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270LC Excavator Repair

TECHNICAL MANUAL 270LC Excavator Repair TM1668 28JAN09 (ENGLISH)

For complete service information also see: 270LC Excavator Operation and Tests. . . . . POWERTECH 4.5 L & 6.8 L (4045 and 6068) Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . Alternators and Starting Motors . . . . . . . . . . Undercarriage Appraisal Manual . . . . . . . . .

TM1667 CTM104 CTM77 SP326

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

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

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

DX,TMIFC –19–29SEP98–1/1

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Introduction

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

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FAX NUMBER:

563-589-5800

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TX,TM,FAX –19–03JUL01–1/1

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Introduction

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Contents 00

SECTION 00—General Information Group 0001—Safety Group 0002—General Specifications Group 0003—Torque Values Group 0004—Fuels and Lubricants

SECTION 33—Excavator Group 3302—Buckets Group 3340—Frames Group 3360—Hydraulic System 01

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

SECTION 01—Tracks Group 0130—Track System

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

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

SECTION 04—Engine Group 0400—Removal and Installation

SECTION 05—Engine Auxiliary System Group 0505—Cold Weather Starting Aids Group 0510—Cooling System Group 0515—Speed Controls Group 0520—Intake System Group 0560—External Fuel Supply System

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

SECTION 16—Electrical System Group 1671—Batteries, Support, and Cables Group 1672—Alternator, Regulator, and Charging System Wiring Group 1674—Wiring Harness and Switches Group 1675—System Controls Group 1676—Instruments and Indicators

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

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

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

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Section 00

General Information Contents Page

Page

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

Mixing of Lubricants . . . . . . . . . . . . . . . . . . .00-0004-8

Group 0002—General Specifications 270LC Specifications. . . . . . . . . . . . . . . . . . .00-0002-1 270LC Engine Specifications. . . . . . . . . . . . .00-0002-3 270LC Drain and Refill Capacities. . . . . . . . .00-0002-3 Group 0003—Torque Values Unified Inch Bolt and Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1 Metric Bolt and Screw Torque Values . . . . . .00-0003-2 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3 Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-5 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6 Service Recommendations For Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-8 Service Recommendations for 37° Flare and 30° Cone Seat Connectors . . . . . . . . .00-0003-9 Service Recommendations For Flared Connections—Straight or Tapered Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . .00-0003-11 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . .00-0003-12 Group 0004—Fuels and Lubricants Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Lubricity Of Diesel Fuels . . . . . . . . . . . . . . . .00-0004-1 Low Sulfur Diesel Fuel Conditioner . . . . . . . .00-0004-2 Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .00-0004-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3 Do Not Use Galvanized Containers. . . . . . . .00-0004-3 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .00-0004-4 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-5 Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6 Track Roller, Front Idler, and Carrier Roller Oil . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6 Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Lubricant Storage . . . . . . . . . . . . . . . . . . . . .00-0004-8 Alternative and Synthetic Lubricants . . . . . . .00-0004-8 TM1668 (28JAN09)

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Group 0001

Safety 00 0001 1

Follow Safe Procedures

TS231

–19–07OCT88

Unsafe work practices are dangerous. Understand service procedure before doing work; do not attempt shortcuts.

TX,05,FF1611 –19–14JUN90–1/1

Prepare for Emergencies Be prepared if 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.

DX,FIRE2 –19–03MAR93–1/1

Handle Fluids Safely—Avoid Fires

TS202

–UN–23AUG88

Handle fuel with care; it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine. Fill fuel tank outdoors.

TX,05,FF1622 –19–14JUN90–1/2

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris.

TS227

–UN–23AUG88

Do not store oily rags; they can ignite and burn spontaneously.

TX,05,FF1622 –19–14JUN90–2/2

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Safety

Prevent Battery Explosions

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

TS204

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

–UN–23AUG88

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

DX,SPARKS –19–03MAR93–1/1

Handle Chemical Products Safely

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

–UN–26NOV90

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

TS1132

00 0001 2

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

DX,MSDS,NA –19–03MAR93–1/1

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Safety 00 0001 3

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself:

1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.

TS203

If acid is swallowed:

–UN–23AUG88

1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

DX,POISON –19–21APR93–1/1

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Avoid High-Pressure Fluids

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

X9811

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

–UN–08DEC08

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

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

DX,FLUID –19–03MAR93–1/1

Warn Others of Service Work Unexpected machine movement can cause serious injury.

–UN–08JUN90

Before performing any work on the machine, attach a “Do Not Operate” tag on the right control lever.

T7273AP

00 0001 4

TX,05,RR,566 –19–23JUL91–1/1

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Safety 00 0001 5

Park Machine Safely Before working on the machine: • Park machine on a level surface. • Lower bucket to the ground. • Turn auto-idle switch off. • Run engine with engine RPM dial at 1/3 position for 2 minutes. • Move engine RPM dial to slow idle position. • Turn key switch to OFF. Remove key from switch. • Pull pilot control shut-off lever to locked position. • Allow engine to cool.

TX,05,DH5002 –19–28MAY96–1/1

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

TS229

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

–UN–23AUG88

Support Machine Properly

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator’s manual.

DX,LOWER –19–24FEB00–1/1

Operate Only from Operator’s Seat

T6607AO

NEVER start engine while standing on ground. Start engine only from operator’s seat.

–UN–18OCT88

Avoid possible injury or machine damage. Do not start engine by shorting across starter terminals.

TX,05,FF1615 –19–14JUN90–1/1

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Safety

Stay Clear of Moving Parts

T7273AS

To prevent accidents, use care when working around rotating parts.

–UN–08JUN90

Entanglements in moving parts can cause serious injury.

TX,05,RR,572 –19–12JUN90–1/1

Avoid Power Lines

T7273AD

Never move any part of the machine or load closer to electric line than 3 m (10 ft) plus twice the line insulator length.

–UN–08JUN90

Serious injury or death can result from contact with electric lines.

TX,05,RR,594 –19–12JUN90–1/1

Use Handholds and Steps

When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine. Do not use any controls as handholds. Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

–UN–15JUN89

Falling is one of the major causes of personal injury.

T6981AN

00 0001 6

TX,05,DH832 –19–16MAR92–1/1

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Safety 00 0001 7

Keep Riders Off Machine

T7273AH

Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator’s view resulting in the machine being operated in an unsafe manner.

–UN–08JUN90

Only allow the operator on the machine. Keep riders off.

TX,05,RR,560 –19–05OCT90–1/1

Move and Operate Machine Safely

Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

T7273AL

Always keep the travel alarm in working condition. It warns people when the machine starts to move.

–UN–08JUN90

Bystanders can be run over. Know the location of bystanders before moving, swinging, or operating the machine.

TX,05,FF1806 –19–05OCT90–1/1

Wear Protective Clothing

TS206

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

–UN–23AUG88

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

DX,WEAR2 –19–03MAR93–1/1

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Safety

Protect Against Flying Debris

T6642DK

–UN–18OCT88

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

TX,05,FF1613 –19–14JUN90–1/1

Protect Against Noise

TS207

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

–UN–23AUG88

Prolonged exposure to loud noise can cause impairment or loss of hearing.

DX,NOISE –19–03MAR93–1/1

TS223

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

–UN–23AUG88

Illuminate Work Area Safely

DX,LIGHT –19–04JUN90–1/1

Service Machines Safely

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

–UN–23AUG88

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

TS228

00 0001 8

DX,LOOSE –19–04JUN90–1/1

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Safety 00 0001 9

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

TS953

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

–UN–15MAY90

Avoid Heating Near Pressurized Fluid Lines

DX,TORCH –19–10DEC04–1/1

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Safety

Beware of Exhaust Fumes

T6458AO

If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

–UN–18OCT88

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

02T,05,J9 –19–07JAN91–1/1

Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

TS226

–UN–23AUG88

Follow recommended procedure for removal and installation of components in the manual.

DX,LIFT –19–04JUN90–1/1

Service Cooling System Safely

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.

TS281

00 0001 10

DX,RCAP –19–04JUN90–1/1

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Safety 00 0001 11

Dispose of Waste Properly

Do not pour waste onto the ground, down a drain, or into any water source.

TS1133

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

–UN–26NOV90

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

DX,DRAIN –19–03MAR93–1/1

Work in a Clean Area Before starting a job, clean the work area. Remove objects that may be a safety hazard to the mechanic or bystanders.

TX,05,FF1624 –19–14JUN90–1/1

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Safety

Use Tools Properly

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS779

Use power tools only to loosen threaded tools and fasteners.

–UN–08NOV89

Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards.

Use only recommended replacement parts. (See Parts Catalog.)

TX,05,FF1614 –19–14JUN90–1/1

Replace Safety Signs

TS201

–UN–23AUG88

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

DX,SIGNS1 –19–04JUN90–1/1

Live With Safety

–19–07OCT88

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

TS231

00 0001 12

DX,LIVE –19–25SEP92–1/1

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Group 0002

General Specifications 00 0002 1

T102388

–UN–26JUL96

270LC Specifications

A—Sprocket Center to Idler Center B—Undercarriage Length C—Counterweight Clearance D—Rear End Swing Radius

D1—Rear End Swing Radius E—Overall Width (Excluding Back Mirrors) F—Cab Height

G—Minimum Ground Clearance H—Center of Sprocket to Center of Sprocket

NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with PCSA and SAE standards. Except where otherwise noted these specifications are based on a

I—Track Shoe Width J—Undercarriage Width K—Overall Length L—Transport Height

machine equipped with 800 mm (32 in.) shoes, counterweight, 3.75 m (12 ft 4 in.) arm, 891 kg (1966 lb) 1.34 m3 (1.75 yd3) bucket, full fuel tank, 79 kg (175 lb) operator and standard equipment.

Item

Measurement

Specification

A—Sprocket Center to Idler Center

Distance

4010 mm (13 ft 2 in.)

B—Undercarriage

Length

4860 mm (15 ft 11 in.)

C—Counterweight Clearance

Distance

1160 mm (3 ft 10 in.)

D—Rear End Swing Radius

Distance

2940 mm (9 ft 8 in.)

D1—Rear End Swing Radius

Distance

2940 mm (9 ft 8 in.)

Continued on next page

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General Specifications 00 0002 2

Item

Measurement

Specification

E—Overall Width (Excluding Back Mirrors)

Distance

2870 mm (9 ft 5 in.)

F—Cab

Height

3030 mm (9 ft 11 in.)

G—Minimum Ground Clearance

Distance

500 mm (1 ft 8 in.)

H—Center of Sprocket to Center of Sprocket

Distance

2590 mm (8 ft 6 in.)

I—Track Shoe

Width

600 mm (24 in.) or 800 mm (32 in.)

J—Undercarriage

Width

3190 mm (10 ft 6 in.) or 3390 mm (11 ft. 1 in.)

K—Machine

Overall Length

With 3100 mm (10 ft 2 in.) Arm: 10290 mm (33 ft 9 in.) With 3750 mm (12 ft 4 in.) Arm: 10310 mm (33 ft 10 in.)

Overall Length

L—Machine

Transport Height Transport Height

With 3100 mm (10 ft 2 in.) Arm: 3170 mm (10 ft 5 in.) With 3750 mm (12 ft 4 in.) Arm: 3350 mm (12 ft 0 in.)

TX,115,DH5703 –19–04APR00–2/2

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General Specifications 00 0002 3

270LC Engine Specifications Item

Measurement

Specification

John Deere POWERTECH 6.8 L Engine

Type

4-stroke cycle, turbocharged, charge air cooled diesel 106 x 127 mm (4.17 x 5.0 in.) 6 1-5-3-6-2-4 6.8 L (414 cu in.) 736 N•m (542 lb-ft) Suction 17:1 Pressure system with full-flow filter 24 Volt 400 Minutes @ 25 amps Reserve Capacity 134 kW (180 hp) Net SAE 27 515 kg (60,660 lb)

Bore and Stroke Cylinders Firing Order Displacement Net Torque @ 1400 RPM Cooling Fan Compression Ratio Lubrication Electrical System Batteries (2) 12 volt Rated Power @ 2150 RPM Operating Weight

POWERTECH is a trademark of Deere & Company.

TX,115,DH5429 –19–04APR00–1/1

270LC Drain and Refill Capacities Item

Measurement

Specification

Fuel Tank

Capacity

310 L (82 gal)

Cooling System

Capacity

22 L (6 gal)

Engine Oil

Capacity

19 L (5 gal) including filter change

Hydraulic Tank Oil

Capacity

148 L (39 gal)

Hydraulic System Oil

Capacity

270 L (71 gal)

Swing Gearbox Oil

Capacity

13 L (14 qt)

Propel Gearbox Oil (Each)

Capacity

6.0 L (6.5 qt)

Pump Drive Gearbox Oil

Capacity

1.0 L (1.1 qt)

TX,115,DH5535 –19–04APR00–1/1

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General Specifications 00 0002 4

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Group 0003

Torque Values 00 0003 1

Unified Inch Bolt and Screw Torque Values TS1671 –UN–01MAY03

Bolt or

SAE Grade 2a

SAE Grade 1 b

Lubricatedb

SAE Grade 5, 5.1 or 5.2 Lubricatedb

Dryc

Size

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

3.7

4.7

7.5

9.5

106

5/16

3/8

7/16

7.7

13.5

120

194

N•m

lb-ft

9.8

106

15.5

137

17.5

155

194

240

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

20.5

32.5

SAE Grade 8 or 8.2 Lubricatedb

Lubricated

1/4

Dry

Dryc

Screw

N•m

lb-in

Dryc N•m

lb-in

13.5

120

150

N•m

lb-ft

N•m

lb-ft

20.5

19.5

172

221

N•m

lb-ft

N•m

lb-ft

32.5

100

1/2

110

120

155

115

9/16

35.5

125

155

115

175

130

220

165

5/8

105

135

100

170

125

215

160

240

175

305

225

3/4

120

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

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

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, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C zinc flake coating. c

“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.

DX,TORQ1 –19–24APR03–1/1

TM1668 (28JAN09)

00-0003-1

270LC Excavator Repair 012809

PN=25

Torque Values

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

–UN–01MAY03

Metric Bolt and Screw Torque Values

TS1670

00 0003 2

Bolt or

Class 4.8

Class 8.8 or 9.8

Lubricateda

Size

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

4.7

8.9

11.3

100

M10

M12

11.5

102

204

N•m

lb-ft

29.5

Dryb

Lubricateda

Class 10.9

Screw

Dryb

Lubricateda N•m

lb-in

Class 12.9 Dryb

N•m

Lubricateda

lb-in

N•m

lb-in

Dryb N•m

lb-in

115

16.5

146

15.5

137

19.5

172

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

23.5

29.5

27.5

14.5

128

194

27.5

243

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

110

140

105

130

165

120

M14

120

150

110

175

130

220

165

205

150

260

190

M16

100

125

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

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C zinc flake coating. b

“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.

DX,TORQ2 –19–24APR03–1/1

TM1668 (28JAN09)

00-0003-2

270LC Excavator Repair 012809

PN=26

Torque Values 00 0003 3 –UN–18OCT88

Additional Metric Cap Screw Torque Values

T6873AA

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

–UN–18OCT88

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

T6873AB

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

–UN–18OCT88

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

T6873AC

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

Continued on next page

TM1668 (28JAN09)

00-0003-3

04T,90,M170 –19–29SEP99–1/2

270LC Excavator Repair 012809

PN=27

Torque Values 00 0003 4

METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

Nominal Dia

N•m

lb-ft

12 14

N•m

lb-ft

M-Bolt N•m

lb-ft

108

176

130

137

101

265

195

206

152

392

289

294

217

118

539

398

392

289

167

125

735

542

539

398

216

159

931

687

686

506

274

202

1372

1012

1029

759

392

289

1911

1410

1421

1049

539

398

2548

1890

1911

1410

735

542

3136

2314

2401

1772

931

687

Torque tolerance is ±10%.

04T,90,M170 –19–29SEP99–2/2

TM1668 (28JAN09)

00-0003-4

270LC Excavator Repair 012809

PN=28

Torque Values 00 0003 5

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.

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–08DEC08

Check Oil Lines And Fittings

Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately. Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.

TX,90,DH1559 –19–01AUG94–1/1

TM1668 (28JAN09)

00-0003-5

270LC Excavator Repair 012809

PN=29

Torque Values

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

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

T6243AE

00 0003 6

3. Tighten fitting to torque value shown on chart.

Continued on next page

TM1668 (28JAN09)

00-0003-6

04T,90,K66 –19–29SEP99–1/2

270LC Excavator Repair 012809

PN=30

Torque Values 00 0003 7

Angle Fitting

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

T6520AB

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

–UN–18OCT88

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

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

N•m

lb-ft

3/8-24 UNF

7/16-20 UNF

1/2-20 UNF

9/16-18 UNF

3/4-16 UNF

7/8-14 UNF

1-1/16-12 UN

102

1-3/16-12 UN

122

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

NOTE: Torque tolerance is ± 10%.

04T,90,K66 –19–29SEP99–2/2

TM1668 (28JAN09)

00-0003-7

270LC Excavator Repair 012809

PN=31

Torque Values 00 0003 8

Service Recommendations For Flat Face O-Ring Seal Fittings 1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.

fittings, use backup wrench on straight hose couplings.

2. Lubricate O-rings and install into grove using petroleum jelly to hold in place.

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

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

3/8-24

5/8

9/16

7/16-20

5/8

1/2-20

3/4

11/16

9/16-18

3/4

N•m

lb-ft

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

TM1668 (28JAN09)

00-0003-8

270LC Excavator Repair 012809

PN=32

Torque Values 00 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

TM1668 (28JAN09)

00-0003-9

270LC Excavator Repair 012809

PN=33

Torque Values

Service Recommendations For Flared Connections—Straight or Tapered Threads

–UN–18OCT88

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

T6873AE

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

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

–UN–18OCT88

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

Tapered Thread

Thread Size

N•m

lb-ft

N•m

lb-ft

1/8

1/4

3/8

1/2

3/4

176

130

157

116

343

253

1-1/2

196

145

539

398

255

188

588

434

Torque tolerance is ±10%.

With seat face.

T6873AD

00 0003 10

Tapered Thread

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

04T,90,M171 –19–28JAN92–1/1

TM1668 (28JAN09)

00-0003-10

270LC Excavator Repair 012809

PN=34

Torque Values 00 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. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

D—Single Piece Flange TORQUE CHART N•m

lb-ft

Nominal Flange Size

Cap Screw Size Min

Max

Min

Max

1/2

5/16-18 UNC

3/4

3/8-16 UNC

1-1/4

7/16-14 UNC

1-1/2

1/2-13 UNC

131

1/2-13 UNC

131

2-1/2

1/2-13 UNC

107

131

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

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

04T,90,K174 –19–01AUG94–1/1

TM1668 (28JAN09)

00-0003-11

270LC Excavator Repair 012809

PN=35

Torque Values

–UN–01MAR90

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB

00 0003 12

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

D—Single Piece Flange

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

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

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

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

TORQUE CHARTa

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

Thread

N•m

M10

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

M12

M14

157

116

M16

217

160

M18

334

246

M20

421

318

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

lb-ft

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

Metric standard thread.

04T,90,K175 –19–29SEP99–1/1

TM1668 (28JAN09)

00-0003-12

270LC Excavator Repair 012809

PN=36

Group 0004

Fuels and Lubricants 00 0004 1

Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Diesel fuels specified to EN 590 or ASTM D975 are recommended. In all cases, the fuel shall meet the following properties: • Cetane Number 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft). • Cold Filter Plugging Point(CFPP) below the expected low temperature OR Cloud Point at least 5°C (9°F) below the expected low temperature.

• Fuel Lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. • Sulfur content: – Sulfur content should not exceed 0.5% Sulfur content less than 0.05% is preferred. – If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%. – DO NOT use diesel fuel with sulfur content greater than 1.0%. Bio-diesel fuels with properties and meeting DIN 51606 or equivalent specifications may be used. DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

TX,45,JC1132 –19–22MAY96–1/1

Lubricity Of Diesel Fuels Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components. Diesel fuels for highway use in the United States and Canada now require sulfur content less than 0.05%. Diesel fuel in the European Union will require sulfur content less than 0.05% by 1 October 1996. Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks.

engine speed instability, hard starting, low power, and engine smoke. Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test. If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Consult your John Deere engine distributor or servicing dealer for more information.

Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion,

TX,45,JC1771 –19–08JAN97–1/1

TM1668 (28JAN09)

00-0004-1

270LC Excavator Repair 012809

PN=37

Fuels and Lubricants 00 0004 2

Low Sulfur Diesel Fuel Conditioner When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels. If the local fuel distributor will supply only low sulfur fuel, order and use John Deere PREMIUM DIESEL FUEL CONDITIONER. It provides lubricating properties along with other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion inhibitor and others. John Deere PREMIUM DIESEL FUEL CONDITIONER is specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only improve cold weather flow and stabilize long-term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps.

TX,45,DH5857 –19–15AUG97–1/1

Diesel Fuel Storage Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water and sediment from bottom of tank. Store fuel in a convenient place away from buildings. IMPORTANT: DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters, damage injection nozzles and injection pump. DO NOT use brass-coated containers for fuel storage. Brass is an alloy of copper and zinc.

Store diesel fuel in plastic, aluminum, and steel containers specially coated for diesel fuel storage. Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior to use, or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather. Consult your John Deere engine distributor or servicing dealer for recommendations and local availability. Always follow manufacturer’s directions on label.

TX,45,JC1772 –19–08JAN97–1/1

TM1668 (28JAN09)

00-0004-2

270LC Excavator Repair 012809

PN=38

Fuels and Lubricants 00 0004 3

Fuel Tank CAUTION: Handle fuel carefully. If the engine is hot or running, do not fill the fuel tank. Do not smoke while you fill fuel tank or work on fuel system. To avoid condensation, fill the fuel tank at the end of each day’s operation. Capacity is 310 L (82 gal).

TX,45,DH5538 –19–01JUL96–1/1

Do Not Use Galvanized Containers IMPORTANT: Diesel fuel stored in galvanized containers reacts with zinc coating on the container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and fuel pumps. DO NOT USE a galvanized container to store diesel fuel.

Store fuel in: • plastic containers. • aluminum containers. • specially coated steel containers made for diesel fuel. DO NOT USE brass-coated containers: brass is an alloy of copper and zinc.

MX,FLBT,C –19–04JUN90–1/1

TM1668 (28JAN09)

00-0004-3

270LC Excavator Repair 012809

PN=39

Other oils may be used if they meet one or more of the following:

40 o C

104o F

30 o C

86 o F

20 o C

68 o F

10 o C

50 o F

0o C

32 o F

-10 o C

14 o F

-20 o C

-4 o F

-30 o C

-22 o F

-40 o C

-40 o F

–UN–18JUL07

Extended service intervals may apply when John Deere PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 engine oils are used. Consult your John Deere dealer for more information.

122o F

TS1687

• ACEA Oil Sequence E7 • ACEA Oil Sequence E6 • ACEA Oil Sequence E5 • ACEA Oil Sequence E4

SAE 0W-40

Oils meeting one of the following specifications are also recommended:

SAE 5W-30

SAE-15W-40

John Deere PLUS-50 oil is preferred.

SAE 10W-30

Use oil viscosity based on the expected air temperature range during the period between oil changes.

50 o C

SAE 40

Diesel Engine Oil

SAE 10W-40

00 0004 4

SAE 30

Fuels and Lubricants

Oil Viscosities for Air Temperature Ranges

• John Deere TORQ-GARD SUPREME • API Service Category CJ-4 • API Service Category CI-4 PLUS • API Service Category CI-4 • API Service Category CH-4 • API Service Category CG-4 • API Service Category CF-4 • ACEA Oil Sequence E3 • ACEA Oil Sequence E2 If oils meeting API CG-4, API CF-4, or ACEA E2 are used, reduce the service interval by 50%. Multi-viscosity diesel engine oils are preferred. Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates. If diesel fuel with sulfur content greater than 0.50% (5000 ppm) is used, reduce the service interval by 50%.

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

TM1668 (28JAN09)

Continued on next page

00-0004-4

DX,ENOIL –19–06APR07–1/2

270LC Excavator Repair 012809

PN=40

Fuels and Lubricants 00 0004 5

DO NOT use diesel fuel with sulfur content greater than 1.00% (10 000 ppm).

DX,ENOIL –19–06APR07–2/2

Hydraulic Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: • John Deere HY-GARD • John Deere Low Viscosity HY-GARD Other oils may be used if they meet one of the following:

–UN–10OCT97

• John Deere Standard JDM J20C • John Deere Standard JDM J20D Use the following oil when a biodegradable fluid is required:

Manufacturer

Oil

Mobil

DTE 25

Shell

Tellus 46

Caltex Oil

Rando Oil HD46

Texaco Inc.

Rando Oil HD46

Chevron U.S.A. Inc.

Chevron AW46

Esso Standard Oil

NUTO H46

TS1660

• John Deere1 BIO-HY-GARD

HY-GARD is a trademark of Deere & Company BIO-HY-GARD is a trademark of Deere & Company 1 BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD should not be mixed with mineral oils because this reduces the biodegradability and makes proper oil recycling impossible.

CED,TX14740,6951 –19–07JAN00–1/1

TM1668 (28JAN09)

00-0004-5

270LC Excavator Repair 012809

PN=41

Fuels and Lubricants

Gear Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: • John Deere GL-5 GEAR LUBRICANT • John Deere EXTREME-GARD

–UN–14MAR96

Other oils may be used if they meet API Service Classification GL-5.

TS1653

00 0004 6

EXTREME-GARD is a trademark of Deere & Company.

DX,GEOIL –19–07JUL99–1/1

Track Roller, Front Idler, and Carrier Roller Oil Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105B or MIL-L-2105C).

TX,45,DH5142 –19–09AUG96–1/1

TM1668 (28JAN09)

00-0004-6

270LC Excavator Repair 012809

PN=42

Fuels and Lubricants 00 0004 7

Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following greases are preferred: • John Deere SD POLYUREA GREASE

Other greases may be used if they meet the following: • NLGI Performance Classification GC-LB

TS1667

• John Deere HD MOLY GREASE • John Deere HD LITHIUM COMPLEX GREASE • John Deere HD WATER RESISTANT GREASE • John Deere GREASE-GARD

–UN–30JUN99

The following greases are also recommended:

IMPORTANT: Some types of grease thickener are not compatible with others.

CED,TX14740,6952 –19–07JAN00–1/1

Oil Filters Filtration of oils is critical to proper operation and lubrication. Always change filters regularly as specified in this manual. Use filters meeting John Deere performance specifications.

DX,FILT –19–18MAR96–1/1

TM1668 (28JAN09)

00-0004-7

270LC Excavator Repair 012809

PN=43

Fuels and Lubricants 00 0004 8

Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used.

Make certain that all containers are properly marked to identify their contents.

Use clean containers to handle all lubricants.

Properly dispose of all old containers and any residual lubricant they may contain.

Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation.

DX,LUBST –19–18MAR96–1/1

Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Consult your John Deere dealer to obtain information and recommendations.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

DX,ALTER –19–15JUN00–1/1

Mixing of Lubricants In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.

Consult your John Deere dealer to obtain specific information and recommendations.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

DX,LUBMIX –19–18MAR96–1/1

TM1668 (28JAN09)

00-0004-8

270LC Excavator Repair 012809

PN=44

Section 01

Tracks Contents

Page

Group 0130—Track System Service Equipment and Tools . . . . . . . . . . . .01-0130-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .01-0130-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5 Track Roller Measure Wear . . . . . . . . . . . . . . . . . . . . . .01-0130-7 Remove and Install . . . . . . . . . . . . . . . . . .01-0130-8 Disassemble and Assemble. . . . . . . . . . .01-0130-10 Test for Oil Leakage . . . . . . . . . . . . . . . .01-0130-12 Track Carrier Roller Measure Wear . . . . . . . . . . . . . . . . . . . . .01-0130-13 Remove and Install . . . . . . . . . . . . . . . . .01-0130-13 Disassemble and Assemble. . . . . . . . . . .01-0130-15 Metal Face Seals Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-17 Track Shoe Grouser Measure Wear . . . . . . . . . . . . . . . . . . . . .01-0130-19 Remove and Install . . . . . . . . . . . . . . . . .01-0130-20 Track Link Measure Wear . . . . . . . . . . . . . . . . . . . . .01-0130-21 Track Bushing Measure Wear . . . . . . . . . . . . . . . . . . . . .01-0130-22 Track Pitch Measure . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-23 Track Chain Remove . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-24 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-26 Disassemble and Assemble. . . . . . . . . . .01-0130-28 Disassemble and Assemble to Replace Broken Part . . . . . . . . . . . . . . . . . . . . .01-0130-29 Track Sag Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-31 Sprocket Remove and Install . . . . . . . . . . . . . . . . .01-0130-33 Front Idler Measue Wear . . . . . . . . . . . . . . . . . . . . .01-0130-34 Remove and Install . . . . . . . . . . . . . . . . .01-0130-35 Disassemble . . . . . . . . . . . . . . . . . . . . . .01-0130-36 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-37 Test for Oil Leakage . . . . . . . . . . . . . . . .01-0130-39 Track Adjuster and Recoil Spring Remove and Install . . . . . . . . . . . . . . . . .01-0130-40 Disassemble and Assemble. . . . . . . . . . .01-0130-41 Track Adjuster Cylinder Disassemble and Assemble. . . . . . . . . . .01-0130-46

TM1668 (28JAN09)

01-1

270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

01-2

270LC Excavator Repair 012809

PN=2

Group 0130

Track System Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

01 0130 1

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21701 –19–23MAY00–1/16

Special Roller Caliper. . . . . . . . . . . . . . . . . . JT055191 To measure undercarriage component wear.

1 Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

CED,OUOE003,21701 –19–23MAY00–2/16

17-1/2 and 30-Ton Puller Set. . . . . . . . . . . . D01047AA To remove brackets and bushings from track rollers and front idler. CED,OUOE003,21701 –19–23MAY00–3/16

Rubber Stopper/Leak Detector Kit. . . . . . . . . D05361ST To test lower track roller and front idler for oil leakage.

CED,OUOE003,21701 –19–23MAY00–4/16

Gauge To measure pressure.

CED,OUOE003,21701 –19–23MAY00–5/16

Hex Key Wrench . . . . . . . . . . . . . . . . . . . . . . . . 8 mm To loosen cap screws for track carrier roller removal.

Continued on next page

TM1668 (28JAN09)

01-0130-1

CED,OUOE003,21701 –19–23MAY00–6/16

270LC Excavator Repair 012809

PN=47

Track System Depth Gauge (200 mm Ruler) . . . . . . . . . . . . JT055211 To measure undercarriage components for wear. 01 0130 2

1 Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

CED,OUOE003,21701 –19–23MAY00–7/16

Right Angle Attachment . . . . . . . . . . . . . . . . JT055341 To measure undercarriage components for wear.

1 Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

CED,OUOE003,21701 –19–23MAY00–8/16

300 mm Ruler . . . . . . . . . . . . . . . . . . . . . D05231ST1 To measure undercarriage components for wear.

1 Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

CED,OUOE003,21701 –19–23MAY00–9/16

100 mm Caliper . . . . . . . . . . . . . . . . . . . .D17524C11 To measure outer diameter of track chain bushings

1 Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

Continued on next page

TM1668 (28JAN09)

01-0130-2

CED,OUOE003,21701 –19–23MAY00–10/16

270LC Excavator Repair 012809

PN=48

Track System Metric Tape Measure . . . . . . . . . . . . . . . . . . JT055201 To measure undercarriage components for wear. 01 0130 3

1 Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

CED,OUOE003,21701 –19–23MAY00–11/16

50-Ton Master Pin Pusher/Installer . . . . . . . . D01030AA To remove and install master pin in track train master link.

CED,OUOE003,21701 –19–23MAY00–12/16

18t (20-Ton) Jack To place under track recoil spring disassembly and assembly tool. CED,OUOE003,21701 –19–23MAY00–13/16

Track Recoil Spring Disassembly and Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST49201 To compress the track recoil spring for disassembly and assembly.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21701 –19–23MAY00–14/16

Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11101 To install on bottom plate of ST4920 Track Recoil Spring Disassembly and Assembly Tool.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

Continued on next page

TM1668 (28JAN09)

01-0130-3

CED,OUOE003,21701 –19–23MAY00–15/16

270LC Excavator Repair 012809

PN=49

Track System Track Recoil Spring Disassembly and Assembly Guard Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT10871

01 0130 4

Used with ST4920 Track Recoil Spring Disassembly and Assembly Tool.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21701 –19–23MAY00–16/16

Other Material Number

Name

Use

PT569 (U.S.) TY6332 (Canadian)

NEVER-SEEZ Anti-Seize Lubricant

Apply to pin, bracket bore, and shaft for carrier and lower track rollers and front idler.

TY16285 (U.S.) CXTY16285 (Canadian) 7649 (LOCTITE)

Cure Primer

To speed cure time of adhesives and sealants.

TY9375 (U.S.) TY9480 (Canadian) 592 (LOCTITE)

Pipe Sealant

Apply to threads of plugs and threaded fittings.

TY2098 (U.S.)

Multi-Purpose Grease

To provide a light seal between surfaces.

T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE)

Thread Lock and Sealer (High Strength)

Apply to threads of sprocket cap screws.

T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)

Thread Lock and Sealer (Medium Strength)

Apply to threads of front idler drain plug.

NEVER-SEEZ is a trademark of Emhart Chemical Group LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

CED,OUOE003,21702 –19–23MAY00–1/1

01-0130-4

270LC Excavator Repair 012809

PN=50

Track System

Specifications Item

Measurement

Specification

Track Roller Track Roller Tread

175.0 mm (6.89 in.) new 165.0 mm (6.50 in.) minimum used

Machine

Weight

27 515 kg (60,660 lb) approximate

Track Roller

Weight

55 kg (120 lb) approximate

Roller-to-Frame Cap Screw

Torque

540 N•m (400 lb-ft)

Roller Guard Cap Screw

Torque

450 N•m (332 lb-ft)

Plug

Torque

29 N•m (21 lb-ft)

Track Carrier Roller Tread

120.0 mm (4.72 in.) new 110.0 mm (4.33 in.) minimum used

Roller-to-Frame Cap Screw

Torque

265 N•m (195 lb-ft)

Roller-to-Support Cap Screw

Torque

64 N•m (47 lb-ft)

600 mm (24 in.) Track Shoe Grouser

Height

26.0 mm (1.02 in.) new 20.0 mm (0.78 in.) minimum used

800 mm (32 in.) Track Shoe Grouser

Height

31.0 mm (1.22 in.) new 25.0 mm (0.98 in.) minimum used

Shoe-to-Link Cap Screw

Torque

298 N•m (220 lb-ft) plus 1/2 turn

Wear

116.4 mm (4.58 in.) new 111.0 mm (4.37 in.) minimum used

01 0130 5

Track Carrier Roller

Track Shoe

Track Link Track Link

Continued on next page

TM1668 (28JAN09)

01-0130-5

CED,OUOE003,21704 –19–23MAY00–1/3

270LC Excavator Repair 012809

PN=51

Track System

Item

Measurement

Specification

Track Chain Bushing

66.7 mm (2.63 in.) new 61.9 mm (2.44 in.) minimum used

Track Chain

Pitch

816.0 mm (32.13 in.) new 834.0 mm (32.83 in.) maximum used

Track with 800 mm (32 in.) Shoes

Weight

2304 kg (5080 lb) approximate

Track with 600 mm (24 in.) Shoes

Weight

1839 kg (4055 lb) approximate

Shoe-to-Link Cap Screw

Torque

298 N•m (220 lb-ft) plus 1/2 turn

Machine

Weight

27 515 kg (60,660 lb)

Track

Sag

340—380 mm (13-3/8—15 in.)

Nut and Valve Assembly

Torque

147 N•m (108 lb-ft)

Sprocket

Weight

65 kg (145 lb) approximate

Sprocket-to-Propel Gearbox Cap Screw

Torque

470 N•m (350 lb-ft)

Front Idler Flange

Height

22.5 mm (0.89 in.) new 27.5 mm (1.08 in.) maximum used

Front Idler

Weight

165 kg (360 lb) approximate

Yoke-to-Bracket Cap Screw

Torque

206 N•m (152 lb-ft)

Track Chain 01 0130 6

Sprocket

Front Idler

Track Adjuster and Recoil Spring Track Adjuster Cylinder and Recoil Weight Spring

151 kg (330 lb) approximate

Recoil Spring Disassembly and Assembly Tool

225 kg (496 lb) approximate

Weight

Continued on next page

TM1668 (28JAN09)

01-0130-6

CED,OUOE003,21704 –19–23MAY00–2/3

270LC Excavator Repair 012809

PN=52

Track System

Item

Measurement

Specification

Recoil Spring

Free Length Compressed Length

677 mm (26.7 in.) approximate 557 mm (21.93 in.)

Special Plug

Torque

15 N•m (11 lb-ft)

Nut

Torque

147 N•m (110 lb-ft)

Flange Cap Screw

Torque

64 N•m (47 lb-ft)

01 0130 7

CED,OUOE003,21704 –19–23MAY00–3/3

Measure Track Roller Wear SPECIFICATIONS

175.0 mm (6.89 in.) new

Track Roller Tread OD

165.0 mm (6.50 in.) minimum used

SERVICE EQUIPMENT AND TOOLS JT05519a Special Roller Caliper a

Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

T87973

Track Roller Tread OD

–UN–08NOV88

Track Roller

Minimum used is the maximum allowable wear for rebuilding roller tread. Under some conditions roller wear can be uneven. If wear is uneven, rollers may be interchanged to even out the wear. Measure roller tread diameter using a caliper such as the JT05519 Special Roller Caliper. Track Roller—Specification Track Roller Tread—OD...................................... 175.0 mm (6.89 in.) new OD ............................................................... 165.0 mm (6.50 in.) minimum used

NOTE: See Track Roller Measurement (Without Rock Guards) for additional information.

TX,01,UU3726 –19–26JAN09–1/1

TM1668 (28JAN09)

01-0130-7

270LC Excavator Repair 012809

PN=53

Track System

Remove and Install Track Roller

–UN–06DEC88 T6876FG

CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing lower track roller. The approximate weight of machine is 27 515 kg (60,660 lb). Track Roller—Specification Machine—Weight .................................................... 27 515 kg (60,660 lb) approximate

2. Put shop stands under machine.

TX,01,UU3727 –19–06APR00–1/3

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

–UN–28NOV90

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

T7396DZ

01 0130 8

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.

Continued on next page

TM1668 (28JAN09)

01-0130-8

TX,01,UU3727 –19–06APR00–2/3

270LC Excavator Repair 012809

PN=54

Track System

CAUTION: The approximate weight of track roller is 55 kg (120 lb).

–UN–25OCT88

Track Roller—Specification Track Roller—Weight ...................................... 55 kg (120 lb) approximate

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

T6585TN

5. Repair or replace parts where necessary. (See following procedure in this group.) 6. Install roller on track link with flat portion of bracket pointing toward undercarriage.

A—Cap Screw (4 used) B—Track Roller

7. Lower excavator enough to allow cap screws (A) to be installed. 8. Tighten cap screws (A). Track Roller—Specification Roller-to-Frame Cap Screw— Torque ......................................................................... 540 N•m (400 lb-ft)

9. If removed, install roller guard and tighten cap screws. Track Roller—Specification Roller Guard Cap Screw—Torque .............................. 450 N•m (332 lb-ft)

10. Adjust track sag. (See procedure in this group).

TX,01,UU3727 –19–06APR00–3/3

TM1668 (28JAN09)

01-0130-9

270LC Excavator Repair 012809

PN=55

01 0130 9

Track System

Disassemble and Assemble Track Roller

T8310AG

–UN–27SEP94

01 0130 10

A—Bracket (2 used) B—Roller C—Bushing (2 used)

D—Metal Face Seal (2 used) E—Bracket

F—O-Ring (2 used) G—Pin (2 used)

H—Plug (2 used) I—Axle

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

1. Remove plug (H) and drain oil. 2. Remove pin (G). 3. Remove bracket (E) using a bearing puller attachment and adapters from puller set.

6. Remove axle (I) from roller.

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: Only remove bushing if replacement is necessary. 7. Remove bushing (C) using a 2 jaw puller and adapters from puller set. 8. Replace parts as necessary.

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

Continued on next page

TM1668 (28JAN09)

01-0130-10

TX,0130,VV2677 –19–23MAY00–1/3

270LC Excavator Repair 012809

PN=56

Track System

T8310AH

–UN–21SEP94

01 0130 11

A—Plug (2 used) B—Bracket (2 used)

C—Pin (2 used) D—O-Ring (2 used)

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

G—Roller H—Axle

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

9. Apply a thin film of oil to bushings (F). Install bushings. 10. Install O-ring (D) on axle (H).

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

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.

16. Install axle to bracket.

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

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

12. Install O-ring in seal rings.

18. Install axle and assembled parts to roller (G).

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

19. With plug (A) removed, check and add oil as necessary. (See Track Roller, Front Idler, and Carrier Roller Oil in Group 0004.)

NEVER-SEEZ is a trademark of Emhart Chemical Group.

TM1668 (28JAN09)

20. Repeat procedure for other side of axle.

Continued on next page

01-0130-11

TX,0130,VV2677 –19–23MAY00–2/3

270LC Excavator Repair 012809

PN=57

Track System 21. Install plug (A) and tighten. Track Roller—Specification Plug—Torque ............................................................ 29 N•m (21 lb-ft) 01 0130 12

TX,0130,VV2677 –19–23MAY00–3/3

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

2. Remove the plug.

4. Holding plug so it is not pushed out, slowly pressurize oil cavity to 110 ± 18 kPa (1.1 ± 0.3 bar) (16 ± 4 psi) using air. 5. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has decreased.

T109691B

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

A—Plug, Adapter, and Connector B—Connector 1/8 M NPT x 7/16-20 M 37° C—Air Hose D—Pressure Gauge E—Snubber (Needle) Valve F—Air Pressure Regulator

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

TX,0130,VV2678 –19–06APR00–1/1

TM1668 (28JAN09)

01-0130-12

270LC Excavator Repair 012809

PN=58

Track System

Measure Track Carrier Roller Wear SPECIFICATIONS

Track Carrier Roller Tread OD

120.0 mm (4.72 in.) new

Track Carrier Roller Tread OD

110.0 mm (4.33 in.) minimum used

–UN–29JAN98

Track Carrier Roller

SERVICE EQUIPMENT AND TOOLS a

T6813AQ

JT05519 Special Roller Caliper a

Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

Used minimum tread diameter is the maximum allowable wear for rebuilding wear surface. Measure roller tread diameter using a caliper such as the JT05519 Special Roller Caliper. Track Carrier Roller—Specification Track Carrier Roller Tread—OD ......................... 120.0 mm (4.72 in.) new OD ............................................................... 110.0 mm (4.33 in.) minimum used

NOTE: See Carrier Roller Measurement for additional information.

TX,0130,VV2679 –19–26JAN09–1/1

Remove and Install Track Carrier Roller

–UN–28NOV90

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

T7396DZ

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

Continued on next page

TM1668 (28JAN09)

01-0130-13

TX,0130,VV2680 –19–06APR00–1/4

270LC Excavator Repair 012809

PN=59

01 0130 13

Track System 2. Using a jack, raise track link enough to permit carrier roller removal.

–UN–02JUN97

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

T108834B

3. Install wooden blocks between track link and frame.

TX,0130,VV2680 –19–06APR00–2/4

4. Remove cap screws (B) and carrier roller (A). 5. Repair or replace parts where necessary. (See following procedure in this group.) –UN–03APR97

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

7. Check carrier roller oil level by removing plug in cover and add oil as necessary. (See Track Roller, Front Idler, and Carrier Roller Oil in Group 0004.)

T108835B

Track Carrier Roller—Specification Roller-to-Frame Cap Screw— Torque ......................................................................... 265 N•m (195 lb-ft)

A—Carrier Roller B—Cap Screw (4 used)

TX,0130,VV2680 –19–06APR00–3/4

8. Remove wooden blocks and jack.

–UN–02JUN97

9. Adjust track sag. (See procedure in this group).

T108834B

01 0130 14

TX,0130,VV2680 –19–06APR00–4/4

TM1668 (28JAN09)

01-0130-14

270LC Excavator Repair 012809

PN=60

Track System

Disassemble and Assemble Track Carrier Roller

T101920

–UN–12JUL96

01 0130 15

A—Plug B—Cover

C—Cap Screw (2 used) D—Thrust Washer

E—Bushing F—Roller

1. Remove plug (A) to drain oil.

G—Metal Face Seal H—Support

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

2. Loosen two cap screws (C) by placing an 8 mm hex key wrench through oil plug drain hole.

Continued on next page

TM1668 (28JAN09)

01-0130-15

TX,0130,VV2681 –19–04MAY00–1/2

270LC Excavator Repair 012809

PN=61

Track System

01 0130 16

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

A volatile, non-petroleum base solvent or talcum power may be used as a lubricant. 10. Install one half of metal face seal into support (H). 11. Apply a thin coat of oil to the metal faces on each half of the seal. (See Track Roller, Front Idler, and Carrier Roller Oil in Fuels and Lubricants Group.)

4. Inspect bushing (E) and shaft on support (H). IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A seal must be kept together as a set because of wear patterns on seal ring face. 5. Remove metal face seal (G) from roller (F) and support (H). Keep seal rings together as a matched set with faces together to protect surfaces. 6. Inspect metal face seal. (See procedure listed in this group.) Metal face seals may be reused if they are not worn or damaged. 7. Replace parts as necessary. IMPORTANT: O-rings may slip when roller is turning if O-rings and seat surfaces are not clean, dry and oil free. 8. Thoroughly clean the O-rings and seat surfaces in roller, support, and seal bushings using a volatile, non-petroleum base solvent and lint-free tissue.

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

15. Fill roller with approximately 85 mL (2.9 oz.) of clean oil through plug (A) hole. (See Track Roller, Front Idler, and Carrier Roller Oil in Fuels and Lubricants Group.) 16. Clean threads of plug (B). Apply cure primer. 17. Apply pipe sealant to thread of plug. Install plug.

9. Install O-ring on seal rings. NOTE: Current carrier roller metal face seals use a tapered fit. There is no longer the “pop” into place fit previously used.

TX,0130,VV2681 –19–04MAY00–2/2

TM1668 (28JAN09)

01-0130-16

270LC Excavator Repair 012809

PN=62

Track System

Inspect Metal Face Seals 1. Inspect for the following conditions to determine if seal rings (A) can be reused: 01 0130 17

• The narrow, highly polished sealing area (E) must be in the outer half of seal ring face (D). • Sealing area must be uniform and concentric with the ID and OD of seal ring (A). • 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)

TX,0130,VV2682 –19–06APR00–1/3

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

–UN–05DEC96

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

T85080

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

Continued on next page

TM1668 (28JAN09)

01-0130-17

TX,0130,VV2682 –19–06APR00–2/3

270LC Excavator Repair 012809

PN=63

Track System

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. 5. Apply a thin film of oil to seal ring face. Put face of seal rings together to protect sealing surfaces.

T82840

01 0130 18

–UN–23FEB89

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

A—Seal Face

TX,0130,VV2682 –19–06APR00–3/3

TM1668 (28JAN09)

01-0130-18

270LC Excavator Repair 012809

PN=64

Track System

Measure Track Shoe Grouser Wear SPECIFICATIONS

26.0 mm (1.02 in.) new

600 mm (24 in.) Track Shoe Grouser Height

20.0 mm (0.78 in.) minimum used

800 mm (32 in.) Track Shoe Grouser New

31.0 mm (1.22 in.) new

800 mm (32 in.) Track Shoe Grouser Height

25.0 mm (0.98 in.) minimum used

T82859

600 mm (24 in.) Track Shoe Grouser Height

–UN–08NOV88

Track Shoe

SERVICE EQUIPMENT AND TOOLS JT05521a Depth Gauge (200 mm Ruler) JT05534a Right Angle Attachment D05231STa 300 mm Ruler a

Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

Minimum used is the maximum allowable wear for rebuilding grouser bars with weld. Measure grouser height of several track shoes to find an average using a depth gauge such as the JT05521 200 mm Ruler, JT05534 Right Angle Attachment, and D05231ST 300 mm Ruler. Track Shoe—Specification 600 mm (24 in.) Track Shoe Grouser—Height .................................................... 26.0 mm (1.02 in.) new 600 mm (24 in.) Track Shoe Grouser—Height ................................... 20.0 mm (0.78 in.) minimum used 800 mm (32 in.) Track Shoe Grouser—Height .................................................... 31.0 mm (1.22 in.) new 800 mm (32 in.) Track Shoe Grouser—Height ................................... 25.0 mm (0.98 in.) minimum used

NOTE: See Grouser Bar Height for additional information.

TX,01,UU3728 –19–26JAN09–1/1

TM1668 (28JAN09)

01-0130-19

270LC Excavator Repair 012809

PN=65

01 0130 19

Track System

Remove and Install Track Shoe 1. Remove nuts, cap screws, and shoe.

–UN–25OCT88

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

T6557DO

3. Install all track shoe nuts with rounded corners (A) against the link and chamfered edges (B) away from the link. Be sure nut is properly positioned in the link so there is full contact between the nut and the link. 4. Tighten cap screws in pattern shown to 298 N•m (220 lb-ft) plus 1/2 turn. Specification Shoe-to-Link Cap Screw—Torque ......... 298 N•m (220 lb-ft) plus 1/2 turn

–UN–23FEB89

T6794AM

–UN–23FEB89

A—Rounded Edge B—Chamfered Edge

T6352AH

01 0130 20

Tightening Pattern

TX,01,UU3729 –19–05DEC96–1/1

TM1668 (28JAN09)

01-0130-20

270LC Excavator Repair 012809

PN=66

Track System

Measure Track Chain Link Height Wear SPECIFICATIONS

Track Link Wear

116.4 mm (4.58 in.) new

Track Link Wear

111.0 mm (4.37 in.) minimum used

T82864

SERVICE EQUIPMENT AND TOOLS

–UN–08NOV88

Track Link

JT05521 Depth Gauge (200 mm Ruler) JT05534a Right Angle Attachment D05231STa 300 mm Ruler a

Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

Minimum used is the maximum allowable wear for rebuilding links. Measure height of several links to find an average using a depth gauge such as the JT05521 200 mm Ruler, JT05534 Right Angle Attachment, and D05231ST 300 mm Ruler. Track Link—Specification Track Link—Wear ................................................ 116.4 mm (4.58 in.) new Wear ............................................................ 111.0 mm (4.37 in.) minimum used

NOTE: See Link Height for additional information.

TX,01,UU3730 –19–26JAN09–1/1

TM1668 (28JAN09)

01-0130-21

270LC Excavator Repair 012809

PN=67

01 0130 21

Track System

Measure Track Chain Bushing Wear SPECIFICATIONS

Track Chain Bushing OD

66.7 mm (2.63 in.) new

Track Chain Bushing OD

61.9 mm (2.44 in.) minimum used

SERVICE EQUIPMENT AND TOOLS D17524C1a 100 mm Caliper

T82865

01 0130 22

–UN–08NOV88

Track Chain

Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit. Use Caliper to Measure Wear

Minimum used is the maximum allowable wear for turning pins and bushings. Measure bushing outer diameter at the two worn places using a caliper such as the D17524C1 100 mm Caliper. Track Chain—Specification Track Chain Bushing—OD .................................... 66.7 mm (2.63 in.) new Track Chain Bushing—OD ................... 61.9 mm (2.44 in.) minimum used

NOTE: See Bushing Outer Diameter—Sealed and Lubricated Track Chain for additional information.

TX,01,UU3731 –19–26JAN09–1/1

TM1668 (28JAN09)

01-0130-22

270LC Excavator Repair 012809

PN=68

Track System

Measure Track Chain Pitch SPECIFICATIONS

816.0 mm (32.13 in.) new

Trach Chain Pitch

834.0 mm (32.83 in.) maximum used

SERVICE EQUIPMENT AND TOOLS a

JT05520 Metric Tape Measure a

Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

T6813AL

Track Chain Pitch

–UN–29JAN98

Trach Chain

Maximum used is the maximum allowable wear for turning pins and bushings. 1. Remove slack by putting a wooden block between sprocket and chain, then slowly move machine in reverse to tighten chain. 2. Measure pitch across several four-link sections as shown, except section on either side of master pin, to find average chain wear. Use a tape measure such as the JT05520 Metric Tape. Track Chain—Specification Track Chain—Pitch............................................ 816.0 mm (32.13 in.) new Track Chain—Pitch................................... 834.0 mm (32.83 in.) maximum used

NOTE: See Track Chain Pitch Extension—Sealed and Lubricated Track Chain for additional information.

TX,01,UU3732 –19–26JAN09–1/1

TM1668 (28JAN09)

01-0130-23

270LC Excavator Repair 012809

PN=69

01 0130 23

Track System

Remove Track Chain

–UN–28NOV90 T7396DZ

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

TX,01,UU3733 –19–06APR00–1/3

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

–UN–25OCT88

2. Move track chain so master pin (A) is over front idler or sprocket. 3. Remove snap ring (B). 4. Remove the track shoe on each side of master pin.

T6585TH

01 0130 24

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

5. Put wooden blocks in front of idler and under chain so chain does not fall when master pin is removed. A—Master Pin B—Snap Ring

6. Raise machine so sprocket teeth clear chain.

Continued on next page

TM1668 (28JAN09)

01-0130-24

TX,01,UU3733 –19–06APR00–2/3

270LC Excavator Repair 012809

PN=70

Track System

Track Chain—Specification Track with 800 mm (32 in.) Shoes—Weight .......................................... 2304 kg (5080 lb) approximate Track with 600 mm (24 in.) Shoes—Weight .......................................... 1839 kg (4055 lb) approximate

T7945AA

The approximate weight of each track with 600 mm (24 in.) shoes is 1839 kg (4055 lb).

–UN–23APR93

CAUTION: The approximate weight of each track with 800 mm (32 in.) shoes is 2304 kg (5080 lb).

NOTE: The OD of master pin at the snap ring end is larger than the other end. The master pin OD differences shown are exaggerated.

8. Pry apart chain and lower end of track. 9. Remove spacers (B). 10. Slowly turn sprocket in reverse direction to remove track chain from excavator.

T6876BO

–UN–06DEC88

7. Remove master pin (A) through snap ring side of track using a 50-Ton Master Pin Pusher/Installer.

A—Master Pin B—Spacer (2 used) C—Link D—Master Bushing E—Link F—Master Link G—Snap

TX,01,UU3733 –19–06APR00–3/3

TM1668 (28JAN09)

01-0130-25

270LC Excavator Repair 012809

PN=71

01 0130 25

Track System

Install Track Chain 1. Position track chain so section on ground has pin boss on links toward rear of unit. 2. Install end of chain on sprocket and slowly turn sprocket in forward direction to pull chain across top of frame to front idler.

T6557DN

–UN–25OCT88

3. Install spacers. Pull ends of chain together.

TX,0130,VV2689 –19–06APR00–1/5

4. Install master pin (A) and snap ring (B) from snap ring side of track. 5. Lower machine.

T6585TH

–UN–25OCT88

A—Master Pin B—Snap Ring

TX,0130,VV2689 –19–06APR00–2/5

–UN–25OCT88

6. Apply a light coat of oil to cap screws threads and install shoes.

T6557DO

01 0130 26

Continued on next page

TM1668 (28JAN09)

01-0130-26

TX,0130,VV2689 –19–06APR00–3/5

270LC Excavator Repair 012809

PN=72

Track System 7. Install all track shoe nuts with rounded edges (A) against the link and chamfered edges (B) away from the link. Be sure nut is properly positioned in the link so there is full contact between the nut and the link.

T6794AM

–UN–23FEB89

A—Rounded Edge B—Conferred Edge

TX,0130,VV2689 –19–06APR00–4/5

8. Tighten cap screws in the sequence shown plus 1/2 turn.

T6352AH

9. Adjust track sag. (See procedure in this group.)

–UN–23FEB89

Track Chain—Specification Shoe-to-Link Cap Screw—Torque ......... 298 N•m (220 lb-ft) plus 1/2 turn

TX,0130,VV2689 –19–06APR00–5/5

TM1668 (28JAN09)

01-0130-27

270LC Excavator Repair 012809

PN=73

01 0130 27

Track System

Disassemble and Assemble Track Chain

T109680

–UN–30MAY97

01 0130 28

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

E—Master Bushing F—Spacer (2 used) G—Track Link (48 used) H—Seal (96 used)

I—Bushing (50 used) J—Shoe (49 used) K—Pin (48 used)

1. Measure track components (A—K). (See procedures in this group. For more detailed measurements, see Undercarriage Wear)

L—Chamfer Side (Bushing Side) M—Concentric Ring Side

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

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

3. Install seal (H) so side with chamfer (L) is toward bushing and side with concentric rings (M) is toward link.

TX,01,UU3996 –19–26JAN09–1/1

TM1668 (28JAN09)

01-0130-28

270LC Excavator Repair 012809

PN=74

Track System

Disassemble and Assemble Track Chain to Replace Broken Part

–UN–26OCT88

1. Remove track shoe from broken link assembly. Remove the track. (See procedure in this group.)

T5821AG

IMPORTANT: When making cuts using cutting torch, be careful not to cut or gouge good parts. 2. Cut links, bushing, and pin at points (A) to remove broken link (B). A—Cut Points B—Broken Link

TX,0130,VV2691 –19–26JAN09–1/4

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

T5821AH

–UN–26OCT88

A—Grind Points

TX,0130,VV2691 –19–26JAN09–2/4

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

T5821AI

–UN–26OCT88

A—Pin Stubs B—Hammer

Continued on next page

TM1668 (28JAN09)

01-0130-29

TX,0130,VV2691 –19–26JAN09–3/4

270LC Excavator Repair 012809

PN=75

01 0130 29

Track System NOTE: When new parts are ordered, have dealer assemble the new links and master bushing.

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

–UN–24MAY89

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

T5821AJ

01 0130 30

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

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

TX,0130,VV2691 –19–26JAN09–4/4

TM1668 (28JAN09)

01-0130-30

270LC Excavator Repair 012809

PN=76

Track System

Adjust Track Sag SPECIFICATIONS

Machine Weight

27 515 kg (60,660 lb)

Track Sag

340—380 mm (13-3/8—15 in.)

Nut and Valve Assembly Torque

147 N•m (108 lb-ft)

–UN–06DEC88

Track Chain

T6876FG

OTHER MATERIAL TY2098 Multi-Purpose Grease

1. Swing upperstructure to side. Lower boom to raise track off the ground. Keep the angle between boom and arm at 90—110° with the round side of bucket on the ground. CAUTION: Prevent possible injury from unexpected machine movement. Put blocks or shop stands under machine frame to support machine while measuring track sag. The approximate weight of machine is 27 515 kg (60,660 lb). Track Chain—Specification Machine—Weight .................................................... 27 515 kg (60,660 lb)

2. Put blocks or shop stands under the machine to support machine. 3. Slowly turn the track forward for two revolution and then in reverse for two revolution. Stop the track while moving in reverse direction so all track sag is at the bottom.

TX,01,UU3734 –19–06APR00–1/3

4. Measure track sag (A) between track shoe and track roller mounting surface.

–UN–23FEB89

Track Chain—Specification Track—Sag ................................................ 340—380 mm (13-3/8—15 in.)

T6457DL

A—Track Sag

Continued on next page

TM1668 (28JAN09)

01-0130-31

TX,01,UU3734 –19–06APR00–2/3

270LC Excavator Repair 012809

PN=77

01 0130 31

Track System

CAUTION: Prevent possible injury from high pressure grease in track adjuster cylinder. Do not remove grease fitting or nut and valve assembly to release grease.

5. To decrease track sag, add multi-purpose grease to track adjuster cylinder through grease fitting (A) using a grease gun with a maximum capacity of 68 950 kPa (690 bar) (10 000 psi).

–UN–28NOV90

IMPORTANT: Prevent possible damage to track components. Do not use the grease fitting on track adjuster cylinder for lubrication. Use this grease fitting only for track adjustment.

T7396DZ

01 0130 32

A—Grease Fitting B—Nut and Valve Assembly C—Track Adjuster Grease Relief

To increase track sag, loosen nut and valve assembly (B) one turn to release grease from track adjuster cylinder through hole (C) in rod. Tighten nut and valve assembly when track sag is correct. Track Chain—Specification Nut and Valve Assembly—Torque .............................. 147 N•m (108 lb-ft)

NOTE: If piston in track adjuster cylinder does not move, remove the cylinder to make repairs.

TX,01,UU3734 –19–06APR00–3/3

TM1668 (28JAN09)

01-0130-32

270LC Excavator Repair 012809

PN=78

Track System

Remove and Install Sprocket

T6876AL

–UN–25OCT88

IMPORTANT: Sprocket must be replaced when the tooth tips become excessively rounded, worn, or chipped to prevent excessive wear to chain. If machine is driven in one direction a majority of the time, wear will be on one side of teeth. To extend service life, change sprockets from one side of machine to the other. 1. Disconnect and remove track chain from sprocket (A). (See procedure in this group.) 2. Lift side of machine so sprocket teeth clear chain.

–UN–25OCT88

3. Remove cap screws (B). CAUTION: The approximate weight of sprocket is 65 kg (145 lb).

4. Attach sprocket to hoist, remove and move to other side of machine or replace. 5. Clean threads of cap screws (B). Apply cure primer and thread lock and sealer (high strength).

T6876AM

Sprocket—Specification Sprocket—Weight ............................................ 65 kg (145 lb) approximate

A—Sprocket B—Cap Screw (24 used)

6. Install sprocket (A) and tighten cap screws (B). Sprocket—Specification Sprocket-to-Propel Gearbox Cap Screw—Torque ............................................................ 470 N•m (350 lb-ft)

7. Lower machine. 8. Install track chain. (See procedure in this group.) 9. Adjust track sag. (See procedure in this group.)

TX,01,UU3735 –19–06APR00–1/1

TM1668 (28JAN09)

01-0130-33

270LC Excavator Repair 012809

PN=79

01 0130 33

Track System

Measure Front Idler Wear SPECIFICATIONS

Front Idler Flange Height

22.5 mm (0.89 in.) new

Front Idler Flange Height

27.5 mm (1.08 in.) maximum used

SERVICE EQUIPMENT AND TOOLS

T87972

01 0130 34

–UN–08NOV88

Front Idler

JT05521 Depth Gauge (200 mm Ruler) JT05534a Right Angle Attachment D05231STa 300 mm Ruler a

Tools are available in a kit such as the JT05518A or JT05523 Undercarriage Inspection Service Tool Kit.

Maximum used flange height is the maximum allowable height of flange for rebuilding wear surface. Measure height of flange using a depth gauge such as the JT05521 200 mm Ruler, JT05534 Right Angle Attachment, and D05231ST 300 mm Ruler. Front Idler—Specification Front Idler Flange—Height .................................... 22.5 mm (0.89 in.) new Height ........................................................... 27.5 mm (1.08 in.) maximum used

NOTE: See Front Idler Flange Height for additional information.

TX,01,UU3736 –19–26JAN09–1/1

TM1668 (28JAN09)

01-0130-34

270LC Excavator Repair 012809

PN=80

Track System

Remove and Install Front Idler 1. Disconnect track chain. (See procedure in this group.)

–UN–25OCT88

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

T6876BU

CAUTION: The approximate weight of front idler is 165 kg (360 lb). Front Idler—Specification Front Idler—Weight ....................................... 165 kg (360 lb) approximate

3. Attach front idler to hoist, remove from frame, and repair or replace idler. (See procedure in this group.)

A—Front Idler

4. Install front idler and slide rearward into frame as far as possible.

TX,01,UU3737 –19–06APR00–1/1

TM1668 (28JAN09)

01-0130-35

270LC Excavator Repair 012809

PN=81

01 0130 35

Track System

Disassemble Front Idler

T102031

–UN–12JUL96

01 0130 36

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

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

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

G—O-Ring (2 used) H—Axle

I—Yoke J—Cap Screw (4 used)

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

2. Remove drain plug (D) and drain oil. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

NOTE: Remove bushings only if replacement is necessary. 6. Remove bushing using a 2-jaw puller and adapters from 17-1/2 and 30-ton puller set. 7. Replace parts as necessary.

3. Remove pins (A), brackets (E), O-rings (G) and metal face seals (F). 4. Inspect metal face seals. (See procedure in this group.) Keep seal rings together as a matched set with seal ring faces together to protect surfaces.

TX,0130,VV2696 –19–05DEC96–1/1

TM1668 (28JAN09)

01-0130-36

270LC Excavator Repair 012809

PN=82

Track System

Assemble Front Idler

T8312AA

–UN–21SEP94

01 0130 37

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

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

G—O-Ring (2 used) H—Axle

1. Apply a thin film of oil to bushings (B). Install bushings so flange is tight against shoulder of idler. 2. Install O-rings (G) on axle. 3. Apply a thin layer of NEVER-SEEZ anti-seize lubricant or an equivalent to end of axle from O-ring to end of axle and to bore in bracket (E). 4. Install axle into bracket.

I—Yoke J—Cap Screw (4 used)

free so O-rings do not slip when idler is turning. 6. Thoroughly clean the O-rings and seat surfaces in idler, brackets, and seal rings using volatile, non-petroleum base solvent and lint-free tissues. 7. Install O-ring on seal rings. NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant.

5. Apply NEVER-SEEZ anti-seize lubricant or an equivalent to pin (A). Install pin. IMPORTANT: O-rings and seat surfaces for O-rings must be clean, dry, and oil

8. Install seals in bracket and idler. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore.

NEVER-SEEZ is a trademark of Emhart Chemical Group.

Continued on next page

TM1668 (28JAN09)

01-0130-37

TX,0130,VV2697 –19–23MAY00–1/2

270LC Excavator Repair 012809

PN=83

Track System

01 0130 38

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

13. Clean threads of drain plug (D). Apply cure primer.

10. Install axle (H) into idler.

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

11. Repeat procedure for other side of idler.

Front Idler—Specification Yoke-to-Bracket Cap Screw— Torque................................................................... 206 N•m (152 lb-ft)

12. Fill front idler with approximately 265 mL (8.96 oz) of oil. (See Track Roller, Front Idler, and Carrier Roller Oil in Group 0004.)

14. Apply pipe sealant to threads of plug and install.

TX,0130,VV2697 –19–23MAY00–2/2

TM1668 (28JAN09)

01-0130-38

270LC Excavator Repair 012809

PN=84

Track System

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

01 0130 39

3. Install parts (A—F) as shown. Plug, adapter, and connector are from a leak detector kit such as the D05361ST Rubber Stopper/Leak Detector Kit. 4. Holding plug so it is not pushed out, slowly pressurize oil cavity to 110 ± 28 kPa (1.1 ± 0.3 bar) (16 ± 4 psi) using air. 5. Close valve and wait for a minimum of 30 seconds to check for oil leakage. Check gauge to see if air pressure has decreased.

–UN–13JUN97

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

T109791B

7. Check oil level in idler. If the oil level is down and there is no external leakage, check for a leak from oil cavity to interior of idler wheel. 8. Clean threads of plug using clean and cure primer. 9. Apply thread lock and sealer (medium strength) to threads of plug (G). Install and tighten plug.

A—Plug, Adapter and Connector B—Connector 1/8 M NPT x 7/16-20 M 37° C—Hose D—Pressure Gauge E—Snubber (Needle) Valve F—Air Pressure Regulator G—Drain Plug

TX,0130,VV2698 –19–05DEC96–1/1

TM1668 (28JAN09)

01-0130-39

270LC Excavator Repair 012809

PN=85

Track System

Remove and Install Track Adjuster and Recoil Spring

T6557CX

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

A—Track Adjuster

A compression tool must be used for disassembly and assembly because of the extreme preload on spring. 2. Slide track adjuster (A) forward, using a pry bar.

TX,01,UU3738 –19–06APR00–1/2

CAUTION: The approximate weight of track adjuster cylinder and recoil spring is 151 kg (330 lb). Track Adjuster and Recoil Spring—Specification Track Adjuster Cylinder and Recoil Spring—Weight .................................. 151 kg (330 lb) approximate

–UN–25OCT88

3. Attach track adjuster to hoist, remove from frame, and repair or replace.

T6557CY

0130 40

–UN–25OCT88

1. Remove track chain and front idler. (See procedures in this group.) 01

TX,01,UU3738 –19–06APR00–2/2

TM1668 (28JAN09)

01-0130-40

270LC Excavator Repair 012809

PN=86

Track System

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

01 0130 41

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

–UN–25OCT88

The approximate weight of track recoil spring disassembly and assembly tool is 225 kg (496 lb).

T6557DY

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

1. Place an 18t (20-ton) jack on bottom of ST4920 Track Recoil Spring Disassembly and Assembly Tool (A). Remove nuts (B) and top plate (C). (See Section 99 for instruction to make tool.)

A—Track Recoil Spring Disassembly and Assembly Tool B—Nut (12 used) C—Top Plate

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

Continued on next page

TM1668 (28JAN09)

01-0130-41

TX,0130,VV2700 –19–06APR00–1/4

270LC Excavator Repair 012809

PN=87

Track System

3. Connect track adjuster (B) to a hoist using a lifting strap (A). 4. Put track adjuster in assembly tool with cylinder end on DFT1110 Spacer (C). (See Section 99 for instructions to make tool.) 5. Remove lifting strap.

–UN–28APR92

A—Lifting Strap B—Track Adjuster C—Spacer

T7720AF

01 0130 42

Continued on next page

TM1668 (28JAN09)

01-0130-42

TX,0130,VV2700 –19–06APR00–2/4

270LC Excavator Repair 012809

PN=88

Track System 6. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (F). (See Section 99 for instruction to make tool.) 7. Install plate (A) and nuts (B) with smallest opening to allow access to nut (D).

01 0130 43

8. Extend jack ram so there is enough travel to release spring to specified free length. Track Adjuster and Recoil Spring—Specification Recoil Spring—Free Length ..................... 677 mm (26.7 in.) approximate

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

TM1668 (28JAN09)

01-0130-43

TX,0130,VV2700 –19–06APR00–3/4

270LC Excavator Repair 012809

PN=89

Track System 11. Raise upper half of guard tool (F). Tighten T-handles. 12. Operate jack to compress spring just enough so nut (D) can be removed. 13. Lower jack ram to release spring force. 14. Disassemble and assemble track adjuster cylinder. (See procedure in this group.) 15. Put track adjuster cylinder in assembly in assembly tool with cylinder end on spacer. 16. Install spacer on rod. 17. Install spring using a hoist and lifting strap. 18. Install retainer plate.

–UN–28APR92

19. Install guard tool. 20. Install top plate. Install nuts. 21. Raise upper half of guard tool. Tighten T-handles.

T7720AH

01 0130 44

22. Operate jack to compress spring to specified length. Track Adjuster and Recoil Spring—Specification Recoil Spring—Compressed Length .......................................................................... 557 mm (21.93 in.)

