Install fittings (3 and 4) and pressure switch (2). 12. Install lines on controller. See Propel Hydraulic System Line Identification—35D or see Propel Hydraulic System Line Identification—50D. (Group 9025-15.)

33 3360 33

Continued on next page

TM2264 (15OCT08)

33-3360-33

OUO1017,0000B59 –19–17FEB05–1/2

Repair 101508

PN=355

Hydraulic System 13. Connect wire connector (1). 14. Lower operator station. See Tilting the Operator Station . (Operator’s Manual.) 15. Install front section of floor mat. 16. Install pedal / lever assemblies.

OUO1017,0000B59 –19–17FEB05–2/2

33 3360 34

TM2264 (15OCT08)

33-3360-34

Repair 101508

PN=356

Hydraulic System

33 3360 35

TM2264 (15OCT08)

33-3360-35

Repair 101508

PN=357

Hydraulic System

Propel Pilot Controller Disassemble and Assemble

34 33 7

32 31 30

10 14

15 26

17 24

20 33 3360 36

T208792

Continued on next page

TM2264 (15OCT08)

33-3360-36

T208792

–UN–25FEB05

OUO1017,0000B5A –19–18MAR05–1/2

Repair 101508

PN=358

Hydraulic System 1—Cap Screw (2 used) 2—Cover 3—Spring Pin (2 used) 4—Spring Pin (2 used) 5—Cam (2 used) 6—Bushing (4 used) 7—Housing 8—Spring Washer (4 used) 9—Socket Head Cap Screw (4 used)

10—Spring Pin (2 used) 11—Bracket 12—Spring Pin (2 used) 13—Spring Pin (2 used) 14—O-Ring (4 used) 15—Sleeve (4 used) 16—Pusher (4 used) 17—Spring Guide (4 used) 18—Balance Spring (4 used)

IMPORTANT: Spools (24) are matched to the bores in the spool housing (23). If spools are removed, they must be installed in the same housing they were removed from. The quantity of shims (27) has been determined during performance testing at the factory. Keep the shims together with the spool they were removed from.

19—O-Ring (2 used) 20—Plug (2 used) 21—Plug (2 used) 22—O-Ring (2 used) 23—Spool Housing 24—Spool (4 used) 25—Return Spring (4 used) 26—Spacer (4 used) 27—Shim (12 used)

28—Seal (4 used) 29—Spring Washer (2 used) 30—Socket Head Cap Screw (2 used) 31—Rubber Seal (2 used) 32—Damper (2 used) 33—Ring (2 used) 34—O-Ring (2 used) 35—Pin (2 used)

6. Install sleeves (15), O-rings (14), and seals (28). 7. Install housing (7) using cap screws (30). Specification Propel Pilot Controller Cam Housing Socket Head Cap Screws—Torque ........................................................................ 7 N•m 62 lb-in.

8. Install cams (5), pins (35), and dampers (32). 1. Remove cap screws (1) and remove cover (2). 9. Install cover (2) with cap screws (1). Tighten to specification.

2. Remove pins (35) and cams (5). 3. Remove socket head cap screws (30) and housing (7). 4. Repair or replace parts as required.

Specification Propel Pilot Controller Cover Cap Screws—Torque ................................................................ 5 N•m 44 lb-in.

5. Apply grease to the top of pushers (16).

OUO1017,0000B5A –19–18MAR05–2/2

33 3360 37

TM2264 (15OCT08)

33-3360-37

Repair 101508

PN=359

Hydraulic System

Boom Swing or Auxiliary Pilot Controller Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 1. Loosen cap to release air pressure in hydraulic oil tank. –UN–25FEB05

2. Remove front section of floor mat. 3. Remove cap screw (1) and plate (2).

T208811A

4. Remove cap screws (3) and pedal (4). 5. Remove socket head cap screws (5) and pedal bracket (6). 1—Cap Screw 2—Plate 3—Cap Screw (2 used) 4—Pedal 5—Socket Head Cap Screw (2 used) 6—Pedal Bracket 7—Cap Screw (2 used) 8—Bracket

6. Tilt operator station. See Tilting the Operator Station . (Operator’s Manual.) 7. Tag and disconnect hydraulic lines. See Main Hydraulic Pilot System Line Identification—35D or see Main Hydraulic Pilot System Line Identification—50D. (Group 9025-15.) Install plugs and caps. 8. Remove cap screws (7) and bracket (8). 9. Remove boom or auxiliary pilot controller. 10. Repair or replace parts as required. 11. Install pilot controller, bracket (8), and cap screws (7). Tighten to specification. Specification Boom or Auxiliary Pilot Controller Mounting Cap Screws—Torque ..................................................... 30 N•m 22 lb-ft

33 3360 38

12. Install hydraulic lines. See Main Hydraulic Pilot System Line Identification—35D or see Main Hydraulic Pilot System Line Identification—50D. (Group 9025-15.)

Continued on next page

TM2264 (15OCT08)

33-3360-38

OUO1017,0000B5B –19–18MAR05–1/2

Repair 101508

PN=360

Hydraulic System 13. Lower operator station. See Tilting the Operator Station . (Operator’s Manual.) 14. Install pedal bracket and pedal. 15. Install plate. 16. Install front section of floor mat.

OUO1017,0000B5B –19–18MAR05–2/2

33 3360 39

TM2264 (15OCT08)

33-3360-39

Repair 101508

PN=361

Hydraulic System

Boom Swing or Auxiliary Pilot Controller Disassemble and Assemble

12 2

13 13

14 5

15 16

14 15 16

6 7

17 17

18 19

18 20

8 9 9 10

21 10

11 11

T160028

–UN–07OCT02

33 3360 40

T160028

Continued on next page

TM2264 (15OCT08)

33-3360-40

OUO1017,0000B5C –19–18FEB05–1/2

Repair 101508

PN=362

Hydraulic System 1—Boot 2—Set Screw 3—Cam 4—Steel Ball (2 used) 5—Cap Screw (2 used) 6—Bushing (2 used)

7—Shaft 8—Bracket 9—Packing (2 used) 10—Plug (2 used) 11—O-Ring (2 used)

12—Push Rod (2 used) 13—Spring Seat (2 used) 14—Inner Spring (2 used) 15—Shim (2 used) 16—Washer (2 used)

IMPORTANT: If damage to cam (3), bracket (8), push rods (12), spools (17), or housing (21) is noticed, the pilot controller must be replaced.

17—Spool (2 used) 18—Outer Spring (2 used) 19—Plug 20—O-Ring 21—Housing

Compress the spring just enough to install spring seats (13) onto spools through the larger diameter hole. 8. Install the outer spring (18).

1. Take notice of part location with respect to its mating part for assembly.

9. Carefully install spool assemblies into the same ports from which they were removed.

2. Remove set screw (2). Thread Lock and Sealer T43512 (medium strength) is used on the threads of set screws. Remove shaft (7) to remove cam (3) from bracket (8). Steel balls (4) cannot be removed. 3. Loosen the cap screws (5) to relieve the slight spring force. Remove bracket (8) from housing (21). 4. Remove packing (9), plugs (10), O-rings (11), and push rods (12). IMPORTANT: The spool assemblies are adjusted for equal pressure using shims. The shims and washers must be kept with their respective spool. The spools must be installed into the same port from which they were removed. 5. Remove spool assemblies (13—17) and outer springs (18). Keep parts for each spool together. 6. Clean and repair or replace parts as necessary. 7. Install washer (16), shim (15), and inner spring (14) onto their original spool (17).

14. Install cams (3). Install the shafts (7) through cover and cam so hole in shaft aligns with tapped hole in cam. 15. Apply T43512 Thread Lock and Sealer (medium strength) to threads of set screw (2). Tighten set screw. Specification Cam-to-Shaft Set Screw— Torque.................................................................................... 5.0 N•m 44 lb-in.

33 3360 41

OUO1017,0000B5C –19–18FEB05–2/2

TM2264 (15OCT08)

33-3360-41

Repair 101508

PN=363

Hydraulic System

Control Valve Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 1. Loosen cap to release air pressure in hydraulic oil tank. 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. Specification Hydraulic Oil—35D—Capacity ............................................................ 42 L 11 gal Hydraulic Oil—50D—Capacity ............................................................ 65 L 17.25 gal

3. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

Continued on next page

MM61211,00008E6 –19–21FEB05–1/2

33 3360 42

TM2264 (15OCT08)

33-3360-42

Repair 101508

PN=364

Hydraulic System

–UN–23AUG88

X9811

4. Identify lines for assembly. See Control Valve Operation—35D or see Control Valve Operation—50D. (Group 9025-05.) Install caps and plugs. 5. Disconnect lines from control valve (1). 6. Remove four cap screws (2) from underside of main frame . CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

–UN–25FEB05

Specification Control Valve—Weight ..................................................................... 58 kg 130 lb

T208920A

7. Install sling under cap on control valve, and lift control valve (1) off the main frame plate. 8. Repair or replace parts as necessary. See Control Valve Disassemble and Assemble. (Group 3360.) 9. Using a hoist, install control valve (1). 10. Install cap screws (2).

–UN–25FEB05

Specification Control Valve-to-Main frame Plate Cap Screw—Torque ....................................................................... 50 N•m 37 lb-ft

11. Connect lines.

13. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

T208921A

12. Check oil level in the hydraulic oil tank. See Check Hydraulic Oil Tank Level. (Operator’s Manual.) Add oil as necessary. See Hydraulic Oil. (Operator’s Manual.)

33 3360 43

1—Control Valve 2—Cap Screw (4 used)

MM61211,00008E6 –19–21FEB05–2/2

TM2264 (15OCT08)

33-3360-43

Repair 101508

PN=365

Hydraulic System

Control Valve Disassemble and Assemble

T163354

–UN–23JAN03

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Control Valve—Rear Sections Continued on next page

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Repair 101508

PN=366

Hydraulic System 1—Bucket Control Valve 2—Cover 3—Cap Screw (2 used) 4—Guide 5—Spring 6—Guide 7—O-Ring 8—Spool 9—Circuit Relief Valve 10—Plug 11—O-Ring 12—Spring 13—Poppet 14—Plug 15—O-Ring 16—Spring 17—Poppet 18—Circuit Relief Valve 19—O-Ring 20—Guide 21—Spring 22—Guide 23—Cap Screw (2 used) 24—Cover 25—Stud (4 used) 26—Nut (4 used) 27—Housing

30—Boom Control Valve 31—Cover 32—Cap Screw (2 used) 33—Guide 34—Spring 35—Guide 36—O-Ring 37—Spool 38—Circuit Relief Valve 39—Circuit Relief Valve 40—Plug 41—Plug 42—O-Ring 43—Spring 44—Poppet 45—Poppet 46—Spring 47—O-Ring 48—Backup Ring 49—Spacer 50—O-Ring 51—O-Ring 52—Guide 53—Spring 54—Guide 55—Housing 56—Plug

57—Piston 58—Spring 59—Plug 60—O-Ring 61—Spool 62—Sleeve 63—Backup Ring 64—O-Ring 65—O-Ring 66—Backup Ring 67—Poppet 68—Valve Seat 69—Spring 70—Cap Screw (5 used) 71—Housing 72—O-Ring 75—Left Propel Control Valve 76—Cover 77—Cap Screw (2 used) 78—Guide 79—Spring 80—Guide 81—O-Ring 82—Spool 83—Spring 84—Poppet

Continued on next page

85—Plug 86—O-Ring 87—Guide 88—Spring 89—Guide 90—Cap Screw (2 used) 91—Cover 92—O-Ring 93—Housing 95—Inlet Section 96—Plug 97—Filter 98—Cover 99—Cap Screw (2 used) 100—O-Ring 101—Spool 102—System Relief Valve 103—O-Ring 104—Plug 105—System Relief Valve 106—O-Ring 107—Cap Screw (2 used) 108—Cover 109—Plug 110—O-Ring 111—Housing

JP51892,0000010 –19–21FEB05–2/10

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Repair 101508

PN=367

Hydraulic System

T163355

–UN–24JAN03

33 3360 46

Control Valve—Middle Sections

Continued on next page

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Repair 101508

PN=368

Hydraulic System 115—Right Propel Control Valve 116—Cover 117—Cap Screw (2 used) 118—Guide 119—Spring 120—Guide 121—O-Ring 122—Spool 123—O-Ring 124—Plug 125—O-Ring 126—Guide 127—Spring 128—Guide 129—Cap Screw (2 used) 130—Cover 131—Poppet 132—Spring 133—Housing 135—Arm Control Valve 136—Cover 137—Cap Screw (2 used)

138—Guide 139—Spring 140—O-Ring 141—Guide 142—Spool 143—Circuit Relief Valve 144—O-Ring 145—O-Ring 146—O-Ring 147—Plug 148—O-Ring 149—Spring 150—Poppet 151—Circuit Relief Valve 152—O-Ring 153—Guide 154—Spring 155—Guide 156—Cap Screw (2 used) 157—Cover 158—Plug 159—Poppet 160—Spring

161—O-Ring 162—Plug 163—Housing 165—Auxiliary Control Valve 166—Cover 167—Cap Screw (2 used) 168—Guide 169—Spring 170—O-Ring 171—Guide 172—Spool 173—Plug 174—O-Ring 175—Plug 176—O-Ring 177—Spring 178—Poppet 179—Plug 180—O-Ring 181—Spring 182—Plug 183—Plug 184—Plug

Continued on next page

185—O-Ring 186—Guide 187—Spring 188—Guide 189—Cap Screw (2 used) 190—Cover 191—Housing 195—Auxiliary Flow Combiner Section 196—Cover 197—Cap Screw (2 used) 198—Guide 199—Spring 200—O-Ring 201—Guide 202—Spool 203—Plug 204—Plug 205—O-Ring 206—Cap Screw (2 used) 207—Cover 208—Housing

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Repair 101508

PN=369

Hydraulic System

T163356

–UN–23JAN03

33 3360 48

Control Valve—Front Sections

Continued on next page

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Repair 101508

PN=370

Hydraulic System 215—Boom Swing Control Valve 216—Cover 217—Cap Screw (2 used) 218—Guide 219—Spring 220—Guide 221—O-Ring 222—Spool 223—Poppet 224—Spring 225—Plug 226—O-Ring 227—Spring 228—Poppet 229—O-Ring 230—Guide 231—Spring 232—Guide 233—Cap Screw (2 used)

234—Cover 235—O-Ring 236—Housing 240—Swing Control Valve 241—Cover 242—Cap Screw (2 used) 243—Guide 244—Spring 245—Guide 246—O-Ring 247—Spool 248—Plug 249—O-Ring 250—Spring 251—Poppet 252—O-Ring 253—Guide 254—Spring 255—Guide 256—Cap Screw (2 used)

257—Cover 258—O-Ring 259—Housing 265—Blade Control Valve 266—Cover 267—Cap Screw (2 used) 268—Guide 269—Spring 270—Guide 271—O-Ring 272—Spool 273—Plug 274—O-Ring 275—Spring 276—Poppet 277—O-Ring 278—Guide 279—Spring 280—Guide 281—Cap Screw (2 used)

282—Cover 283—O-Ring 284—Housing 290—Flow Combiner Valve 291—Cover 292—Cap Screw (2 used) 293—Guide 294—Spring 295—Guide 296—O-Ring 297—Spool 298—System Relief Valve 299—Nut (4 used) 300—Plug 301—O-Ring 302—Cap Screw (2 used) 303—Plug 304—Cover 305—O-Ring 306—Housing

NOTE: Complete control valve must be removed from machine to remove individual valve sections.