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

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

Track Adjuster and Recoil Spring—Specification Special Plug—Torque...................................................... 15 N•m (11 lb-ft)

24. Tighten nut. Track Adjuster and Recoil Spring—Specification Nut—Torque ................................................................ 147 N•m (110 lb-ft)

TX,0130,VV2700 –19–06APR00–4/4

TM1668 (28JAN09)

01-0130-44

270LC Excavator Repair 012809

PN=90

Track System

01 0130 45

TM1668 (28JAN09)

01-0130-45

270LC Excavator Repair 012809

PN=91

Track System

Disassemble and Assemble Track Adjuster Cylinder

T109275

–UN–17JUN97

01 0130 46

Continued on next page

TM1668 (28JAN09)

01-0130-46

TX,0130,VV2701 –19–23MAY00–1/3

270LC Excavator Repair 012809

PN=92

Track System A—Cap Screw (4 used) B—Flange C—Piston (Rod) D—Wear Ring

E—U-Ring Packing F—Snap Ring G—Rod H—O-Ring

I—Cylinder J—Recoil Spring K—Spacer L—Retainer Plate

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

M—Special Plug N—Nut O—Valve P—Dust Seal

NOTE: It is not necessary to remove the recoil spring to replace wear ring (D) and U-ring packing (E). To replace O-ring (H), remove recoil spring (J) and rod (G). The recoil spring is removed using the ST4920 Track Recoil Spring Disassembly and Assembly Tool. (See procedure in this group.) 1. Remove recoil spring if necessary. (See Disassemble and Assemble Track Adjuster and Recoil Spring in this group.)

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

Continued on next page

TM1668 (28JAN09)

01-0130-47

TX,0130,VV2701 –19–23MAY00–2/3

270LC Excavator Repair 012809

PN=93

01 0130 47

Track System

T105584

–UN–05DEC96

01 0130 48

A—Cap Screw (4 used) B—Flange C—Piston (Rod)

D—Wear Ring E—U-Ring Packing

F—Snap Ring G—Rod

H—O-Ring I—Cylinder

2. If necessary, remove rod (G) from cylinder (I) using a press.

5. Install U-ring packing (E) with lip towards inside of cylinder.

3. Repair or replace parts as necessary.

6. Tighten cap screws (A).

4. Apply multi-purpose grease to U-ring packing (E), wear ring (D), and O-ring (H). Fill grooves inside flange (B) with grease.

Track Adjuster and Recoil Spring—Specification Flange Cap Screw—Torque ..................................... 64 N•m (47 lb-ft)

TX,0130,VV2701 –19–23MAY00–3/3

TM1668 (28JAN09)

01-0130-48

270LC Excavator Repair 012809

PN=94

Section 02

Axles and Suspension Systems Contents Page

Group 0250—Axle Shaft, Bearings, and Reduction Gears Service Equipment and Tools . . . . . . . . . . . .02-0250-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0250-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Towing Machine . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Propel Gearbox Remove and Install . . . . . . . . . . . . . . . . . .02-0250-4 Disassemble . . . . . . . . . . . . . . . . . . . . . . .02-0250-8 Metal Face Seals Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-16 Propel Gearbox Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-18

Group 0260—Hydraulic System Essential Tools . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Service Equipment and Tools . . . . . . . . . . . .02-0260-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0260-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0260-4 Propel Motor and Park Brake Remove and Install . . . . . . . . . . . . . . . . . .02-0260-5 Start-Up Procedure . . . . . . . . . . . . . . . . . .02-0260-7 Disassemble . . . . . . . . . . . . . . . . . . . . . . .02-0260-8 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0260-14 Propel Motor Brake Valve Housing Disassemble and Assemble. . . . . . . . . . .02-0260-22 Rotary Manifold Remove and Install . . . . . . . . . . . . . . . . .02-0260-26 Disassemble and Assemble. . . . . . . . . . .02-0260-30 Air Test . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-32

TM1668 (28JAN09)

02-1

270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

02-2

270LC Excavator Repair 012809

PN=2

Group 0250

Axle Shaft, Bearings, and Reduction Gears Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21576 –19–08MAY00–1/4

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . JT01748 To remove and install ring gear, drum, and sprocket.

CED,OUOE003,21576 –19–08MAY00–2/4

Propel Gearbox Nut Wrench . . . . . . . . . . . . . DF1036A1 To remove and install propel gearbox retaining nut.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21576 –19–08MAY00–3/4

Holding Bar . . . . . . . . . . . . . . . . . . . . . . . . DFT11091 Used as a support guide when removing and installing propel gearbox retaining nut.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21576 –19–08MAY00–4/4

TM1668 (28JAN09)

02-0250-1

270LC Excavator Repair 012809

PN=97

02 0250 1

Axle Shaft, Bearings, and Reduction Gears

Other Material Number

Name

Use

TY16285 (U.S.) CXTY16285 (Canadian) 7649 (LOCTITE)

Cure Primer

To speed cure time of adhesives and sealants.

Thread Lock and Sealer (High Strength)

Apply to threads of lock plate and ring gear-to-drum cap screws.

T43514 (U.S.) TY9475 (Canadian) 277 (LOCTITE)

Rigid Form-In-Place Gasket

Apply to ring gear and drum mounting surfaces and cover.

T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)

Thread Lock and Sealer (Medium Strength)

Apply to threads of cover cap screws.

TY9375 (U.S.) TY9480 (Canadian) 592 (LOCTITE)

Pipe Sealant

Apply to threads of fill plug.

T43513 (U.S.) TY9474 (Canadian) 02 271 (LOCTITE) 0250 2

LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

CED,OUOE003,21578 –19–08MAY00–1/1

02-0250-2

270LC Excavator Repair 012809

PN=98

Axle Shaft, Bearings, and Reduction Gears

Specifications Item

Measurement

Specification

Propel Gearbox and Motor

Weight

440 kg (972 lb) approximate

Gearbox-to-Frame Cap Screw

Torque

620 N•m (457 lb-ft)

Propel Motor Mainframe Cover Cap Screw

Torque

177 N•m (130 lb-ft)

Gearbox Bearing Nut

Torque

785 N•m (578 lb-ft)

Gearbox Bearing Nut Lock Plate Cap Screw

Torque

90 N•m (66 lb-ft)

Ring Gear-to-Drum Cap Screw

Torque

265 N•m (195 lb-ft)

Cover-to-Ring Gear Cap Screw

Torque

110 N•m (81 lb-ft)

Fill Plug

Torque

50 N•m (37 lb-ft)

Propel Gearbox

02 0250 3

CED,OUOE003,21579 –19–08MAY00–1/1

Towing Machine CAUTION: Prevent possible injury from unexpected machine movement. Block both tracks when disconnecting propel gearboxes. When propel gearboxes are disconnected, machine has no brakes and can move. The machine will roll free on a slope or while being towed. 1. Block tracks. 2. Drain oil from each propel gearbox. Approximate oil capacity is 6 L (6.5 qt). 3. Remove cover from each gearbox.

Continued on next page

TM1668 (28JAN09)

02-0250-3

TX,02,UU3753 –19–06APR00–1/3

270LC Excavator Repair 012809

PN=99

Axle Shaft, Bearings, and Reduction Gears 4. Remove propel shaft (first planet sun gear) (A) from each gearbox.

–UN–06DEC88

5. Install cover. Fill gearbox with oil. (See Swing Gearbox, Propel Gearbox, and Pump Gearbox Oils in Group 0004).

T6879EG

A—Sun Gear

02 0250 4

TX,02,UU3753 –19–06APR00–2/3

6. Attach a tow line (A) around machine frame as shown.

T6457DV

–UN–18OCT88

A—Tow Line

TX,02,UU3753 –19–06APR00–3/3

Remove and Install Propel Gearbox

–UN–06DEC88

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. Put a support stand under the undercarriage.

T6876FG

2. Disconnect track. (See Remove Track Chain, Group 0130.)

Continued on next page

TM1668 (28JAN09)

02-0250-4

TX,02,UU3754 –19–26JAN09–1/4

270LC Excavator Repair 012809

PN=100

Axle Shaft, Bearings, and Reduction Gears

–UN–12NOV92

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Do not remove vent plug (A). Release pressure by loosening vent plug. 3. Loosen vent plug (A) to release air pressure.

T7869AT

4. Remove propel motor cover. A—Vent Plug

Continued on next page

TM1668 (28JAN09)

02-0250-5

TX,02,UU3754 –19–26JAN09–2/4

270LC Excavator Repair 012809

PN=101

02 0250 5

Axle Shaft, Bearings, and Reduction Gears

–UN–08DEC08

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. 5. Disconnect lines (A, C, E, and G).

X9811

CAUTION: The approximate weight of propel gearbox and motor is 440 kg (972 lb). Propel Gearbox—Specification Propel Gearbox and Motor— Weight............................................................ 440 kg (972 lb) approximate

6. Connect propel gearbox and motor to a hoist. NOTE: For propel motor repair, see Group 0260. 7. Remove cap screws (D). Remove gearbox.

–UN–20SEP94

8. Replace parts as necessary. 9. Install propel gearbox and motor. Tighten cap screws. Propel Gearbox—Specification Gearbox-to-Frame Cap Screw— Torque ......................................................................... 620 N•m (457 lb-ft)

T8316AO

02 0250 6

A—Port AV (Forward)-to-Rotary Manifold Port 1 Line B—Cap Screw (4 used) C—Motor Drain Port-to-Rotary Manifold Bottom Tee Line D—Cap Screw (17 used) E—Motor Speed Change Port-to-Rotary Manifold Top Port Line F—Cap Screw (4 used) G—Port BV (Reverse)-to-Rotary Manifold Port 2 Line

Continued on next page

TM1668 (28JAN09)

02-0250-6

TX,02,UU3754 –19–26JAN09–3/4

270LC Excavator Repair 012809

PN=102

Axle Shaft, Bearings, and Reduction Gears 10. Connect lines (A, C, E and G). 11. Add gear oil (See Swing Gearbox, Propel Gearbox, Group 0004). 12. Do propel motor start-up procedure. (See procedure in Group 0260.)

14. Install track. Adjust track sag. (See procedure in Group 0130.)

T8316AO

Propel Gearbox—Specification Propel Motor Mainframe Cover Cap Screw—Torque .................................................... 177 N•m (130 lb-ft)

–UN–20SEP94

13. Install propel motor cover. Tighten cap screws.

TX,02,UU3754 –19–26JAN09–4/4

TM1668 (28JAN09)

02-0250-7

270LC Excavator Repair 012809

PN=103

02 0250 7

Axle Shaft, Bearings, and Reduction Gears

Disassemble Propel Gearbox

T8071AS

–19–06FEB94

02 0250 8

Continued on next page

TM1668 (28JAN09)

02-0250-8

TX,02,UU3756 –19–06APR00–1/16

270LC Excavator Repair 012809

PN=104

Axle Shaft, Bearings, and Reduction Gears A—Sprocket B—Drum C—Propel Motor D—Propel Shaft (First Planet Sun Gear) E—Housing

F—Seal G—Nut H—Third Planet Carrier I—Ring Gear J—Second Planet Carrier K—First Planet Carrier

L—Third Planet Sun Gear M—Ball Bearing and Thrust Plug N—Second Planet Sun Gear O—First Planet Gear (3 used) P—Second Planet Gear (3 used)

1. Remove drain plugs to drain gearbox oil. Approximate capacity is 6 L (6.5 qt).

Q—Third Planet Gear (3 used) R—Cap Screw (2 used) S—Lock Plate T—Propel Gearbox

2. Remove propel motor and brake from gearbox. (See procedure in Group 0260.)

CAUTION: The approximate weight of propel motor and gearbox is 440 kg (972 lb).

3. Remove sprocket from gearbox housing. (See procedure in Group 0130.)

02 0250 9

Propel Gearbox—Specification Propel Motor and Gearbox— Weight ..................................................... 440 kg (972 lb) approximate

TX,02,UU3756 –19–06APR00–2/16

4. Remove cap screws (A). Remove cover (B).

T6557BS

–UN–19OCT88

A—Cap Screw (12 used) B—Cover

Continued on next page

TM1668 (28JAN09)

02-0250-9

TX,02,UU3756 –19–06APR00–3/16

270LC Excavator Repair 012809

PN=105

Axle Shaft, Bearings, and Reduction Gears 5. If replacement is necessary, remove snap ring (A), pin (B), and bearing (C) from cover.

T7966DP

–UN–04MAY93

A—Snap Ring B—Pin C—Bearing

02 0250 10

TX,02,UU3756 –19–06APR00–4/16

CAUTION: Planet gears may turn. Keep fingers away from gears. 6. Remove propel shaft (first planet sun gear). –UN–19OCT88

Remove first planet carrier (A).

T8011AF

–UN–18MAY93

T6639GK

A—First Planet Carrier

Continued on next page

TM1668 (28JAN09)

02-0250-10

TX,02,UU3756 –19–06APR00–5/16

270LC Excavator Repair 012809

PN=106

Axle Shaft, Bearings, and Reduction Gears 7. Disassemble first planet carrier (36).

T109297

–UN–18JUL97

35—Thrust Washer 36—First Planet Carrier 37—First Planet Gear (3 used) 38—Needle Bearing (3 used) 39—Thrust Washer (6 used) 40—Pin (3 used) 41—Spring Pin (3 used)

TX,02,UU3756 –19–06APR00–6/16

8. Remove second planet sun gear (B) and second planet carrier (A).

T6557BV

–UN–19OCT88

A—Second Planet Carrier B—Second Planet Sun Gear

Continued on next page

TM1668 (28JAN09)

02-0250-11

TX,02,UU3756 –19–06APR00–7/16

270LC Excavator Repair 012809

PN=107

02 0250 11

Axle Shaft, Bearings, and Reduction Gears 9. Disassemble second planet carrier (27). 20—Third Planet Sun Gear 27—Second Planet Carrier 28—Thrust Washer 29—Second Planet Sun Gear (3 used) 30—Needle Bearing (3 used) 31—Thrust Washer (6 used) 32—Pin (3 used) 33—Spring Pin (3 used)

T109298

–UN–18JUL97

02 0250 12

TX,02,UU3756 –19–06APR00–8/16

10. Remove third planet sun gear (A).

T6557BW

–UN–19OCT88

A—Third Planet Sun Gear

Continued on next page

TM1668 (28JAN09)

02-0250-12

TX,02,UU3756 –19–06APR00–9/16

270LC Excavator Repair 012809

PN=108

Axle Shaft, Bearings, and Reduction Gears 11. Remove cap screws (A). CAUTION: Use a lifting device for heavy components. 12. Remove ring gear (B) using lifting brackets, such as JT01748 Lifting Brackets, lifting strap, and a hoist. A—Cap Screw B—Ring Gear

T6557BX

–UN–19OCT88

02 0250 13

TX,02,UU3756 –19–06APR00–10/16

13. Remove third planet carrier (A).

T6557BY

–UN–19OCT88

A—Third Planet Carrier

Continued on next page

TM1668 (28JAN09)

02-0250-13

TX,02,UU3756 –19–06APR00–11/16

270LC Excavator Repair 012809

PN=109

Axle Shaft, Bearings, and Reduction Gears 14. Disassemble third planet carrier (14). 14—Third Planet Carrier 15—Third Planet Gear (3 used) 17—Thrust Washer (6 used) 18—Pin (3 used) 19—Spring Pin (3 used) 21—Needle Bearing (6 used) 28—Thrust Washer

T109299

–UN–18JUL97

02 0250 14

TX,02,UU3756 –19–06APR00–12/16

15. Remove cap screws and lock plate (A).

–UN–19OCT88

16. Remove nut (B) using DF1036A Propel Gearbox Nut Wrench (C) and DFT1109 Holding Bar (D). (See Section 99 for instructions to make tools.)

T7966DQ

–UN–04MAY93

T6557BZ

A—Lock Plate B—Nut C—DF1036A Propel Gearbox Nut Wrench D—DFT1109 Holding Bar

Continued on next page

TM1668 (28JAN09)

02-0250-14

TX,02,UU3756 –19–06APR00–13/16

270LC Excavator Repair 012809

PN=110

Axle Shaft, Bearings, and Reduction Gears

CAUTION: Use a lifting device for heavy components. 17. Remove bearing cone (C). Bearing cone is a press fit. 18. Remove housing (A) from drum (B) using lifting brackets, such as JT01748 Lifting Brackets, lifting strap, and hoist. A—Housing B—Drum C—Bearing Cone

T6557CA

–UN–19OCT88

02 0250 15

TX,02,UU3756 –19–06APR00–14/16

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. 19. Remove seal ring and O-ring (A). Keep seal rings together as a matched set with metal faces together to protect surfaces. 20. Inspect metal face seal. (See procedure in this group.) For seals that are reused, put a piece of cardboard between seal rings to protect seal ring face. 21. Remove bearing cone (B) only if replacement is necessary. Bearing cone is a press fit.

T6557CB

–UN–19OCT88

A—O-Ring B—Bearing Cone

Continued on next page

TM1668 (28JAN09)

02-0250-15

TX,02,UU3756 –19–06APR00–15/16

270LC Excavator Repair 012809

PN=111

Axle Shaft, Bearings, and Reduction Gears 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.

T6557CC

23. Inspect metal face seal. (See procedure in this group.) For seals that are reused, put a piece of cardboard between seal rings to protect seal ring face. A—Seal Ring and O-Ring B—Bearing Cup C—Bearing Cup

24. Remove bearing cups (B and C) only if replacement is necessary. Bearing cups are press fit.

TX,02,UU3756 –19–06APR00–16/16

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

–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)

T85079

02 0250 16

–UN–19OCT88

22. Remove seal ring and O-ring (A). Keep seal rings together as a matched set with metal faces together to protect surfaces.

Continued on next page

TM1668 (28JAN09)

02-0250-16

TX,0130,VV2682 –19–06APR00–1/3

270LC Excavator Repair 012809

PN=112

Axle Shaft, Bearings, and Reduction Gears 2. Illustration shows examples of worn seal rings (A).

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

T85080

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

–UN–05DEC96

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

02 0250 17

TX,0130,VV2682 –19–06APR00–2/3

5. Apply a thin film of oil to seal ring face. Put face of seal rings together to protect sealing surfaces.

T82840

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.

–UN–23FEB89

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

A—Seal Face

TX,0130,VV2682 –19–06APR00–3/3

TM1668 (28JAN09)

02-0250-17

270LC Excavator Repair 012809

PN=113

Axle Shaft, Bearings, and Reduction Gears

Assemble Propel Gearbox

T109286

–UN–25APR97

02 0250 18

Continued on next page

TM1668 (28JAN09)

02-0250-18

TX,02,UU3757 –19–26JAN09–1/17

270LC Excavator Repair 012809

PN=114

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

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

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

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

TX,02,UU3757 –19–26JAN09–2/17

1. Install cups (B and C) tight against bottom of bore. Cups are a press fit.

–UN–19OCT88

IMPORTANT: O-ring and seat surfaces for O-ring must be clean, dry, and oil free so O-ring does not slip.

T6557CC

2. Thoroughly clean O-ring and seat surfaces in housing and seal ring using volatile, non-petroleum base solvent and lint-free tissues. NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage the O-ring or leave an oil residue.

A—Seal Ring and O-Ring B—Bearing Cup C—Bearing Cup

3. Apply equal pressure with fingers at four equally spaced points on seal face surface. Seal ring and O-ring (A) must “pop” down into place so O-ring is tight against seal bore and seal is installed squarely. 4. Wipe finger prints and foreign material off seal face using clean oil and lint-free tissues. 5. Apply a thin film of oil on seal face.

Continued on next page

TM1668 (28JAN09)

02-0250-19

TX,02,UU3757 –19–26JAN09–3/17

270LC Excavator Repair 012809

PN=115

02 0250 19

Axle Shaft, Bearings, and Reduction Gears

–UN–23AUG88

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

IMPORTANT: O-ring and seat surfaces for O-ring must be clean, dry, and oil free so O-ring does not slip. 7. Thoroughly clean O-ring and seat surfaces in housing and seal ring using volatile, non-petroleum base solvent and lint-free tissues. NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage the O-ring or leave an oil residue. 8. Apply equal pressure with fingers at four equally spaced points on seal face surface. Seal ring and O-ring (A) must "pop" down into place so O-ring is tight against seal bore and seal is installed squarely. 9. Wipe finger prints and foreign material off seal face using clean oil and lint-free tissues.

–UN–19OCT88

10. Apply a thin film of oil on seal face. A—Seal and O-Ring B—Bearing Cone

T6557CB

02 0250 20

TS227

6. Heat bearing cone (B) to 50—70°C (122—158°F). Install cone tight against shoulder. Cone is a press fit.

Continued on next page

TM1668 (28JAN09)

02-0250-20

TX,02,UU3757 –19–26JAN09–4/17

270LC Excavator Repair 012809

PN=116

Axle Shaft, Bearings, and Reduction Gears 11. Install drum (A) on housing (B). 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. 12. Heat bearing cone (C) to 50—70°C (122—158°F). Install cone tight against cup.

02 0250 21

T6557CL

–UN–19OCT88

A—Drum B—Housing C—Bearing Cone

TX,02,UU3757 –19–26JAN09–5/17

13. Install nut (D) with the 0.5 mm (0.020 in.) step (E) towards bearing.

–UN–04MAY93

14. Tighten nut (D) using DF1036A Propel Gearbox Nut Wrench (B) and DFT1109 Holding Bar (A). Fasten holding bar to ring gear (C). (See Section 99 for instructions to make tools.)

T7995AY

Propel Gearbox—Specification Gearbox Bearing Nut—Torque ................................... 785 N•m (578 lb-ft)

15. Tap on ring gear (C) using a plastic hammer. T7978AA –UN–01APR93

16. Turn drum three times to the right and left to seat roller bearings. Drum must turn smoothly. 17. Repeat procedure again to be sure roller bearings are seated.

A—DFT1109 Holding Bar B—DF1036A Propel Gearbox Nut Wrench C—Ring Gear D—Nut E—0.5 mm (0.020 in.) Step

Continued on next page

TM1668 (28JAN09)

02-0250-21

TX,02,UU3757 –19–26JAN09–6/17

270LC Excavator Repair 012809

PN=117

Axle Shaft, Bearings, and Reduction Gears 18. Clean threads of cap screws. Apply cure primer and thread lock and sealer (high strength).

–UN–19OCT88

19. Install lock plate (A) so tang engages notch in housing. Tighten nut (B) as needed to install cap screws. Tighten cap screws.

T6557BZ

Propel Gearbox—Specification Gearbox Bearing Nut Lock Plate Cap Screw—Torque ........................................................ 90 N•m (66 lb-ft)

A—Lock Plate B—Nut

TX,02,UU3757 –19–26JAN09–7/17

20. Install the thrust washer (28) into third planet carrier. 21. Install needle bearings (21), thrust washers (17), third planet gears (15), and pins (18). 22. Install spring pins (19) so slit is towards the nearest end of pin.

T109299

–UN–18JUL97

14—Third Planet Carrier 15—Third Planet Gear (3 used) 17—Thrust Washer (6 used) 18—Pin (3 used) 19—Spring Pin (3 used) 21—Needle Bearing (6 used) 28—Thrust Washer

TX,02,UU3757 –19–26JAN09–8/17

23. Install third planet carrier (A). 24. Clean ring gear and drum mounting surfaces. Apply cure primer and rigid form-in-place gasket. –UN–19OCT88

A—Third Planet Carrier

T6557BY

02 0250 22

Continued on next page

TM1668 (28JAN09)

02-0250-22

TX,02,UU3757 –19–26JAN09–9/17

270LC Excavator Repair 012809

PN=118

Axle Shaft, Bearings, and Reduction Gears 25. Clean threads of cap screws (A). Apply cure primer and thread lock and sealer (high strength). 26. Install ring gear (B) and tighten cap screws. Propel Gearbox—Specification Ring Gear-to-Drum Cap Screw— Torque ......................................................................... 265 N•m (195 lb-ft)

A—Cap Screw (24 used) B—Ring Gear

T6557BX

–UN–19OCT88

02 0250 23

TX,02,UU3757 –19–26JAN09–10/17

27. Install third planet sun gear (A) with longer teeth mating with the third planet carrier.

T6557BW

–UN–19OCT88

A—Third Planet Sun Gear

Continued on next page

TM1668 (28JAN09)

02-0250-23

TX,02,UU3757 –19–26JAN09–11/17

270LC Excavator Repair 012809

PN=119

Axle Shaft, Bearings, and Reduction Gears 28. Install thrust washer (28) into second planet carrier (27). 29. Install needle bearings (30), thrust washers (31), second planet gears (29), and pins (32). 30. Install spring pins (33) so slit is towards the nearest end of pin.

T109298

–UN–18JUL97

20—Third Planet Sun Gear 27—Second Planet Carrier 28—Thrust Washer 29—Second Planet Sun Gear (3 used) 30—Needle Bearing (3 used) 31—Thrust Washer (6 used) 32—Pin (3 used) 33—Spring Pin (3 used)

TX,02,UU3757 –19–26JAN09–12/17

31. Install second planet carrier (A). 32. Install second planet sun gear (B) with longer teeth mating with the second planet carrier.

–UN–19OCT88

A—Second Planet Carrier B—Second Planet Sun Gear

T6557BV

02 0250 24

Continued on next page

TM1668 (28JAN09)

02-0250-24

TX,02,UU3757 –19–26JAN09–13/17

270LC Excavator Repair 012809

PN=120

Axle Shaft, Bearings, and Reduction Gears 33. Install thrust washer (35) into first planet carrier (36). 34. Install needle bearings (38), thrust washers (39), first planet gears (37), and pins (40). 35. Install spring pins (41) so slit is towards the nearest end of pin.

T109297

–UN–18JUL97

35—Thrust Washer 36—First Planet Carrier 37—First Planet Gear (3 used) 38—Needle Bearing (3 used) 39—Thrust Washer (6 used) 40—Pin (3 used) 41—Spring Pin (3 used)

TX,02,UU3757 –19–26JAN09–14/17

36. Install first planet carrier (A). 37. Install propel shaft (first planet sun gear).

T8011AF

–UN–18MAY93

A—First Planet Carrier

Continued on next page

TM1668 (28JAN09)

02-0250-25

TX,02,UU3757 –19–26JAN09–15/17

270LC Excavator Repair 012809

PN=121

02 0250 25

Axle Shaft, Bearings, and Reduction Gears 38. If removed, install bearing (C), pin (B), and snap ring (A) in cover.

–UN–04MAY93

39. Clean cover and ring gear mounting surfaces. Apply cure primer and rigid form-in-place gasket.

T7966DP

A—Snap Ring B—Pin C—Bearing 02 0250 26

TX,02,UU3757 –19–26JAN09–16/17

40. Clean threads of cap screws (A). Apply cure primer and thread lock and sealer (medium strength). 41. Install cover (B). Tighten cap screws (A). Propel Gearbox—Specification Cover-to-Ring Gear Cap Screw— Torque ........................................................................... 110 N•m (81 lb-ft)

42. Install sprocket. (See procedure in Group 0130.) 43. Install propel motor and brake. (See procedure in Group 0260.) 44. Add gear oil. (See Swing Gearbox, Propel Gearbox, Oils, Group 0004.)

Propel Gearbox—Specification Fill Plug—Torque ............................................................. 50 N•m (37 lb-ft)

T6557BS

A—Cap Screw B—Cover

–UN–19OCT88

45. Clean threads of plugs. Apply cure primer and pipe sealant. Tighten plugs.

TX,02,UU3757 –19–26JAN09–17/17

TM1668 (28JAN09)

02-0250-26

270LC Excavator Repair 012809

PN=122

Group 0260

Hydraulic System Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21580 –19–08MAY00–1/2 T7782AH –UN–19JUN92

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . .JDG911 To remove and install special slotted nut.

CED,OUOE003,21580 –19–08MAY00–2/2

Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21581 –19–08MAY00–1/9

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . DF10631 Use with DFT1130 to remove and install propel motor.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

Continued on next page

TM1668 (28JAN09)

02-0260-1

CED,OUOE003,21581 –19–08MAY00–2/9

270LC Excavator Repair 012809

PN=123

02 0260 1

Hydraulic System Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11301 Use with DF1063 to remove and install propel motor.

02 0260 2

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21581 –19–08MAY00–3/9

Torque Adapter. . . . . . . . . . . . . . . . . . . . . . DF10381 To check rolling drag torque of propel motor rotor drive shaft.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21581 –19–08MAY00–4/9

Allen Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm Install in pivot plug to hold valve plate and link in position.

CED,OUOE003,21581 –19–08MAY00–5/9

Wooden Dowel . . . . . . . . . . . . . . . . . 4.8 mm (3/16 in.) To assist in aligning motor valve housing with motor shaft and brake housing during installation. CED,OUOE003,21581 –19–08MAY00–6/9

Hex Key Wrench . . . . . . . . . . . . . . . . . . . . . . . . 8 mm To tighten ball seat.

Continued on next page

TM1668 (28JAN09)

02-0260-2

CED,OUOE003,21581 –19–08MAY00–7/9

270LC Excavator Repair 012809

PN=124

Hydraulic System Rotary Manifold Lifting Tool1 To remove and install rotary manifold.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21581 –19–08MAY00–8/9

Air Test Plug . . . . . . . . . . . . . . . . . . . . . . . . JDG185 To seal port and apply air pressure to rotary manifold for pressure test. CED,OUOE003,21581 –19–08MAY00–9/9

Other Material Number

Name

Use

T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE)

Thread Lock and Sealer (High Strength)

Apply to threads of servo piston link pivot plugs. Apply to threads of ball seat.

T43514 (U.S.) TY9475 (Canadian) 277 (LOCTITE)

Rigid Form-In-Place Gasket

Apply to OD of motor shaft lip seal.

TY2098 (U.S.)

Multi-Purpose Grease

To provide a light seal between surfaces.

TY16285 (U.S.) CXTY16285 (Canadian) 7649 (LOCTITE)

Cure Primer

To speed cure time of adhesives and sealants.

LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

CED,OUOE003,21582 –19–08MAY00–1/1

02-0260-3

270LC Excavator Repair 012809

PN=125

02 0260 3

Hydraulic System

Specifications Item

Measurement

Specification

Propel Motor and Brake

Weight

93 kg (205 lb) approximate

Propel Motor and Brake-to-Frame Cap Screw

Torque

265 N•m (195 lb-ft)

Propel Motor Cover Cap Screw

Torque

265 N•m (195 lb-ft)

Disk Spring

Height

6.4—6.5 mm (0.25—0.26 in.)

Disk

Thickness

3.25—3.30 mm (0.128—0.130 in.)

Plate

Thickness

1.75—1.80 mm (0.069—0.071 in.)

Pivot Plug

Torque

49 N•m (36 lb-ft)

Shoulder Bolt

Torque

49 N•m (36 lb-ft)

Servo Piston Cover Cap Screw

Torque

88 N•m (65 lb-ft)

Motor Drive Shaft

Rolling Drag Torque

2.5—3.5 N•m (22—31 lb-in.)

Propel Motor and Park Brake

02 0260 4

Brake Valve-to-Motor Housing Cap Torque Screw

217 N•m (160 lb-ft)

Brake Pressure Reducing Spool Plug

Torque

34 N•m (25 lb-ft)

Alignment Port Plug

Torque

88 N•m (65 lb-ft)

Shuttle Valve Ball Seat

Torque

14.5 N•m (128 lb-in.)

Park Brake Release Shuttle Valve Plug

Torque

14.5 N•m (128 lb-in.)

Servo Piston Operating Shuttle Valve Plug

Torque

14.5 N•m (128 lb-in.)

Counterbalance Valve Plug

Torque

340 N•m (251 lb-ft)

Relief Valve

Torque

540 N•m (398 lb-ft)

Propel Motor Brake Valve Housing

Continued on next page

TM1668 (28JAN09)

02-0260-4

CED,OUOE003,21583 –19–08MAY00–1/2

270LC Excavator Repair 012809

PN=126

Hydraulic System

Item

Measurement

Specification

Check Valve Plug

Torque

235 N•m (173 lb-ft)

Brake Pressure Reducing Valve Plug

Torque

34 N•m (25 lb-ft)

Rotary Manifold

Weight

27 kg (60 lb) approximate

Manifold-to-Frame Cap Screw

Torque

34 N•m (25 lb-ft)

Stop Cap Screw

Torque

65 N•m (50 lb-ft)

Cover-to-Housing Cap Screw

Torque

50 N•m (37 lb-ft)

Rotary Manifold 02 0260 5

CED,OUOE003,21583 –19–08MAY00–2/2

Remove and Install Propel Motor and Park Brake 1. Swing upperstructure 90°. Lower bucket to ground.

T6811AJ

–UN–18OCT88

CAUTION: Prevent possible injury from unexpected machine movement. Block both tracks when removing propel motors. When propel motors are removed, machine has no brakes and can move. The machine will roll free on a slope or while being towed. 2. Block tracks. 3. Drain oil from propel gearbox. Approximate oil capacity is 6 L (6.5 qt).

TX,02,UU3759 –19–26JAN09–1/4

–UN–12NOV92

T7869AT

A—Vent Plug

Continued on next page

TM1668 (28JAN09)

02-0260-5

TX,02,UU3759 –19–26JAN09–2/4

270LC Excavator Repair 012809

PN=127

Hydraulic System

–UN–08DEC08

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. NOTE: Port AV is forward port for right motor. Port BV is on top and is the forward port for the left motor.

X9811

5. Disconnect lines (A—D). CAUTION: The approximate weight of propel motor and brake is 93 kg (205 lb). Propel Motor and Park Brake—Specification Propel Motor and Brake—Weight ................... 93 kg (205 lb) approximate

6. Loosen four socket head cap screws with lock washers (E).

T8318AB

–UN–28SEP94

7. Connect propel motor and brake to a hoist using lifting straps or chains and DF1063 Lifting Bracket and DFT1130 Adapter. (See Section 99 for instructions to make tools.) NOTE: To assist in removal and installation of propel motor and brake, remove the hex head from two M18 x 2.5, 200 mm long cap screws. Use cap screws as guide pins in the cap screw holes. 8. Remove socket head cap screws and lock washers to remove propel motor and brake. Remove O-ring. 9. Replace parts as necessary.

–UN–20SEP94

NOTE: If splines of the motor cannot be aligned during installation, remove cover from propel gearbox and remove propel shaft (first planet sun gear). Finish motor installation and then install propel shaft and cover. 10. Install O-ring. Install propel motor and brake. Tighten cap screws (E).

T8318AC

02 0260 6

Propel Motor and Park Brake—Specification Propel Motor and Brake-to-Frame Cap Screw—Torque .................................................... 265 N•m (195 lb-ft)

Right Side Shown A—Motor Drain Port-to-Rotary Manifold Bottom Tee Line B—Port AV-to-Rotary Manifold Port 1 Line C—Motor Speed Change Port-to-Rotary Manifold Top Port Line D—Port BV-to-Rotary Manifold Port 2 Line E—Cap Screw and Lock Washer (4 used)

Continued on next page

TM1668 (28JAN09)

02-0260-6

TX,02,UU3759 –19–26JAN09–3/4

270LC Excavator Repair 012809

PN=128

Hydraulic System 11. Connect lines. 12. Add gear oil. (See Swing Gearbox, Propel Gearbox, Oil, Group 0004.) 13. Do propel motor start-up procedure. (See procedure in this group.) 14. Install motor cover and tighten cap screws. Propel Motor and Park Brake—Specification Propel Motor Cover Cap Screw— Torque ......................................................................... 265 N•m (195 lb-ft)

02 0260 7

TX,02,UU3759 –19–26JAN09–4/4

Propel Motor and Park Brake Start-Up Procedure

T7915BB

–UN–11JAN93

IMPORTANT: Propel motor will be damaged if not filled with oil before operating propel function. Procedure must be performed whenever a new propel motor is installed or oil has been drained from the motor. 1. Disconnect propel motor drain line (A). 2. Fill motor with hydraulic oil until oil reaches the top of drain port.

A—Propel Motor Drain Line

NOTE: Use a funnel with suitable diameter neck to allow air to escape while filling. 3. Connect line (A).

TX,02,UU3763 –19–06APR00–1/1

TM1668 (28JAN09)

02-0260-7

270LC Excavator Repair 012809

PN=129

Hydraulic System

Disassemble Propel Motor and Park Brake

T8319AF

–UN–28SEP94

02 0260 8

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TM1668 (28JAN09)

02-0260-8

TX,02,UU3760 –19–06APR00–1/12

270LC Excavator Repair 012809

PN=130

Hydraulic System 1—Motor Valve Housing 2—Bushing 3—Plate 4—Valve Plate 5—O-Ring 6—O-Ring 7—Disk Spring 8—Piston 9—O-Ring

10—O-Ring 11—Disk (4 used) 12—Plate (5 used) 13—Spacer 14—Bearing 15—Spacer 16—Bearing 17—Nut

18—Snap Ring 19—Lip Seal 20—Center Shaft 21—Motor Shaft and Brake Housing 22—Pin 23—Piston (7 used) 24—Rotor

25—Spring 26—Link 27—Piston Seal (2 used) 28—O-Ring 29—Servo Piston 30—Cover 31—Socket Head Screws (4 used)

TX,02,UU3760 –19–06APR00–2/12

CAUTION: Use a lifting device for heavy components.

–UN–20SEP94

IMPORTANT: Valve plate and pistons have machined surfaces. Do not let valve plate and pistons drop.

T8319BJ

1. Remove four cap screws to remove propel motor valve housing (A) from propel motor housing (F). Make sure valve plate in valve housing is not damaged. 2. Remove parts (B—D and G). A—Propel Motor Valve Housing B—O-Ring C—Disk Spring D—O-Ring E—Rotor Assembly F—Propel Motor Shaft and Brake Housing G—O-Ring

IMPORTANT: Pistons must be installed into the same bores because of wear pattern. Mark pistons and respective rotor and shaft bores for assembly. 3. Mark pistons and bores in rotor (E) so pistons are installed into the same bores at assembly. Remove rotor assembly.

TX,02,UU3760 –19–06APR00–3/12

4. Remove retaining ring (A) to disassemble parts (B—E).

T8319BO

–UN–26SEP94

A—Retaining Ring B—Rotor C—Spring D—Center Shaft E—Pin

Continued on next page

TM1668 (28JAN09)

02-0260-9

TX,02,UU3760 –19–06APR00–4/12

270LC Excavator Repair 012809

PN=131

02 0260 9

Hydraulic System 5. Mark pistons and bores in shaft so pistons are installed into the same bores at assembly.

T8319BP

–UN–20SEP94

Move piston towards the center of the assembly to remove piston. Remove remaining pistons.

02 0260 10

TX,02,UU3760 –19–06APR00–5/12

NOTE: Remove piston evenly from bore. Do not scratch or damage piston or bore. 6. Make sure brake port (A) is clear to allow air to enter as piston (B) is removed from bore. 7. Remove brake parts (B—G). NOTE: If parts are not within specification, replace parts. 8. Inspect brake parts for wear or damage.

–UN–20SEP94

If parts are not within specification, replace parts.

T8319BR

Propel Motor and Park Brake—Specification Disk Spring—Height .................................... 6.4—6.5 mm (0.25—0.26 in.) Disk—Thickness .................................. 3.25—3.30 mm (0.128—0.130 in.) Plate—Thickness ................................. 1.75—1.80 mm (0.069—0.071 in.)

A—Brake Port B—Piston C—O-Ring D—O-Ring E—Disk (4 used) F—Plate (5 used) G—Spacer

Continued on next page

TM1668 (28JAN09)

02-0260-10

TX,02,UU3760 –19–06APR00–6/12

270LC Excavator Repair 012809

PN=132

Hydraulic System 9. Turn motor shaft and brake housing over. Hit end of drive shaft with a soft-faced hammer to remove motor drive shaft assembly from housing.

–UN–20SEP94

10. Remove snap ring (A) and lip seal (B).

T8319BY

A—Snap Ring B—Lip Seal

TX,02,UU3760 –19–06APR00–7/12

11. Remove nut (B) using JDG911 Spanner Wrench. 12. Use a knife edge puller and a press to remove parts (C—E) from shaft (A). 13. Replace parts as necessary.

T8320AE

–UN–11OCT94

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

Continued on next page

TM1668 (28JAN09)

02-0260-11

TX,02,UU3760 –19–06APR00–8/12

270LC Excavator Repair 012809

PN=133

02 0260 11

Hydraulic System 14. Remove cover (A) and O-ring. IMPORTANT: Valve plate and slide plate have machined surfaces. Do not let plates drop. 15. Remove plug and O-ring (B) from valve housing to remove shoulder bolt (C) using an Allen wrench. Remove valve plate and link assembly (D). Make sure machined surfaces are not damaged during removal.

T8321AF

–UN–20SEP94

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

TX,02,UU3760 –19–06APR00–9/12

16. Remove remaining parts (B—D) from valve housing. 17. Inspect piston seals (E) for wear or damage, replace as necessary.

–UN–20SEP94

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

T8321AG

02 0260 12

Continued on next page

TM1668 (28JAN09)

02-0260-12

TX,02,UU3760 –19–06APR00–10/12

270LC Excavator Repair 012809

PN=134

Hydraulic System 18. Disassemble servo piston parts (A—E).

T7685IE

–UN–27APR92

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

TX,02,UU3760 –19–06APR00–11/12

20. If necessary, remove pivot plugs (A) to remove valve plate (C). Mark valve plate so plate can be installed in same position as removed.

T8321AH

A—Pivot Plugs B—Bushing C—Valve Plate

–UN–20SEP94

19. Inspect bushing (B). Remove bushing if replacement is necessary.

TX,02,UU3760 –19–06APR00–12/12

TM1668 (28JAN09)

02-0260-13

270LC Excavator Repair 012809

PN=135

02 0260 13

Hydraulic System

Assemble Propel Motor and Park Brake

T8320AF

–UN–26SEP94

02 0260 14

Continued on next page

TM1668 (28JAN09)

02-0260-14

TX,02,UU3761 –19–06APR00–1/14

270LC Excavator Repair 012809

PN=136

Hydraulic System 02—Motor Shaft and Brake Housing 04—Motor Drive Shaft 06—Roller Bearing 07—Roller Bearing 08—Spacer 09—Nut 11—Lip Seal 12—Snap Ring 14—Rotor 17—Piston (7 used)

19—Center Shaft 20—Spring 21—Pin 22—Retaining Ring 24—Disk (4 used) 25—Plate (5 used) 26—Spacer 28—Piston 29—O-Ring 30—O-Ring

31—Disk Spring 33—O-Ring 34—O-Ring 37—Motor Valve Housing 38—Cap Screw (4 used) 40—Plate 45—Valve Plate 46—Bushing 48—Link 49—Pivot Plug (2 used)

51—Shoulder Bolt 53—Servo Piston 55—Piston Seal (2 used) 57—O-Ring 60—Plug 61—O-Ring 62—Plug 63—O-Ring 64—Cover 65—Cap Screw (4 used)

TX,02,UU3761 –19–06APR00–2/14

1. Install bushing (B) using disk drivers, until bushing is even with valve plate (C).

–UN–20SEP94

2. If removed, apply thread lock and sealer (high strength) to threads of pivot plugs (A). DO NOT allow thread lock and sealer on the smooth portion of the pivot plugs.

T8321AH

3. Install valve plate and pivot plugs (A) in link. Tighten pivot plugs. Propel Motor and Park Brake—Specification Pivot Plug—Torque ......................................................... 49 N•m (36 lb-ft) A—Pivot Plug (2 used) B—Bushing C—Valve Plate

TX,02,UU3761 –19–06APR00–3/14

IMPORTANT: Piston seals are brittle. Use care not to chip, crack or break seals. 4. Assemble servo piston parts (A—E).

T7685IE

–UN–27APR92

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

Continued on next page

TM1668 (28JAN09)

02-0260-15

TX,02,UU3761 –19–06APR00–4/14

270LC Excavator Repair 012809

PN=137

02 0260 15

Hydraulic System 5. Apply clean oil to all internal parts. 6. Use fingers to compress piston seals (E) while installing servo piston (D). IMPORTANT: Valve plate and slide plate have machined surfaces. Use care not damage or scratch machined surfaces. 7. Apply petroleum jelly to both sides of plate (B).

–UN–20SEP94

8. Install parts (A—C). Align link assembly with servo piston.

T8321AG

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

TX,02,UU3761 –19–06APR00–5/14

9. Install shoulder bolt (C) through link assembly (D) and end of servo piston. Tighten bolt. Propel Motor and Park Brake—Specification Shoulder Bolt—Torque .................................................... 49 N•m (36 lb-ft)

10. Install plug and O-ring (B). 11. Install O-ring and cover (A). Tighten cover cap screws.

–UN–20SEP94

Propel Motor and Park Brake—Specification Servo Piston Cover Cap Screw— Torque ............................................................................. 88 N•m (65 lb-ft)

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

T8321AF

02 0260 16

Continued on next page

TM1668 (28JAN09)

02-0260-16

TX,02,UU3761 –19–06APR00–6/14

270LC Excavator Repair 012809

PN=138

Hydraulic System

–UN–23AUG88

TS227

12. Heat bearing cones (C and E) to 70—90°C (158— 194°F). 13. Install bearing cone (E) on motor drive shaft (A). Make sure cone is tight against shoulder of shaft. Install outer race of bearing. 14. Install outer race of bearing (C) in spacer (D). Make sure race is tight to bottom of bore. Install race and spacer with spacer notches towards larger bearing. 15. Install bearing cone (C) tight against outer race. 16. Apply clean oil to threads of a new nut (B). Install nut with thin shoulder away from bearing.

T8320AE

–UN–11OCT94

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

Continued on next page

TM1668 (28JAN09)

02-0260-17

TX,02,UU3761 –19–06APR00–7/14

270LC Excavator Repair 012809

PN=139

02 0260 17

Hydraulic System

A—Nut

T8320AP

T8320AO

–UN–11OCT94

–UN–26SEP94

02 0260 18

B—DF1038 Torque Adapter

17. Tighten nut (A) using JDG911 Spanner Wrench (C) until rolling drag torque is to specification. Propel Motor and Park Brake—Specification Motor Drive Shaft—Rolling Drag Torque........................................... 2.5—3.5 N•m (22—31 lb-in.)

C—JDG911 Spanner Wrench

18. Check rolling drag torque using the DF1038 Torque Adapter (B). (See Section 99 for instructions to make tool.) 19. Stake nut in one place on the thin shoulder.

Continued on next page

TM1668 (28JAN09)

02-0260-18

TX,02,UU3761 –19–06APR00–8/14

270LC Excavator Repair 012809

PN=140

Hydraulic System 20. Apply rigid form-in-place gasket to outer diameter of oil seal (B).

23. Install snap ring (A).

–UN–20SEP94

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

T8319BY

21. Install seal with spring side into bore first. Use a disk driver to push seal to bottom of bore. 22. Apply multi-purpose grease to seal lips.

A—Snap Ring B—Oil Seal

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

TX,02,UU3761 –19–06APR00–9/14

25. Install spacer (G) with notches to bottom of bore and aligned with notches in housing. 26. Install plates (F) and disks (E): • Begin with one plate and align notches in plate with notches in housing gear. • Install one disk. • Repeat step, alternating plates and disks. Keep notches of disks aligned with one another.

–UN–20SEP94

27. Apply petroleum jelly to O-rings (C and D). Install O-rings on piston (B) with rounded side out. 28. Make sure brake port (A) is clear to allow air to exit as piston is installed.

T8319BR

NOTE: To ease installation of piston, apply petroleum jelly to piston outer diameter. 29. Install piston evenly into bore. A—Brake Port B—Piston C—O-Ring D—O-Ring E—Disk (4 used) F—Plate (5 used) G—Spacer

Continued on next page

TM1668 (28JAN09)

02-0260-19

TX,02,UU3761 –19–06APR00–10/14

270LC Excavator Repair 012809

PN=141

02 0260 19

Hydraulic System

T8319BP

–UN–20SEP94

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

02 0260 20

TX,02,UU3761 –19–06APR00–11/14

31. Assemble parts (A—E). Make sure pin (E) fits into groove of rotor (B).

T8319BO

–UN–26SEP94

A—Retaining Ring B—Rotor C—Spring D—Center Shaft E—Pin

TX,02,UU3761 –19–06APR00–12/14

32. Install rotor (E) so pistons are installed into the same bores as removed.

–UN–20SEP94

33. Install disk spring (C) so inner diameter contacts the piston. 34. Install O-rings (B, D and G).

T8319BJ

A—Propel Motor Valve Housing B—O-Ring C—Disk Spring D—O-Ring E—Rotor Assembly F—Propel Motor Shaft and Brake Housing G—O-Ring

Continued on next page

TM1668 (28JAN09)

02-0260-20

TX,02,UU3761 –19–06APR00–13/14

270LC Excavator Repair 012809

PN=142

Hydraulic System 35. Remove parts (A—C) from motor valve housing (D).

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

T8322BC

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

–UN–20SEP94

36. Remove plug and O-ring from port (E) on side of valve housing.

39. Lift motor valve housing into position over motor shaft and brake housing. Align housings and put dowel into bore of center shaft (G). Carefully bring the housings together. 40. Install and tighten four housing cap screws. Propel Motor and Park Brake—Specification Brake Valve-to-Motor Housing Cap Screw—Torque .................................................... 217 N•m (160 lb-ft)

41. Remove dowel and install parts (A—C). Tighten plug. Propel Motor and Park Brake—Specification Brake Pressure Reducing Spool Plug—Torque................................................................... 34 N•m (25 lb-ft)

Propel Motor and Park Brake—Specification Alignment Port Plug—Torque.......................................... 88 N•m (65 lb-ft)

T8322BD

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

–UN–20SEP94

42. Remove allen wrench. Install and tighten plug and O-ring.

TX,02,UU3761 –19–06APR00–14/14

TM1668 (28JAN09)

02-0260-21

270LC Excavator Repair 012809

PN=143

02 0260 21

Hydraulic System

Disassemble and Assemble Propel Motor Brake Valve Housing

T8322BE

–UN–26SEP94

02 0260 22

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

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

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

Continued on next page

TM1668 (28JAN09)

02-0260-22

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

TX,02,UU3762 –19–08MAY00–1/7

270LC Excavator Repair 012809

PN=144

Hydraulic System Park Brake Release Shuttle Valve NOTE: Valve can be removed with propel motor on machine. –UN–20SEP94

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

T8323AB

Install ball (C) and seat (B). Tighten seat (B) using an 8 mm hex key wrench. Propel Motor Brake Valve Housing—Specification Shuttle Valve Ball Seat—Torque .............................. 14.5 N•m (128 lb-in.) A—Plug with O-Ring B—Ball Seat C—Ball

Install and tighten plug and O-ring (A). Propel Motor Brake Valve Housing—Specification Park Brake Release Shuttle Valve Plug—Torque............................................................. 14.5 N•m (128 lb-in.)

TX,02,UU3762 –19–08MAY00–2/7

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

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

T8323AJ

Install ball (C) and seat (B). Tighten seat (B) using an 8 mm hex key wrench. Propel Motor Park Brake Valve Housing—Specification Shuttle Valve Ball Seat—Torque .............................. 14.5 N•m (128 lb-in.) A—Plug with O-Ring B—Ball Seat C—Ball

Install and tighten plug and O-ring (A). Propel Motor Park Brake Valve Housing—Specification Servo Piston Operating Shuttle Valve Plug—Torque .................................................. 14.5 N•m (128 lb-in.)

Continued on next page

TM1668 (28JAN09)

02-0260-23

TX,02,UU3762 –19–08MAY00–3/7

270LC Excavator Repair 012809

PN=145

02 0260 23

Hydraulic System Counterbalance Valve NOTE: Valve can be removed with propel motor on machine. Apply clean oil to spool (D). Install spool plug (C) with smaller diameter toward spool. Install and tighten plug and O-ring (A). Propel Motor Park Brake Valve Housing—Specification Counterbalance Valve Plug— Torque ......................................................................... 340 N•m (251 lb-ft)

T8323AE

–UN–20SEP94

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

TX,02,UU3762 –19–08MAY00–4/7

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

Tighten relief valve (A).

T8323AK

Propel Motor Park Brake Valve Housing—Specification Relief Valve—Torque .................................................. 540 N•m (398 lb-ft)

–UN–20SEP94

A—Relief Valve B—O-Ring C—Backup Ring (2 used) D—O-Ring

T8323AL

02 0260 24

Continued on next page

TM1668 (28JAN09)

02-0260-24

TX,02,UU3762 –19–08MAY00–5/7

270LC Excavator Repair 012809

PN=146

Hydraulic System Check Valves

Tighten plug (C). Propel Motor Park Brake Valve Housing—Specification Check Valve Plug—Torque ......................................... 235 N•m (173 lb-ft)

T8323AT

Install parts (A—C).

–UN–20SEP94

NOTE: Valves can be removed with propel motor on machine.

A—Plug with O-Ring (2 used) B—Spring (2 used) C—Poppet (2 used)

TX,02,UU3762 –19–08MAY00–6/7

Brake Pressure Reducing Valve

Tighten plug (A). Propel Motor Park Brake Valve Housing—Specification Brake Pressure Reducing Valve Plug—Torque................................................................... 34 N•m (25 lb-ft)

T8322BC

Install parts (A—C).

–UN–20SEP94

NOTE: Valve can be removed with propel motor on machine.

A—Plug and O-Ring B—Spool C—Spring

TX,02,UU3762 –19–08MAY00–7/7

TM1668 (28JAN09)

02-0260-25

270LC Excavator Repair 012809

PN=147

02 0260 25

Hydraulic System

Remove and Install Rotary Manifold

T109207

–UN–24APR97

02 0260 26

Continued on next page

TM1668 (28JAN09)

02-0260-26

TX,02,UU3764 –19–08MAY00–1/6

270LC Excavator Repair 012809

PN=148

Hydraulic System 00—Hose (2 used) 01—Hose (2 used) 04—Adapter (4 used) 04A—O-Ring (4 used) 05—Adapter (4 used) 05A—O-Ring (4 used) 08—O-Ring (8 used) 14—Hose (2 used) 15—Tee Fitting 15A—O-Ring

16—Elbow (2 used) 16A—O-Ring (2 used) 21—Hose (2 used) 22—Adapter (2 used) 22A—O-Ring (2 used) 23—Adapter (2 used) 23A—O-Ring (2 used) 27—Rubber Bushing (2 used) 28—Rubber Bushing 2 used) 31—Hose Clamp (2 used)

32—Hose Clamp (2 used) 35—Cap Screw (2 used) 37—Tie Band (4 used) 38A—Hose Protector 38B—Hose 39—O-Ring (4 used) 40—Cap Screw (16 used) 41—Split Flange (8 used) 42A—Hose Protector

42B—Hose 43A—Hose Protector 43B—Hose 44A—Hose Protector 44B—Hose 45—O-Ring (4 used) 46—Adapter (2 used) 47—Adapter (2 used) 47A—O-Ring (2 used)

TX,02,UU3764 –19–08MAY00–2/6

–UN–12NOV92

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Do not remove vent plug. Release pressure by loosening vent plug.

T7869AT

1. Loosen vent plug (A) to release air pressure in hydraulic tanks. A—Vent Plug

Continued on next page

TM1668 (28JAN09)

02-0260-27

TX,02,UU3764 –19–08MAY00–3/6

270LC Excavator Repair 012809

PN=149

02 0260 27

Hydraulic System

–UN–08DEC08

CAUTION: The approximate weight of rotary manifold is 27 kg (60 lb). Rotary Manifold—Specification Rotary Manifold—Weight................................... 27 kg (60 lb) approximate

–UN–04MAY93

4. Attach the rotary manifold to a hoist using a lifting strap and two rotary manifold lifting tools. (See Section 99 for instructions to make tools.) A—Port 3-to-Left Propel Section Bottom (Reverse) Port Line B—Cap Screw (2 used) C—Stop D—Port 1-to-Right Propel Section Bottom (Reverse) Port Line E—Rotary Manifold P1 Port-to-Pilot Pressure Regulating and Solenoid Valve Manifold "SA" Port Line F—Port 2-to-Right Propel Section Top (Forward) Port Line G—Port 4-to-Left Propel Section Top (Forward) Port Line H—Rotary Manifold D Port-to-Reservoir Port Line

T7966DT

02 0260 28

X9811

3. Remove cap screws (B). Remove stop (C).

Continued on next page

TM1668 (28JAN09)

02-0260-28

TX,02,UU3764 –19–08MAY00–4/6

270LC Excavator Repair 012809

PN=150

Hydraulic System 5. Disconnect lines (A—H). 6. Remove cap screws (I). Lower rotary manifold. Do not damage rubber boot. 7. Replace parts as necessary. 8. Raise rotary manifold into position so the letter R on mounting flange and the work port number 1 and 2 are towards the right side of machine. 02 0260 29

9. Install cap screws (I) and tighen. Rotary Manifold—Specification Manifold-to-Frame Cap Screw— Torque ............................................................................. 34 N•m (25 lb-ft)

10. Connect lines (A—H).

T7685JC

–UN–27APR92

T7685JB

–UN–27APR92

A—Port P1-to-Right Propel Motor Servo Piston Port Line B—Port 2-to-Right Propel Motor "AV" (Forward) Port Line C—Port 1-to-Right Propel Motor "BV" (Reverse) Port Line D— Bottom Port-to-Right Propel Motor Top Drain Port Line E—Bottom Port-to-Left Propel Motor Top Drain Port Line F—Port 3-to-Left Propel Motor "AV" (Reverse) Port Line G—Port P1-to-Left Propel Motor Servo Piston Port Line H—Port 4-to-Left Propel Motor "BV" (Forward) Port Line I—Cap Screw (4 used)

Continued on next page

TM1668 (28JAN09)

02-0260-29

TX,02,UU3764 –19–08MAY00–5/6

270LC Excavator Repair 012809

PN=151

Hydraulic System 11. Remove lifting device. Install stop (C). Tighten cap screws (B).

–UN–04MAY93

Rotary Manifold—Specification Stop Cap Screw—Torque ............................................... 65 N•m (50 lb-ft)

12. Connect lines (A and D—H).

T7966DT

TX,02,UU3764 –19–08MAY00–6/6

Disassemble and Assemble Rotary Manifold

–UN–09JAN92

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

T7626DX

02 0260 30

A—Port 3-to-Left Propel Section Bottom (Reverse) Port Line B—Cap Screw (2 used) C—Stop D—Port 1-to-Right Propel Section Bottom (Reverse) Port Line E—Rotary Manifold P1 Port-to-Pilot Pressure Regulating and Solenoid Valve Manifold "SA" Port Line F—Port 2-to-Right Propel Section Top (Forward) Port Line G—Port 4-to-Left Propel Section Top (Forward) Port Line H—Rotary Manifold D Port-to-Reservoir Port Line

Continued on next page

TM1668 (28JAN09)

02-0260-30

TX,02,UU3765 –19–06APR00–1/2

270LC Excavator Repair 012809

PN=152

Hydraulic System 1. Make a mark on spindle (A), body (F) and cover (J) to aid in assembly. 2. Remove cap screws (K), washers (L) and cover (J) Inspect O-ring (I) and replace if necessary. 3. Remove snap ring (H) and washer (G). 4. Carefully, remove spindle assembly (A—E) from housing (F). 02 0260 31

5. Remove plugs in spindle to clean ports. Install plugs. 6. Remove O-ring (C), seals (B and E) and bushing (D). 7. Inspect and repair as necessary. Keep hydraulic oil on all disassembled parts.

–UN–09JAN92

8. Install bushing (D), O-ring (C) and dust seal (B) in housing (F). 9. Install seal rings (E) on spindle (A).

11. Install ring (G) with chamfered side towards spindle. Install snap ring (H) with flat side against ring (G). 12. Install O-ring (I) and cover (J) with nameplate on cover (J) towards “L” mark on housing (F) mounting flange. Install washers (L) and cap screws (K). Rotary Manifold—Specification Cover-to-Housing Cap Screw— Torque ............................................................................. 50 N•m (37 lb-ft)

T7626DY

10. Install spindle (A—E) in housing (F) so the mounting holes for stop are towards the pointed indicator on mounting flange and work port numbers are towards the same side as housing. A—Spindle B—Oil Seal C—O-Ring D—Bushing E—Oil Seal Ring (6 used) F—Housing G—Ring H—Snap Ring I—O-Ring J—Cover K—Cap Screw L—Lock Washer

TX,02,UU3765 –19–06APR00–2/2

TM1668 (28JAN09)

02-0260-31

270LC Excavator Repair 012809

PN=153

Hydraulic System

Rotary Manifold Air Test

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

T6557JB

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

–UN–01NOV88

1. Install a plug in one port.

02 0260 32

TX,02,SB846 –19–22FEB92–1/1

TM1668 (28JAN09)

02-0260-32

270LC Excavator Repair 012809

PN=154

Section 04

Engine Contents Page

Group 0400—Removal and Installation POWERTECH 6.8 L (6068) John Deere Engine—Use PowerTech 6.8L Engine-Tier 1/Stage I . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-1 Alternators and Starting Motors Use CTM77 . . . . . . . . . . . . . . . . . . . . . . . .04-0400-1 Essential Tools . . . . . . . . . . . . . . . . . . . . . . .04-0400-1 Service Equipment and Tools . . . . . . . . . . . .04-0400-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .04-0400-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .04-0400-4 Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-5 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-8 Oil Pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-10 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-10 Fuel Injection Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-11 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-12 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-13 Fuel System Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-16 Engine Crankcase Vent Tube Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-16 Engine Valve Lash Check and Adjust . . . . . . . . . . . . . . . . . .04-0400-17 Firing Order, 6-Cylinder Engine . . . . . . . . . .04-0400-20 Starter Remove and Install . . . . . . . . . . . . . . . . .04-0400-20

TM1668 (28JAN09)

04-1

270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

04-2

270LC Excavator Repair 012809

PN=2

Group 0400

Removal and Installation

M44215

–UN–07SEP88

POWERTECH 6.8 L (6068) John Deere Engine—Use PowerTech 6.8L Engine-Tier 1/Stage I

POWERTECH is a trademark of Deere & Company.

TX,04,DH5326 –19–26JAN09–1/1

Alternators and Starting Motors—See Foreword

TS225

–UN–17JAN89

04 0400 1

TX,16,UU3487 –19–26JAN09–1/1

Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21678 –19–16MAY00–1/5

Lifting Sling . . . . . . . . . . . . . . . . . . . . . . . . . . JDG23 To remove engine.

CED,OUOE003,21678 –19–16MAY00–2/5

Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4 To lock engine at TDC.

Continued on next page

TM1668 (28JAN09)

04-0400-1

CED,OUOE003,21678 –19–16MAY00–3/5

270LC Excavator Repair 012809

PN=157

Removal and Installation Injection Pump Timing Pin. . . . . . . . . . . . . . . . JDG886 To lock fuel injection pump timing prior to removal of pump. CED,OUOE003,21678 –19–16MAY00–4/5

Flywheel Turning Tool . . . . . . . . . . . . . . . . . . JDG820 To rotate crankshaft to position number one piston at “TDC” on compression stroke. CED,OUOE003,21678 –19–16MAY00–5/5

Service Equipment and Tools 04 0400 2

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21679 –19–16MAY00–1/3

Pump Support . . . . . . . . . . . . . . . . . . . . . . DFT11191 To support hydraulic pump and gearbox.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.

CED,OUOE003,21679 –19–16MAY00–2/3

CED,OUOE003,21679 –19–16MAY00–3/3

TM1668 (28JAN09)

04-0400-2

270LC Excavator Repair 012809

PN=158

Removal and Installation

Other Material Number

Name

Use

TY6304 (U.S.) TY9484 (Canadian) 515 (LOCTITE)

Flexible Form-In-Place Gasket

To seal oil pan gasket surface.

TY9375 (U.S.) TY9480 (Canadian) 592 (LOCTITE)

Pipe Sealant

Apply to threads of plugs and shuttle valve set screws.

04 0400 3 LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

CED,OUOE003,21680 –19–16MAY00–1/1

04-0400-3

270LC Excavator Repair 012809

PN=159

Removal and Installation

Specifications Item

Measurement

Specification

Hydraulic Pump

Weight

167 kg (370 lb) approximate

Engine

Weight

954 kg (2100 lb) approximate

Engine Mount Cap Screw

Torque

350 N•m (260 lb-ft)

Oil Pan-to-Gasket Cap Screw

Torque

35 N•m (26 lb-ft)

Drain Plug

Torque

47 N•m (35 lb-ft)

Pump-to-Front Plate Mounting Stud

Torque

70 N•m (52 lb-ft)

Drive Gear-to-Pump Hub Cap Screw

Torque

47 N•m (35 lb-ft)

Injection Line Connector

Torque

27 N•m (20 lb-ft)

Injection Line Nut

Torque

27 N•m (20 lb-ft)

Intake Valve

Clearance

0.36 mm (0.014 in.)

Exhaust Valve

Clearance

0.46 mm (0.018 in.)

Jam Nut

Torque

27 N•m (20 lb-ft)

Rocker Arm Cover Cap Screw

Torque

10.8 N•m (96 lb-in.)

Starter

Weight

23 kg (50 lb) approximate

Mounting Flange-to-Housing Cap Screw

Torque

47 N•m (35 lb-ft)

Engine

Engine Oil Pan 04 0400 4

Fuel Injection Pump

Engine Valve

Starter

CED,OUOE003,21681 –19–16MAY00–1/1

TM1668 (28JAN09)

04-0400-4

270LC Excavator Repair 012809

PN=160

Removal and Installation

Remove Engine

–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. Disconnect negative (-) battery cable. 2. Drain coolant. Cooling capacity is approximately 22 L (6 gal).

04 0400 5 TX,04,UU3864 –19–12MAY00–1/5

3. Remove hood and hood support (A).

T104488

–UN–17OCT96

A—Hood Support

Continued on next page

TM1668 (28JAN09)

04-0400-5

TX,04,UU3864 –19–12MAY00–2/5

270LC Excavator Repair 012809

PN=161

Removal and Installation 4. Remove air intake hoses and coupling (B) above the rocker arm cover. 5. Remove fan guard. –UN–17OCT96

6. Remove upper and lower radiator hoses. 7. Remove fan and fan spacer.

T104490

8. Remove muffler and muffler bracket. 9. Disconnect wiring harnesses. B—Hoses and Coupling

10. Disconnect fuel lines. Plug openings. 11. Disconnect heater hoses. Plug openings. 12. Remove air conditioner compressor and bracket from engine. It is not necessary to discharge the air conditioning system. 13. Secure compressor so it does not interfere when removing the engine.

TX,04,UU3864 –19–12MAY00–3/5

CAUTION: The approximate weight of hydraulic pump is 167 kg (370 lb). Engine—Specification Hydraulic Pump—Weight .............................. 167 kg (370 lb) approximate

14. Support main hydraulic pump and gearbox using DFT1119 Pump Support (A) and a small winch hoist (B).

–UN–17OCT96

A—DFT1119 Pump Support B—Winch Hoist

T104491

04 0400 6

Continued on next page

TM1668 (28JAN09)

04-0400-6

TX,04,UU3864 –19–12MAY00–4/5

270LC Excavator Repair 012809

PN=162

Removal and Installation

CAUTION: The approximate weight of engine is 954 kg (2100 lb). The recommended method for lifting the engine is using the JDG23 Lifting Sling. The lifting force must be at 90° at the lifting points. Engine—Specification Engine—Weight ........................................... 954 kg (2100 lb) approximate

15. Attach JDG23 Lifting Sling (A) to engine as shown. 16. Remove pump gearbox-to-flywheel housing cap screws. 17. Remove engine mount cap screws. 04 0400 7

–UN–17OCT96

18. Raise engine slightly and push engine away from hydraulic pump. Lift engine when engine is disengaged from pump drive coupling.

T104492

A—Lifting Sling

TX,04,UU3864 –19–12MAY00–5/5

TM1668 (28JAN09)

04-0400-7

270LC Excavator Repair 012809

PN=163

Removal and Installation

Install Engine

T104493

–UN–14NOV96

04 0400 8

A—Bracket, Right Front B—Bracket, Left Front C—Bracket, Rear (2 used)

D—Cap Screw (4 used) E—Washer (8 used) F—Stop (8 used)

1. Lower engine into excavator.

G—Rubber Mount (4 used) H—Rubber Mount (4 used) I—Nut (4 used)

J—Washer (14 used) K—Cap Screw (14 used)

3. Install cap screws (D) and nuts (I). Tighten cap screws.

2. Slide engine toward hydraulic pump to engage pump coupler. Continued on next page

TM1668 (28JAN09)

04-0400-8

TX,04,UU3865 –19–12MAY00–1/4

270LC Excavator Repair 012809

PN=164

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

TX,04,UU3865 –19–12MAY00–2/4

4. Install hydraulic pump using DFT1119 Pump Support (A) and a small winch hoist (B). (See procedure in Group 3360.) 5. Connect heater hoses. 6. Install air conditioner compressor and bracket, if equipped. 04 0400 9

7. Connect all wiring harnesses and starter cables. 8. Install speed control linkage. (See procedure in Group 0515.)

T104491

–UN–17OCT96

A—DFT1119 Pump Support B—Winch Hoist

TX,04,UU3865 –19–12MAY00–3/4

9. Install air intake hose coupler (B) and intake hoses. 10. Install fan, shroud, and guards. (See procedure in Group 0510.)

12. Fill radiator and reservoir to proper level. 13. Bleed fuel system. (See procedure in this group.) 14. Connect battery cables.

T104490

–UN–17OCT96

11. Install muffler and muffler bracket.

B—Hoses and Coupling

TX,04,UU3865 –19–12MAY00–4/4

TM1668 (28JAN09)

04-0400-9

270LC Excavator Repair 012809

PN=165

Removal and Installation

Remove Oil Pan Engine must be removed to remove oil pan. (See procedure in this group.) TX,04,SB147 –19–23JUN87–1/1

Install Oil Pan 1. Apply LOCTITE Flexible Form-In-Place Gasket to oil pan rail where flywheel housing, front plate, and timing gear cover attach to cylinder block. 2. Install oil pan gasket. 04 0400 10

3. Install oil pan and tighten cap screws. Engine Oil Pan—Specification Oil Pan-to-Gasket Cap Screw— Torque ............................................................................. 35 N•m (26 lb-ft)

4. Install aluminum or copper washer on drain plug with raised center against plug. Tighten drain plug. Engine Oil Pan—Specification Drain Plug—Torque ......................................................... 47 N•m (35 lb-ft)

If equipped with elbow drain fittings, the threads and sealing surfaces must be free of oil film to insure an effective seal. Apply pipe sealant to fitting, except for the leading one to three threads. Install and tighten fitting. 5. Fill engine crankcase with correct grade and viscosity engine oil. (See Group 0004.)

LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

TX,04,DH5306 –19–11NOV96–1/1

04-0400-10

270LC Excavator Repair 012809

PN=166

Removal and Installation

Remove In-Line Fuel Injection Pump

–UN–06DEC96

IMPORTANT: Never steam clean or pour cold water on an injection pump while pump is running or while it is still warm. To do so may cause seizure of pump parts.

RG7748

1. Clean injection lines and area around the injection pump with cleaning solvent or a steam cleaner. 2. Rotate engine flywheel (in normal running direction) until No. 1 piston is at “TDC” of its compression stroke. At this point, JDE81-4 Timing Pin should enter hole in flywheel.

04 0400 11 TX,04,UU3866 –19–12MAY00–1/3

3. Remove injection pump drive gear cover and O-ring.

–UN–12NOV96

4. Install JDG886 Injection Pump Timing Pin (A) through injection pump drive gear into injection pump hub until it bottoms. In some instances it may be necessary to rotate the pump drive hub slightly to get the pin installed.

T105061

5. Disconnect injection pump lubrication line (B). 6. Disconnect fuel shut-off solenoid electrical connector (C). 7. Remove fuel inlet line (D). Remove fuel leak-off line (E).

–UN–12NOV96

8. Disconnect fuel tank-to-transfer pump line (F). 9. Disconnect transfer pump-to-fuel filter line. (G).

T105065

A—JDG886 Injection Pump Timing Pin B—Injection Pump Lubrication Line C—Fuel Shut-Off Solenoid Electrical Connector D—Fuel Filter-to-Injection Pump Inlet Line E—Fuel Leak-Off Line F—Fuel Tank-to-Transfer Pump Line G—Transfer Pump-to-Fuel Filter Line H—Fuel Shut-Off Solenoid

Continued on next page

TM1668 (28JAN09)

04-0400-11

TX,04,UU3866 –19–12MAY00–2/3

270LC Excavator Repair 012809

PN=167

Removal and Installation 10. Remove fuel injection line nuts (A). 11. Remove four injection pump drive gear cap screws (C). –UN–12NOV96

12. Remove four injection pump-to-cylinder block mounting stud nuts (B).

T105070

13. Remove injection pump from mounting studs and place pump on a clean, flat surface. A—Fuel Injection Line Nut (6 used) B—Mounting Stud Nut (4 used) C—Cap Screw (4 used)

T105079

–UN–12NOV96

04 0400 12

TX,04,UU3866 –19–12MAY00–3/3

Repair In-Line Fuel Injection Pump

–UN–12NOV96

IMPORTANT: Do not disassemble fuel injection pump further than necessary for installing available service parts, not even for cleaning.

NOTE: Remove JDG886 Injection Pump Timing Pin (A) when sending an injection pump out for repair.

T105061

Be sure injection pump serial tag is in place and all identification numbers are legible so pump is set to the correct specifications for its intended use. A— JDG886 Injection Pump Timing Pin

For injection pump repair and testing, have an authorized diesel injection station perform the work. Unauthorized repairs made to the injection pump will void warranty.

TX,04,DH5308 –19–12MAY00–1/1

TM1668 (28JAN09)

04-0400-12

270LC Excavator Repair 012809

PN=168

Removal and Installation

Install In-Line Fuel Injection Pump

–UN–17JAN97

1. If engine was rotated after injection pump was removed, rotate flywheel until JDE81-4 Timing Pin (A) enters flywheel at No. 1 cylinder’s “TDC” compression stroke.

T105092

NOTE: When No. 1 cylinder is at “TDC” compression stroke, intake and exhaust valves for No. 1 cylinder will be closed, and both rocker arms will be loose. A—JDE81-4 Timing Pin

04 0400 13 TX,04,DH5309 –19–12MAY00–1/6

2. Rotate injection pump drive hub (B) until marks on drive hub and pointer (A) are aligned.

–UN–12NOV96

NOTE: It may be necessary to rotate pump hub slightly to allow JDG886 Injection Pump Timing Pin (E) to enter bearing plate.

T105102

3. Thread JDG886 Timing Pin into drive hub as shown, and tighten until it bottoms against bearing plate (D). 4. Install a new O-ring (C) on bearing plate (D). Lightly lubricate O-ring with AR54749 Soap Lubricant to aid in pump installation, and prevent O-ring damage.

–UN–12NOV96

5. Install injection pump using forward pressure and slight rocking motion to work O-ring into mounting bore. Injection pump flange should seat solidly against cylinder block. 6. Install mounting stud nuts and tighten.

T105107

Fuel Injection Pump—Specification Pump-to-Front Plate Mounting Stud—Torque .................................................................. 70 N•m (52 lb-ft)

A—Pointer B—Drive Hub C—O-Ring D—Bearing Plate E—JDG886 Injection Pump Timing Pin

Continued on next page

TM1668 (28JAN09)

04-0400-13

TX,04,DH5309 –19–12MAY00–2/6

270LC Excavator Repair 012809

PN=169

Removal and Installation 7. Install drive gear on pump drive hub, positioning gear so mounting screws are approximately centered in mounting slots.

–UN–12NOV96

8. Install drive gear-to-pump hub cap screws (B) and tighten.

T105117

Fuel Injection Pump—Specification Drive Gear-to-Pump Hub Cap Screw—Torque ................................................................ 47 N•m (35 lb-ft)

9. Remove JDG886 Injection Pump Timing Pin (A) from injection pump hub. 10. Install injection pump drive gear cover and new O-ring, if needed. Tighten cap screws.

–UN–12NOV96

Fuel Injection Pump—Specification Injection Line Connector—Torque................................... 27 N•m (20 lb-ft)

T105061

A—JDG886 Injection Pump Timing Pin B—Cap Screw (4 used)

TX,04,DH5309 –19–12MAY00–3/6

–UN–12NOV96

IMPORTANT: DO NOT move delivery valve fittings while tightening line nuts. If delivery valve and barrel housing rotate while tightening a fuel line nut, injection pump fuel delivery will be altered. The injection pump will have to be recalibrated on a test stand at an authorized diesel repair station. NOTE: Remove protective caps and plugs that were installed on fuel system components during injection pump removal.

T105126

04 0400 14

A—Injection Line Nut (6 used)

11. Connect fuel delivery lines and tighten injection line nuts (A). Fuel Injection Pump—Specification Injection Line Nut—Torque.............................................. 27 N•m (20 lb-ft)

Continued on next page

TM1668 (28JAN09)

04-0400-14

TX,04,DH5309 –19–12MAY00–4/6

270LC Excavator Repair 012809

PN=170

Removal and Installation 12. Connect fuel tank-to-transfer pump line (B). 13. Connect transfer pump-to-fuel filter line (C).

–UN–12NOV96

14. Connect fuel inlet line (D) and fuel leak-off line (E). 15. Connect injection pump lubrication line (A) to cylinder block fitting.

T105127

16. Connect fuel shut-off solenoid connector.

A—Injection Pump Lubrication Line B—Fuel Tank-to-Transfer Pump line C—Transfer Pump-to-Fuel Filter Line D—Fuel Inlet Line E—Fuel Leak-off Line

04 0400 15

TX,04,DH5309 –19–12MAY00–5/6

17. Remove oil fill plug (A) from governor housing and add 1/2 pint of clean engine oil. Install plug.

T105128

19. Connect throttle levers and adjust engine speeds as required. (See Check and Adjust Fast and Slow Idle in Group 0515.)

–UN–12NOV96

18. Bleed fuel system. (See Bleed Fuel System in this group.)

A—Oil Fill Plug

TX,04,DH5309 –19–12MAY00–6/6

TM1668 (28JAN09)

04-0400-15

270LC Excavator Repair 012809

PN=171

Removal and Installation

Bleed Fuel System

3. Tighten water separator bleed screw. 4. Pump water separator primer (B) until fuel escapes from final fuel filter bleed screw (A).

T102672

2. Pump water separator primer (B) until fuel fills separator bowl and until fuel escapes from water separator bleed screw.

–UN–02AUG96

1. Open bleed screws (A) on fuel filter and on water separator.

5. Tighten final fuel filter bleed screw (A).

T102673

–UN–02AUG96

A—Bleed Screw B—Water Separator Primer

TX,04,UU3867 –19–12MAY00–1/1

Clean the Engine Crankcase Ventilation Tube Clean the engine crankcase ventilation tube (A) when you measure and adjust engine valve clearance (lash). –UN–02AUG96

A—Engine Crankcase Ventilation Tube

T102675

04 0400 16

TX,85,DH5151 –19–12MAY00–1/1

TM1668 (28JAN09)

04-0400-16

270LC Excavator Repair 012809

PN=172

Removal and Installation

Check and Adjust Engine Valve Lash (Clearance) CAUTION: Prevent accidental starting of engine while performing valve adjustments. Always disconnect NEGATIVE (-) battery terminal. IMPORTANT: Valve clearance MUST BE checked and adjusted with engine COLD. 1. Remove rocker arm cover and engine crankcase ventilation tube. Clean tube with solvent or diesel fuel. Check that O-ring in rocker arm cover is in good condition. 04 0400 17 TX,04,UU3868 –19–12MAY00–1/4

–UN–06AUG96

IMPORTANT: Visually inspect contact surfaces of valve tips and rocker arm wear pads. Check all parts for excessive wear, breakage, or cracks. Replace parts that show visible damage.

RG7408

Rocker arms that exhibit excessive valve clearance should be inspected more thoroughly to identify damaged parts. 2. Remove plug (A). Install JDG820 Flywheel Turning Tool. Remove cap screw (B). Install JDE814 Timing Pin.

A—Plug B—Cap Screw

Continued on next page

TM1668 (28JAN09)

04-0400-17

TX,04,UU3868 –19–12MAY00–2/4

270LC Excavator Repair 012809

PN=173

Removal and Installation 3. Turn flywheel until timing pin goes into hole in flywheel.

–UN–06AUG96

4. Using engine rotation tool, rotate engine flywheel in running direction (clockwise viewed from front) until No. 1 cylinder is at “TDC” Compression stroke.

RG7409

IMPORTANT: If No. 1 cylinder rocker arms are loose, the engine is at No. 1 “TDC” Compression. If No. 1 cylinder rocker arms are not loose, rotate engine one full revolution (360°) to No. 1 “TDC” Compression. A—Jam Nut

To change piston position, remove timing pin and rotate flywheel. 04 0400 18

5. Check and adjust valve clearance to specifications as directed in the following procedures. 6. Loosen jam nut (A) and adjust clearance with a screwdriver, as shown.

Continued on next page

TM1668 (28JAN09)

04-0400-18

TX,04,UU3868 –19–12MAY00–3/4

270LC Excavator Repair 012809

PN=174

Removal and Installation 7. Adjust No. 1, 3, and 5 exhaust valves and No. 1, 2, and 4 intake valves.

–UN–18MAY94

Engine Valve—Specification Intake Valve—Clearance ............................................ 0.36 mm (0.014 in.) Exhaust Valve—Clearance......................................... 0.46 mm (0.018 in.)

T6872AG

8. Rotate engine 360° and repeat step 7 for the remaining intake and exhaust valves. 9. Tighten jam nut. Engine Valve—Specification Jam Nut—Torque ............................................................ 27 N•m (20 lb-ft)

10. Clean cylinder head and rocker arm cover mating surfaces.

A—No. 1 TDC Compression Stroke B—No. 1 TDC Exhaust Stroke C—Fan End of Engine 04 0400 19

11. Install rocker arm cover gasket. Do not use sealant on the gasket. 12. Install rocker arm cover. Tighten screws to specification. Do not over tighten cap screws. Engine Valve—Specification Rocker Arm Cover Cap Screw— Torque ......................................................................... 10.8 N•m (96 lb-in.)

13. Remove turning tool and timing pin. 14. Install parts. Center muffler to turbocharger inlet tube before fastening muffler into place.

TX,04,UU3868 –19–12MAY00–4/4

TM1668 (28JAN09)

04-0400-19

270LC Excavator Repair 012809

PN=175

Removal and Installation

Firing Order, 6-Cylinder Engine NOTE: Firing order is 1-5-3-6-2-4.

–UN–31OCT97

Lock No. 1 piston at TDC compression stroke (B). Adjust valve clearance on No. 1, 3, and 5 exhaust valves and No. 1, 2, and 4 intake valves.

RG4777

Turn crankshaft 360°. Lock No. 6 piston is at TDC compression stroke (C). Adjust valve clearance on No. 2, 4, and 6 exhaust valves and No. 3, 5, and 6 intake valves.

A—Toward Front of Engine B—No. 1 Piston at TDC Compression Stroke C—No. 6 Piston at TDC Compression Stroke

04 0400 20 TX,85,DH5134 –19–12MAY00–1/1

Remove and Install Starter IMPORTANT: Always disconnect the negative (-) battery cables before removing starter or a short circuit could result. 1. Disconnect negative (—) battery cables at battery.

Continued on next page

TM1668 (28JAN09)

04-0400-20

TX,04,UU3869 –19–12NOV96–1/2

270LC Excavator Repair 012809

PN=176

Removal and Installation 2. Remove nut (A) to disconnect positive battery cable. 3. Remove nut (B) to disconnect negative (ground) cable.

–UN–23OCT96

4. Disconnect solenoid connector (C).

T104596

CAUTION: The approximate weight of starter is 23 kg (50 lb). Specification Starter—Approximate Weight ................................................. 23 kg (50 lb)

5. Remove cap screws and lock washers (D). Remove starter. 6. Replace parts as necessary.

A—Nut B—Nut C—Solenoid Connector D—Cap Screw and Lock Washer (3 used)

04 0400 21

7. Install starter. 8. Tighten cap screws to 47 N•m (35 lb-ft). Specification Mounting Flange-to-Housing Cap Screws—Torque .............................................................. 47 N•m (35 lb-ft)

9. Connect solenoid connector. 10. Connect positive battery cable. 11. Connect negative cable. 12. Connect negative battery cables at battery.

TX,04,UU3869 –19–12NOV96–2/2

TM1668 (28JAN09)

04-0400-21

270LC Excavator Repair 012809

PN=177

Removal and Installation

04 0400 22

TM1668 (28JAN09)

04-0400-22

270LC Excavator Repair 012809

PN=178

Section 05

Engine Auxiliary System Contents Page

Page

Group 0505—Cold Weather Starting Aids Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Engine Coolant Heater Remove and Install . . . . . . . . . . . . . . . . . .05-0505-1

Fuel Tank Remove and Install . . . . . . . . . . . . . . . . . .05-0560-2 Primary Fuel Filter Remove and Install . . . . . . . . . . . . . . . . . .05-0560-4 Element, Remove and Install . . . . . . . . . . .05-0560-6 Final Fuel Filter Remove and Install . . . . . . . . . . . . . . . . . .05-0560-8 Element, Remove and Install . . . . . . . . . . .05-0560-9 Bleed Fuel System . . . . . . . . . . . . . . . . . . .05-0560-11

Group 0510—Cooling System Service Equipment and Tools . . . . . . . . . . . .05-0510-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1 Radiator, Oil Cooler, and Fan Shroud Remove and Install . . . . . . . . . . . . . . . . . .05-0510-2 Fan and Fan Guard Remove and Install . . . . . . . . . . . . . . . . . .05-0510-4 Fan Belt Remove and Install . . . . . . . . . . . . . . . . . .05-0510-5 Thermostats Remove and Install . . . . . . . . . . . . . . . . . .05-0510-5

Group 0515—Speed Controls Service Equipment and Tools . . . . . . . . . . . .05-0515-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0515-2 Fast and Slow Idle Check and Adjust . . . . . . . . . . . . . . . . . . .05-0515-2 Engine Speed Control Cable Remove and Install . . . . . . . . . . . . . . . . . .05-0515-5 Engine Control Motor and Sensor Remove and Install . . . . . . . . . . . . . . . . . .05-0515-6 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .05-0515-7 Engine Speed Learning Procedure . . . . . . . . . . . .05-0515-8 Fuel Shut-Off Solenoid Linkage Remove And Install . . . . . . . . . . . . . . . . .05-0515-10 Check and Adjust . . . . . . . . . . . . . . . . . .05-0515-11 Group 0520—Intake System Essential Tools . . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Air Intake System Leakage Test . . . . . . . . . .05-0520-2 Air Cleaner Remove and Install . . . . . . . . . . . . . . . . . .05-0520-2 Charge Air Cooler Remove and Install . . . . . . . . . . . . . . . . . .05-0520-6 Group 0560—External Fuel Supply System Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1 TM1668 (28JAN09)

05-1

270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

05-2

270LC Excavator Repair 012809

PN=2

Group 0505

Cold Weather Starting Aids Specifications Item

Measurement

Specification

Cooling System

Approximate Capacity

22.0 L (6.0 gal.)

Nut

Torque

34 N•m (25 lb-ft)

Engine Coolant Heater

TX,05,VV2812 –19–14NOV96–1/1

Remove and Install Engine Coolant Heater

–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. Unplug heater from electrical power source. 2. Drain cooling system. Capacity is approximately 22.0 L (6.0 gal.). Specification Cooling System—Approximate Capacity ............................................................................. 22.0 L (6.0 gal)

Continued on next page

TM1668 (28JAN09)

05-0505-1

TX,05,VV2814 –19–14NOV96–1/2

270LC Excavator Repair 012809

PN=181

05 0505 1

Cold Weather Starting Aids 3. Remove wiring lead (A). 4. Loosen nut (C) and pull heater element from block.

T6427AO

–UN–21OCT88

CAUTION: Do not plug coolant heater into electrical power unless heating element is immersed in coolant. Sheath could burst and result in personal injury. Use a heavy-duty grounded cord to connect coolant heater to electrical power. 5. Repair or replace parts as necessary. 6. Install heater element (G) through adapter (D) and install nut (C), but do not tighten. 7. Install heater into cylinder block with element pointing to rear. 05 0505 2

A—Wiring Lead B—Cap C—Nut D—Adapter E—Gasket F—O-Ring G—Heater Element

8. Tighten adapter. 9. Turn element clockwise, then counterclockwise, until element contacts casting. Move element to the center position. 10. Hold element using wrench and tighten nut to 34 N•m (25 lb-ft). Specification Nut—Torque .................................................................... 34 N•m (25 lb-ft)

TX,05,VV2814 –19–14NOV96–2/2

TM1668 (28JAN09)

05-0505-2

270LC Excavator Repair 012809

PN=182

Group 0510

Cooling System Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21586 –19–08MAY00–1/3

Vacuum Pump To minimize leakage when disconnecting hydraulic lines.

CED,OUOE003,21586 –19–08MAY00–2/3

05 0510 1

Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 mm To pull tension adjuster idler toward front of machine when replacing fan belt. CED,OUOE003,21586 –19–08MAY00–3/3

Specifications Item

Measurement

Specification

Torque

70 N•m (50 lb-ft)

Torque

70 N•m (50 lb-ft)

Fan and Fan Guard Fan Guard Cap Screw

Thermostat Gasket and Housing Cover-to-Thermostat Cap Screw

CED,OUOE003,21588 –19–08MAY00–1/1

TM1668 (28JAN09)

05-0510-1

270LC Excavator Repair 012809

PN=183

Cooling System

Remove and Install Radiator, Oil Cooler, and Fan Shroud

–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. Drain coolant from radiator. Approximate capacity is 22.0 L (6.0 gal.).

TX,05,VV2815 –19–08MAY00–1/3

2. Remove parts (A—E). 3. Unlock and remove reservoir cap.

–UN–17APR97

4. Install vacuum pump. 5. Remove access panel under the radiator and oil cooler. 6. Disconnect oil cooler lines. Cap lines.

T109138B

05 0510 2

7. Remove cap screws from radiator braces (F). A—Upper Radiator Hose B—Fan Guard C—Lower Radiator Hose D—Fan E—Fan Spacer F—Radiator Braces (2 used) G—Radiator Bracket-to-Frame (4 used)

Continued on next page

TM1668 (28JAN09)

05-0510-2

TX,05,VV2815 –19–08MAY00–2/3

270LC Excavator Repair 012809

PN=184

Cooling System 8. Remove four cap screws from radiator brackets (G). 9. Lift radiator, oil cooler, and fan shroud. 10. Remove fan shroud. 11. Replace parts as necessary. 12. Install fan shroud. 13. Install radiator and oil cooler. 14. Install hardware, fan, and guard. 15. Connect cooler lines. 16. Install radiator hoses.

–UN–14NOV96

17. Fill radiator with coolant. 18. Start engine. Check for leaks.

T105162

G—Cap Screw (4 used)

TX,05,VV2815 –19–08MAY00–3/3

TM1668 (28JAN09)

05-0510-3

270LC Excavator Repair 012809

PN=185

05 0510 3

Cooling System

Remove and Install Fan and Fan Guard

1. Open hood.

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 cap completely.

–UN–23AUG88

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

2. Remove cap screws (A). Remove guard. 3. Remove cap screws (B). Remove fan.

5. Install fan. Tighten cap screws. 05 0510 4

Fan and Fan Guard—Specification Fan Guard Cap Screw—Torque ..................................... 70 N•m (50 lb-ft)

T105161C

–UN–19NOV96

4. Replace parts as necessary.

A—Guard Cap Screw B—Fan Cap Screw

TX,05,VV2816 –19–06APR00–1/1

TM1668 (28JAN09)

05-0510-4

270LC Excavator Repair 012809

PN=186

Cooling System

Remove and Install Fan Belt 1. Remove fan guard. (See procedure this group.)

–UN–08AUG00

2. Place a 15 mm wrench over the hex (A) in the center of the tension adjuster idler.

T129933B

3. Pull idler toward front of machine (see arrow) and remove old belt. 4. Loosen air conditioning compressor, if equipped, and remove belt from crankshaft pulley. A—Hex B—Fan Belt

NOTE: It is not necessary to remove fan. 5. Remove fan belt (B). 6. Install new fan belt. 7. Fit belt around all pulleys except adjuster. 8. Pull adjuster forward and slide belt behind adjuster idler.

05 0510 5

9. Slowly release adjuster. 10. Adjust and tighten compressor belt. 11. Replace fan guard.

TX,05,VV2817 –19–06APR00–1/1

Remove and Install Thermostats

–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 radiator fill cap. 2. Remove upper radiator hose from thermostat housing.

Continued on next page

TM1668 (28JAN09)

05-0510-5

TX,05,VV2818 –19–06APR00–1/3

270LC Excavator Repair 012809

PN=187

Cooling System 3. Remove cap screws (A). Remove housing cover.

T105183

–UN–14NOV96

A—Cap Screw (3 used)

TX,05,VV2818 –19–06APR00–2/3

IMPORTANT: Note the location of the thermostats. Top and bottom thermostats are different. Failure to install in correct location may cause overheating.

5. Remove gasket from mounting surface. 6. Install blocking thermostat (B) (AR48675) in top hole. 7. Install non-blocking thermostat (C) (RE33705) in bottom hole.

T105184

05 0510 6

–UN–14NOV96

4. Remove thermostats (B and C).

B—Blocking Thermostat C—Non-Blocking Thermostat

8. Install new gasket and housing cover. 9. Tighten cap screws. Thermostat—Specification Gasket and Housing Cover-to-Thermostat Cap Screw—Torque ................................................................ 70 N•m (50 lb-ft)

TX,05,VV2818 –19–06APR00–3/3

TM1668 (28JAN09)

05-0510-6

270LC Excavator Repair 012809

PN=188

Group 0515

Speed Controls Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21706 –19–24MAY00–1/6

Clamp-On Electronic Tachometer . . . . . . . . . . . JT05801 To check engine speed.

CED,OUOE003,21706 –19–24MAY00–2/6

05 0515 1

Laptop Computer . . . . . . . . . . . . . . . . . . . . . JT07294 To display information read and monitored by the excavator diagnostics program. CED,OUOE003,21706 –19–24MAY00–3/6

Excavator Diagnostics Program Disk . . . . . . . . JT07274J To read and monitor information available from engine and pump controller. CED,OUOE003,21706 –19–24MAY00–4/6

Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT07273 To connect the laptop computer to diagnostic port of excavator. CED,OUOE003,21706 –19–24MAY00–5/6

Feeler Gauge . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.) To check shut-off lever-to-run position stop clearance.

CED,OUOE003,21706 –19–24MAY00–6/6

TM1668 (28JAN09)

05-0515-1

270LC Excavator Repair 012809

PN=189

Speed Controls

Specifications Item

Measurement

Specification

Slow Idle Stop Screw

Speed

900 ± 25 rpm

Fast Idle Stop Screw

Speed

2300 ± 25 rpm

Torque

13 N•m (115 lb-in)

Engine Slow Idle

Speed

900 ± 25 rpm

Engine Auto-Idle

Speed

1200 ± 25 rpm

E (Economy) Mode

Speed

2030 ± 25 rpm

Fast Idle in Standard Mode

Speed

2230 ± 25 rpm

Engine

Engine Control Motor and Sensor Arm-to-Engine Control Motor Shaft Cap Screw

Engine Speed Learning Procedure

05 0515 2

CED,OUOE003,21708 –19–24MAY00–1/1

Check and Adjust Fast and Slow Idle 1. Connect a tachometer or the JT07294 Laptop Computer with excavator diagnostic software to check engine speeds. 2. Warm engine to normal operating temperature. 3. Stop the engine. 4. Disconnect speed control cable at injection pump lever.

Continued on next page

TM1668 (28JAN09)

05-0515-2

TX,05,VV2820 –19–06APR00–1/3

270LC Excavator Repair 012809

PN=190

T103678

–UN–16SEP96

Speed Controls

A—Nut B—Slow Idle Stop Screw

C—Nut D—Supplemental Idle Screw

5. Push injection pump lever against fast idle stop screw (F). Record engine speed.

E—Nut

F—Fast Idle Stop Screw

9. Turn the supplementary idle screw in until slow idle increases, no more than 30 rpm, to specification. Hold screw and tighten nut.

Push injection pump lever against slow idle stop screw (B). Record engine speed. Adjust fast and slow idle stop screws on injection pump as needed. Engine—Specification Slow Idle Stop Screw—Speed ...................................... 900 ± 25 rpm Fast Idle Stop Screw—Speed ..................................... 2300 ± 25 rpm

6. Loosen nut (C). Turn supplementary idle screw (D) out three turns. 7. Loosen nut (A) on the slow idle stop screw (B). 8. Hold injection pump lever against slow idle stop screw. Turn the screw out to obtain an idle speed on the low side of desired slow idle setting within 30 rpm. Hold screw and tighten nut.

10. Pull injection pump lever rapidly to fast idle then decelerate to slow idle. Slow idle must be to specification. NOTE: Increasing slow idle setting a small amount, but no more than the maximum specifications, may help to reduce surging or hunting. If surging or hunting continues, repair injection pump. 11. Loosen nut (E) on fast idle stop screw (F). Pull lever against fast idle stop screw. Turn screw in to decrease engine speed; turn screw out to increase engine speed. Hold screw and tighten nut.

Continued on next page

TM1668 (28JAN09)

05-0515-3

TX,05,VV2820 –19–06APR00–2/3

270LC Excavator Repair 012809

PN=191

05 0515 3

Speed Controls NOTE: The fast idle stop screw serves as the stop when the HP (high power) mode is actuated.

13. Do Engine Control Motor and Sensor Adjustment and then the Engine Speed Learning Procedure. (See procedures in this group.)

12. Stop the engine. Connect the cable to lever. TX,05,VV2820 –19–06APR00–3/3

05 0515 4

TM1668 (28JAN09)

05-0515-4

270LC Excavator Repair 012809

PN=192

Speed Controls

T105226

–UN–26NOV96

Remove and Install Engine Speed Control Cable

A—Nut (2 used) B—Lock Washer (2 used) C—Injection Pump Lever

D—Ball Joint (2 used) E—Bracket F—Speed Control Cable

G—Cap Screw and Lock Washer (6 used) H—Bracket

IMPORTANT: The ball joints (D) are installed on the cable to full thread engagement. A ball joint can be used to lengthen a cable end, if needed, but must have at least 6 mm (1/4 in.) of thread engagement to avoid stripping the threads on cable end.

I—Engine Control Motor Arm J—Engine Control Motor

cable are centered in brackets. As needed, adjust cable in brackets to connect ball joint to lever or arm. 3. Connect ball joint to the outer hole of engine control motor arm (I). 4. Do Engine Control Motor Adjustment and then the Engine Speed Learning Procedure. (See procedures in this group.)

1. Install ball joints (D) to full thread engagement. Tighten the nuts. 2. Install speed control cable (F) in brackets (E and H). Initially, tighten nuts so threaded portions of

TX,05,VV2821 –19–18NOV96–1/1

TM1668 (28JAN09)

05-0515-5

270LC Excavator Repair 012809

PN=193

05 0515 5

Speed Controls

D—Cap Screw (3 used) E—Bracket (2 used) F—Engine Control Motor Connector (4-Wire)

G—Engine Control Motor Sensor Connector (3-Wire)

NOTE: The engine control angle sensor is located inside the engine control motor housing. The sensor is serviced as an assembly with the engine control motor.

H—Engine Control Motor and Sensor

I—Bracket J—Arm

1. Install arm (J). Do not tighten cap screw in arm at this time.

TX,05,VV2822 –19–06APR00–1/2

2. Install ball joint (B) in the outer hole (C) of arm.

4. Do Engine Control Motor and Sensor Adjustment and then the Engine Speed Learning Procedure. (See procedures in this group.)

–UN–24APR97

3. Adjust arm on control motor shaft or speed control cable (A) in bracket so cable is vertical.

T108915B

05 0515 6

T105227

–UN–26NOV96

Remove and Install Engine Control Motor and Sensor

A—Speed Control Cable B—Ball Joint C—Outer Hole

TX,05,VV2822 –19–06APR00–2/2

TM1668 (28JAN09)

05-0515-6

270LC Excavator Repair 012809

PN=194

Speed Controls

Engine Control Motor and Sensor Adjustment When the following components are repaired or replaced, or when engine speeds deviate from specification, the engine control motor adjustment and engine speed learning procedure must be performed. • Engine • Engine speed control cable • Engine control motor and sensor • Engine and pump controller • Fast and slow idle stops 1. Check that fast and slow idle stop screws on the injection pump are adjusted to specification. (See Check and Adjust Fast and Slow Idle in this group.) 2. Turn key switch to ON. 3. Turn the engine rpm dial to slow idle. 05 0515 7

TX,05,VV2823 –19–06APR00–1/2

4. Loosen cap screw (A) in engine control motor arm (B).

Engine Control Motor and Sensor—Specification Arm-to-Engine Control Motor Shaft Cap Screw—Torque ............................................ 13 N•m (115 lb-in)

7. Do Engine Speed Learning Procedure in this group.

T109243

6. Tighten cap screw (A).

–UN–24APR97

5. Adjust the arm (B) on the shaft so the injection pump lever just contact the slow idle stop screw.

A—Cap Screw B—Control Motor Arm

TX,05,VV2823 –19–06APR00–2/2

TM1668 (28JAN09)

05-0515-7

270LC Excavator Repair 012809

PN=195

Speed Controls

Engine Speed Learning Procedure SPECIFICATIONS Engine Slow Idle Speed

900 ± 25 rpm

Engine Auto-Idle Speed

1200 ± 25 rpm

E (Economy) Mode Speed

2030 ± 25 rpm

Fast Idle in Standard Mode Speed

2230 ± 25 rpm

When the following components are repaired or replaced, or when engine speeds deviate from specification, the engine control motor adjustment and engine learning control procedure must be performed. • Engine • Engine speed control cable • Engine control motor and sensor • Engine and pump controller • Fast and slow idle stops 05 0515 8

1. Stop the engine. 2. Disconnect the laptop computer from the test connector. Wait for 5 seconds.

Continued on next page

TM1668 (28JAN09)

05-0515-8

TX,9010,UU3408 –19–26JAN09–1/2

270LC Excavator Repair 012809

PN=196

Speed Controls 3. Push engine learning switch (C) up to top position. The switch is a three position switch. Make sure it is in the top position. 4. Turn key switch ON. Wait 5 seconds. 5. Turn key switch OFF. Wait 5 seconds. 6. Push engine learning switch to middle position. 7. Check engine speeds.

T103674

NOTE: The laptop computer with the excavator diagnostic Program can be used to change the default speeds for slow idle, auto-idle, economy mode, and fast idle in standard mode.

–UN–11SEP96

Engine Speed Learning Procedure—Specification Engine Slow Idle—Speed .................................................... 900 ± 25 rpm Engine Auto-Idle—Speed ................................................... 1200 ± 25 rpm E (Economy) Mode—Speed .............................................. 2030 ± 25 rpm Fast Idle in Standard Mode— Speed ................................................................................. 2230 ± 25 rpm

C—Engine Learning Switch

05 0515 9

TX,9010,UU3408 –19–26JAN09–2/2

TM1668 (28JAN09)

05-0515-9

270LC Excavator Repair 012809

PN=197

Speed Controls

–UN–20NOV96

Remove and Install Fuel Shut-Off Solenoid Linkage

T105277

05 0515 10

A—Cap Screw (2 used) B—Cap Screw (2 used) C—Cap Screw (4 used) D—Shut-Off Solenoid Bracket

E—Nut (4 used) F—Shut-Off Solenoid G—Cap Screw H—Ball Joint

I—Fuel Shut-Off Lever J—Lock Nut K—Nut L—Washer

The shut-off solenoid (F) and ball joint (H) are replaced as an assembly. When a solenoid and ball joint assembly is replaced, check the linkage adjustment.

M—Speed Control Cable Bracket N—Washer (2 used)

(See Check and Adjust Fuel Shut-Off Solenoid Linkage in this group.)

TX,05,VV2825 –19–02DEC96–1/1

TM1668 (28JAN09)

05-0515-10

270LC Excavator Repair 012809

PN=198

Speed Controls

Check and Adjust Fuel Shut-Off Solenoid Linkage 1. Disconnect ball joint (C) from fuel shut-off lever (D). 2. Turn key switch to ON. It is not necessary to start engine for this procedure.

–UN–04DEC96

3. Push plunger (F) into solenoid housing until the plunger bottoms. With key switch ON, solenoid hold coil is energized and will hold plunger in the run position

T105518

4. Manually pull fuel shut-off lever (D) up against the run position stop (upper stop) (H). 5. Check that hole in ball joint (C) is 3—6 mm (1/8—1/4 in.) short of aligning with hole in fuel shut-off lever. The 3—6 mm (1/8—1/4 in.) is the amount of overtravel needed to compress the spring in the plunger to hold the shut-off lever against the run position stop when plunger is bottomed in the solenoid housing.

05 0515 11

–UN–04DEC96

Adjust ball joint as necessary. 6. Manually pull fuel shut-off lever up against the run position stop (upper stop).

T105519

Adjust ball joint so hole is aligned with hole in shut-off lever and then turn ball joint to shorten linkage by three turns. Hold ball joint and tighten nut to 8 N•m (70 lb-in.).

A—Shut-Off Solenoid B—Cap Screw C—Ball Joint D—Fuel Shut-Off Lever E—Lock Nut F—Plunger G—Stop Position Stop (Lower Stop) H—Run Position Stop (Upper Stop)

7. Turn key switch to OFF. 8. Connect ball joint to fuel shut-off lever using cap screw (B) and nut (E). IMPORTANT: Failure to have the shut-off lever tight against run position stop (upper stop) can result in low engine horsepower. 9. Turn the key switch to ON. Push plunger into solenoid housing so hold coil holds the plunger in the run position.

Continued on next page

TM1668 (28JAN09)

05-0515-11

TX,05,VV2826 –19–19NOV96–1/2

270LC Excavator Repair 012809

PN=199

Speed Controls Check that shut-off lever is tight against run position stop using a 0.025 mm (0.001 in.) feeler gauge. If feeler gauge passes between shut-off lever and stop, shorten the linkage two more turns. 10. Turn key switch to OFF. The spring inside the solenoid housing boot will extend the plunger to push the shut-off lever down to the stop position stop (lower stop) (G). Check that shut-off lever is within 3 mm (0.125 in.) of stop position stop.

TX,05,VV2826 –19–19NOV96–2/2

05 0515 12

TM1668 (28JAN09)

05-0515-12

270LC Excavator Repair 012809

PN=200

Group 0520

Intake System Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21709 –19–24MAY00–1/3

Inlet Air Adapter . . . . . . . . . . . . . . . . . . . . . . . JDG51 To perform intake manifold pressure test on engine.

CED,OUOE003,21709 –19–24MAY00–2/3

05 0520 1

Manifold Pressure Tester . . . . . . . . . . . . . . . . JDE147 To perform intake manifold pressure test on engine.

CED,OUOE003,21709 –19–24MAY00–3/3

Specifications Item

Measurement

Specification

Air Intake System Leakage Test

Pressure

14—21 kPa (0.14—0.21 bar) (2—3 psi)

CED,OUOE003,21710 –19–24MAY00–1/1

TM1668 (28JAN09)

05-0520-1

270LC Excavator Repair 012809

PN=201

Intake System

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

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

T5906AP

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

T6089AR

6. Pressurize air intake system. If intake system cannot be pressurized, turn engine crankshaft slightly to close valves. Specification Air Intake System Leakage Test—Pressure ............................................. 14—21 kPa (0.14—0.21 bar) (2—3 psi)

A—JDG51 Air Inlet Adapter Kit

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

TX,05,VV2830 –19–06APR00–1/1

Remove and Install Air Cleaner 1. Disconnect wiring connector (A).

–UN–05MAR92

2. Loosen clamp (B). Disconnect hose (C). A—Wiring Connector B—Clamp C—Hose

T7685HC

05 0520 2

–UN–25OCT88

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

Continued on next page

TM1668 (28JAN09)

05-0520-2

TX,05,VV2831 –19–06APR00–1/4

270LC Excavator Repair 012809

PN=202

Intake System 3. Remove cap screws, washers, and lock washers (A). Remove air cleaner. 4. Replace parts as necessary. –UN–05MAR92

5. Install air cleaner.

T7685HD

6. Connect hose. Tighten clamp until hose starts to deform around clamp band. 7. Connect wiring connector. A—Cap Screw, Washer, and Lock Washer (4 used)

Continued on next page

TX,05,VV2831 –19–06APR00–2/4

05 0520 3

TM1668 (28JAN09)

05-0520-3

270LC Excavator Repair 012809

PN=203

Intake System

T104814

–UN–14NOV96

05 0520 4

Continued on next page

TM1668 (28JAN09)

05-0520-4

TX,05,VV2831 –19–06APR00–3/4

270LC Excavator Repair 012809

PN=204

Intake System B—Secondary Filter Element C—Primary Filter Element D—Wing Nut E—Wing Nut (2 used) F—Cover H—Snap Ring I—Gasket

J—Valve K—Air Restriction Indicator 1—Air Cleaner 2—Cap Screw (10 used) 3—Hose 4—Pipe 5—Hose

6—Pipe 7—Hose 8—Bracket 9—Hose Clamp (3 used) 10—Hose Clamp (2 used) 11—Hose Clamp

12—Spacer (Pipe) (2 used) 13—Lock Washer (2 used) 14—Washer (2 used) 17—Cap Screw (2 used) 18—Washer (10 used) 21—Washer (10 used)

TX,05,VV2831 –19–06APR00–4/4

05 0520 5

TM1668 (28JAN09)

05-0520-5

270LC Excavator Repair 012809

PN=205

Intake System

Remove and Install Charge Air Cooler

T110312

–UN–01JUL97

05 0520 6

1—Hose Clamp (8 used) 2—Hose 3—Hose

4—Mounting Bracket (2 used) 5—Air Cooler 6—Hose

7—Turbo Charger 8—Hose 9—Clamp

10—Tube 11—Tube

Tighten air cooler hose clamps (1) until hose starts to deform around clamp band.

TX,05,VV2926 –19–08MAY00–1/1

TM1668 (28JAN09)

05-0520-6

270LC Excavator Repair 012809

PN=206

Group 0560

External Fuel Supply System Other Material Number

Name

Use

T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)

Thread Lock and Sealer (Medium Strength)

Apply to threads of float and gasket-to-fuel tank screws.

LOCTITE is a trademark of Loctite Corp.

CED,OUOE003,21599 –19–08MAY00–1/1

Specifications Item

Measurement

Specification

Fuel Tank (Empty)

Weight

65 kg (144 lb) approximate

Float and Gasket-to-Fuel Tank Screw

Torque

4.5 N•m (40 lb-in)

Frame-to-Fuel Tank Cap Screw

Torque

205 N•m (152 lb-ft)

Fuel Tank 05 0560 1

CED,OUOE003,21600 –19–08MAY00–1/1

TM1668 (28JAN09)

05-0560-1

270LC Excavator Repair 012809

PN=207

External Fuel Supply System

Remove and Install Fuel Tank

T105203

–UN–19NOV96

05 0560 2

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

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

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

Continued on next page

TM1668 (28JAN09)

05-0560-2

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

TX,05,VV2833 –19–20NOV96–1/2

270LC Excavator Repair 012809

PN=208

External Fuel Supply System

CAUTION: The approximate weight of fuel tank (without fuel) is 65 kg (144 lb). Specification Fuel Tank (without Fuel)— Approximate Weight ...................................................... 65 kg (144 lb)

1. Drain fuel from fuel tank; approximate capacity is 310 L (82 gal). Specification Fuel Tank—Approximate Capacity ........................................................................ 310 L (82 gal)

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

4. Tighten cap screws (22) to 205 N•m (152 lb-ft). Specification Frame-to-Fuel Tank Cap Screws—Torque ................................................... 205 N•m (152 lb-ft)

5. Fill fuel tank with propel fuel (See Fuel Specifications in Fuels and Lubricants Group.)

2. Disconnect wiring connector (26). 3. Apply thread lock and sealer (medium strength) to thread of screws (12). Tighten screws to 4.5 N•m

05 0560 3

TX,05,VV2833 –19–20NOV96–2/2

TM1668 (28JAN09)

05-0560-3

270LC Excavator Repair 012809

PN=209

External Fuel Supply System

Remove and Install Primary Fuel Filter (Water Separator)

T105336

–UN–26NOV96

05 0560 4

00—Clamp (6 used) 01—Tie Band 03—Cap Screw and Lock Washer (7 used) 05—Clip (4 used) 07A—Filter-to-Transfer Pump Hose

07B—Hose Guard 08A—Fuel Tank-to-Filter Hose 08B—Hose Guard 10A—Injection Pump Overflow-to-Fuel Tank Hose

10B—Hose Guard 11—Clamp (2 used) 12—Clip 14—Cap Screw, Lock Washer and Washer

Continued on next page

TM1668 (28JAN09)

05-0560-4

15—Primary Fuel Filter Head 16—Fitting (2 used) 17—Plug (2 used) 18—O-Ring (4 used)

TX,05,VV2834 –19–21NOV96–1/2

270LC Excavator Repair 012809

PN=210

External Fuel Supply System 1. Loosen drain valve to drain fuel into a container. Dispose of fuel properly.

3. Remove cap screws (14) to remove primary fuel filter (15).

2. Loosen clamps (00) to disconnect hoses (08A and 07A).

TX,05,VV2834 –19–21NOV96–2/2

05 0560 5

TM1668 (28JAN09)

05-0560-5

270LC Excavator Repair 012809

PN=211

External Fuel Supply System

Remove and Install Primary Fuel Filter Element (Water Separator) 1. Loosen drain valve (31) to drain fuel into a container. Dispose of fuel properly. 2. Loosen element retainer (24) to remove filter element (23). Remove sediment bowl (28). Clean the bowl. 3. Slowly loosen retainer for hand primer (19) to release spring force. Remove hand primer. Remove the diaphragm and O-ring from filter head (15). 4. Remove plug from inlet passage (36). Clean debris from cavity (37) in filter head.

–UN–26NOV96 T105348 –UN–22NOV96 T105353B –UN–26NOV96 T105349

05 0560 6

15—Filter Head 16—Fitting (2 used) 17—Plug (2 used) 18—O-Ring (4 used) 19—Hand Primer 20—Bleed Screw 21—O-Ring 22—Seal 23—Primary Filter Element 24—Element Retainer 25—O-Ring 26—Sediment Bowl Adapter 27—O-Ring 28—Sediment Bowl 29—Seal 30—O-Ring 31—Drain Valve 32—Clamp 33—Drain Hose 34—Screw 35—O-Ring

Continued on next page

TM1668 (28JAN09)

05-0560-6

TX,05,VV2835 –19–06APR00–1/2

270LC Excavator Repair 012809

PN=212

External Fuel Supply System IMPORTANT: The filter elements for the final and primary filter are not interchangeable because of the filter medium. The final filter element has three keys and the primary filter element has four keys. To install, the keys on the filter element must align with the notches in filter head. 5. Install filter element so keys on element engage notches in filter head. 6. Bleed the fuel system. (See procedure in this group.) 15—Filter Head 16—Fitting (2 used) 17—Plug (2 used) 18—O-Ring (4 used) 19—Hand Primer 20—Bleed Screw 21—O-Ring 22—Seal 23—Primary Filter Element 24—Element Retainer 25—O-Ring 26—Sediment Bowl Adapter 27—O-Ring 28—Sediment Bowl 29—Seal 30—O-Ring 31—Drain Valve 32—Clamp 33—Drain Hose 34—Screw 35—O-Ring

T105307

–UN–26NOV96

05 0560 7

TX,05,VV2835 –19–06APR00–2/2

TM1668 (28JAN09)

05-0560-7

270LC Excavator Repair 012809

PN=213

External Fuel Supply System

Remove and Install Final Fuel Filter

T105312

–UN–26NOV96

05 0560 8

1—Flange Nut 2—Filter-to-Injection Pump Fuel Line 3—Transfer Pump-to-Filter Fuel Line 4—Cap Screw 5—Clamp 6—Cap Screw 7—Washer

8—Washer 9—Bracket 10—To Exhaust Manifold 11—90° Elbow 12—To Injection Pump 13—Fitting 14—To Transfer Pump 15—Filter Head

1. Loosen drain valve (24) to drain fuel into a container. Dispose of fuel properly.

16—Bracket (To Cylinder Head) 17—Cap Screw (4 used) 18—Plug 19—O-Ring (4 used) 20—O-Ring 21—Bleed Screw 22—O-Ring

23—Seal 24—Drain Valve 25—Clamp 26—Drain Hose 27—Element Retainer 28—Filter Element 29—Seal 30—Fitting (2 used)

2. Disconnect lines (2 and 3). Remove cap screw (17) to remove final filter.

TX,05,VV2836 –19–20NOV96–1/1

TM1668 (28JAN09)

05-0560-8

270LC Excavator Repair 012809

PN=214

External Fuel Supply System

Remove and Install Final Fuel Filter Element 1. Loosen drain valve (24) to drain fuel into a container. Dispose of fuel properly. –UN–30JUL96

2. Turn element retainer (27) to remove filter element (28). 3. Remove drain valve (24), clamp (25) and hose (26).

T102304

A—Final Fuel Filter 15—Filter Head 18—Plug 19—O-Ring (4 used) 20—O-Ring 21—Bleed Screw 22—O-Ring 23—Seal 24—Drain Valve 25—Clamp 26—Drain Hose 27—Element Retainer 28—Filter Element 29—Seal 30—Fitting (2 used)

T105327

–UN–26NOV96

05 0560 9

Continued on next page

TM1668 (28JAN09)

05-0560-9

TX,05,VV2837 –19–22NOV96–1/2

270LC Excavator Repair 012809

PN=215

External Fuel Supply System 4. Remove parts (31—34) and plug from inlet passage (36) to clean debris from cavity (37) in filter head (15)

5. Install filter element so keys on element engage notches in filter head.

–UN–26NOV96

15—Filter Head 31—Header Cap Retainer 32—Header Cap 33—O-Ring 34—Volume Plug 36—Inlet Passage 37—Cavity

T105349

05 0560 10

T105324

6. Bleed the fuel system. (See procedure in this group.)

–UN–26NOV96

IMPORTANT: The filter elements for the final and primary filter are not interchangeable because of the filter medium. The final filter element has three keys and the primary filter element has four keys. To install, the keys on the filter element must align with the notches in filter head.

TX,05,VV2837 –19–22NOV96–2/2

TM1668 (28JAN09)

05-0560-10

270LC Excavator Repair 012809

PN=216

External Fuel Supply System

Bleed Fuel System 1. Loosen bleed screws (A) on the final fuel filter and primary fuel filter (water separator). –UN–02AUG96

2. Push and release hand primer (B) until fuel fill the sediment bowl and fuel flows from bleed screw. Tighten bleed screw on primary filter.

T102672

3. Continue to operate hand primer until fuel flows from bleed screw of final filter. Tighten bleed screw. Final Fuel Filter

T102673

–UN–02AUG96

A—Bleed Screw B—Hand Primer

Primary Fuel Filter TX,05,VV2838 –19–06APR00–1/1

TM1668 (28JAN09)

05-0560-11

270LC Excavator Repair 012809

PN=217

05 0560 11

External Fuel Supply System

05 0560 12

TM1668 (28JAN09)

05-0560-12

270LC Excavator Repair 012809

PN=218

Section 07

Dampener Drive (Flex Coupling) Contents Page

Group 0752—Elements Service Equipment and Tools . . . . . . . . . . . .07-0752-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .07-0752-2 Dampener Drive (Flex Coupling) Remove and Install . . . . . . . . . . . . . . . . . .07-0752-2

TM1668 (28JAN09)

07-1

270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

07-2

270LC Excavator Repair 012809

PN=2

Group 0752

Elements Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21711 –19–24MAY00–1/2

M12-1.75 Metric Lifting Eyebolt (2 used) . . . . . . JT05550 To lift hydraulic pump.

CED,OUOE003,21711 –19–24MAY00–2/2

Other Material Number

Name

Use

T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)

Thread Lock and Sealer (Medium Strength)

Apply to flex coupling cap screws.

LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

07 0752 1

CED,OUOE003,21712 –19–24MAY00–1/1

07-0752-1

270LC Excavator Repair 012809

PN=221

Elements

Specifications Item

Measurement

Specification

Weight

170 kg (375 lb) approximate

Dampener Drive (Flex Coupling) Hydraulic Pump

108 N•m (80 lb-ft)

Insert-to-Coupling Cap Screw

Torque

215 N•m (159 lb-ft)

Insert-to-Flywheel Cap Screw

Torque

215 N•m (159 lb-ft)

Pump-to-Flywheel Housing Cap Screw

Torque

49 N•m (36 lb-ft)

Pump Outlet Line Flange-to-Housing Cap Screw

Torque

74 N•m (55 lb-ft)

Pump Inlet Line Flange-to-Housing Torque Cap Screw

93 N•m (69 lb-ft)

CED,OUOE003,21713 –19–24MAY00–1/1

Remove and Install Dampener Drive (Flex Coupling)

–UN–12NOV92

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Do not remove vent plug (A). Relieve pressure by loosening vent plug.

T7869AT

07 0752 2

Coupling-to-Pump Shaft Set Screw Torque

1. Loosen vent plug (A) to relieve reservoir pressure. 2. Drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal).

A—Vent Plug

3. Drain pump drive gearbox. Approximate oil capacity is 1.0 L (1.1 qt).

Continued on next page

TM1668 (28JAN09)

07-0752-2

TX,07,UU3903 –19–06APR00–1/3

270LC Excavator Repair 012809

PN=222

Elements

–UN–08DEC08

X9811

5. Disconnect all hydraulic lines from the pump. 6. Disconnect electrical connectors (A, B, and C). CAUTION: Approximate weight of hydraulic pump is 170 kg (375 lb).

–UN–20NOV96

Dampener Drive (Flex Coupling)—Specification Hydraulic Pump—Weight .............................. 170 kg (375 lb) approximate

7. Install lifting eyebolts in top of hydraulic pump.

T105283

8. Attach hoist to lifting eyes using a lifting strap. 9. Remove cap screws that attach hydraulic pump to engine. 10. Pull pump away from engine to remove.

A—Electrical Connector B—Electrical Connector C—Electrical Connector

Continued on next page

TM1668 (28JAN09)

07-0752-3

07 0752 3

TX,07,UU3903 –19–06APR00–2/3

270LC Excavator Repair 012809

PN=223

Elements NOTE: Flex coupling may come off with pump or stay on flywheel. 11. Remove parts (A—H). –UN–13MAY92

12. Replace parts as necessary.

T7685JE

13. Install parts (A—H). Apply thread lock and sealer (medium strength) to set screws (B) and to cap screws (D and G). 14. Tighten set screws (B). Dampener Drive (Flex Coupling)—Specification Coupling-to-Pump Shaft Set Screw—Torque .............................................................. 108 N•m (80 lb-ft)

15. Tighten cap screws (D and G). Dampener Drive (Flex Coupling)—Specification Insert-to-Coupling Cap Screw— Torque ......................................................................... 215 N•m (159 lb-ft) Insert-to-Flywheel Cap Screw— Torque ......................................................................... 215 N•m (159 lb-ft)

16. Install pump and tighten cap screws. Dampener Drive (Flex Coupling)—Specification Pump-to-Flywheel Housing Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

17. Connect hydraulic hoses and lines.

–UN–20NOV96

Dampener Drive (Flex Coupling)—Specification Pump Outlet Line Flange-to-Housing Cap Screw— Torque ............................................................................. 74 N•m (55 lb-ft) Pump Inlet Line Flange-to-Housing Cap Screw— Torque ............................................................................. 93 N•m (69 lb-ft)

T105285

07 0752 4

18. Connect wiring harnesses. 19. Install muffler and bracket. 20. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in Group 3360.)

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

TX,07,UU3903 –19–06APR00–3/3

TM1668 (28JAN09)

07-0752-4

270LC Excavator Repair 012809

PN=224

Section 16

Electrical System Contents Page

Group 1671—Batteries, Support, and Cables Service Equipment and Tools . . . . . . . . . . . .16-1671-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Batteries Handle Safely . . . . . . . . . . . . . . . . . . . . . .16-1671-3 Procedure for Testing . . . . . . . . . . . . . . . .16-1671-4 Electrolyte Specific Gravity Checking . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-5 Battery Check Electrolyte Level and Terminals . . .16-1671-7 Using Booster Batteries—24-Volt System . . .16-1671-9 Battery Charge. . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-10 Engine Speed Learning Procedure . . . . . . . . . . .16-1671-12 Batteries Remove and Install . . . . . . . . . . . . . . . . .16-1671-14 Install Replacement . . . . . . . . . . . . . . . . .16-1671-15 12-Volt Accessories Adding . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-16 Group 1672—Alternator, Regulator, and Charging System Wiring Alternators and Starting Motors Use CTM77 . . . . . . . . . . . . . . . . . . . . . . . .16-1672-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1672-1 Alternator Remove and Install . . . . . . . . . . . . . . . . . .16-1672-2 Group 1674—Wiring Harness and Switches Essential Tools . . . . . . . . . . . . . . . . . . . . . . .16-1674-1 Fuse Specifications . . . . . . . . . . . . . . . . . . . .16-1674-3 Component Identification Front Chassis Electrical . . . . . . . . . . . . . . .16-1674-4 Functional Schematic and Component Location Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-6 Component Identification Cab Electrical . . . . . . . . . . . . . . . . . . . . .16-1674-10 Hydraulic Electrical . . . . . . . . . . . . . . . . .16-1674-12 Fuses Replacing. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-14 Fuse (Blade-Type) Color Code . . . . . . . . . . . . .16-1674-15 Control Panel Switches Remove and Install . . . . . . . . . . . . . . . . .16-1674-16 TM1668 (28JAN09)

Page

Dome Light Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-16 Travel Alarm Cancel Switch and Start Aid Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-17 Starter Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-17 Cab Ground Straps Remove and Install . . . . . . . . . . . . . . . . .16-1674-18 Engine Overheat Alarm Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-18 Charge Air Temperature Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-19 Engine Coolant Level Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-19 Engine Oil Pressure Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-19 Engine Oil Level Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-19 Engine Coolant Temperature Sensor Remove and Install . . . . . . . . . . . . . . . . .16-1674-20 Fuel Level Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-20 16 Fuel Level Sensor Remove and Install . . . . . . . . . . . . . . . . .16-1674-20 Travel Alarm Remove and Install . . . . . . . . . . . . . . . . .16-1674-21 Dig Function Pressure Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-21 Propel Function Pressure Sensor Remove and Install . . . . . . . . . . . . . . . . .16-1674-22 Rear Pump Pressure Sensor Remove and Install . . . . . . . . . . . . . . . . .16-1674-22 Front Pump Pressure Sensor Remove and Install . . . . . . . . . . . . . . . . .16-1674-22 Engine Speed Sensor Remove and Install . . . . . . . . . . . . . . . . .16-1674-23 Pump Control Pressure Sensor Remove and Install . . . . . . . . . . . . . . . . .16-1674-23 Proportional Solenoids Remove and Install . . . . . . . . . . . . . . . . .16-1674-23 Windshield wiper enable switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-24

16-1

Continued on next page

270LC Excavator Repair 012809

PN=1

Contents

Page

Air Filter Restriction Switch Remove and Install . . . . . . . . . . . . . . . . .16-1674-24 Engine and Pump Controller (EPC) Remove and Install . . . . . . . . . . . . . . . . .16-1674-25 Spring Wire Retainer Connectors Disconnect. . . . . . . . . . . . . . . . . . . . . . . .16-1674-25 Battery Relay Remove and Install . . . . . . . . . . . . . . . . .16-1674-26 Relay Starter Solenoid Remove and Install . . . . . . . . . . . . . . . . .16-1674-26 Replace DEUTSCH Connectors . . . . . . . .16-1674-27 Install DEUTSCH Contact. . . . . . . . . . . . .16-1674-28 Replace WEATHER PACK Connector . . .16-1674-30 Install WEATHER PACK Contact . . . . . . .16-1674-31 Remove Connector Body from Blade Terminals. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-32 Group 1675—System Controls Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1675-1 Welding on Machine . . . . . . . . . . . . . . . . . . .16-1675-1 Engine Speed Learning Procedure . . . . . . . . . . . .16-1675-2 Engine and Pump Controller (EPC) Harness Connector Connecting . . . . . . . . . . . . . . . . . . . . . . . .16-1675-3 Engine and Pump Controller (EPC) Remove and Install . . . . . . . . . . . . . . . . . .16-1675-4 Monitor Controller Remove and Install . . . . . . . . . . . . . . . . . .16-1675-4 16

Group 1676—Instruments and Indicators Replace Monitor Panel and Switch Panel Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1676-1 Monitor Panel Remove and Install . . . . . . . . . . . . . . . . . .16-1676-1 Hour Meter Remove and Install . . . . . . . . . . . . . . . . . .16-1676-2 Engine Hour Meter Switch Remove and Install . . . . . . . . . . . . . . . . . .16-1676-3 Travel Alarm Volume Change . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1676-3

TM1668 (28JAN09)

16-2

270LC Excavator Repair 012809

PN=2

Group 1671

Batteries, Support, and Cables Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21715 –19–24MAY00–1/4

Battery Post and Clamp Cleaner . . . . . . . . . . . JT05838 To clean corrosion off battery posts and clamps.

CED,OUOE003,21715 –19–24MAY00–2/4

Coolant and Battery Tester . . . . . . . . . . . . . . . JT05460 To check battery electrolyte specific gravity.

CED,OUOE003,21715 –19–24MAY00–3/4

Battery Load Tester . . . . . . . . . . . . . . . . . . . . JT05832 To check battery capacity.

CED,OUOE003,21715 –19–24MAY00–4/4

TM1668 (28JAN09)

16-1671-1

270LC Excavator Repair 012809

PN=227

16 1671 1

Batteries, Support, and Cables

Specifications Item

Measurement

Specification

Engine Slow Idle

Speed

900 ± 25 rpm

Engine Auto-Idle

Speed

1200 ± 25 rpm

E (Economy) Mode

Speed

2030 ± 25 rpm

Fast Idle in Standard Mode

Speed

2230 ± 25 rpm

Voltage Cold Cranking Power Reserve Capacity BCI Group Size Electrolyte Specific Gravity

12 Volts 1100 amps at -18°C (0°F) 400 minutes at 25 amps and 26.7°C (80°F) 4D 1.265—1.280 fully charged

System Voltage

Voltage

24 volts

Cable Clamp Nut

Torque

18 N•m (156 lb-in.)

Engine Speed Learning Procedure

Battery Battery

16 1671 2

CED,OUOE003,21717 –19–24AUG01–1/1

TM1668 (28JAN09)

16-1671-2

270LC Excavator Repair 012809

PN=228

Batteries, Support, and Cables

Never lay a metal object on top of a battery as a short circuit can result. Battery acid is harmful on contact with skin or fabrics. If acid spills, follow these first aid tips:

TS204

CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Make sure the batteries are charged in a well ventilated area.

–UN–23AUG88

Handle Batteries Safely

1. Immediately remove any clothing on which acid spills. 2. If acid contacts the skin, rinse the affected area with running water for 10 to 15 minutes. 3. If acid comes into contact with the eyes, flood the eyes with running water for 15 to 30 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor. 4. To neutralize acid spilled on the floor, use one of the following mixtures: 0.5 kg (1 lb) of baking soda in 4 L (1 gal) of water, or 0.4 L (1 pt) of household ammonia in 4 L (1 gal) of water. 5. Acid from the batteries can also damage the paint and metal surfaces of the machine. Avoid over filling the battery cells.

16 1671 3

TX,16,UU3478 –19–04MAR97–1/1

TM1668 (28JAN09)

16-1671-3

270LC Excavator Repair 012809

PN=229

Batteries, Support, and Cables

Procedure for Testing Batteries Record specific gravity reading for each cell.

1. VISUAL CHECK a. Check for damage such as cracked or broken case and electrolyte leakage.

If high and low readings vary LESS than 0.050 and average specific gravity is between 1.225 and 1.280, battery is fully charged, go to LOAD TEST.

If damage is seen, replace battery. b. Check electrolyte level. (See procedure in this group.) If low, add distilled water to specified level and charge battery. c. Check terminals for corrosion. If corroded, clean using a wire brush or battery post cleaner such as JT05838 Battery Post/Clamp Cleaner.

If high and low readings vary LESS than 0.050 and average specific gravity is LESS than 1.225, charge battery and repeat test. If average specific gravity is still LESS than 1.225, replace both batteries. If high and low readings vary MORE than 0.050, charge battery and repeat test. If high and low readings still vary MORE than 0.050, replace both batteries. 3. LOAD TEST Check battery capacity with a load tester such as JT05832 Battery Load Tester. Follow tester manufacturer’s instructions for proper load test procedures.

d. Check posts for looseness. If posts are loose, replace battery.

If one battery fails load test, replace both batteries.

2. HYDROMETER TEST Check specific gravity with a hydrometer or battery tester such as JT05460 Coolant/Battery Tester.

16 1671 4

TX,16,UU3479 –19–01SEP95–1/1

TM1668 (28JAN09)

16-1671-4

270LC Excavator Repair 012809

PN=230

Batteries, Support, and Cables

Checking Electrolyte Specific Gravity

–UN–23AUG88

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

TS204

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself:

–UN–23AUG88

1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

TS203

If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts). 3. Get medical attention immediately.

–UN–10NOV88

Check the specific gravity of electrolyte in each battery cell using a battery and coolant tester such as JT05460 Battery/Coolant Tester.

T85402

Follow directions included with the tester.

Continued on next page

TM1668 (28JAN09)

16-1671-5

TX,16,UU3480 –19–21SEP94–1/2

270LC Excavator Repair 012809

PN=231

16 1671 5

Batteries, Support, and Cables A fully charged battery will have a corrected specific gravity reading of 1.260. If the reading is below 1.200, charge the battery. NOTE: In tropical areas, use 1.225 for the full charge reading. In cold areas, use 1.280 for the full-charge reading.

TX,16,UU3480 –19–21SEP94–2/2

16 1671 6

TM1668 (28JAN09)

16-1671-6

270LC Excavator Repair 012809

PN=232

Batteries, Support, and Cables

Check Battery Electrolyte Level and Terminals CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. –UN–23AUG88

Avoid the hazard by:

TS203

1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10—15 minutes. Get medical attention immediately.

16 1671 7

If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. 1. Remove hold-down clamps. 2. Remove hold-down clamps.

Continued on next page

TM1668 (28JAN09)

16-1671-7

TX,16,UU3481 –19–01SEP95–1/2

270LC Excavator Repair 012809

PN=233

Batteries, Support, and Cables

–UN–09SEP03

IMPORTANT: During freezing weather, batteries must be charged after water is added to prevent battery freezing. Charge battery using a battery charger or by running the engine.

T6996DB

3. Fill each cell to within specified range with distilled water. DO NOT overfill. A—Battery Post B—Fill Tube C—Electrolyte Level Range

T6996DA

–UN–09SEP03

Single Level Fill Tube Application

Dual Level Fill Tube Application TX,16,UU3481 –19–01SEP95–2/2

16 1671 8

TM1668 (28JAN09)

16-1671-8

270LC Excavator Repair 012809

PN=234

Batteries, Support, and Cables

Using Booster Batteries—24-Volt System 1. Turn key switch to OFF.

–UN–23AUG88

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

TS204

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last.

–UN–21MAY90

IMPORTANT: Machine electrical system is 24-volt negative (-) ground. Use only 24-volt booster batteries Disconnect PVC and monitor controller from harness in case batteries are connected incorrectly.

T7233JN

2. Connect booster batteries (B) to machine batteries (A) making the last connection at machine frame, away from batteries. Two Battery Application

Rock the clamps to make sure they make good contact.

A—Machine Batteries B—Booster Batteries

When possible, use equipment with a switch in the cable that connects booster batteries to machine batteries. 16 1671 9

Continued on next page

TM1668 (28JAN09)

16-1671-9

TX,16,UU3482 –19–10MAY00–1/2

270LC Excavator Repair 012809

PN=235

Batteries, Support, and Cables

CAUTION: Avoid possible injury or death from machinery runaway.

–UN–18OCT88

Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.

T6607AO

NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park. 3. Start engine while seated on operator’s seat. After engine starts, disconnect clamp at machine frame first and then disconnect remaining clamps.

TX,16,UU3482 –19–10MAY00–2/2

Charge Battery

–UN–23AUG88

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

16 1671 10

TS204

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. IMPORTANT: When charging a battery in the machine, battery cables and PVC and EC controller connectors must be disconnected to avoid damage to electrical components and controllers if battery charger cables are inadvertently connected to battery wrong. NOTE: Follow manufacturer’s instructions to use battery charger as a booster to start engine. 1. Disconnect all battery cables starting at the negative (-) ground cable.

Continued on next page

TM1668 (28JAN09)

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TX,16,UU3483 –19–07APR00–1/3

270LC Excavator Repair 012809

PN=236

Batteries, Support, and Cables 2. Remove cap screws (A and C) and the fuse box cover (B) to remove the rear console cover.

T107932B

–UN–07MAR97

A—Cap Screw (4 used) B—Box Cover C—Cap Screw (4 used)

TX,16,UU3483 –19–07APR00–2/3

3. Loosen EPC connectors and remove connectors (A— C). 4. Turn charger off before connecting or disconnecting it. –UN–06MAR97

5. Charge battery following manufacturer’s instructions for your battery charger.

T105437B

6. After battery is charged, connect the positive battery (+) cable, then connect the negative (-) ground cable. 7. Push connectors into EPC controller. 8. Install rear console cover and fuse box cover 9. After connecting batteries, engine speeds must be recalibrated.

A—EPC Connector B—EPC Connector C—EPC Connector

TX,16,UU3483 –19–07APR00–3/3

TM1668 (28JAN09)

16-1671-11

270LC Excavator Repair 012809

PN=237

16 1671 11

Batteries, Support, and Cables

Engine Speed Learning Procedure SPECIFICATIONS Engine Slow Idle Speed

900 ± 25 rpm

Engine Auto-Idle Speed

1200 ± 25 rpm

E (Economy) Mode Speed

2030 ± 25 rpm

Fast Idle in Standard Mode Speed

2230 ± 25 rpm

16 1671 12

Continued on next page

TM1668 (28JAN09)

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TX,9010,UU3408 –19–26JAN09–1/2

270LC Excavator Repair 012809

PN=238

Batteries, Support, and Cables 3. Push engine learning switch (C) up to top position. The switch is a three position switch. Make sure it is in the top position. 4. Turn key switch ON. Wait 5 seconds. 5. Turn key switch OFF. Wait 5 seconds. 6. Push engine learning switch to middle position. 7. Check engine speeds.

T103674

NOTE: The laptop computer with the excavator diagnostic Program can be used to change the default speeds for slow idle, auto-idle, economy mode, and fast idle in standard mode.

–UN–11SEP96

C—Engine Learning Switch

TX,9010,UU3408 –19–26JAN09–2/2

16 1671 13

TM1668 (28JAN09)

16-1671-13

270LC Excavator Repair 012809

PN=239

Batteries, Support, and Cables

Remove and Install Batteries

–UN–23AUG88

CAUTION: Prevent personal injury from exploding battery. Keep sparks and flames away from battery. 1. Disconnect ground cables (E).

TS204

2. Disconnect positive cable (C) and jumper cable (D). 3. Remove parts (B—F). 4. Remove batteries. 5. Check cables and clamps for wear or corrosion. Make sure batteries are fully charged.

–UN–10DEC96

IMPORTANT: If one battery in a 24-volt system has failed, replace both batteries.

Battery—Specification Battery—Voltage............................................................................ 12 Volts Cold Cranking Power ....................................... 1100 amps at -18°C (0°F) Reserve Capacity ......................................... 400 minutes at 25 amps and 26.7°C (80°F) BCI Group Size ...................................................................................... 4D Electrolyte Specific Gravity.............................. 1.265—1.280 fully charged System Voltage—Voltage .............................................................. 24 volts

7. Clean battery posts and cables. 16 1671 14

T105555B

6. Install batteries.

A—Nut (2 used) B—Bracket (2 used) C—Positive Cable D—Jumper Cable E—Ground Cable F—Ground Cable

8. Install parts (A and B). 9. Connect positive cables (C), ground cables (E) and jumper cable (D). Tighten terminal nuts. Specification Cable Clamp Nut—Torque ........................................... 18 N•m (156 lb-in.)