3. Remove circuit relief valves (9, 18, 38, 39, 143, and 151).

1. See Control Valve Remove and Install for removal procedure. (Group 3360.)

4. Remove nuts (26) and studs (25) to disassemble the control valve into sections.

2. Remove system relief valves (102, 105, and 298).

Continued on next page

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PN=371

Hydraulic System

147

148

149 150 152

141 137 139

154

156

138

140

153

136

–UN–24JAN03

155 157

142

135

T163430

159 T163430

Arm Control Valve Section Shown

135

146

145 159

160 161

T163449

162 Arm Regenerative Valve

Continued on next page

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–UN–24JAN03

310

T163449

33 3360 50

135—Arm Control Valve Housing 136—Cover 137—Cap Screw (2 used) 138—Guide 139—Spring 140—O-Ring 141—Guide 142—Spool 147—Plug 148—O-Ring 149—Spring 150—Lift Check Poppet 152—O-Ring 153—Guide 154—Spring 155—Guide 156—Cap Screw (2 used) 157—Cover 159—Arm Regenerative Valve Poppet 160—Spring 161—O-Ring 162—Plug 310—Orifice

33-3360-50

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Repair 101508

PN=372

Hydraulic System IMPORTANT: Because spools are fitted to a bore and the design is different for each section, spools must be installed into the same bores from which they were removed for proper operation. Spools are disassembled for inspection and cleaning only. Each spool and housing is serviced as an assembly. 5. Spool Disassemble and Assemble: a. Remove parts (136—142, 150, and 152—157). b. Replace parts as necessary. c. Install parts. d. Tighten cap screws (137 and 156). Specification Cover-to-Housing Cap Screw— Torque ....................................................................................... 7—10 N•m 61—87 lb-in.

6. Arm Regenerative Valve, Check Valve, and Orifice Disassemble and Assemble: a. Remove parts (145—150, 159—162, and 310). b. Replace parts as necessary. c. Install orifice. Specification Arm Regenerative Valve Orifice-to-Housing—Torque ............................................................. 2 N•m 17 lb-in.

d. Apply grease to O-rings. 33 3360 51

e. Install parts. Specification Arm Regenerative Valve Plug-to-Housing—Torque ............................................................ 29.4 N•m 22 lb-ft

Continued on next page

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PN=373

Hydraulic System Specification Lift Check Plug-to-Housing— Torque ......................................................................................... 29.4 N•m 22 lb-ft

7. Boom Reduce Leakage Valve Disassemble and Assemble: a. Remove cap screws (70) to remove housing (55) from boom control valve (30). b. Remove parts (45—69). c. Replace parts as necessary. d. Tighten cap screws (70). Specification Boom Reduce Leakage Valve Housing-to-Boom Control Valve Housing Cap Screw—Torque.................................................... 7—10 N•m 61—87 lb-in.

e. Tighten plug (59). Specification Plug-to-Boom Reduce Leakage Valve Housing—Torque .............................................................. 29.4 N•m 22 lb-ft

f. Tighten plug (56) into plug (59). Specification Piston and Spring Plug-to-Boom Reduce Leakage Valve Plug— Torque ......................................................................................... 29.4 N•m 22 lb-ft

33 3360 52

8. Tighten system relief valves (102, 105, and 298). Specification System Relief Valve-to-Valve Housing—Torque..................................................................... 59—69 N•m 43—51 lb-ft

Continued on next page

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Repair 101508

PN=374

Hydraulic System 9. Tighten circuit relief valves (9, 18, 38, 39, 143, and 151). Specification Circuit Relief Valve-to-Valve Housing—Torque..................................................................... 59—69 N•m 43—51 lb-ft

10. Tighten nuts (26) and studs (25). Specification Housing-to-Housing Stud and Nut—Torque ...................................................................... 26.5—28.4 N•m 20—21 lb-ft

11. See Control Valve Remove and Install for installation. (Group 3360.)

JP51892,0000010 –19–21FEB05–10/10

Pilot Controller Pattern Conversion Valve Remove and Install CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 1. Loosen cap to relieve the air pressure in hydraulic oil tank.

Continued on next page

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Repair 101508

PN=375

Hydraulic System 2. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 3. Remove two nuts (1) on back of cab.

6. Remove two cap screws (3) and pilot controller pattern conversion valve (4).

T208798A

5. Attach identification tags to hydraulic lines (2) to aid with assembly. Disconnect hydraulic lines (2). See Pilot Controller to Pattern Conversion Valve Line Connection (Group 9015.)

–UN–25FEB05

4. Tilt operator station back to normal position.

7. Repair or replace parts as necessary. 8. Connect hydraulic lines (2). 9. Install cap screws (3).

–UN–25FEB05

10. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 11. Install two nuts (1) on back of cab.

T208797A

12. Check oil level and add oil if necessary. See Hydraulic Oil. (Operator’s Manual.) 1—Pilot Controller Pattern Conversion Valve Nut (2 used) 2—Hydraulic Lines (8 used) 3—Cap Screw (2 used) 4—Pilot Controller Pattern Conversion Valve

MM61211,00008F2 –19–25FEB05–2/2

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PN=376

Hydraulic System

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Repair 101508

PN=377

Hydraulic System

Pilot Controller Pattern Conversion Valve Disassemble and Assemble

T204414

–UN–05NOV04

33 3360 56

Pilot Controller Pattern Conversion Valve Continued on next page

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Repair 101508

PN=378

Hydraulic System 0—Pilot Controller Pattern Conversion Valve 1—Housing 2—Spindle 4—Cover 5—Cover

6—Plug 7—Handle 8—Spring 9—Detent Ball 10—Packing

11—O-Ring 12—Packing 13—Backup Ring 14—Bolt 15—Spring Pin

1. Remove plug (6), spring (8), and detent ball (9) before removing spindle (2) from housing (1). 2. Install spindle (2) into housing (1).

17—Identification Plate 18—Ring 19—Rivet 51—Housing 52—Seal Kit

4. Install plug (6). 5. Install Pilot Controller Pattern Conversion Valve. See Pilot Controller Pattern Conversion Valve Remove and Install. (Group 3360.)

3. Install detent ball (9) and spring (8).

MM61211,00008E0 –19–17FEB05–2/2

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PN=379

Hydraulic System

Hydraulic Oil Tank Remove and Install—35D CAUTION: Prevent possible injury. Heavy component, ensure side cover is properly supported before removing. 1. Remove cap screws (1) and side cover (2). 2. Remove cap screws (3) and cover plate (4). 3. Disconnect battery (5) and remove. –UN–02MAR05

4. Remove cap screws (6) that mount battery tray to hydraulic oil tank (14).

T209173A

5. Remove cap screws (7) and coolant bottle bracket (8). CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank.

1—Cap Screw (2 used) 2—Side Cover 3—Cap Screw (4 used) 4—Cover Plate 5—Battery 6—Cap Screw (6 used) 7—Cap Screw (2 used) 8—Coolant Bottle Bracket 9—Cap 10—Hydraulic Line (4 used) 11—Upper and Lower Hoses 12—Bracket and Clamp (4 used) 13—Cap Screw (2 used) 14—Hydraulic Oil Tank

6. Loosen cap (9) to release air pressure in hydraulic oil tank (14). 7. Drain oil from hydraulic tank. 8. Identify and disconnect hydraulic lines (10) at front of tank. 9. Remove upper and lower hydraulic hoses (11). 10. Remove brackets and clamps (12). 11. Remove cap screws (13) and hydraulic oil tank (14). 12. Repair or replace parts as necessary. 13. Installation is done in reverse order of removal.

33 3360 58

14. Add hydraulic oil to tank. See Check Hydraulic Oil Tank Level for procedure. (Operator’s Manual.) See Hydraulic Oil for correct oil to use. (Operator’s Manual.)

Continued on next page

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Repair 101508

PN=380

Hydraulic System IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 15. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

OUO1030,0000129 –19–28FEB05–2/2

Hydraulic Oil Tank Remove and Install—50D 1. Remove radiator. See Radiator Remove and Install— 50D. (Group 0510.) 2. Remove fuel tank. See Fuel Tank Remove and Install—50D. (Group 0560.) CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 3. Loosen cap to release air pressure in hydraulic oil tank. NOTE: Filter replacement does not require draining and removing the hydraulic oil tank. 4. See Replace Hydraulic Oil Tank Filter for filter replacement. (Operator’s Manual.)

Continued on next page

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Repair 101508

PN=381

Hydraulic System 5. Disconnect lines (1—4) at front of tank. 6. Remove two cap screws (5) on front of hydraulic tank.

T209164A

–UN–03MAR05

1—Hydraulic Oil Line 2—Hydraulic Oil Line 3—Hydraulic Oil Line 4—Hydraulic Oil Line 5—Cap Screw (2 used)

Continued on next page

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PN=382

Hydraulic System

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Hydraulic System

T209163

–UN–03MAR05

33 3360 62

Continued on next page

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Repair 101508

PN=384

Hydraulic System 6—Cap Screw (2 used) 7—Hydraulic Oil Tank 8—Bracket

9—Bracket 10—Drain Plug 11—Strainer, Rod, and Nut

7. Remove plug (10) to drain hydraulic oil tank. Approximate oil capacity is 65.0 L (17.25 gal). 8. See Change Hydraulic Tank Oil and Cleaning Suction Screen for removal and installation of strainer, rod, and nut (11). (Operator’s Manual.) 9. Disconnect lines at return (17) and suction tube (16). Identify lines for assembly. 10. Remove bracket (8).

12—Hose 13—Cap 14—Isolator

15—Level Gauge 16—Suction Tube 17—Return Line

14. Add hydraulic oil to tank until it is between marks on sight glass. See Check Hydraulic Oil Tank Level for procedure. (Operator’s Manual.) See Hydraulic Oil for correct oil to use. (Operator’s Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank.

11. Remove two cap screws (6) and hydraulic oil tank. 12. Repair or replace parts as necessary.

15. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

13. Install hydraulic oil tank.

CED,OUOE003,21214 –19–18MAR05–4/4

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PN=385

Hydraulic System

Hydraulic Oil Cooler Remove and Install— 35D

–UN–23AUG88

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

TS281

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Remove right-side access cover. 2. Loosen cap to release air pressure in hydraulic oil tank.

–UN–25JAN05

NOTE: If using a vacuum pump to pull vacuum, cap off all disconnected hydraulic lines while hydraulic cooler is being serviced.

T207384A

3. Pull a vacuum in hydraulic oil tank using a vacuum pump, or drain hydraulic oil tank. Approximate oil capacity is 42 L (11 gal). 4. Disconnect hoses (2 and 3). 5. Remove cap screws (4). 1—Hydraulic Tank Cap 2—Upper Hydraulic Hose 3—Lower Hydraulic Hose 4—Cap Screw (2 used)

NOTE: When removing oil cooler, make certain that oil cooler does not scrape, rub, or hit the frame bracket. 6. Carefully move oil cooler past frame bracket and remove. 7. Inspect oil cooler for damage or leakage. Repair or replace oil cooler as needed. 8. Install oil cooler. 9. Connect hoses (2 and 3) and tighten clamps. 33 3360 64

10. Install two cap screws (4). 11. Check oil level in hydraulic oil tank. Add oil as necessary. See Hydraulic Oil. (Operator’s Manual.)

Continued on next page

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Repair 101508

PN=386

Hydraulic System IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 12. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

MM61211,00007C1 –19–02FEB05–2/2

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Repair 101508

PN=387

Hydraulic System

Hydraulic Oil Cooler Remove and Install— 50D

–UN–23AUG88

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

TS271

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. Remove right-side access cover. 2. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 3. Remove counterweight. See Counterweight Remove and Install—50D. (Group 1749.)

–UN–04FEB05

4. Remove two cap screws (1) securing tool box. 5. Remove cover (2).

T207696A

6. Remove air cleaner hoses (3). 7. Remove two cap screws (4) and air cleaner assembly.

T207864A

–UN–07FEB05

1—Tool Box Cap Screw (2 used) 2—Cover 3—Air Cleaner Hoses 4—Cap Screw (2 used)

33 3360 66

Continued on next page

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MM61211,00007C2 –19–02FEB05–1/3

Repair 101508

PN=388

Hydraulic System 8. Remove three cap screws (5) securing radiator frame bracket and frame bracket (6). 9. Remove four cap screws (7) securing receiver-dryer (8) and vapor condenser (9) from radiator. 10. Disconnect overflow hose (10). –UN–07FEB05

11. Remove radiator support bracket (11).

T207865A

12. Remove two cap screws (12) securing hydraulic tube to radiator bracket. 13. Remove four cap screws (13) securing hydraulic oil cooler to radiator bracket. 14. Loosen cap to release air pressure in hydraulic oil tank. NOTE: If using a vacuum pump to pull vacuum, cap off all disconnected hydraulic lines while hydraulic cooler is being serviced.

–UN–07FEB05

15. Pull a vacuum in hydraulic oil tank using a vacuum pump, or drain hydraulic oil tank. Approximate oil capacity is 42 L (11 gal).

T207866A

16. Disconnect hoses (14 and 15). NOTE: When removing oil cooler, make certain that oil cooler does not scrape, rub, or hit any bracket or hoses. 17. Carefully move oil cooler (16) past any brackets or hoses, and remove.

T207867A

–UN–07FEB05

5—Radiator Frame Bracket Cap Screw 6—Frame Bracket 7—Cap Screw (4 used) 8—Receive-Dryer 9—Vapor Condenser 10—Overflow Hose 11—Radiator Support Bracket 12—Cap Screw (2 used) 13—Cap Screw (2 used) 14—Oil Cooler Hose 15—Oil Cooler Hose 16—Oil Cooler

Continued on next page

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PN=389

33 3360 67

Hydraulic System 18. Inspect oil cooler for damage or leakage. Repair or replace oil cooler as needed. 19. Install oil cooler (16). 20. Connect hoses (14 and 15) and tighten clamps. 21. Install oil cooler cap screws (12 and 13). 22. Install radiator support bracket (11). 23. Connect overflow hose (10). 24. Install cap screws (7) securing receiver-dryer (8) and vapor condenser (9) to radiator. 25. Install three cap screws (5) securing radiator frame bracket and frame bracket (6). 26. Install air cleaner assembly. 27. Install cover (2). 28. Install tool box. 29. Check oil level in hydraulic oil tank. Add oil as necessary. See Hydraulic Oil. (Operator’s Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 30. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

MM61211,00007C2 –19–02FEB05–3/3

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Repair 101508

PN=390

Hydraulic System

Boom Cylinder Remove and Install 1. Park machine on firm, level surface. 2. Retract arm cylinder and bucket cylinder, and lower bucket to ground. CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 3. Slowly loosen cap to relieve air pressure in hydraulic oil tank. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Boom Cylinder—35D—Weight approximate ....................................................................................... 35 kg 77 lb Boom Cylinder—50D—Weight approximate ....................................................................................... 55 kg 121 lb

4. Attach boom cylinder to hoist with lifting straps.

OUO1030,0000125 –19–24FEB05–1/5

5. Remove parts (1—7).

T124958

–UN–29OCT99

1—Cover 2—Cap Screw and Washer 3—Shim (2 used) 4—Shim (2 used) 5—Boom Cylinder-to-Boom Pin 6—Cap Screw 7—Bushing

Boom Cylinder Rod End

Continued on next page

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PN=391

33 3360 69

Hydraulic System

–UN–23AUG88

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 6. Loosen boom cylinder hydraulic lines (1 and 2) at frame end of boom to release any residual pressure.

X9811

7. Identify lines for assembly, and disconnect lines (1 and 2). See Main Hydraulic Working System Line Identification—35D or See Main Hydraulic Working System Line Identification—50D. (Group 9025-15.) Install caps and plugs. 8. Remove parts (3—6). 9. Lower boom cylinder onto floor stand.

–UN–01MAR05

10. Repair or replace parts as necessary. See Boom Cylinder Disassemble and Assemble. (Group 3360.)

T209070A

11. Install shims (6) on each side of cylinder head end to get minimum amount of clearance in joint. Specification Boom, Arm, and Cylinder Joints— Clearance ....................................................................................... 0.5 mm 0.020 in.

Boom Cylinder Removal—35D Shown 1—Hydraulic Line 2—Hydraulic Line 3—Nut (2 used) 4—Cap Screw 5—Frame-to-Boom Cylinder Pin 6—Shim (35D 3 used) (50D 4 used)

12. Connect boom cylinder head end to frame. Install pin (5) and cap screw (4). 13. Apply T43513 Thread Lock and Sealer (high strength) to threads of nuts. Tighten the nuts against each other, not the boss. There must be clearance between nuts and boss. Cap screw (4) must be free to turn in hole.

33 3360 70

Specification Boom Cylinder-to-Frame Pin Cap Screw and Nuts—35D—Torque ..................................................... 50N•m 37 lb-ft Boom Cylinder-to-Frame Pin Cap Screw and Nuts—50D—Torque ..................................................... 90 N•m 66 lb-ft Nut-to-Boss—Clearance ............................................................... 3—5 mm 0.12—0.20 in.

Continued on next page

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OUO1030,0000125 –19–24FEB05–3/5

Repair 101508

PN=392

Hydraulic System 14. Lift cylinder by hoist. 15. Connect lines (1 and 2). IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and can ignite the oil used for assembly, causing cap seal and ring damage. Start with the cylinder rod retracted and the rod end filled with clean oil. Connect the cylinder head end and line. Perform function to slowly extend rod. This procedure will eliminate most of the air and reduce the possibility of damage. 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. 16. Start engine and slowly extend boom cylinder to align pin bores.

Continued on next page

OUO1030,0000125 –19–24FEB05–4/5

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Repair 101508

PN=393

Hydraulic System 17. Install shims (3) to get minimum amount of clearance between boom and boom cylinder rod end.

–UN–29OCT99

18. Install boom cylinder-to-boom pin (5). Install cap screw (6) and bushing (7).

T124958

Specification Boom-to-Cylinder Pin Cap Screw—Torque ............................................................................. 140 N•m 103 lb-ft

19. Install cover (1) and cap screw (2). Boom Cylinder Rod End Specification Cover-to-Boom Cylinder Cap Screw—35D—Torque..................................................................... 50 N•m 37 lb-ft Cover-to-Boom Cylinder Cap Screw—50D—Torque..................................................................... 90 N•m 66 lb-ft

1—Cover 2—Cap Screw and Washer 3—Shim (2 used) 4—Shim (2 used) 5—Boom Cylinder-to-Boom Pin 6—Cap Screw 7—Bushing

20. Apply grease to all pivot joints. See Grease. (Operator’s Manual.) 21. Check hydraulic oil level. See Check Hydraulic Oil Tank Level. (Operator’s Manual.)

OUO1030,0000125 –19–24FEB05–5/5

Arm Cylinder Remove and Install 1. Park machine on firm, level surface. 2. Retract arm cylinder and bucket cylinder, and lower bucket to ground. 33 3360 72

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TM2264 (15OCT08)

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OUO1030,0000127 –19–24FEB05–1/3

Repair 101508

PN=394

Hydraulic System

–UN–23AUG88

X9811

5. Identify lines for assembly, and disconnect lines. See Main Hydraulic Working System Line Identification— 35D or See Main Hydraulic Working System Line Identification—50D. (Group 9025-15.) Install caps and plugs. 6. Insert wood block (4) between arm cylinder (5) and boom. 7. Attach arm cylinder to hoist with lifting straps. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T164887

–UN–06FEB03

Specification Arm Cylinder—35D—Weight approximate ....................................................................................... 34 kg 75 lb Arm Cylinder—50D—Weight approximate ....................................................................................... 42 kg 93 lb

8. Remove parts (1—3 and 7—9).

Arm Cylinder

NOTE: Mark location of shims (3 and 7) to aid in assembly.

1—Cap Screw 2—Pin Fastener 3—Shims (4 used) 4—Wood Block 5—Arm Cylinder 6—Line (2 used) 7—Shims (4 used) 8—Pin Fastener 9—Cap Screw

9. Repair or replace parts as necessary. See Arm Cylinder Disassemble and Assemble. (Group 3360.)

33 3360 73

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Repair 101508

PN=395

Hydraulic System 10. Install shims (7) equally on each side of cylinder to get minimum amount of clearance in joints. 11. Align pin bores, and install pin fastener (8) and cap screw (9). Specification Pin Fastener-to-Boom Cap Screw—Torque ............................................................................. 137 N•m 101 lb-ft

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.

T164887

–UN–06FEB03

12. Connect lines (6).

Arm Cylinder 1—Cap Screw 2—Pin Fastener 3—Shims (4 used) 4—Wood Block 5—Arm Cylinder 6—Line (2 used) 7—Shims (4 used) 8—Pin Fastener 9—Cap Screw

13. Start engine and slowly extend arm cylinder to align pin bores. 14. Install shims (3) equally on each side of cylinder to get minimum amount of clearance in joints. 15. Align pin bores and install pin fastener (2) and cap screw (1). Specification Pin Fastener-to-Boom Cap Screw—Torque ............................................................................ 137 N•m 101 lb-ft

33 3360 74

16. Apply grease to all pivot joints. See Grease. (Operator’s Manual.) 17. Check hydraulic oil level. See Check Hydraulic Oil Tank Level. (Operator’s Manual.)

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TM2264 (15OCT08)

33-3360-74

Repair 101508

PN=396

Hydraulic System

Bucket Cylinder Remove and Install—35D 1. Park machine on firm, level surface.

OUO1030,0000126 –19–24FEB05–1/6

2. Retract arm cylinder and bucket cylinder (B), and lower bucket to ground. Position end of arm (C) on wood block (D).

T106135

–UN–09JAN97

Bucket Position B—Bucket Cylinder C—Arm D—Wood Block

OUO1030,0000126 –19–24FEB05–2/6

IMPORTANT: Secure the links (11 and 12) using wire to prevent the link from falling when pin (7) is removed. 4. Remove ring (4) and pin (6) from the links (11 and 12). Remove pin (7).

T164860

–UN–06FEB03

3—Shim (8 used) 4—Ring 5—Cylinder Rod 6—Pin 7—Pin Fastener 11—Side Link (2 used) 12—Center Link

Bucket Cylinder Pin Fastener

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Repair 101508

PN=397

33 3360 75

Hydraulic System

–UN–23AUG88

X9811

5. Identify lines to aid assembly, and disconnect lines (10). See Main Hydraulic Working System Line Identification—35D. (Group 9025-15.) Install caps and plugs.

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TM2264 (15OCT08)

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Repair 101508

PN=398

Hydraulic System

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Bucket Cylinder—35D—Weight approximate ...................................................................................... 23 kg 51 lb

6. Attach bucket cylinder (1) to hoist. Remove cap screw (9), pin (10) and shims (3). Note how the shims are arranged for installation. –UN–06FEB03

7. Remove bucket cylinder (1).

T164864

8. Repair or replace parts as necessary. See Bucket Cylinder Disassemble and Assemble. (Group 3360.) 9. Install bucket cylinder (1) and connect hoses. Bucket Cylinder Arm Pin

10. Insert pin (8) and install cap screw (9).

1—Bucket Cylinder 8—Pin 9—Cap Screw 10—Line (2 used)

Specification Bucket Cylinder-to-Arm Pin Cap Screw—Torque ............................................................................... 90 N•m 66 lb-ft

IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and can ignite the oil used for assembly, causing cap seal and ring damage. Start with the cylinder rod retracted and the rod end filled with clean oil. Connect the cylinder head end and line. Perform function to slowly extend rod. This procedure will eliminate most of the air and reduce the possibility of damage. 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. 33 3360 77

11. Start engine and slowly extend bucket cylinder rod (5) to align rod hole with links (11 and 12). Install shims (3).

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Repair 101508

PN=399

Hydraulic System 12. Insert pin fastener (7). 13. Insert pin (6) into links and pin fastener. Install ring (4). 14. Apply grease to all pivot joints. See Grease. (Operator’s Manual.) 15. Check hydraulic oil level. See Check Hydraulic Oil Tank Level. (Operator’s Manual.)

OUO1030,0000126 –19–24FEB05–6/6

Bucket Cylinder Remove and Install—50D 1. Park machine on firm, level surface.

OUO1030,0000126 –19–24FEB05–1/6

2. Retract arm cylinder and bucket cylinder (B), and lower bucket to ground. Position end of arm (C) on wood block (D).

T106135

–UN–09JAN97

Bucket Position B—Bucket Cylinder C—Arm D—Wood Block

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TM2264 (15OCT08)

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Repair 101508

PN=400

Hydraulic System 4. Remove nuts (4) and cap screw (6) from the links (11 and 12). Remove pin (7).

T209087

–UN–22MAR05

3—Shim (8 used) 4—Nut (2 used) 5—Cylinder Rod 6—Cap Screw 7—Pin 11—Side Link (2 used) 12—Center Link

OUO1030,0000126 –19–24FEB05–3/6

–UN–23AUG88

X9811

5. Label and disconnect lines (10). See Main Hydraulic Working System Line Identification—50D. (Group 9025-15.) Install caps and plugs.

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TM2264 (15OCT08)

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Repair 101508

PN=401

Hydraulic System

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Bucket Cylinder—50D—Weight approximate ...................................................................................... 33 kg 73 lb

6. Attach bucket cylinder (1) to hoist. Remove cap screw (9), pin (10), and shims (3). Note how the shims are arranged for installation. –UN–06FEB03

7. Remove bucket cylinder (1).

T164864

8. Repair or replace parts as necessary. See Bucket Cylinder Disassemble and Assemble. (Group 3360.) 9. Install bucket cylinder (1) and connect hoses. Bucket Cylinder Arm Pin

10. Insert pin (8) and install cap screw (9).

1—Bucket Cylinder 8—Pin 9—Cap Screw 10—Line (2 used)

Specification Bucket Cylinder-to-Arm Pin Cap Screw—50D—Torque................................................................... 140 N•m 103 lb-ft

11. Start engine and slowly extend bucket cylinder rod (5) to align rod hole with links (11 and 12). Install shims (3).

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Repair 101508

PN=402

Hydraulic System 12. Insert pin (7), cap screw (6), and nuts (4). Tighten the nuts against each other, not the boss. There must be clearance between nuts and boss. Cap screw must be free to turn in hole. Specification Bucket Cylinder-to-Link Pin Cap Screw and Nuts—50D—Torque ................................................... 210 N•m 155 lb-ft Nut-to-Boss—Clearance ............................................................... 3—5 mm 0.12—0.20 in.

13. Apply grease to all pivot joints. See Grease. (Operator’s Manual.) 14. Check hydraulic oil level. See Check Hydraulic Oil Tank Level. (Operator’s Manual.)

OUO1030,0000126 –19–24FEB05–6/6

Boom Swing Cylinder Remove and Install 1. Park machine on firm and level surface. 2. Rotate operator station ninety degrees to right of the blade. 3. Retract boom, arm and bucket cylinders, and lower bucket to ground. 4. Turn off machine. CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Cap must be loosened to relieve the air pressure in hydraulic oil tank. 5. Slowly loosen cap to relieve the air pressure in hydraulic oil tank. 33 3360 81

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Repair 101508

PN=403

Hydraulic System 6. Remove front cover (1). 7. Insert wood block between boom swing cylinder (5) and frame. 8. Remove nuts (2), cap screw (3), and pin (4). Using a hoist, attach lifting strap to rod end. –UN–01MAR05

9. Remove two access panels located under right side of the operator station.

T209098A

1—Cover 2—Nut (2 used) 3—Cap Screw 4—Pin 5—Boom Swing Cylinder

Boom Swing Cylinder—50D

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TM2264 (15OCT08)

33-3360-82

Repair 101508

PN=404

Hydraulic System

–UN–23AUG88

X9811

11. Identify lines to aid in assembly, and disconnect lines. See Main Hydraulic Working System Line Identification—35D or See Main Hydraulic Working System Line Identification—50D. (Group 9025-15.) Install caps and plugs. 12. Remove cap screw (7) and pin (8).

–UN–01MAR05

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T209099A

Specification Boom Swing Cylinder—35D— Weight approximate........................................................................... 33 kg 73 lb Boom Swing Cylinder—50D— Weight approximate........................................................................... 48 kg 106 lb

Boom Swing Cylinder Line—50D

13. Remove boom swing cylinder (9) using hoist and lifting straps.

6—Hydraulic Line 7—Cap Screw and Washer 8—Pin 9—Boom Swing Cylinder

14. Repair or replace parts as necessary. See Blade and Boom Swing Cylinder Disassemble and Assemble. (Group 3360.) 15. Install boom swing cylinder (9). 16. Install pin (8), cap screw (7), and hydraulic lines (6). Secure access plates. Specification Retainer Cap Screw—35D— Torque ......................................................................................... 140 N•m 103 lb-ft Retainer Cap Screw—50D— Torque ........................................................................................... 90 N•m 66 lb-ft

33 3360 83

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OUO1030,0000128 –19–25FEB05–3/4

Repair 101508

PN=405

Hydraulic System 17. Align rod end and install pin (4). 18. Apply T43513 Thread Lock and Sealer (high strength) to threads of nuts (2). Install cap screw (3), and tighten the nuts against each other, not the boss. There must be clearance between nuts and boss. Cap screw must be free to turn in hole. Specification Boom Swing Cap Screw Nut-to-Nut—Torque ..................................................................... 137 N•m 101 lb-ft Nut-to-Boss—Clearance ............................................................... 3—5 mm 0.12—0.20 in.

19. Install cover (1) and apply grease to all pivot joints. See Grease. (Operator’s Manual.) 20. Check hydraulic oil level. See Check Hydraulic Oil Tank Level. (Operator’s Manual.)

OUO1030,0000128 –19–25FEB05–4/4

33 3360 84

TM2264 (15OCT08)

33-3360-84

Repair 101508

PN=406

Hydraulic System

T159624

–UN–01OCT02

Boom Cylinder Disassemble and Assemble

1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring 6—O-Ring 7—Bushing

8—Backup Ring—35D Only 9—U-Cup Seal 10—Connector Ring 11—Snap Ring 12—Retainer 13—Backup Ring 14—O-Ring

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Boom Cylinder—35D—Weight approximate ................................................................................ 35 kg 77 lb

15—Cushion Ring 16—Spacer 17—Snap Ring 18—Cushion 19—Wear Ring 20—Piston

Boom Cylinder—50D—Weight approximate ................................................................................ 55 kg 121 lb

1. Fasten head end of cylinder to cylinder service stand. 33 3360 85

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TM2264 (15OCT08)

21—Steel Ball 22—Set Screw 23—O-Ring 24—Cap Seal 25—Wear Ring 26—Cylinder Barrel

33-3360-85

MM61211,00008E7 –19–24FEB05–1/4

Repair 101508

PN=407

Hydraulic System

14 13

28 1 11 8

7 6 5 4 3

22 21

30 26

19 18

T159623

–UN–04FEB03

33 3360 86

T159623

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MM61211,00008E7 –19–24FEB05–2/4

Repair 101508

PN=408

Hydraulic System 1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring 6—O-Ring 7—Bushing 8—Backup Ring—35D Only

9—U-Cup Seal 10—Connector Ring 11—Snap Ring 12—Retainer 13—Backup Ring 14—O-Ring 15—Cushion Ring 16—Spacer

17—Snap Ring 18—Cushion 19—Wear Ring 20—Piston 21—Steel Ball 22—Set Screw 23—O-Ring 24—Cap Seal

2. Bend the crimp from notch in rod guide (3), being careful not to damage the end of cylinder barrel (26).

25—Wear Ring 26—Cylinder Barrel 27—Dust Seal (4 used) 28—Bushing 29—Grease Fitting 30—Bushing 31—Grease Fitting

13. Install wiper seal (2) so lip is toward the outside of rod guide. 14. Install O-ring (6), backup ring (5), and O-ring (4).