TX,16,GG2754 –19–24AUG01–1/1

TM1668 (28JAN09)

16-1671-14

270LC Excavator Repair 012809

PN=240

Batteries, Support, and Cables

Install Replacement Batteries

–UN–10DEC96

1. Remove original batteries. (See procedure in this group.)

T105555B

A—Nut (2 used) B—Bracket (2 used) C—Positive Cable D—Jumper Cable E—Ground Cable F—Ground Cable

TX,16,GG2755 –19–24AUG01–1/2

3. Install positive cable, jumper cable, and ground cable.

T105419B

–UN–12DEC96

2. Install new batteries and parts (B—I).

A—Screw B—Plate C—Bracket (2 used) D—Screw (4 used) E—Nut (4 used) F—Washer (4 used) G—Oversized Nut (2 used) H—Nut (2 used) I—Cap Screw (2 used)

TX,16,GG2755 –19–24AUG01–2/2

TM1668 (28JAN09)

16-1671-15

270LC Excavator Repair 012809

PN=241

16 1671 15

Batteries, Support, and Cables

Adding 12-Volt Accessories IMPORTANT: This machine has a 24-volt electrical system. –UN–18OCT88

Specification Machine Electrical System— Voltage.............................................................................................. 24 volt

When possible, use 24-volt accessories. If 12-volt accessories are added, use a 24-volt-to-12-volt converter. Converters are available from your John Deere dealer or electronic retail stores. This converter may be wired into the ACC terminal of the ignition switch (see drawing). Converter capacity requirements depend on the load of the accessories installed. Follow electronic dealer and manufacturer’s recommendations to determine the capacity of the converter required and its installation requirements.

T6520AJ1

Installing 12-volt accessories without addition of 24-volt-to-12-volt converter may cause battery failure. See your John Deere dealer. A—Battery B—24 Volts C—Ignition Switch D—ACC Terminal E—Converter F—12 Volts G—In-Line Fuse H—12-Volt Accessory

DO NOT connect an accessory to one battery. Connecting a 12-volt accessory to one battery will cause one battery to overcharge, and the other battery to undercharge, causing battery failure.

16 1671 16

TX,16,UU3486 –19–26JAN09–1/1

TM1668 (28JAN09)

16-1671-16

270LC Excavator Repair 012809

PN=242

Group 1672

Alternator, Regulator, and Charging System Wiring

TS225

–UN–17JAN89

Alternators and Starting Motors—See Foreword

TX,16,UU3487 –19–26JAN09–1/1

Specifications Item

Measurement

Specification

Alternator Alternator Mounting Top Strap Cap Torque Screw

27 N•m (20 lb-ft)

Alternator Mounting Cap Screw and Nut

Torque

47 N•m (35 lb-ft)

Ground Terminal Nut

Torque

2.3 N•m (20 lb-in.)

BAT (Output) Terminal Nut

Torque

3.6 N•m (32 lb-in.)

D+ Terminal Nut

Torque

2.3 N•m (20 lb-in.)

CED,OUOE003,21640 –19–10MAY00–1/1

TM1668 (28JAN09)

16-1672-1

270LC Excavator Repair 012809

PN=243

16 1672 1

Alternator, Regulator, and Charging System Wiring

Remove and Install Alternator

–UN–14NOV96

IMPORTANT: Always disconnect battery negative (-) cables before removing alternator or a short circuit could result. 1. Disconnect the battery negative (-) cables.

T105164

2. Pull tension adjuster idler away from belt using a 15 mm wrench on the head of cap screw (A) in idler. 3. Slide belt off alternator pulley. A—Hex Head of Cap Screw

T108219

–UN–25MAR97

16 1672 2

Continued on next page

TM1668 (28JAN09)

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TX,16,UU3489 –19–07APR00–1/2

270LC Excavator Repair 012809

PN=244

Alternator, Regulator, and Charging System Wiring 4. Disconnect wiring leads (C—E). 5. Remove cap screw and washer (A) and cap screw and nut (B) to remove alternator. –UN–06SEP94

6. Replace parts as necessary.

T8314AC

7. Install alternator. Install lower cap screw and nut (B) so head of cap screw is toward belt. 8. Install cap screw and washer (A). 9. Tighten cap screw (A) and cap screw and nut (B) . Alternator—Specification Alternator Mounting Top Strap Cap Screw—Torque ........................................................ 27 N•m (20 lb-ft) Alternator Mounting Cap Screw and Nut—Torque ............................................................. 47 N•m (35 lb-ft)

A—Cap Screw, Washer B—Cap Screw, Nut C—Ground Terminal Wiring Lead D—D+ Terminal (BLU/YEL) E—BAT Terminal Wiring Lead

10. Connect wiring leads. Tighten ground terminal nut. Tighten output BAT terminal nut. Alternator—Specification Ground Terminal Nut—Torque ...................................... 2.3 N•m (20 lb-in.) BAT (Output) Terminal Nut— Torque ........................................................................... 3.6 N•m (32 lb-in.) D+ Terminal Nut—Torque ............................................. 2.3 N•m (20 lb-in.)

11. Slowly turn ratchet clockwise to place tension adjuster assembly against belt. Tension is automatically adjusted. 12. Remove ratchet from assembly.

16 1672 3

TX,16,UU3489 –19–07APR00–2/2

TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=245

Alternator, Regulator, and Charging System Wiring

16 1672 4

TM1668 (28JAN09)

16-1672-4

270LC Excavator Repair 012809

PN=246

Group 1674

Wiring Harness and Switches Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,1156 –19–09MAY00–1/4 TS447 –UN–22JUN89

DEUTSCH Electrical Repair Tool Kit . . . . . . . . JDG359 To repair DEUTSCH electrical connector bodies. Crimper. . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG360 To adjust selector for correct wire size. Extractor Tool (Set of Two) . . . . . . . . . . . . . . . JDG361 To remove 12 to 14 gauge wire. Extractor Tool (Set of Two) . . . . . . . . . . . . . . . JDG362 To remove 16 to 18 gauge wire. Extractor Tool (Set of Two) . . . . . . . . . . . . . . . JDG363 16 1674 1

To remove 20 gauge wire.

DEUTSCH is a trademark of the Deutsch Co.

CED,OUOE003,1156 –19–09MAY00–2/4 RG6783 –UN–05DEC97

WEATHER PACK Extraction Tool . . . . . . . . .JDG3641 Used to replace terminal contact in WEATHER PACK connector body.

JDG364

WEATHER PACK is a trademark of Packard Electric. 1

Included in JT07195A Electrical Repair Kit. Continued on next page

TM1668 (28JAN09)

16-1674-1

CED,OUOE003,1156 –19–09MAY00–3/4

270LC Excavator Repair 012809

PN=247

Wiring Harness and Switches RW25542 –UN–20AUG96

WEATHER PACK Crimping Tool . . . . . . . . . . JDG783 Use to crimp WEATHER PACK terminals. JDG783

WEATHER PACK is a trademark of Packard Electric.

CED,OUOE003,1156 –19–09MAY00–4/4

16 1674 2

TM1668 (28JAN09)

16-1674-2

270LC Excavator Repair 012809

PN=248

Wiring Harness and Switches

Fuse Specifications IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload. NOTE: The “marked” name in parenthesis is the fuse name shown on the fuseblock cover.

T7713AJ

F1—Radio and Monitor Controller Backup 5-Amp Fuse (marked Back Up) F2—Engine and Pump Controller 10-Amp Fuse (marked Controller) F3—Engine Control (EC) Motor 10-Amp Fuse (marked EC Motor) F4—Solenoid 5-Amp Fuse (marked Solenoid) F5—Power On 10-Amp Fuse (marked Pow. On) F6—Monitor Controller and Display 5-Amp Fuse (marked Sw. Box) F7—Switched Power 5-Amp Fuse (marked Option 1) F8—Switched Power 10-Amp Fuse (marked Option 2) F9—Battery Power 5-Amp Fuse (marked Option 3) F10—Travel Alarm 5-Amp Fuse (marked Travel) F11—Work and Drive Lights 20-Amp Fuse (marked Lamp) F12—Windshield Wiper 10-Amp Fuse (marked Wiper) F13—Blower Motor 20-Amp Fuse (marked Heater) F14—Air Conditioner Controller and Relays 5-Amp Fuse (marked Air Con) F15—Horn 10-Amp Fuse (marked Horn) F16—Radio 5-Amp Fuse (marked Radio) F17—Lighter 10-Amp Fuse (marked Lighter) F18—Dome Light 5-Amp Fuse (marked Room Lamp) F19—Auxiliary 10-Amp Fuse (marked Auxiliary) F20—Start Aid 20-Amp Fuse (marked Start Aid) (Not used)

–UN–06MAR92

Fuse block is located behind the operators seat under a fuse block cover.

16 1674 3

CED,TX02661,227 –19–15MAY00–1/1

TM1668 (28JAN09)

16-1674-3

270LC Excavator Repair 012809

PN=249

Wiring Harness and Switches

Front Chassis Electrical Component Identification

T107870

–UN–14MAR97

16 1674 4

Continued on next page

TM1668 (28JAN09)

16-1674-4

TX,16,UU3491 –19–11JUL92–1/2

270LC Excavator Repair 012809

PN=250

Wiring Harness and Switches 1—(E14) Work Light (RED/BLU) 2—(B8) Fuel Level Sensor (BRN, BLK)

3—(B22) Fuel level Switch WHT, YEL)

4—(B12) Horns (RED/GRN, BLK)

NOTE: The identification letters and numbers shown in parenthesis (E1) are those used on the wiring diagrams and schematics in the

5—(E15) Drive Light (RED, BLK)

operation and tests manual. In the second set of parenthesis are the color of wiring leads connected to that electrical component.

TX,16,UU3491 –19–11JUL92–2/2

16 1674 5

TM1668 (28JAN09)

16-1674-5

270LC Excavator Repair 012809

PN=251

Wiring Harness and Switches

Functional Schematic and Component Location Legend NOTE: A2—Engine and Pump Controller (SE8, W2) A2 indicates component identification number. Engine and Pump Controller indicates component name. SE8 indicates section numbers of SYSTEM FUNCTIONAL SCHEMATIC where component is located. W2 is the identification number of the COMPONENT LOCATION and HARNESS CONNECTOR (WITH WIRE AND PIN LOCATION) drawings for the component. This would indicate that the Engine and Pump Controller is connected to W2 Cab Harness. • A1—Radio (SE14, W2) • A2— Engine and Pump Controller (SE8, W2) • A3— Air Conditioner Controller (SE17, W9) • A4— Engine Mode and RPM Control Unit (SE4, W2) • A5— Monitor Controller and Display (SE5, W3) • B1—Air Filter Restriction Switch (SE6, W1) • B2—Fuel Level Switch (SE6, W1) • B3— Engine Coolant Temperature Switch (SE6, W1) • B4— Engine Oil Pressure Switch (SE6, W1) • B5— Hydraulic Oil Level Switch (SE6, W1) • B6— Engine Coolant Level Switch (SE6, W1) 16 • B7— Engine Oil Level Switch (SE6, W1) 1674 • B8— Fuel Level Sensor (SE6, W1) 6 • B9— Engine Coolant Temperature Sensor (SE4, W1) • B10—Not Used • B11—Not Used • B12—Charge Air Temperature Switch (SE6, W1) • B13—Boom Up Pressure Switch (SE7, W1) • B14—Dig Pressure Switch (SE7, W1) • B15—Propel Pressure Switch (SE7, W1) • B16—Engine Speed (N) Sensor (SE8, W1) • B17—Engine Control (EC) Sensor (Located Inside Engine Control Motor Housing) (SE7, W1) • B18—Rear Pump Pressure Sensor (SE7, W1) • B19—Front Pump Pressure Sensor (SE7, W1)

• B20—Arm In Pressure Sensor (SE7, W1) • B21—Rear Pump Control Pressure Sensor (SE7, W1) • B22—Front Pump Control Pressure Sensor (SE7, W1) • B23—Right Speaker (SE14, W2) • B24—Left Speaker (SE14, W2) • B25—High Note Horn (SE15, W1) • B26—Low Note Horn (SE15, W1) • B27—Air Conditioner High and Low Pressure Switch (SE17, W9) • B28—Not Used • B29—Air Conditioner and Heater Thermistor (SE17, W9) • E1—Work Light (SE13, W1) • E2—Drive Light (SE13, W1) • E3—Cab Dome Light (SE15, W2) • E4—Monitor Controller and Display Backlight (SE5, W3) • E5—Engine RPM Dial Backlight (SE4, W2) • F1—Radio and Monitor Controller Backup 5 Amp Fuse (marked Back Up) (SE6, W2) • F2—Engine and Pump Controller 10 Amp Fuse (marked Controller) (SE9, W2) • F3—Engine Control (EC) Motor 10 Amp Fuse (marked EC Motor) (SE9, W2) • F4—Solenoid 5 Amp Fuse (marked Solenoid) (SE9, W2) • F5— Power On 10 Amp Fuse (marked Pow. On) (SE3, W2) • F6—Monitor Controller and Display 5 Amp Fuse (marked Sw. Box) (SE4, W2) • F7—Switched Power 5 Amp Fuse (marked Option 1) (SE18, W2) • F8—Switched Power 10 Amp Fuse (marked Option 2) (SE18, W2) • F9—Battery Power 5 Amp Fuse (marked Option 3) (SE18, W2) • F10—Travel Alarm 5 Amp Fuse (marked Option 1) (SE10, W2) • F11—Work and Drive Lights 20 Amp Fuse (marked Lamp) (SE13, W2)

Continued on next page

TM1668 (28JAN09)

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CED,TX02661,228 –19–03FEB99–1/4

270LC Excavator Repair 012809

PN=252

Wiring Harness and Switches • F12—Windshield Wiper 10 Amp Fuse (marked Wiper) (SE12, W2) • F13—Blower Motor 20 Amp Fuse (marked Heater) (SE16, W2) • F14—Air Conditioner Controller and Relays 5 Amp Fuse (marked Heater) (SE17, W2) • F15—Horn 10 Amp Fuse (marked Horn) (SE15, W2) • F16—Radio 5 Amp Fuse (marked Radio) (SE14, W2) • F17—Lighter 10 Amp Fuse (marked Lighter) (SE15, W2) • F18—Dome Light 5 Amp Fuse (marked Room Lamp) (SE15, W2) • F19—Auxiliary 10 Amp Fuse (marked Auxiliary) (SE18, W2) • F20—Start Aid 20 Amp Fuse (marked Start Aid) (Not Used—Field Option) • F21—Battery Power 40 Amp Fusible Link (SE1, W1) • F22—Alternator Power 60 Amp Fusible Link (SE1, W1) • F23—Fuel Shutoff 40 Amp Fusible Link (SE1, W1) • G1—Battery (SE1, W1) • G2—Battery (SE1, W1) • G3—Alternator (SE3, W1) • G4—24 Volt Power Plug (SE15, W3) • H1—Dig Mode Indicator Light (SE5, W3) • H2—Grading Mode Indicator Light (SE5, W3) • H3—Precision Mode Indicator Light (SE5, W3) • H4—Attachment Mode Indicator Light (SE5, W3) • H5—High Power Mode Indicator Light (SE4, W3) • H6—Economy Mode Indicator Light (SE4, W3) • H7—Auto Idle Mode Indicator Light (SE4, W3) • H8—Monitor Controller and Display Alarm (SE5, W3) • H9—Not Used • H10—Travel Alarm (SE10, W1) • H11—Spare Indicator Light (SE4, W3) • H12—Hydraulic Oil Level Indicator Light (SE4, W3) • H13—Fuel Level Indicator Light (SE4, W3) • H14—Air Filter Restriction Indicator Light (SE4, W3) • H15—Charge Air Temperature Indicator Light (SE4, W3) • H16—Engine Coolant Temperature Indicator Light (SE4, W3)

• H17—Engine Oil Pressure Indicator Light (SE4, W3) • H18—Alternator Voltage Indicator Light (SE4, W3) • H19—Engine Oil Level Indicator Light (SE4, W3) • H20—Engine Coolant Level Indicator Light (SE4, W3) • H21—Spare Indicator Light (SE4, W3) • K1—Alternator Shut Down Relay (Marked R1) (SE3, W3) • K2—Windshield Washer Relay (Marked R2) (SE11, W3) • K3—Work Light Relay (Marked R3) (SE13, W3) • K4—Drive Light Relay (Marked R4) (SE13, W3) • K5—Horn Relay (Marked R5) (SE15, W3) • K6—Windshield Wiper Relay (Motor Ground and Intermittent) (Marked R6) (SE11, W3) • K7—Windshield Wiper Relay (Wiper Run) (Marked R7) (SE12, W3) • K8—Windshield Wiper Relay (Hold for Park) (Marked R8) (SE12, W3) • K9—Windshield Wiper Relay (Motor Ground for Park) (Marked R9) (SE12, W3) • K10—Propel Auto Idle Relay (Marked R10) (SE7, W3) • K11—Starter Protection Relay (Marked R11) (SE2, W3) • K12—Start Aid Relay (Marked R12) (Not Used— Field Option) • K13—Starter Relay (SE2, W1) • K14—Battery Relay (SE1, W1) • K15—Fuel Shutoff Relay (SE3, W1) • K16—Not Used • K17—Not Used • K18—Not Used • K19—Not Used • K20—Not Used • K21—Not Used • K22—Not Used • K23—Not Used • K24—Air Conditioner Blower Motor and Main Power (Low Speed) Relay (SE17, W9) • K25—Air Conditioner Compressor Clutch Relay (SE17, W9) • K26—Air Conditioner Blower Motor (Low Medium Speed) Relay (SE17, W9)

Continued on next page

TM1668 (28JAN09)

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CED,TX02661,228 –19–03FEB99–2/4

270LC Excavator Repair 012809

PN=253

16 1674 7

Wiring Harness and Switches • K27—Air Conditioner Blower Motor (Medium Speed) Relay (SE17, W9) • K28—Air Conditioner Blower Motor (High Speed) Relay (SE17, W9) • M1—Starter (SE2, W1) • M2—Engine Control (EC) Motor (SE8, W1) • M3—Windshield Wiper Motor (SE11, W3) • M4—Windshield Washer Motor (SE11, W1) • M5—Heater Blower Motor (Without Air Conditioner) (SE16, W2) • M6—Air Conditioner and Heater Blower Motor (SE17, W9) • M7—Not Used • M8—Not Used • M9—Air Conditioner Internal and External Cab Air Servomotor (SE17, W9) • M10—Air Conditioner Blower Port Change Servomotor (SE17, W9) • M11—Air Conditioner Air Mixer Servomotor (SE17, W9) • P1—Hour Meter (SE5, W3) • P2—Engine Coolant Temperature Gauge (SE4, W3) • P3—Fuel Gauge (SE4, W3) • R1—Not Used • R2—Heater Blower Motor Dropping Resistor Block (Without Air Conditioner) (SE16, W2) • R3—Not Used • R4—Engine Coolant Temperature Gauge Resistor (150 ohms) (SE5, W3) 16 • R5—Fuel Gauge Resistor (220 ohms) (SE5, W3) 1674 • R6—Alternator Excitation Resistor (SE3, W2) 8 • R7—Not Used • R8—Not Used • R9—Not Used • R10—Engine RPM Dial (SE4, W2) • R11—Air Conditioner and Heater Blower Motor Dropping Resistor Block (SE17, W9) • S1—Key Switch (SE1, W2) • S2—Horn Switch (SE15, W2) • S3—Dome Light Switch (SE15, W2) • S4—Heater Blower Motor Switch (Without Air Conditioner) (SE16, W2)

• S5—Fluid Level Check Switch (SE5, W3) • S6—Buzzer Stop Switch (SE5, W3) • S7—Work Mode Selection Switch (SE5, W3) • S8—Propel Speed Change Switch (SE5, W3) • S9—Wiper Speed Switch (SE5, W3) • S10—Drive and Work Light Switch (SE5, W3) • S11—Economy (E) Mode Switch (SE4, W2) • S12—High Power (HP) Mode Switch (SE4, W2) • S13—Auto Idle Switch (SE5, W3) • S14—Windshield Wiper Enable Switch (SE4, W2) • S15—Windshield Washer Switch (SE5, W3) • S16—Learning Switch (SE9, W2) • S17—Travel Alarm Cancel Switch (SE10, W2) • S18—Start Aid Switch (Not Used—Field Option) • S19—Power Boost Switch (SE9, W2) • V1—Start Aid Diode (Not Used—Field Option) • V2—Alternator Shut Down Relay Isolation Diode (SE3, W2) (Red/Wht and Red/Blk) • V3—Auxiliary Power Fuse (19) Suppression Diode (SE18, W2) (Blk and Red) • V4—Propel Auto Idle Relay (marked R10) Isolation Diode (SE7, W2) (Wht/Blk and Yel) • V5—Windshield Wiper Relay (marked R8) Isolation Diode (SE12, W3) (Blu/Blk and Blu/Red) • V6—Windshield Wiper Motor Suppression Diode (SE11, W3) (Blk and LGrn/Wht) • V7—Windshield Wiper Motor Suppression Diode (SE11, W3) (Blk and Blu/Wht) • V8—Fuel Shutoff Solenoid Hold-In Coil Suppression Diode (SE3, W2) (Brn/Blk and Blk) • V9—Start Relay Coil Suppression Diode (SE2, W2) (Yel/Grn and Blk/Wht) • V10—Fuel Shutoff Solenoid Pull-In Coil Suppression Diode (SE3, W2) (Red/Blk and Blk) • V11—Battery Relay Coil Suppression Diode (SE1, W1) (Blk and Red/Wht) • W1—Engine and Frame Harness • W2—Cab Harness • W3—Monitor and Relay Harness • W4—Radio Antenna (SE14, W2) • W5—Battery to Frame Ground (W1) • W6—Engine and Frame Harness to Frame Ground (W1) • W7—Cab Harness to Frame Ground (W2)

Continued on next page

TM1668 (28JAN09)

16-1674-8

CED,TX02661,228 –19–03FEB99–3/4

270LC Excavator Repair 012809

PN=254

Wiring Harness and Switches • W8—Starter to Frame Ground (SE2, W1) • W9—Air Conditioner Harness • X1—Diagnostic Connector (SE9, W2) • X2—Learning Switch Connector (SE9, W2) • X3—Attachment Pressure Switch Connector (SE9, W2) • X4—Accel Connector (SE8, W2) • X5—Optional Connector (SE18, W2) • X6—Auxiliary Connector (SE18, W2) • X7—Optional Right Speaker Connector (SE14, W2) • X8—Engine and Frame Harness to Cab Harness Connector (W1, W2) • X9—Engine and Frame Harness to Cab Harness Connector (W1, W2) • X10—Monitor Controller and Display Connector (20-Pin) (W3) • X11—Monitor Controller and Display Connector (16-Pin) (W3) • X12—Monitor Controller and Display Connector (12-Pin) (W3) • X13—Engine and Pump Controller Connector (26-Pin) (W2) • X14—Engine and Pump Controller Connector (16-Pin) (W2) • X15—Engine and Pump Controller Connector (22-Pin) (W2) • X16—Air Conditioner Harness to Cab Harness Connector (SE17, W2, W9)

• X17—Air Conditioner Controller Connector (16-Pin) (SE17, W9) • X18—Air Conditioner Controller Connector (12-Pin) (SE17, W9) • X19—Monitor and Relay Harness to Cab Harness Connector (2-Pin) (W2, W3) • X20—Monitor and Relay Harness to Cab Harness Connector (6-Pin) (W2, W3) • X21—Monitor and Relay Harness to Cab Harness Connector (12-Pin) (W2, W3) • X22—Monitor and Relay Harness to Cab Harness Connector (16-Pin) (W2, W3) • X23—Monitor and Relay Harness to Cab Harness Connector (8-Pin) (W2, W3) • X24—Optional Connector (W3) • X25—Optional Connector (W3) • Y1—Air Conditioner Compressor Clutch (SE17, W1 and W9) • Y2—Not Used • Y3—Not Used • Y4—Not Used • Y5—Power Boost Proportional Solenoid (SE7, W1) • Y6—Propel Speed Change Proportional Solenoid (SE8, W1) • Y7—Fuel Shutoff Solenoid (SE3, W1) • Y8—Speed Sense Proportional Solenoid (SE7, W1) • Y9—Arm Regenerative Proportional Solenoid (SE7, W1)

16 1674 9

CED,TX02661,228 –19–03FEB99–4/4

TM1668 (28JAN09)

16-1674-9

270LC Excavator Repair 012809

PN=255

Wiring Harness and Switches

Cab Electrical Component Identification

W4 X7

S14

X13 X15 A4

S12 X6

S19

16 1674 10

S16 X20 M5 X8 X3

X22 W7

T130003

–UN–08MAY00

S17

T130003

Continued on next page

TM1668 (28JAN09)

16-1674-10

TX,16,UU3915 –19–07APR00–1/2

270LC Excavator Repair 012809

PN=256

Wiring Harness and Switches

S3 X14

X19

B24 R10 X5 X1

S11

16 1674 11

X21

X23 X9

V1, V2, V3, V4, V8, V9, V10

X4 A1

T130005

–UN–08MAY00

T130005

TX,16,UU3915 –19–07APR00–2/2

TM1668 (28JAN09)

16-1674-11

270LC Excavator Repair 012809

PN=257

Wiring Harness and Switches

Hydraulic Electrical Component Identification

B19

B16

B21

B17

V11 F21

B8 K14

B6 K15

16 1674 12

B1 B26

B20 H10 B25

T130006

–UN–08MAY00

B15

T130006

Continued on next page

TM1668 (28JAN09)

16-1674-12

TX,16,UU3916 –19–07APR00–1/2

270LC Excavator Repair 012809

PN=258

Wiring Harness and Switches

B18

B22

Y6 B5

M1 W8 Y7 B12

F22

F23 K13

G1 G2

16 1674 13

M4 B13 X8 B14

T130007

–UN–08MAY00

T130007

TX,16,UU3916 –19–07APR00–2/2

TM1668 (28JAN09)

16-1674-13

270LC Excavator Repair 012809

PN=259

Wiring Harness and Switches

Replacing Fuses

–UN–06SEP90

Fuse box (A) is located behind the right control lever console, next to heater/air conditioner control panel (C). Fuse location/specification decal (B) is attached to fuse box cover.

T7356AE1

Remove fuse box cover (D) by lifting outward. Spare fuses (E) are located on underside of cover.

T7356AF1

–UN–06SEP90

A—Fuse Box B—Decal C—Heater Control Panel D—Fuse Box Cover E—Spare Fuses

Continued on next page

TX,16,UU3917 –19–24MAY00–1/2

16 1674 14

TM1668 (28JAN09)

16-1674-14

270LC Excavator Repair 012809

PN=260

Wiring Harness and Switches

T113934

1—Radio and Monitor Controller Backup 5 Amp Fuse 2—Engine and Pump Controller 10 Amp Fuse 3—Engine Control (EC) Motor 10 Amp Fuse 4—Solenoid 5 Amp Fuse 5—Power On 10 Amp Fuse 6—Monitor Controller and Display 5 Amp Fuse 7—Switched Power 5 Amp Fuse (Option 1) 8—Switched Power 10 Amp Fuse (Option 2) 9—Battery Power 5 Amp Fuse (Option 3) 10—Travel Alarm 5 Amp Fuse 11—Work and Drive Lights 20 Amp Fuse 12—Windshield Wiper 10 Amp Fuse 13—Blower Motor 20 Amp Fuse 14—Air Conditioner Controller and Relays 5 Amp Fuse 15—Horn 10 Amp Fuse 16—Radio 5 Amp Fuse 17—Lighter 10 Amp Fuse 18—Dome Light 5 Amp Fuse 19—Auxiliary 10 Amp Fuse 20—Start Aid 20 Amp Fuse

–UN–07APR98

IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

TX,16,UU3917 –19–24MAY00–2/2

Fuse (Blade-Type) Color Codes Amperage Rating

Color

Black

Violet

Pink

Tan

7-1/2

Brown

Red

Light Blue

Yellow

Natural (White)

Light Green

TX,16,UU3496 –19–28SEP92–1/1

TM1668 (28JAN09)

16-1674-15

270LC Excavator Repair 012809

PN=261

16 1674 15

Wiring Harness and Switches

Remove and Install Control Panel Switches 1. Remove screws 2. Replace monitor control panel.

T101584

–UN–27JUN96

A—Level Check Switch B—Attachment Mode Indicator C—Precision Mode Indicator D—Grading Mode Indicator E—General Purpose Indicator F—Work Mode Switch G—Buzzer Stop Switch H—Propel Speed Switch I—Auto-Idle Switch J—Wiper Switch K—Washer Switch L—Operating Lights Switch

TX,16,UU3497 –19–02JAN97–1/1

Remove and Install Dome Light Switch 1. Remove cap screws (A) and cover (B).

–UN–19OCT88

2. Disconnect connector (C). 3. Remove caps screws (D) and switch (E). Repair or replace as needed.

T6585NG

–UN–19OCT88

A—Cap Screw (2 used) B—Cover C—Connector D—Cap Screw (2 used) E—Switch

–UN–19OCT88

T6557JI

4. Install parts (A—E).

T6557LM

16 1674 16

TX,16,UU3498 –19–08JUN87–1/1

TM1668 (28JAN09)

16-1674-16

270LC Excavator Repair 012809

PN=262

Wiring Harness and Switches

Remove and Install Travel Alarm Cancel Switch and Start Aid Switch

–UN–06MAR97

1. Disconnect battery ground (-) cable. 2. Remove cap screws. Remove upper cover.

T105433B

3. Disconnect wires (C and D). Remove switches (A and B). 4. Replace parts as necessary. 5. Install switches.

A—Travel Alarm Cancel Switch B—Ether Aid Switch (not shown) C—Ether Aid Wire (not shown) D—Travel Alarm Wire

6. Connect wiring connectors. 7. Install covers. 8. Connect battery ground (-) cable.

TX,16,UU3918 –19–24MAY00–1/1

Remove and Install Starter Switch 1. Disconnect battery ground (-) cable.

–UN–06MAR97

2. Remove four cap screws from under control lever boot. 3. Turn cover. Remove cap screws.

T105435B

4. Disconnect wiring harness connector (B). 5. Replace parts as necessary. A—Screw (3 used) B—Connector C—Key Switch

Continued on next page

TM1668 (28JAN09)

16-1674-17

TX,16,UU3919 –19–24MAY00–1/2

270LC Excavator Repair 012809

PN=263

16 1674 17

Wiring Harness and Switches 6. Connect wiring harness to connector (D). 7. Install switch (C) and spring washer (B) through bracket and install nut (A). –UN–22JAN92

8. Install covers and boot. 9. Connect battery ground (-) cable.

T7681CX

10. After connecting batteries, the engine controller must be recalibrated or reset for engine speed. Machine can now be started and operated as usual. A—Nut B—Spring Washer C—Start Switch D—Wiring Harness Connector

TX,16,UU3919 –19–24MAY00–2/2

Remove and Install Cab Ground Straps

–UN–02JUN92

Remove cover under cab for access to ground straps (C) and nuts (A and B).

T7685EW

A—Nut B—Nut C—Ground Strap (4 used)

16 1674 18

TX,16,UU3920 –19–08JUN92–1/1

1. Disconnect connector (A) to remove and replace switch (B).

T105549B

2. Install and tighten switch (B) and connect connector (A).

–UN–12DEC96

Remove and Install Engine Overheat Alarm Switch

A—Connector B—Overheat Alarm Switch

TX,16,UU3921 –19–07APR00–1/1

TM1668 (28JAN09)

16-1674-18

270LC Excavator Repair 012809

PN=264

Wiring Harness and Switches

Remove and Install Charge Air Temperature Switch

–UN–15MAY97

1. Disconnect connector to remove and replace switch (A). 2. Install and tighten switch (A) and connector.

T109513B

A—Air Temperature Switch

TX,16,UU3922 –19–07APR00–1/1

Remove and Install Engine Coolant Level Switch

–UN–15MAY97

1. Disconnect connector to remove and replace switch (A). 2. Install and tighten switch (A) and connector.

T109518B

A—Coolant Level Switch

TX,16,UU3923 –19–07APR00–1/1

Remove and Install Engine Oil Pressure Switch

–UN–28MAY97

1. Disconnect connector to remove and replace switch (A). 2. Install and tighten switch (A) and connector.

T109621B

A—Oil Pressure Switch

TX,16,UU3924 –19–07APR00–1/1

Remove and Install Engine Oil Level Switch 1. Disconnect connector to remove and replace switch (A). –UN–27MAY97

2. Install and tighten switch (A) and connector.

T109620B

A—Oil Level Switch

TX,16,UU3925 –19–07APR00–1/1

TM1668 (28JAN09)

16-1674-19

270LC Excavator Repair 012809

PN=265

16 1674 19

Wiring Harness and Switches

Remove and Install Engine Coolant Temperature Sensor

–UN–27MAY97

1. Disconnect connector to remove and replace switch (A). 2. Install and tighten switch (A) and connector.

T109619B

A—Coolant Temperature Sensor

TX,16,UU3926 –19–07APR00–1/1

Remove and Install Fuel Level Sensor

2. Install sensor (B). Replace cap screws (A) and connect connector.

T109512B

A—Cap Screw B—Fuel Level Sensor

–UN–15MAY97

1. Disconnect connector and remove cap screws (A) to remove and replace sensor (B).

TX,16,UU3927 –19–07APR00–1/1

Remove and Install Fuel Level Switch

2. Install and tighten switch (A) and connect connector. A—Fuel Level Switch

T109519B

1674 20

–UN–15MAY97

1. Disconnect connector to remove and replace switch (A). 16

TX,16,UU3928 –19–07APR00–1/1

TM1668 (28JAN09)

16-1674-20

270LC Excavator Repair 012809

PN=266

Wiring Harness and Switches

Remove and Install Travel Alarm 1. Disconnect wiring connector (B).

–UN–05MAR92

NOTE: The travel alarm is located in the hydraulic pump compartment. 2. Remove two cap screws (A).

T7685HF

3. Remove travel alarm. 4. Replace alarm as necessary. A—Cap Screw (2 used) B—Wiring Connector

5. Install travel alarm. Connect wiring harness.

TX,16,UU3929 –19–10MAY00–1/1

Remove and Install Dig Function Pressure Switch

T105556B

2. Install and tighten switch (A) and connect connector (B).

–UN–10DEC96

1. Disconnect connector (B) to remove and replace switch (A).

A—Dig Function Pressure Switch B—Connector

TX,16,UU3931 –19–07APR00–1/1

TM1668 (28JAN09)

16-1674-21

270LC Excavator Repair 012809

PN=267

16 1674 21

Wiring Harness and Switches

Remove and Install Propel Function Pressure Sensor

T105557B

2. Install and tighten sensor (A) and connect connector (B).

–UN–10DEC96

1. Disconnect connector (B) to remove and replace sensor (A).

A—Propel Function Pressure Sensor B—Connector

TX,16,UU3932 –19–10MAY00–1/1

Remove and Install Rear Pump Pressure Sensor

2. Install and tighten sensor (A) and connect connector.

T109430B

A—Rear Pump Pressure Sensor

–UN–08MAY97

1. Disconnect connector to remove and replace sensor (A).

16 1674 22

TX,16,UU3933 –19–07APR00–1/1

Remove and Install Front Pump Pressure Sensor

2. Install and tighten sensor (A) and connect connector.

T109431B

A—Front Pump Pressure Sensor

–UN–08MAY97

1. Disconnect connector to remove and replace sensor (A).

TX,16,UU3934 –19–07APR00–1/1

TM1668 (28JAN09)

16-1674-22

270LC Excavator Repair 012809

PN=268

Wiring Harness and Switches

Remove and Install Engine Speed Sensor

2. Install and tighten sensor (A) and connect connector.

T109432B

A—Engine Speed Sensor

–UN–08MAY97

1. Disconnect connector to remove and replace sensor (A).

TX,16,UU3935 –19–07APR00–1/1

2. Install and tighten sensor (A or B) and connect connector. A—Front Pump Control Pressure Sensor B—Rear Pump Control Pressure Sensor (not shown)

T109459B

1. Disconnect connector to remove and replace front pump control pressure sensor (A) or rear pump control pressure sensor (B).

–UN–09MAY97

Remove and Install Pump Control Pressure Sensor

TX,16,UU3936 –19–02JAN97–1/1

Remove and Install Proportional Solenoids

2. Remove screws (E) to replace solenoid (A—D).

T109444B

3. Install solenoid, connect connector and install wire clip

–UN–08MAY97

1. Remove wire clip (F) to disconnect connector (G) or to remove and replace sensor (A).

A—Arm Regenerative Proportional Solenoid B—Speed Sensing Proportional Solenoid C—Propel Speed Change Proportional Solenoid D—Power Boost Proportional Solenoid E—Screw F—Wire Clip G—Connector

TX,16,UU3937 –19–02JAN97–1/1

TM1668 (28JAN09)

16-1674-23

270LC Excavator Repair 012809

PN=269

16 1674 23

Wiring Harness and Switches

Remove and Install Windshield Wiper Enable Switch

2. Install and tighten switch (A) and connect connector.

T109517B

A—Wiper Enable Switch

–UN–15MAY97

1. Disconnect connector to remove and replace switch (A).

TX,16,UU3939 –19–07APR00–1/1

Remove and Install Air Filter Restriction Switch

T105553B

2. Install and tighten switch (B) and connect connectors (A and C).

–UN–13DEC96

1. Disconnect connectors (A and C) to remove and replace switch (B).

A—Connector B—Switch C—Connector

16 1674 24

TX,16,UU3940 –19–07APR00–1/1

TM1668 (28JAN09)

16-1674-24

270LC Excavator Repair 012809

PN=270

Wiring Harness and Switches

Remove and Install Engine and Pump Controller (EPC)

–UN–06MAR97

IMPORTANT: If a controller problem is indicated, the real problem may be poor connector pin contact. Before replacing controller, remove and install controller connectors. Check machine operation.

T105437C

1. Disconnect battery ground cable. 2. Move seat forward and remove access cover. 3. Disconnect cable connectors (A—C). 4. Remove cap screws (F) and remove engine and pump controller (G). 5. Install engine and pump controller.

A—Connector B—Connector C—Connector D—Cover Plate E—Screws F—Screw (4 used) G—Engine and Pump Controller (EPC)

TX,16,UU3942 –19–13SEP94–1/1

Disconnecting Spring Wire Retainer Connectors 1. Remove wire retainer. Grasp connector halves; move half of connector from side-to-side as it’s being pulled apart. Do not pull on wiring leads.

16 1674 25

T8197AO

–UN–14MAR94

2. To reconnect, replace wire retainer and push together until wire retainer “clicks” over tabs.

TX,16,UU3945 –19–10MAY00–1/1

TM1668 (28JAN09)

16-1674-25

270LC Excavator Repair 012809

PN=271

Wiring Harness and Switches

Remove and Install Battery Relay 1. Disconnect cables and fusible links (A—G) to remove and replace relay. 2. Install and tighten relay and connect cables and fusible links (A—G).

T105554B

–UN–10DEC96

A—Positive Lead-To-Ignition B—Negative Ground C—Fusible Link D—Fusible Link E—Cable F—Fusible Link G—Cable

TX,16,UU3946 –19–02JAN97–1/1

Remove and Install Relay Starter Solenoid

2. Install solenoid. Connect connector (C) and leads (B and D). A—Solenoid B—Wiring Lead C—Connector D—Wiring Lead

T6557KB

1674 26

–UN–19OCT88

1. Disconnect leads (B and D) and connector (C) to remove and replace solenoid (A). 16

TX,16,UU3947 –19–19JUN87–1/1

TM1668 (28JAN09)

16-1674-26

270LC Excavator Repair 012809

PN=272

Wiring Harness and Switches

Replace DEUTSCH Connectors 1. Select correct size extractor tool for size of wire to be removed: • JDG361 Extractor Tool1 for 12 to 14 gauge wire. • JDG362 Extractor Tool1 for 16 to 18 gauge wire. • JDG363 Extractor Tool1 for 20 gauge wire.

DEUTSCH is a trademark of the Deutsch Co. 1

Included in JDG359 DEUTSCH Electrical Repair Kit. ECONN,J –19–03NOV94–1/3

2. Start correct size extractor tool over wire at handle (A). 3. Slide extractor tool rearward along wire until tool tip snaps onto wire. –UN–23AUG88

IMPORTANT: Do NOT twist tool when inserting in connector.

TS0124

4. Slide extractor tool along wire into connector body until it is positioned over terminal contact. 5. Pull wire out of connector body, using extractor tool.

TS120

–UN–23AUG88

A—Extractor Tool Handle

Continued on next page

TM1668 (28JAN09)

16-1674-27

ECONN,J –19–03NOV94–2/3

270LC Excavator Repair 012809

PN=273

16 1674 27

Wiring Harness and Switches IMPORTANT: Install contact in proper location using correct size grommet.

–UN–23AUG88

6. Push contact straight into connector body until positive stop is felt. 7. Pull on wire slightly to be certain contact is locked in place.

TS122

8. Transfer remaining wires to correct terminal in new connector.

ECONN,J –19–03NOV94–3/3

Install DEUTSCH Contact 1. Strip 6 mm (1/4 in.) insulation from wire.

–UN–23AUG88

2. Adjust selector (A) on JDG360 Crimper1 for correct wire size.

TS117

3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops. A—Crimper Selector B—Lock Nut C—Adjusting Screw

16 1674 28

DEUTSCH is a trademark of the Deutsch Co. 1

Included in JDG359 Deutsch Electrical Repair Kit. Continued on next page

TM1668 (28JAN09)

16-1674-28

ECONN,W –19–04JUN90–1/4

270LC Excavator Repair 012809

PN=274

Wiring Harness and Switches IMPORTANT: Select proper size contact “sleeve” or “pin” to fit connector body.

–UN–23AUG88

4. Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B). 5. Tighten lock nut (C).

TS0134

A—Contact B—Cover C—Lock Nut D—Adjusting Screw

ECONN,W –19–04JUN90–2/4

IMPORTANT: Contact must remain centered between indentors while crimping.

–UN–23AUG88

6. Insert wire in contact and crimp until handle touches stop.

TS118

7. Release handle and remove contact.

ECONN,W –19–04JUN90–3/4

NOTE: Readjust crimping tool for each crimping procedure.

TS0135

8. Inspect contact to be certain all wires are in crimped barrel.

–UN–23AUG88

IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.

ECONN,W –19–04JUN90–4/4

TM1668 (28JAN09)

16-1674-29

270LC Excavator Repair 012809

PN=275

16 1674 29

Wiring Harness and Switches

Replace WEATHER PACK Connector

2. Insert JDG364 Extraction Tool1 over terminal contact in connector body. 3. Hold extractor tool fully seated and pull wire from connector body.

TS0128

1. Open connector body.

–UN–23AUG88

IMPORTANT: Identify wire color locations with connector terminal letters.

NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector.

WEATHER PACK is a trademark of Packard Electric. 1

Included in JT07195A Electrical Repair Kit. ECONN,O –19–03NOV94–1/2

IMPORTANT: Carefully spread contact lances to assure good seating on connector body.

4. Push contact into new connector body until fully seated. 5. Pull on wire slightly to be certain contact is locked in place.

–UN–23AUG88

NOTE: Connector bodies are “keyed” for proper contact mating. Be sure contacts are in proper alignment.

TS0130

16 1674 30

6. Transfer remaining wires to correct terminal in new connector. 7. Close connector body.

ECONN,O –19–03NOV94–2/2

TM1668 (28JAN09)

16-1674-30

270LC Excavator Repair 012809

PN=276

Wiring Harness and Switches

Install WEATHER PACK Contact NOTE: Cable seals are color coded for three sizes of wire: –UN–23AUG88

• Green - 18 to 20 gauge wire • Gray - 14 to 16 gauge wire • Blue - 10 to 12 gauge wire

TS0136

1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.

Correct Size Cable

NOTE: Contacts have numbered identification for two sizes of wire:

–UN–02NOV94

• #15 for 14 to 16 gauge wire • #19 for 18 to 20 gauge wire

TS1623

3. Put proper size contact on wire and crimp in place with a “W” type crimp, using JDG783 Crimping Tool.

Strip Insulation

WEATHER PACK is a trademark of Packard Electric.

ECONN,AA –19–04JUN90–1/2

IMPORTANT: Proper contact installation for “sleeve” (A) and “pin” (B) is shown.

–UN–02DEC88

4. Secure cable seal to contact as shown, using JDG783 Crimping Tool.

TS0139

A—Sleeve B—Pin

Contact Installation

ECONN,AA –19–04JUN90–2/2

TM1668 (28JAN09)

16-1674-31

270LC Excavator Repair 012809

PN=277

16 1674 31

Wiring Harness and Switches

Remove Connector Body from Blade Terminals

RW4218

2. Be sure to bend locking tang back to its original position (B) before installing connector body.

–UN–23AUG88

1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.

DX,ECONN,V1 –19–02NOV94–1/1

16 1674 32

TM1668 (28JAN09)

16-1674-32

270LC Excavator Repair 012809

PN=278

Group 1675

System Controls Specifications Item

Measurement

Specification

Engine Slow Idle

Speed

900 ± 25 rpm

Engine Auto-Idle

Speed

1200 ± 25 rpm

E (Economy) Mode

Speed

2030 ± 25 rpm

Fast Idle in Standard Mode

Speed

2230 ± 25 rpm

Engine Speed Learning Procedure

CED,OUOE003,21720 –19–24MAY00–1/1

Welding On Machine IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, EPC controller. Disconnect battery ground cable and EPC electrical connectors before welding on the machine. 16 1675 1

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

TX,16,UU3948 –19–07APR00–1/3

1. Inside the cab, remove four cap screws (A and C) and the fuse box cover (B) to remove the rear console cover.

–UN–07MAR97

2. Disconnect the battery ground and positive cables.

T107932B

A—Cap Screw (4 used) B—Fuse Box Cover C—Cap Screw (4 used)

Continued on next page

TM1668 (28JAN09)

16-1675-1

TX,16,UU3948 –19–07APR00–2/3

270LC Excavator Repair 012809

PN=279

System Controls 3. Disconnect the engine and pump controller electrical connectors.

–UN–06MAR97

After reconnecting batteries, engine speeds must be recalibrated. (See Engine Speed Learning Procedure this group.)

T105437B

A—EPC Connector B—EPC Connector C—EPC Connector

TX,16,UU3948 –19–07APR00–3/3

Engine Speed Learning Procedure SPECIFICATIONS Engine Slow Idle Speed

900 ± 25 rpm

Engine Auto-Idle Speed

1200 ± 25 rpm

E (Economy) Mode Speed

2030 ± 25 rpm

Fast Idle in Standard Mode Speed

2230 ± 25 rpm

When the following components are repaired or replaced, or when engine speeds deviate from specification, the engine control motor adjustment and engine learning control procedure must be performed. • Engine • Engine speed control cable • Engine control motor and sensor 16 • Engine and pump controller 1675 • Fast and slow idle stops 2

1. Stop the engine. 2. Disconnect the laptop computer from the test connector. Wait for 5 seconds.

Continued on next page

TM1668 (28JAN09)

16-1675-2

TX,9010,UU3408 –19–26JAN09–1/2

270LC Excavator Repair 012809

PN=280

System Controls 3. Push engine learning switch (C) up to top position. The switch is a three position switch. Make sure it is in the top position. 4. Turn key switch ON. Wait 5 seconds. 5. Turn key switch OFF. Wait 5 seconds. 6. Push engine learning switch to middle position. 7. Check engine speeds.

T103674

NOTE: The laptop computer with the excavator diagnostic Program can be used to change the default speeds for slow idle, auto-idle, economy mode, and fast idle in standard mode.

–UN–11SEP96

C—Engine Learning Switch

TX,9010,UU3408 –19–26JAN09–2/2

Connecting Engine and Pump Controller (EPC) Harness Connector

T105437B

–UN–06MAR97

IMPORTANT: Do not disconnect electrical connectors while the engine is running. Damage to Engine and Pump Controller, or other components may result. Disconnect connectors only when instructed during a test or check. 1. Push connectors into engine and pump controller. 2. Complete engine speed learning procedure

A—EPC Connector B—EPC Connector C—EPC Connector

TX,16,UU3950 –19–07APR00–1/1

TM1668 (28JAN09)

16-1675-3

270LC Excavator Repair 012809

PN=281

16 1675 3

System Controls

Remove and Install Engine and Pump Controller (EPC)

–UN–06MAR97

IMPORTANT: If a controller problem is indicated, the real problem may be poor connector pin contact. Before replacing controller, remove and install controller connectors. Check machine operation.

T105437C

A—Connector B—Connector C—Connector D—Cover Plate E—Screws F—Screw (4 used) G—Engine and Pump Controller (EPC)

6. Recalibrate engine speeds. (See Engine Speed Learning Procedure in this group.)

TX,16,UU3951 –19–07APR00–1/1

Remove and Install Monitor Controller 1. Disconnect battery ground cable.

–UN–06MAR97

2. Move seat forward and remove access cover. 3. Disconnect wiring harness connectors (C). 4. Remove screws (B) and monitor controller (A). 5. Install monitor controller and connect wiring harnesses.

T105427B

16 1675 4

6. Install cover and connect battery cable. Do engine speed recalibration. (See Engine and Pump Controller (EPC) in this group.)

TX,16,UU3323 –19–23JUN94–1/1

TM1668 (28JAN09)

16-1675-4

270LC Excavator Repair 012809

PN=282

Group 1676

Instruments and Indicators Replace Monitor Panel and Switch Panel Bulb

–UN–18MAR98

1. Remove and Install Monitor Controller. (See procedure in Group 1675.) 2. Remove cap screws (C) and bracket (B).

T113808

3. Remove cap screws (D) and monitor controller (A). 4. Replace bulbs (E and F) as necessary.

T113809

–UN–18MAR98

A—Monitor Controller B—Bracket C—Cap Screw (4 used) D—Cap Screw (6 used) E—Monitor Panel Bulb (12 used) F—Switch Panel Bulb (2 used)

CED,OUTX818,71 –19–26JAN09–1/1

Remove and Install Monitor Panel 1. Remove monitor controller. (See Remove and Install Monitor Controller) CED,OUTX818,72 –19–26JAN09–1/3

2. Remove panel control knobs (A).

T113813

–UN–18MAR98

A—Control Knob (3 used)

Continued on next page

TM1668 (28JAN09)

16-1676-1

CED,OUTX818,72 –19–26JAN09–2/3

270LC Excavator Repair 012809

PN=283

16 1676 1

Instruments and Indicators 3. Remove cap screws (C) and bracket (B). 4. Remove cap screws (D) and monitor controller (A).

–UN–18MAR98

5. Remove cap screws (F) and switch panel (E). 6. Replace parts as necessary.

T113814

–UN–18MAR98

T113808

A—Monitor Controller B—Bracket C—Cap Screw (4 used) D—Cap Screw (6 used) E—Switch Panel F—Cap Screw (3 used)

CED,OUTX818,72 –19–26JAN09–3/3

Remove and Install Hour Meter 1. Remove bottom panel.

–UN–06MAR97

2. Remove connector (C). 3. Remove screws (A and B). Remove hour meter. 4. Repair or replace parts as required.

T105416B

16 1676 2

5. Install hour meter. 6. Install bottom panel.

A—Screw B—Screw C—Connector

CED,OUTX818,73 –19–07APR00–1/1

TM1668 (28JAN09)

16-1676-2

270LC Excavator Repair 012809

PN=284

Instruments and Indicators

Remove and Install Engine Hour Meter Switch

–UN–12DEC96

1. Disconnect connector (B) to remove and replace switch (A).

T105550B

2. Install and tighten sensor (A) and connect connector (A). A—Engine Hour Meter Switch B—Connector

TX,16,UU3938 –19–07APR00–1/1

Changing Travel Alarm Volume

–UN–08MAY00

IMPORTANT: It may be necessary to adjust travel alarm volume to meet local regulations. NOTE: Alarm removed from machine for clarity.

T129942B

1. Remove four sheet metal screws to remove travel alarm front cover. NOTE: This machine is shipped with the travel alarm set in the “High” position as shown. 2. Adjust volume level of travel alarm by connecting metallic bar (C) to appropriate terminals. The alarm can be set at “LOW”, “MED” (medium), or “HIGH” volume levels.

C—Metallic Bar D—Low Park Stud

3. Install front cover.

CED,OUOE003,21721 –19–24MAY00–1/1

TM1668 (28JAN09)

16-1676-3

270LC Excavator Repair 012809

PN=285

16 1676 3

Instruments and Indicators

16 1676 4

TM1668 (28JAN09)

16-1676-4

270LC Excavator Repair 012809

PN=286

Section 17

Frame or Supporting Structure Contents Page

Group 1740—Frame Installation Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1 Welding on Machine . . . . . . . . . . . . . . . . . . .17-1740-1 Welding Repair of Major Structure. . . . . . . . .17-1740-3 Group 1749—Chassis Weights Service Equipment and Tools . . . . . . . . . . . .17-1749-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1 Counterweight Remove and Install . . . . . . . . . . . . . . . . . .17-1749-2

TM1668 (28JAN09)

17-1

270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

17-2

270LC Excavator Repair 012809

PN=2

Group 1740

Frame Installation Specifications Item

Measurement

Specification

Weld Metal

Tensile Strength Yield Strength Elongation

482.6 mPa (70 000 psi) 413.7 mPa (60 000 psi) 22%

Structural Assembly

Preheat Temperature

38°C (100°F)

Ground Engaging Tool

Preheat Temperature

177°C (350°F)

Welding Repair of Major Structure

TX,17,UU3906 –19–04APR97–1/1

17 1740 1 TX,16,UU3948 –19–07APR00–1/3

1. Inside the cab, remove four cap screws (A and C) and the fuse box cover (B) to remove the rear console cover.

–UN–07MAR97

2. Disconnect the battery ground and positive cables.

T107932B

A—Cap Screw (4 used) B—Fuse Box Cover C—Cap Screw (4 used)

Continued on next page

TM1668 (28JAN09)

17-1740-1

TX,16,UU3948 –19–07APR00–2/3

270LC Excavator Repair 012809

PN=289

Frame Installation

After reconnecting batteries, engine speeds must be recalibrated. (See Engine Speed Learning Procedure this group.)

T105437B

A—EPC Connector B—EPC Connector C—EPC Connector

–UN–06MAR97

3. Disconnect the engine and pump controller electrical connectors.

TX,16,UU3948 –19–07APR00–3/3

17 1740 2

TM1668 (28JAN09)

17-1740-2

270LC Excavator Repair 012809

PN=290

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.

Specification Weld Metal—Tensile Strength ....................... 482.6 mPa (70 000 psi) Yield Strength ................................................ 413.7 mPa (60 000 psi) Elongation ..................................................................................... 22%

IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Specification Structural Assemblies— Minimum Preheat Temperature ...................................... 38°C (100°F)

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. 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.

Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). Specification Ground Engaging Tools— Preheat Temperature.................................................... 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). Specification Structural Assemblies— Minimum Preheat Temperature ...................................... 38°C (100°F)

TX,17,UU3908 –19–10JAN97–1/1

TM1668 (28JAN09)

17-1740-3

270LC Excavator Repair 012809

PN=291

17 1740 3

Frame Installation

17 1740 4

TM1668 (28JAN09)

17-1740-4

270LC Excavator Repair 012809

PN=292

Group 1749

Chassis Weights Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21665 –19–15MAY00–1/3

M42-4.5 Metric Lifting Eyebolt (2 used) . . . . . . . JT05558 To remove and install counterweight.

CED,OUOE003,21665 –19–15MAY00–2/3

Spreader Bar To remove and install counterweight.

CED,OUOE003,21665 –19–15MAY00–3/3

Specifications Item

Measurement

Specification

Counterweight

Weight

5700 kg (12,600 lb) approximate

Frame-to-Counterweight Cap Screw

Torque

1910 N•m (1410 lb-ft)

17 1749 1 CED,OUOE003,21667 –19–15MAY00–1/1

TM1668 (28JAN09)

17-1749-1

270LC Excavator Repair 012809

PN=293

Chassis Weights

Remove and Install Counterweight 1. Park machine on level ground. 2. Remove two plastic caps from top of counterweight (D). CAUTION: The approximate weight of counterweight is 5 700 kg (12 600 lb). The lifting capacity of a lifting eyebolt decreases as the lift angle increases from vertical. A spreader bar should be used to obtain, as close as possible, a vertical lift from eyebolts. Specification Counterweight—Approximate Weight........................................................................ 5 700 kg (12 600 lb)

–UN–01MAY92

3. Connect the counterweight to a hoist (A) using a spreader bar (B) and M42-4.5 metric lifting eyebolts (C) such as JT05558 Metric Lifting Eyebolt.

T7720AT

4. Remove cap screws and washers (E). 5. Remove counterweight. 6. Install cap screws and washers. Tighten cap screws to 1 910 N•m (1 410 lb-ft). Specification Frame-to-Counterweight Cap Screws—Torque .................................................... 1 910 N•m (1 410 lb-ft)

–UN–01MAY92

7. Remove hoist, spreader bar, and eyebolts.

T7720AU

8. Install plastic caps.

17 1749 2 A—Hoist B—Spreader Bar C—M42-4.5 Metric Lifting Eyebolt (2 used) D—Counterweight E—Cap Screw and Washer (4 used)

TX,17,UU3911 –19–04APR97–1/1

TM1668 (28JAN09)

17-1749-2

270LC Excavator Repair 012809

PN=294

Section 18

Operator’s Station Contents Page

Page

Group 1800—Removal and Installation Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Cab Remove and Install . . . . . . . . . . . . . . . . . .18-1800-1

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-23 Inspect Manifolds. . . . . . . . . . . . . . . . . . .18-1830-26 Reciever Dryer Remove and Install . . . . . . . . . . . . . . . . .18-1830-28 Evaporator Remove and Install . . . . . . . . . . . . . . . . .18-1830-30 Condenser Remove and Install . . . . . . . . . . . . . . . . .18-1830-32 Heater Core Remove and Install . . . . . . . . . . . . . . . . .18-1830-34 Heater Core and Blower Motor Remove and Install . . . . . . . . . . . . . . . . .18-1830-35 Heater Hoses Remove and Install . . . . . . . . . . . . . . . . .18-1830-37

Group 1810—Operator Enclosure Service Equipment and Tools . . . . . . . . . . . .18-1810-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Windowpane Remove and Install Two Piece Molding . . .18-1810-1 Remove and Install One Piece Molding . . .18-1810-2 Sliding Windows Remove and Install . . . . . . . . . . . . . . . . . .18-1810-3 Windowpane Dimensions . . . . . . . . . . . . . . .18-1810-4 Group 1821—Seat and Seat Belt Seat Check Adjustments . . . . . . . . . . . . . . . . . .18-1821-1 Remove and Install . . . . . . . . . . . . . . . . . .18-1821-2 Seat Belt Remove and Install . . . . . . . . . . . . . . . . . .18-1821-8 Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9 Group 1830—Heating and Air Conditioning Essential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Service Equipment and Tools . . . . . . . . . . . .18-1830-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Proper R134a Refrigerant Handling. . . . . . . .18-1830-4 R134a Refrigerant Cautions . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 R134a Compressor Oil Charge Check . . . . . . . . . . . . . . . . . . . . . .18-1830-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 R134a Component Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 R134a Refrigerant Recovery, Recycling, Charging Station Installation Procedure . . . . . . . . . .18-1830-8 Recover R134a System . . . . . . . . . . . . . . .18-1830-9 Evacuate R134a System . . . . . . . . . . . . .18-1830-10 Charge R134a System. . . . . . . . . . . . . . .18-1830-11 Air Conditioning Compressor Belt Tension, Check. . . . . . . . . . . . . . . . .18-1830-12 Remove and Install . . . . . . . . . . . . . . . . .18-1830-14 Disassemble and Inspect . . . . . . . . . . . . .18-1830-15 TM1668 (28JAN09)

18-1

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PN=1

Contents

TM1668 (28JAN09)

18-2

270LC Excavator Repair 012809

PN=2

Group 1800

Removal and Installation Specifications Item

Measurement

Specification

Cab

Weight

250 kg (551 lb) approximate

Rubber Mount-to-Frame Cap Screw

Torque

108 N•m (80 lb-ft)

Cab-to-Platform Cap Screw

Torque

64 N•m (47 lb-ft)

Cab

Cab and Platform-to-Rubber Mount Torque Lock Nut

205 N•m (152 lb-ft)

CED,OUOE003,21668 –19–15MAY00–1/1

Remove and Install Cab NOTE: It is not necessary to remove the seat to remove the cab. –UN–16DEC96

1. Remove cap screws (D) and screws (E) to remove the rear console cover behind the seat.

T105712

2. Disconnect battery ground cable. 3. Remove cab floor mat. D—Cap Screw (4 used) E—Screw (3 used)

Continued on next page

TX,18,VV2505 –19–07APR00–1/6

18 1800 1

TM1668 (28JAN09)

18-1800-1

270LC Excavator Repair 012809

PN=297

Removal and Installation 4. Remove screws (A) to remove cover (B). 5. Remove spring pin (D) to remove pilot shut-off lever (C).

T105963B

–UN–13JAN97

IMPORTANT: To avoid possible damage to switch panel during assembly, be sure to mark all corresponding bullet connector wiring leads before disassembly. Connecting bullet connectors to the wrong wiring leads will damage components in the switch panel. 6. Disconnect all main wire harness connectors, radio speaker wires and radio antenna (if equipped), windshield wiper motor, dome light and bullet connectors as required.

–UN–13JAN97

7. Loosen and remove the fresh air intake cowl cap screws and remove cowl from inside rear wall of cab.

T105992B

8. Disconnect windshield washer fluid tube from windshield washer pump located in the compartment behind the cab. A—Screw (4 used) B—Cover C—Pilot Shut-Off Lever D—Spring Pin

TX,18,VV2505 –19–07APR00–2/6

9. Remove lock nuts (A) and washers located at the four inside corners of cab.

–UN–17OCT88

10. Remove the two cab-to-platform cap screws and washers from each of the four sides of cab. A—Lock Nut

T6585OE

18 1800 2

Continued on next page

TM1668 (28JAN09)

18-1800-2

TX,18,VV2505 –19–07APR00–3/6

270LC Excavator Repair 012809

PN=298

Removal and Installation

CAUTION: The approximate weight of cab is 250 kg (551 lb).

–UN–15JAN97

Cab—Specification Cab—Weight ................................................. 250 kg (551 lb) approximate

11. Connect cab to hoist, using lifting straps.

T106453

12. Slowly lift cab from platform. Move cab slightly forward as cab is being raised so front of cab can clear front of propel pedals.

Continued on next page

TX,18,VV2505 –19–07APR00–4/6

18 1800 3

TM1668 (28JAN09)

18-1800-3

270LC Excavator Repair 012809

PN=299

Removal and Installation

TP47992

–UN–30SEP99

18 1800 4

1—Rubber Mount (6 used) 2—Cap Screw (12 used)

3—Lock Washer (12 used) 5—Washer (6 used)

6—Lock Nut 7—Cap Screw (4 used)

Continued on next page

TM1668 (28JAN09)

18-1800-4

9—Cap Screw (4 used) 10—Washer (8 used)

TX,18,VV2505 –19–07APR00–5/6

270LC Excavator Repair 012809

PN=300

Removal and Installation 13. Repair or replace parts as necessary. Lift each corner of platform to remove and install rubber mounts (1).

15. Install the cap screw (9) with hex head at the front and left side. Install the cap screw (7) with socket head at the rear and right side. Tighten cap screws. Tighten lock nuts (6).

Tighten cap screw (2). Cab—Specification Rubber Mount-to-Frame Cap Screw—Torque ....................................................... 108 N•m (80 lb-ft)

Cab—Specification Cab-to-Platform Cap Screw— Torque....................................................................... 64 N•m (47 lb-ft) Cab and Platform-to-Rubber Mount Lock Nut—Torque ..................................... 205 N•m (152 lb-ft)

14. Before installing cab, check that all lines and wiring harnesses are out of the way so they are not pinched when cab is installed.

TX,18,VV2505 –19–07APR00–6/6

18 1800 5

TM1668 (28JAN09)

18-1800-5

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PN=301

Removal and Installation

18 1800 6

TM1668 (28JAN09)

18-1800-6

270LC Excavator Repair 012809

PN=302

Group 1810

Operator Enclosure Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21670 –19–15MAY00–1/2

Weather-Strip Installing Tool To install locking strip in molding around windowpane.

CED,OUOE003,21670 –19–15MAY00–2/2

Other Material Number

Name

Use

TY21517 (U.S.) NA (Canadian) 454 (LOCTITE)

Instant Gel Adhesive

Apply to frame channel of molding during installation. Apply to cab flange when installing sliding windows and frame.

LOCTITE is a trademark of Loctite Corp.

CED,OUOE003,21671 –19–15MAY00–1/1

Remove and Install Windowpane and Two Piece Molding

–UN–19OCT88

1. Remove locking strip (A) from molding using insert tool.

T5903AI

A—Locking Strip

Continued on next page

TM1668 (28JAN09)

18-1810-1

TX,1800,VV2501 –19–07APR00–1/4

270LC Excavator Repair 012809

PN=303

18 1810 1

Operator Enclosure IMPORTANT: Use extreme care to avoid damaging the windowpane. 2. Carefully push out windowpane from molding.

T5903AJ

–UN–19OCT88

3. Inspect molding for damage; replace if necessary.

TX,1800,VV2501 –19–07APR00–2/4

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

–UN–19OCT88

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

T5903AK

A—Insert Tool B—Molding

TX,1800,VV2501 –19–07APR00–3/4

6. Install locking strip (A) using weather-strip installing tool (B).

T5903AL

–UN–19OCT88

A—Locking Strip B—Installing Tool

TX,1800,VV2501 –19–07APR00–4/4

Remove and Install Windowpane and One Piece Molding

–UN–19OCT88

1. Lift inside of molding over cab frame and carefully push windowpane and molding out. 2. Remove molding from windowpane; replace if necessary.

T6439XE

18 1810 2

Continued on next page

TM1668 (28JAN09)

18-1810-2

TX,18,VV2502 –19–07APR00–1/2

270LC Excavator Repair 012809

PN=304

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

–UN–19OCT88

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

T6439XD

A—Drain Notches

TX,18,VV2502 –19–07APR00–2/2

Remove and Install Sliding Windows 1. Pull molding (D) from inside of window. 2. Cut the adhesive (E) between cab flange and window frame (B) using a putty knife. IMPORTANT: Use extreme care to avoid damaging frame and windowpane. Remove window using two people; one to push window out, the other to keep window from falling. 3. Carefully push window frame from cab. 4. Lift frame slightly at the top-center to remove and install windowpanes.

–UN–05DEC89

5. Apply instant gel adhesive to cab flange. 6. Install windows and frame with spacers (C) at the bottom and two on each end of frame.

T6439TD

7. Install three spacers (A) at top of frame. 8. Using water as a lubricant, push window frame tight against cab flange. 9. Install molding (D) around window and cab flange.

A—Top Spacer (3 used) B—Window Frame C—Bottom and Side Spacer D—Molding E—Adhesive

18 1810 3

TX,18,VV2503 –19–10JAN97–1/1

TM1668 (28JAN09)

18-1810-3

270LC Excavator Repair 012809

PN=305

Operator Enclosure

Windowpane Dimensions

T105924

–UN–29SEP99

18 1810 4

Continued on next page

TM1668 (28JAN09)

18-1810-4

TX,18,VV2504 –19–11JAN97–1/2

270LC Excavator Repair 012809

PN=306

Operator Enclosure

T105925

–UN–13JAN97

18 1810 5

TX,18,VV2504 –19–11JAN97–2/2

TM1668 (28JAN09)

18-1810-5

270LC Excavator Repair 012809

PN=307

Operator Enclosure

18 1810 6

TM1668 (28JAN09)

18-1810-6

270LC Excavator Repair 012809

PN=308

Group 1821

Seat and Seat Belt Check Seat Adjustments 1. Turn weight adjustment knob (A) to adjust seat to weight of operator. Weight is displayed on knob. 2. Push seat height and angle adjustment lever (B) down while sitting on seat or while standing and pulling up on seat to obtain desired height. Release lever. Push down lever while sitting on seat to adjust seat to desired angle. Release lever. 3. Push console and seat fore-aft adjustment lever (C) down to adjust seat and both right and left consoles to desired distance from propel pedals and levers. Release lever to lock seat and consoles into position. 4. Pull seat fore-aft adjustment lever (D) up to unlock seat from both consoles. Slide the seat to desired distance from control levers. Release the lever.

T102204

–UN–26JUL96

5. Pull backrest adjustment lever (E) up to release backrest lock. Move backrest to desired position. Release the lever.

A—Weight Adjustment Knob B—Seat Height and Angle Adjustment Lever C—Console and Seat Fore-Aft Adjustment Lever D—Seat Fore-Aft Adjustment Lever E—Backrest Adjustment Lever

TX,18,GG2448 –19–14JAN97–1/1

18 1821 1

TM1668 (28JAN09)

18-1821-1

270LC Excavator Repair 012809

PN=309

Seat and Seat Belt

Remove and Install Seat

T106446

–UN–15JAN97

1. Pull the seat and consoles as far forward as possible.

Continued on next page

TX,18,GG2446 –19–07APR00–1/6

18 1821 2

TM1668 (28JAN09)

18-1821-2

270LC Excavator Repair 012809

PN=310

Seat and Seat Belt 2. Remove the screws (B) to remove cover (A). 3. Remove cap screws (L). 4. Tip the console up. 5. Remove a quick lock pin (C) to remove pin (D). Lay the console on cover behind the seat. –UN–15JAN97

6. Remove nuts and washers (E).

T106445

A—Cover B—Screw (2 used) C—Quick Lock Pin D—Pin E—Nut and Washer (4 used) K—Console L—Cap Screw and Washer

T105912

–UN–02JAN97

Left Console Shown

Continued on next page

TX,18,GG2446 –19–07APR00–2/6

18 1821 3

TM1668 (28JAN09)

18-1821-3

270LC Excavator Repair 012809

PN=311

Seat and Seat Belt

TP48111

–UN–05AUG96

18 1821 4

Continued on next page

TM1668 (28JAN09)

18-1821-4

TX,18,GG2446 –19–07APR00–3/6

270LC Excavator Repair 012809

PN=312

Seat and Seat Belt 00—Seat

01—Cap Screw (4 used)

03—Bracket

CAUTION: The approximate weight of seat and carrier is 35 kg (75 lb).

04—Cap Screw, Lock Washer and Washer (2 used)

7. Remove the seat (00) and carrier.

Continued on next page

TX,18,GG2446 –19–07APR00–4/6

18 1821 5

TM1668 (28JAN09)

18-1821-5

270LC Excavator Repair 012809

PN=313

Seat and Seat Belt

TP48112

–UN–07AUG96

18 1821 6

Continued on next page

TM1668 (28JAN09)

18-1821-6

TX,18,GG2446 –19–07APR00–5/6

270LC Excavator Repair 012809

PN=314

Seat and Seat Belt 00—Seat Stand A—Carrier B—Bracket C—Bracket D—Cap Screw, Lock Washer and Washer (4 used)

E—Seat Slide F—Nut (8 used) G—Lock Washer (8 used) H—Seat Base 02—Quick Lock Pin (4 used)

8. Remove the seat base (H) if replacement of seat slides (E) is necessary.

03—Pin 04—Washer 05—Pin 07—Cap Screw, Lock Washer and Washer (4 used)

08—Cap Screw, Lock Washer and Washer (3 used) 09—Cover 10—Screw, Lock Washer and Washer (4 used)

9. Repair or replace parts as needed.

TX,18,GG2446 –19–07APR00–6/6

18 1821 7

TM1668 (28JAN09)

18-1821-7

270LC Excavator Repair 012809

PN=315

Seat and Seat Belt

Remove and Install Seat Belt

TP48113

–UN–05AUG96

18 1821 8

Continued on next page

TM1668 (28JAN09)

18-1821-8

TX,18,GG2447 –19–14JAN97–1/2

270LC Excavator Repair 012809

PN=316

Seat and Seat Belt 00—Seat Belt 01—Bracket 03—Belt

04—Belt 05—Spacer (Sleeve)

06—Spacer (Sleeve) (2 used) 08—Cap Screw

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

TX,18,GG2447 –19–14JAN97–2/2

T8415AA

–UN–09FEB95

Inspect Seat Belt

Seat belt and mounting hardware must be inspected for wear or damage before operating the machine. Replace the belt or mounting hardware if worn or damaged.

Replace the complete seat belt assembly every three years regardless of appearance. A date label, to determine the age of the belt, is attached to each belt.

TX,18,GG2449 –19–14JAN97–1/1

18 1821 9

TM1668 (28JAN09)

18-1821-9

270LC Excavator Repair 012809

PN=317

Seat and Seat Belt

18 1821 10

TM1668 (28JAN09)

18-1821-10

270LC Excavator Repair 012809

PN=318

Group 1830

Heating and Air Conditioning Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21672 –19–15MAY00–1/3 T7530AZ –UN–29MAY91

Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D05267ST To evacuate air conditioning system.

CED,OUOE003,21672 –19–15MAY00–2/3

R134a Refrigerant Recovery/Recycling and Charging Station . . . . . . . . . . . . . . . . . . . . . . . . . . . JT020451 Servicing air conditioning system using R134a refrigerant.

1 JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.

CED,OUOE003,21672 –19–15MAY00–3/3

SERVICEGARD is a trademark of Deere & Company

CED,OUOE003,21673 –19–15MAY00–1/17

Belt Tension Gauge To check compressor belt tension.

Continued on next page

TM1668 (28JAN09)

18-1830-1

CED,OUOE003,21673 –19–15MAY00–2/17

270LC Excavator Repair 012809

PN=319

Heating and Air Conditioning Bench Mounted Holding Fixture . . . . . . . . . . D01006AA Hold compressor during repair.

CED,OUOE003,21673 –19–15MAY00–3/17

Clutch Hub Holding Tool To hold clutch hub while removing retaining nut.

CED,OUOE003,21673 –19–15MAY00–4/17

Clutch Hub Remover Used with forcing screw for removing clutch hub.

CED,OUOE003,21673 –19–15MAY00–5/17

Forcing Screw Used with clutch hub remover for removing clutch hub.

CED,OUOE003,21673 –19–15MAY00–6/17

Puller Adapter Used with three jaw puller to remove clutch pulley.

CED,OUOE003,21673 –19–15MAY00–7/17

Three Jaw Puller Used with puller adapter to remove clutch pulley.

CED,OUOE003,21673 –19–15MAY00–8/17

18 1830 2

Special Hex Drive To remove compressor through-bolts.

CED,OUOE003,21673 –19–15MAY00–9/17

Valve Plate Remover To remove valve plate from compressor head.

Continued on next page

TM1668 (28JAN09)

18-1830-2

CED,OUOE003,21673 –19–15MAY00–10/17

270LC Excavator Repair 012809

PN=320

Heating and Air Conditioning Pulley Support To support pulley when removing bearing.

CED,OUOE003,21673 –19–15MAY00–11/17

Bearing Adapter To remove and install bearing in pulley.

CED,OUOE003,21673 –19–15MAY00–12/17

Shaft Seal Seat Remover To remove shaft seal seat from compressor head.

CED,OUOE003,21673 –19–15MAY00–13/17

Shaft Seal Seat Installer To install shaft seal seat in compressor head.

CED,OUOE003,21673 –19–15MAY00–14/17

Shaft Key Installer To install shaft key in key way.

CED,OUOE003,21673 –19–15MAY00–15/17

Feeler Gauge To check pulley-to-hub clearance.

CED,OUOE003,21673 –19–15MAY00–16/17

Hex Drive

18 1830 3

To remove front and rear head cap screws.

CED,OUOE003,21673 –19–15MAY00–17/17

TM1668 (28JAN09)

18-1830-3

270LC Excavator Repair 012809

PN=321

Heating and Air Conditioning

Other Material Number

Name

Use

TY16134 (U.S.)

R134a Flushing Solvent

Flush R134a air conditioning system.

TY22025 (U.S.)

R134a Compressor Oil

Lubricate R134a air conditioning system.

TY15949 (12 oz) (U.S.)

R134a Refrigerant

Charge R134a air conditioning system.

TY15950 (15 lb) (U.S.)

R134a Refrigerant

Charge R134a air conditioning system.

TY15951 (30 lb) (U.S.)

R134a Refrigerant

Charge R134a air conditioning system.

CED,OUOE003,21674 –19–15MAY00–1/1

Specifications Item

Measurement

Specification

Compressor Head-to-Housing Cap Screw

Torque

26 N•m (19 lb-ft)

Pulley-to-Hub

Clearance

0.53—0.91 mm (0.021—0.036 in.)

Clutch Hub Nut

Torque

16 N•m (12 lb-ft)

CED,OUOE003,21676 –19–15MAY00–1/1

Proper R134a Refrigerant Handling The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. 18 1830 4

IMPORTANT: To meet government standards relating to the use of refrigerants, 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. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerants, hoses, fittings, components or refrigerant oils. Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants.

TX,18,UU3709 –19–23JUN97–1/1

TM1668 (28JAN09)

18-1830-4

270LC Excavator Repair 012809

PN=322

Heating and Air Conditioning

R134a Refrigerant Cautions Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.

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.

DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves.

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.

If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.

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

(R12 ONLY) Refrigerant exposed to high temperature forms phosgene gas. Inhaling toxic phosgene gas may result in serious illness or death. Phosgene gas has an odor like new mown hay or green corn. If you inhale phosgene gas, go to a physician or hospital immediately for treatment.

DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container.

TX,18,UU3710 –19–13AUG96–1/1

R134a Compressor Oil Charge Check Remove compressor if R134a leakage was detected and repaired. See Remove and Install Compressor in Repair Manual.

3. Flush the complete system with TY16134 air conditioning flushing solvent.

Drain oil from the compressor and record the amount. See Compressor Oil Removal procedure in this group.

4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil.

NOTE: Drain oil and save if this is a new compressor.

5. Install a new receiver-dryer.

If the oil drained from a compressor removed from operation is very black or the amount of oil is less than 6 mL (0.2 fl oz), perform the following:

6. Install required amount of TY22025 refrigerant oil in the compressor. (See R134a Component Oil Charge in this group.)

1. Remove and discard the receiver-dryer.

7. Connect all components, evacuate and charge the system.

2. Remove, clean, but do not disassemble the expansion valve.

TX,18,UU3711 –19–13AUG96–1/1

TM1668 (28JAN09)

18-1830-5

270LC Excavator Repair 012809

PN=323

18 1830 5

Heating and Air Conditioning

R134a Compressor Oil Removal 1. Remove compressor from machine. See Remove and Install Compressor in Repair Manual. 2. Remove inlet/outlet manifold from compressor, and clutch dust cover. 3. Drain oil into graduated container while rotating compressor shaft. 4. Record measured oil and discard oil properly. 5. Install new oil. See R134a Component Oil Charge in this Group. 6. Install compressor. See Remove and Install Compressor in Repair Manual.

TX,18,UU3712 –19–13AUG96–1/1

18 1830 6

TM1668 (28JAN09)

18-1830-6

270LC Excavator Repair 012809

PN=324

Heating and Air Conditioning

R134a Component Oil Charge CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. Compressors can be divided into three categories when determining the correct oil charge for the system. • New compressor from parts depot. • Used compressor removed from operation. • Compressor internally washed with flushing solvent. Determining the amount of system oil charge prior to installation of compressor on a machine. 1. When the complete system, lines, and components were flushed add the correct amount of oil as described. • New compressor from parts depot contains the amount of new oil of 230 ± 20 mL (7.7 ± 0.7 fl oz.). System requires an additional amount of new oil of 100 mL (3.4 fl oz.) of new oil. • Used compressor removed from operation, oil drained, and flushed requires 330 ± 20 mL (11.1 ± 0.7 fl oz.) of new oil.

• Used compressor removed from operation and oil drained. (See Compressor Oil Removal procedure in this group.) Add 45 mL (1.5 fl oz.) of new oil. • Used compressor removed from operation, oil drained, and flushed add 60 mL (2.0 fl oz.) of new oil. NOTE: Components listed below which have been removed, drained, or flushed, require the removal of the compressor to determine the correct oil charge. Use the following chart as a guide for adding oil to components: Evaporator

130 mL (4.4 fl oz)

Condenser

65 mL (2.2 fl oz)

Receiver-Dryer

30 mL (1.0 fl oz)

Hoses

60 mL (2.0 fl oz)

NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz. per ft). Approximate total length equals 600 cm (20 ft). If any section of hose is removed and flushed or replaced, measure the length of hose and use the formula to determine the correct amount of oil to be added.

2. When the complete system was not flushed add the correct amount of oil for the compressor plus amount of oil for each component that was serviced. • New compressor from parts depot, drain and return 45 mL (1.5 fl oz.) of oil to the compressor. (See Compressor Oil Removal procedure in this group.)

CAUTION: DO NOT leave the system or R134a compressor oil containers open. This 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.

18 1830 7

TX,18,UU3713 –19–13AUG96–1/1

TM1668 (28JAN09)

18-1830-7

270LC Excavator Repair 012809

PN=325

Heating and Air Conditioning

R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (J). –UN–10SEP96

2. Remove cap from low pressure test port (A).

4. Connect high pressure red hose (I) to high pressure quick disconnect (F). 5. Follow the manufacturer’s instructions when using the refrigerant recovery, recycling and charging station.

T101551

3. Connect low pressure blue hose (G) from refrigerant recovery, recycling and charging station (J) to low pressure test port (A) on compressor.

A—Low Pressure Test Port B—High Pressure Relief Valve C—Low Pressure Hose D—Low Pressure Switch E—High Pressure Switch F—High Pressure Quick-Disconnect G—Blue Hose H—High Pressure Hose I—Red Hose J—Refrigerant Recovery/Recycling and Charging Station

TX,18,UU3714 –19–13AUG96–1/1

18 1830 8

TM1668 (28JAN09)

18-1830-8

270LC Excavator Repair 012809

PN=326

Heating and Air Conditioning

Recover R134a System NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

–UN–10SEP96

NOTE: Run the air conditioning system for three minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps. 1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.)

T101551

2. Follow the manufacturer’s instructions when using the refrigerant recovery, recycling and charging station. A—Low Pressure Test Port B—High Pressure Relief Valve C—Low Pressure Hose D—Low Pressure Switch E—High Pressure Switch F—High Pressure Quick-Disconnect G—Blue Hose H—High Pressure Hose I—Red Hose J—Refrigerant Recovery/Recycling and Charging Station

TX,18,UU3716 –19–26MAY00–1/1

18 1830 9

TM1668 (28JAN09)

18-1830-9

270LC Excavator Repair 012809

PN=327

Heating and Air Conditioning

Evacuate R134a System NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. Do not run compressor while evacuating.

–UN–10SEP96

1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.)

T101551

2. Open low and high pressure valves on refrigerant recovery, recycling and charging station. 3. Follow the manufacturer’s instructions and evacuate the system. A—Low Pressure Test Port B—High Pressure Relief Valve C—Low Pressure Hose D—Low Pressure Switch E—High Pressure Switch F—High Pressure Quick-Disconnect G—Blue Hose H—High Pressure Hose I—Red Hose J—Refrigerant Recovery/Recycling and Charging Station

4. Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum. If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test the system for leaks. (See Leak Testing, 9031-25). Correct any leaks. NOTE: The 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. 5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off. 18 1830 10

6. If the vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in the system. 7. Repair leak.

Continued on next page

TM1668 (28JAN09)

18-1830-10

TX,18,UU3717 –19–13AUG96–1/2

270LC Excavator Repair 012809

PN=328

Heating and Air Conditioning 8. Start to evacuate. 9. Open low-side and high-side valves. 10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 11. Close low-side and high-side valves. Stop evacuation. 12. Charge the system. (See procedure in this group.)

TX,18,UU3717 –19–13AUG96–2/2

Charge R134a System NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. CAUTION: Do not remove high pressure relief valve (B). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Connect R134a refrigerant recovery, recycling and charging station. (See installation procedure in this group.)

3. Follow the manufacturer’s instructions and charge the system. 4. Do air conditioner checks and tests in Groups 9031-10 and 9031-25.

T101551

NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

–UN–10SEP96

2. Evacuate the system. (See Evacuate Air Conditioning System, this group.)

18 1830 11

TX,18,UU3718 –19–26MAY00–1/1

TM1668 (28JAN09)

18-1830-11

270LC Excavator Repair 012809

PN=329

Heating and Air Conditioning

Check and Adjust Air Conditioning Compressor Belt Tension IMPORTANT: Never over tighten belt. Over tightening may cause belt cord damage and excessive load on bearings.

IMPORTANT: Force to adjust belt must be applied to front of compressor housing only to prevent damage to compressor.

1. Run engine for five minutes. Stop the engine, then immediately check tension using a belt tension gauge. Measure strand tension or deflection at a point halfway between pulleys.

3. Loosen compressor mounting cap screws. Apply force to front of compressor housing to tighten belt. Tighten cap screws. 4. Repeat Steps 1 and 2 to check belts.

2. Belt must deflect 19 mm (0.75 in.) at 400 N (90 lb force). If not, allow belt to cool for 8—10 minutes.

TX,9031,UU3160 –19–13AUG96–1/1

18 1830 12

TM1668 (28JAN09)

18-1830-12

270LC Excavator Repair 012809

PN=330

Heating and Air Conditioning

18 1830 13

TM1668 (28JAN09)

18-1830-13

270LC Excavator Repair 012809

PN=331

Heating and Air Conditioning

Remove and Install Air Conditioning Compressor

T108980

–UN–14JUL97

18 1830 14

Continued on next page

TM1668 (28JAN09)

18-1830-14

TX,1830,SB562 –19–07APR00–1/2

270LC Excavator Repair 012809

PN=332

Heating and Air Conditioning 00—Bracket 01—Cap Screw 2—Compressor 03—Bracket 04—Spacer 05—Cap Screw 06—Washer 07—Washer 10—Receiver Tank

11—Washer 12—Nut 14—Cap Screws 15—Adjusting Bolt 16—Cap Screw 17—Lock Washer 18—Nut 19—Cap Screw 20—Belt

22—Bracket 23—Bracket 24—Cap Screw 25—Bracket 26—Cap Screw 30—Condenser 31—Hose 32—Hose

33—Cap Screw 34—Cap Screw 37—Cap Screw 39—Wiring Harness 43—Tie Band 44—Clip 45—Cap Screw 46—Tie Band

1. Recover the refrigerant from the system. (See procedure in this group.)

3. Evacuate and charge the system. (See procedures in this group.)

2. Remove and install compressor (02). Install caps and plugs to close all open lines.

4. Adjust air conditioning compressor belt tension. (See procedure in this group.)

Repair or replace compressor as necessary.

TX,1830,SB562 –19–07APR00–2/2

Disassemble and Inspect Air Conditioning Compressor 1. Mount holding fixture in a bench vise and support compressor on holding fixture. NOTE: Mounting fixture can be made with two pieces of flat stock and two lengths of threaded rod. Weld one piece of stack perpendicular to other, drill two holes and install threaded rod as shown. Compressor can also be mounted in pivoting D01006AA Bench Mounted Holding Fixture or similar holding device.

RW3654

–UN–23JAN89

2. Put compressor in a bench holding fixture.

Continued on next page

TM1668 (28JAN09)

18-1830-15

T52,1830,K184 –19–07APR00–1/26

270LC Excavator Repair 012809

PN=333

18 1830 15

Heating and Air Conditioning 3. Remove six dust cover cap screws (A) and remove cover.

RW3655

–UN–23JAN89

A—Cap Screw (6 used)

T52,1830,K184 –19–07APR00–2/26

4. Hold clutch hub with clutch hub holding tool (A), and remove clutch hub retaining nut from shaft.

–UN–23JAN89

NOTE: If clutch drive plate slips on hub, drill a 1/4 in. hole through flanges of drive plate and hub. Insert a punch to hold clutch hub for removal of hub retaining nut.

RW3656

A—Clutch Hub Holding Tool

T52,1830,K184 –19–07APR00–3/26

5. Screw lower portion (A) clutch hub remover into hub. 6. Install forcing screw (B). Hold hub and tighten forcing screw until hub can be removed.

RW3657

–UN–23JAN89

A—Lower Portion of Hub Remover B—Forcing Screw

T52,1830,K184 –19–07APR00–4/26

7. Remove shims (A) from shaft and note quantity. Save shims for reinstallation. 8. Remove and discard snap ring (B) and shaft key (C). –UN–23JAN89

A—Shims B—Snap Ring C—Shaft Key

RW3658

18 1830 16

Continued on next page

TM1668 (28JAN09)

18-1830-16

T52,1830,K184 –19–07APR00–5/26

270LC Excavator Repair 012809

PN=334

Heating and Air Conditioning 9. Install puller adapter (A) and use a suitable three jaw puller as shown to remove clutch pulley.

RW3659

–UN–23JAN89

A—Puller Adapter

T52,1830,K184 –19–07APR00–6/26

10. Remove snap ring (A) and disconnect clutch field coil wire from compressor body. Remove clutch field coil.

RW3660

–UN–23JAN89

A—Snap Ring

T52,1830,K184 –19–07APR00–7/26

11. Remove six through-bolts using special hex drive (A).

–UN–23JAN89

IMPORTANT: Do not remove through-bolts unless suction and discharge manifolds are in place and tight.

RW3661

12. Carefully pry head from body using a screw driver. Pry only slightly around the circumference of the head. Repeat this procedure until head is removed. A—Special Hex Drive

18 1830 17

Continued on next page

TM1668 (28JAN09)

18-1830-17

T52,1830,K184 –19–07APR00–8/26

270LC Excavator Repair 012809

PN=335

Heating and Air Conditioning 13. Remove and discard shaft seal (A).

–UN–07DEC88

14. Use two screw drivers to remove discharge valve plate (B).

RW10908

A—Shaft Seal B—Discharge Valve Plate

T52,1830,K184 –19–07APR00–9/26

15. If shaft seal and valve plate remain with compressor head, carefully separate inlet reed valve (A) from valve plate (C). Do not lose locating dowel pin (B).

RW10909

–UN–07DEC88

A—Inlet Reed Valve B—Dowel Pin C—Valve Plate

T52,1830,K184 –19–07APR00–10/26

16. Install valve plate remover (A) and carefully pull valve plate (B) from head (C).

RW3663

–UN–23JAN89

A—Valve Plate Remover B—Valve Plate C—Head

T52,1830,K184 –19–07APR00–11/26

17. Inspect valve plate side of inlet reed valves for a complete circular wear pattern (A). 18. If wear pattern has any voids in it, replace reed valve. –UN–23JAN89

A—Wear Pattern

RW3665

18 1830 18

Continued on next page

TM1668 (28JAN09)

18-1830-18

T52,1830,K184 –19–07APR00–12/26

270LC Excavator Repair 012809

PN=336

Heating and Air Conditioning 19. Inspect discharge valve for general condition. Valves (A) should have slight pressure against valve plate.

–UN–07DEC88

20. Hold valve plate up to light and verify that valve is against its seat. If condition is doubtful, replace valve plate.

RW10001

A—Discharge Valves

T52,1830,K184 –19–07APR00–13/26

RW3668

–UN–23JAN89

21. Turn compressor over and remove rear head by prying on the small tabs cast into the head. Pry lightly around circumference of head.

T52,1830,K184 –19–07APR00–14/26

22. Remove inlet reed valve from valve plate. 23. Install valve plate remover (A) and carefully pull valve plate (B) from head (C).

RW3663

–UN–23JAN89

A—Valve Plate Remover B—Valve Plate C—Compressor Head

T52,1830,K184 –19–07APR00–15/26

24. Inspect valve plate side of inlet reed valves for a complete circular wear pattern (A).

18 1830 19

25. If wear pattern has any voids in it, replace reed valve.

RW3665

–UN–23JAN89

A—Wear Pattern

Continued on next page

TM1668 (28JAN09)

18-1830-19

T52,1830,K184 –19–07APR00–16/26

270LC Excavator Repair 012809

PN=337

Heating and Air Conditioning 26. Inspect discharge valve for general condition. Valves (A) should have slight pressure against valve plate.

–UN–07DEC88

27. Hold valve plate up to light and verify that valve is against its seat. If condition is doubtful, replace valve plate.

RW10001

A—Discharge Valves

T52,1830,K184 –19–07APR00–17/26

28. Inspect cylinders for scoring or excessive wear. If cylinders are scored or damaged, replace compressor.

RW3667

–UN–23JAN89

NOTE: Some cylinder scuffing (light scratches) is normal.

T52,1830,K184 –19–07APR00–18/26

29. Inspect surfaces of clutch pulley (A) and clutch hub (B). If pulley is more than 0.3 mm (0.012 in.) from flat, replace pulley and clutch hub.

–UN–23JAN89

30. Rotate bearing in pulley. If pulley is rough or has evidence of loss of lube, replace bearing. 31. Clean as necessary.

RW3677

A—Clutch Pulley B—Clutch Hub

18 1830 20

Continued on next page

TM1668 (28JAN09)

18-1830-20

T52,1830,K184 –19–07APR00–19/26

270LC Excavator Repair 012809

PN=338

Heating and Air Conditioning 32. Remove retaining ring (A) from pulley bore.

RW3670

–UN–23JAN89

A—Retaining Ring

T52,1830,K184 –19–07APR00–20/26

33. Put pulley on pulley support (A). Press bearing from pulley using bearing adapter (B) and puller adapter (C).

RW3671

–UN–23JAN89

A—Pulley Support B—Bearing Adapter C—Puller Adapter

T52,1830,K184 –19–07APR00–21/26

RW3672

–UN–23JAN89

34. Install dust shield, lip edge facing up, in pulley.

Continued on next page

T52,1830,K184 –19–07APR00–22/26

18 1830 21

TM1668 (28JAN09)

18-1830-21

270LC Excavator Repair 012809

PN=339

Heating and Air Conditioning 35. Put pulley on pulley bearing support (A). Make sure dust shield seats in support before putting bearing on pulley.

–UN–23JAN89

36. Press bearing into pulley until bearing bottoms on dust shield using a bearing adapter (B) and pulley adapter.

RW3673

37. Install bearing retaining ring. A—Bearing Support B—Bearing Adapter C—Pulley Adapter

T52,1830,K184 –19–07APR00–23/26

RW3674

–UN–23JAN89

38. Remove seat from head using a shaft seal seat remover.

T52,1830,K184 –19–07APR00–24/26

39. Apply a small amount of clean refrigerant oil to O-ring (A).

A—O-Ring B—Seal Seat

RW3675

18 1830 22

–UN–23JAN89

40. Install seal seat (B) in bore with grooved surface of seat facing up as shown.

Continued on next page

TM1668 (28JAN09)

18-1830-22

T52,1830,K184 –19–07APR00–25/26

270LC Excavator Repair 012809

PN=340

Heating and Air Conditioning

RW3676

–UN–23JAN89

41. Press seal seat in head until seat bottoms in bore using shaft seal seat installer.

T52,1830,K184 –19–07APR00–26/26

Assemble Air Conditioning Compressor 1. Remove gaskets from both front and rear heads. Be sure all gasket material is removed. Wash all parts in clean solvent before assembly. 2. Place suction reed valve against compressor side of rear head. Install locating dowel pin to assure that reed valve and valve plate are properly indexed. Set in place in compressor. 3. Carefully install new head gasket. Be sure it is properly in place. 4. Carefully install rear head. Be sure locating dowel pin is correctly positioned in head. Lightly tap head into place. 5. Turn compressor over and install suction reed and valve plate. Install new head gasket.

Continued on next page

T52,1830,J21 –19–07APR00–1/6

18 1830 23

TM1668 (28JAN09)

18-1830-23

270LC Excavator Repair 012809

PN=341

Heating and Air Conditioning IMPORTANT: Draft seal is a two piece seal. Be sure they are properly installed or breakage will occur during assembly of front head. –UN–23JAN89

6. Install new shaft seal (A) as shown. Be sure slotted rear side of seal engages with flats on compressor shaft.

RW3662

A—Shaft Seal

T52,1830,J21 –19–07APR00–2/6

7. Align head with dowel pin and install head. Use six bolts to draw head down EVENLY, then tighten.

–UN–23JAN89

Specification Compressor Head-to-Housing Cap Screw—Torque ........................................................ 26 N•m (19 lb-ft)

8. Install new shaft key in key way. Position shaft key installer (A) with slotted area (B) over key.

RW3678

9. Tap installer with a small hammer until key bottoms in key way. A—Shaft Key Installer B—Slotted Area

T52,1830,J21 –19–07APR00–3/6

10. Align clutch coil with roll pin (B) in head and install coil. Install snap ring (A) with round edge facing upward.

–UN–23JAN89

11. Connect clutch coil wire to ground screw on compressor. A—Snap Ring B—Roll Pin

RW3679

18 1830 24

Continued on next page

TM1668 (28JAN09)

18-1830-24

T52,1830,J21 –19–07APR00–4/6

270LC Excavator Repair 012809

PN=342

Heating and Air Conditioning

14. Align clutch head key way with key and install hub. 15. Tighten nut until clutch hub is tight against shims on compressor shaft shoulder.

RW3684

13. Install new snap ring (A) with rounded edge of snap ring facing upward. Install removed shims (B) on front head.

–UN–23JAN89

12. Install pulley. Slight tap may be needed to properly position pulley on shaft.

A—Snap Ring B—Shims

T52,1830,J21 –19–07APR00–5/6

16. Check pulley-to-hub for clearance in three equally spread locations around hub using a feeler gauge.

RW3682

17. Turn pulley one-half turn (180°) and check clearance in three equally spaced locations. Remove or install shims as necessary for proper clearance.

–UN–23JAN89

Specification Pulley-to-Hub—Clearance ................... 0.53—0.91 mm (0.021—0.036 in.)

18. Tighten clutch hub nut. Specification Clutch Hub Nut—Torque ................................................. 16 N•m (12 lb-ft)

T52,1830,J21 –19–07APR00–6/6

18 1830 25

TM1668 (28JAN09)

18-1830-25

270LC Excavator Repair 012809

PN=343

Heating and Air Conditioning

Inspect Air Conditioning Compressor Manifolds

RW4983

IMPORTANT: Do not remove manifolds unless front and rear head cap screws are installed and tightened.

–UN–23JAN89

1. Recover the refrigerant from the system. (See procedure in this group.)

2. Remove cap screws using hex drive (A). 3. Inspect parting surfaces and O-rings. 4. Replace parts as necessary.

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

RW4984

A—Hex Drive

–UN–23JAN89

5. Install manifolds.

TX,1830,DV2015 –19–07APR00–1/1

18 1830 26

TM1668 (28JAN09)

18-1830-26

270LC Excavator Repair 012809

PN=344

Heating and Air Conditioning

18 1830 27

TM1668 (28JAN09)

18-1830-27

270LC Excavator Repair 012809

PN=345

Heating and Air Conditioning

Remove and Install Receiver Dryer

T108980

–UN–14JUL97

18 1830 28

Continued on next page

TM1668 (28JAN09)

18-1830-28

TX,18,SB743 –19–10APR97–1/2

270LC Excavator Repair 012809

PN=346

Heating and Air Conditioning 00—Bracket 01—Cap Screw 2—Compressor 03—Bracket 04—Spacer 05—Cap Screw 06—Washer 07—Washer 10—Receiver Dryer

11—Washer 12—Nut 14—Cap Screws 15—Adjusting Bolt 16—Cap Screw 17—Lock Washer 18—Nut 19—Cap Screw 20—Belt

1. Recover the refrigerant from the system. (See procedure in this group.)

22—Bracket 23—Bracket 24—Cap Screw 25—Bracket 26—Cap Screw 30—Condenser 31—Hose 32—Hose

33—Cap Screw 34—Cap Screw 37—Cap Screw 39—Wiring Harness 43—Tie Band 44—Clip 45—Cap Screw 46—Tie Band

3. Evacuate and charge the system. (See procedures in this group.)

2. Remove and install receiver dryer (10).

TX,18,SB743 –19–10APR97–2/2

18 1830 29

TM1668 (28JAN09)

18-1830-29

270LC Excavator Repair 012809

PN=347

Heating and Air Conditioning

Remove and Install Evaporator

TP48104

–UN–06AUG96

18 1830 30

Continued on next page

TM1668 (28JAN09)

18-1830-30

TX,1830,SB564 –19–10JAN97–1/2

270LC Excavator Repair 012809

PN=348

Heating and Air Conditioning 1—Cap Screw, Lock Washer, Washer (11 used) 3—Heater Hose 4—Heater Hose 5—Hose Clamp (4 used) 6—Tube (2 used)

7—Bushing 8—Grommet 9—Bushing 10—Grommet (2 used) 12—Plug (13 used) 14—Control

NOTE: Evaporator is serviced as part of the air conditioning unit. 1. Recover the refrigerant from the system. (See procedure in this group.)

15—Screw (4 used) 16—Wiring Harness 18—Hose (2 used) 19—Tie Band (7 used) 26—Air Duct 27—Cap Screw, Lock Washer, Washer (2 used)

28—Cap Screw and Washer (2 used) 29—Air Conditioning Unit 30—Housing 31—Plug

2. Remove and install air conditioning unit (29). 3. Evacuate and charge the system. (See procedures in this group.)

TX,1830,SB564 –19–10JAN97–2/2

18 1830 31

TM1668 (28JAN09)

18-1830-31

270LC Excavator Repair 012809

PN=349

Heating and Air Conditioning

Remove and Install Condenser

T108980

–UN–14JUL97

18 1830 32

Continued on next page

TM1668 (28JAN09)

18-1830-32

TX,18,SB744 –19–10APR97–1/2

270LC Excavator Repair 012809

PN=350

Heating and Air Conditioning 00—Bracket 01—Cap Screw 2—Compressor 03—Bracket 04—Spacer 05—Cap Screw 06—Washer 07—Washer 10—Receiver Tank

11—Washer 12—Nut 14—Cap Screws 15—Adjusting Bolt 16—Cap Screw 17—Lock Washer 18—Nut 19—Cap Screw 20—Belt

1. Recover the refrigerant from the system. (See procedure in this group.)

22—Bracket 23—Bracket 24—Cap Screw 25—Bracket 26—Cap Screw 30—Condenser 31—Hose 32—Hose

33—Cap Screw 34—Cap Screw 37—Cap Screw 39—Wiring Harness 43—Tie Band 44—Clip 45—Cap Screw 46—Tie Band

3. Evacuate and charge the system. (See procedures in this group.)

2. Remove and install condenser (30) as shown.

TX,18,SB744 –19–10APR97–2/2

18 1830 33

TM1668 (28JAN09)

18-1830-33

270LC Excavator Repair 012809

PN=351

Heating and Air Conditioning

Remove and Install Heater Core—Machine With Air Conditioning

TP48104

–UN–06AUG96

18 1830 34

Continued on next page

TM1668 (28JAN09)

18-1830-34

TX,1830,SB566 –19–10JAN97–1/2

270LC Excavator Repair 012809

PN=352

Heating and Air Conditioning 1—Cap Screw, Lock Washer, Washer (11 used) 3—Heater Hose 4—Heater Hose 5—Hose Clamp (4 used) 6—Tube (2 used)

7—Bushing 8—Grommet 9—Bushing 10—Grommet (2 used) 12—Plug (13 used) 14—Control

15—Screw (4 used) 16—Wiring Harness 18—Hose (2 used) 19—Tie Band (7 used) 26—Air Duct 27—Cap Screw, Lock Washer, Washer (2 used)

1. Recover the refrigerant from the system. (See procedure in this group.)

28—Cap Screw and Washer (2 used) 29—Air Conditioning Unit 30—Housing 31—Plug

3. Evacuate and charge the system. (See procedures in this group.)

2. Remove and install air conditioning unit (29).

TX,1830,SB566 –19–10JAN97–2/2

Remove and Install Heater Core and Blower Motor

–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. Close the shut-off valves on the engine or drain coolant from radiator. The approximate coolant system capacity is 22.0 L (6 gal).

Continued on next page

TX,1830,SB567 –19–10JAN97–1/3

18 1830 35

TM1668 (28JAN09)

18-1830-35

270LC Excavator Repair 012809

PN=353

Heating and Air Conditioning

TP48102

–UN–06AUG96

18 1830 36

Continued on next page

TM1668 (28JAN09)

18-1830-36

TX,1830,SB567 –19–10JAN97–2/3

270LC Excavator Repair 012809

PN=354

Heating and Air Conditioning 0—Heater 1—Screw (3 used) 3—Support 5—Air Duct 6—Cap Screw, Lock Washer, Washer (10 used)

7—Control 9—Air Duct 10—Screw, With Washer (2 used) 11—Lock Washer, Cap Screw, Washer (4 used)

13—Grommet 14—Plug 15—Plug (2 used) 16—Plug 17—Plug (16 used) 23—Hose

2. Remove and install blower motor and heater core (0).

24—Hose 25—Hose Clamp (4 used) 26—Tube (2 used) 28—Tie Band (3 used) 29—Tray 30—Screw (4 used)

3. Tighten the hose clamps (25) until the hose just starts to deform around the clamp.

TX,1830,SB567 –19–10JAN97–3/3

Remove and Install Heater Hoses

–UN–23AUG88

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

TS281

Continued on next page

TX,18,SB747 –19–11APR97–1/2

18 1830 37

TM1668 (28JAN09)

18-1830-37

270LC Excavator Repair 012809

PN=355

T109030

–UN–16APR97

Heating and Air Conditioning

Heater Hoses Without Air Conditioning

2. Tighten the hose clamps (03) until the hose just starts to deform around the clamp.

–UN–16APR97

00—Hose 01—Hose 03—Hose Clamp 07—Tie Band 09—Clip 10—Cap Screw

T109031

18 1830 38

Heater Hose Connections With Air Conditioning

TX,18,SB747 –19–11APR97–2/2

TM1668 (28JAN09)

18-1830-38

270LC Excavator Repair 012809

PN=356

Section 33

Excavator Contents Page

Group 3302—Buckets Specifications . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1 Bucket Tooth Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1 Bucket Tooth Tip, Heavy-Duty Bucket Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-3 Welding on Machine . . . . . . . . . . . . . . . . . . .33-3302-3 Tooth Shank Remove and Install . . . . . . . . . . . . . . . . . .33-3302-4 Cutting Edge Replace Welded . . . . . . . . . . . . . . . . . . . .33-3302-8 Repair Crack . . . . . . . . . . . . . . . . . . . . . . .33-3302-9 Bucket Remove and Install . . . . . . . . . . . . . . . . .33-3302-10 Adjust Pivot End Play . . . . . . . . . . . . . . .33-3302-11 Disassemble and Assemble. . . . . . . . . . .33-3302-12 Pin-Up Data . . . . . . . . . . . . . . . . . . . . . . .33-3302-14 Group 3340—Frames Service Equipment and Tools . . . . . . . . . . . .33-3340-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .33-3340-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .33-3340-2 Bucket Links Remove and Install . . . . . . . . . . . . . . . . . .33-3340-5 Arm Remove and Install . . . . . . . . . . . . . . . . . .33-3340-7 Boom Remove and Install . . . . . . . . . . . . . . . . . .33-3340-9 Arm and Boom Pins and Bushings Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-13 Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . .33-3340-16 Group 3360—Hydraulic System Essential Tools . . . . . . . . . . . . . . . . . . . . . . .33-3360-1 Service Equipment and Tools . . . . . . . . . . . .33-3360-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .33-3360-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . .33-3360-6 Control Lever Pattern Conversion . . . . . . . .33-3360-15 Lower Boom with Engine Stopped. . . . . . . .33-3360-17 Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy . . . . . . . . . . . . . . . .33-3360-18 Hydraulic Pump and Drive Gearbox Remove and Install . . . . . . . . . . . . . . . . .33-3360-19 Start-Up Procedure . . . . . . . . . . . . . . . . .33-3360-21 Disassemble . . . . . . . . . . . . . . . . . . . . . .33-3360-22 TM1668 (28JAN09)

Page

Pilot Pump Drive Shaft and Gear Disassemble and Assemble. . . . . . . . . . .33-3360-36 Hydraulic Pump and Drive Gearbox Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-37 Hydraulic Pump Regulator Disassemble and Assemble. . . . . . . . . . .33-3360-46 Pilot Pump Remove and Install . . . . . . . . . . . . . . . . .33-3360-49 Disassemble and Assemble. . . . . . . . . . .33-3360-50 Pilot Pressure Regulating Valve and Filter Remove and Install . . . . . . . . . . . . . . . . .33-3360-52 Disassemble and Assemble. . . . . . . . . . .33-3360-54 Pilot Shut-Off Valve Remove and Install . . . . . . . . . . . . . . . . .33-3360-54 Linkage Adjustment . . . . . . . . . . . . . . . . .33-3360-56 Disassemble and Assemble. . . . . . . . . . .33-3360-57 Solenoid Valve Manifold Remove and Install . . . . . . . . . . . . . . . . .33-3360-59 Proportional Solenoid Valve Disassemble and Assemble. . . . . . . . . . .33-3360-62 Dig Function Pilot Controller Remove and Install . . . . . . . . . . . . . . . . .33-3360-65 Disassemble and Assemble. . . . . . . . . . .33-3360-68 Propel Pilot Controller Remove and Install . . . . . . . . . . . . . . . . .33-3360-71 Disassemble and Assemble. . . . . . . . . . .33-3360-73 Flow Regulator Valve Remove and Install . . . . . . . . . . . . . . . . .33-3360-77 Disassemble and Assemble. . . . . . . . . . .33-3360-79 Control Valve Remove and Install . . . . . . . . . . . . . . . . .33-3360-80 Disassemble and Assemble. . . . . . . . . . .33-3360-89 System Relief Valve Disassemble and Assemble. . . . . . . . . . 33-3360-107 Circuit Relief and Anti-Cavitation Valve Disassemble and Assemble. . . . . . . . . . 33-3360-109 Hydraulic Oil Tank Remove and Install . . . . . . . . . . . . . . . . 33-3360-110 Disassemble and Assemble. . . . . . . . . . 33-3360-116 33 Return Filter and Bypass Valve Remove and Install . . . . . . . . . . . . . . . . 33-3360-117 Suction Filter Remove and Install . . . . . . . . . . . . . . . . 33-3360-120

33-1

Continued on next page

270LC Excavator Repair 012809

PN=1

Contents

Page

Hydraulic Oil Tank Relief Valve and Breather Filter Cap Disassemble and Assemble. . . . . . . . . . 33-3360-122 Swing Motor Make-Up Oil Restriction Valve Remove and Install . . . . . . . . . . . . . . . . 33-3360-123 Oil Cooler Bypass Valve Remove and Install . . . . . . . . . . . . . . . . 33-3360-125 Oil Cooler Remove and Install . . . . . . . . . . . . . . . . 33-3360-127 Cylinder Boom, Remove and Install. . . . . . . . . . . 33-3360-131 Arm, Remove and Install . . . . . . . . . . . . 33-3360-134 Bucket, Remove and Install . . . . . . . . . . 33-3360-137 Hydraulic Bleed Procedure . . . . . . . . . . 33-3360-141 Boom, Arm or Bucket, Disassemble. . . . 33-3360-142 Boom, Arm or Bucket, Assemble . . . . . . 33-3360-150

TM1668 (28JAN09)

33-2

270LC Excavator Repair 012809

PN=2

Group 3302

Buckets Specifications Item

Measurement

Specification

Tooth Shank and Cutting Edge

Preheat Temperature

204—316°C (400—600°F)

Tooth Shank

Fillet Weld Distance

12.7 mm (0.5 in.) 25 ± 6 mm (0.98 ± 0.24 in.) from weld edge

Bucket

Weight

892 kg (1966 lb) approximate

Bucket Pivot Bushing-to-Arm

Clearance

As close to but not less than 0.5 mm (0.020 in.)

Bucket Pivot Shim-to-Plate Cap Screw

Torque

88 N•m (65 lb-ft)

Tooth Shank

Bucket

CED,OUOE003,21685 –19–16MAY00–1/1

Replace Bucket Tooth CAUTION: Guard against injury from flying pieces of metal; wear goggles or safety glasses. –UN–10NOV88

IMPORTANT: Hold the drift at an angle towards the bucket to avoid damaging the rubber pin lock.

T95784

1. Use a hammer and drift to drive out locking pin. Hold the drift at an angle towards the bucket. NOTE: Alternate buckets may use different tooth assemblies. 2. Remove tooth.

Continued on next page

TX,33,GG2393 –19–16MAY00–1/3

33 3302 1

TM1668 (28JAN09)

33-3302-1

270LC Excavator Repair 012809

PN=359

Buckets 3. Inspect rubber pin lock (A) for damage. Replace if necessary.

–UN–10NOV88

4. If rubber pin lock has moved, reposition in slot in adapter tooth shank.

T95785

A—Rubber Pin Lock

TX,33,GG2393 –19–16MAY00–2/3

5. Install the new tooth over the tooth shank. 6. Drive the locking pin into the hole fully.

T95786

–UN–10NOV88

NOTE: Check bucket teeth periodically so that wear does not extend to the bucket tooth shank.

TX,33,GG2393 –19–16MAY00–3/3

33 3302 2

TM1668 (28JAN09)

33-3302-2

270LC Excavator Repair 012809

PN=360

Buckets

Replace Bucket Tooth Tip—Heavy-Duty Bucket 1. Clean tooth (A) and tooth tip (B). –UN–06DEC88

2. Insert lock removal tool under U-shaped pin (C).

T6879EE

CAUTION: Avoid possible injury. Pin may fly after it is released from tooth tip. Keep a firm grip on pin to prevent injury. 3. Remove pin. 4. Turn tooth tip counterclockwise and pull it towards you to remove.

–UN–27JUN91

5. Clean tooth shank. 6. Replace U-shaped pin at same time you replace tooth tip.

T7527DO

7. Insert tooth tip on shank turning tip clockwise. 8. Install U-shaped pin. Side of pin marked "FRONT" (D) must be towards tooth tip. Make sure pin is firmly engaged over tooth tip.

A—Tooth B—Tooth Tip C—Pin D—"Front" Mark

TX,33,GG2395 –19–13DEC96–1/1

33 3302 3

Continued on next page

TM1668 (28JAN09)

33-3302-3

TX,16,UU3948 –19–07APR00–1/3

270LC Excavator Repair 012809

PN=361

Buckets 1. Inside the cab, remove four cap screws (A and C) and the fuse box cover (B) to remove the rear console cover.

–UN–07MAR97

2. Disconnect the battery ground and positive cables.

T107932B

A—Cap Screw (4 used) B—Fuse Box Cover C—Cap Screw (4 used)

TX,16,UU3948 –19–07APR00–2/3

3. Disconnect the engine and pump controller electrical connectors.

–UN–06MAR97

After reconnecting batteries, engine speeds must be recalibrated. (See Engine Speed Learning Procedure this group.)

T105437B

A—EPC Connector B—EPC Connector C—EPC Connector

TX,16,UU3948 –19–07APR00–3/3

Remove and Install Tooth Shank IMPORTANT: Electrical current traveling from the welder through the machine’s electrical system may damage the electrical system, including the battery, and the engine and pump controller. Before welding on the machine, the battery ground cable and wiring harness connectors to the engine and pump controller must be disconnected to protect the machine’s electrical system. 1. Disconnect the battery ground strap and the wiring harness connectors to the engine and pump controller. (See Welding on Machine in this group.)

Continued on next page

TX,33,GG2396 –19–16MAY00–1/5

33 3302 4

TM1668 (28JAN09)

33-3302-4

270LC Excavator Repair 012809

PN=362

Buckets 2. Being careful not to cut into cutting edge, remove weld using a cutting torch or air arc equipment to remove shank.

T92510

–UN–31OCT88

T92509

–UN–31OCT88

3. Grind all surfaces smooth.

Continued on next page

TX,33,GG2396 –19–16MAY00–2/5

33 3302 5

TM1668 (28JAN09)

33-3302-5

270LC Excavator Repair 012809

PN=363

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. 33 3302 6

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

TM1668 (28JAN09)

33-3302-6

TX,33,GG2396 –19–16MAY00–3/5

270LC Excavator Repair 012809

PN=364

Buckets Use E7018 electrodes for welding or Lincoln Electric Co. gasless flux core process electrode type NS3M. 3/32 or 1/8 in. rod may be used.

TX,33,GG2396 –19–16MAY00–4/5

7. Preheat shank and cutting edge. Check temperature using a temperature stick to be sure correct temperature is obtained.

–UN–31OCT88

Tooth Shank—Specification Tooth Shank and Cutting Edge— Preheat Temperature ....................................... 204—316°C (400—600°F)

T82798

IMPORTANT: All weld beads must be continuous starting at rear center, 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).

–UN–31OCT88

Tooth Shank—Specification Tooth Shank—Fillet Weld .............................................. 12.7 mm (0.5 in.)

T82799

Starting at the rear center of shank, weld a continuous bead across end, around the corner, and along the side stopping from edge of cutting edge as specified. Tooth Shank—Specification Tooth Shank—Distance......................... 25 ± 6 mm (0.98 ± 0.24 in.) from weld edge 1—Fillet Weld

Alternating from side to side, make as many passes as necessary to get the specified bead size. 9. Allow the weld area to cool slowly at room temperature.

TX,33,GG2396 –19–16MAY00–5/5

33 3302 7

TM1668 (28JAN09)

33-3302-7

270LC Excavator Repair 012809

PN=365

Buckets

Replace Welded Cutting Edge IMPORTANT: Electrical current traveling from the welder through the machine’s electrical system may damage the electrical system, including the battery, and the engine and pump controller. Before welding on the machine, the battery ground cable and wiring harness connectors to the engine and pump controller must be disconnected to protect the machine’s electrical system. 1. Disconnect the battery ground strap and the wiring harness connectors to the engine and pump controller. (See Welding on Machine in this group.) 2. Perform welding in an environment with a minimum ambient temperature of 10°C (50°F). 3. Clean all joints to be welded of all foreign matter such as dirt, rust, mill scale, oil, etc. with grinders and/or solvents. 4. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: gas metal arc welding (CO 2 or argon CO 2) AWS-E70S6 or flux cored arc welding AWS-E70T1.

PREHEAT TEMPERATURE MUST BE THROUGHOUT THE ENTIRE THICKNESS OF THE PARTS JOINED AND AT LEAST 51 mm (2 in.) BACK FROM THE JOINT. Maintain preheat throughout the entire welding operation. Tempilstiks should be used if possible. 6. Tack weld preheated plates starting at center of bucket and working towards the outside ends. 7. Final weld preheated plates starting at the center of front edge of bucket backing plate and working towards the outside ends. Repeat this operation at back edge of plates. Tack welds may be incorporated into the final weld, providing they have been made with electrodes that meet the requirements of the final welds and no cracking has occurred in the weld metal. Tack welds not meeting these requirements must be completely removed by grinding or air arc gouging just prior to making the final weld in that area. 8. Do not remove bucket from welding environment until weld metal temperature has dropped to the ambient temperature. Do not force cooling rate of weld metal.

5. Preheat parts to be welded (both tack and final welds) to 204—316°C (400—600°F). Specification Parts to Be Welded—Minimum Preheat Temperature................................. 204—316°C (400—600°F)

TX,33,GG2397 –19–14DEC96–1/1

33 3302 8

TM1668 (28JAN09)

33-3302-8

270LC Excavator Repair 012809

PN=366

Buckets

Repair Cracked Cutting Edge IMPORTANT: Electrical current traveling from the welder through the machine’s electrical system may damage the electrical system, including the battery, and the engine and pump controller. Before welding on the machine, the battery ground cable and wiring harness connectors to the engine and pump controller must be disconnected to protect the machine’s electrical system.

2. For any crack in cutting edge, clean the area to find end of crack.

1. Disconnect the battery ground strap and the wiring harness connectors to the engine and pump controller. (See Welding on Machine in this group.)

6. Fill the V-grooves with weld. Use E7018 electrodes. Extend the weld approximately 13 mm (0.5 in.) beyond end of crack.

3. Drill a small hole at end of crack to prevent spreading. 4. Grind a V-groove along crack on top and bottom of cutting edge. 5. Preheat the cracked area to approximately 149— 260°C (300—500°F).

TX,33,GG2398 –19–14DEC96–1/1

33 3302 9

TM1668 (28JAN09)

33-3302-9

270LC Excavator Repair 012809

PN=367

Buckets

T105321

–UN–16DEC96

Remove and Install Bucket

A—O-Ring (4 used) B—Retainer Ring (2 used)

C—Pin (2 used)

D—Pin (2 used)

CAUTION: The approximate weight of bucket is 892 kg (1966 lb). Bucket—Specification Bucket—Weight .................................... 892 kg (1966 lb) approximate

1. Position bucket (E) on level surface.

E—Bucket

3. Remove parts (B—D). 4. Repair or replace bucket as necessary. 5. Before installing pins (D), align the pin bores in bucket with pin bores in arm and link so as not to damage dust seal when pins are installed.

2. Slide the O-rings (A) up on the boss of bucket (E).

TX,33,UU3680 –19–16MAY00–1/1

33 3302 10

TM1668 (28JAN09)

33-3302-10

270LC Excavator Repair 012809

PN=368

Buckets

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

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

T95775

Adjust the clearance as close to specification.

–UN–10NOV88

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

NOTE: Alternate buckets may have different adjustment procedures.

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

T6879DU

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

–UN–06DEC88

3. Remove plate (F).

6. Slide O-ring back into position.

T95788

–UN–10NOV88

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

TX,33,GG2403 –19–24MAY00–1/1

33 3302 11

TM1668 (28JAN09)

33-3302-11

270LC Excavator Repair 012809

PN=369

Buckets

–UN–29SEP94

Disassemble and Assemble Bucket

TP46052

33 3302 12

Continued on next page

TM1668 (28JAN09)

33-3302-12

TX,33,GG2404 –19–14DEC96–1/2

270LC Excavator Repair 012809

PN=370

Buckets 4—Self-Aligning Bushing 5—Dowel Pin 6—Washer (as required) 7—Shim (as required) 8—Plate 9—Cap Screw (3 used) 10—Lock Washer (3 used)

11—Bushing (2 used) 13—Pivot 14—Plate 15—Cutting Edge 16—Upper Vertical Cutter 17—Upper Vertical Cutter 18—Insert Vertical Cutter

19—Insert Vertical Cutter 20—Moldboard 21—Cutting Edge 22—Cutting Edge 23—Bolt (6 used) 24—Lock Washer (6 used) 25—Nut (6 used)

27—Inner Wear Bar 28—Outer Wear Bar (2 used) 29—Wear Shroud 30—Wear Shroud 31—Nut (6 used) 40—Bucket

Inspect parts for wear or damage; replace as necessary.

To replace cutting edges, see Replace Welded Cutting Edge in this group.

To repair cracks, see Repair Cracked Cutting Edge in this group.

To adjust self-aligning bushing (4), see Adjust Bucket Pivot End Play in this group.

TX,33,GG2404 –19–14DEC96–2/2

33 3302 13

TM1668 (28JAN09)

33-3302-13

270LC Excavator Repair 012809

PN=371

Buckets

Bucket Pin-Up Data

TX,33,GG2766 –19–16JUL97–1/1

TM1668 (28JAN09)

33-3302-14

T110634

–19–17JUL97

33 3302 14

270LC Excavator Repair 012809

PN=372

Group 3340

Frames Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21687 –19–16MAY00–1/4

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . JT01748 Use with a hoist to lift components.

CED,OUOE003,21687 –19–16MAY00–2/4

Floor Stand To support load of boom and boom cylinder.

CED,OUOE003,21687 –19–16MAY00–3/4

Bushing, Bearing and Seal Driver Set Use with puller set to remove and install bushings in boom and arm. CED,OUOE003,21687 –19–16MAY00–4/4

Other Material Number

Name

Use

TY2098 (U.S.)

Multi-Purpose Grease

To provide a light seal between surfaces.

CED,OUOE003,21688 –19–16MAY00–1/1

33 3340 1

TM1668 (28JAN09)

33-3340-1

270LC Excavator Repair 012809

PN=373

Frames

Specifications Item

Measurement

Specification

Short Arm

Weight

685 kg (1510 lb) approximate

Standard Arm

Weight

754 kg (1663 lb)

Long Arm

Weight

878 kg (1936 lb) approximate

Arm Cylinder

Weight

318 kg (700 lb) approximate

Arm Cylinder Head End-to-Boom Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Arm Cylinder Head End-to-Boom Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Arm Cylinder Head End-to-Boom Joint Boss

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Arm Cylinder Rod End-to-Arm Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Arm Cylinder Rod End-to-Arm Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Arm Cylinder Rod End-to-Arm Joint Boss

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Bucket Cylinder

Weight

222 kg (490 lb) approximate

Bucket Cylinder Head End-to-Arm Joint Pin

OD OD

80.0 mm (3.15 in.) nominal 79.0 mm (3.11 in.) limit of use

Bucket Cylinder Head End-to-Arm Joint Bushing

ID ID

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Bucket Cylinder Head End-to-Arm Joint Boss

ID ID

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Bucket Cylinder Rod End-to-Side and Center Links Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Arm

Bucket

33 3340 2

Continued on next page

TM1668 (28JAN09)

33-3340-2

CED,OUOE003,21722 –19–24MAY00–1/3

270LC Excavator Repair 012809

PN=374

Frames

Item

Measurement

Specification

Bucket Cylinder Rod End-to-Side and Center Links Joint Bushings

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Bucket Cylinder Rod End-to-Side and Center Links Joint Boss

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Link-to-Arm Joint Pin

OD OD

80.0 mm (3.15 in.) nominal 79.0 mm (3.11 in.) limit of use

Link-to-Arm Joint Bushing

ID ID

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Link-to-Bucket Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Link-to-Bucket Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Bucket-to-Arm Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Bucket-to-Arm Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Boom Cylinder

Weight

255 kg (562 lb) approximate

Boom

Weight

1800 kg (3969 lb) approximate

Boom-to-Frame Pin M20 Cap Screw Nut

Torque

540 N•m (400 lb-ft) tighten nuts against each other, not the retainer

Boom Cylinder Head End-to-Frame Joint Pin

OD OD

100.0 mm (3.94 in.) nominal 99.0 mm (3.90 in.) limit of use

Boom Cylinder Head End-to-Frame Joint Bushing

ID ID

100.0 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom Cylinder Head End-to-Frame Joint Boss

ID ID

100.0 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom Cylinder Rod End-to-Boom Joint Pin

OD OD

100.00 mm (3.94 in.) nominal 99.0 mm (3.90 in.) limit of use

Boom

33 3340 3

Continued on next page

TM1668 (28JAN09)

33-3340-3

CED,OUOE003,21722 –19–24MAY00–2/3

270LC Excavator Repair 012809

PN=375

Frames

Item

Measurement

Specification

Boom Cylinder Rod End-to-Boom Joint Bushing

ID ID

100.00 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom Cylinder Rod End-to-Boom Joint Boss

ID ID

100.00 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom-to-Frame Joint Pin

OD OD

100.00 mm (3.94 in.) nominal 99.0 mm (3.90 in.) limit of use

Boom-to-Frame Joint Bushing

ID ID

100.00 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom-to-Arm Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Boom-to-Arm Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

CED,OUOE003,21722 –19–24MAY00–3/3

33 3340 4

TM1668 (28JAN09)

33-3340-4

270LC Excavator Repair 012809

PN=376

Frames

T105322

–UN–17DEC96

Remove and Install Bucket Links

A—Left Side Link B—Retainer Ring (2 used) C—Pin (2 used)

D—Links-to-Bucket Cylinder Pin E—Right Side 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 Remove and Install Bucket in Group 3302.) 1. Connect center link (H) to a hoist using a lifting strap. Put a wooden block (G) between the bucket

F—Links-to-Arm Pin G—Wooden Block

H—Center Link I—Washer (as required)

cylinder and arm to hold cylinder up when links-to-bucket cylinder pin (D) is removed. 2. Remove the retainer rings (B) and pins (C). As links-to-bucket cylinder pin (D) is removed, lower the left (A) and right (E) side links to the ground.

Continued on next page

TX,33,GG2406 –19–24MAY00–1/2

33 3340 5

TM1668 (28JAN09)

33-3340-5

270LC Excavator Repair 012809

PN=377

T105335

–UN–19DEC96

Frames

A—Left Side Link B—Retainer Ring (2 used) C—Pin (2 used) D—Links-to-Bucket Cylinder Pin

E—Right Side Link F—Links-to-Arm Pin H—Center Link

I—Washer (As Required) J—Lubrication Fitting (2 used) K—Dust Seal (6 used)

3. Inspect the bushings (L and M) and dust seals (K). (See Inspect Arm and Boom Pins and Bushings in this group.)

L—Bushing (2 used) M—Bushing (2 used) N—Lubrication Fitting (2 used)

4. Before installing pins, align the pin bores so as not to damage the dust seal when pins are installed. 5. Apply grease to all lubrication fitting.

Replace parts as necessary.

TX,33,GG2406 –19–24MAY00–2/2

33 3340 6

TM1668 (28JAN09)

33-3340-6

270LC Excavator Repair 012809

PN=378

Frames

Remove and Install Arm 1. Remove the bucket. (See Remove and Install Bucket in Group 3302). 2. Retract arm cylinder. 3. Put a floor stand under end of boom so load is on boom, not on arm cylinder. Extend arm cylinder just enough to put end of arm on the ground. 4. Stop the engine. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Release pressure from tank by loosening vent plug. It is not necessary to remove vent plug. 5. Loosen vent plug to release pressure from hydraulic oil tank. NOTE: Arm can also be removed with bucket cylinder and links installed. 6. Remove bucket cylinder and links. (See procedure in this group and Group 3360.)

Continued on next page

TX,33,UU3682 –19–24MAY00–1/2

33 3340 7

TM1668 (28JAN09)

33-3340-7

270LC Excavator Repair 012809

PN=379

Frames

CAUTION: The approximate weight of short arm is 685 kg (1510 lb).

–UN–26MAR90

The approximate weight of standard arm is 754 kg (1663 lb).

T6641DC

Tthe approximate weight of long arm is 878 kg (1936 lb). The approximate weight of bucket cylinder is 222 kg (490 lb). Arm—Specification Short Arm—Weight...................................... 685 kg (1510 lb) approximate Standard Arm—Weight..................................................... 754 kg (1663 lb) Long Arm—Weight ...................................... 878 kg (1936 lb) approximate

Arm Without Bucket Cylinder

Bucket—Specification Bucket Cylinder—Weight............................... 222 kg (490 lb) approximate

7. Remove arm without bucket cylinder or with bucket cylinder installed. Bucket end of arm is the heavy end when hoist is connected to mounting bracket for bucket cylinder. Put a wooden block between the arm cylinder and boom to hold cylinder up when arm-to-arm cylinder pin (F) is removed. 8. Inspect the bushings and dust seals. (See Inspect Arm and Boom Pins and Bushings in this group.)

–UN–31OCT88

Repair or replace parts as necessary. (See Remove and Install Bushings and Seals in this group.)

10. Before installing pins, align the pin bores so as not to damage the dust seal when pins are installed.

T6626JC

9. Install washer equally on each side of arm to get the minimal amount of clearance between boom and arm. There must be some clearance between boom and arm. Arm With Bucket Cylinder A—Retainer Ring B—Retainer Ring C—Pin D—Pin E—Arm-to-Boom Pin F—Arm-to-Arm Cylinder Pin

11. Apply grease to all lubrication fitting.

33 3340 8

TX,33,UU3682 –19–24MAY00–2/2

TM1668 (28JAN09)

33-3340-8

270LC Excavator Repair 012809

PN=380

Frames

Remove and Install Boom 1. Remove bucket and arm. (See procedures in Group 3302 and in this group.) 2. Lower boom to the ground. 3. Stop the engine. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Release pressure from tank by loosening vent plug. It is not necessary to remove vent plug. 4. Loosen vent plug to release air pressure from hydraulic oil tank. 5. Remove arm cylinder only if necessary to repair boom. (See Remove and Install Arm Cylinder in Group 3360.) 6. Disconnect wiring harness and lubrication lines. 7. Disconnect arm and bucket lines at frame end of boom.

Continued on next page

TX,33,UU3684 –19–16MAY00–1/5

33 3340 9

TM1668 (28JAN09)

33-3340-9

270LC Excavator Repair 012809

PN=381

Frames

CAUTION: The approximate weight of boom cylinder is 255 kg (562 lb).

–UN–30DEC96

Boom—Specification Boom Cylinder—Weight ................................ 255 kg (562 lb) approximate

8. Attach a boom cylinder (F) to hoist using a lifting strap.

T105734

9. Remove retainer rings (A), pins (C), retainers (B) and shims (D). 10. Push boom cylinder-to-boom pin (E) into the boom. 11. Lower boom cylinder (F) on a floor stand. 12. Repeat procedure for the second boom cylinder

T105828

–UN–30DEC96

A—Retainer Ring (2 used) B—Retainer (2 used) C—Pin (2 used) D—Shim (As Required) E—Boom Cylinder-to-Boom Pin F—Boom Cylinder (2 used)

Continued on next page

TX,33,UU3684 –19–16MAY00–2/5

33 3340 10

TM1668 (28JAN09)

33-3340-10

270LC Excavator Repair 012809

PN=382

Frames

CAUTION: The approximate weight of boom is 1800 kg (3969 lb). The approximate weight of arm cylinder is 318 kg (700 lb). Boom—Specification Boom—Weight........................................... 1800 kg (3969 lb) approximate Arm—Specification Arm Cylinder—Weight ................................... 318 kg (700 lb) approximate

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

T6626JW

–UN–31OCT88

NOTE: The arm end of boom is the heavy end with arm cylinder installed. The frame end is the heavy end when the arm cylinder is removed.

Continued on next page

TX,33,UU3684 –19–16MAY00–3/5

33 3340 11

TM1668 (28JAN09)

33-3340-11

270LC Excavator Repair 012809

PN=383

Frames 14. Remove nuts (C) and cap screws (A). 15. Remove pin (D) using a slide hammer and adapter. Remove any washers (B) between frame and boom. –UN–17DEC96

16. Inspect the bushings and dust seals. (See Inspect Arm and Boom Pins and Bushings in this group.)

17. Install washer (B) equally on each side of boom to get the minimal amount of clearance between boom and frame. There must be some clearance between boom and frame.

T105736

Repair or replace parts as necessary. (See Remove and Install Bushings and Seals in this group.)

A—Cap Screw B—Washer C—Nut D—Pin

18. Before installing pin (D), align the pin bores so as not to damage the dust seal when pins is installed. Tighten the nuts (C) against each other, not the retainer. Cap screw (A) must be free to turn in hole. Boom—Specification Boom-to-Frame Pin M20 Cap Screw Nut—Torque ................................. 540 N•m (400 lb-ft) tighten nuts against each other, not the retainer

TX,33,UU3684 –19–16MAY00–4/5

Install shims (D) equally on each side to get the minimum amount of clearance between boom and cylinder rod end. There must be some clearance between boom and cylinder rod end. 20. Apply grease to all lubrication fitting.

33 3340 12

T105734

A—Retainer Ring (2 used) B—Retainer (2 used) C—Pin (2 used) D—Shim (As Required) E—Boom Cylinder-to-Boom Pin

–UN–30DEC96

19. Install boom cylinders to boom.

TX,33,UU3684 –19–16MAY00–5/5

TM1668 (28JAN09)

33-3340-12

270LC Excavator Repair 012809

PN=384

Frames

T7779AC

–UN–11JUN92

Inspect Arm and Boom Pins and Bushings

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

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

Item

G—Bucket Cylinder Head End H—Bucket Cylinder Rod End I—Link-to-Arm Joint

J—Link-to-Bucket Joint K—Bucket-to-Arm Joint

Measurement

Specification

Boom Cylinder Head End-to-Frame Joint Pin

OD OD

100.0 mm (3.94 in.) nominal 99.0 mm (3.90 in.) limit of use

Boom Cylinder Head End-to-Frame Joint Bushing

ID ID

100.0 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom Cylinder Head End-to-Frame Joint Boss

ID ID

100.0 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom Cylinder Rod End-to-Boom Joint Pin

OD OD

100.00 mm (3.94 in.) nominal 99.0 mm (3.90 in.) limit of use

Boom Cylinder Rod End-to-Boom Joint Bushing

ID ID

100.00 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom Cylinder Rod End-to-Boom Joint Boss

ID ID

100.00 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom-to-Frame Joint Pin

OD OD

100.00 mm (3.94 in.) nominal 99.0 mm (3.90 in.) limit of use

Boom-to-Frame Joint Bushing

ID ID

100.00 mm (3.94 in.) nominal 101.5 mm (4.00 in.) limit of use

Boom-to-Arm Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Boom

33 3340 13

Continued on next page

TM1668 (28JAN09)

33-3340-13

TX,33,GG2356 –19–24MAY00–1/3

270LC Excavator Repair 012809

PN=385

Frames

Item

Measurement

Specification

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Arm Cylinder Head End-to-Boom Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Arm Cylinder Head End-to-Boom Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Arm Cylinder Head End-to-Boom Joint Boss

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Arm Cylinder Rod End-to-Arm Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Arm Cylinder Rod End-to-Arm Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Arm Cylinder Rod End-to-Arm Joint Boss

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Bucket Cylinder Head End-to-Arm Joint Pin

OD OD

80.0 mm (3.15 in.) nominal 79.0 mm (3.11 in.) limit of use

Bucket Cylinder Head End-to-Arm Joint Bushing

ID ID

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Bucket Cylinder Head End-to-Arm Joint Boss

ID ID

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Bucket Cylinder Rod End-to-Side and Center Links Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Bucket Cylinder Rod End-to-Side and Center Links Joint Bushings

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Bucket Cylinder Rod End-to-Side and Center Links Joint Boss

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Link-to-Arm Joint Pin

OD OD

80.0 mm (3.15 in.) nominal 79.0 mm (3.11 in.) limit of use

Boom-to-Arm Joint Bushing

Arm

Bucket

33 3340 14

Continued on next page

TM1668 (28JAN09)

33-3340-14

TX,33,GG2356 –19–24MAY00–2/3

270LC Excavator Repair 012809

PN=386

Frames

Item

Measurement

Specification

Link-to-Arm Joint Bushing

ID ID

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Link-to-Bucket Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Link-to-Bucket Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

Bucket-to-Arm Joint Pin

OD OD

90.0 mm (3.54 in.) nominal 89.0 mm (3.50 in.) limit of use

Bucket-to-Arm Joint Bushing

ID ID

90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

TX,33,GG2356 –19–24MAY00–3/3

33 3340 15

TM1668 (28JAN09)

33-3340-15

270LC Excavator Repair 012809

PN=387

Frames

Remove and Install Bushings and Seals IMPORTANT: Only install bushings using press as shown. Bushings will be damaged if installed with driver. NOTE: Bushing can also be removed by welding three to five weld beads on the inside of bushing. Bushing will shrink enough to permit removal using a hammer. 1. Remove bushings (C) and dust seals using bushing, bearing, and seal driver set. 2. Install bushings with lubrication hole aligned with lubrication passage in pivot.

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

T6641CW

–UN–31OCT88

T95237

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

–UN–01NOV88

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

CED,OUOE023,2178 –19–18JAN01–1/1

33 3340 16

TM1668 (28JAN09)

33-3340-16

270LC Excavator Repair 012809

PN=388

Group 3360

Hydraulic System Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21690 –19–17MAY00–1/3 T7782AH –UN–19JUN92

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . JDG769 To remove and install bearing nut from drive shaft for propel motor or hydraulic pump. CED,OUOE003,21690 –19–17MAY00–2/3 T105612 –UN–12DEC96

Aligning Bar (Pump Timing Tool) . . . . . . . . . . JDG1054 To time pump when installing new parts.

CED,OUOE003,21690 –19–17MAY00–3/3

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21691 –19–17MAY00–1/27

Portable Filter Caddy To transfer and clean hydraulic oil.

Continued on next page

CED,OUOE003,21691 –19–17MAY00–2/27

33 3360 1

TM1668 (28JAN09)

33-3360-1

270LC Excavator Repair 012809

PN=389

Hydraulic System 3658 mm (12 ft) x 3/4 in. I.D. 100R1 Hoses with 3/4 M NPT Ends (2 used) Use with portable filter caddy to transfer and clean hydraulic oil.

CED,OUOE003,21691 –19–17MAY00–3/27

Quick Disconnect Fittings To connect suction and discharge wands to portable filter caddy. CED,OUOE003,21691 –19–17MAY00–4/27

Suction Wand To connect to portable filter caddy for installation into reservoir. CED,OUOE003,21691 –19–17MAY00–5/27

Discharge Wand To connect to portable filter caddy for installation into reservoir. CED,OUOE003,21691 –19–17MAY00–6/27

M12-1.75 Metric Lifting Eyebolts (3 used). . . . . . JT05550 Used to remove hydraulic pump.

CED,OUOE003,21691 –19–17MAY00–7/27

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . JT01748 Use with a hoist to lift components.

CED,OUOE003,21691 –19–17MAY00–8/27

33 3360 2

Hex Key Wrench . . . . . . . . . . . . . . . . . . . . . . . . 6 mm To remove and install servo piston set screw.

Continued on next page

TM1668 (28JAN09)

33-3360-2

CED,OUOE003,21691 –19–17MAY00–9/27

270LC Excavator Repair 012809

PN=390

Hydraulic System Blind-Hole Puller To remove ball bearing.

CED,OUOE003,21691 –19–17MAY00–10/27

Internal Pullers To remove ball bearing.

CED,OUOE003,21691 –19–17MAY00–11/27

Two Temperature Heat Gun . . . . . . . . . . . . . . JT07010 To heat the pump housing for installation of drive shafts and bearings. CED,OUOE003,21691 –19–17MAY00–12/27

Vacuum Pump To pull vacuum in hydraulic oil tank.

CED,OUOE003,21691 –19–17MAY00–13/27

M8-1.25 Cap Screw (2 used) To temporarily hold plate on top of dig function pilot controller while removing and installing the U-joint. CED,OUOE003,21691 –19–17MAY00–14/27

M16-2.0 Cap Screw To pull plate from the bottom of dig function pilot controller. CED,OUOE003,21691 –19–17MAY00–15/27

Hex Key Wrench . . . . . . . . . . . . . . . . . . . . . . . . 4 mm To release locking pin and remove hydraulic oil tank filler cap. CED,OUOE003,21691 –19–17MAY00–16/27

33 3360 3

Floor Stand To support load of boom and boom cylinder.