IMPORTANT: Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly. 3. Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using JDG28 Spanner Wrench.

15. Install cushion ring (15). Install spacer (16) so notches are toward the cushion ring. Install snap ring (17). 16. Install O-ring (14) and backup ring (13). 17. Install retainer (12), connector ring (10), and snap ring (11).

4. Attach rod to a hoist using a lifting strap. 5. Pull rod and piston (20) from cylinder barrel (26). 6. Remove the staking from piston and set screw (22). Remove set screw and steel ball (21).

18. Install O-ring (23) and cap seal (24). Check that O-ring is not twisted. 19. Install wear rings (25 and 19) so the splits are offset.

7. Remove piston (20) and cushion (18). 20. Install rod guide (3) onto rod (1). 8. Remove rod guide. IMPORTANT: Take care not to damage other parts when removing seals. Do not reuse wear rings (19 and 25), cap seal (24), or O-ring (23).

21. Install cushion (18), tapered end first. Install piston (20). Tighten piston. Specification Piston-to-Rod—35D—Torque .............................................. 1620 N•m 1200 lb-ft Piston-to-Rod—50D—Torque .............................................. 2170 N•m 1600 lb-ft

9. Repair or replace parts as necessary. 10. Clean and dry parts to be reused. Apply a light film of clean hydraulic oil to all sealing parts and machined surfaces. 11. Install bushing (7) so it is even with the end of rod guide. Bushing is a pressed fit. 12. Install backup ring (8). Install U-cup seal (9) so flat side is toward the rod end.

22. Install steel ball (21) and set screw (22). Tighten set screw. Stake the set screw head in two places to prevent loosening. Specification Piston-to-Rod Set Screw— 35D—Torque ........................................................................ 16.7 N•m 148 lb-in. Piston-to-Rod Set Screw— 50D—Torque ........................................................................ 31.2 N•m 276 lb-in.

Continued on next page

TM2264 (15OCT08)

33-3360-87

MM61211,00008E7 –19–24FEB05–3/4

Repair 101508

PN=409

33 3360 87

Hydraulic System 23. Install rod and piston. Make sure wear rings do not come off while installing rod and piston. 24. Tighten rod guide. Specification Rod Guide-to-Cylinder Barrel— 35D—Torque ......................................................................... 490 N•m 360 lb-ft

Rod Guide-to-Cylinder Barrel——Torque ................................................................... 569 N•m 420 lb-ft

25. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.

MM61211,00008E7 –19–24FEB05–4/4

33 3360 88

TM2264 (15OCT08)

33-3360-88

Repair 101508

PN=410

Hydraulic System

T159627

–UN–10OCT02

Arm Cylinder Disassemble and Assemble

1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring 6—O-Ring 7—Backup Ring—35D Only

8—U-Cup Seal 9—Bushing 10—Backup Ring 11—O-Ring 12—Cushion Ring 13—Spacer 14—Snap Ring

15—Cushion 16—Wear Ring 17—Piston 18—Steel Ball 19—Set Screw 20—Cap Seal

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Arm Cylinder—35D—Weight approximate ................................................................................ 33 kg 73 lb

Arm Cylinder—50D—Weight approximate ............................................................................... 43 kg 95 lb

1. Fasten head end of cylinder to cylinder service stand. 33 3360 89

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TM2264 (15OCT08)

21—O-Ring 22—Wear Ring 23—Cushion 24—Washer 25—Cap Screw 26—Cylinder Barrel

33-3360-89

MM61211,00008E8 –19–24FEB05–1/4

Repair 101508

PN=411

Hydraulic System

T159625

–UN–01OCT02

33 3360 90

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33-3360-90

MM61211,00008E8 –19–24FEB05–2/4

Repair 101508

PN=412

Hydraulic System 1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring 6—O-Ring 7—Backup Ring—35D Only

8—U-Cup Seal 9—Bushing 10—Backup Ring 11—O-Ring 12—Cushion Ring 13—Spacer 14—Snap Ring

15—Cushion 16—Wear Ring 17—Piston 18—Steel Ball 19—Set Screw 20—Cap Seal

2. Bend the crimp from notch in rod guide (3), being careful not to damage the end of cylinder barrel (26). IMPORTANT: Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly. 3. Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using JDG28 Spanner Wrench.

21—O-Ring 22—Wear Ring 23—Cushion 24—Washer 25—Cap Screw 26—Cylinder Barrel

12. Install bushing (9) to bottom of bore. Bushing is a pressed fit. 13. Install backup ring (7). Install U-cup seal (8) so flat side is toward the rod end. 14. Install wiper ring (2) so lip is toward the outside of rod guide. 15. Install O-ring (6), backup ring (5), and O-ring (4). 16. Install O-ring (11) and backup ring (10).

4. Attach rod to a hoist using a lifting strap. 17. Install cushion ring (12). Install spacer (13) so notches are toward the cushion ring. Install snap ring (14).

5. Pull rod and piston from cylinder barrel (26). 6. Heat cap screw (25) for 10 to 15 seconds to loosen the T43513 Thread Lock and Sealer (high strength). Remove cap screw to remove washer (24) and cushion (23). 7. Remove the staking from piston and set screw (19). Remove set screw and steel ball (18).

18. Install O-ring (21) and cap ring (20). Check that O-ring is not twisted. 19. Install wear rings (22 and 16) so the splits are offset. 20. Install rod guide (3) onto rod (1). 21. Install cushion (15), tapered end first. Install piston (17). Tighten piston.

8. Remove piston (17) and cushion (15). 9. Remove rod guide. IMPORTANT: Take care not to damage other parts when removing seals. Do not reuse wear rings (16 and 22), cap seal (20), or O-ring (21). 10. Repair or replace parts as necessary.

Specification Piston-to-Rod—35D—Torque .............................................. 1076 N•m 790 lb-ft Piston-to-Rod—50D—Torque .............................................. 1435 N•m 1060 lb-ft

22. Install steel ball (18) and set screw (19). Tighten set screw. Stake the set screw head in two places to prevent loosening. 33 3360 91

11. Clean and dry parts to be reused. Apply a light film of clean hydraulic oil to all sealing parts and machined surfaces.

Continued on next page

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Repair 101508

PN=413

Hydraulic System Specification Piston-to-Rod Set Screw— 35D—Torque ........................................................................ 16.7 N•m 148 lb-in. Piston-to-Rod Set Screw— 50D—Torque ........................................................................ 31.2 N•m 276 lb-in.

23. Install cushion (23) so tapered end is toward threaded of rod. Apply T43513 Thread Lock and Sealer (high strength) to cap screw (25). Install washer (24) and cap screw. Specification Cushion-to-Rod Cap Screw— 35D—Torque ........................................................................ 16.7 N•m 148 lb-in. Cushion-to-Rod Cap Screw— 50D—Torque ........................................................................ 31.2 N•m 276 lb-in.

24. Install rod and piston. Make sure wear rings do not come off while installing rod and piston. 25. Tighten rod guide (3). Specification Rod Guide-to-Arm Cylinder Barrel—35D—Torque ............................................................ 422 N•m 310 lb-ft Rod Guide-to-Arm Cylinder Barrel—50D—Torque ............................................................ 451 N•m 330 lb-ft

26. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.

MM61211,00008E8 –19–24FEB05–4/4

33 3360 92

TM2264 (15OCT08)

33-3360-92

Repair 101508

PN=414

Hydraulic System

T159629

–UN–01OCT02

Bucket Cylinder Disassemble and Assemble

1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring 6—O-Ring

7—Backup Ring—35D Only 8—U-Cup Seal 9—Bushing 10—Wear Ring 11—Piston 12—Steel Ball

13—Set Screw 14—Cap Seal 15—O-Ring 16—Wear Ring 17—Cylinder Barrel

18—Dust Seal 19—Bushing 20—Grease Fitting 21—Grease Fitting 22—Bushing

Bucket Cylinder—50D—Weight approximate ................................................................................ 32 kg 71 lb

1. Fasten head end of cylinder to cylinder service stand.

33 3360 93

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MM61211,00008F5 –19–25FEB05–1/4

Repair 101508

PN=415

Hydraulic System

18 19 16 15 14

9 8 7 6 5 4

3 2

T159628

–UN–01OCT02

33 3360 94

T159628

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33-3360-94

MM61211,00008F5 –19–25FEB05–2/4

Repair 101508

PN=416

Hydraulic System 1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring 6—O-Ring

7—Backup Ring—35D Only 8—U-Cup Seal 9—Bushing 10—Wear Ring 11—Piston 12—Steel Ball

2. Bend the crimp from notch in rod guide (3), being careful not to damage the end of cylinder barrel (17).

13—Set Screw 14—Cap Seal 15—O-Ring 16—Wear Ring 17—Cylinder Barrel

18—Dust Seal 19—Bushing 20—Grease Fitting 21—Grease Fitting 22—Bushing

13. Install wiper seal (2) so lip is toward the outside of rod guide. 14. Install O-ring (6), backup ring (5), and O-ring (4).

IMPORTANT: Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly.

15. Install O-ring (15) and cap seal (14). Check that O-ring is not twisted. 16. Install wear rings (16 and 10) so the splits are offset.

3. Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using JDG28 Spanner Wrench.

17. Install rod guide (3) onto rod (1). 4. Attach rod to a hoist using a lifting strap. 18. Install piston (11). Tighten piston. 5. Pull rod from cylinder barrel (17). 6. Remove the staking from piston and set screw (13). Remove set screw and steel ball (12).

Specification Piston-to-Rod—35D—Torque ................................................ 586 N•m 430 lb-ft Piston-to-Rod—50D—Torque ................................................ 861 N•m 640 lb-ft

7. Remove piston (11). 19. Install steel ball (12) and set screw (13). Tighten set screw. Stake the set screw head in two places to prevent loosening.

8. Remove rod guide (3). IMPORTANT: Take care not to damage other parts when removing seals. Do not reuse wear rings (10 and 16), cap seal (14), or O-ring (15). 9. Repair or replace parts as necessary. 10. Clean and dry parts to be reused. Apply a light film of clean hydraulic oil to all sealing parts and machined surfaces.

Specification Piston-to-Rod Set Screw— 35D—Torque ........................................................................ 16.2 N•m 143 lb-in. Piston-to-Rod Set Screw— 50D—Torque ........................................................................ 31.2 N•m 276 lb-in.

20. Install rod and piston. Make sure wear rings do not come off while installing rod and piston. 21. Tighten rod guide.

11. Install bushing (9) so it is even with the top end of bore. Bushing is a pressed fit. 12. Install backup ring (7). Install U-cup seal (8) so flat side is toward the rod end.

Specification Rod Guide-to-Cylinder Barrel— 35D—Torque ......................................................................... 343 N•m 255 lb-ft

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MM61211,00008F5 –19–25FEB05–3/4

Repair 101508

PN=417

33 3360 95

Hydraulic System Specification Rod Guide-to-Cylinder Barrel— 50D—Torque ......................................................................... 422 N•m 310 lb-ft

22. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.

MM61211,00008F5 –19–25FEB05–4/4

33 3360 96

TM2264 (15OCT08)

33-3360-96

Repair 101508

PN=418

Hydraulic System

T126379

–UN–14JAN00

Blade and Boom Swing Cylinder Disassemble and Assemble

Cylinder Cross Section 1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring

6—O-Ring 7—Bushing 8—O-Ring 9—Backup Ring 10—Retaining Ring

11—Wear Ring 12—Piston 13—Steel Ball 14—Set Screw

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Blade Cylinder—35D—Weight ................................................ 24.2 kg 53 lb Blade Cylinder—50D—Weight ................................................... 34 kg 75 lb Boom Swing Cylinder—35D— Weight ......................................................................................... 32 kg 71 lb

Boom Swing Cylinder—50D— Weight ......................................................................................... 44 kg 97 lb

NOTE: Disassembly procedure is the same for both blade and boom swing cylinders. 1. Fasten head end of cylinder to cylinder service stand.

Continued on next page

TM2264 (15OCT08)

15—Cap Seal 16—O-Ring 17—Wear Ring 18—Cylinder Barrel

33-3360-97

33 3360 97

MM61211,00008E9 –19–24FEB05–1/4

Repair 101508

PN=419

Hydraulic System

10 9

8 7 6 1

5 4 3 2

15 12

14 13

11 19

20 19

T159565

–UN–01OCT02

33 3360 98

T159565 Blade Cylinder Exploded View—35D

Continued on next page

TM2264 (15OCT08)

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MM61211,00008E9 –19–24FEB05–2/4

Repair 101508

PN=420

Hydraulic System 1—Rod 2—Wiper Seal 3—Rod Guide 4—O-Ring 5—Backup Ring

6—O-Ring 7—Bushing 8—O-Ring 9—Backup Ring 10—Retaining Ring

11—Wear Ring 12—Piston 13—Steel Ball 14—Set Screw 15—Cap Seal

2. Bend the crimp from notch in rod guide (3) being careful not to damage the end of cylinder barrel (18). IMPORTANT: Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly. 3. Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using a JDG28 Spanner Wrench or equivalent.

16—O-Ring 17—Wear Ring 18—Cylinder Barrel 19—Seal (4 used) 20—Bushing (2 used)

13. Install O-ring seal (8) so flat side is toward the rod end. Install backup ring (9) and retaining ring (10). 14. Install wiper seal (2) so lip is toward the outside of rod guide. 15. Install O-ring (16). Check that O-ring is not twisted. Install cap seal (15) using JDG840-3 Installer and JGD840-6 Pusher. 16. Install wear rings (17 and 11) so the splits are offset.

4. Attach rod to a hoist using a lifting strap. 17. Install rod guide (3) onto rod. 5. Pull rod from cylinder barrel (18). 18. Install piston (12). Tighten piston. 6. Remove the staking from piston and set screw (14). Remove set screw and steel ball (13). 7. Remove piston (12). 8. Remove rod guide (3). IMPORTANT: Take care not to damage other parts when removing seals. Do not reuse wear rings (11 and 17), cap seal (15), or O-ring (16). 9. Repair or replace parts as necessary. 10. Clean and dry parts to be reused. Apply a light film of clean hydraulic oil to all sealing parts and machined surfaces. NOTE: Assembly procedure is the same for both blade and boom swing cylinders. 11. Install bushing (7) so it is even with top end of bore. Bushing is a press fit. 12. Install O-ring (6), backup ring (5), and O-ring (4).

Specification Blade Cylinder Piston-to-Rod— 35D—Torque ....................................................................... 1080 N•m 800 lb-ft Blade Cylinder Piston-to-Rod— 50D—Torque ....................................................................... 1420 N•m 1050 lb-ft Boom Swing Cylinder Piston-to-Rod—35D—Torque .............................................. 1252 N•m 920 lb-ft Boom Swing Cylinder Piston-to-Rod—50D—Torque .............................................. 1820 N•m 1340 lb-ft

19. Install steel ball (13) and set screw (14). Tighten set screw. Stake set screw head in two places to prevent loosening. Specification Blade Cylinder Piston-to-Rod Set Screw—35D—Torque .................................................... 16.2 N•m 143 lb-in. Blade Cylinder Piston-to-Rod Set Screw—50D—Torque .................................................... 31.2 N•m 276 lb-ft Boom Swing Cylinder Piston-to-Rod Set Screw— 35D—Torque ........................................................................ 16.2 N•m 143 lb-in.

Continued on next page

TM2264 (15OCT08)

33-3360-99

MM61211,00008E9 –19–24FEB05–3/4

Repair 101508

PN=421

33 3360 99

Hydraulic System Specification Boom Swing Cylinder Piston-to-Rod Set Screw— 50D—Torque ........................................................................ 31.2 N•m 276 lb-in.