Continued on next page

TM1668 (28JAN09)

33-3360-3

CED,OUOE003,21691 –19–17MAY00–17/27

270LC Excavator Repair 012809

PN=391

Hydraulic System Cylinder Service Stand . . . . . . . . . . . . . . . . . . JT30043 To disassemble and assemble hydraulic cylinders.

CED,OUOE003,21691 –19–17MAY00–18/27

Hex Piston Nut Wrench . . . . . . . . . . . . . . .JT30043-30 To remove and install rod-to-piston nut.

CED,OUOE003,21691 –19–17MAY00–19/27

Steel Flat Stock . . 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) To avoid gouging side of nut.

CED,OUOE003,21691 –19–17MAY00–20/27

Driver Disk To push wear ring to bottom or cylinder bore.

CED,OUOE003,21691 –19–17MAY00–21/27

Press To push wear ring to bottom or cylinder bore.

CED,OUOE003,21691 –19–17MAY00–22/27

Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG841 To expand the cap seal as it is pushed on the bucket cylinder piston. CED,OUOE003,21691 –19–17MAY00–23/27

Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG917 To expand the cap seal as it is pushed on the boom cylinder piston. CED,OUOE003,21691 –19–17MAY00–24/27

33 3360 4

Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG918 To expand the cap seal as it is pushed on the arm cylinder piston. Continued on next page

TM1668 (28JAN09)

33-3360-4

CED,OUOE003,21691 –19–17MAY00–25/27

270LC Excavator Repair 012809

PN=392

Hydraulic System Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG840-6 To push cap seal on the cylinder pistons.

CED,OUOE003,21691 –19–17MAY00–26/27

Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG901-3 To push cap seal on the cylinder pistons.

CED,OUOE003,21691 –19–17MAY00–27/27

Other Material Number

Name

Use

TY9375 (U.S.) TY9480 (Canadian) 592 (LOCTITE)

Pipe Sealant

Apply to drain plug for pump drive gearbox.

TY2098 (U.S.)

Multi-Purpose Grease

To provide a light seal between surfaces.

T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)

Thread Lock and Sealer (Medium Strength)

Apply to threads of feedback link dowel pins in front and rear pump valve plates. Apply to threads of pin-to-servo piston set screw. Apply to threads of set screw in dampener drive hub. Apply to threads of U-joint in dig function pilot controller.

T43514 (U.S.) TY9475 (Canadian) 277 (LOCTITE)

Rigid Form-In-Place Gasket

Apply to pilot pump mounting surface. Apply to mounting surface for pilot pump on pump splitter drive.

T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE)

Thread Lock and Sealer (High Strength)

Apply to threads of arm regenerative valve spool spacer. Apply to threads of boom regenerative valve plugs in boom spool.

33 3360 5

LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

CED,OUOE003,21692 –19–17MAY00–1/1

33-3360-5

270LC Excavator Repair 012809

PN=393

Hydraulic System

Specifications Item

Measurement

Specification

Manual Release Screw

Torque

6.9 N•m (60 lb-in.)

Boom Anti-Drift Valve-to-Housing Nut

Torque

13 N•m (115 lb-in.)

Hydraulic Oil Tank Filtering

Capacity Time

148 L (39 gal) approximate 13 minutes approximate

Hydraulic System Filtering

Capacity Time

270 L (71 gal) approximate 43 minutes approximate

Hydraulic Pump and Drive Gearbox

Weight

170 kg (375 lb) approximate

Drive Gearbox-to-Flywheel Housing Cap Screw

Torque

49 N•m (36 lb-ft)

Pump Drive and Driven Gear Backlash

Clearance Clearance

0.68 mm (0.027 in.) nominal 1.50 mm (0.059 in.) limit of use

Cylinder Head

Weight

30 kg (66 lb) approximate

Piston Connecting Rod Ball End-to-Drive Shaft Socket

Play Play

0.058 mm (0.0023 in.) nominal 0.400 mm (0.0157 in.) limit of use

Cylinder Block-to-Piston Bore

Clearance Clearance

0.043 mm (0.0017 in.) nominal 0.080 mm (0.0032 in.) limit of use

Piston-to-Connecting Rod

Play Play

0.150 mm (0.0059 in.) nominal 0.400 mm (0.0157 in.) limit of use

Rear Pump Drive Shaft Oil Seal Contact Surface (A)

OD OD

45 mm (1.77 in.) nominal 44.8 mm (1.76 in.) limit of use

Rear Pump Drive Shaft Oil Seal Contact Surface (B)

OD OD

55 mm (2.17 in.) nominal 54.8 mm (2.16 in.) limit of use

Lower Boom with Engine Stopped

Hydraulic Oil Cleanup Procedure

Hydraulic Pump and Drive Gearbox

33 3360 6

Continued on next page

TM1668 (28JAN09)

33-3360-6

CED,OUOE003,21726 –19–26MAY00–1/9

270LC Excavator Repair 012809

PN=394

Hydraulic System

Item

Measurement

Specification

Front Pump Drive Shaft Oil Seal Contact Surface (D)

OD OD

55 mm (2.17 in.) nominal 54.8 mm (2.16 in.) limit of use

Servo Piston-to-Cylinder Head Bore

Clearance Clearance

0.079 mm (0.0033 in.) nominal 0.200 mm (0.0078 in.) limit of use

Servo Piston Pin-to-Valve Plate Bore

Clearance Clearance

0.051 mm (0.0020 in.) nominal 0.300 mm (0.0118 in.) limit of use

Roller Bearing

Temperature

50—80°C (122—176°F)

Front and Rear Pump Drive Shaft Bearing Nut

Rolling Drag Torque

2.16 ± 0.49 N•m (19 ± 4 lb-in.)

Special Plug-to-Pump Housing

Torque

34 N•m (300 lb-in.)

Feedback Link Dowel Pin-to-Front and Rear Pump Valve Plate

Torque

9.8 N•m (86 lb-in.)

Servo Piston-to-Pin Set Screw

Torque

34 N•m (300 lb-in.)

Stop and Cover-to-Cylinder Head Cap Screw

Torque

19.5 N•m (180 lb-in.)

Cylinder Head-to-Pump Housing Cap Screw

Torque

108 N•m (80 lb-ft)

Regulator-to-Pump Housing Cap Screw

Torque

49 N•m (36 lb-ft)

Pump Pressure Sensor-to-Pump Housing

Torque

98 N•m (72 lb-ft)

Pump Housing-to-Gearbox Housing Cap Screw

Torque

147 N•m (109 lb-ft)

Pilot Pump-to-Gearbox Cap Screw

Torque

49 N•m (36 lb-ft)

Hub-to-Rear Pump Drive Shaft Set Torque Screw

108 N•m (80 lb-ft)

Hydraulic Pump Regulator End Plate and Cover-to-Housing Cap Screws

Torque

19.8 N•m (180 lb-in.) 33 3360 7

Continued on next page

TM1668 (28JAN09)

33-3360-7

CED,OUOE003,21726 –19–26MAY00–2/9

270LC Excavator Repair 012809

PN=395

Hydraulic System

Item

Measurement

Specification

Housing-to-Pump Housing Cap Screws

Torque

49 N•m (36 lb-ft)

Air Bleed Plug-to-Housing

Torque

78 N•m (58 lb-ft)

Pump-to-Drive Gearbox Cap Screw

Torque

49 N•m (36 lb-ft)

Cover-to-Flange Cap Screw

Torque

41 N•m (31 lb-ft)

Pilot Filter Element Housing-to-Filter Head

Torque

25 N•m (220 lb-in.)

Regulating Valve Housing-to-Filter Head Cap Screw

Torque

20 N•m (175 lb-in.)

Filter Head-to-Support Cap Screw

Torque

49 N•m (36 lb-ft)

Plug-to-Housing

Torque

49 N•m (36 lb-ft)

Housing-to-Cab Platform Cap Screw

Torque

49 N•m (36 lb-ft)

Pilot Shut-Off Valve Lever-to-Cap Screw Head

Clearance

1.5 ± 0.5 mm (0.06 ± 0.02 in.)

Lever-to-Spool Pin Cap Screw

Torque

44 N•m (33 lb-ft)

Torque

3 N•m (24 lb-in.)

Pilot Pump

Pilot Pressure Regulating Valve and Filter

Pilot Shut-Off Valve

Proportional Solenoid Valve Solenoid Valve Housing-to-Manifold Cap Screw

33 3360 8

Continued on next page

TM1668 (28JAN09)

33-3360-8

CED,OUOE003,21726 –19–26MAY00–3/9

270LC Excavator Repair 012809

PN=396

Hydraulic System

Item

Measurement

Specification

Bottom Plate-to-Housing Cap Screw

Torque

49 N•m (36 lb-ft)

U-Joint-to-Housing

Torque

24 N•m (216 lb-in.)

Cam-to-Pusher

Clearance

0—0.20 mm (0—0.008 in.)

Coupling-to-Cam and U-Joint

Torque

78 N•m (58 lb-ft)

Controller-to-Cap Platform Cap Screw

Torque

49 N•m (36 lb-ft)

Propel Pedal-to-Lever Cap Screw

Torque

49 N•m (36 lb-ft)

Holder-to-Housing Cap Screw

Torque

49 N•m (36 lb-ft)

Plug-to-Housing

Torque

34 N•m (25 lb-ft)

Spool-to-Housing Plug

Torque

49 N•m (36 lb-ft)

Check Valve Ball-to-Housing Plug

Torque

10 N•m (86 lb-in.)

Orifice-to-Housing

Torque

10 N•m (86 lb-in.)

Control Valve

Weight

180 kg (400 lb) approximate

Mounting Bracket-to-Valve Housing Cap Screw

Torque

205 N•m (150 lb-ft)

Split Flange Fitting-to-Housing M10 Cap Screw

Torque

64 N•m (47 lb-ft)

Split Flange Fitting-to-Housing M12 Cap Screw

Torque

108 N•m (80 lb-ft)

Front and Rear Pump Control Valve-to-Housing

Torque

84 N•m (62 lb-ft)

Dig Function Pilot Controller

Propel Pilot Controller

Flow Regulator Valve

Control Valve

Continued on next page

TM1668 (28JAN09)

33-3360-9

33 3360 9

CED,OUOE003,21726 –19–26MAY00–4/9

270LC Excavator Repair 012809

PN=397

Hydraulic System

Item

Measurement

Specification

Pilot Plate-to-Housing Cap Screw

Torque

78 N•m (58 lb-ft)

Plug-to-Propel Flow Control Valve Pilot Plate

Torque

98 N•m (72 lb-ft)

Circuit Relief and Anti-Cavitation Valve-to-Control Valve Housing

Torque

83 N•m 62 lb-ft)

System Relief Valve Top Nut

Torque

64 N•m (47 lb-ft)

System Relief Valve Bottom Nut

Torque

83 N•m (61 lb-ft)

System Relief Valve-to-Housing

Torque

83 N•m (61 lb-ft)

Arm In Anti-Drift Valve Housing-to-Housing Cap Screw

Torque

78 N•m (58 lb-ft)

Plug-to-Arm In Anti-Drift Valve Housing

Torque

29 N•m (255 lb-in.)

Spacer-to-Arm Regenerative Valve Torque Spool

18.6 N•m (165 lb-in.)

Special Cap Screw-to-Control Valve Spool

Torque

15 N•m (133 lb-in.)

Pilot Cap-to-Control Housing Cap Screw

Torque

78 N•m (58 lb-ft)

Front and Rear Pump Control Valve-to-Housing

Torque

84 N•m (62 lb-ft)

Plug-to-Bucket Flow Control Valve Poppet

Torque

39 N•m (348 lb-in.)

Bucket Flow Control Valve Housing-to-Control Valve Housing Cap Screw

Torque

78 N•m (58 lb-ft)

Pilot Valve-to-Bucket Flow Control Valve Housing Plug

Torque

71 N•m (52 lb-ft)

Flow Combiner Valve Spool-to-Control Valve Housing Plug

Torque

157 N•m (116 lb-ft)

33 3360 10

Continued on next page

TM1668 (28JAN09)

33-3360-10

CED,OUOE003,21726 –19–26MAY00–5/9

270LC Excavator Repair 012809

PN=398

Hydraulic System

Item

Measurement

Specification

Pilot Pressure Inlet Fitting and Filter-to-Control Valve Housing

Torque

76 N•m (56 lb-ft)

Circuit Relief and Anti-Cavitation Valve-to-Housing

Torque

83 N•m (62 lb-ft)

Boom Regenerative Valve-to-Control Valve Spool Plug

Torque

15 N•m (130 lb-in.)

Boom Anti-Drift Valve Housing-to-Control Valve Housing Cap Screw

Torque

78 N•m (58 lb-ft)

Spool-to-Boom Anti-Drift Valve Housing Plug

Torque

29 N•m (255 lb-in.)

Screw for Boom Lower-to-Boom Anti-Drift Valve Housing

Torque

6.9 N•m (60 lb-in.)

Nut-to-Screw for Boom Lower

Torque

13 N•m (115 lb-in.)

Special Cap Screw-to-Control Valve Spool

Torque

15 N•m (133 lb-in.)

Pilot Cap-to-Control Housing Cap Screw

Torque

78 N•m (58 lb-ft)

System Relief Valve Isolation Check Valve Cover-to-Control Valve Housing Cap Screw

Torque

61 N•m (45 lb-ft)

Flow Combiner Valve Check Valve Torque Cover-to-Control Valve Housing Cap Screw

61 N•m (45 lb-ft)

Propel Flow Control Valve Filter, Orifice and Check Valve Poppet-to-Control Valve Housing Fitting

Torque

76 N•m (56 lb-ft)

Front and Rear Pump Control Valve-to-Control Valve Housing Fitting with Orifice

Torque

34 N•m (25 lb-ft)

33 3360 11

Continued on next page

TM1668 (28JAN09)

33-3360-11

CED,OUOE003,21726 –19–26MAY00–6/9

270LC Excavator Repair 012809

PN=399

Hydraulic System

Item

Measurement

Specification

System Relief Valve Top Nut

Torque

64 N•m (47 lb-ft)

System Relief Valve Bottom Nut

Torque

83 N•m (61 lb-ft)

System Relief Valve-to-Housing

Torque

83 N•m (61 lb-ft)

Nut-to-Circuit Relief and Anti-Cavitation Valve Adjusting Screw

Torque

29.5 N•m (264 lb-in.)

Circuit Relief and Anti-Cavitation Valve-to-Control Valve Housing

Torque

83 N•m (62 lb-ft)

Hydraulic Oil Tank

Weight

147 kg (325 lb) approximate

Frame-to-Oil Tank Cap Screw

Torque

205 N•m (152 lb-ft)

Return Lines-to-Oil Tank Coupling Nut

Torque

10.3—12.4 N•m (91—110 lb-in.)

Oil Tank Elbow-to-Suction Line T-Bolt Type Clamp

Torque

4.4 N•m (40 lb-in.)

Oil Tank Elbow-to-Suction Line Worm Gear Type Clamp

Torque

5.9—6.9 N•m (52—61 lb-in.)

Cover-to-Oil Tank Cap Screw

Torque

49 N•m (36 lb-ft)

Rod and Suction Strainer

Length

670 mm (26.4 in.)

Rod-to-Suction Strainer Nut

Torque

17 N•m (153 lb-in.)

Torque

10.3—12.4 N•m (91—110 lb-in.)

System Relief Valve

Circuit Relief and Anti-Cavitation Valve

Hydraulic Oil Tank

Swing Motor Make-Up Oil Restriction Valve

33 3360 12

Return Line-to-Oil Tank Coupling Nut

Continued on next page

TM1668 (28JAN09)

33-3360-12

CED,OUOE003,21726 –19–26MAY00–7/9

270LC Excavator Repair 012809

PN=400

Hydraulic System

Item

Measurement

Specification

Torque

10.3—12.4 N•m (91—110 lb-in.)

Radiator and Oil Cooler

Weight

141 kg (310 lb) approximate

Return Line-to-Oil Tank Coupling Nut

Torque

10.3—12.4 N•m (91—110 lb-in.)

Oil Tank Elbow-to-Suction Line Worm Gear Type Clamp

Torque

5.9—6.9 N•m (52—61 lb-in.)

Boom Cylinder

Weight

255 kg (562 lb) approximate

Piston-to-Rod Nut

Torque

4780 N•m (3525 lb-ft)

Head End or Rod End Bushing

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Boom Rod

Curvature

0.5 mm per 1 m (0.020 in. per 3.25 ft)

Boom Rod Allowable Scratch

Depth

0.1 mm (0.004 in.) (enough to detect by a fingernail)

Boom Rod

90 + 0.036 mm — 0.090 mm (3.543 + 0.001 in. — 0.004 in.)

Piston-to-Rod Nut

Torque

4780 N•m (3525 lb-ft)

Nut-to-Rod Set Screw

Torque

57 N•m (42 lb-ft)

Rod Guide-to-Barrel Cap Screw

Torque

833 N•m (615 lb-ft)

Arm Cylinder

Weight

318 kg (700 lb) approximate

Piston-to-Rod Nut

Torque

9460 N•m (6980 lb-ft)

Oil Cooler Bypass Valve Return Line-to-Oil Tank Coupling Nut

Oil Cooler

Boom Cylinder

Arm Cylinder

Continued on next page

TM1668 (28JAN09)

33-3360-13

33 3360 13

CED,OUOE003,21726 –19–26MAY00–8/9

270LC Excavator Repair 012809

PN=401

Hydraulic System

Item

Measurement

Specification

Head End or Rod End Bushing

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Arm Rod

Curvature

0.5 mm per 1 m (0.020 in. per 3.25 ft)

Arm Rod Allowable Scratch

Depth

0.1 mm (0.004 in.) (enough to detect by a fingernail)

Arm Rod

100 +.036 mm — 0.090 mm (3.937 + 0.001 in. — 0.004 in.)

Piston-to-Rod Nut

Torque

9460 N•m (6980 lb-ft)

Nut-to-Rod Set Screw

Torque

57 N•m (42 lb-ft)

Rod Guide-to-Barrel Cap Screw

Torque

833 N•m (615 lb-ft)

Bucket Cylinder

Weight

222 kg (490 lb) approximate

Piston-to-Rod Nut

Torque

5640 N•m (4160 lb-ft)

Head End Bushing

71.0 mm (2.80 in.) nominal 72.5 mm (2.85 in.) limit of use

Rod End Bushing

80.0 mm (3.15 in.) nominal 81.5 mm (3.21 in.) limit of use

Bucket Rod

Curvature

0.5 mm per 1 m (0.020 in. per 3.25 ft)

Bucket Rod Allowable Scratch

Depth

0.1 mm (0.004 in.) (enough to detect by a fingernail)

Bucket Rod

85 + 0.036 mm — 0.090 mm (3.346 + 0.001 in. — 0.004 in.)

Piston-to-Rod Nut

Torque

5640 N•m (4160 lb-ft)

Nut-to-Rod Set Screw

Torque

57 N•m (42 lb-ft)

Rod Guide-to-Barrel Cap Screw

Torque

833 N•m (615 lb-ft)

Bucket Cylinder

33 3360 14

CED,OUOE003,21726 –19–26MAY00–9/9

TM1668 (28JAN09)

33-3360-14

270LC Excavator Repair 012809

PN=402

Hydraulic System

Control Lever Pattern Conversion To change your machine pilot control levers from the standard pattern to a John Deere pattern: –UN–29APR97

1. Lower bucket to the ground. 2. Turn key switch to OFF to stop engine.

T109340

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic oil tank is pressurized. Loosen vent plug to release air pressure. 1

3. Loosen vent plug (K) to release air pressure from hydraulic oil tank.

4. Open door on storage compartment behind cab. 5. Remove cover above flow regulator valve.

–UN–28APR00

NOTE: Do not use manufacturer’s identification tags or markings on line ends to identify lines for this conversion procedure. The conversion must be done on the front (cab side) of flow regulator valve. F 6. Switch hoses in a X pattern. 4

T128763

Switch hose (1) with hose (3). Switch hose (2) with hose (4).

SAE Pattern

CAUTION: Prevent injury from unexpected control lever function. Install new decals on control consoles.

3 4

7. Install new black on yellow decals for John Deere pattern on control consoles near the base of control levers. The decals are enclosed in Operator’s Manual package. Additional decals are available through parts.

F 2

T128778

–UN–28APR00

1—Hose F from Right Pilot Controller Port 4 2—Hose B from Left Pilot Controller Port 2 3—Hose A from Left Pilot Controller Port 4 4—Hose E from Right Pilot Controller Port 2 K—Vent Plug

T128778 John Deere Pattern Continued on next page

TM1668 (28JAN09)

33-3360-15

TX,15,GG2237 –19–25APR00–1/2

270LC Excavator Repair 012809

PN=403

33 3360 15

Hydraulic System When changing back to the standard pattern, install new black on white decals.

TX,15,GG2237 –19–25APR00–2/2

33 3360 16

TM1668 (28JAN09)

33-3360-16

270LC Excavator Repair 012809

PN=404

Hydraulic System

Lower Boom With Engine Stopped SPECIFICATIONS

Manual Release Screw Torque

6.9 N•m (60 lb-in.)

Boom Anti-Drift Valve-to-Housing Nut Torque

13 N•m (115 lb-in.) –UN–08DEC08

Lower Boom with Engine Stopped

SERVICE EQUIPMENT AND TOOLS

X9811

13 mm Combination Wrench 4 mm Hex Key Wrench

When an engine stops during operation, the boom cannot be lowered using the pilot controller because there is no pilot pressure oil to move the boom valve spool. 1. Remove the control valve access cover. CAUTION: To avoid injury from escaping fluid under pressure, never loosen screw more than two turns as screw may come out. Tighten screw and nut before applying pressure. Prevent possible injury from unexpected machine movement. Clear all persons from the area before lowering the boom with the engine stopped. 2. Loosen the small nut (B) on the boom anti-drift valve housing (C). –UN–07AUG96

Slowly loosen screw (A) 1/2 turn using a 4 mm hex key wrench. The boom will start to lower.

3. After bucket is lowered to the ground, tighten the screw to specification, and then the nut. Lower Boom with Engine Stopped—Specification Manual Release Screw—Torque .................................. 6.9 N•m (60 lb-in.) Boom Anti-Drift Valve-to-Housing Nut—Torque ................................................................. 13 N•m (115 lb-in.)

T102664

The boom lowering speed can be increased somewhat by loosening screw an additional 1-1/2 turns. Never loosen screw more than two turns. Boom Anti-Drift Valve A—4 mm Hex Screw B—Small Nut C—Valve Housing

33 3360 17

TX,25,GG2230 –19–24MAY00–1/1

TM1668 (28JAN09)

33-3360-17

270LC Excavator Repair 012809

PN=405

Hydraulic System

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy 1. Install new return filter elements.

5. Start the engine and run it at fast idle.

NOTE: For a failure that creates a lot of debris, remove access cover from hydraulic tank. Drain hydraulic tank. Connect filter caddy suction line to drain port. Add a minimum of 19 L (5 gal) of oil to reservoir. Operate filter caddy and wash out the hydraulic tank.

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

IMPORTANT: The minimum ID for a connector is 13 mm (1/2 in.) to prevent cavitation of filter caddy pump. 2. Put filter caddy suction and discharge wands into hydraulic tank filler hole so ends are as far apart as possible to obtain a thorough cleaning of oil. 3. Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy until all the oil in hydraulic tank has been circulated through the filter a minimum of four times. Hydraulic Oil Cleanup Procedure—Specification Hydraulic Oil Tank Filtering— Capacity ................................................... 148 L (39 gal) approximate Time ............................................................... 13 minutes approximate

NOTE: Filtering time for hydraulic tank is 0.089 minute x number of liters (0.33 minutes x number of gallons). 4. Leave filter caddy operating for the next step.

6. Starting with the smallest capacity circuit, operate each function through a complete cycle. Repeat procedure until the total system capacity has circulated through filter caddy seven times. Each function must go through a minimum of three complete cycles for a thorough cleaning of oil. Hydraulic Oil Cleanup Procedure—Specification Hydraulic System Filtering— Capacity ................................................... 270 L (71 gal) approximate Time ............................................................... 43 minutes approximate

NOTE: Filtering time for complete hydraulic system is 0.158 minute x number of liters (0.6 minute x number of gallons). Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger. 7. Stop the engine. Remove the filter caddy. 8. Install new return filter elements. 9. Check oil level in hydraulic tank, add oil if necessary. (See Fuels and Lubricants Group in General Information Section.)

TX,33,UU3686 –19–16MAY00–1/1

33 3360 18

TM1668 (28JAN09)

33-3360-18

270LC Excavator Repair 012809

PN=406

Hydraulic System

Remove and Install Hydraulic Pump and Drive Gearbox

T7869AT

–UN–12NOV92

CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Release pressure from tank by loosening vent plug. It is not necessary to remove vent plug. 1. Loosen vent plug (A) to release air pressure in hydraulic oil tank. A—Vent Plug

2. Drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal). 3. Drain pump drive gearbox. Approximate oil capacity is 1.0 L (1.1 qt). 4. Remove the hood. Remove the hood support and covers. 5. Remove the muffler and muffler bracket.

TX,33,UU3687 –19–16MAY00–1/3

6. Disconnect wiring harness connectors from engine speed sensor (A) and pump pressure sensors (B and C). Remove wiring harness clamps from pump housing.

T105283

–UN–20NOV96

A—Engine Speed Sensor B—Pump Pressure Sensor C—Pump Pressure Sensor

Continued on next page

TX,33,UU3687 –19–16MAY00–2/3

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TM1668 (28JAN09)

33-3360-19

270LC Excavator Repair 012809

PN=407

Hydraulic System

–UN–08DEC08

X9811

CAUTION: The approximate weight of hydraulic pump and drive gearbox is 170 kg (375 lb). Hydraulic Pump—Specification Hydraulic Pump and Drive Gearbox—Weight .......................................... 170 kg (375 lb) approximate

8. Install M12-1.75 metric lifting eyebolts, such as JT05550 Metric Lifting Eyebolts, in tapped holes in air bleed plugs (F) and pump drive gearbox housing. Connect a hoist to eyebolts using lifting straps. 9. Remove pump drive gearbox-to-flywheel cap screw to remove pump. Repair or replace pump. 10. Tighten pump drive gearbox-to-flywheel cap screw.

11. Fill pump housing and pump drive gearbox with oil. (See Hydraulic Pump and Drive Gearbox Start-Up Procedure in this group.) Apply pipe sealant to drain plug threads. 12. Check pump regulator adjustments. (See Hydraulic Pump Regulator Test and Adjustments in Group 9025-25.)

T105620

IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank.

–UN–11DEC96

Hydraulic Pump—Specification Drive Gearbox-to-Flywheel Housing Cap Screw—Torque.......................................... 49 N•m (36 lb-ft)

A—Engine Speed Sensor B—Front Pump Pressure Sensor C—Rear Pump Pressure Sensor D—Regulator-to-Rear Pump Control Valve Line E—Regulator-to-Front Pump Control Valve Line F—Air Bleed Plug G—Outlet-to-Right Control Valve Line H—Attenuator Line I—Inlet-to-Hydraulic Oil Tank Line J—Attenuator Line K—Pilot Pump Outlet-to-Pilot Filter Line L—Outlet-to-Left Control Valve M—Pilot Pump Inlet Line N—Regulator-to-Speed Sensing Solenoid Valve Line

33 3360 20

TX,33,UU3687 –19–16MAY00–3/3

TM1668 (28JAN09)

33-3360-20

270LC Excavator Repair 012809

PN=408

Hydraulic System

Hydraulic Pump and Drive Gearbox Start-Up Procedure IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank. Procedure is to ensure the pumps and gearbox are filled with oil and air is bled from suction side of pumps to prevent cavitation.

–UN–15JUL96

1. Remove air bleed plugs (C) from the top of pump regulators to allow housing to fill with oil from the hydraulic oil tank and to let air escape. 2. When pump housing is full of oil, install plugs.

4. Start engine and run at slow idle. Slowly raise boom to full height and then lower to pressurize hydraulic oil tank.

T101875

3. As necessary, add oil to hydraulic oil tank until it is between marks on sight glass. (See Hydraulic Oil in the Fuels and Lubricants group.) Tighten tank cap. Tighten vent plug. C—Air Bleed Plug (2 used)

5. Purge air from the hydraulic system by slowly operating each function through three cycles. Air in pilot circuits are purged automatically.

TX,25,GG2226 –19–26JAN09–1/2

6. Fill pump drive gearbox with oil through filler pipe (B) so level is above “H” mark on dipstick (A). (See Swing Gearbox, Propel Gearbox Oils in Fuels and Lubricants Group.)

T101493

–UN–15JUL96

A—Dipstick B—Filler Pipe

TX,25,GG2226 –19–26JAN09–2/2

TM1668 (28JAN09)

33-3360-21

270LC Excavator Repair 012809

PN=409

33 3360 21

Hydraulic System

T105622

–UN–11DEC96

Disassemble Hydraulic Pump and Drive Gearbox

33 3360 22

Continued on next page

TM1668 (28JAN09)

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TX,33,UU3688 –19–16MAY00–1/17

270LC Excavator Repair 012809

PN=410

Hydraulic System A—Front Pump Discharge Port B—Front Pump C—Rear Pump D—Rear Pump Discharge Port E—Dipstick

F—Pilot Pump G—Pump Drive Gearbox H—Rear Pump Drive Shaft I—Engine Speed Sensor J—Air Bleed Plug (2 used)

K—Fill Plug and Breather L—Rear Pump Regulator M—Front Pump Regulator N—Front Pump Pressure Sensor Continued on next page

O—Pump Inlet Port P—Rear Pump Pressure Sensor

TX,33,UU3688 –19–16MAY00–2/17

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TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=411

T105623

–UN–11DEC96

Hydraulic System

33 3360 24

A—Front Pump Discharge Port B—Pump Inlet Port C—Rear Pump Discharge Port D—Rear Pump Drive Shaft

E—Front Pump Drive Shaft F—Feedback Link G—Pump Regulator

H—Pump Housing I—Center Shaft J—Piston

Continued on next page

TM1668 (28JAN09)

33-3360-24

K—Servo Piston L—Valve Plate M—Cylinder Block

TX,33,UU3688 –19–16MAY00–3/17

270LC Excavator Repair 012809

PN=412

Hydraulic System

33 3360 25

TM1668 (28JAN09)

33-3360-25

270LC Excavator Repair 012809

PN=413

T105621

–UN–11DEC96

Hydraulic System

Continued on next page

TX,33,UU3688 –19–16MAY00–4/17

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TM1668 (28JAN09)

33-3360-26

270LC Excavator Repair 012809

PN=414

Hydraulic System 1—Pump Drive Gearbox Case 3—Pilot Pump Drive Gear 4—Pilot Pump Drive Shaft 5—Ball Bearing (2 used) 6—Snap Ring 7—Snap Ring 10—Pump Housing 12—Screw (2 used) 14—Front Pump Driven Gear 15—Rear Pump Drive Gear 16—Snap Ring (2 used) 18—Spring Pin (2 used) 21—Cap Screw (6 used) 22—Lock Washer (6 used)

23—Gasket 25—Oil Seal 26—Snap Ring 28—Pilot Pump 30—Cap Screw (2 used) 31—Lock Washer (2 used) 32—Washer (2 used) 34—Adapter (2 used) 36—Plug and Breather 37—Dipstick 39—Dipstick Tube 40—Gasket 41—Cap Screw (2 used) 43—Drain Plug

CAUTION: The approximate weight of hydraulic pump and drive gearbox is 170 kg (375 lb). Hydraulic Pump and Drive Gearbox—Specification Hydraulic Pump and Drive Gearbox—Weight ................................... 170 kg (375 lb) approximate

43A—O-Ring 45—Engine Speed Sensor 46—O-Ring 47—Washer 48—Cap Screw 50—Oil Line 51—Fitting (2 used) 51A—O-Ring (2 used) 53—Adapter 53A—O-Ring 54—Plug (2 used) 54A—O-Ring (2 used) 55—Fitting (2 used)

55A—O-Ring (2 used) 56—Oil Line 57—Clamp (2 used) 58—Cap Screw 59—Lock Washer 63—Dampener Drive 63A—Hub 63B—Set Screw (2 used) 63C—Spring Pin (4 used) 63D—Insert (4 used) 63E—Cap Screw (4 used) 63F—Flex Coupling, Insert, Cap Screw and Hub

3. Remove oil lines (50 and 56) and dipstick tube (39). 4. Remove pilot pump (28). 5. Remove cap screws (21) and lock washers (22) to remove pump (10) from pump drive gearbox case (1).

1. Remove the engine speed sensor (45). 2. Loosen set screws (63B). Remove hub (63A).

Continued on next page

TX,33,UU3688 –19–16MAY00–5/17

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TM1668 (28JAN09)

33-3360-27

270LC Excavator Repair 012809

PN=415

Hydraulic System 6. To aid assembly, make timing marks on the drive shafts (A and C), drive (E) and driven (F) gears. The gears are not interchangeable.

–UN–11DEC96

Measure the amount of backlash between gears. Remove snap rings (F) to remove gears.

T105624

Hydraulic Pump and Drive Gearbox—Specification Pump Drive and Driven Gear Backlash—Clearance .................................... 0.68 mm (0.027 in.) nominal Clearance ................................................. 1.50 mm (0.059 in.) limit of use

Continued on next page

TX,33,UU3688 –19–16MAY00–6/17

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TM1668 (28JAN09)

33-3360-28

270LC Excavator Repair 012809

PN=416

Hydraulic System

33 3360 29

TM1668 (28JAN09)

33-3360-29

270LC Excavator Repair 012809

PN=417

TP47903

–UN–10MAY96

Hydraulic System

33 3360 30

Continued on next page

TM1668 (28JAN09)

33-3360-30

TX,33,UU3688 –19–16MAY00–7/17

270LC Excavator Repair 012809

PN=418

Hydraulic System 1—Pump Housing 3—Rear Pump Drive Shaft 4—Front Pump Drive Shaft 6—Roller Bearing (2 used) 7—Ring (2 used) 8—Roller Bearing (2 used) 9—Bearing Nut (2 used) 10—Ring (Rear Pump Drive Shaft Only) 12—Oil Seal (2 used) 13—Snap Ring (2 used) 15—Special Fitting (2 used) 16—O-Ring (2 used) 19—Piston (14 used) 21—Center Shaft (2 used)

22—Pin (2 used) 23—Spring (2 used) 25—Cylinder Block (Rotor) (2 used) 27—Front Pump Valve Plate 28—Rear Pump Valve Plate 29—Dowel Pin (4 used) 31—Feedback Link (2 used) 32—Lever (4 used) 33—Dowel Pin (4 used) 34—Dowel Pin (2 used) 35—Snap Ring (12 used) 36—Dowel Pin (2 used) 41—Cylinder Head (Cover)

7. Remove pump pressure sensors (64).

42—Servo Piston (2 used) 43—Pin (2 used) 44—Set Screw (2 used) 46—O-Ring (2 used) 47—Stop (2 used) 50—O-Ring (2 used) 51—Cover (2 used) 54—O-Ring (20 used) 55—Cap Screw (16 used) 56—Lock Washer (16 used) 57—Backup Ring 58—Spring Pin (2 used) 59—O-Ring 60—Cap Screw (12 used)

64—Pump Pressure Sensor (2 used) 64A—O-Ring (2 used) 67—Plug (Fitting) (2 used) 67A—O-Ring (2 used) 69—Pump Regulator (2 used) 72—Spring Pin (4 used) 73—O-Ring (4 used) 74—O-Ring (2 used) 80—Plug (Fitting) (2 used) 80A—O-Ring 82—Bracket 83—Cap Screw 84—Lock Washer

10. Remove servo pistons (42) only if replacement is necessary.

8. Remove pump regulators (69). (For repair, see Disassemble and Assemble Hydraulic Pump Regulator in this group.)

Heat the set screw (44) to loosen the thread lock and sealer (medium strength). Remove set screw using a 6 mm hex key wrench. Remove pin (43).

CAUTION: The approximate weight of cylinder head is 30 kg (66 lb).

11. Remove snap rings (35) and pins (33) to disconnect feedback linkage.

Hydraulic Pump and Drive Gearbox—Specification Cylinder Head—Weight .............................. 30 kg (66 lb) approximate

IMPORTANT: The front and rear pump valve plates (27 and 28) may stick to cylinder head (41) when head is removed. The valve plates are connected to the feedback linkage and must remain on the cylinder blocks (25). The valve plates and end of cylinder blocks are made with highly machined surfaces and can be damaged.

IMPORTANT: The front pump (27) and rear pump (28) valve plates are not interchangeable. Take notice of the location and position of ports in plate. The inlet port in valve plate is located towards the center and top of pump housing. 12. Remove the front pump (27) and rear pump (28) valve plates. Protect machined surfaces of plates from damage. 13. Remove cylinder blocks (25).

9. Remove cap screws (60). Checking that valve plates (27 and 28) remain on the cylinder blocks, carefully remove cylinder head (41).

14. Remove the pistons (19) by tipping piston toward center of shaft and lifting up.

Continued on next page

TX,33,UU3688 –19–16MAY00–8/17

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TM1668 (28JAN09)

33-3360-31

270LC Excavator Repair 012809

PN=419

Hydraulic System 15. Remove special fittings (15) before removing front (4) and rear (3) pump drive shafts

T105626

–UN–11DEC96

3—Rear Pump Drive Shaft 4—Front Pump Drive Shaft 15—Special Fitting (2 used)

TX,33,UU3688 –19–16MAY00–9/17

16. Remove spacer ring (10) for rear pump drive shaft from bore.

T105628

–UN–11DEC96

10—Spacer Ring

TX,33,UU3688 –19–16MAY00–10/17

17. Remove bearing nut (9) using the JDG769 Spanner Wrench.

–UN–12DEC96

18. Remove roller bearings (6 and 8) using a knife edge puller and a press.

T105629

3—Rear Pump Drive Shaft 4—Front Pump Drive Shaft 6—Roller Bearing 7—Spacer Ring 8—Roller Bearing 9—Bearing Nut

–UN–12DEC96

Rear Pump Drive Shaft

T105630

33 3360 32

Front Pump Drive Shaft Continued on next page

TM1668 (28JAN09)

33-3360-32

TX,33,UU3688 –19–16MAY00–11/17

270LC Excavator Repair 012809

PN=420

Hydraulic System 19. Measure diameter of oil seal contact surfaces (A, B, and D) on front (E) and rear (C) pump drive shaft.

T105725

–UN–09JAN97

Hydraulic Pump and Drive Gearbox—Specification Rear Pump Drive Shaft Oil Seal Contact Surface (A)—OD ................................... 45 mm (1.77 in.) nominal OD .............................................................. 44.8 mm (1.76 in.) limit of use Rear Pump Drive Shaft Oil Seal Contact Surface (B)—OD ................................... 55 mm (2.17 in.) nominal OD .............................................................. 54.8 mm (2.16 in.) limit of use Front Pump Drive Shaft Oil Seal Contact Surface (D)—OD................................... 55 mm (2.17 in.) nominal OD .............................................................. 54.8 mm (2.16 in.) limit of use

A—Rear Oil Seal Contact Surface B—Rear Oil Seal Contact Surface C—Rear Pump Drive Shaft D—Front Oil Seal Contact Surface E—Front Pump Drive Shaft

TX,33,UU3688 –19–16MAY00–12/17

20. Measure play (H) between the piston connecting rod (F) and socket in front and rear drive shafts (G). Hydraulic Pump and Drive Gearbox—Specification Piston Connecting Rod Ball End-to-Drive Shaft Socket—Play .............. 0.058 mm (0.0023 in.) nominal Play ....................................................... 0.400 mm (0.0157 in.) limit of use

T105726

–UN–09JAN97

F—Piston Connecting Rod G—Drive Shaft H—Piston Connecting Rod and Drive Shaft Play

Continued on next page

TX,33,UU3688 –19–16MAY00–13/17

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TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=421

Hydraulic System 21. Measure ID of cylinder block piston bore. Measure OD of piston. Subtract the OD from the ID for clearance.

T6557EN

–UN–18OCT88

T6557EM

–UN–18OCT88

Hydraulic Pump and Drive Gearbox—Specification Cylinder Block-to-Piston Bore— Clearance .................................................. 0.043 mm (0.0017 in.) nominal Clearance ............................................. 0.080 mm (0.0032 in.) limit of use

TX,33,UU3688 –19–16MAY00–14/17

22. Clamp the connecting rod end of a piston in a vise with soft-jaw faces. Measure play between connecting rod and piston.

T6557EK

–UN–18OCT88

Hydraulic Pump and Drive Gearbox—Specification Piston-to-Connecting Rod—Play ............... 0.150 mm (0.0059 in.) nominal Play ....................................................... 0.400 mm (0.0157 in.) limit of use

Continued on next page

TX,33,UU3688 –19–16MAY00–15/17

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TM1668 (28JAN09)

33-3360-34

270LC Excavator Repair 012809

PN=422

Hydraulic System 23. Measure OD (C) of small and large end of servo piston (D). Measure ID (B) of small and large end of bore in cylinder head (A). Subtract the OD from the ID for clearances. Hydraulic Pump and Drive Gearbox—Specification Servo Piston-to-Cylinder Head Bore—Clearance ....................................... 0.079 mm (0.0033 in.) nominal Clearance ............................................. 0.200 mm (0.0078 in.) limit of use

T105727

–UN–19DEC96

A—Cylinder Head B—Bore ID C—Servo Piston OD D—Servo Piston

TX,33,UU3688 –19–16MAY00–16/17

Hydraulic Pump and Drive Gearbox—Specification Servo Piston Pin-to-Valve Plate Bore—Clearance ....................................... 0.051 mm (0.0020 in.) nominal Clearance ............................................. 0.300 mm (0.0118 in.) limit of use

T105729

A—Valve Plate B—Servo Piston Pin C—OD of Servo Piston Pin D—ID of Bore in Valve Plate

–UN–09JAN97

24. Measure OD (C) of servo piston pin (B). Measure ID (D) of bore in valve plate (A). Subtract the OD from the ID for the clearance.

TX,33,UU3688 –19–16MAY00–17/17

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TM1668 (28JAN09)

33-3360-35

270LC Excavator Repair 012809

PN=423

Hydraulic System

Disassemble and Assemble Pilot Pump Drive Shaft and Gear

3. Remove pilot pump drive gear (C) through opening for hydraulic pump.

T105640

2. Remove pilot pump drive shaft (E) and upper ball bearing (D) using a blind-hole puller or an internal pullers. Ball bearings are a press fit in the drive shaft and in the housing.

–UN–12DEC96

1. Remove snap ring (A).

T105641

–UN–12DEC96

T105657

–UN–12DEC96

1—Pump Drive Gearbox Case 3—Pilot Pump Drive Gear 4—Pilot Pump Drive Shaft 5—Ball Bearing (2 used) 6—Snap Ring 7—Snap Ring

CED,OUOE003,21689 –19–16MAY00–1/1

33 3360 36

TM1668 (28JAN09)

33-3360-36

270LC Excavator Repair 012809

PN=424

Hydraulic System

Assemble Hydraulic Pump and Drive Gearbox

–UN–12DEC96

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. 1. Heat roller bearings (6 and 8).

T105658

Hydraulic Pump and Drive Gearbox—Specification Roller Bearing—Temperature............................... 50—80°C (122—176°F)

2. Apply oil to bearing. Push roller bearing (6) on drive shaft so inner race is tight against shoulder. 3. Install spacer ring (7) and roller bearing (8). 4. Apply oil to threads of bearing nut (9).

–UN–12DEC96

5. Tighten bearing nut so rolling drag torque is to specification. Use JDG769 Spanner Wrench to tighten nut.

T105660

Hydraulic Pump and Drive Gearbox—Specification Front and Rear Pump Drive Shaft Bearing Nut—Rolling Drag Torque ....................................................... 2.16 ± 0.49 N•m (19 ± 4 lb-in.)

3—Rear Pump Drive Shaft 4—Front Pump Drive Shaft 6—Roller Bearing 7—Spacer Ring 8—Roller Bearing 9—Bearing Nut

TX,33,UU3689 –19–16MAY00–1/9

6. Install spacer ring (10) into housing bore for rear pump drive shaft.

T105628

–UN–11DEC96

10—Spacer Ring

Continued on next page

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Hydraulic System 7. To help installation of drive shafts (3 and 4), heat pump housing to 50—80°C (122—176°F) using a heat gun such as the JT07010 Two Temperature Heat Gun.

–UN–11DEC96

8. Apply a film of oil to outer race of bearings. Install the drive shafts. 9. Install and tighten special fittings (15).

T105626

Hydraulic Pump and Drive Gearbox—Specification Special Plug-to-Pump Housing— Torque .......................................................................... 34 N•m (300 lb-in.)

10. Apply grease to lips of oil seals. Install oil seals with lip (spring side) towards inside of housing. Install snap rings.

3—Drive Shaft 4—Drive Shaft 15—Special Fitting (2 used)

Continued on next page

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Hydraulic System 11. For original parts, install drive (E) and driven (F) gears on shafts so timing marks (A, B, and C) are aligned.

–UN–11DEC96

For new parts, install the JDG1054 Aligning Bar on the socket (I and J) end of drive shafts.

T105624

Install aligning bar so end marked “Long Shaft Side” is to the rear pump drive shaft (H). Turn shafts so socket alignment dowels (L and M) engage a socket in drive shafts. The socket for front pump drive shaft is slightly below the centerline of socket for rear pump drive shaft when shafts are timed correctly. Install cap screws (N) to hold bar in position.

–UN–04OCT94

12. From the splined end of shafts, turn shafts to the left to remove any play between socket alignment dowels and sockets.

T8323AQ

13. Install gear on the rear pump drive shaft. Install the snap ring. Install gear on front pump drive shaft. As necessary, turn shaft slightly or turn gear to another position so teeth on gears engage. Install snap ring.

A—Front Pump Drive Shaft-to-Driven Gear Timing Mark B—Driven Gear-to-Drive Gear Timing Mark C—Rear Pump Drive Shaft-to-Drive Gear Timing Mark D—Snap Ring (2 used) E—Drive Gear F—Driven Gear G—JDG1054 Aligning Bar (Pump Timing Tool) H—Rear Pump Drive Shaft I—Socket J—Socket K—Front Pump Drive Shaft L—Socket Alignment Dowel M—Socket Alignment Dowel N—M8-1.25 Cap Screw (2 used)

Continued on next page

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TP47903

–UN–10MAY96

Hydraulic System

33 3360 40

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PN=428

14. Apply oil to center shaft (21), pistons (19) and cylinder blocks (25). Use petroleum jelly to hold pin (22) in hole in center shaft.

Tighten set screw (44) using a 6 mm hex key wrench. Hydraulic Pump and Drive Gearbox—Specification Servo Piston-to-Pin Set Screw—Torque ...................................................... 34 N•m (300 lb-in.)

15. Install cylinder block so pin engages slot in cylinder block. 16. Apply thread lock and sealer (medium strength) to threads of dowel pins (29). Tighten dowel pins into front pump (27) and rear pump (28) valve plates. Hydraulic Pump and Drive Gearbox—Specification Feedback Link Dowel Pin-to-Front and Rear Pump Valve Plate—Torque............................................... 9.8 N•m (86 lb-in.)

IMPORTANT: The front pump (27) and rear pump (28) valve plates are not interchangeable. The inlet port in valve plate is located towards the center and top of pump housing.

Tighten cap screws (55) for stop (47) and cover (51). Hydraulic Pump and Drive Gearbox—Specification Stop and Cover-to-Cylinder Head Cap Screw—Torque ................................. 19.5 N•m (180 lb-in.)

19. Install cylinder head (41) checking to be sure that pins engage middle hole in valves plates. Tighten cap screws (60). Hydraulic Pump and Drive Gearbox—Specification Cylinder Head-to-Pump Housing Cap Screw—Torque ................................. 108 N•m (80 lb-ft)

20. Remove air bleed plugs from pump regulators (69).

17. Apply oil to valve plates. Install valve plates so inlet port is towards the center and top of pump housing. Connect levers (32) for feedback linkage to valve plates.

Install regulators making sure groove in remote control sleeve and load sleeve engage dowel pin (34) in feedback link (31). Check through hole that groove in sleeves engage dowel pin. Tighten cap screws.

18. Install servo pistons (42) and pins (43). Apply thread lock and sealer (medium strength) to threads of set screw (44).

Hydraulic Pump and Drive Gearbox—Specification Regulator-to-Pump Housing Cap Screw—Torque ................................................. 49 N•m (36 lb-ft)

33 3360 41

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Hydraulic System 21. Tighten pump pressure sensors (64). Hydraulic Pump and Drive Gearbox—Specification Pump Pressure Sensor-to-Pump Housing— Torque....................................................................... 98 N•m (72 lb-ft)

Continued on next page

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Hydraulic System

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T105621

–UN–11DEC96

Hydraulic System

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22. Tighten pump housing-to-gearbox housing cap screws (21). Hydraulic Pump and Drive Gearbox—Specification Pump Housing-to-Gearbox Housing Cap Screw—Torque ............................... 147 N•m (109 lb-ft)

23. Apply rigid form-in-place gasket to mounting surface for pilot pump (28). Tighten cap screws (30).

43A—O-Ring 45—Engine Speed Sensor 46—O-Ring 47—Washer 48—Cap Screw 50—Oil Line 51—Fitting (2 used) 51A—O-Ring (2 used) 53—Adapter 53A—O-Ring 54—Plug 54A—O-Ring 55—Fitting (2 used)

24. Apply grease to lips of oil seal (25). Install oil seal with lip (spring side) towards inside of housing. 25. Apply thread lock and sealer (medium strength) to threads of set screws (63B) in dampener drive hub. Tighten set screws. (For assembly of dampener drive, see Remove and Install Dampener Drive in Group 0752.) Hydraulic Pump and Drive Gearbox—Specification Hub-to-Rear Pump Drive Shaft Set Screw—Torque ................................................ 108 N•m (80 lb-ft)

26. Fill pump and pump drive gearbox with oil. (See Hydraulic Pump and Drive Gearbox Start-Up Procedure in this group.)

Hydraulic Pump and Drive Gearbox—Specification Pilot Pump-to-Gearbox Cap Screw—Torque ......................................................... 49 N•m (36 lb-ft)

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Hydraulic System

–UN–10MAY96

Disassemble and Assemble Hydraulic Pump Regulator

TP47902

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Hydraulic System 0—Pump Regulator 2—Load Sleeve 3—Load Spool 5—Cylinder 6—Load Piston 7—O-Ring 8—Backup Ring 9—O-Ring 12—Load Adjusting Cartridge (Stop)

—Flow Adjusting Cartridge (Stop) 13—Load Adjusting Screw (Stop) 14—O-Ring (3 used) 15—O-Ring (2 used) 16—Nut (2 used) 17—Nut (2 used) 20—Piston 21—Cylinder

24—Maximum Flow Adjusting Screw (Stop) 27—Remote Control Sleeve 28—Remote Control Spool 29—Minimum Flow Adjusting Screw 34—Nut 35—End Plate 36—Cover

37—Cap Screw (8 used) 38—Lock Washer (8 used) 40—Air Bleed Plug 41—O-Ring 43—Cap Screw (4 used) 44—Lock Washer (4 used) 47—Outer Spring 48—Inner Spring 49—Spring

IMPORTANT: Removal of adjusting screws (13, 24 and 29) and cartridges (12) from end plate (35) and cover (36) will required the adjustment of pump regulators. Only remove parts from end plate and cover if replacement is necessary. 4. Remove the end plate (35) and cover (36) with the adjusting screws and cartridges installed.

2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal). Specification Hydraulic Oil Tank— Approximate Oil Capacity ............................................. 148 L (39 gal)

3. Remove cap screw (43) to remove pump regulator (0).

5. Repair or replace parts as necessary. 6. Tighten cap screws (37) to 19.8 N•m (180 lb-in.). Specification End Plate and Cover-to-Housing Cap Screws—Torque ................................................. 19.8 N•m (180 lb-in.)

Continued on next page

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T105706

–UN–09JAN97

Hydraulic System

2—Load Sleeve 3—Load Spool 5—Cylinder 6—Load Piston 12—Load Adjusting Cartridge (Stop) —Flow Adjusting Cartridge (Stop)

13—Load Adjusting Screw (Stop) 16—Nut (2 used) 17—Nut (2 used) 20—Piston 21—Cylinder 24—Maximum Flow Adjusting Screw (Stop)

7. Remove air bleed plugs from pump regulators. Install regulators making sure groove in remote control sleeve (27) and load sleeve (2) engage dowel pin in feedback link. Check through hole that groove in sleeves engage dowel pin.

27—Remote Control Sleeve 28—Remote Control Spool 29—Minimum Flow Adjusting Screw 34—Nut 35—End Plate

36—Cover 37—Cap Screw (8 used) 47—Outer Spring 48—Inner Spring 49—Spring

IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump installed or oil has been drained from the pump or hydraulic oil tank.

Tighten cap screws to 49 N•m (36 lb-ft). Specification Housing-to-Pump Housing Cap Screws—Torque ....................................................... 49 N•m (36 lb-ft)

Tighten air bleed plug to 78 N•m (58 lb-ft). Specification Air Bleed Plug-to-Housing— Torque....................................................................... 78 N•m (58 lb-ft)

8. Fill pump housing with oil. (See Hydraulic Pump and Drive Gearbox Start-Up Procedure in this group.) 9. Check pump regulator adjustments. (See Hydraulic Pump Regulator Test and Adjustments in Group 9025-25.)

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Hydraulic System

Remove and Install Pilot Pump CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Release pressure from tank by loosening vent plug. It is not necessary to remove vent plug. 1. Loosen vent plug to release air pressure in hydraulic oil tank. 2. Remove drain plug (E) to drain pump drive gearbox. Approximate oil capacity is 1.0 L (1.1 qt). 3. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal). –UN–19DEC96

Specification Hydraulic Oil Tank—Approximate Oil Capacity ......................................................................... 148 L (39 gal)

T105711

4. Disconnect lines (B, F and G). 5. Remove cap screws (D) to remove pilot pump (F). 6. Replace parts as necessary. (See Disassemble and Assemble Pilot Pump in this group.) 7. Apply plastic gasket to mounting surface for pilot pump. 8. Tighten cap screw to 49 N•m (36 lb-ft).

A—Filler Pipe B—Pilot Pump Inlet-to-Hydraulic Oil Tank Line C—Dipstick D—Cap Screw, Washer and Lock Washer (2 used) E—Drain Plug F—Pilot Pump Outlet-to-Hydraulic Pump Line G—Pilot Pump Outlet-to-Pilot Filter Line H—Pilot Pump

Specification Pump-to-Drive Gearbox Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

9. Connect lines. 10. Fill pump drive gearbox with oil through filler pipe (A) so level is above “H” mark on dipstick (C). (See Swing Gearbox, Propel Gearbox (Oils in Fuels and Lubricants Group.)

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Hydraulic System

–UN–13MAY96

Disassemble and Assemble Pilot Pump

TP47901

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Hydraulic System 0—Pilot Pump 2—Flange 3—Oil Seal

5—Snap Ring 6—Seal (2 used) 9—Backup Retainer (2 used)

10—Key (2 used) 12—O-Ring (2 used) 15—Washer (4 used)

16—Cap Screw and Washer (4 used)

1. Remove cap screws (16) to remove end plate and flange (2) from housing.

TX,33,GG2387 –19–16MAY00–2/3

2. Remove drive (A), driven (C) gears, bushings (D) and keys (B).

–UN–13MAY92

3. Check bushings (D). If inside diameter and surface toward gear are rough or worn, replace pump.

T7685IX

4. Check gears (A and C) and housing. If gear teeth, shaft, and inside of housing is rough or worn, replace pump. IMPORTANT: Apply clean hydraulic oil to all parts. Pump failure can result if pump is assembled dry. A—Drive Gear B—Key (4 used) C—Driven Gear D—Bushing (4 used)

5. Apply clean hydraulic oil to all parts. 6. Apply grease to lip of oil seal. Install oil seal with lip (spring side) towards inside of housing. 7. Install cap screws and tighten. Pilot Pump—Specification Cover-to-Flange Cap Screw— Torque ............................................................................. 41 N•m (31 lb-ft)

8. Do Pilot Pressure Regulating Valve Test and Adjustment to check pressure setting. (See procedure in Group 9025-25.)

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Hydraulic System

Remove and Install Pilot Pressure Regulating Valve and Filter

T7869AT

–UN–12NOV92

Continued on next page

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Hydraulic System 2. Disconnect lines (A—D). 3. Remove cap screws and lock washers (H) to remove pilot pressure regulating valve and pilot filter.

5. Install new pilot filter element. Tighten filter element housing. Pilot Pressure Regulating Valve and Filter—Specification Pilot Filter Element Housing-to-Filter Head—Torque .................................. 25 N•m (220 lb-in.)

T102755

–UN–02AUG96

4. Replace parts as necessary.

6. Tighten cap screws (J). Pilot Pressure Regulating Valve and Filter—Specification Regulating Valve Housing-to-Filter Head Cap Screw—Torque ............................................................. 20 N•m (175 lb-in.)

7. Tighten cap screws (H). Pilot Pressure Regulating Valve and Filter—Specification Filter Head-to-Support Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

8. Connect lines.

–UN–19DEC96

9. Do Pilot Pressure Regulating Valve Test and Adjustment to check pressure setting. (See procedure in Group 9025-25.)

T105738

A—To Pilot Shut-Off Valve Line B—To Hydraulic Oil Tank Return Manifold Line C—To Right Control Valve Line D—From Pilot Pump Line E—Filter Head F—Pilot Pressure Regulating Valve Housing G—Pilot Filter H—Cap Screw and Lock Washer (2 used) I—Plug J—Cap Screw (4 used)

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Hydraulic System

Disassemble and Assemble Pilot Pressure Regulating Valve and Filter 1. Remove plugs (A and G). –UN–02AUG96

2. Push piston (C) and spring (D) to the right to remove. 3. Inspect and clean parts.

T102751

4. Check that poppet (C) slides smoothly in pilot pressure regulating valve housing (B). 5. Tighten plugs (A and G).

A—Plug B—Pilot Pressure Regulating Valve Housing C—Poppet D—Spring E—Shim (as required) F—O-Ring G—Plug

Pilot Pressure Regulating Valve and Filter—Specification Plug-to-Housing—Torque ................................................ 49 N•m (36 lb-ft)

TX,33,SB24 –19–24MAY00–1/1

Remove and Install Pilot Shut-Off Valve

T7869AT

–UN–12NOV92

Continued on next page

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Hydraulic System 2. Turn upperstructure 90° to tracks. 3. Remove cover under storage compartment behind cab. 4. Disconnect pilot shut-off valve linkage (K). 5. Mark lines for to aid assembly. Disconnect lines (A—I and L). 6. Remove cap screws (J) to remove pilot shut-off valve. 7. Repair or replace valve as necessary. 8. Install valve and tighten cap screws. Pilot Shut-Off Valve—Specification Housing-to-Cab Platform Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

T102765

10. Connect linkage. Check pilot shut-off valve linkage adjustment. (See procedure in this group.)

–UN–16DEC96

9. Connect lines.

A—To Right Pilot Controller P Port B—To Propel Pilot Controller P Port C—To Left Pilot Controller P Port D—From Left Pilot Controller T Port E—To Flow Regulator Valve F—From Pilot Pressure Regulating Valve G—From Propel Pilot Controller T Port H—To Solenoid Valve Manifold DP Port I—From Right Pilot Controller T Port J—Cap Screw (2 used) K—Pilot Shut-Off Valve Linkage L—To Solenoid Valve Manifold PF Port

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Hydraulic System

T7660AL

–19–06DEC91

Pilot Shut-Off Valve Linkage Adjustment

A—Pilot Shut-Off Lever B—Rod

C—Pilot Shut-Off Valve

D—Valve Lever

1. Stop engine.

E—Cap Screw Head

5. Pull pilot shut-off lever to the OFF position. Check that lever is against the rear stop.

2. Remove cover underneath operator’s station. CAUTION: Machine may move if adjustment is incorrect. Before checking pilot shut-off lever adjustment, make sure the area around machine is clear.

3. Push pilot shut-off lever (A) forward to the ON position. Check that lever is against the front stop. 4. Adjust ball joints on rod (B) to get the specified clearance between valve lever (D) and head of cap screw (E). Pilot Shut-Off Valve—Specification Pilot Shut-Off Valve Lever-to-Cap Screw Head— Clearance............................................. 1.5 ± 0.5 mm (0.06 ± 0.02 in.)

6. Start the engine. Run engine at slow idle. Actuate the hydraulic functions. Hydraulic functions must not move with the pilot shut-off lever in the OFF position. If hydraulic function move, repeat adjustment procedure.

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Hydraulic System

T105751

–UN–09JAN97

Disassemble and Assemble Pilot Shut-Off Valve

A—Snap Ring (2 used) B—Washer (2 used) C—Backup Ring (2 used)

D—O-Ring (2 used) E—Housing F—Steel Ball

G—Cap Screw (Lever Stop) H—Spool

I—Lever J—Spring Pin 33 3360 57

1. Make a mark on spool (H) and lever (I) with respect to housing (E) to aid assembly.

Continued on next page

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T105752

–UN–30DEC96

Hydraulic System

A—Snap Ring (2 used) B—Washer (2 used) C—Backup Ring (2 used)

D—O-Ring (2 used) E—Housing F—Steel Ball

G—Cap Screw (Lever Stop) H—Spool I—Lever

2. Remove snap ring (A) to remove parts (B—D and H).

J—Spring Pin K—Slot L—Inlet Port

6. Install parts (A—D). 7. Install lever (I) and spring pin (J).

3. Inspect and replace parts as necessary. 8. Torque cap screw (G). 4. Apply grease to backup rings (C) and O-rings (D). Apply clean oil to spool (H). 5. Install spool (H) so slot (K) is toward inlet port (L).

Pilot Shut-Off Valve—Specification Lever-to-Spool Pin Cap Screw—Torque ......................................................... 44 N•m (33 lb-ft)

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Hydraulic System

Remove and Install Proportional Solenoid Valve

T7869AT

–UN–12NOV92

CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Release pressure from tank by loosening vent plug. It is not necessary to remove vent plug. 1. Loosen vent plug (A) to relieve hydraulic pressure in reservoir. A—Vent Plug

Continued on next page

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T105847

–UN–20DEC96

Hydraulic System

Right Rear B—Right Control Valve— 4-Spool C—Left Control Valve— 5-Spool D—Proportional Solenoid Valve Manifold E—From Propel Flow Control Valve

F—To Flow Regulator Valve G—To Swing Motor Park Brake Release Valve Top Port H—To Rear Pump Control Valve I—To Power Boost Port in System Relief Valve

NOTE: The individual proportional solenoid valves can be removed with manifold on the machine.

J—To Hydraulic Oil Tank K—To Propel Motor Speed Change Valve L—To Front and Rear Pump Regulating Valve Speed Sensing Port

M—From Bucket Flow Control Valve N—From Pilot Shut-Off Valve O—To Arm Regenerative Valve P—To Front Pump Control Valve

2. Disconnect lines (E—P).

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Hydraulic System 3. Disconnect wiring harness connectors at each solenoid valve (Q—T). 4. Remove cap screws (U) to remove proportional solenoid valve manifold (D). Repair or replace part as necessary. –UN–30DEC96

5. Install solenoid valve manifold. 6. Connect wiring harness connectors.

8. Check pressure setting of proportional solenoid valves. (See Proportional Solenoid Valve Test and Adjustment in Group 9025-25.)

T105730

7. Connect lines.

D—Proportional Solenoid Valve Manifold Q—Power Boost Solenoid Valve (BLU/BLK and BLU/RED Wiring Leads R—Propel Speed Change Solenoid Valve (LGRN/RED and LGRN/BLK Wiring Leads) S—Speed Sensing Solenoid Valve (RED/YEL and RED/WHT Wiring Leads) T—Arm Regenerative Solenoid Valve (BLU/WHT and BLU/ORN Wiring Leads) U—Cap Screw (2 used)

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Hydraulic System

T105731

–UN–02JAN97

T105732

–UN–02JAN97

Disassemble and Assemble Proportional Solenoid Valve

33 3360 62

A—Cap Screw (4 used) B—Lock Nut C—O-Ring D—Adjusting Screw E—Spring

F—Solenoid Coil G—Spring H—O-Ring I—Diaphragm J—Spool

K—Washer L—Spring M—O-Ring N—O-Ring

O—O-Ring P—Sleeve Q—Plate R—Washer

1. Keep the parts for each solenoid valve together. Continued on next page

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PN=450

Hydraulic System When removing the solenoid coil (F), do not lose spring (G). Only remove the lock nut (B) and adjusting screw (D) if replacement of O-ring (C) is necessary. Pressure setting of proportional solenoid valve will

need to be adjusted. (See Proportional Solenoid Valve Test and Adjustment in Group 9025-25.) 2. Repair or replace parts as necessary. 3. Install washer (R) and plate (Q).

TX,33,GG2414 –19–16MAY00–2/5

4. Apply clean oil to sleeve (P) and O-rings (M, N and O). 5. Install sleeve so ports align with ports in manifold (S).

T105864

–UN–30DEC96

M—O-Ring N—O-Ring O—O-Ring P—Sleeve S—Manifold

Continued on next page

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Hydraulic System 6. Apply clean oil to spool (J).

After installing spool, push spool against spring to check that spool slides smoothly in sleeve.

T105866

–UN–30DEC96

T105865

I—Diaphragm J—Spool K—Washer L—Spring P—Sleeve

–UN–30DEC96

7. Install washer (K) and spring (L) on spool. Install spool.

TX,33,GG2414 –19–16MAY00–4/5

8. Check to be sure spring (G) remains in position when installing solenoid coil (F).

Proportional Solenoid Valve—Specification Solenoid Valve Housing-to-Manifold Cap Screw— Torque .............................................................................. 3 N•m (24 lb-in.)

T105867

A—Cap Screw (2 used) F—Solenoid Coil G—Spring

–UN–30DEC96

9. Tighten cap screws (A).

TX,33,GG2414 –19–16MAY00–5/5

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Hydraulic System

Remove and Install Dig Function Pilot Controller

T7869AT

–UN–12NOV92

TX,33,GG2415 –19–16MAY00–1/6

2. Remove cover (D) by pulling at front edge. 3. Remove all covers (A, G and H) and boot (F) from the console (K).

T105880

–UN–30DEC96

A—Cover B—Screw (2 used) C—Screw (2 used) D—Cover E—Screw (4 used) F—Boot G—Cover H—Cover I—Screw (4 used) J—Screw (2 used) K—Console

Left Console Shown

Continued on next page

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PN=453

Hydraulic System 4. Loosen nut (L) and carefully remove lever (M) along with wiring harness.

T115641

–UN–01JUL98

L—Nut M—Lever

TX,33,GG2415 –19–16MAY00–3/6

5. Pull the seat and consoles as far forward as possible. 6. Remove cap screws (L) so the console can be tipped back.

T105912

–UN–02JAN97

K—Console L—Cap Screw (4 used)

Continued on next page

TX,33,GG2415 –19–16MAY00–4/6

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PN=454

Hydraulic System 7. Remove screws to disconnect hose boot from console. 8. Remove cap screws to remove pilot controller from console.

T105913

–UN–03JAN97

O—Cap Screw (4 used) P—Pilot Controller Q—Cap Screw (2 used) R—Hose Boot

TX,33,GG2415 –19–16MAY00–5/6

9. Disconnect lines (P, T and 1—4) from pilot controller. Identify the lines by the numbers and letters stamped on the controller housing.

10. After pilot controller is installed, check the operation of all functions to be sure they operate as shown on the decal on console.

T105914

P—Hydraulic Line T—Hydraulic Line 1—Hydraulic Line 2—Hydraulic Line 3—Hydraulic Line 4—Hydraulic Line

–UN–19DEC96

Install caps and plugs to close all openings.

TX,33,GG2415 –19–16MAY00–6/6

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PN=455

Hydraulic System

Disassemble and Assemble Dig Function Pilot Controller 1. Remove coupling (1) and cam (2).

T105909

–UN–02JAN97

1—Coupling 2—Cam 3—U-Joint 4—Plate 5—Oil Seal (4 used) 6—O-Ring (4 used) 7—Bushing (2 used) 8—Pusher (2 used) 9—Spring Guide (2 used) 10—Spring Guide (2 used) 11—Pusher (2 used) 12—Bushing (2 used) 13—Cap Screw 14—Plate 15—O-Ring 16—Seal 17—Housing 18—Piston (4 used) 19—Spool (4 used) 20—Spacer (Retainer) (4 used) 21—Shim (20 used) 22—Return Spring (2 used) 23—Balance Spring (2 used) 24—Return Spring (2 used) 25—Balance Spring (2 used)

Continued on next page

TX,33,GG2416 –19–18DEC96–1/3

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PN=456

T105881

–UN–03JAN97

Hydraulic System

1—Coupling 2—Cam 3—U-Joint 4—Plate 5—Oil Seal (4 used) 6—O-Ring (4 used) 7—Bushing (2 used)

8—Pusher (2 used) 9—Spring Guide (2 used) 10—Spring Guide (2 used) 11—Pusher (2 used) 12—Bushing (2 used) 13—Cap Screw

14—Plate 15—O-Ring 16—Seal 17—Housing 18—Piston (4 used) 19—Spool (4 used)

33 3360 69

Continued on next page

TM1668 (28JAN09)

20—Spacer (Retainer) (4 used) 21—Shim (20 used) 22—Return Spring (2 used) 23—Balance Spring (2 used) 24—Return Spring (2 used) 25—Balance Spring (2 used)

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270LC Excavator Repair 012809

PN=457

Hydraulic System IMPORTANT: The housing (17) and spools (19) are replaced as an assembly because the spools are select fitted to bores in housing. Some of the parts from ports 1 and 3 are different than parts from ports 2 and 4. Parts for each port must be keep together and installed into the same port from which it was removed. The port numbers are stamped on the housing. 2. Temporarily install M8-1.25 cap screws to hold the plate (4) on housing. Remove the U-joint (3).

9. Apply grease to oil seals (5). 10. Install the parts into housing. Temporarily install M8-1.25 cap screws to hold the plate (4) on housing. 11. Install the pistons (18), small end first, into the spools 12. Install plate (14). Tighten cap screw (13) to 49 N•m (36 lb-ft). Specification Bottom Plate-to-Housing Cap Screw—Torque ......................................................... 49 N•m (36 lb-ft)

13. Apply thread lock and sealer (medium strength) to threads on one end of U-joint (3).

3. Remove cap screw (13). Pull plate (14) from housing using a M16-2.0 cap screw.

Tighten U-joint into housing to 24 N•m (216 lb-in.). Specification U-Joint-to-Housing—Torque .................................. 24 N•m (216 lb-in.)

4. Remove pistons (18). These pistons must be remove first and install last.

Remove the temporarily installed cap screws.

5. Slowly loosen the cap screws to release the spring force of return springs on plate.

14. Apply grease to the end of each pusher (8 and 11) and to the joint of U-joint.

6. Remove parts from housing. Remember to keep the parts removed from each port together. Identify each group of parts by the port numbers stamped on the housing.

15. Install cam on U-joint so clearance between pushers and cam is 0—0.20 mm (0—0.008 in.). Specification Cam-to-Pushers—Clearance .................... 0—0.20 mm (0—0.008 in.)

7. Repair or replace parts as necessary. Hold the cam and tighten coupling (1) to 78 N•m (58 lb-ft).

8. Install the same number of shims (21) on each spool (19) as were removed. Push the balance spring (23 and 25) down and then install the spacer (retainer) (20) so the recess side is against the spring.

Specification Coupling-to-Cam and U-Joint— Torque....................................................................... 78 N•m (58 lb-ft)

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Hydraulic System

Remove and Install Propel Pilot Controller

T7869AT

–UN–12NOV92

Continued on next page

TX,33,GG2557 –19–16MAY00–1/2

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Hydraulic System 2. Disconnect lines (C—H). Install plugs and caps. 3. Remove cap screws to remove pedals (K), levers, and damper brackets. 4. Remove cap screws (I) to remove propel pilot controller (J). 5. Repair or replace parts as necessary.

7. Tighten pedal-to-lever cap screws. Propel Pilot Controller—Specification Propel Pedal-to-Lever Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

T108085

Propel Pilot Controller—Specification Controller-to-Cap Platform Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

–UN–11MAR97

6. Tighten cap screws (I).

–UN–11MAR97

8. After propel pilot controller is installed, check the operation of all functions to be sure they operate correctly.

T108073B

B—Propel Pedal Dampener C—To Pilot Shut-Off Valve D—From Pilot Shut-Off Valve E—To Right Propel Reverse Top Pilot Cap F—To Left Propel Reverse Top Pilot Cap G—To Right Propel Forward Bottom Pilot Cap H—To Left Propel Forward Bottom Pilot Cap I—Cap Screw (2 used) J—Propel Pilot Controller K—Pedal, Lever and Bracket

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Hydraulic System

T108098

–UN–12MAR97

Disassemble and Assemble Propel Pilot Controller

0—Propel Pilot Controller 1—Spacer (4 used) 2—Shim (12 used) 3—Balance Spring (4 used) 4—Spring Guide (4 used) 5—Return Spring (4 used) 6—Plunger (4 used)

6B—Seal (4 used) 6C—O-Ring (4 used) 6D—Plunger (4 used) 7—Holder 7B—Bushing (2 used) 7C—Bushing (2 used) 8—Cap Screw (2 used)

9—Lock Washer (2 used) 10—Cam (2 used) 11—Pin (2 used) 11A—Bushing (4 used) 12—Spring Pin (2 used) 13—Spring Pin (2 used) 14—Cover

IMPORTANT: The housing and spools (30) are replace as an assembly because the spools are select fitted to bores in housing. Spools must be installed into the same ports from which they were removed.

1. Remove cover (14). 2. Slowly loosen the cap screws (8) to release the spring force of balance spring (3) and return springs 33 (5) on holder (7).

3360 73

Continued on next page

TM1668 (28JAN09)

15—Cap Screw, Lock Washer, Washer (2 used) 16—Plug 17—O-Ring 23—Plate 30—Housing and Spools

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270LC Excavator Repair 012809

PN=461

Hydraulic System 3. Remove the cams (10) only if replacement of parts is necessary. To remove, drive the inner spring pin (13) out first. Then drive the outer spring pin (12) out through the top of cam so that pin is against shoulder at bottom of cam. After spring pins are installed, bend part of flange over pins to prevent then from coming out.

each group of parts by the port numbers stamped on housing. Take note of the number of spacers (1) and shims (2) on each spool. 5. Remove plug (16). 6. Repair or replace parts as necessary.

4. Remove parts from housing. Remember to keep the parts removed from each port together. Identify

Continued on next page

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Hydraulic System

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PN=463

–UN–05AUG97

Hydraulic System

TP54575

33 3360 76

Continued on next page

TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=464

Hydraulic System 0—Propel Pilot Controller 1—Spacer (4 used) 2—Shim (12 used) 3—Balance Spring (4 used) 4—Spring Guide (4 used) 5—Return Spring (4 used) 6—Plunger (4 used)

6A—Bushing (4 used) 6B—Seal (4 used) 6C—O-Ring (4 used) 6D—Plunger (4 used) 7—Holder 7B—Bushing (2 used) 7C—Bushing (2 used)

8—Cap Screw (2 used) 9—Lock Washer (2 used) 10—Cam (2 used) 11—Pin (2 used) 12—Spring Pin (2 used) 13—Spring Pin (2 used) 14—Cover

7. Install the same number of spacers (1) and shims (2) on each spool as were removed. Push the balance spring (3) down and then install the spring guide (4) so the concave side is against the spring. 8. Apply grease to oil seals (6B) and O-rings (6C). 9. Install the parts into housing. Remember to install the spools into the same ports from which they were removed.

15—Cap Screw, Lock Washer, and Washer (2 used) 16—Plug 17—O-Ring 23—Plate 30—Housing and Spools

Tighten cap screws (6). Propel Pilot Controller—Specification Holder-to-Housing Cap Screw—Torque ......................................................... 49 N•m (36 lb-ft)

10. Tighten plug (16). Propel Pilot Controller—Specification Plug-to-Housing—Torque ......................................... 34 N•m (25 lb-ft)

11. Apply grease to the end of plungers (6D).

Slowly push holder down to compress springs and push parts into housing.

TX,33,GG2558 –19–24MAY00–4/4

Remove and Install Flow Regulator Valve

T7869AT

–UN–12NOV92

Continued on next page

TX,33,GG2419 –19–16MAY00–1/2

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PN=465

Hydraulic System 2. After lines are connected to flow regulator valve, check the operation of all functions to be sure they operate as shown on the decal on console.

T105946

–UN–06JAN97

A—Flow Regulator Valve B—To Swing Left, Bottom Pilot Cap C—To Swing Right Top Pilot Cap D—To Bucket Dump Bottom Pilot Cap E—To Bucket Load Top Pilot Cap F—To Boom Up Bottom Pilot Cap G—To Boom Down Top Pilot Cap H—To Arm Out Bottom Pilot Cap I—To Arm In Top Pilot Cap J—From Pilot Shut-Off Valve K—From Port 1 Left Pilot Controller L—From Port 3 Left Pilot Controller M—From Port 2 Right Pilot Controller N—From Port 4 Right Pilot Controller O—From Port 3 Right Pilot Controller P—From Port 4 Right Pilot Controller Q—From Port 2 Left Pilot Controller R—From Port 4 Left Pilot Controller S—Boom Up Pilot Pressure Switch T—Arm In Pilot Pressure Sensor

SAE Pattern Shown

TX,33,GG2419 –19–16MAY00–2/2

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PN=466

Hydraulic System

TP47943

–UN–22MAY96

Disassemble and Assemble Flow Regulator Valve

0—Flow Regulator Valve 3—Spring (4 used) 4—Plug (2 used) 8—Plug (4 used)

9—Spring (4 used) 11—Orifice 15—Plug (2 used) 16—Screw

17—Ball (4 used) 18—Ball (4 used) 20—O-Ring (4 used) 22—O-Ring (4 used) Continued on next page

TM1668 (28JAN09)

33-3360-79

33 3360 79

24—Plunger (Spool, Orifice and Ring) 25—Plunger (Spool, Orifice and Ring) TX,33,GG2420 –19–16MAY00–1/2

270LC Excavator Repair 012809

PN=467

Hydraulic System IMPORTANT: The orifice size in the plungers (24 and 25) are a different size. Plungers with the correct size orifice must be install into the same bore from which they were removed for proper operation. 1. Check that plungers (24 and 25) slide smoothly in bore. Check that orifice in plungers are clean.

2. Check seats in housing for check valve balls (18). Tighten plug (8). Flow Regulator Valve—Specification Check Valve Ball-to-Housing Plug—Torque ........................................................... 10 N•m (86 lb-in.)

3. Check that orifice (11) is clean. Tighten orifice. Flow Regulator Valve—Specification Orifice-to-Housing—Torque ..................................... 10 N•m (86 lb-in.)

Orifice size for plunger (25) in the arm in circuit is 3.2 mm (0.126 in.). Orifice size for plunger (24) in the boom up circuit is 2.5 mm (0.098 in.). Tighten plug (4). Flow Regulator Valve—Specification Spool-to-Housing Plug—Torque ............................... 49 N•m (36 lb-ft)

TX,33,GG2420 –19–16MAY00–2/2

Remove and Install Control Valve

T7869AT

–UN–12NOV92

A—Vent Plug

Continued on next page

TX,33,GG2421 –19–16MAY00–1/8

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Hydraulic System

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PN=469

T109233

–UN–07MAY97

Hydraulic System

Left Front

Continued on next page

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Hydraulic System 1—Left Control Valve—5-Spool 2—Right Control Valve— 4-Spool 3—To Rear Pump Control Valve Pressure Sensor and Rear Pump Regulator 4—Pilot Pressure Signal to Propel Flow Control Valve 5—To Rear Pump Control Valve 6—Inlet Flow From Front Pump 7—Pilot Signal to Swing Motor Park Brake Release Valve— Bottom Port 8—Pilot Pressure From Pilot Pressure Regulating Valve 9—Power Boost Solenoid Valve to System Relief Valve

10—Return to Hydraulic Tank 11—Return From Pilot Shut-Off Valve 12—Pilot Pressure to Swing Motor Park Brake Release Valve Top Port 13—Return From Bucket Flow Control Valve to Solenoid Valve Manifold 14—Return From Propel Flow Control Valve to Solenoid Valve Manifold 15—Pilot Pressure From Pilot Shut-Off Valve to Solenoid Valve Manifold 16—Pilot Pressure to Front Pump Control Valve 17—Arm In Pilot to Bucket Flow Control Valve—Front Bottom Port

18—Arm In Pilot From Left Pilot Controller—SAE Pattern 19—Boom Down Pilot From Right Pilot Controller— SAE Pattern 20—Bucket Load Pilot From Right Pilot Controller 21—Right Propel Reverse Pilot From Propel Pilot Controller 22—Swing Right Pilot From Left Pilot Controller 23—Left Propel Reverse Pilot From Propel Pilot Controller 24—To Swing Motor Make-Up Oil Port

Continued on next page

25—To Hydraulic Oil Cooler 26—To Swing Motor Front Port—Left Swing 27—To Swing Motor Rear Port—Right Swing 28—To Arm Cylinder Rod End—Arm Out 29—To Arm Cylinder Head End—Arm In 30—Left Propel Forward To Rotary Manifold Left Front Port 31—Left Propel Reverse To Rotary Manifold Left Rear Port

TX,33,GG2421 –19–16MAY00–3/8

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T109234

–UN–25APR97

Hydraulic System

Right Rear

Continued on next page

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PN=472

Hydraulic System 1—Left Control Valve—5-Spool 2—Right Control Valve— 4-Spool 5—To Rear Pump Control Valve 7—To Swing Motor Park Brake Release Valve—Bottom Port 9—Power Boost Solenoid Valve to System Relief Valve 10—Return to Hydraulic Tank 11—Return From Pilot Shut-Off Valve 12—Pilot Signal to Swing Motor Park Brake Release Valve—Top Port 13—Return From Bucket Flow Control Valve to Solenoid Valve Manifold 14—Return From Propel Flow Control Valve to Solenoid Valve Manifold

15—Pilot Pressure From Pilot Shut-Off Valve to Solenoid Valve Manifold 16—Pilot Pressure to Front Pump Control Valve 17—Arm In Pilot to Bucket Flow Control Valve—Front Bottom Port 18—Arm In Pilot From Left Pilot Controller—SAE Pattern 19—Boom Down Pilot From Right Pilot Controller— SAE Pattern 20—Bucket Curl Pilot From Right Pilot Controller 21—Right Propel Reverse Pilot From Propel Pilot Controller 22—Swing Right Pilot From Left Pilot Controller 23—Left Propel Reverse Pilot From Propel Pilot Controller

24—To Swing Motor Make-Up Oil Port 25—To Hydraulic Oil Cooler 32—To Propel Motor Speed Change Valve 33—Speed Sensing Solenoid Valve to Front and Rear Pump Regulator Speed Sensing Port 34—Arm Regenerative Solenoid Valve to Arm Regenerative Valve 35—Supply Oil From Front Pump 36—Right Propel Forward to Rotary Manifold Right Front Port 37—Right Propel Reverse to Rotary Manifold Right Rear Port 38—To Bucket Cylinder Rod End—Bucket Dump

Continued on next page

39—To Bucket Cylinder Head End—Bucket Curl 40—To Boom Cylinder Head End—Boom Up 41—To Boom Cylinder Rod End—Boom Down 42—Pilot Pressure From Boom Up Pilot Cap to Bucket Flow Control Valve 43—Return to Hydraulic Tank 44—Supply Oil From Rear Pump 45—To Front Pump Control Valve Pressure Sensor and Front Pump Regulator 46—Return From Front Pump Control Valve and Warm-Up Circuit to Hydraulic Tank

TX,33,GG2421 –19–16MAY00–5/8

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T109235

–UN–08MAY97

Hydraulic System

Bottom 1—Left Control Valve—5-Spool 2—Right Control Valve— 4-Spool 13—Return From Bucket Flow Control Valve to Solenoid Valve Manifold 17—Arm In Pilot to Bucket Flow Control Valve—Front Bottom Port 37—Right Propel Reverse to Rotary Manifold Right Rear Port

39—To Bucket Cylinder Head End—Bucket Curl 41—To Boom Cylinder Rod End—Boom Down 42—Bucket Flow Control Valve Front Top Port to Right Side Boom Up Pilot Cap 47—Arm II To Arm I Pilot— Arm Out 48—Arm Out Pilot From Left Pilot Controller—SAE Pattern

49—Swing Left Pilot From Left Pilot Controller 50—Bucket Dump Pilot From Right Pilot Controller 51—Boom Up Pilot From Right Pilot Controller—SAE Pattern 52—Boom II to Boom I Pilot— Boom Up

53—Right Propel Forward Pilot From Propel Pilot Controller 54—Left Propel Forward Pilot From Propel Pilot Controller 55—To Hydraulic Tank— Return From Rear Pump Control Valve

3. Disconnect the lines (37—55). Install caps and plugs. 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.

4. Disconnect wiring harness connectors from propel pressure switch, dig pressure switch, and the four proportional solenoid valves.

33 3360 86

Continued on next page

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PN=474

Hydraulic System

CAUTION: The approximate weight of control valve is 180 kg (400 lb). Control Valve—Specification Control Valve—Weight .................................. 180 kg (400 lb) approximate

5. Remove cap screw (C) and lock washer (B) to remove control valve (A). 6. Repair or replace parts as necessary. 7. Tighten cap screws (C). Control Valve—Specification Mounting Bracket-to-Valve Housing Cap Screw—Torque...................................... 205 N•m (150 lb-ft)

8. Tighten the split flange fitting-to-housing M10 and M12 cap screws.

T105957

–UN–20DEC96

Control Valve—Specification Split Flange Fitting-to-Housing M10 Cap Screw—Torque ................................................ 64 N•m (47 lb-ft) Split Flange Fitting-to-Housing M12 Cap Screw—Torque .............................................. 108 N•m (80 lb-ft)

A—Control Valve B—Lock Washer C—Cap Screw

Continued on next page

TX,33,GG2421 –19–16MAY00–7/8

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PN=475

Hydraulic System 9. Connect wiring harness connectors to solenoid valves (Q—T). 10. Connect wiring harness connectors to dig and propel pressure switches.

–UN–30DEC96

11. Check oil level in the hydraulic tank. Add oil as necessary. (See Hydraulic Oil in the Fuels and Lubricants Group.)

T105730

12. Do the Hydraulic Pump Start-Up Procedure. (See procedure in this group.)

TX,33,GG2421 –19–16MAY00–8/8

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PN=476

Hydraulic System

T109048

–UN–15APR97

Disassemble and Assemble Control Valve

Left Front 1—Left Control Valve—5-Spool 2—Right Control Valve— 4-Spool 56—System Relief Valve Isolation Check Valve 57—System Relief Valve and Power Boost 58—Dig Pressure Switch 59—Flow Combiner Valve Circuit Check Valve 60—System Relief Valve Isolation Check Valve 61—Propel Pressure Switch

62—Pilot Pressure Inlet Filter 63—Solenoid Valve Manifold 64—Arm II Valve 65—Boom I Valve and Boom Regenerative Valve 66—Boom Anti-Drift Valve 67—Bucket Valve 68—Right Propel Valve 69—Left Propel Valve 70—Auxiliary Valve 71—Boom II Valve 71A—Propel-Boom Down Selector Valve

72—Arm I Valve 73—Swing Valve 74—Arm Anti-Drift Valve 75—Arm Out Circuit Relief and Anti-Cavitation Valve 76—Plug 77—Swing Lift Check Valve 78—Arm I Power and Neutral Passage Lift Check Valves and Restriction Orifice 79—Boom II Power Passage (Lift Check) Valve 80—Auxiliary Power Passage (Lift Check) Valve

Continued on next page

TM1668 (28JAN09)

33-3360-89

81—Propel Flow Control Valve 82—Propel Power and Neutral Passage (Lift Check) Valves 83—Rear Pump Control Valve 84—Filter and Orifice for Pilot Pressure to Rear Pump Control Valve 84A—Check Valve and Orifice for Propel Flow Control Valve 33 3360 89

TX,33,GG2422 –19–16MAY00–1/16

270LC Excavator Repair 012809

PN=477

T109052

–UN–15APR97

Hydraulic System

Right Rear 1—Left Control Valve—5-Spool 2—Right Control Valve— 4-Spool 57—System Relief Valve and Power Boost 63—Solenoid Valve Manifold 64—Arm II Valve 65—Boom I Valve and Boom Regenerative Valve 66—Boom Anti-Drift Valve 67—Bucket Valve 68—Right Propel Valve

69—Left Propel Valve 70—Auxiliary Valve 71—Boom II Valve 72—Arm I Valve 73—Swing Valve 85—Arm Regenerative Valve 86—Arm II to Arm I Neutral Passage (Check Valve) 87—Boom Up Circuit Relief Valve 88—Bucket Dump Circuit Relief Valve

89—Power Boost Solenoid Valve 90—Propel Speed Change Solenoid Valve 91—Speed Sensing Solenoid Valve 92—Arm Regenerative Solenoid Valve 93—Flow Combiner Valve 94—Bucket Flow Control Valve 95—Bucket Check Valve (Lift Check)

96—Boom I Power and Neutral Passage Check Valves (Lift Checks) 97—Arm II Power and Neutral Passage Check Valves and Restriction Orifice 98—Front Pump Control Valve 99—Filter and Orifice for Pilot Pressure to Front Pump Control Valve 105—Oil Cooler Bypass Valve

33 3360 90

Continued on next page

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270LC Excavator Repair 012809

PN=478

T109053

–UN–15APR97

Hydraulic System

Bottom 1—Left Control Valve—5-Spool 2—Right Control Valve— 4-Spool 64—Arm II Valve 65—Boom I Valve 67—Bucket Valve

68—Right Propel Valve 69—Left Propel Valve 70—Auxiliary Valve 71—Boom II Valve 72—Arm I Valve 73—Swing Valve

94—Bucket Flow Control Valve 100—Arm Regenerative Circuit Check Valve 101—Boom Down Circuit Relief and Anti-Cavitation Valve

102—Bucket Curl Circuit Relief and Anti-Cavitation Valve 103—Plug 104—Arm In Circuit Relief and Anti-Cavitation Valve

1. Use the three previous illustrations to locate individual components on the assembled control valve.

Continued on next page

TX,33,GG2422 –19–16MAY00–3/16

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PN=479

T105964

–UN–03JAN97

Hydraulic System

Left Control Valve—5-Spool

33 3360 92

4—Propel Flow Control Valve Spool 5—Seat 6—Spring 7—O-Ring 8—Plug 11—Check Valve Poppet 12—Check Valve Poppet 14—Spring (6 used) 24—Rear Pump Control Valve 30—Plug and O-Ring

31—Sleeve 32—Check Valve Poppet 33—Spring 35—Lock Nut 36—Adjusting Screw 37—Washer 38—O-Ring 39—Plug 40—O-Ring 41—Relief Valve Spring 42—Spring Seat

43—Relief Valve Spool 44—Sleeve 45—O-Ring (2 used) 46—Flow Sense Spool 47—Sleeve 48—O-Ring (3 used) 49—Spring Seat (2 used) 50—Snap Ring 51—Flow Sense Spring 52—Housing—5-Spool

Continued on next page

TM1668 (28JAN09)

33-3360-92

55—Pilot Plate 56—Pilot Plate 63—Plug and O-Ring (3 used) 69—Cap Screw (14 used) 72—Cap (2 used) 73—O-Ring (2 used) 75—Cap Screw (8 used) 81—O-Ring (8 used) 82—O-Ring (3 used) 83—O-Ring

TX,33,GG2422 –19–16MAY00–4/16

270LC Excavator Repair 012809

PN=480

Hydraulic System NOTE: It is not always necessary to remove the control valve to remove individual components. The letters, A, B, and D, are used in the illustration to indicate the location of parts in housing. 2. Rear Pump Control Valve (24): Disassemble valve for cleaning and inspection only. Valve is serviced as an assembly. Valve is set at the factory so adjustment in the field should not be necessary. a. If removal of lock nuts (35) and adjusting screw (36) from plug (39) is necessary, check valve pressure setting after assembly. (See Pump Control Valve Test in Group 9025-25.) b. Pull flow sense spool (46) and sleeve (47) from housing (52) using a M8-1.25 nut on threaded end of spool.

d. Tighten plug (39). Control Valve—Specification Front and Rear Pump Control Valve-to-Housing—Torque ....................................... 84 N•m (62 lb-ft)

e. Tighten cap screws (69). Control Valve—Specification Pilot Plate-to-Housing Cap Screw—Torque ......................................................... 78 N•m (58 lb-ft)

f. Tighten plug (8). Control Valve—Specification Plug-to-Propel Flow Control Valve Pilot Plate—Torque ........................................ 98 N•m (72 lb-ft)

c. Inspect valve for wear or damage. Replace as necessary.

Continued on next page

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270LC Excavator Repair 012809

PN=481

T105973

–UN–15JAN97

Hydraulic System

Left Control Valve—5-Spool

Continued on next page

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270LC Excavator Repair 012809

PN=482

Hydraulic System 1—Housing—5-Spool 2—Swing Spool 3—Arm I Spool 4—Boom II Spool 5—Auxiliary Spool 8—Special Cap Screw (5 used) 9—Spring Seat (10 used) 10—Spring (5 used) 11—Left Propel Spool 16—Arm Anti-Drift Check Valve Poppet 17—Spring 18—Spacer 20—Plug 21—O-Ring 22—Spacer

23—O-Ring 24—Spring 25—Spring Seat 26—Anti-Drift Valve Spool 27—O-Ring 28—Plug 34—Sleeve 35—Propel-Boom Down Selector Spool 36—Spring 37A—Arm Regenerative Valve Spool 37B—O-Ring 37C—Backup Ring 37D—Spacer 38—Spring

3. Circuit Relief and Anti-Cavitation Valve (51 and 95): Disassemble valves for cleaning and inspection only. Valves are serviced as assemblies. a. Inspect valves for wear or damage. Replace as necessary. b. Tighten valves into housing.

39—Check Valve Poppet 40—Spring 41—Spacer 50—System Relief Valve 51—Arm In Circuit Relief and Anti-Cavitation Valve 52—Plug, O-Ring, Backup Ring and O-Ring (2 used) 59—Bottom Pilot Cap 60—Top Pilot Cap 62—Arm in Anti-Drift Valve Housing 65—Plug and O-Ring 68—Cap Screw (12 used) 69—Cap Screw (2 used)

77—Plug 78—Plug 81—O-Ring 82—O-Ring 83—O-Ring (6 used) 84—O-Ring (3 used) 85—O-Ring (3 used) 86—O-Ring (10 used) 88—O-Ring 90—O-Ring 91—O-Ring 92—Backup Ring 93—Backup Ring 95—Arm Out Circuit Relief and Anti-Cavitation Valve

c. Tighten bottom nut. Control Valve—Specification System Relief Valve Bottom Nut—Torque ............................................................. 83 N•m (61 lb-ft)

d. Tighten valve into housing.

Control Valve—Specification Circuit Relief and Anti-Cavitation Valve-to-Control Valve Housing—Torque.............................................. 83 N•m 62 lb-ft)

Control Valve—Specification System Relief Valve-to-Housing—Torque ....................................... 83 N•m (61 lb-ft)

c. Check and adjust pressure setting. (See Circuit Relief Valve Test and Adjustment in Group 9025-25.)

e. Check and adjust pressure setting for system relief valve and power boost after assembly. (See System Relief Valve Test and Adjustment in Group 9025-25.)

4. System Relief Valve (50): Disassemble valve for cleaning and inspection only. Valve is serviced as an assembly. a. Inspect valve for wear or damage. Replace as necessary. b. Tighten top nut. Control Valve—Specification System Relief Valve Top Nut— Torque....................................................................... 64 N•m (47 lb-ft)

5. Arm In Anti-Drift Valve: Spring (17) may force spacer (18) out of housing (62). a. Remove cap screw (69). b. Pull spacer (18) from housing (1) using a M5-0.8 cap screw. c. Inspect valve for wear or damage. Replace as necessary.

33 3360 95

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270LC Excavator Repair 012809

PN=483

Hydraulic System d. Tighten cap screws (69).

Inspect valves for wear or damage. Replace as necessary.

Control Valve—Specification Arm In Anti-Drift Valve Housing-to-Housing Cap Screw—Torque ......................................................... 78 N•m (58 lb-ft)

e. Tighten plug (28). Control Valve—Specification Plug-to-Arm In Anti-Drift Valve Housing—Torque ................................................... 29 N•m (255 lb-in.)

IMPORTANT: The spools are select fitted to bores in housing and are a different design for each function. Spools must be installed into the same bores from which they were removed for proper operation of machine. 8. Valve Spools (2—5 and 11): a. Remove special cap screws (8). b. Inspect valve spools for wear or damage. Replace as necessary.

6. Arm Regenerative Valve (37A—38): Heat spacer (37D) and spool (37A) using a heat gun to breakdown the high strength thread lock and sealer.

NOTE: Hold the spool in a vise by the chamfered end. c. Tighten special cap screws (8).

a. Inspect valves for wear or damage. Replace as necessary. b. Apply high strength thread lock and sealer to threads of spacer (37D). NOTE: Hold spool in a vise using wooden blocks to protect the spool.

Control Valve—Specification Special Cap Screw-to-Control Valve Spool—Torque............................................. 15 N•m (133 lb-in.)

d. Tighten pilot cap-to-housing cap screws (68). Control Valve—Specification Pilot Cap-to-Control Housing Cap Screw—Torque ................................................. 78 N•m (58 lb-ft)

c. Tighten spacer into spool. Control Valve—Specification Spacer-to-Arm Regenerative Valve Spool—Torque.......................................... 18.6 N•m (165 lb-in.)

7. Arm II to Arm I Neutral Passage Check Valve (39): Pull spacer (41) out of housing (1) using a M6-1.0 cap screw.

Continued on next page

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270LC Excavator Repair 012809

PN=484

Hydraulic System

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TM1668 (28JAN09)

33-3360-97

270LC Excavator Repair 012809

PN=485

T105976

–UN–07JAN97

Hydraulic System

Right Control Valve—4-Spool Continued on next page

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270LC Excavator Repair 012809

PN=486

Hydraulic System 1—Housing—4-Spool 2—Flow Combiner Valve Spool 3—Pilot Pressure Inlet Fitting, Filter and O-Rings 4—Plug and O-Ring 5—Spring 11—Check Valve Poppet (3 used) 13—Check Valve Poppet (2 used) 14—Spring (5 used) 24—Front Pump Control Valve 25—Snap Ring 26—Spring Seat (2 used) 27—Spring 28—O-Ring

29—Sleeve 30—Load Sense Valve Spool 31—O-Ring 32—Sleeve 33—Relief Valve Spool 34—Spring Seat 35—Spring 36—O-Ring 37—Plug 38—O-Ring 39—Washer 40—Lock Nut 41—Adjusting Screw 47—Bucket Flow Control Valve Poppet 48—Spring

NOTE: The letters, A—D, are used in the illustration to indicate the location of parts in housing. 9. Front Pump Control Valve (24): Disassemble valve for cleaning and inspection only. Valve is serviced as an assembly. Valve is set at the factory so adjustment in the field should not be necessary. a. If removal of lock nuts (40) and adjusting screw (41) from plug (37) is necessary, check valve pressure setting after assembly. (See Pump Control Valve Test in Group 9025-25.) b. Pull flow sense spool (30) and sleeve (29) from housing using a M8-1.25 nut on threaded end of spool. c. Inspect valve for wear or damage. Replace as necessary.

49—Spacer 50—Spring 53—Bucket Flow Control Valve 54—Housing 55—Bucket Flow Control Valve Housing 56—Bucket Flow Control Valve Pilot Spool 57—Spring Seat 58—Spring 59—O-Ring 60—Plug (2 used) 61—Snap Ring 62—Spring Seat 63—Plug and O-Ring (6 used)

64—Plug and O-Ring 65—Spring 66—Bucket Flow Control Valve Pilot Spool 69—Cap Screw (12 used) 70—Pipe Plug 71—Plug 72—O-Ring 73—Backup Ring 74—Cover 75—Cap Screw (4 used) 76—O-Ring 81—O-Ring (7 used) 82—O-Ring 83—O-Ring

b. Tighten plug into poppet (47). Control Valve—Specification Plug-to-Bucket Flow Control Valve Poppet—Torque .......................................... 39 N•m (348 lb-in.)

c. Tighten housing-to-control valve housing cap screws (69). Control Valve—Specification Bucket Flow Control Valve Housing-to-Control Valve Housing Cap Screw—Torque ................................... 78 N•m (58 lb-ft)

d. Tighten plugs (60) into housing. Control Valve—Specification Pilot Valve-to-Bucket Flow Control Valve Housing Plug— Torque....................................................................... 71 N•m (52 lb-ft)

d. Tighten plug (37). Control Valve—Specification Front and Rear Pump Control Valve-to-Housing—Torque ....................................... 84 N•m (62 lb-ft)

11. Flow Combiner Valve (2): a. Inspect valve for wear or damage. Replace as necessary.

10. Bucket Flow Control Valve (53): a. Inspect valve for wear or damage. Replace as necessary.

33 3360 99

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270LC Excavator Repair 012809

PN=487

Hydraulic System b. Tighten plug (4) into housing.

a. Inspect valve for wear or damage. Replace as necessary.

Control Valve—Specification Flow Combiner Valve Spool-to-Control Valve Housing Plug—Torque ........................................................ 157 N•m (116 lb-ft)

b. Tighten fitting into housing. Control Valve—Specification Pilot Pressure Inlet Fitting and Filter-to-Control Valve Housing—Torque ...................................................... 76 N•m (56 lb-ft)

12. Pilot Pressure Inlet Fitting and Filter (3):

Continued on next page

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PN=488

Hydraulic System

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TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=489

T105977

–UN–15JAN97

Hydraulic System

Right Control Valve—4-Spool

Continued on next page

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PN=490

Hydraulic System 1—Pilot Cap 2—Cap Screw (14 used) 3—Arm Anti-Drift Valve Housing 4—Cap Screw (2 used) 5—O-Ring 6—Plug 7—Lock Nut 8—Screw (Poppet) 9—O-Ring 10—Plug 11—Plug 12—Spool 13—Spring Seat 14—Spring 15—O-Ring 16—Spacer

17—O-Ring 18—Housing—4-Spool 19—O-Ring (3 used) 20—O-Ring (4 used) 21—Pilot Cap 22—Boom Down Circuit Relief and Anti-Cavitation Valve 23—Right Propel Spool 24—Bucket Spool 25—Boom I Spool 26—Backup Ring 27—Plug 28—O-Ring 29—Spring 30—Washer 31—Sleeve

IMPORTANT: Spools (23—25 and 36) are select fitted to bores in housing and are a different design for each function. Spools must be installed into the same bores from which they were removed for proper operation. NOTE: The letters, A—F, are used in the illustration to indicate the location of parts in housing. 13. Circuit Relief and Anti-Cavitation Valve (22, 53, 54 and 55): Disassemble valves for cleaning and inspection only. Valves are serviced as assemblies. a. Tighten valve into housing. Control Valve—Specification Circuit Relief and Anti-Cavitation Valve-to-Housing—Torque ....................................... 83 N•m (62 lb-ft)

b. Check and adjust pressure setting after assembly. (See Circuit Relief Valve Test and Adjustment in Group 9025-25.) 14. Boom Regenerative Valve: Heat plugs (27 and 41) in boom I spool (25) using a heat gun to breakdown the high strength thread lock and

32—Boom Down Regenerative Valve Poppet 33—Special Cap Screw (4 used) 34—Spring Seat (8 used) 35—Spring (4 used) 36—Arm II Spool 37—Poppet 38—Spring 39—O-Ring 40—Backup Ring 41—Plug 42—Arm Anti-Drift Check Valve Poppet 43—Spring 44—O-Ring

45—Backup Ring 46—Spacer 47—Arm Regenerative Check Valve Poppet 48—Spring 49—O-Ring 50—Backup Ring 51—O-Ring 52—Spacer 53—Bucket Load Circuit Relief and Anti-Cavitation Valve 54—Bucket Dump Circuit Relief and Anti-Cavitation Valve 55—Boom Up Circuit Relief and Anti-Cavitation Valve

sealer. Hold the spool in a vise using wooden blocks to protect it. Apply high strength thread lock and sealer to threads of plug (27 and 41). Tighten plugs. Hold the spool in a vise using wooden blocks to protect it. Control Valve—Specification Boom Regenerative Valve-to-Control Valve Spool Plug—Torque ......................................................... 15 N•m (130 lb-in.)

15. Boom Anti-Drift Valve: Pull spacer (46) from housing using a M5-0.8 cap screw. a. Tighten anti-drift valve housing-to-housing cap screws. Control Valve—Specification Boom Anti-Drift Valve Housing-to-Control Valve Housing Cap Screw—Torque ................................... 78 N•m (58 lb-ft)

b. Tighten plug (11) into housing. Control Valve—Specification Spool-to-Boom Anti-Drift Valve Housing Plug—Torque .......................................... 29 N•m (255 lb-in.)

33 3360 ,103

Continued on next page

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TX,33,GG2422 –19–16MAY00–13/16

270LC Excavator Repair 012809

PN=491

Hydraulic System c. Tighten screw (poppet) (8). Control Valve—Specification Screw for Boom Lower-to-Boom Anti-Drift Valve Housing—Torque .................................................... 6.9 N•m (60 lb-in.)

17. Valve Spools (23—25 and 36): Tighten special cap screws (33). Hold spool in a vise by the chamfered end. Control Valve—Specification Special Cap Screw-to-Control Valve Spool—Torque............................................. 15 N•m (133 lb-in.)

Tighten pilot cap-to-housing cap screws (2). d. Hold screw and tighten lock nut (7). Control Valve—Specification Nut-to-Screw for Boom Lower— Torque.................................................................... 13 N•m (115 lb-in.)

Control Valve—Specification Pilot Cap-to-Control Housing Cap Screw—Torque ................................................. 78 N•m (58 lb-ft)

16. Arm Regenerative Check Valve Poppet (47):Pull spacer (52) from housing using a M6-1.0 cap screw.

Continued on next page

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270LC Excavator Repair 012809

PN=492

T105978

–UN–09JAN97

Hydraulic System

2—Cover (3 used) 3—Left Control Valve—5-Spool 4—Right Control Valve— 4-Spool 22A—System Relief Valve Isolation Check Valve Poppet 22B—Flow Combiner Valve Check Valve Poppet

22C—System Relief Valve Isolation Check Valve Poppet 23—Spring (3 used) 25—Fitting with Orifice, O-Ring and Filter (2 used) 26—Fitting and O-Ring

27—Spring 28—Filter, Orifice and Check Valve Poppet Propel Flow Control Valve 63—Plug and O-Ring (2 used) 64—Plug and O-Ring 65—Plug and O-Ring (5 used)

66—Plug and O-Ring (5 used) 67—Cap Screw (12 used) 75—Cap Screw (6 used) 81—O-Ring (8 used) 82—O-Ring (7 used) 84—O-Ring (16 used) 85—O-Ring (2 used) 33 3360 ,105

18. System Relief Valve Isolation Check Valve Poppet (22A and 22C): Tighten cap screws (75). Continued on next page

TM1668 (28JAN09)

33-3360-105

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270LC Excavator Repair 012809

PN=493

Hydraulic System Control Valve—Specification System Relief Valve Isolation Check Valve Cover-to-Control Valve Housing Cap Screw— Torque....................................................................... 61 N•m (45 lb-ft)

Control Valve—Specification Propel Flow Control Valve Filter, Orifice and Check Valve Poppet-to-Control Valve Housing Fitting—Torque ........................................... 76 N•m (56 lb-ft)

19. Flow Combiner Valve Check Valve Poppet (22B): Tighten cap screws (75).

21. Fitting with Orifice, O-Ring and Filter (25) for Front and Rear Pump Control Valves: Tighten fitting.

Control Valve—Specification Flow Combiner Valve Check Valve Cover-to-Control Valve Housing Cap Screw—Torque ................................... 61 N•m (45 lb-ft)

Control Valve—Specification Front and Rear Pump Control Valve-to-Control Valve Housing Fitting with Orifice—Torque ...................................... 34 N•m (25 lb-ft)

20. Check Valve and Orifice (28) for Propel Flow Control Valve: Tighten fitting (26).

TX,33,GG2422 –19–16MAY00–16/16

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TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=494

Hydraulic System

T105981

–UN–13JAN97

Disassemble and Assemble System Relief Valve

A—Main Poppet Seat B—Main Poppet C—Main Poppet Spring D—Pilot Poppet Seat E—Pilot Poppet

F—Pilot Poppet Spring G—Cartridge H—Piston I—Bottom Nut

J—Second Adjusting Plug K—Top Nut L—First Adjusting Plug M—O-Ring

1. Disassemble valve for cleaning and inspection only. Valve is serviced as an assembly.

N—O-Ring O—O-Ring P—Backup Ring Q—O-Ring

Tighten bottom nut (I) to 83 N•m (61 lb-ft).

2. Tighten top nut (K) to 64 N•m (47 lb-ft).

Specification System Relief Valve Bottom Nut—Torque ............................................................. 83 N•m (61 lb-ft)

Specification System Relief Valve Top Nut— Torque....................................................................... 64 N•m (47 lb-ft)

Tighten valve cartridge (G) into housing to 83 N•m (61 lb-ft). 33 3360 ,107

Continued on next page

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TX,33,GG2423 –19–23DEC96–1/2

270LC Excavator Repair 012809

PN=495

Hydraulic System Specification System Relief Valve-to-Housing—Torque ....................................... 83 N•m (61 lb-ft)

3. Check and adjust pressure setting for system relief valve and power boost. (See System Relief Valve Test and Adjustment in Group 9025-25.)

TX,33,GG2423 –19–23DEC96–2/2

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270LC Excavator Repair 012809

PN=496

Hydraulic System

T7996AE

–UN–04MAY93

Disassemble and Assemble Circuit Relief and Anti-Cavitation Valve

A—Nut B—Plug C—O-Ring (2 used) D—Backup Ring E—O-Ring

F—O-Ring G—Backup Ring H—Anti-Cavitation Sleeve I—Piston J—Main Poppet

1. Disassemble valves for cleaning and inspection only. Valves are serviced as assemblies.

K—Piston and Main Poppet Spring L—Cartridge M—Pilot Poppet N—Anti-Cavitation Sleeve Spring

O—Pilot Poppet Spring P—O-Ring Q—Adjusting Screw

3. Check and adjust pressure setting. (See Circuit Relief Valve Test and Adjustment in Group 9025-25.)

2. Tighten nut (A) to 29.5 N•m (264 lb-in.). Specification Nut-to-Circuit Relief and Anti-Cavitation Valve Adjusting Screw—Torque ................................................... 29.5 N•m (264 lb-in.)

Tighten valve into housing to 83 N•m (62 lb-ft). Specification Circuit Relief and Anti-Cavitation Valve-to-Control Valve Housing—Torque............................................ 83 N•m (62 lb-ft)

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TM1668 (28JAN09)

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PN=497

Hydraulic System

Remove and Install Hydraulic Oil Tank

T7869AT

–UN–12NOV92

A—Vent Plug

NOTE: It is not necessary to drain and remove the hydraulic oil tank if only the return filter element is being removed. (See procedures in this group.) 3. Drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal).

TX,33,UU3692 –19–26MAY00–1/6

4. Loosen hose clamps (2 and 3) at the bottom of oil tank (1). Slide hose (4) off elbow.

T106028

–UN–15JAN97

1—Oil Tank 2—Hose Clamp 3—Hose Clamp 4—Hose

Continued on next page

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PN=498

Hydraulic System 5. Loosen nuts on couplings (7). Slide couplings onto return lines (8 and 9). Install caps and plugs.

T106023

–UN–15JAN97

1—Hydraulic Oil Tank 5—Oil Cooler 6—Control Valve 7—Coupling (2 used) 8—Control Valve-to-Hydraulic Oil Tank Return Line 9—Oil Cooler-to-Hydraulic Oil Tank Return Line

Continued on next page

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PN=499

T106032

–UN–15JAN97

Hydraulic System

1—Hydraulic Oil Tank 11—Solenoid Valve Manifold Pilot Return Line 12—Fitting and O-Ring

13—Rear Pump Control Valve Pilot Return Line 14—Elbow and O-Ring

6. Disconnect lines (11, 13 and 18). Install caps and plugs.

15—Plug and O-Ring 16—Plug and O-Ring 17—Fitting and O-Ring

18—Front Pump Control Valve Pilot Return Line 19—Solenoid Valve Manifold

Disconnect wiring harness for hydraulic oil level sensor.

Continued on next page

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PN=500

T106033

T106036

–UN–15JAN97

Hydraulic System

1—Hydraulic Oil Tank 6—Control Valve 20—Fitting and O-Ring (2 used) 21—Tee and O-Ring (2 used) 22—Pump Control Valve Pressure Sensor and O-Ring (2 used)

23—Front Pump Control Valve-to-Bulkhead Pilot Line 24—Rear Pump Control Valve-to-Bulkhead Pilot Line

7. Disconnect lines (23, 24, 25 and 26) at bulkhead. Install caps and plugs. 8. Disconnect wiring harness connectors from pump control valve pressure sensors (22) and hydraulic oil level switch. 9. Remove cap screws (31), lock washers (30) and washers (29). CAUTION: The approximate weight of hydraulic oil tank is 147 kg (325 lb).

25—Bulkhead-to-Rear Pump Regulator Pilot Line 26—Bulkhead-to-Front Pump Regulator Pilot Line 27—Front Pump Regulator

28—Rear Pump Regulator 29—Washer (4 used) 30—Lock Washer (4 used) 31—Cap Screw (4 used)

12. Install hydraulic oil tank. Hydraulic Oil Tank—Specification Frame-to-Oil Tank Cap Screw—Torque ..................................................... 205 N•m (152 lb-ft) Return Lines-to-Oil Tank Coupling Nut—Torque ................................ 10.3—12.4 N•m (91—110 lb-in.) Oil Tank Elbow-to-Suction Line T-Bolt Type Clamp—Torque................................... 4.4 N•m (40 lb-in.) Oil Tank Elbow-to-Suction Line Worm Gear Type Clamp— Torque.................................................... 5.9—6.9 N•m (52—61 lb-in.)

13. Connect wiring harness connectors.

Hydraulic Oil Tank—Specification Hydraulic Oil Tank—Weight ................... 147 kg (325 lb) approximate

10. Remove hydraulic oil tank using a hoist and lifting straps.

14. Add hydraulic oil to tank until it is between marks on sight glass. (See Hydraulic Oil in the Fuels and Lubricant Group.)

11. Repair or replace parts as necessary.

33 3360 ,113

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TX,33,UU3692 –19–26MAY00–5/6

270LC Excavator Repair 012809

PN=501

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. Do the Hydraulic Pump Start-Up Procedure. (See procedure in this group.)

TX,33,UU3692 –19–26MAY00–6/6

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PN=502

Hydraulic System

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PN=503

Hydraulic System

TP48165

–UN–29AUG96

Disassemble and Assemble Hydraulic Oil Tank

33 3360 ,116

Continued on next page

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TX,33,GG2759 –19–14JUL97–1/2

270LC Excavator Repair 012809

PN=504

Hydraulic System 0—Hydraulic Oil Tank 1—Cap Screw (4 used) 2—Lock Washer (4 used) 3—Washer (4 used) 5—Return Filter Element 7—Filter Bypass Valve 8—Spring 10—Cover 11—O-Ring 12—Cap Screw and Lock Washer (6 used)

14—Cap and Relief Valve 14A—O-Ring 14B—Breather Filter 15—Cap Screw (3 used) 16—Base (Housing) 17—Packing 18—Cover 19—O-Ring 20—Vent Plug

20A—O-Ring 21—Cap Screw and Lock Washer (6 used) 22—Nut (3 used) 23—Rod 24—Suction Strainer 25—O-Ring 26—Drain Plug 27—Cap Screw and Lock Washer (5 used)

NOTE: It is not necessary to drain and remove the hydraulic oil tank (0) if only the return filter element (5) is being removed. (See procedures in this group.) 1. Tighten cap screws (12, 21 and 27) to 49 N•m (36 lb-ft).

28—Level Gauge 28A—Fitting (2 used) 29—Washer (Seal) (4 used) 30—Elbow 33—Hydraulic Oil Level Switch 34—Bracket 35—Cap Screw and Lock Washer

Specification Rod and Suction Strainer— Length ..................................................................... 670 mm (26.4 in.)

Tighten nut (22) to 17 N•m (153 lb-in.). Specification Rod-to-Suction Strainer Nut— Torque.................................................................... 17 N•m (153 lb-in.)

Specification Cover-to-Oil Tank Cap Screws—Torque ....................................................... 49 N•m (36 lb-ft)

2. Adjust the rod (23) so length from end of rod to bottom of strainer (24) is 670 mm (26.4 in.).

TX,33,GG2759 –19–14JUL97–2/2

Remove and Install Return Filter and Bypass Valve

T7869AT

–UN–12NOV92

33 3360 ,117

A—Vent Plug

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270LC Excavator Repair 012809

PN=505

Hydraulic System 2. Hold down cover (A) against light spring (D) force when removing the last two cap screws (B).

–UN–04MAY93

3. Remove the spring (D), filter bypass valve (E) and return filter element (F).

T7995AL

4. Inspect element for metal particles and debris. Check for metal particles and debris at the bottom of filter case. Excessive amounts of brass and steel particles can indicate a hydraulic pump, motor or valve malfunction, or a malfunction in process. A rubber type of material can indicate a cylinder packing problem. As necessary, drain the hydraulic oil tank and clean the filter case and tank. Approximate oil capacity is 148 L (39 gal).

T6557GN

–UN–20OCT88

A—Cover B—Cap Screw and Lock Washer (6 used) C—O-Ring D—Spring E—Filter Bypass Valve F—Return Filter Element

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Hydraulic System 5. Install element (D) making sure it is pushed down on its seat at bottom of case. 6. Install filter bypass valve (E), spring (C), O-ring (F), cover (A) and cap screws (B). Tighten cap screws. Hydraulic Oil Tank—Specification Cover-to-Oil Tank Cap Screw— Torque ............................................................................. 49 N•m (36 lb-ft)

7. Add hydraulic oil as necessary. (See Hydraulic Oil in the Fuels and Lubricant Group.)

T6457ED

8. If hydraulic oil tank was drained, do the Hydraulic Pump Start-Up Procedure. (See procedure in this group.)

–UN–18OCT88

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.

A—Cover B—Cap Screw C—Spring D—Element E—Filter Bypass Valve F—O-Ring

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Hydraulic System

Remove and Install Suction Strainer

T7995AM

–UN–04MAY93

CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Release pressure from tank by loosening vent plug. It is not necessary to remove vent plug. 1. Loosen vent plug (B) to release air pressure in hydraulic oil tank. 2. Drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal).

A—Filler Cap B—Vent Plug C—Cover

3. Remove the filler cap (A) and cover (C).

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Hydraulic System 4. Remove parts (D—H). Replace parts as necessary. IMPORTANT: To ensure suction strainer is held in position on suction tube, the rod and suction strainer must be adjusted to the correct length. 5. Adjust the rod so the length of rod and strainer is 670 mm (26.4 in.) (J). Tighten nut (I). Hydraulic Oil Tank—Specification Rod-to-Suction Strainer Nut— Torque .......................................................................... 17 N•m (153 lb-in.)

6. Install suction strainer and rod (D and E) making sure it is pushed down on suction tube at bottom of oil tank.

–UN–20OCT88

7. Install cover (C). Make sure rod is through hole in cover. Tighten cap screws. Install parts (A, B, and F—H).

T6557GL

Hydraulic Oil Tank—Specification Cover-to-Oil Tank Cap Screw— Torque ............................................................................. 49 N•m (36 lb-ft)

8. Add hydraulic oil to tank until it is between marks on sight glass. (See Hydraulic Oil in the Fuels and Lubricant Group.)

T7168AN

–UN–14NOV89

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. 9. Do the Hydraulic Pump Start-Up Procedure. (See procedure in this group.) A—Filler Cap B—Vent Plug C—Cover D—Rod and Nuts E—Suction Strainer F—Housing G—Relief Valve H—Filter I—Nut J—670 mm (26.4 in.)

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Hydraulic System

1. Loosen vent plug (A) to release air pressure in hydraulic tank.

T7869AT

–UN–12NOV92

Disassemble and Assemble Hydraulic Oil Tank Relief Valve and Breather Filter Cap

A—Vent Plug

TX,33,GG2429 –19–17MAY00–1/2

2. Insert a 4 mm hex key wrench in base and turn to release locking pin. Remove cap (A). 3. Remove cap screw (E). Remove parts (B—D). –UN–04MAY93

Replace parts as necessary.

T7995AX

–UN–04MAY93

T7995AN

A—Cap B—Breather Filter C—Seal D—Relief Valve E—Cap Screw (3 used)

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Hydraulic System

Remove and Install Swing Motor Make-Up Oil Restriction Valve

T7869AT

–UN–12NOV92

2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal).

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T106003

–UN–15JAN97

Hydraulic System

A—Hydraulic Oil Tank B—Coupling (2 used) C—Control Valve-to-Hydraulic Oil Tank Return Line D—Oil Cooler-to-Hydraulic Oil Tank Return Line

E—Cap Screw and Lock Washer (2 used) F—Clamp (2 used) G—Swing Motor Make-Up Oil Restriction Valve

3. Loosen nuts on coupling (I). Slide coupling onto oil cooler-to-hydraulic oil tank return line (D).

H—Snap Ring I—Coupling J—Oil Cooler K—Control Valve

L—Oil Cooler Bypass Valve M—O-Ring N—Cap Screw (2 used)

Repair or replace swing motor make-up oil restriction valve (G) and snap ring (H).

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Hydraulic System 4. Tighten nuts on coupling. Swing Motor Make-Up Oil Restriction Valve—Specification Return Line-to-Oil Tank Coupling Nut—Torque ................................ 10.3—12.4 N•m (91—110 lb-in.)

5. Check oil level in hydraulic oil tank. Add oil as necessary. (See Hydraulic Oil in the Fuels and Lubricants Group.)

TX,33,UU3694 –19–17MAY00–3/3

Remove and Install Oil Cooler Bypass Valve

T7869AT

–UN–12NOV92

A—Vent Plug

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T106003

–UN–15JAN97

Hydraulic System

A—Hydraulic Oil Tank B—Coupling (2 used) C—Control Valve-to-Hydraulic Oil Tank Return Line D—Oil Cooler-to-Hydraulic Oil Tank Return Line

E—Cap Screw and Lock Washer (2 used) F—Clamp (2 used) G—Swing Motor Make-Up Oil Restriction Valve

3. Loosen nuts on coupling (B). Slide coupling onto the control valve-to-hydraulic oil tank return line (C). Remove cap screws (N) to remove line.

H—Snap Ring I—Coupling J—Oil Cooler K—Control Valve

L—Oil Cooler Bypass Valve M—O-Ring N—Cap Screw (2 used)

Repair or replace oil cooler bypass valve (L).

33 3360 ,126

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Hydraulic System 4. Tighten nuts on coupling. Oil Cooler Bypass Valve—Specification Return Line-to-Oil Tank Coupling Nut—Torque ................................ 10.3—12.4 N•m (91—110 lb-in.)

5. Check oil level in hydraulic oil tank. Add oil as necessary. (See Hydraulic Oil in the Fuels and Lubricants Group.)

TX,33,UU3695 –19–17MAY00–3/3

Remove and Install Oil Cooler

–UN–23AUG88

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

TS281

TX,33,UU3696 –19–23JUN97–1/6

–UN–12NOV92

T7869AT

2. Loosen vent plug (A) to release air pressure from hydraulic oil tank. A—Vent Plug

33 3360 ,127

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Hydraulic System 3. Remove parts (A—E).

–UN–19NOV96

4. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal). 5. Remove cover under the radiator and oil cooler.

T105161B

6. For machines with air conditioning, remove cap screws and lay the condenser on the battery cover. CAUTION: The approximate weight of radiator and oil cooler is 141 kg (310 lb). Oil Cooler—Specification Radiator and Oil Cooler—Weight .................. 141 kg (310 lb) approximate

7. Connect a hoist to lifting eyes on radiator. 8. Disconnect upper radiator hose (A). Remove fan guard (B), fan (D) and fan spacer (E). Remove cap screws from radiator braces (F). 9. Disconnect lower radiator hose (C). Remove cap screws (M) and clamps (L). Loosen nuts on couplings (H and N). Slide couplings onto the lines (K and O). Install cap and plugs. –UN–16JAN97

10. Remove the frame-to-radiator bracket cap screws (G).

T106221

A—Upper Radiator Hose B—Fan Guard C—Lower Radiator Hose D—Fan E—Fan Spacer F—Radiator Braces (2 used) G—Frame-to-Radiator Bracket Cap Screw (4 used) H—Coupling I—Snap Ring J—Swing Motor Make-Up Oil Restriction Valve K—Oil Cooler-to-Hydraulic Oil Tank Return Line L—Clamp (2 used) M—Cap Screw and Lock Washer (2 used) N—Coupling O—Control Valve-to-Oil Cooler Line P—Oil Cooler

33 3360 ,128

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Hydraulic System 11. Carefully remove radiator and oil cooler.

Continued on next page

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–UN–17JAN97

Hydraulic System

TP54452

33 3360 ,130

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Hydraulic System 1—Fan Guard 2—Cap Screw (4 used) 3—Washer (4 used) 4—Radiator 5—Drain Valve 6—Radiator Cap

7—Radiator Support 8—Nut (2 used) 9—Radiator Support 10—Nut (2 used) 11—Nut 12—Shroud

13—Washer (2 used) 14—Cap Screw (2 used) 15—Lock Washer (6 used) 16—Cap Screw (8 used) 17—Washer (16 used) 18—Cap Screw (20 used)

12. Repair or replace oil cooler. 13. Tighten nuts on couplings for oil cooler lines. Oil Cooler—Specification Return Line-to-Oil Tank Coupling Nut—Torque ................................ 10.3—12.4 N•m (91—110 lb-in.)

Tighten worm gear type clamps on upper and lower radiator hoses. Oil Cooler—Specification Oil Tank Elbow-to-Suction Line Worm Gear Type Clamp— Torque.................................................... 5.9—6.9 N•m (52—61 lb-in.)

19—Washer (20 used) 20—Baffle (2 used) 21—Baffle 25—Oil Cooler 26—Bracket

14. Check oil level in hydraulic oil tank. Add oil as necessary. (See Hydraulic Oil in the Fuels and Lubricants Group.) 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. Do the Hydraulic Pump Start-Up Procedure. (See procedure in this group.)

TX,33,UU3696 –19–23JUN97–6/6

Remove and Install Boom Cylinder NOTE: Procedure is the same for both left and right boom cylinders; right boom cylinder is shown. –UN–10JAN97

1. Park machine on a firm, level surface.

T106031

Retract arm and bucket cylinders. Lower boom so bucket in on the ground. Stop the engine.

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Hydraulic System

–UN–12NOV92

T7869AT

2. Loosen vent plug (A) to release air pressure from hydraulic oil tank. A—Vent Plug

TX,33,UU3697 –19–17MAY00–2/5

3. Disconnect lubricant line at rod end of cylinder. CAUTION: The approximate weight of boom cylinder is 255 kg (562 lb). –UN–30DEC96

Boom Cylinder—Specification Boom Cylinder—Weight ................................ 255 kg (562 lb) approximate

T105734

4. Connect boom cylinder (F) to hoist using a lifting strap. 5. Remove retainer ring (A), pin (C), retainer (B) and shims (D). Take notice of location of shim for assembly. 6. Push boom cylinder-to-boom pin (E) into the boom. Lower boom cylinder (F) onto a floor stand.

T105828

–UN–30DEC96

A—Retainer Ring B—Retainer C—Pin D—Shim (as required) E—Boom Cylinder-to-Boom Pin F—Boom Cylinder

33 3360 ,132

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Hydraulic System

–UN–08DEC08

X9811

8. Take notice of washer (J) locations for assembly. Remove parts (H—K) to remove cylinder. 9. Repair or replace cylinder. 10. Install washers (J) equally on each side of cylinder head end to get the minimum amount of clearance in joint.

–UN–09JAN97

11. Align pin bores so dust seals are not damaged as boom cylinder-to-frame pin (K) is installed.

T106085

Install pin (H) and retainer ring (I). 12. Connect the lines (G). G—Rod End-to-Boom Section Bottom Port Line —Head End-to-Boom Section Top Port Line H—Pin I—Retainer Ring J—Washer (as required) K—Boom Cylinder-to-Frame Pin

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Hydraulic System

–UN–30DEC96

IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retracted and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage.

T105828

13. Start the engine. Slowly extend boom cylinder (F) to align pin bores so dust seals are not damaged as cylinder-to-boom pin (E) is installed. 14. Install shims (D) to get the minimum amount of clearance between boom and cylinder rod end.

–UN–30DEC96

Install retainer (B), pin (C) and retainer ring (A). 15. Connect lubricant line.

T105734

Lubricate all pivot joints. (See Grease in the Fuels and Lubricant Group.) 16. Bleed air from cylinder. (See procedure in this group.) 17. Check oil level in hydraulic oil tank. Add oil as necessary. (See Hydraulic Oil in the Fuels and Lubricants Group.)

A—Retainer Ring B—Retainer C—Pin D—Shim (As Required) E—Boom Cylinder-to-Boom Pin F—Boom Cylinder

TX,33,UU3697 –19–17MAY00–5/5

Remove and Install Arm Cylinder 1. Park machine on a firm, level surface.

–UN–10JAN97

Stop the engine.

T106031

33 3360 ,134

Retract arm and bucket cylinders. Lower boom so bucket in on the ground.

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Hydraulic System

–UN–12NOV92

T7869AT

2. Loosen vent plug (A) to release air pressure from hydraulic oil tank. A—Vent Plug

TX,33,UU3698 –19–17MAY00–2/5

CAUTION: The approximate weight of arm cylinder is 318 kg (700 lb).

–UN–09JAN97

Arm Cylinder—Specification Arm Cylinder—Weight ................................... 318 kg (700 lb) approximate

3. Connect arm cylinder (A) to a hoist using lifting straps.

T106116

4. Remove retainer ring (B) and pin (C). 5. Take notice of washer (D) locations for assembly. Remove arm cylinder-to-arm pin (E). A—Arm Cylinder B—Retainer Ring C—Pin D—Washer (As Required) E—Arm Cylinder-to-Arm Pin

Continued on next page

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Hydraulic System

–UN–08DEC08

X9811

7. Remove parts (H—K) to remove arm cylinder (A). Take notice of location of washers (I) for assembly. 8. Repair or replace cylinder. 9. Install washers (I) equally on each side of cylinder head and rod ends to get the minimum amount of clearance in joints.

–UN–09JAN97

10. Align pin bores so dust seals are not damaged as arm cylinder-to-boom pin (J) is installed. Install pin (H) and retainer ring (K).

T106127

11. Connect lubricant line (G) and hydraulic lines (F).

A—Arm Cylinder F—Arm Cylinder Head End-to-Arm Section Bottom Port Line —Arm Cylinder Rod End-to-Arm Section Top Port Line G—Lubricant Line H—Pin I—Washer (As Required) J—Arm Cylinder-to-Boom Pin K—Retainer Ring

12. Start the engine. Slowly extend cylinder to align pin bores so dust seals are not damaged as arm cylinder-to-arm pin is installed. Install pin and retainer ring. 13. Lubricate all pivot joints. (See Grease in the Fuels and Lubricant Group.) 14. Bleed air from cylinder. (See procedure in this group.) 33 3360 ,136

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Hydraulic System 15. Check oil level in hydraulic oil tank. Add oil as necessary. (See Hydraulic Oil in the Fuels and Lubricants Group.)

TX,33,UU3698 –19–17MAY00–5/5

Remove and Install Bucket Cylinder 1. Park machine on a firm, level surface.

–UN–10JAN97

2. Retract arm and bucket (B) cylinders. Lower boom so bucket is on the ground and end of arm (C) is on a wooden block (D).

T106031

3. Stop the engine.

T106135

–UN–09JAN97

B—Bucket C—End of Arm D—Wooden Block

TX,33,UU3699 –19–17MAY00–1/5

–UN–12NOV92

T7869AT

4. Loosen vent plug (A) to release hydraulic pressure in reservoir. A—Vent Plug

33 3360 ,137

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Hydraulic System

–UN–08DEC08

X9811

6. Connect center link to a hoist using a lifting strap. 7. Put a wooden block between bucket cylinder and arm to hold cylinder up when side and center links-to-bucket cylinder pin (I) is removed. 8. Remove retainer ring (E) and pin (F).

–UN–09JAN97

9. As side and center links-to-bucket cylinder pin is removed, lower links to the ground. Take notice of washer (G) locations for assembly.

T106137

–UN–09JAN97

T106136

B—Bucket Cylinder E—Retainer Ring F—Pin G—Washer (As Required) H—Bucket Cylinder Rod End-to-Bucket Section Top Port Line —Bucket Cylinder Head End-to-Bucket Section Bottom Port Line I—Side and Center Links-to-Bucket Cylinder Pin J—Side Link

Continued on next page

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Hydraulic System

CAUTION: The approximate weight of bucket cylinder is 222 kg (490 lb).

–UN–09JAN97

Bucket Cylinder—Specification Bucket Cylinder—Weight............................... 222 kg (490 lb) approximate

10. Connect bucket cylinder (B) to hoist using a lifting strap.

T106142

11. Remove retainer ring (K) and pin (L). 12. Take notice of washer (M) locations for assembly. Remove bucket cylinder-to-arm pin (N). Remove cylinder. 13. Repair or replace cylinder.

B—Bucket Cylinder K—Retainer Ring L—Pin M—Washer (As Required) N—Bucket Cylinder-to-Arm Pin

14. Install washers equally on each side of bucket cylinder head end to get the minimum amount of clearance in joint. 15. Align pin bores so dust seals are not damaged as bucket cylinder-to-arm pin is installed. Install pin and retainer ring. 16. Connect the hydraulic lines.

Continued on next page

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Hydraulic System

T106136

–UN–09JAN97

IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 17. Start the engine. Slowly extend bucket cylinder (B) to align pin bores so dust seals are not damaged as bucket cylinder-to-side and center links pin (I) is installed.

–UN–09JAN97

18. Install washers (G) equally on each side of cylinder rod end and side links to get the minimum amount of clearance in joint.

T106137

Install pin (F) and retainer ring (E). 19. Lubricate all pivot joints. (See Grease in the Fuels and Lubricant Group.) 20. Bleed air from cylinder. (See procedure in this group.) 21. Check oil level in hydraulic oil tank. Add oil as necessary. (See Hydraulic Oil in the Fuels and Lubricants Group.)

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Hydraulic System

Hydraulic Cylinder Bleed Procedure IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. NOTE: Bleed air at initial start-up, whenever major repairs or maintenance (oil change) is done on hydraulic system, or when machine has been in storage for a period of time. 1. Run engine at slow idle. 2. Slowly operate function to move cylinder to the most horizontal position possible. 3. Slowly extend and retract cylinder several times to approximately 100 mm (4 in.) from end of stroke. 4. Operate cylinder several times to full stroke.

TX,33,GG2374 –19–06DEC96–1/1

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Hydraulic System

T106211

–UN–16JAN97

Disassemble Boom, Arm or Bucket Cylinder

Boom Cylinder 1—Cylinder Barrel and Bushing 2—Rod and Bushing 3—Rod Guide 4—Wear Ring 5—Snap Ring

6—Buffer Ring Seal 7—U-Cup Seal 8—Backup Ring 9—Wiper Seal 10—O-Ring 11—Backup Ring

12—Cap Screw (12 used) 13—Cushion 14—Cushion Seal 15—Piston 16—Cap Seal and O-Ring 17—Backup Ring (2 used)

Continued on next page

18—Buffer Seal (2 used) 19—Wear Ring 20—Shim 21—Nut 22—Set Screw 23—Steel Ball

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T106126

–UN–16JAN97

Hydraulic System

Arm Cylinder 1—Cylinder Barrel and Bushing 2—Rod and Bushing 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal

7—U-Cup Seal 8—Backup Ring 9—Wiper Seal 10—O-Ring 11—Backup Ring 12—Cap Screw (12 used) 13—Cushion

14—Cushion Seal 15—Piston 16—Cap Seal and O-Ring 17—Backup Ring (2 used) 18—Buffer Seal (2 used) 19—Wear Ring 20—Shim

Continued on next page

21—Nut 22—Set Screw 23—Steel Ball 24—Cushion 25—Cushion Seal 26—Retainer Ring 27—Ring

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PN=531

T106212

–UN–17JAN97

Hydraulic System

Bucket Cylinder 1—Cylinder Barrel and Bushing 2—Rod and Bushing 3—Rod Guide 4—Wear Ring 5—Snap Ring

6—Buffer Ring Seal 7—U-Cup Seal 8—Backup Ring 9—Wiper Seal 10—O-Ring 11—Backup Ring

12—Cap Screw (12 used) 13—Cushion 14—Piston 15—Cap Seal and O-Ring 16—Backup Ring (2 used) 17—Buffer Seal (2 used)

Continued on next page

18—Wear Ring 19—Shim 20—Nut 21—Set Screw 22—Steel Ball

TX,33,UU3700 –19–21JAN09–3/11

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PN=532

Hydraulic System

CAUTION: The approximate weight of boom cylinder is 255 kg (560 lb).

–UN–27OCT88

The approximate weight of arm cylinder is 318 kg (700 lb). The approximate weight of bucket cylinder is 222 kg (490 lb).

Arm Cylinder—Specification Arm Cylinder—Weight ................................... 318 kg (700 lb) approximate

T6557HI

Boom Cylinder—Specification Boom Cylinder—Weight ................................ 255 kg (560 lb) approximate

A—Cap Screw B—Line

Bucket Cylinder—Specification Bucket Cylinder—Weight............................... 222 kg (490 lb) approximate

NOTE: Disassemble procedure is the same for all cylinders except as noted. Disassemble of cylinder is shown using the JT30043 Cylinder Service Stand. 1. Fasten head end of cylinder to cylinder service stand. 2. Remove line (B). 3. Pull rod out so piston is against rod guide. 4. Connect rod to a hoist using a lifting strap. 5. Remove cap screws (A). 6. Pull rod, rod guide and piston from barrel.

TX,33,UU3700 –19–21JAN09–4/11

7. Install rod eye in sliding housing (B). Install housing in the cylinder service stand.

T6557HK

–UN–27OCT88

B—Sliding Housing and Stand Assembly

Continued on next page

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270LC Excavator Repair 012809

PN=533

33 3360 ,145

Hydraulic System 8. Remove the staked material from set screw (A) hole using a small air grinder or a drill and bit. 9. Remove set screw (A). Remove the steel ball (B).

T6585XI

–UN–27OCT88

A—Set Screw B—Steel Ball

TX,33,UU3700 –19–21JAN09–6/11

10. Loosen the nut (A) using JT5794 Wrench and JT05797 Adapter Plate for bucket cylinder, JT07332 Adapter Plate for boom cylinder, or JT05798 Adapter Plate for arm cylinder. Boom Cylinder—Specification Piston-to-Rod Nut—Torque ..................................... 4780 N•m (3525 lb-ft) Arm Cylinder—Specification Piston-to-Rod Nut—Torque ..................................... 9460 N•m (6980 lb-ft)

T6557HM

–UN–27OCT88

Bucket Cylinder—Specification Piston-to-Rod Nut—Torque ..................................... 5640 N•m (4160 lb-ft)

Continued on next page

TX,33,UU3700 –19–21JAN09–7/11

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PN=534

Hydraulic System 11. Remove nut (A), shim (B), piston (C), and cushion (D).

–UN–27OCT88

Take notice of the direction of flat face (E) on cushion and notches (G) in cushion seal and cushion for assembly. For bucket cylinder, no cushion seal is used.

T8286BL

–UN–16JUL94

T6585XK

A—Nut B—Shim C—Piston D—Cushion E—Flat Face F—Notch G—Cushion Seal

TX,33,UU3700 –19–21JAN09–8/11

12. For arm cylinder, remove ring (A) using a punch and a hammer. Push cushion (C) against shoulder. –UN–10JUN92

Remove retainer ring (B). Remove cushion.

T7778AU

Take notice of the direction of flat face on cushion and notches in cushion seal for assembly. Remove cushion seal (D). Arm Cylinder Rod End Cushion

13. Remove the rod guide. Remove parts from rod guide and piston. Inspect the piston, inside the rod guide and barrel for wear, scratches and nicks that may cut or damage a seal or wear ring.

A—Ring B—Retainer Ring C—Cushion D—Cushion Seal

33 3360 ,147

Continued on next page

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270LC Excavator Repair 012809

PN=535

Hydraulic System 14. Inspect dust seals (A) and bushing (B) for wear or damage, replace as necessary. (See Remove and Install Bushings and Seals in Group 3340.)