20. Install rod and piston. Make sure wear rings do not come off while installing rod and piston. 21. Tighten rod guide (3). Specification Rod Guide-to-Blade Cylinder Barrel—35D—Torque ............................................................ 735 N•m 540 lb-ft

Rod Guide-to-Blade Cylinder Barrel—50D—Torque ............................................................ 863 N•m 640 lb-ft Rod Guide-to-Boom Swing Cylinder Barrel—35D—Torque .............................................. 490 N•m 360 lb-ft Rod Guide-to-Boom Swing Cylinder Barrel—50D—Torque .............................................. 530 N•m 390 lb-ft

22. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.

MM61211,00008E9 –19–24FEB05–4/4

Hydraulic Cylinder Bleed Procedure IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and can ignite the oil used for assembly, causing cap seal and ring damage. Start with the cylinder rod retracted and the rod end filled with clean oil. Connect the cylinder head end and line. Perform function to slowly extend rod. This procedure will eliminate most of the air and reduce the possibility of damage. 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. 33 3360 ,100

2. Slowly perform 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.

TX,33,GG2374 –19–07FEB03–1/1

TM2264 (15OCT08)

33-3360-100

Repair 101508

PN=422

Section 43

Swing or Pivoting System Contents Page

Group 4350—Mechanical Drive Elements Swing Gearbox Remove and Install—35D. . .43-4350-1 Swing Gearbox Remove and Install—50D. . .43-4350-3 Swing Gearbox Disassemble and Assemble—35D . . . . . . . . . . . . . . . . . . . . .43-4350-6 Swing Gearbox Disassemble and Assemble—50D . . . . . . . . . . . . . . . . . . . .43-4350-10 Upperstructure Remove and Install . . . . . . .43-4350-15 Swing Bearing Remove and Install . . . . . . .43-4350-17 Group 4360—Hydraulic System Swing Motor and Park Brake Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-1 Swing Motor and Park Brake Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . .43-4360-2 Swing Motor Start-Up Procedure. . . . . . . . . .43-4360-6

TM2264 (15OCT08)

43-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

43-2

Repair 101508

PN=2

Group 4350

Mechanical Drive Elements Swing Gearbox Remove and Install—35D 1. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

X9811

–UN–23AUG88

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Disconnect hydraulic lines (1—5). Install caps and plugs. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Swing Motor and Gearbox assembly—35D—Weight approximate ....................................................................................... 38 kg 84 lb

–UN–01FEB05

3. Remove cap screws (6). Attach swing gearbox to hoist using JT05548 Lifting Eye .

T207465A

NOTE: When removing the swing gearbox, the swing motor and gearbox are usually removed as a unit. The swing motor can be removed from the swing gearbox if desired. See Swing Motor and Park Brake Remove and Install. 4. Remove swing motor and gearbox.

1—PB from Pilot Control Shut-Off Solenoid Valve Line 2—A2 from Swing Valve Spool Line 3—M to Control Valve Line 4—B2 from Swing Valve Spool Line 5—DB to Return Manifold Line 6—Cap Screw (6 used) Line

5. Make repairs as necessary. 6. Install the swing motor and gearbox. Tighten cap screws (6) to specification. Specification Swing Gearbox Housing-to-Frame Cap Screw—35D—Torque ........................................................... 144 N•m 103 lb-ft

7. Connect hydraulic lines. 8. Lower and secure operator station. 43 4350 1

Continued on next page

TM2264 (15OCT08)

43-4350-1

OUO1030,000010A –19–28JAN05–1/2

Repair 101508

PN=425

Mechanical Drive Elements 9. Perform Swing Motor Start-Up Procedure. (Group 4360.)

OUO1030,000010A –19–28JAN05–2/2

43 4350 2

TM2264 (15OCT08)

43-4350-2

Repair 101508

PN=426

Mechanical Drive Elements

Swing Gearbox Remove and Install—50D 1. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

X9811

–UN–23AUG88

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Disconnect hydraulic lines (1, 2, and 4—6). Install caps and plugs. 3. If equipped with air conditioning, disconnect hose from condensation pan (3). CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

–UN–25JAN05

Specification Swing Motor and Gearbox Assembly—50D—Weight approximate ....................................................................................... 43 kg 95 lb

T207432A

1—PB from Pilot Control Shut-Off Solenoid Valve Line 2—A1 from Swing Valve Spool Line 3—Hose to Condensation Pan 4—M to Control Valve Line 5—D4 to Return Manifold Line 6—B1 from Swing Valve Spool Line 7—Cap Screw (8 used)

5. Remove the swing motor and gearbox. 6. Make repairs as necessary. 7. Install the swing motor and gearbox. Tighten cap screws (7) to specification. Specification Swing Gearbox Housing-to-Frame Cap Screw—50D—Torque ........................................................... 210 N•m 155 lb-ft

43 4350 3

Continued on next page

TM2264 (15OCT08)

43-4350-3

OUO1030,000010B –19–31JAN05–1/2

Repair 101508

PN=427

Mechanical Drive Elements 8. If equipped with air conditioning, connect condensation pan hose. 9. Connect hydraulic lines. 10. Lower and secure operator station. 11. Perform Swing Motor Start-Up Procedure. (Group 4360.)

OUO1030,000010B –19–31JAN05–2/2

43 4350 4

TM2264 (15OCT08)

43-4350-4

Repair 101508

PN=428

Mechanical Drive Elements

43 4350 5

TM2264 (15OCT08)

43-4350-5

Repair 101508

PN=429

Mechanical Drive Elements

–UN–14JAN00

Swing Gearbox Disassemble and Assemble—35D

T126517

43 4350 6

Continued on next page

TM2264 (15OCT08)

43-4350-6

OUO1030,000010C –19–31JAN05–1/4

Repair 101508

PN=430

Mechanical Drive Elements 1—Shaft 2—Collar 3—Plate 4—Bearing 5—Housing 6—Oil Seal 7—Bearing 8—Cap Screw (2 used)

9—Split Retaining Ring 10—Collar 11—Second Planetary Carrier 12—Thrust Washer (4 used) 13—Inner Race (4 used) 14—Needle Bearing (4 used) 15—Second Planetary Gear (4 used)

1. Remove cap screws (8). Remove swing gearbox from swing motor.

16—Thrust Plate 17—Cap Screw (4 used) 18—Second Planetary Sun Gear 19—First Planetary Carrier 20—Thrust Washer (4 used) 21—Inner Race (4 used)

22—Needle Bearing (4 used) 23—First Planetary Gear (4 used) 24—Thrust Plate 25—First Planetary Sun Gear 26—O-Ring

7. Remove thrust plate (16), second planetary gear (15), needle bearing (14), inner race (13), and thrust washer (12) in this order.

2. Remove first planetary sun gear (25). 3. Remove thrust plate (24), first planetary gear (23), needle bearing (22), inner race (21), thrust washer (20), and first planetary carrier (19) from housing (5).

8. Remove collar (10) and split retaining ring (9) from housing (5). 9. Remove shaft (1) from housing (5) using a press. 10. Remove inner race of bearing (4) using a press. Remove plate (3) and collar (2) from shaft (1).

4. Remove second planetary sun gear (18) from housing (5).

11. Remove oil seal (6) from housing (5). 5. Remove second planetary carrier (11) from housing (5).

12. Remove outer race of bearing (7) from housing (5).

6. Remove cap screws (17).

Continued on next page

OUO1030,000010C –19–31JAN05–2/4

43 4350 7

TM2264 (15OCT08)

43-4350-7

Repair 101508

PN=431

–UN–14JAN00

Mechanical Drive Elements

T126516

43 4350 8

Continued on next page

TM2264 (15OCT08)

43-4350-8

OUO1030,000010C –19–31JAN05–3/4

Repair 101508

PN=432

Mechanical Drive Elements 1—Shaft 2—Collar 3—Plate 4—Bearing 5—Housing 6—Oil Seal 7—Bearing 8—Cap Screw (2 used)

9—Split Retaining Ring 10—Collar 11—Second Planetary Carrier 12—Thrust Washer (4 used) 13—Inner Race (4 used) 14—Needle Bearing (4 used) 15—Second Planetary Gear (4 used)

1. Install oil seal (6) into housing (5).

16—Thrust Plate 17—Cap Screw (4 used) 18—Second Planetary Sun Gear 19—First Planetary Carrier 20—Thrust Washer (4 used) 21—Inner Race (4 used)

22—Needle Bearing (4 used) 23—First Planetary Gear (4 used) 24—Thrust Plate 25—First Planetary Sun Gear 26—O-Ring 27—Swing Motor

11. Install second planetary carrier assembly into housing (5).

2. Install outer race of bearing (7) into housing (5) using a press.

12. Install second planetary sun gear (18).

3. Pack inner race of bearing (4) with grease. 4. Install collar (2), plate (3), and inner race of bearing (4) onto shaft (1) using a press. IMPORTANT: Do not damage oil seal (6) by the spline part of the shaft (1).

13. Assemble thrust washer (20), inner race (21), needle bearing (22), first planetary gear (23), and thrust plate (24) on first planetary carrier (19) in this order. 14. Install first planetary carrier (19) into housing (5). 15. Install O-ring (26) on swing motor. Install swing motor into housing with cap screws and tighten.

5. Install shaft (1) into housing (5).

Specification Swing Motor-to-Gearbox Cap Screw—35D—Torque ............................................................ 128 N•m 94 lb-ft

6. Install inner race of bearing (7) into housing (5) using a press. 7. Install split retaining ring (9) and collar (10). 8. Install thrust washer (12), inner race (13), needle bearing (14), second planetary gear (15), and thrust plate (16) on second planetary carrier (11).

16. Install swing gearbox. See Swing Gearbox Remove and Install—35D. (Group 4350.)

9. Apply T43513 Thread Lock and Sealer (high strength) to threads of cap screws (17). 10. Tighten cap screws (17) to specification. Specification Second planetary Carrier-to-Thrust Plate Cap Screw—35D—Torque ................................................................ 4 N•m 35 lb-in.

OUO1030,000010C –19–31JAN05–4/4

43 4350 9

TM2264 (15OCT08)

43-4350-9

Repair 101508

PN=433

Mechanical Drive Elements

Swing Gearbox Disassemble and Assemble—50D

8 7 5

4 3 2

1 16

13 12

14 13 14

20 19

21 20

43 4350 10

T207712

–UN–03MAR05

T207712

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TM2264 (15OCT08)

43-4350-10

OUO1030,000010D –19–31JAN05–1/5

Repair 101508

PN=434

Mechanical Drive Elements 1—Shaft 2—Spacer 3—Spring Plate 4—Tapered Roller Bearing 5—Housing 6—Oil Seal 7—Tapered Roller Bearing 8—Split Retaining Ring

9—Collar 10—Ring Gear 11—Socket Head Cap Screw (11 used) 12—Inner Ring (4 used) 13—Needle Bearing (4 used) 14—Second Stage Planetary Gear (4 used)

1. Remove socket head cap screw (11) from swing motor. Remove swing motor from ring gear (10). 2. Remove the first stage planetary pinion carrier (19) assembly, second stage planetary sun gear (18), and the second stage planetary pinion carrier (15) assembly. 3. Remove socket head cap screws (11) from ring gear (10). Remove ring gear (10) from housing (5).

15—Second Stage Planetary Pinion Carrier 16—Plate 17—Socket Head Cap Screw 18—Second Stage Planetary Sun Gear 19—First Stage Planetary Pinion Carrier

20—Inner Ring (3 used) 21—Needle Bearing (3 used) 22—First Stage Planetary Gear (3 used) 23—First Stage Planetary Sun Gear 24—O-Ring

4. Remove socket head cap screw (17) from the first stage planetary pinion carrier (19) assembly. Remove plate (16), first stage planetary sun gear (23), first stage planetary gears (22), needle bearings (21), and inner rings (20). 5. Remove socket head cap screws (17) from the second stage planetary pinion carrier (15) assembly. Remove second stage planetary gears (14), needle bearings (13) and inner rings (12).

Continued on next page

OUO1030,000010D –19–31JAN05–2/5

43 4350 11

TM2264 (15OCT08)

43-4350-11

Repair 101508

PN=435

Mechanical Drive Elements 6. Remove collar (9) and split retaining ring (8) from shaft (1). To remove split retaining ring (8), use ST4147 Bearing Tool (25) and apply a downward force to the tapered roller bearing (7). 7. Remove shaft (1) from housing (5) by using a soft face hammer. 8. Remove the roller bearing (4), spring plate (3), and spacer (2) from shaft (1) using a press. 9. Remove oil seal (6) from housing (5). –UN–08MAR05

IMPORTANT: Install oil seal (6) with the metallic surface facing up (motor side).

T207736

10. Install oil seal (6) into housing (5). 11. Apply grease to roller bearing (4). If roller bearings (4 and 7) are being replaced, install the cup of the roller bearing (4 and 7) to housing (5) using a press.

25—ST4147 Bearing Tool 26—Clearance

12. Install spacer (2), spring plate (3), and the cone of the roller bearing (4) to shaft (1) using a press. IMPORTANT: Do not damage oil seal (6) by the spline part of the shaft (1). 13. Install the shaft (1) assembly into housing (5). 14. Install roller bearing (7). 15. Adjust the roller bearing preload. a. Push down on roller bearing (7) using ST4147 Bearing Tool (25) and a press. Specification Gearbox Bearing—Force................................................................ 3430 N 771 lb-force

b. Rotate housing (5) 10 turns. c. Measure clearance (26) between the top of the roller bearing (7) and the bottom end of the splined shaft (1). 43 4350 12

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TM2264 (15OCT08)

43-4350-12

OUO1030,000010D –19–31JAN05–3/5

Repair 101508

PN=436

Mechanical Drive Elements d. Check the table and select a split retaining ring (8) according to clearance (26). Measured Value of Clearance (25)

Thickness of Retaining Ring

6.54—6.65 mm 0.257—0.261 in.

6.70 mm 0.263 in.

6.66—6.80 mm 0.262—0.267 in.

6.85 mm 0.269 in.

6.81—6.95 mm 0.268—0.273 in.

7.00 mm 0.275 in.

6.96—7.10 mm 0.274—0.279 in.

7.15 mm 0.281 in.

7.11—7.25 mm 0.279—0.285 in.

7.30 mm 0.287 in.

7.26—7.40 mm 0.285—0.291 in.

7.45 mm 0.293 in.

16. Push roller bearing (7) to specification and install the split retaining ring (8). Specification Gearbox Bearing Split Retaining Ring—Force.................................................................................... 5048 N 1135 lbf

17. Install collar (9). 18. Apply TY16135 Form-in-Place Gasket onto mounting surface of housing (5). Install ring gear (10) to housing (5). Tighten socket head cap screws (11). Specification Ring Gear To Housing—Torque .................................................. 108 N•m 80 lb-ft

19. Install inner rings (12), needle bearings (13), and second stage planetary gears (14) to the second stage planetary pinion carrier (15). Tighten plate (16) with socket head cap screws (17). Specification Second Stage Carrier Plate— Torque ............................................................................................ 15 N•m 11 lb-ft

43 4350 13

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TM2264 (15OCT08)

43-4350-13

OUO1030,000010D –19–31JAN05–4/5

Repair 101508

PN=437

Mechanical Drive Elements 20. Install inner rings (20), needle bearings (21), first stage planetary gears (22), and the first stage planetary sun gear (23) to the first stage carrier (19). Install plate with socket head cap screws (17). Specification First Stage Carrier Plate Torque—Torque ............................................................................. 15 N•m 11 lb-ft

21. Install the second stage carrier assembly (15), second stage planetary sun gear (18), and the first stage carrier assembly (19) to the housing assembly (5). 22. Install O-ring (24) to ring gear (10). 23. Add hydraulic oil to the swing gearbox reduction gears. Specification Hydraulic Oil Quantity for Swing Gearbox—Volume .............................................................................. 0.6 L 0.63 qt

24. Install swing motor-to-ring gear (10) with socket head cap screws (11). Specification Swing Motor—Torque................................................................... 108 N•m 80 lb-ft

25. Install swing gearbox. See Swing Gearbox Remove and Install—50D. (Group 4350.)

OUO1030,000010D –19–31JAN05–5/5

43 4350 14

TM2264 (15OCT08)

43-4350-14

Repair 101508

PN=438

Mechanical Drive Elements

Upperstructure Remove and Install 1. Clean the machine thoroughly. 2. See Canopy Remove and Install for removal procedure. (Group 1800.) See Cab Remove and Install for removal procedure. (Group 1800.) 3. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.) 4. Disconnect hydraulic lines from rotary manifold. Install caps and plugs. 5. Secure operator station.

OUO1030,000012A –19–01MAR05–1/4

6. Make alignment marks on swing bearing (A) and upperstructure to aid in assembly.

–UN–06DEC88

7. Remove swing bearing-to-upperstructure cap screws and washers (B).

T6626JK

1—Swing Bearing 2—Cap Screws and Washer (22 used—35D) (27 used—50D)

Continued on next page

OUO1030,000012A –19–01MAR05–2/4

43 4350 15

TM2264 (15OCT08)

43-4350-15

Repair 101508

PN=439

T209147

–UN–11MAR05

Mechanical Drive Elements

1—Arm Cylinder Mounting Bracket

2—Chain

3—Metric Lifting Eyebolt (2 used)

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Upperstructure—35D—Weight approximate ............................................................................ 2182 kg 4810 lb Upperstructure—50D—Weight approximate ............................................................................ 2923 kg 6444 lb

43 4350 16

8. Attach upperstructure to a hoist using chains (2), a spreader bar, and M16x2.5 lifting eyebolts such as JT05551 (35D) Metric Lifting Eyebolts (3) or M20x2.5 lifting eyebolts such as JT05552 (50D)

Metric Lifting Eyebolts (3). Install eyebolts in the rear counterweight. Attach chain to arm cylinder mounting bracket (1). 9. Adjust length of chains as needed to balance the upperstructure (4). Remove all slack from chains. 10. Lift upperstructure (4) slowly from undercarriage. 11. Make repairs as necessary. 12. See Swing Bearing Remove and Install for procedure to remove swing bearing (A). (Group 4350.)

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TM2264 (15OCT08)

4—Upperstructure

43-4350-16

OUO1030,000012A –19–01MAR05–3/4

Repair 101508

PN=440

Mechanical Drive Elements 13. Clean mating surfaces of swing bearing and upperstructure (4). 14. Slowly lower upperstructure (4) onto undercarriage while making sure the marks previously made are aligned. 15. Install swing bearing-to-upperstructure (4) cap screws and washers (B). Tighten to specification. Specification Swing Bearing-to-Upperstructure Cap Screw—35D—Torque ............................................................ 108 N•m 80 lb-ft

Swing Bearing-to-Upperstructure Cap Screw—50D—Torque ............................................................ 175 N•m 130 lb-ft

16. Tilt operator station, connect hydraulic lines, and secure station. 17. Install canopy or cab. 18. Check hydraulic oil tank level and service as required. See Hydraulic Oil. (Operator’s Manual.)

OUO1030,000012A –19–01MAR05–4/4

Swing Bearing Remove and Install

–UN–28JAN03

1. Remove upperstructure. See Upperstructure Remove and Install. (Group 4350.)

T164480

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Swing Bearing—35D—Weight approximate ....................................................................................... 39 kg 86 lb Swing Bearing—50D—Weight approximate ....................................................................................... 41 kg 90 lb

1—Swing Bearing Inner Race 2—Undercarriage Frame 3—Alignment Marks

2. Make alignment marks (3) on swing bearing inner race (1) and undercarriage (2).

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OUO1030,000010E –19–02FEB05–1/4

43 4350 17

TM2264 (15OCT08)

43-4350-17

Repair 101508

PN=441

Mechanical Drive Elements 3. Remove cap screws (1) from swing bearing inner race (2).

T207845

–UN–10FEB05

1—Cap Screws (20 used—35D) (24 used—50D) 2—Swing Bearing Inner Race

OUO1030,000010E –19–02FEB05–2/4

4. Attach swing bearing to a hoist using lifting brackets (1) such as JT01748 Lifting Brackets. Remove swing bearing. 5. Replace parts as necessary.

T207846

7. Apply T43514 Rigid Form-in-Place Gasket to mating surfaces on swing bearing.

–UN–10FEB05

6. Clean mating surfaces of swing bearing, upperstructure, and undercarriage.

Continued on next page

OUO1030,000010E –19–02FEB05–3/4

43 4350 18

TM2264 (15OCT08)

43-4350-18

Repair 101508

PN=442

Mechanical Drive Elements IMPORTANT: The inner and outer bearing races are marked with the letter “S” to indicate the “soft zone”. The area marked with this letter must be installed on the left side of machine so the use of that part of swing bearing is minimized. 8. Install swing bearing on undercarriage.

T164483

–UN–28JAN03

a. 35D: Install swing bearing on undercarriage so the area on both inner and outer races marked with an “S” is to the left side of machine at approximately the 282° position as shown. b. 50D: Install swing bearing on undercarriage so the area on both inner and outer races marked with an “S” is to the left side of machine at approximately the 279° position as shown. Position grease fitting as shown.

35D Shown

0˚

9. Install swing bearing-to-undercarriage cap screws. Tighten to specification. Specification Swing Bearing-to-Undercarriage Cap Screw—Torque ..................................................................... 108 N•m 80 lb-ft

1 25˚

279˚

16˚

11. Install upperstructure. See Upperstructure Remove and Install. (Group 4350.) T165662 1—Outer Race “S” Location 2—Inner Race “S” Location 3—Front of Machine 4—Grease Fitting Positions (50D only)

180˚

–UN–20FEB03

90˚

T165662

10. Apply multi-purpose (extreme-pressure) grease to swing bearing teeth and pinion shaft. See Grease. (Operator’s Manual.)

270˚

50D Shown

OUO1030,000010E –19–02FEB05–4/4

43 4350 19

TM2264 (15OCT08)

43-4350-19

Repair 101508

PN=443

Mechanical Drive Elements

43 4350 20

TM2264 (15OCT08)

43-4350-20

Repair 101508

PN=444

Group 4360

Hydraulic System Swing Motor and Park Brake Remove and Install NOTE: Model 50D is shown; 35D is similar. –UN–23AUG88

1. Tilt operator station. See Tilting the Operator Station. (Operator’s Manual.)

X9811

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. 2. If equipped with air conditioning, disconnect hose from condensation pan (2). 3. Disconnect hydraulic lines (3—7). 4. Remove socket head cap screws (1) to remove swing motor. 5. Make repairs as necessary.

7. Connect hydraulic lines. 8. Lower and secure operator station. 9. Perform Hydraulic Pump Start-Up Procedure. (Group 3360.)

T207541A

Specification Swing Motor-to-Swing Gearbox Cap Screw—35D—Torque ........................................................... 128 N•m 94 lb-ft Swing Motor-to-Swing Gearbox Cap Screw—50D—Torque ........................................................... 108 N•m 80 lb-ft

–UN–01FEB05

6. Install the swing motor. Tighten socket head cap screws to specification.

1—Socket Head Cap Screw (2 used) 2—Hose to Condensation Pan 3—A1 from Swing Valve Spool Line 4—D4 to Return Manifold Line 5—M to Control Valve Line 6—B1 from Swing Valve Spool Line 7—PB from Pilot Control Shut-Off Solenoid Valve Line

10. Perform Swing Motor Start-Up Procedure. (Group 4360.)

43 4360 1

OUO1030,0000105 –19–28JAN05–1/1

TM2264 (15OCT08)

43-4360-1

Repair 101508

PN=445

Hydraulic System

–UN–14JAN00

Swing Motor and Park Brake Disassemble and Assemble

T126553

43 4360 2

Continued on next page

TM2264 (15OCT08)

43-4360-2

TX19495,0000001 –19–18MAR05–1/5

Repair 101508

PN=446

Hydraulic System 1—Relief Valve (2 used) 2—Anti-Cavitation Valve (2 used) 3—Housing 4—Bearing 5—Shaft 6—Swash Plate 7—Piston (9 used) 8—Retainer

9—Holder 10—Cap Screw (2 used) 11—O-Ring 12—Plug 13—Orifice 14—Pin (3 used) 15—Cylinder Block 16—Collar 17—Spring

18—Washer 19—Retaining Ring 20—Disk Plate 21—O-Ring 22—O-Ring 23—Brake Piston 24—Spring Seat (2 used) 25—Disk Spring 26—O-Ring

27—Valve Plate 28—Pin 29—Bearing 30—Pin 31—Cover 32—Cap Screw (5 used) 33—O-Ring (2 used) 34—Plug (2 used) 35—O-Ring (2 used)

7. Remove pistons (7), retainer (8), holder (9), and pins (14) from cylinder block (15).

1. Evenly loosen five cap screws (32). IMPORTANT: Care must be taken when removing cover (31). Valve plate (27) may fall, causing damage to plate.

CAUTION: Serious injury may result. Washer (18) and spring (17) may fly out if retaining ring (19) is removed without compressing spring (17). Always use a press to compress spring (17).

2. Remove cap screws, cover (31), valve plate (27), and O-ring (26). 3. Remove bearing (29) and O-rings (35) from cover (31). 4. Remove disk spring (25) and spring seats (24) from housing (3). 5. Remove brake piston (23) and O-rings (21 and 22) from housing (3). IMPORTANT: Be careful so as not to damage the sliding surface of swash plate (6) while removing it from housing (3). 6. Remove cylinder block (15), piston assembly, swash plate (6), and disk plate (20) from housing (3).

8. Remove retaining ring (19), washer (18), spring (17), and collar (16) from cylinder block (15) using a press. 9. Remove shaft (5) from housing (3) by striking end of shaft with a plastic hammer. 10. Remove bearing (4) from shaft (5) using a press. IMPORTANT: Apply clean hydraulic oil to all moving parts during the assembly process. 11. Repair or replace parts as necessary.

TX19495,0000001 –19–18MAR05–2/5

12. Install bearing (4) onto shaft (5) so snap ring is toward shaft splines as shown in illustration.

T126564

–UN–14JAN00

4—Bearing 5—Shaft

Continued on next page

TM2264 (15OCT08)

43-4360-3

TX19495,0000001 –19–18MAR05–3/5

Repair 101508

PN=447

43 4360 3

T126552

–UN–14JAN00

Hydraulic System

1—Relief Valve (2 used) 2—Anti-Cavitation Valve (2 used) 3—Housing 4—Bearing 5—Shaft 6—Swash Plate 7—Piston (9 used) 8—Retainer

9—Holder 10—Cap Screw (2 used) 11—O-Ring 12—Plug 13—Orifice 14—Pin (3 used) 15—Cylinder Block 16—Collar 17—Spring

18—Washer 19—Snap Ring 20—Disk Plate 21—O-Ring 22—O-Ring 23—Brake Piston 24—Spring Seat (2 used) 25—Disk Spring 26—O-Ring

IMPORTANT: Forcing bearing (4) beyond where snap ring contacts the housing wall will cause snap ring to deform. 13. Install shaft and bearing into housing (3) until snap ring on bearing (4) just contacts the housing wall. 14. Install collar (16), spring (17), and washer (18) into cylinder block (15). Beveled side of collar must be toward cylinder block.

27—Valve Plate 28—Pin 29—Bearing 30—Pin 31—Cover 32—Cap Screw (5 used) 33—O-Ring (2 used) 34—Plug (2 used) 35—O-Ring (2 used)

17. Install holder (9) on pin (14). 18. Install pistons (7) and retainer (8) assembly into cylinder block (15). 19. Install swash plate (6) into housing (3) so beveled side is toward housing and the polished side contacts the cylinder block pistons. 20. Install cylinder block (15) and piston assembly into housing (3).

15. Compress spring (17) to install snap ring (19). 43 4360 4

16. Apply petroleum jelly to pin (14), and install pin (14) into cylinder block (15).

21. Install O-rings (21 and 22) onto brake piston (23), then install them into housing (3).

Continued on next page

TM2264 (15OCT08)

43-4360-4

TX19495,0000001 –19–18MAR05–4/5

Repair 101508

PN=448

Hydraulic System 22. Install spring seats (24) and disk spring (25) into housing (3) as shown. 23. Install O-ring (26) into housing (3). –UN–14JAN00

24. Install bearing (29) into cover (31).

Install O-rings (35) and valve plate (27) onto cover (31). 26. Install cover (31) onto housing (3) using cap screws (32).

T126565

25. Apply petroleum jelly to mating surfaces of valve plate (27) and cover (31) to hold valve plate in position to prevent it from falling.

24—Spring Seat (2 used) 25—Disk Spring

27. Evenly tighten cap screws (32) to specification. Specification Cover-to-Housing Cap Screw— Torque .......................................................................................... 128 N•m 94 lb-ft

28. Install swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.)

TX19495,0000001 –19–18MAR05–5/5

43 4360 5

TM2264 (15OCT08)

43-4360-5

Repair 101508

PN=449

Hydraulic System

Swing Motor Start-Up Procedure

–UN–14JAN00

IMPORTANT: Swing motor will be damaged if not filled with oil before operating swing function. This procedure must be performed whenever a new swing motor is installed or oil has been drained from the motor.

T126424

This procedure is to ensure the swing motor is filled with oil before operating the swing function. 1. Disconnect swing motor drain line (1). 1—Drain Line

2. Fill motor with hydraulic oil through drain port until oil reaches the level of drain port. Air must be allowed to escape from the swing motor while filling. See Hydraulic Oil. (Operator’s Manual.) 3. Connect drain line.

CED,OUOE003,21217 –19–24JAN03–1/1

43 4360 6

TM2264 (15OCT08)

43-4360-6

Repair 101508

PN=450

Section 99

Dealer Fabricated Tools Contents Page

Group 9900—Dealer Fabricated Tools ST4920 Track Recoil Spring Disassembly and Assembly Tool . . . . . . . . . . . . . . . . . .99-9900-1 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. . .99-9900-5

TM2264 (15OCT08)

99-1

Repair 101508

PN=1

Contents

TM2264 (15OCT08)

99-2

Repair 101508

PN=2

Group 9900

Dealer Fabricated Tools ST4920 Track Recoil Spring Disassembly and Assembly Tool 99 9900 1

NOTE: See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool that is recommended to be used with track recoil spring disassembly and assembly tool. Dimensions given are metric. Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size hole for the nut on that track adjuster. Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring in track adjuster repair.

–UN–24MAR98

Material required:

T6585UY

• 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G). • “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H). • “F” Grade (SAE Grade 8) for Studs (B). Print Numbers: A—Nut (12 used) B—Stud (4 used) C—Holder D—Eyebolt (2 used) E—Supporting Plate F—Base Plate G—Base (4 used) H—Cap Screw (8 used) I—Lock Washer (8 used)

• A-ST4050 Nut • B-ST4045 Bolt • C-ST4035 Holder (plate) • -ST4036 Holder (plate) • -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

Continued on next page

TM2264 (15OCT08)

99-9900-1

TX,9900,AA3574 –19–20FEB92–1/4

Repair 101508

PN=453

Dealer Fabricated Tools

T217469

–UN–16DEC05

99 9900 2

Continued on next page

TM2264 (15OCT08)

99-9900-2

TX,9900,AA3574 –19–20FEB92–2/4

Repair 101508

PN=454

Dealer Fabricated Tools

T7029CH

–UN–06JUL89

99 9900 3

Continued on next page

TM2264 (15OCT08)

99-9900-3

TX,9900,AA3574 –19–20FEB92–3/4

Repair 101508

PN=455

Dealer Fabricated Tools

T7029CG

–UN–06JUL89

99 9900 4

TX,9900,AA3574 –19–20FEB92–4/4

TM2264 (15OCT08)

99-9900-4

Repair 101508

PN=456

Dealer Fabricated Tools

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

T7162AF

–UN–17OCT89

99 9900 5

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.

E—1/2 x 3 in. Steel Round Stock (2 used)

• 3/16 in. 1020 CR Steel Plate (A) • 1/2 in. Nut (C) (2 used) • 1/2 x 2 in. Cap Screw (D) (2 used) • 1/2 x 3 in. Steel Round Stock (E) (2 used)

Material required:

TX,9900,BA499 –19–26AUG05–1/1

TM2264 (15OCT08)

99-9900-5

Repair 101508

PN=457

Dealer Fabricated Tools

99 9900 6

TM2264 (15OCT08)

99-9900-6

Repair 101508

PN=458

Index Page

A Adjuster Track, disassemble and assemble . . . .01-0130-27 Track, remove and install . . . . . . . . . . .01-0130-22 Adjuster and recoil spring Track, disassemble and assemble . . . .01-0130-23 Air conditioner AC/heater module, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-14 Compressor, remove and install . . . . . .18-1830-11 Condenser, remove and install . . . . . . .18-1830-13 Receiver-dryer, remove and install . . . .18-1830-12 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-10 Evacuate R134a system . . . . . . . . . . . . .18-1830-9 Flush and purge system . . . . . . . . . . . . .18-1830-3 Recover R134a refrigerant . . . . . . . . . . .18-1830-8 Refrigerant handling and cautions. . . . . .18-1830-1 Refrigerant recovery and charging station installation . . . . . . . . . . . . . . . . . . . . . .18-1830-7 R134a refrigerant oil information . . . . . . .18-1830-6 Arm Remove and install . . . . . . . . . . . . . . . . .33-3340-4 Arm cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-100 Disassemble and assemble . . . . . . . . .33-3360-89 Remove and install . . . . . . . . . . . . . . . .33-3360-72 Arm pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-16 Attachments Adding safely . . . . . . . . . . . . . . . . . . . 000-0001-10 Operating safely . . . . . . . . . . . . . . . . . 000-0001-10

B Backover accidents Avoiding . . . . . . . . . . . . . . . . . . . . . . . .000-0001-8 Battery explosions Prevent . . . . . . . . . . . . . . . . . . . . . . . . .000-0001-4 Bearings Main, failure analysis . . . . . . . . . . . . . .04-0400-78 Blade Disassemble and assemble . . . . . . . . . .32-3201-4 Remove and install . . . . . . . . . . . . . . . . .32-3201-1 Blade cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-100 Disassemble and assemble . . . . . . . . .33-3360-97 Remove and install . . . . . . . . . . . . . . . . .32-3260-1 Blade pilot controller Disassemble and assemble . . . . . . . . . .32-3260-6 TM2264 (15OCT08)

Page

Remove and install . . . . . . . . . . . . . . . . .32-3260-3 Bleed fuel system . . . . . . . . . . . . . . . . . . . .05-0560-6 Boom Remove and install . . . . . . . . . . . . . . . . .33-3340-8 Swing, remove and install . . . . . . . . . . .33-3340-13 Boom cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-100 Disassemble and assemble . . . . . . . . .33-3360-85 Remove and install . . . . . . . . . . . . . . . .33-3360-69 Boom pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-16 Boom swing Remove and install . . . . . . . . . . . . . . . .33-3360-81 Boom swing cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-100 Disassemble and assemble . . . . . . . . .33-3360-97 Boom swing or auxiliary pilot controller Disassemble and assemble . . . . . . . . .33-3360-40 Remove and install . . . . . . . . . . . . . . . .33-3360-38 Brake Park, propel motor disassemble-35D . . .02-0260-1 Park, propel motor disassemble-50D . .02-0260-10 Bucket Links, remove and install. . . . . . . . . . . . .33-3340-1 Bucket cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-100 Disassemble and assemble . . . . . . . . .33-3360-93 Remove and install - 50D . . . . . . . . . . .33-3360-78 Remove and install-35D . . . . . . . . . . . .33-3360-75 Bushing Measure wear, track chain . . . . . . . . . .01-0130-12 Bushings Piston pin inspect . . . . . . . . . . . . . . . . .04-0400-67 Bushings and pins, arm and boom Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-16 Bushings and seals Remove and install . . . . . . . . . . . . . . . .33-3340-20

C Cab Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Cab guarding . . . . . . . . . . . . . . . . . . . . . .000-0001-2 Cam followers Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-99 Camshaft Check end play . . . . . . . . . . . . . . . . . . .04-0400-93 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-96 Install . . . . . . . . . . . . . . . . . . . . . . . . . 04-0400-101 Measure bushing and bores . . . . . . . . .04-0400-73 Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-95

Index-1

Repair 101508

PN=1

Indx 1

Index

Indx 2

Page

Remove and install . . . . . . . . . . . . . . . .04-0400-95 Canopy Remove and install . . . . . . . . . . . . . . . . .18-1800-3 Carrier roller Track, measure wear . . . . . . . . . . . . . . .01-0130-7 Track, remove and install . . . . . . . . . . . .01-0130-7 Charge R134a system . . . . . . . . . . . . . . .18-1830-10 Chemical products Handling . . . . . . . . . . . . . . . . . . . . . . . .000-0001-5 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-13 Connecting rod Disassemble . . . . . . . . . . . . . . . . . . . . .04-0400-61 Disassemble and assemble . . . . . . . . .04-0400-61 Connecting rod bearing clearance Measure . . . . . . . . . . . . . . . . . . . . . . . .04-0400-53 Connecting rod side play Measure . . . . . . . . . . . . . . . . . . . . . . . .04-0400-53 Connecting rods Measure bearings . . . . . . . . . . . . . . . . .04-0400-69 Preliminary checks . . . . . . . . . . . . . . . .04-0400-60 Remove and install . . . . . . . . . . . . . . . .04-0400-53 Control valve Disassemble and assemble . . . . . . . . .33-3360-44 Remove and install . . . . . . . . . . . . . . . .33-3360-42 Controller Blade pilot, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .32-3260-6 Blade pilot, remove and install . . . . . . . .32-3260-3 Boom swing or auxiliary pilot, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-40 Boom swing or auxiliary pilot, Remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-38 Propel pilot, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-36 Propel pilot, remove and install . . . . . . .33-3360-33 Controller, pilot Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-29 Counterbalance valve Propel motor disassemble-35D . . . . . . . .02-0260-1 Propel motor disassemble-50D . . . . . . .02-0260-10 Counterweight Remove and Install-35D . . . . . . . . . . . . .17-1749-1 Remove and Install-50D . . . . . . . . . . . . .17-1749-3 Crankcase extension housing Remove and install . . . . . . . . . . . . . . . .04-0400-81 Crankshaft Check end play . . . . . . . . . . . . . . . . . . .04-0400-79 Failure analysis . . . . . . . . . . . . . . . . . . .04-0400-78 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-84 Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-89 Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-82

Repair . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-82 Replace front oil seal . . . . . . . . . . . . . .04-0400-78 Replace rear oil seal . . . . . . . . . . . . . . .04-0400-80 Cylinder Arm, disassemble and assemble. . . . . .33-3360-89 Arm, remove and install . . . . . . . . . . . .33-3360-72 Blade, disassemble and assemble . . . .33-3360-97 Bleed procedure, hydraulic . . . . . . . . . 33-3360-100 Boom swing, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-97 Boom Swing, remove and install . . . . . .33-3360-81 Boom, disassemble and assemble . . . .33-3360-85 Boom, remove and install . . . . . . . . . . .33-3360-69 Bucket, disassemble and assemble . . .33-3360-93 Bucket, remove and install - 50D . . . . .33-3360-78 Bucket, remove and install-35D. . . . . . .33-3360-75 Install bushings and seals . . . . . . . . . . .33-3340-20 Track adjuster, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-27 Cylinder block Clean and inspect . . . . . . . . . . . . . . . . .04-0400-72 Measure camshaft bushing and bores . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-73 Measure camshaft follower bores . . . . .04-0400-72 Repair . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-72 Cylinder bores Deglaze . . . . . . . . . . . . . . . . . . . . . . . .04-0400-76 Inspect and measure . . . . . . . . . . . . . .04-0400-75 Cylinder Head Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-43 Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-39 Remove and install . . . . . . . . . . . . . . . .04-0400-39 Cylinder head and valve Checks . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-41 Cylinder head and valves Assemble . . . . . . . . . . . . . . . . . . . . . . .04-0400-52 Disassemble . . . . . . . . . . . . . . . . . . . . .04-0400-45 Disassemble and assemble . . . . . . . . .04-0400-45 Cylinder head flatness Check . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-40 Cylinder head-to-piston clearance Measure . . . . . . . . . . . . . . . . . . . . . . . .04-0400-41

TM2264 (15OCT08)

D Dampener drive (flex coupling) Remove and install . . . . . . . . . . . . . . . .33-3360-26 Dealer fabricated tools DFT1087 track recoil spring guard . . . . .99-9900-5 ST4920 track recoil spring assembly. . . .99-9900-1

Index-2

Repair 101508

PN=2

Index

Page

Drive sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-18 Driving metal pins. . . . . . . . . . . . . . . . . . 000-0001-12

Gearbox Propel, disassemble and assemble-35D . . . . . . . . . . . . . . . . . . .02-0250-6 Propel, disassemble and assemble-50D . . . . . . . . . . . . . . . . . .02-0250-15 Propel, remove and install. . . . . . . . . . . .02-0250-1 Swing, disassemble and assemble-35D . . . . . . . . . . . . . . . . . . .43-4350-6 Swing, disassemble and assemble-50D . . . . . . . . . . . . . . . . . .43-4350-10 Swing, remove and install-35D . . . . . . . .43-4350-1 Swing, remove and install-50D . . . . . . . .43-4350-3 Grouser Track shoe, measure wear . . . . . . . . . .01-0130-11

E Electrical Precautions before welding . . . . . . . . . . .17-1740-1 Emergency preparation . . . . . . . . . . . . . .000-0001-5 Engine Check for excessive tightness. . . . . . . .04-0400-77 Remove and install-35D . . . . . . . . . . . . .04-0400-1 Remove and install-50D . . . . . . . . . . . . .04-0400-6 Evacuate R134a system. . . . . . . . . . . . . . .18-1830-9 Exhaust fumes . . . . . . . . . . . . . . . . . . . . .000-0001-4 Exhaust manifold Remove and install-35D . . . . . . . . . . . .04-0400-11 Remove and install-50D . . . . . . . . . . . .04-0400-13 Explosion Battery . . . . . . . . . . . . . . . . . . . . . . . . .000-0001-4

F Fire prevention . . . . . . . . . . . . . . . . . . . . .000-0001-4 Flush air conditioner system . . . . . . . . . . . .18-1830-3 Flywheel Remove and install . . . . . . . . . . . . . . . .04-0400-80 Flywheel housing Remove and install . . . . . . . . . . . . . . . .04-0400-82 Front idler Disassemble and assemble . . . . . . . . .01-0130-20 Front Idler Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Fuel injection nozzles Disassemble and assemble . . . . . . . . .04-0400-32 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-32 Remove and install . . . . . . . . . . . . . . . .04-0400-29 Fuel injection pump Remove and install . . . . . . . . . . . . . . . .04-0400-20 Fuel system Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-6 Fuel tank Remove and install-35D . . . . . . . . . . . . .05-0560-1 Remove and install-50D . . . . . . . . . . . . .05-0560-4

G Gear Idler, remove and install . . . . . . . . . . . 04-0400-102 TM2264 (15OCT08)

H Handhold use . . . . . . . . . . . . . . . . . . . . . .000-0001-6 Heater Control valve, remove and install . . . . .18-1830-17 Heater and air conditioner module Remove and install . . . . . . . . . . . . . . . .18-1830-14 Hydraulic Fittings, 30&deg; cone seat. . . . . . . . . .000-0003-9 Fittings, 37&deg; flare . . . . . . . . . . . . . .000-0003-9 Hydraulic cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-100 Hydraulic fitting Flared connections . . . . . . . . . . . . . . . 000-0003-10 Hydraulic oil tank Remove and install - 35D . . . . . . . . . . .33-3360-58 Remove and install - 50D . . . . . . . . . . .33-3360-59 Hydraulic pump Assemble - 35D . . . . . . . . . . . . . . . . . .33-3360-14 Assemble - 50D . . . . . . . . . . . . . . . . . .33-3360-23 Disassemble - 35D . . . . . . . . . . . . . . . . .33-3360-6 Disassemble - 50D . . . . . . . . . . . . . . . .33-3360-20 Remove and install . . . . . . . . . . . . . . . . .33-3360-1 Remove and install-50D . . . . . . . . . . . . .33-3360-3 Start-up procedure . . . . . . . . . . . . . . . .33-3360-26

I Idler Front, remove and install . . . . . . . . . . .01-0130-19 Idler gear Inspect . . . . . . . . . . . . . . . . . . . . . . . . 04-0400-103 Install . . . . . . . . . . . . . . . . . . . . . . . . . 04-0400-103 Remove . . . . . . . . . . . . . . . . . . . . . . . 04-0400-102 Remove and install . . . . . . . . . . . . . . . 04-0400-102

Index-3

Repair 101508

PN=3

Indx 3

Index

Indx 4

Page

Idler, front Disassemble and assemble . . . . . . . . .01-0130-20 Inch bolt and cap screw Torque value. . . . . . . . . . . . . . . . . . . . .000-0003-4 Injection pump Remove and install . . . . . . . . . . . . . . . .04-0400-20 Inspect machine . . . . . . . . . . . . . . . . . . . .000-0001-3 Intake manifold Remove and install . . . . . . . . . . . . . . . .04-0400-19

Swing, start-up procedure . . . . . . . . . . . .43-4360-6 Moving parts Safety . . . . . . . . . . . . . . . . . . . . . . . . . .000-0001-3 Servicing . . . . . . . . . . . . . . . . . . . . . . . .000-0001-3 Muffler Remove and install-35D . . . . . . . . . . . .04-0400-12 Remove and install-50D . . . . . . . . . . . .04-0400-15

L Lifting objects Special care . . . . . . . . . . . . . . . . . . . . .000-0001-9 Link Measure wear, track chain . . . . . . . . . .01-0130-12 Links Bucket, remove and install . . . . . . . . . . .33-3340-1

Nozzles Fuel Injection, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .04-0400-32 Fuel injection, inspect . . . . . . . . . . . . . .04-0400-32 Fuel injection, remove and install . . . . .04-0400-29

M Machine inspection. . . . . . . . . . . . . . . . . .000-0001-3 Machine movement Unintended . . . . . . . . . . . . . . . . . . . . . .000-0001-7 Machine tip over Avoiding . . . . . . . . . . . . . . . . . . . . . . . .000-0001-9 Main bearings Check clearance . . . . . . . . . . . . . . . . . .04-0400-87 Failure analysis . . . . . . . . . . . . . . . . . . .04-0400-78 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-84 Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-89 Repair . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-82 Manifold Exhaust, remove and install-35D. . . . . .04-0400-11 Exhaust, remove and install-50D. . . . . .04-0400-13 Intake, remove and install . . . . . . . . . . .04-0400-19 Rotary, disassemble and assemble. . . .02-0260-20 Measure connecting rod bearing clearance . . . . . . . . . . . . . . . . . . . . . . .04-0400-53 Measure connecting rod side play . . . . . .04-0400-53 Measure piston-to-cylinder head clearance . . . . . . . . . . . . . . . . . . . . . . .04-0400-41 Metal face seals Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . 000-0001-12 Metric bolt and cap screw Torque value. . . . . . . . . . . . . . . . . . . . .000-0003-1 Motor Swing, disassemble and assemble . . . . .43-4360-2 Swing, remove and install . . . . . . . . . . . .43-4360-1

TM2264 (15OCT08)

O-ring boss fittings . . . . . . . . . . . . . . . . . .000-0003-6 Oil Cooler Remove and Install - 35D . . . . . . . . . . .33-3360-64 Remove and Install - 50D . . . . . . . . . . .33-3360-66 Oil filter adapter Remove and install . . . . . . . . . . . . . . . 04-0400-110 Oil information R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6 Oil Leakage test Track roller . . . . . . . . . . . . . . . . . . . . . . .01-0130-3 Oil lines and fittings Checking. . . . . . . . . . . . . . . . . . . . . . . .000-0003-5 Oil pan Remove and install . . . . . . . . . . . . . . . 04-0400-105 Replace extension housing . . . . . . . . . .04-0400-81 Oil pressure regulating valve Remove and install . . . . . . . . . . . . . . . 04-0400-109 Oil pump Disassemble and inspect . . . . . . . . . . 04-0400-107 Remove and install . . . . . . . . . . . . . . . 04-0400-106 Oil seal Crankshaft front, replace . . . . . . . . . . . .04-0400-78 Operation qualification . . . . . . . . . . . . . . .000-0001-1

P Park brake Propel motor disassemble-35D . . . . . . . .02-0260-1 Propel motor disassemble-50D . . . . . . .02-0260-10

Index-4

Repair 101508

PN=4

Index

Page

Swing motor, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .43-4360-2 Swing motor, remove and install . . . . . . .43-4360-1 Pilot control shutoff lever . . . . . . . . . . . . .000-0001-7 Pilot Controler Pattern Conversion Valve Disassemble and Assemble . . . . . . . . .33-3360-56 Pilot controller Boom swing or auxiliary, Disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-40 Boom wing or auxiliary, Remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-38 Disassemble and assemble . . . . . . . . .33-3360-36 pilot controller Disassemble and assemble . . . . . . . . .33-3360-31 Pilot controller Propel, remove and install. . . . . . . . . . .33-3360-33 Remove and install . . . . . . . . . . . . . . . .33-3360-29 Pilot controller pattern conversion valve Remove and Install . . . . . . . . . . . . . . . .33-3360-53 Pins and bushings, arm and boom Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-16 Piston Disassemble . . . . . . . . . . . . . . . . . . . . .04-0400-61 Disassemble and assemble . . . . . . . . .04-0400-61 Piston pin bushings Measure . . . . . . . . . . . . . . . . . . . . . . . .04-0400-68 Piston pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-67 Measure . . . . . . . . . . . . . . . . . . . . . . . .04-0400-67 Measure bore in piston . . . . . . . . . . . . .04-0400-65 Piston rings Check groove wear . . . . . . . . . . . . . . . .04-0400-64 Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-71 Measure end gap . . . . . . . . . . . . . . . . .04-0400-64 Piston-to-cylinder head clearance Measure . . . . . . . . . . . . . . . . . . . . . . . .04-0400-41 Pistons Clean . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-62 Measure diameter . . . . . . . . . . . . . . . . .04-0400-66 Measure pin bore . . . . . . . . . . . . . . . . .04-0400-65 Preliminary checks . . . . . . . . . . . . . . . .04-0400-60 Remove and install . . . . . . . . . . . . . . . .04-0400-53 Visually inspect . . . . . . . . . . . . . . . . . . .04-0400-63 Pistons and connecting rods Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-55 Pitch Track chain, measure wear . . . . . . . . . .01-0130-13 Platform Remove and install . . . . . . . . . . . . . . . . .18-1800-5 Propel gearbox Disassemble and assemble-35D . . . . . . .02-0250-6 Disassemble and assemble-50D . . . . . .02-0250-15 Remove and install . . . . . . . . . . . . . . . . .02-0250-1

Propel motor Counterbalance valve, disassemble-35D . . . . . . . . . . . . . . . . .02-0260-1 Counterbalance valve, disassemble-50D . . . . . . . . . . . . . . . .02-0260-10 Disassemble and assemble-35D . . . . . . .02-0260-1 Disassemble and assemble-50D . . . . . .02-0260-10 Park brake disassemble-35D . . . . . . . . .02-0260-1 Park brake disassemble-50D . . . . . . . .02-0260-10 Propel speed change valve, disassemble-35D . . . . . . . . . . . . . . . . .02-0260-1 Propel speed change valve, disassemble-50D . . . . . . . . . . . . . . . .02-0260-10 Propel pilot controller Disaassemble and assemble. . . . . . . . .33-3360-36 Remove and install . . . . . . . . . . . . . . . .33-3360-33 Propel speed change valve Propel motor disassemble-35D . . . . . . . .02-0260-1 Propel motor disassemble-50D . . . . . . .02-0260-10 Protective equipment . . . . . . . . . . . . . . . .000-0001-2 Pump Hydraulic, assemble - 35D . . . . . . . . . .33-3360-14 Hydraulic, assemble - 50D . . . . . . . . . .33-3360-23 Hydraulic, disassemble - 35D . . . . . . . . .33-3360-6 Hydraulic, disassemble - 50D . . . . . . . .33-3360-20 Hydraulic, Remove and install. . . . . . . . .33-3360-1 Hydraulic, Remove and install-50D . . . . .33-3360-3 Hydraulic, start-up procedure . . . . . . . .33-3360-26 Oil , remove and install . . . . . . . . . . . . 04-0400-106 Oil, disassemble and inspect. . . . . . . . 04-0400-107 Purge air conditioner system . . . . . . . . . . .18-1830-3

TM2264 (15OCT08)

R Radiator Remove and Install-35D . . . . . . . . . . . . .05-0510-1 Remove and Install-50D . . . . . . . . . . . . .05-0510-4 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-12 Recoil spring and track adjuster Disassemble and assemble . . . . . . . . .01-0130-23 Remove and install . . . . . . . . . . . . . . . .01-0130-22 Refrigerant Cautions and proper handling . . . . . . . . .18-1830-1 Recover R134a . . . . . . . . . . . . . . . . . . . .18-1830-8 Recovery and charging station installation . . . . . . . . . . . . . . . . . . . . . .18-1830-7 R134a oil information . . . . . . . . . . . . . . .18-1830-6 Regulating valve, oil pressure Remove and install . . . . . . . . . . . . . . . 04-0400-109

Index-5

Repair 101508

PN=5

Indx 5

Index

Indx 6

Page

Remove and install Arm cylinder . . . . . . . . . . . . . . . . . . . . .33-3360-72 Boom cylinder . . . . . . . . . . . . . . . . . . . .33-3360-69 Boom swing . . . . . . . . . . . . . . . . . . . . .33-3360-81 Canopy . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-3 Counterweight-35D . . . . . . . . . . . . . . . . .17-1749-1 Counterweight-50D . . . . . . . . . . . . . . . . .17-1749-3 Heater control valve . . . . . . . . . . . . . . .18-1830-17 Platform . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-5 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-1 Seat base . . . . . . . . . . . . . . . . . . . . . . . .18-1821-2 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-4 Riding machine. . . . . . . . . . . . . . . . . . . . .000-0001-8 Rocker arm cover Remove and install . . . . . . . . . . . . . . . .04-0400-35 Rocker arm shaft Assemble . . . . . . . . . . . . . . . . . . . . . . .04-0400-38 Disassemble . . . . . . . . . . . . . . . . . . . . .04-0400-36 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-37 Rocker arm shaft assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-36 Roller Track carrier, measure wear . . . . . . . . . .01-0130-7 Track carrier, remove and install . . . . . . .01-0130-7 Track, disassemble and assemble . . . . .01-0130-4 Track, remove and install . . . . . . . . . . . .01-0130-1 Rotary manifold Disassemble and assemble . . . . . . . . .02-0260-20 Rubber track Remove and install . . . . . . . . . . . . . . . . .01-0130-9 Rubber track lugs Measure . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-9 R134a Charge system . . . . . . . . . . . . . . . . . . .18-1830-10 Evacuate system. . . . . . . . . . . . . . . . . . .18-1830-9 Refrigerant oil information . . . . . . . . . . . .18-1830-6 Refrigerant recovery . . . . . . . . . . . . . . . .18-1830-8 Refrigerant recovery and charging station installation . . . . . . . . . . . . . . . . . . . . . .18-1830-7

Metal face, inspect . . . . . . . . . . . . . . . . .01-0130-5 Seat Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Seat base Remove and install . . . . . . . . . . . . . . . . .18-1821-2 Seat belt Remove and install . . . . . . . . . . . . . . . . .18-1821-4 Use and maintenance . . . . . . . . . . . . . .000-0001-6 Servicing machine safely . . . . . . . . . . . . 000-0001-10 Shoe Track, remove and install . . . . . . . . . . 01-0130-13, 01-0130-15 Solenoid valve manifold Disassemble and assemble . . . . . . . . .33-3360-28 Spring Track recoil, remove and install. . . . . . .01-0130-22 Spring and adjuster Track recoil, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-23 Sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-18 Start-up procedure Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-26 Swing motor . . . . . . . . . . . . . . . . . . . . . .43-4360-6 Steel track Components inspection. . . . . . . . . . . . .01-0130-11 Remove and install . . . . . . . . . . . . . . . .01-0130-16 Steps use . . . . . . . . . . . . . . . . . . . . . . . . .000-0001-6 Structure Welding repair of major. . . . . . . . . . . . . .17-1740-2 Swing bearing Remove and install . . . . . . . . . . . . . . . .43-4350-17 Swing gearbox Disassemble and assemble-35D . . . . . . .43-4350-6 Disassemble and assemble-50D . . . . . .43-4350-10 Remove and install-35D . . . . . . . . . . . . .43-4350-1 Remove and install-50D . . . . . . . . . . . . .43-4350-3 Swing motor Start-up procedure . . . . . . . . . . . . . . . . .43-4360-6 Swing motor and park brake Disassemble and assemble . . . . . . . . . .43-4360-2 Remove and install . . . . . . . . . . . . . . . . .43-4360-1

S Safety Operator’s seat . . . . . . . . . . . . . . . . . . .000-0001-6 Safety equipment . . . . . . . . . . . . . . . . . . .000-0001-2 Safety information Recognizing . . . . . . . . . . . . . . . . . . . . .000-0001-1 Safety instructions . . . . . . . . . . . . . . . . . .000-0001-1 Safety symbols . . . . . . . . . . . . . . . . . . . . .000-0001-1 Seal Crankshaft front, replace . . . . . . . . . . . .04-0400-78

TM2264 (15OCT08)

T Tank Fuel, Remove and Install-35D. . . . . . . . .05-0560-1 Fuel, remove and install-50D . . . . . . . . .05-0560-4 Hydraulic oil, remove and install 35D . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-58

Index-6

Repair 101508

PN=6

Index

Page

Hydraulic oil, remove and install 50D . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-59 Thermostat Remove and install . . . . . . . . . . . . . . . .04-0400-16 Timing Gear Backlash Check . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-94 Timing gear cover Remove and install . . . . . . . . . . . . . . . .04-0400-92 Timing gear cover mounting plate Remove and install . . . . . . . . . . . . . . . 04-0400-104 Tip over Avoiding . . . . . . . . . . . . . . . . . . . . . . . .000-0001-9 Tools, dealer fabricated DFT1087 track recoil spring guard . . . . .99-9900-5 ST4920 track recoil spring assembly. . . .99-9900-1 Tooth Shank Remove and install - 35D . . . . . . . . . . . .33-3302-2 Tooth shank Remove and install - 50D . . . . . . . . . . . .33-3302-3 Torque value Flared connections . . . . . . . . . . . . . . . 000-0003-10 Flat face O-ring seal fitting . . . . . . . . . .000-0003-8 Inch SAE four bolt flange fitting. . . . . . 000-0003-11 Metric bolt and cap screw . . . . . . . . . . .000-0003-1 Metric cap screw. . . . . . . . . . . . . . . . . .000-0003-2 Metric four bolt flange fitting . . . . . . . . 000-0003-12 O-Ring boss fitting . . . . . . . . . . . . . . . .000-0003-6 Unified inch bolt and cap screw . . . . . .000-0003-4 30&deg; cone seat hydraulic fittings . . .000-0003-9 37&deg; flare hydraulic fittings . . . . . . .000-0003-9 Track Rubber, remove and install . . . . . . . . . . .01-0130-9 Shoe, remove and install . . . . . . . . . . 01-0130-13, 01-0130-15 Steel, components inspection . . . . . . . .01-0130-11 Steel, remove and install. . . . . . . . . . . .01-0130-16 Track adjuster and recoil spring Disassemble and assemble . . . . . . . . .01-0130-23 Remove and install . . . . . . . . . . . . . . . .01-0130-22 Track adjuster cylinder Disassemble and assemble . . . . . . . . .01-0130-27 Track carrier roller Measure wear . . . . . . . . . . . . . . . . . . . . .01-0130-7 Remove and install . . . . . . . . . . . . . . . . .01-0130-7 Track chain Bushing, measure wear . . . . . . . . . . . .01-0130-12 Link, measure wear. . . . . . . . . . . . . . . .01-0130-12 Pitch, measure wear . . . . . . . . . . . . . . .01-0130-13 Track shoe grouser, measure wear. . . .01-0130-11 Track lugs Rubber, measure . . . . . . . . . . . . . . . . . .01-0130-9 Track roller Disassemble and assemble . . . . . . . . . .01-0130-4

Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Test for oil leakage . . . . . . . . . . . . . . . . .01-0130-3 Track shoe grouser Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-11 Track shoe welded Remove and install . . . . . . . . . . . . . . . .01-0130-13 Track shoe with cap screws Remove and install . . . . . . . . . . . . . . . .01-0130-15

TM2264 (15OCT08)

U Upperstructure Remove and install . . . . . . . . . . . . . . . .43-4350-15

V Valve Control, disassemble and assemble . . .33-3360-44 Control, remove and install . . . . . . . . . .33-3360-42 Counterbalance, propel motor disassemble-35D . . . . . . . . . . . . . . . . .02-0260-1 Counterbalance, propel motor disassemble-50D . . . . . . . . . . . . . . . .02-0260-10 Pilot controller pattern conversion, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-53 Propel speed change, propel motor disassemble-35D . . . . . . . . . . . . . . . . .02-0260-1 Propel speed change, propel motor disassemble-50D . . . . . . . . . . . . . . . .02-0260-10 Valve cover Remove and install . . . . . . . . . . . . . . . .04-0400-35 Valve guides Inspect and measure . . . . . . . . . . . . . .04-0400-49 Valve Guides Replace . . . . . . . . . . . . . . . . . . . . . . . .04-0400-50 Valve lift Measure . . . . . . . . . . . . . . . . . . . . . . . .04-0400-91 Valve recess Check . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-49 Valve seats Grind. . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-46 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-45 Valve springs Inspect . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-51 Valves Clean . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-46 Inspect and measure . . . . . . . . . . . . . .04-0400-47 Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-48

Index-7

Repair 101508

PN=7

Indx 7

Index

Page

Indx 8

Waste disposal . . . . . . . . . . . . . . . . . . . . .000-0001-5 Water pump Remove and install . . . . . . . . . . . . . . . .04-0400-17 Welding on machine . . . . . . . . . . . . . . . . . .17-1740-1 Welding repair of major structure . . . . . . . .17-1740-2 Welding repairs . . . . . . . . . . . . . . . . . . . 000-0001-12

TM2264 (15OCT08)

Index-8

Repair 101508

PN=8