–UN–27OCT88

Boom Cylinder—Specification Head End or Rod End Bushing— ID ....................................................................... 100 mm (3.94 in) nominal 101.5 (4.00) limit of use

T6557HR

Arm Cylinder—Specification Head End or Rod End Bushing— ID ........................................................................ 90 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use Bucket Cylinder—Specification Head End Bushing—ID ................................... 80.0 mm (2.80 in.) nominal 81.5 mm (3.21 in.) limit of use Rod End Bushing—ID ..................................... 90.0 mm (3.54 in.) nominal 91.5 mm (3.60 in.) limit of use

–UN–27OCT88

15. Check for rod curvature.

T6585XG

Put rod on V-blocks. Measure for rod curvature using a dial indicator. Boom Cylinder—Specification Boom Rod—Curvature ..................................................... 0.5 mm per 1 m (0.020 in. per 3.25 ft) Arm Cylinder—Specification Arm Rod—Curvature ........................................................ 0.5 mm per 1 m (0.020 in. per 3.25 ft)

A—Dust seals B—Bushing

Bucket Cylinder—Specification Bucket Rod—Curvature.................................................... 0.5 mm per 1 m (0.020 in. per 3.25 ft)

16. Inspect rod surface for scratches or wear. Boom Cylinder—Specification Boom Rod Allowable Scratch— Depth .......................................................... 0.1 mm (0.004 in.) (enough to detect by a fingernail) Boom Rod—OD........................................... 90 + 0.036 mm — 0.090 mm (3.543 + 0.001 in. — 0.004 in.) Arm Cylinder—Specification Arm Rod Allowable Scratch— Depth .......................................................... 0.1 mm (0.004 in.) (enough to detect by a fingernail) Arm Rod—OD ............................................... 100 +.036 mm — 0.090 mm (3.937 + 0.001 in. — 0.004 in.)

33 3360 ,148

Continued on next page

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TX,33,UU3700 –19–21JAN09–10/11

270LC Excavator Repair 012809

PN=536

Hydraulic System Bucket Cylinder—Specification Bucket Rod Allowable Scratch— Depth .......................................................... 0.1 mm (0.004 in.) (enough to detect by a fingernail) Bucket Rod—OD ......................................... 85 + 0.036 mm — 0.090 mm (3.346 + 0.001 in. — 0.004 in.)

TX,33,UU3700 –19–21JAN09–11/11

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PN=537

Hydraulic System

TP48030

–UN–30MAY96

Assemble Boom, Arm or Bucket Cylinder

Boom Cylinder 33 3360 ,150

Continued on next page

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TX,33,GG2437 –19–21JAN09–1/17

270LC Excavator Repair 012809

PN=538

Hydraulic System 1—Cylinder Barrel and Bushing 1A—Cylinder Barrel 1B—Bushing (2 used) 2—Rod and Bushing 2A—Rod 2B—Bushing (2 used) 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal

7—U-Cup Seal 8—Backup Ring 9—Wiper Seal 10—O-Ring 11—Backup Ring 12—Cap Screw (12 used) 13—Cushion 14—Cushion Seal 15—Piston 16—Cap Seal and O-Ring 17—Backup Ring (2 used)

18—Buffer Seal (2 used) 19—Wear Ring 20—Shim 21—Nut 22—Set Screw 23—Steel Ball 25—Dust Seal (4 used) 26—Head End Line 27—Rod End Line 28—O-Ring 29—Cap Screw (4 used)

Continued on next page

30—O-Ring 31—Cap Screw (4 used) 32—Clamp 33—Clamp 34—Cap Screw (2 used) 35—Lock Washer (2 used) 36—Half Clamp (2 used) 37—Cap Screw 38—Lock Washer 39—Lubrication Fitting

TX,33,GG2437 –19–21JAN09–2/17

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PN=539

TP48028

–UN–30MAY96

Hydraulic System

Arm Cylinder

Continued on next page

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PN=540

Hydraulic System 31—Rod 19—Wear 1—Cylinder End RingLine Ring Barrel and Bushing NOTE:8—Backup Use a cylinder repair kit when assembling a 9—Wiper 20—Shim 32—O-Ring 1A—Cylinder Seal (2 used) Barrel rebuildable cylinder. 10—O-Ring 21—Nut 33—Cap 1B—Bushing Screw (8 used) (2 used) 11—Backup 22—Set 34—Clamp 2—Rod Screw Ring and Bushing The 12—Cap 23—Steel 35—Clamp 2A—Rod Screw Ball left (12 and used)right boom cylinders are the same except(2 for head (26) and rod (27) end 13—Cushion 24—Cushion 36—Cap 2B—Bushing Screw used) (2the used) 14—Cushion 25—Cushion 37—Lock 3—Rod Washer Seal Guide (2 used) lines, and clamps (32 and 33). 15—Piston 26—Retainer 38—Clamp 4—Wear Ring Ring 16—Cap 27—Ring 39—Cap 5—Snap Seal and Screw Ring O-Ring 17—Backup 29—Dust 40—Lock 6—Buffer Seal Washer Ring (4 Ring used) (2 used) Seal 18—Buffer 30—Head 41—Lubrication 7—U-Cup End SealAdapter (2 Fitting Seal used)

Continued on next page

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PN=541

TP48051

–UN–28MAY96

Hydraulic System

Bucket Cylinder

Continued on next page

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PN=542

7—U-Cup Seal 8—Backup Ring 9—Wiper Seal 10—O-Ring 11—Backup Ring 12—Cap Screw (12 used) 13—Cushion 14—Piston 15—Cap Seal and O-Ring 16—Backup Ring (2 used)

17—Buffer Seal (2 used) 18—Wear Ring 19—Shim 20—Nut 21—Set Screw 22—Steel Ball 24—Dust Seal (2 used) 26—Dust Seal (2 used) 27—Elbow Fitting 28—Rod End Line

29—O-Ring (2 used) 30—Cap Screw (8 used) 31—Clamp 32—Clamp 33—Cap Screw (2 used) 34—Lock Washer (2 used) 35—Clamp 36—Cap Screw 37—Lock Washer 38—Lubrication Fitting

1. Install bushing (1B and 2B) to a depth equal to the thickness of dust seals. 2. Install dust seals tight against bushing with seal lip outward. (See Remove and Install Bushings and Seals in Group 3340.)

TX,33,GG2437 –19–21JAN09–6/17

3. Push wear ring (C) to bottom of bore using a driver disk and a press. 4. Install the snap ring (B).

T6585XN

–UN–27OCT88

5. Install backup ring (A) and O-ring (D).

Continued on next page

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PN=543

Hydraulic System 6. Install buffer ring seal (I) with notched side towards wear ring (B) Install black buffer ring (D) with notched side (C) towards the wear ring. Install green buffer ring (E). 7. Install U-cup seal (F) with lip towards wear ring (B) using the bending method (K) Install backup ring (G). 8. Install wiper seal (H) so lip is towards outside of cylinder. 9. Install rod guide (J) on the rod.

–UN–22OCT91

T7963AK

–UN–01APR93

A—Snap Ring B—Wear Ring C—Notched Side D—Black Buffer Ring E—Green Buffer Ring F—U-Cup Seal G—Backup Ring H—Wiper Seal I—Buffer Ring Seal J—Rod Guide K—Bending Method Seal Installation

T7623AF

33 3360 ,156

Continued on next page

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270LC Excavator Repair 012809

PN=544

Hydraulic System 10. Install O-ring (C) into the middle groove of piston. 11. Install the buffer seals (D). The buffer seal in groove above helps support the thin section of installer. The buffer seal below keeps the cap seal from going into that groove if pushed too far. 12. Install the correct installer on the boom, arm or bucket piston. Apply clean oil to installer. 13. Push the cap seal (B) down the installer and into the middle groove over the O-ring (C) using the correct size pusher (A).

T7964AQ

–UN–18MAR93

A—JDG8406 Pusher —JDG9013 Pusher —JDG841 Installer For Bucket —JDG917 Installer For Boom —JDG918 Installer For Arm B—Cap Seal C—O-Ring D—Wear Ring

TX,33,GG2437 –19–21JAN09–9/17

14. Check the cap seal, seal must fit tight against O-ring and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into cylinder barrel. 15. For a cap seal that has been stretched too much, shrink it to its original size using a ring compressor or a plastic tie band and hose clamp. When using a ring compressor, put a piece of shim stock between cap seal and compressor at the joint so it does not damage seal.

T6396AC

–UN–27OCT88

When using a plastic tie band and hose clamp, grind a taper on one end of tie band. Install tie band with the taper against cap seal. Before tightening the hose clamp, check to be sure tie band is under hose clamp all around piston.

Continued on next page

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PN=545

33 3360 ,157

Hydraulic System 16. Install a backup ring (C) on each side of cap seal. 17. Install the buffer seals (B) and wear rings (A).

–UN–27OCT88

Turn the seals and rings so the slits are 180° from each other

T6557HV

A—Wear Ring B—Buffer Seal C—Backup Ring

TX,33,GG2437 –19–21JAN09–11/17

NOTE: For bucket cylinder, no cushion seal is used under the cushion.

–UN–16JUL94

18. For boom cylinder, install cushion seal (G) so notches (F) are towards the piston and threaded section of rod.

T8286BL

For arm cylinder, install cushion seals (A and C) so notches (B) are towards the piston and threaded section of rod. 19. Install cushion (D) so wide end of flat face (E) is towards the rod guide and narrow end is towards the piston.

Boom Cylinder Rod

T7778AV

–UN–10JUN92

A—Cushion Seal B—Notch C—Cushion Seal D—Cushion E—Flat Face F—Notch G—Cushion Seal

Arm Cylinder Rod Continued on next page

TX,33,GG2437 –19–21JAN09–12/17

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PN=546

Hydraulic System 20. For arm cylinder, install cushion (C) so wide end of flat face is towards the end of rod and narrow end is towards the piston.

–UN–10JUN92

Install retainer ring in groove. Pull cushion out against retainer ring.

T7778AU

Install ring (A). A—Ring B—Retainer Ring C—Cushion D—Cushion Seal

Arm Cylinder Rod Cushion

TX,33,GG2437 –19–21JAN09–13/17

21. Install piston (C) so flat side is against the cushion (D) 22. Install shim (B).

T6585XK

–UN–27OCT88

23. Install nut (A).

Continued on next page

TX,33,GG2437 –19–21JAN09–14/17

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PN=547

Hydraulic System 24. Tighten the nut (A) using JT5794 Wrench and JT05797 Adapter Plate for bucket cylinder, JT07332 Adapter Plate for boom cylinder, or JT05798 Adapter Plate for arm cylinder. Boom Cylinder—Specification Piston-to-Rod Nut—Torque ..................................... 4780 N•m (3525 lb-ft) Arm Cylinder—Specification Piston-to-Rod Nut—Torque ..................................... 9460 N•m (6980 lb-ft)

T6557HW

–UN–27OCT88

Bucket Cylinder—Specification Piston-to-Rod Nut—Torque ..................................... 5640 N•m (4160 lb-ft)

TX,33,GG2437 –19–21JAN09–15/17

25. Install steel ball (B).

–UN–27OCT88

If indentation for steel ball in rod is not aligned with tapped hole, make a new indentation using a drill and a 10 mm bit or by striking the steel ball using a hammer and punch. 26. Tighten set screw (A).

T6585XI

Boom Cylinder—Specification Nut-to-Rod Set Screw—Torque ...................................... 57 N•m (42 lb-ft) Arm Cylinder—Specification Nut-to-Rod Set Screw—Torque ...................................... 57 N•m (42 lb-ft) Bucket Cylinder—Specification Nut-to-Rod Set Screw—Torque ...................................... 57 N•m (42 lb-ft)

27. Stake set screw in two places 90° from previous stake marks. 33 3360 ,160

Continued on next page

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TX,33,GG2437 –19–21JAN09–16/17

270LC Excavator Repair 012809

PN=548

Hydraulic System 28. Apply clean oil to piston and seals. Attach a hoist to rod using a lifting strap. Carefully install piston, rod and rod guide into barrel.

Arm Cylinder—Specification Rod Guide-to-Barrel Cap Screw— Torque ......................................................................... 833 N•m (615 lb-ft)

T6557HI

Boom Cylinder—Specification Rod Guide-to-Barrel Cap Screw— Torque ......................................................................... 833 N•m (615 lb-ft)

–UN–27OCT88

29. Tighten cap screws (A).

Bucket Cylinder—Specification Rod Guide-to-Barrel Cap Screw— Torque ......................................................................... 833 N•m (615 lb-ft)

30. Install the lines (B).

TX,33,GG2437 –19–21JAN09–17/17

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PN=549

Hydraulic System

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PN=550

Section 43

Swing or Pivoting System Contents Page

Group 4350—Mechanical Drive Elements Service Equipment and Tools . . . . . . . . . . . .43-4350-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .43-4350-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . .43-4350-3 Swing Gearbox Remove and Install . . . . . . . . . . . . . . . . . .43-4350-4 Start-Up Procedure . . . . . . . . . . . . . . . . . .43-4350-6 Disassemble and Assemble. . . . . . . . . . . .43-4350-8 Upperstructure Remove . . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-15 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-20 Swing Bearing Remove and Install . . . . . . . . . . . . . . . . .43-4350-23 Disassemble and Assemble. . . . . . . . . . .43-4350-25 Install Upper Seal . . . . . . . . . . . . . . . . . .43-4350-28 Install Lower Seal . . . . . . . . . . . . . . . . . .43-4350-29 Group 4360—Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . .43-4360-1 Swing Motor and Park Brake Remove and Install . . . . . . . . . . . . . . . . . .43-4360-1 Start-Up Procedure . . . . . . . . . . . . . . . . . .43-4360-3 Disassemble . . . . . . . . . . . . . . . . . . . . . . .43-4360-4 Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-9 Swing Motor Make-Up and Crossover Relief Valves Disassemble and Assemble. . . . . . . . . . .43-4360-15 Swing Motor Park Brake Release Valve Disassemble and Assemble. . . . . . . . . . .43-4360-17

TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

43-2

270LC Excavator Repair 012809

PN=2

Group 4350

Mechanical Drive Elements Service Equipment and Tools 43 4350 1

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,21695 –19–17MAY00–1/8

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . JT01748 To remove and install swing bearing.

CED,OUOE003,21695 –19–17MAY00–2/8

Barrel Support . . . . . . . . . . . . . . . . . . . . . . DFT10891 Used with bridge planks, hardwood blocks, and a wide flange beam to support the upperstructure.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21695 –19–17MAY00–3/8

Bridge Planks Use with barrel supports to support upperstructure.

CED,OUOE003,21695 –19–17MAY00–4/8

3.7 m (12 ft) Length of W8 x 28 lb Wide Flange Beam Use with barrel supports to support upperstructure.

CED,OUOE003,21695 –19–17MAY00–5/8

Service Jack . . . . . . . . . . . . . . . . . . . . . 18-t (20-Ton) Placed under each end of undercarriage to support upperstructure. Continued on next page

TM1668 (28JAN09)

43-4350-1

CED,OUOE003,21695 –19–17MAY00–6/8

270LC Excavator Repair 012809

PN=553

Mechanical Drive Elements Guide Pin . . . . . . . . . . . . . . . . . . . . . . . . . DFT11441 43 4350 2

To align cap screw holes in swing bearing with holes in main frame.

1 Fabricated tool, dealer made. (See Section 99 for instructions to make tool.)

CED,OUOE003,21695 –19–17MAY00–7/8

M10-1.25 Cap Screw To remove loading plug from swing bearing.

CED,OUOE003,21695 –19–17MAY00–8/8

Other Material Number

Name

Use

T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE)

Thread Lock and Sealer (High Strength)

Apply to swing gearbox seal bore.

TY16285 (U.S.) CXTY16285 (Canadian) 7649 (LOCTITE)

Cure Primer

To speed cure time of adhesives and sealants.

TY9375 (U.S.) TY9480 (Canadian) 592 (LOCTITE)

Pipe Sealant

Apply to swing gearbox cover.

T43514 (U.S.) TY9475 (Canadian) 277 (LOCTITE)

Rigid Form-In-Place Gasket

Apply to the swing bearing mating surface on the undercarriage.

TY2098 (U.S.)

Multi-Purpose Grease

To provide a light seal between surfaces.

TY21517 (U.S.) NA (Canadian) 454 (LOCTITE)

Instant Gel Adhesive

To bond upper and lower seal to swing bearing.

LOCTITE is a trademark of Loctite Corp.

TM1668 (28JAN09)

CED,OUOE003,21696 –19–05JUL01–1/1

43-4350-2

270LC Excavator Repair 012809

PN=554

Mechanical Drive Elements

Specifications Item

43 4350 3

Measurement

Specification

Swing Motor, Brake, and Gearbox

Weight

330 kg (730 lb) approximate

Gearbox-to-Frame Cap Screw

Torque

640 N•m (470 lb-ft)

Swing Motor and Brake

Weight

66 kg (146 lb) approximate

Output Shaft Cover-to-Gearbox Cap Screw

Torque

85 N•m (65 lb-ft)

Ring Gear-to-Housing Cap Screw

Torque

206 N•m (152 lb-ft)

Swing Motor-to-Ring Gear Cap Screw

Torque

88 N•m (65 lb-ft)

Machine

Weight

20 329 kg (44,818 lb)

Boom of Main Frame-to-Floor Clearance

Height

1473 mm (58 in.) minimum 1400 m (55 in.) maximum

Bottom of Main Frame-to-Floor Clearance

Height

1473 mm (58 in.) minimum 1524 mm (60 in.) maximum

Undercarriage

Weight

3039 kg (6700 lb) approximate

Swing Bearing-to-Upperstructure Cap Screw

Torque

640 N•m (470 lb-ft)

Swing Bearing

Weight

331 kg (730 lb) approximate

Undercarriage-to-Bearing Cap Screw

Torque

740 N•m (540 lb-ft)

Swing Gearbox

Upperstructure

Swing Bearing

CED,OUOE003,21697 –19–17MAY00–1/1

TM1668 (28JAN09)

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270LC Excavator Repair 012809

PN=555

Mechanical Drive Elements

Remove and Install Swing Gearbox

–UN–12NOV92

T7869AT

43 4350 4

NOTE: Swing motor may be removed separately. 1. Loosen vent plug (A) to release air pressure from hydraulic oil tank.

A—Vent Plug

2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. Approximate capacity is 148 L (39 gal).

Continued on next page

TM1668 (28JAN09)

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TX,43,UU3702 –19–17MAY00–1/3

270LC Excavator Repair 012809

PN=556

Mechanical Drive Elements

43 4350 5

3. Disconnect lines (A—F).

X9811

4. Remove cap screws (G).

T105900

–UN–19DEC96

T105899

–UN–19DEC96

A—Motor Drain-to-Hydraulic Oil Tank B—To Swing Valve Section (Top) C—To Swing Valve Section (Bottom) D—To Control Valve (Pilot Oil) E—To Solenoid Valve Manifold F—To Control Valve G—Cap Screw (12 used)

Continued on next page

TM1668 (28JAN09)

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TX,43,UU3702 –19–17MAY00–2/3

270LC Excavator Repair 012809

PN=557

Mechanical Drive Elements

Swing Gearbox—Specification Swing Motor, Brake, and Gearbox—Weight .......................................... 330 kg (730 lb) approximate

T7685NL

5. Remove swing motor and gearbox using lifting brackets, such as JT01748 Lifting Brackets, and hoist.

–UN–07MAY92

CAUTION: The approximate weight of swing motor, brake, and gearbox is 330 kg (730 lb).

6. Repair or replace parts as necessary. 7. Install swing motor and gearbox. Tighten cap screws. Swing Gearbox—Specification Gearbox-to-Frame Cap Screw— Torque ......................................................................... 640 N•m (470 lb-ft)

8. Connect lines. 9. Do swing gearbox start-up procedure. Do swing motor and brake start-up procedure. (See procedures in this group and Group 4360.)

TX,43,UU3702 –19–17MAY00–3/3

Swing Gearbox Start-Up Procedure IMPORTANT: Swing gearbox will be damaged if not filled with oil before operating swing function. Procedure must be performed whenever a new swing gearbox is installed or oil has been drained from the gearbox. 1. Check that drain line (A) plug is installed. 2. Remove fill cap (B). Add oil. (See Swing Gearbox, Propel Gearbox 3. Install fill cap. Check oil level on dipstick.

–UN–13JUN97

A—Drain Line B—Fill Cap

T109982B

43 4350 6

TX,43,SB522 –19–26JAN09–1/1

TM1668 (28JAN09)

43-4350-6

270LC Excavator Repair 012809

PN=558

Mechanical Drive Elements

43 4350 7

TM1668 (28JAN09)

43-4350-7

270LC Excavator Repair 012809

PN=559

Mechanical Drive Elements

Disassemble and Assemble Swing Gearbox

TP47900

–UN–14MAY96

43 4350 8

Continued on next page

TM1668 (28JAN09)

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TX,43,UU3703 –19–26JAN09–1/16

270LC Excavator Repair 012809

PN=560

Mechanical Drive Elements 00—Shaft 01—Sleeve 02—O-Ring 04—Roller Bearing 06—Seal 08—Cover 10—Housing 11—Roller Bearing 12—Snap Ring 13—Cap Screw

16—Planet Pinion Carrier 17—Plate 19—Gear 21—Plate 23—Pin 24—Spring Pin 26—O-Ring 28—Ring Gear 29—Screw 30—Sun Gear

32—Planet Pinion Carrier 33—Gear 34—Needle Bearing 35—Plate 36—Pin 37—Spring Pin 39—Sun Gear 41—Plug 43—Oil Line

44—Fitting Plug 70—Motor 71—Snap Ring 73—Screw 74—Pipe 76—Pipe 77—Cap 79—Gauge 82—Screw

43 4350 9

TX,43,UU3703 –19–26JAN09–2/16

1. Drain swing gearbox oil. Approximate capacity 13 L (14 qt).

–UN–07MAY92

CAUTION: The approximate weight of swing motor and brake is 66 kg (146 lb). Swing Gearbox—Specification Swing Motor and Brake—Weight .................... 66 kg (146 lb) approximate

T7685JX

2. Remove cap screws (B). Remove swing motor and brake (A). A—Swing Motor and Brake B—Cap Screw (12 used)

TX,43,UU3703 –19–26JAN09–3/16

3. Make alignment mark (D) on ring gear (E) and housing (F) for assembly.

–UN–19DEC96

4. Remove parts (A—C). Remove ring gear.

T105911

A—First Planet Pinion Carrier B—First Sun Gear C—Cap Screw (12 used) D—Alignment Mark E—Ring Gear F—Housing

Continued on next page

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TX,43,UU3703 –19–26JAN09–4/16

270LC Excavator Repair 012809

PN=561

Mechanical Drive Elements 5. Remove parts (A—C).

T7685JZ

–UN–07MAY92

A—Second Planet Pinion Carrier B—Second Sun Gear C—O-Ring

TX,43,UU3703 –19–26JAN09–5/16

6. Remove parts (A—D).

T7685DB

–UN–22JUN92

A—Cap Screw (8 used) B—Cover and O-Ring C—Seal D—Sleeve and O-Ring

TX,43,UU3703 –19–26JAN09–6/16

7. Remove snap ring (A). 8. Remove output shaft (C) using a press. Remove roller bearing (B).

–UN–07MAY92

T7685KB

–UN–07MAY92

A—Snap Ring B—Roller Bearing C—Output Shaft

T7685KC

43 4350 10

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TX,43,UU3703 –19–26JAN09–7/16

270LC Excavator Repair 012809

PN=562

Mechanical Drive Elements 9. Remove spring pin (E). 43 4350 11

10. Remove parts (A—D, and F).

T7685KD

–UN–07MAY92

A—Plate (6 used) B—First Planet Gear (3 used) C—Plate D—Pin (3 used) E—Spring Pin (3 used) F—Needle Bearing (3 used)

TX,43,UU3703 –19–26JAN09–8/16

11. Remove spring pin (D). 12. Remove parts (A—C and E).

–UN–09SEP98

13. Replace parts as necessary. 14. Install plate (E) with groove side up.

T117075

15. Install parts (A—C). 16. Install spring pin (D) with slit toward end of shaft. A—Plate (6 used) B—Second Planet Gear (3 used) C—Pin (3 used) D—Spring Pin (3 used)

TX,43,UU3703 –19–26JAN09–9/16

17. Install parts (A—D and F). 18. Install spring pin (E) with slit toward end of shaft.

T7685KD

–UN–07MAY92

A—Plate (6 used) B—First Planet Gear (3 used) C—Plate D—Pin (3 used) E—Spring Pin (3 used) F—Needle Bearing (3 used)

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270LC Excavator Repair 012809

PN=563

Mechanical Drive Elements 19. Install wear sleeve (B) tight against gear on shaft (D) as shown. 20. Install O-ring (C) on sleeve. 21. Install bearing (A) on shaft (D).

T105952

–UN–20DEC96

A—Bearing B—Wear Sleeve C—O-Ring D—Shaft

TX,43,UU3703 –19–26JAN09–11/16

22. Install roller bearing (B) and shaft (C). 23. Install snap ring (A).

–UN–07MAY92

T7685KB

–UN–07MAY92

A—Snap Ring B—Roller Bearing C—Shaft

T7685KC

43 4350 12

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270LC Excavator Repair 012809

PN=564

Mechanical Drive Elements 24. Place swing gearbox in a vertical position with output shaft facing up. Apply thread lock and sealer to the seal bore. Install seal (C) into cover (A).

43 4350 13 –UN–07MAY92

25. Clean surface of cover (A). Apply cure primer. Apply pipe sealant to cover.

T7685KA

Apply grease to lips of seal (C). Install cover (A) by turning cover back and forth while pushing down. Make sure seal lips are not rolled over by using a blunt flat tip screwdriver to lift lips. Make sure screwdriver tip has no burrs or sharp edges. Tighten cap screws (B). A—Cover B—Cap Screw (8 used) C—Seal D—Shaft

Swing Gearbox—Specification Output Shaft Cover-to-Gearbox Cap Screw—Torque ........................................................ 85 N•m (65 lb-ft)

TX,43,UU3703 –19–26JAN09–13/16

26. Turn gearbox onto output shaft. Install parts (A—C).

T7685JZ

–UN–07MAY92

A—Second Planet Pinion Gear B—Second Sun Gear C—O-Ring

TX,43,UU3703 –19–26JAN09–14/16

27. Install ring gear (F) aligning marks on housing (G). Tighten cap screws (D).

–UN–07MAY92

Swing Gearbox—Specification Ring Gear-to-Housing Cap Screw—Torque ............................................................ 206 N•m (152 lb-ft)

T7685JY

28. Install parts (A—C). Install first sun gear (C), stepped side down. A—O-Ring B—First Planet Pinion Gear C—First Sun Gear D—Cap Screw (12 used) E—Alignment Mark F—Ring Gear G—Housing

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270LC Excavator Repair 012809

PN=565

Mechanical Drive Elements 29. Install swing motor and brake (A). Tighten cap screws (B).

30. Install drain pipe. 31. Add gear oil. (See Swing Gearbox, Propel Gearbox

–UN–07MAY92

Swing Gearbox—Specification Swing Motor-to-Ring Gear Cap Screw—Torque ................................................................ 88 N•m (65 lb-ft)

T7685JX

43 4350 14

A—Swing Motor and Brake B—Cap Screw (12 used)

TX,43,UU3703 –19–26JAN09–16/16

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270LC Excavator Repair 012809

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Mechanical Drive Elements

Remove Upperstructure 43 4350 15

NOTE: Procedure requires two technicians. The cement floor must be a minimum of 102 mm (4 in.) thick. Area must be large enough so the upperstructure can be turned 180° with the angle between boom and arm at 90—100° and the tracks laid out flat on the floor.

–UN–24FEB92

1. Clean the machine thoroughly.

T7712AG

CAUTION: Keep the angle between boom and arm at 90—100° to prevent machine from sliding backwards. 2. Park machine with boom to the left side (cab side toward sprocket) of undercarriage. 3. Disconnect tracks and lay out flat on the floor to the sprocket end of undercarriage. (See procedure in Group 0130.) NOTE: To make removal of main frame-to-swing bearing cap screws easier after machine is raised into position, loosen the cap screws one turn at this time. 4. Turn upperstructure and raise the right side of machine, using boom down function.

TX,43,UU3704 –19–17MAY00–1/8

5. Put hardwood blocks (B), approximately 254 mm (10 in.), between lower track rollers (A) and track chain (C).

–UN–07MAY92

6. Turn upperstructure back to left side so it is 90° to track.

T7720AM

A—Track Roller B—Hardwood Block (As Required) C—Track Chain

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Mechanical Drive Elements

CAUTION: The approximate weight of machine without tracks is 20 329 kg (44,818 lb). Upperstructure—Specification Machine—Weight .................................................... 20 329 kg (44,818 lb)

7. Put two DFT1089 Barrel Supports (G) under the counterweight (D). (See Section 99 for instructions to make barrel supports.) To provide enough clearance, use bridge planks (E) and hardwood blocks (F) to raise the height of supports and planks to 1473 mm (58 in.). The height is the approximate clearance needed to clear the bottom of rotary manifold. Do not put blocks under cap screw heads. Keep the height to 1400 m (55 in.).

–UN–07MAY92

Upperstructure—Specification Boom of Main Frame-to-Floor Clearance—Height .......................................... 1473 mm (58 in.) minimum Height ................................................................ 1400 m (55 in.) maximum

A—Lower Track Roller B—Hardwood Block (As Required) C—Track Chain D—Counterweight E—Bridge Plank (As Required) F—Hardwood Block (As Required) G—DFT1089 Barrel Support (2 used)

T7720AS

43 4350 16

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Mechanical Drive Elements

T7720AO

–UN–07MAY92

43 4350 17

A—DFT1089 Barrel Support (2 used)

B—3.7 m (12 ft) Length of W8 x 28 lb Wide Flange Beam

C—Hardwood Block (As Required)

8. Slowly raise left side, using boom down function, until machine is level.

10. Lower machine so main frame and corner of cab is on the beam.

9. Put DFT1089 Barrel Supports (A) and a 3.7 m (12 ft) length of W8 x 28 lb Wide Flange Beam (B) under main frame at right boom cylinder and right corner of cab.

Check that bottom of main frame is 1473 mm (58 in.) off the floor and level. Keep height to a maximum of 1524 mm (60 in.).

NOTE: For maximum support, the barrel supports must be positioned so the beam is under the main frame and corner of cab as far as possible.

Upperstructure—Specification Bottom of Main Frame-to-Floor Clearance—Height.................................... 1473 mm (58 in.) minimum Height....................................................... 1524 mm (60 in.) maximum

Install hardwood blocks (C) as needed to make up for any unevenness.

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TX,43,UU3704 –19–17MAY00–4/8

270LC Excavator Repair 012809

PN=569

Mechanical Drive Elements 11. Install a 13 mm (1/2 in.) chain around boom cylinder head end boss on frame and rod end boss on boom. 43 Tighten chain just enough to remove the slack using 4350 a chain binder. 18

T7149AJ

–UN–05OCT89

12. Disconnect the negative battery cables.

TX,43,UU3704 –19–17MAY00–5/8

–UN–12NOV92

T7869AT

13. Loosen vent plug (A) to relieve hydraulic oil tank pressure. A—Vent Plug

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Mechanical Drive Elements

43 4350 19

X9811

14. Disconnect lines (C—H). Remove fittings for more clearance between rotary manifold and upperstructure. 15. Remove stop (A). 16. Remove cover (B).

T105974

–UN–09JAN97

A—Stop B—Cover C—P1-to-Proportional Solenoid Valve SH Port Line D—Port 2-to-Right Propel Section Bottom Port (Reverse) Line E—Port 4-to-Left Propel Section Bottom Port (Reverse) Line F—Port D-to-Return Manifold G—Port 3-to-Left Propel Section Top Port (Forward) Line H—Port 1-to-Right Propel Section Top Port (Forward) Line

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270LC Excavator Repair 012809

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Mechanical Drive Elements

CAUTION: The approximate weight of undercarriage is 3039 kg (6700 lb).

–UN–20DEC96

Upperstructure—Specification Undercarriage—Weight ............................. 3039 kg (6700 lb) approximate

17. Put a 20-ton service jack under each end of undercarriage. Use hardwood blocks is necessary.

T105961

18. Remove cap screws (B) from swing bearing (A). 19. Slowly lower undercarriage onto track chain. A—Swing Bearing B—Cap Screw

20. Lift sprocket end of undercarriage so sprocket clears track chain. 21. Pull undercarriage out from under the upperstructure. 22. Remove swing bearing. (See procedure in this group.)

TX,43,UU3704 –19–17MAY00–8/8

Install Upperstructure 1. Push undercarriage under upperstructure.

–UN–20DEC96

2. Install DFT1144 Guide Pins to help align holes in swing bearing (A) with holes in main frame. (See Section 99 for instructions to make tool.) 3. Raise undercarriage into position using two 20-ton service jacks. It may be necessary to turn swing bearing inner race to align teeth on swing motor pinion shaft.

T105961

43 4350 20

A—Swing Bearing B—Cap Screw (31 used)

NOTE: If all cap screws are not accessible, tighten them after the machine has been lowered and supports have been removed. 4. Install cap screws (B) and tighten cap screws. Upperstructure—Specification Swing Bearing-to-Upperstructure Cap Screw—Torque .................................................... 640 N•m (470 lb-ft)

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TX,43,UU3705 –19–17MAY00–1/4

270LC Excavator Repair 012809

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Mechanical Drive Elements 5. Install cover (B). 43 4350 21

6. Install stop (A). 7. Connect lines (C—H). 8. Connect negative battery cables. 9. Remove chain from boom cylinder.

T105974

–UN–09JAN97

A—Stop B—Cover C—P1-to-Proportional Solenoid Valve SH Port Line D—Port 2-to-Right Propel Section Bottom Port Reverse Line E—Port 4-to-Left Propel Section Bottom Port Reverse Line F—Port D-to-Return Manifold G—Port 3-to-Left Propel Section Top Port Forward Line H—Port 1-to-Right Propel Section Top Port Forward Line

TX,43,UU3705 –19–17MAY00–2/4

10. Put hardwood blocks (B) between lower track rollers (A) and track chain (C) on the counterweight side.

T7720AM

–UN–07MAY92

A—Track Roller B—Hardwood Block (As Required) C—Track Chain

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TX,43,UU3705 –19–17MAY00–3/4

270LC Excavator Repair 012809

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Mechanical Drive Elements

T7720AO

–UN–07MAY92

43 4350 22

A—DFT1089 Barrel Support (2 used)

B—3.7 m (12 ft) Length of W8 x 28 lb Wide Flange Beam

11. Raise machine just enough to remove the hardwood blocks (C), wide flange beam (B), and barrel supports (A). 12. Lower machine so lower track rollers and front idler are on track chain.

C—Hardwood Block (use as required)

15. Lower machine so lower track rollers and front idler are on the track chain. 16. Tighten any of the swing bearing-to-main frame cap screws that could not be tightened. 17. Install track chains.

13. Remove bridge planks and barrel supports from other side.

18. Adjust track sag. (See procedure in Group 0130.)

14. Turn upperstructure to other side and raise machine just enough to remove hardwood blocks between roller and track chain.

TX,43,UU3705 –19–17MAY00–4/4

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Mechanical Drive Elements

Remove and Install Swing Bearing 43 4350 23

1. Remove upperstructure. (See procedure in this group.) CAUTION: The approximate weight of swing bearing is 331 kg (730 lb). Swing Bearing—Specification Swing Bearing—Weight................................. 331 kg (730 lb) approximate

2. Connect swing bearing to a hoist using lifting brackets (C) such as JT01748 Lifting Brackets. 3. Remove cap screws and lock washers (D). Remove bearing. 4. Replace upper and lower seals, steel balls and ball supports as necessary. (See procedures in this group.) –UN–07MAY92

5. Clean mating surfaces of swing bearing, upperstructure, and undercarriage.

T7764AB

Apply cure primer to mating surface on the undercarriage and swing bearing. Apply rigid form-in-place gasket.

C—Lifting Brackets D—Cap Screws and Lock Washers

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TX,43,GG2760 –19–05JUL01–1/2

270LC Excavator Repair 012809

PN=575

Mechanical Drive Elements

–UN–11APR90

IMPORTANT: The tooth marked with the letter “G” or “S” or equivalent is the starting and 43 stopping point for the hardening 4350 process. The tooth and the bearing 24 loading plug must be installed on the right side of the machine so the use of that part of the swing bearing is minimized.

7. Install cap screws and lock washers. Tighten cap screws. Swing Bearing—Specification Undercarriage-to-Bearing Cap Screw—Torque ............................................................ 740 N•m (540 lb-ft)

T5925AA

6. Install swing bearing on undercarriage so the tooth (A) marked “G” or “S” or equivalent and bearing loading plug (B) is to the right side of machine. A—Tooth B—Loading Plug C—Lifting Bracket (3 used) D—Cap Screw and Lock Washer (36 used)

8. Apply multi-purpose grease to swing bearing teeth and pinion shaft. (See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease in Fluids and Lubricants group.)

TX,43,GG2760 –19–05JUL01–2/2

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Mechanical Drive Elements

Disassemble and Assemble Swing Bearing

T6626JP

–UN–07NOV88

43 4350 25

A—Lubrication Fitting (2 used) B—Outer Race

C—Spacer (90 used) D—Steel Ball (90 used)

E—Lower Seal F—Inner Race

G—Upper Seal

1. Install new upper and lower seals (E and G) if torn or damaged. (See procedure in this group.)

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TX,43,GG2761 –19–10APR00–1/4

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Mechanical Drive Elements 2. Grind tack weld (A) off top of taper pin (B). 3. Drive taper pin out from the bottom side of bearing. 4. Remove loading plug (C) using a M10-1.25 cap screw.

T6876FI

–UN–07MAY92

A—Tack Weld B—Taper Pin C—Loading Plug

TX,43,GG2761 –19–10APR00–2/4

5. Remove steel balls (A) using a magnet. 6. Remove spacers (B) using a length of wire. NOTE: Some spacers have a thicker center section. The thick center section spacers are used to remove excess play caused by a tolerance build up between balls and spacers.

–UN–07MAY92

7. Turn inner race to remove remaining steel balls and spacers. 8. Lift outer race off inner race. 9. Install the spacers (B) and steel balls (A).

T6876FI

43 4350 26

Install the same number of thick and thin center section spacers as were removed.

A—Steel Ball B—Spacers C—Loading Plug

Turn inner race as needed to install spacers and steel balls. As needed, replace a thin center section spacer with a thick center section spacer to remove any excess play between spacers and steel balls.

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TX,43,GG2761 –19–10APR00–3/4

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Mechanical Drive Elements 10. Install loading plug (C). 43 4350 27

11. Install taper pin (B) even with top of swing bearing. 12. Tack weld pin (A) to swing bearing.

–UN–07MAY92

13. Add grease to swing bearing through lubrication fittings. (See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease in Fuels and Lubricants group.)

T6876FI

A—Steel Ball B—Spacers C—Loading Plug

TX,43,GG2761 –19–10APR00–4/4

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Mechanical Drive Elements

Install Swing Bearing Upper Seal 1. Remove upperstructure. (See procedure in this group.)

–UN–11APR90

2. Remove old seal (A). 3. Scrape old adhesive from seal groove. Thoroughly clean seal groove and new seal. Apply cure primer.

T5925AM

43 4350 28

4. Apply instant gel adhesive sparingly to seal groove. A—Old Seal

5. Install seal with lip against inner bearing race. Start about 76 mm (3 in.) from end of seal using a blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 6. Before bringing ends of seal together, cut off excess length. 7. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 8. Let adhesive cure for at least 24 hours before using swing function.

TX,43,SB530 –19–10APR00–1/1

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Mechanical Drive Elements

Install Swing Bearing Lower Seal 43 4350 29

NOTE: Part of swing bearing shown cut away to show lower seal in groove. –UN–17MAY89

1. Remove old seal (A). 2. Scrape old adhesive from seal groove (B).

T5936BA

Thoroughly clean seal groove and new seal. Apply cure primer. 3. Apply instant gel adhesive sparingly to seal groove. A—Old Seal B—Seal Groove

4. Install seal with seal lip against outer race. Start about 76 mm (3 in.) from end of seal using a blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 5. Before bringing ends of seal together, cut off excess length. 6. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 7. Let adhesive cure for at least 24 hours before using swing function.

TX,43,UU3706 –19–10APR00–1/1

TM1668 (28JAN09)

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PN=581

Mechanical Drive Elements

43 4350 30

TM1668 (28JAN09)

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Group 4360

Hydraulic System Specifications Item

43 4360 1

Measurement

Specification

Swing Motor and Brake

Weight

66 kg (146 lb) approximate

Motor-to-Gearbox Cap Screw

Torque

88 N•m (65 lb-ft)

Valve Housing-to-Motor Housing Cap Screw

Torque

430 N•m (320 lb-ft)

Make-Up Valve Plug-to-Housing

Torque

330 N•m (245 lb-ft)

Crossover Relief Valve-to-Housing

Torque

176 N•m (130 lb-ft)

Park Brake Release Valve Housing-to-Motor Housing Cap Screw

Torque

9.8 N•m (87 lb-in.)

Swing Motor and Park Brake

Swing Motor Make-Up and Crossover Relief Valves

CED,OUOE003,21698 –19–17MAY00–1/1

Remove and Install Swing Motor and Park Brake

–UN–12NOV92

1. Remove vent plug (A) to release air pressure from hydraulic oil tank.

T7869AT

2. Pull a vacuum in hydraulic oil tank or drain hydraulic oil tank. Approximate oil capacity is 148 L (39 gal). A—Vent Plug

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TX,43,GG2762 –19–10APR00–1/2

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PN=583

Hydraulic System

CAUTION: The approximate weight of swing motor and brake is 66 kg (146 lb).

X9811

3. Disconnect lines (A—F).

–UN–08DEC08

Swing Motor and Park Brake—Specification Swing Motor and Brake—Weight .................... 66 kg (146 lb) approximate

6. Install swing motor and brake. Tighten cap screws (H). Swing Motor and Park Brake—Specification Motor-to-Gearbox Cap Screw— Torque ............................................................................. 88 N•m (65 lb-ft)

T105899

5. Replace parts as necessary.

–UN–19DEC96

4. Remove cap screws (G). Remove swing motor and brake.

7. Connect lines. 8. Do swing motor and park fbrake start-up procedure. (See procedure in this group.)

–UN–09JAN97

A—Motor Drain-to-Hydraulic Oil Tank B—To Swing Valve Section Top Port C—To Swing Valve Section Bottom Port D—Pilot Signal From Top Right Front of Control Valve E—Pilot Pressure From Solenoid Valve Manifold F—To Control Valve G—Cap Screws (8 used)

T105990

43 4360 2

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Hydraulic System

Swing Motor and Park Brake Start-Up Procedure 43 4360 3

T105991

–UN–09JAN97

IMPORTANT: Swing motor will be damaged if not filled with oil before operating swing function. Procedure must be performed whenever a new swing motor is installed or oil has been drained from the motor. Procedure is to ensure the swing motor is filled with oil. A—Swing Motor Drain Line

1. Disconnect swing motor drain line (A). 2. Fill motor with hydraulic oil through drain port until oil reaches the level of drain port. NOTE: Air must be allowed to escape from the swing motor while filling. 3. Connect drain line.

TX,43,GG2763 –19–10APR00–1/1

TM1668 (28JAN09)

43-4360-3

270LC Excavator Repair 012809

PN=585

Hydraulic System

Disassemble Swing Motor and Park Brake

T7181AC

–UN–19DEC89

43 4360 4

A—Spring (24 used) B—Cover C—Valve Plate D—Dowel Pin E—Park Brake Release Valve

F—Cylinder Block G—Force Pin (12 used) H—Slipper I—Retainer

J—Thrust Plate K—Output Shaft L—Oil Seal M—Ball Bushing

Continued on next page

TM1668 (28JAN09)

43-4360-4

N—Piston (9 used) O—Spring P—Separator Plate (3 used) Q—Friction Disk (2 used)

TX,43,GG2764 –19–10APR00–1/8

270LC Excavator Repair 012809

PN=586

Hydraulic System 1. Remove drain plug (A). Drain oil. 43 4360 5

2. Make alignment mark on swing motor valve housing and cover to motor housing for assembly. CAUTION: Swing motor valve housing and cover is under spring pressure. Cap screws must be loosen in even steps to release spring force.

–UN–09JAN97

3. Loosen cap screws (B) in even steps to release spring force. Remove valve housing and cover (C).

T106131B

A—Drain Plug B—Cap Screw (2 used) C—Valve Housing and Cover

TX,43,GG2764 –19–10APR00–2/8

IMPORTANT: Valve plate (D) may remain on valve housing and cover or stay with cylinder block. Be careful not to damage valve plate. –UN–09JAN97

4. Remove parts (C and D).

T106109

D—Valve Plate E—O-Ring

Continued on next page

TM1668 (28JAN09)

43-4360-5

TX,43,GG2764 –19–10APR00–3/8

270LC Excavator Repair 012809

PN=587

Hydraulic System 5. Remove valve plate (B) if not removed. 6. Remove brake springs (A).

–UN–07MAY92

7. Remove parts (C—F).

–UN–07MAY92

T7685KK

–UN–07MAY92

T7685KJ

A—Brake Spring (24 used) B—Valve Plate C—Brake Piston D—O-Ring E—Cylinder Block F—O-Ring

T7685KL

43 4360 6

Continued on next page

TM1668 (28JAN09)

43-4360-6

TX,43,GG2764 –19–10APR00–4/8

270LC Excavator Repair 012809

PN=588

Hydraulic System 8. Remove parts (A—G). 43 4360 7

T7685KM

–UN–07MAY92

A—Thrust Plate B—Piston (9 used) C—Ball Bushing and Washer D—Rod (12 used) E—Separator Plate (3 used) F—Friction Disk (2 used) G—Retainer H—Cylinder Block

TX,43,GG2764 –19–10APR00–5/8

CAUTION: Spring (H) is under pressure. Remove spring load from snap ring before removing it.

–UN–14APR93

9. Push top washer (I) and spring (B) down using a disk and a press. Remove snap ring (G).

T7966CZ

10. Remove washers and spring. The 50 x 61 x 3 mm washer is next to the snap ring and the 47 x 61 x 3 mm washer is at the bottom.

G—Snap Ring H—Spring I—50 x 61 x 3 mm Top Washer (3 used) —47 x 61 x 3 mm Bottom Washer

Continued on next page

TM1668 (28JAN09)

43-4360-7

TX,43,GG2764 –19–10APR00–6/8

270LC Excavator Repair 012809

PN=589

Hydraulic System 11. Remove snap ring (B) from output shaft (D). 12. Remove snap ring (C).

14. Remove O-ring (E).

T7966CV

15. Push output shaft (D) from housing using a press.

–UN–14APR93

13. Remove cover (A).

T7966CW

–UN–14APR93

A—Cover B—Snap Ring C—Snap Ring D—Output Shaft E—O-Ring

TX,43,GG2764 –19–10APR00–7/8

16. Remove snap rings (C) and washers (A).

–UN–14APR93

17. Remove roller bearing (B) using a press. Push bearing to the long end of shaft so oil seal surface on shaft is not damaged. 18. Repair or replace parts as necessary. A—Washer (2 used) B—Roller Bearing C—Snap Ring (2 used)

T7966CX

43 4360 8

TX,43,GG2764 –19–10APR00–8/8

TM1668 (28JAN09)

43-4360-8

270LC Excavator Repair 012809

PN=590

Hydraulic System

Assemble Swing Motor and Park Brake

Continued on next page

TM1668 (28JAN09)

43-4360-9

TP54854

–UN–11JUN97

43 4360 9

TX,43,GG2765 –19–10APR00–1/8

270LC Excavator Repair 012809

PN=591

Hydraulic System 13—Ball Bushing 14—Spring 16—Force Pin (12 used) 17—Washer 18—Washer (47 x 61 x 3 mm) 19—Friction Disk (2 used) 20—Valve Housing and Cover 21—Separator Plate (3 used) 23—Retainer 24—Thrust Plate 26—Packing (2 used) 30—Housing

31—Park Brake Release Valve 32—Snap Ring (2 used) 33—Snap Ring 35—Make-Up Check Valve (2 used) 37—Snap Ring 38—Snap Ring 40—Cap Screw (4 used) 42—Cap Screw (4 used) 43—Roller Bearing 44—Roller Bearing 51—Crossover Relief Valve (2 used)

51A—O-Ring 55—Spring (2 used) 64—Plug 68—Plug (2 used) 69—Plug (2 used) 70—O-Ring 71—O-Ring 72—O-Ring 85—O-Ring 87—O-Ring (2 used) 88—O-Ring (2 used)

TX,43,GG2765 –19–10APR00–2/8

1. Install snap ring (C) in groove next to oil seal surface on output shaft. 2. Install the washer (A). –UN–14APR93

3. Install roller bearing (B) using a press. 4. Install the second washer and snap ring.

T7966CX

43 4360 10

1—Swing Motor 2—Brake Piston 3—Valve Plate 4—Cover 5—Plate 6—Washer (3 used) (50 x 61 x 3 mm) 7—O-Ring 8—Spring (24 used) 9—Oil Seal 10—Output Shaft 11—Piston (9 used) 12—Cylinder Block

A—Washer B—Roller Bearing C—Snap Ring

Continued on next page

TM1668 (28JAN09)

43-4360-10

TX,43,GG2765 –19–10APR00–3/8

270LC Excavator Repair 012809

PN=592

Hydraulic System 5. Install output shaft (D) and roller bearing into housing. 43 4360 11

6. Install O-ring (E) into groove in housing. Apply clean oil to O-ring. –UN–14APR93

7. Install oil seal in cover (A) so seal lip (spring side) is towards the inside of housing. Apply clean oil to seal lips.

T7966CW

8. Install cover and oil seal into housing. 9. Install snap rings (B and C).

T7966CV

–UN–14APR93

A—Cover and Oil Seal B—Snap Ring C—Snap Ring D—Output Shaft E—O-Ring

TX,43,GG2765 –19–10APR00–4/8

10. Install 47 x 61 x 3 mm washer (A) at the bottom of bore in cylinder block, the spring (B), and then the 50 x 61 x 3 mm washer (A).

–UN–07MAY92

11. Compress the spring using a disk and a press. Install the snap ring (C).

T7685KN

A—50 x 61 x 3 mm Top Washer —47 x 61 x 3 mm Bottom Washer B—Spring C—Snap Ring

Continued on next page

TM1668 (28JAN09)

43-4360-11

TX,43,GG2765 –19–10APR00–5/8

270LC Excavator Repair 012809

PN=593

Hydraulic System 12. Install parts (A—H).

–UN–07MAY92

A—Thrust Plate B—Piston (9 used) C—Ball Bushing and Washer D—Force Pin (12 used) E—Separator Plate (3 used) F—Friction Disk (2 used) G—Retainer H—Rotor (Cylinder Block)

T7685KM

43 4360 12

Continued on next page

TM1668 (28JAN09)

43-4360-12

TX,43,GG2765 –19–10APR00–6/8

270LC Excavator Repair 012809

PN=594

Hydraulic System 13. Install parts (A—F). 43 4360 13

T7685KJ

–UN–07MAY92

T7685KK

–UN–07MAY92

T7685KL

–UN–07MAY92

A—Brake Spring (24 used) B—Valve Plate C—Brake Piston D—O-Ring E—Cylinder Block F—O-Ring

Continued on next page

TM1668 (28JAN09)

43-4360-13

TX,43,GG2765 –19–10APR00–7/8

270LC Excavator Repair 012809

PN=595

Hydraulic System 14. Install O-ring (E) and valve plate (D).

Swing Motor and Park Brake—Specification Valve Housing-to-Motor Housing Cap Screw—Torque .................................................... 430 N•m (320 lb-ft)

16. Add oil. (See Hydraulic Oil in Fuels and Lubricants Group.)

T106109

Tighten cap screws (B).

–UN–09JAN97

15. Install valve housing and cover (C) so work ports are towards the machined surface for park brake release valve.

–UN–09JAN97

A—Plug B—Cap Screw (4 used) C—Valve Housing and Cover D—Valve Plate E—O-Ring

T106131B

43 4360 14

TX,43,GG2765 –19–10APR00–8/8

TM1668 (28JAN09)

43-4360-14

270LC Excavator Repair 012809

PN=596

Hydraulic System

Disassemble and Assemble Swing Motor Make-Up and Crossover Relief Valves 43 4360 15 –UN–10JAN97

1. Disassemble make-up valves (A). Remove parts (B— E). 2. Remove crossover relief valves (F).

T106147

3. Replace parts as necessary. 4. Install parts (B—E). Tighten plug (D). Swing Motor Make-Up and Crossover Relief Valves—Specification Make-Up Valve Plug-to-Housing—Torque ............................................ 330 N•m (245 lb-ft)

A—Make-Up Valve (2 used) B—Poppet C—Spring D—Plug E—O-Ring F—Crossover Relief Valve (2 used)

5. Install crossover relief valves (F) and tighten. Swing Motor Make-Up and Crossover Relief Valves—Specification Crossover Relief Valve-to-Housing—Torque .......................................... 176 N•m (130 lb-ft)

TX,43,SB536 –19–10APR00–1/3

6. Take dimension (A) and record for assembly.

T106132B

–UN–09JAN97

A—Dimension

Continued on next page

TM1668 (28JAN09)

43-4360-15

TX,43,SB536 –19–10APR00–2/3

270LC Excavator Repair 012809

PN=597

Hydraulic System

T106134B

–UN–09JAN97

43 4360 16

A—O-Ring B—Body C—Spring

D—Piston E—O-Ring F—Backup Ring

G—Adjusting Plug H—Nut I—Spring Guide

IMPORTANT: Disassembly of relief valve is shown for convenience of cleaning. Service parts are not available. The relief valve must be replaced.

J—Spring K—O-Ring L—Plug

(G) while assembling. Failure to do so will force the plug out the end of body (B). 10. Assemble relief valve (A—L).

7. Disassemble crossover relief valve (A—L). 11. Adjust plug (G) to original dimension (See Step 6). 8. Clean and inspect parts. 9. Replace relief valve if any part is damaged or worn.

12. Check swing crossover relief valve pressure setting. (See procedure in Group 9025-25.)

IMPORTANT: Make sure the poppet in body (B) slides into the bore in adjusting plug

TX,43,SB536 –19–10APR00–3/3

TM1668 (28JAN09)

43-4360-16

270LC Excavator Repair 012809

PN=598

Hydraulic System

Disassemble and Assemble Swing Motor Park Brake Release Valve 43 4360 17

Tighten cap screws (43) to 9.8 N•m (87 lb-in.).

T109946

–UN–09SEP98

T109983B

A—Pilot Pressure From Solenoid Valve Manifold B—Pilot Pressure Signal From Top Right Front Port of Control Valve 31—Housing 32—Spool 33—Spring 34—Plunger 35—Bushing 36—Filter 37—Spacer 38—Orifice 39—Spring 40—O-Ring 41—O-Ring (2 used) 42—Steel Ball 43—Cap Screw (3 used)

–UN–13JUN97

Specification Park Brake Release Valve Housing-to-Motor Housing Cap Screws—Torque ............................................................ 9.8 N•m (87 lb-in.)

TX,43,VV2894 –19–11JUN97–1/1

TM1668 (28JAN09)

43-4360-17

270LC Excavator Repair 012809

PN=599

Hydraulic System

43 4360 18

TM1668 (28JAN09)

43-4360-18

270LC Excavator Repair 012809

PN=600

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 DFT1110 Spacer. . . . . . . . . . . . . . . . . . . . . .99-9900-6 DF1036A Propel Gearbox Nut Wrench . . . . .99-9900-7 DFT1109 Holding Bar . . . . . . . . . . . . . . . . . .99-9900-8 DF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-8 DFT1130 Adapter . . . . . . . . . . . . . . . . . . . .99-9900-10 DF1038 Torque Adapter . . . . . . . . . . . . . . .99-9900-11 Rotary Manifold Lifting Tool. . . . . . . . . . . . .99-9900-12 DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-13 DFT1089 Barrel Support . . . . . . . . . . . . . . .99-9900-14 DFT1144 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-15

TM1668 (28JAN09)

99-1

270LC Excavator Repair 012809

PN=1

Contents

TM1668 (28JAN09)

99-2

270LC Excavator Repair 012809

PN=2

Group 9900

Dealer Fabricated Tools ST4920 Track Recoil Spring Disassembly and Assembly Tool NOTE: It is recommended that DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool be used with track recoil spring disassembly and assembly tool. 99 9900 1

Dimensions given are metric. Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size hole for the nut on that track adjuster. Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring in track adjuster repair.

–UN–24MAR98

Material required:

T6585UY

• 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G). • “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H). • “F” Grade (SAE Grade 8) for Studs (B). Print Numbers: A—Nut (12 used) B—Stud (4 used) C—Holder D—Eyebolt (2 used) E—Supporting Plate F—Base Plate G—Base (4 used) H—Cap Screw (4 used) I—Lock Washer (8 used)

• A-ST4050 Nut • B-ST4045 Bolt • C-ST4035 Holder (Plate) • C-ST4036 Holder (Plate) • C-ST4037 Holder (Plate) • D-ST4047 Eyebolt • E-ST4040 Supporting Base • F-ST4042 Base Plate • G-ST4041 Base • H-ST4046 Cap Screw • I-ST4049 Lock Washer

Continued on next page

TM1668 (28JAN09)

99-9900-1

TX,99,SB548 –19–23MAY00–1/4

270LC Excavator Repair 012809

PN=603

Dealer Fabricated Tools

T130084

–UN–

99 9900 2

Continued on next page

TM1668 (28JAN09)

99-9900-2

TX,99,SB548 –19–23MAY00–2/4

270LC Excavator Repair 012809

PN=604

Dealer Fabricated Tools

T7029CH

–UN–06JUL89

99 9900 3

Continued on next page

TM1668 (28JAN09)

99-9900-3

TX,99,SB548 –19–23MAY00–3/4

270LC Excavator Repair 012809

PN=605

Dealer Fabricated Tools

T7029CG

–UN–06JUL89

99 9900 4

TX,99,SB548 –19–23MAY00–4/4

TM1668 (28JAN09)

99-9900-4

270LC Excavator Repair 012809

PN=606

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. Material required:

E—1/2 x 3 in. Steel Round Stock (2 used)

• 3/16 in. 1020 CR Steel Plate (A) • 9/16 in. Hole (2 places) (B) • 1/2 in. Nut (2 used) (C) • 1/2 x 2 in. Cap Screw (D) (2 used) • 1/2 x 3 in. Steel Round Stock (E) (2 used)

TX,99,SB542 –19–08JAN97–1/1

TM1668 (28JAN09)

99-9900-5

270LC Excavator Repair 012809

PN=607

Dealer Fabricated Tools

DFT1110 Spacer

T7708AC

–UN–23FEB92

99 9900 6

Spacer is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool.

Material Required: • 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy Wall Steel Pipe

Spacer is installed on the bottom plate so force is applied to spring flange on cylinder and not to the piston. Cut the ends of spacer so they are parallel to each other.

TX,99,SB549 –19–08JAN97–1/1

TM1668 (28JAN09)

99-9900-6

270LC Excavator Repair 012809

PN=608

Dealer Fabricated Tools

DF1036A Propel Gearbox Nut Wrench

T7681FZ

–UN–28FEB92

99 9900 7

Propel Gearbox Nut Wrench is used to remove and install the hub-to-housing nut in the propel gearbox. Material required:

• 16 mm (5/8 in.) Flat Bar Stock • M24 (1 in.) Nut • M10-1.5 x 60 mm Cap Screw (2 used) • M10-1.5 Nut (2 used)

TX,99,SB544 –19–23MAY00–1/1

TM1668 (28JAN09)

99-9900-7

270LC Excavator Repair 012809

PN=609

Dealer Fabricated Tools

DFT1109 Holding Bar

T7690AA

–UN–27FEB92

99 9900 8

Holding Bar is used with the DF1036A Propel Gearbox Nut Wrench as a guide when loosening the hub-to-housing nut in the propel gearbox.

Material required: • 16 mm (5/8 in.) Flat Bar Stock TX,99,SB550 –19–23MAY00–1/1

DF1063 Lift Bracket Tool is the same as used on other machines. Only the lift bracket of the tool is used for this machine with adapter DFT1130. Lift Bracket is used to remove and install propel motor. Material required:

T8318AC

–UN–20SEP94

• 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16 in.) Square Tube • 1.3 mm (1/2 in.) 1020 Steel Plate • 1 mm x 38.1 mm (3/8 in. x 1-1/2 in.) Cap Screw with Nut (4 used)

Continued on next page

TM1668 (28JAN09)

99-9900-8

CED,OUTX818,81 –19–11MAY00–1/2

270LC Excavator Repair 012809

PN=610

Dealer Fabricated Tools

T7247BW

–19–25APR90

99 9900 9

CED,OUTX818,81 –19–11MAY00–2/2

TM1668 (28JAN09)

99-9900-9

270LC Excavator Repair 012809

PN=611

Dealer Fabricated Tools

DFT1130 Adapter

T8319BN

–UN–20SEP94

99 9900 10

A—Adapter Plate

B—Tube

C—Stop Plate

Adapter is used with DF1063 Lift Bracket to remove and install propel motor. Material required:

• 1.3 mm (1/2 in.) 1020 Steel Plate (A) • 38.1 mm x 38.1 mm x .48 mm (1-1/2 in. x 1-1/2 in. x 3/16 in.) Square Tube (B) • .6 mm (1/4 in.) 1020 Steel Plate (C)

CED,OUTX818,84 –19–11MAY00–1/1

TM1668 (28JAN09)

99-9900-10

270LC Excavator Repair 012809

PN=612

Dealer Fabricated Tools

DF1038 Torque Adapter

T6557CH

–UN–25OCT95

99 9900 11

Torque Adapter is used to check rolling drag torque on rotor drive shaft.

• 17 mm (0.125 in.) hex head driver

Material required:

CED,OUTX818,83 –19–11MAY00–1/1

TM1668 (28JAN09)

99-9900-11

270LC Excavator Repair 012809

PN=613

Dealer Fabricated Tools

Rotary Manifold Lifting Tool Tool is used to remove and install rotary manifold. Drill and tap disk in fitting cap to M8-1.25 mm threads (A). Material required:

–UN–24OCT88

• 38H1416 Cap (—12) • M8-1.25 Lifting Eyebolt such as JT05548 Metric Lifting Eyebolt

T6641DO

99 9900 12

TX,99,SB546 –19–08JAN97–1/1

TM1668 (28JAN09)

99-9900-12

270LC Excavator Repair 012809

PN=614

Dealer Fabricated Tools

DFT1119 Pump Support

T7955AA

–UN–23APR93

99 9900 13

Pump support is used with a hand hoist to support a pump(s) when an engine is removed. Two end stands are needed. Drill the holes through the square steel tubing so they are centered. Material required: • C3 x 5 Steel Channel

• 88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.) Square Steel Tubing • 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) Square Steel Tubing • 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) Square Steel Tubing • 19 mm (3/4 in.) Flat Bar Stock • M10 x 89 mm or 3/8 x 3-1/2 in. D Grade (SAE Grade 5) Cap Screw (2 used) • M10 or 3/8 in. D Grade (SAE Grade 5) Nut (2 used)

TX,99,SB553 –19–08JAN97–1/1

TM1668 (28JAN09)

99-9900-13

270LC Excavator Repair 012809

PN=615

Dealer Fabricated Tools

DFT1089 Barrel Support Barrel supports are used to support the upperstructure when removing the undercarriage. –UN–09JAN97

Material required: • Clean metal 55 gallon barrels of equal height with lids removed. (Must be 34.5—35.5 in. height x 24 in. wide.) • 1/2 x 4 x 24 in. 1020 CR Plate • 1/2 x 4 x 12 in. 1020 CR Plate • One empty 3 lb coffee can or equivalent • Highway Cement (9 bag mix). Mix extra dry to aid curing time.

T7149AC

99 9900 14

CAUTION: Cutting tops off barrels that contained flammable or explosive material can cause serious injury or death.

A—2 x 4 in. Slotted Hole, Recessed B—1/2 x 4 x 24 in. 1020 CR Plate C—1/2 x 4 x 12 in. 1020 CR Plate D—1/4 in. Fillet Weld E—One Empty 3 lb Coffee Can or Equivalent

Insert hook assembly into barrel before cement is set. Hold assembly in position, using a steel plate or wire, until cement begins to cure. Level off cement with top of barrels. Cement must cure for a minimum of ten days. The approximate weight of each barrel support is 545 kg (1200 lb). The approximate support capacity of each barrel support is 385 560 kg (850 000 lb).

TX,99,SB551 –19–08JAN97–1/1

TM1668 (28JAN09)

99-9900-14

270LC Excavator Repair 012809

PN=616

Dealer Fabricated Tools

DFT1144 Guide Pin

Remove threads for a distance (B) and then grind a taper on same end.

T6641EK

Materials required:

–UN–24OCT88

Guide pin is used to align cap screw holes in swing bearing and upperstructure.

• M20-2.5 x 230 mm (9 in.) Threaded Rod A—230 mm (9 in.) B—100 mm (4 in.)

TX,99,SB552 –19–08JAN97–1/1

TM1668 (28JAN09)

99-9900-15

270LC Excavator Repair 012809

PN=617

99 9900 15

Dealer Fabricated Tools

99 9900 16

TM1668 (28JAN09)

99-9900-16

270LC Excavator Repair 012809

PN=618

Index Page

A Adjuster Track, disassemble and assemble . . . .01-0130-41 Track, remove and install . . . . . . . . . . .01-0130-40 Adjuster cylinder Track, disassemble and assemble . . . .01-0130-46 Adjustment Engine valve lash (clearance) . . . . . . . .04-0400-17 Air cleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-2 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-11 Compressor belt tension . . . . . . . . . . . .18-1830-12 Compressor oil removal . . . . . . . . . . . . .18-1830-6 Compressor, assemble . . . . . . . . . . . . .18-1830-23 Compressor, disassemble and inspect. . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 Compressor, remove and install . . . . . .18-1830-14 Condenser, remove and install . . . . . . .18-1830-32 Evacuate R134a system . . . . . . . . . . . .18-1830-10 Evaporator, remove and install . . . . . . .18-1830-30 Heater core, remove and install . . . . . .18-1830-34 Inspect compressor manifolds. . . . . . . .18-1830-26 Receiver dryer . . . . . . . . . . . . . . . . . . .18-1830-28 Recover R134a system. . . . . . . . . . . . . .18-1830-9 Recovery, recycling and charging R134a refrigerant . . . . . . . . . . . . . . . . . . . . . .18-1830-8 Refrigerant handling . . . . . . . . . . . . . . . .18-1830-4 R134a compressor oil charge check . . . .18-1830-5 Air conditioning R134a component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Air conditioning R134a refrigerant Cautions . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 Air cooler, charge Remove and install . . . . . . . . . . . . . . . . .05-0520-6 Air filter Restriction switch, remove . . . . . . . . . .16-1674-24 Air intake system Leakage test . . . . . . . . . . . . . . . . . . . . . .05-0520-2 Alarm Travel, remove and install . . . . . . . . . . .16-1674-21 Alarm, travel volume Change . . . . . . . . . . . . . . . . . . . . . . . . . .16-1676-3 Alternator Remove and install . . . . . . . . . . . . . . . . .16-1672-2 Arm Remove and install . . . . . . . . . . . . . . . . .33-3340-7 Arm cylinder Assemble . . . . . . . . . . . . . . . . . . . . . . 33-3360-150 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-141 Disassemble . . . . . . . . . . . . . . . . . . . . 33-3360-142 Inspect pins and bushings. . . . . . . . . . .33-3340-13 TM1668 (28JAN09)

Page

Remove and install . . . . . . . . . . . . . . . 33-3360-134 Arm II to arm I neutral passage check valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Arm in anti-drift valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Arm pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-13 Arm regenerative check valve poppet Remove and install . . . . . . . . . . . . . . . .33-3360-89 Arm regenerative valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Indx 1

B Battery Adding 12-V accessories . . . . . . . . . . .16-1671-16 Charge . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-10 Check terminals . . . . . . . . . . . . . . . . . . .16-1671-7 Electrolyte level. . . . . . . . . . . . . . . . . . . .16-1671-7 Electrolyte specific gravity . . . . . . . . . . . .16-1671-5 Handle safely . . . . . . . . . . . . . . . . . . . . .16-1671-3 Install replacement . . . . . . . . . . . . . . . .16-1671-15 Relay, remove and install . . . . . . . . . . .16-1674-26 Remove and install . . . . . . . . . . . . . . . .16-1671-14 Testing . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-4 Using booster-24-volt . . . . . . . . . . . . . . .16-1671-9 Bearing Swing, disassemble and assemble . . . .43-4350-25 Swing, install lower seal . . . . . . . . . . . .43-4350-29 Swing, install upper seal . . . . . . . . . . . .43-4350-28 Swing, remove and install . . . . . . . . . . .43-4350-23 Belt Compressor, check and adjust tension. . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Seat, inspect . . . . . . . . . . . . . . . . . . . . . .18-1821-9 Seat, remove and install . . . . . . . . . . . . .18-1821-8 Bleed fuel system . . . . . . . . . . . . . . . . . . .05-0560-11 Blower motor and heater core Remove and install . . . . . . . . . . . . . . . .18-1830-35 Boom Lower with engine stopped . . . . . . . . . .33-3360-17 Remove and install . . . . . . . . . . . . . . . . .33-3340-9 Boom anti-drift valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Boom cylinder Assemble . . . . . . . . . . . . . . . . . . . . . . 33-3360-150 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-141 Disassemble . . . . . . . . . . . . . . . . . . . . 33-3360-142 Inspect pins and bushing . . . . . . . . . . .33-3340-13 Remove and install . . . . . . . . . . . . . . . 33-3360-131

Index-1

270LC Excavator Repair 012809

PN=1

Index

Page

Boom pins and bushing Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-13 Boom regenerative valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Brake Swing motor park, assemble . . . . . . . . . .43-4360-9 Swing motor park, disassemble. . . . . . . .43-4360-4 Swing motor park, remove and install . . .43-4360-1 Brake pressure reducing valve Propel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22 Brake, propel motor, valve housing Disassemble . . . . . . . . . . . . . . . . . . . . .02-0260-22 Indx Breather filter 2 Hydraulic oil tank, disassemble . . . . . . 33-3360-122 Bucket Adjust pivot end play. . . . . . . . . . . . . . .33-3302-11 Disassemble and assemble . . . . . . . . .33-3302-12 Links, remove and install. . . . . . . . . . . . .33-3340-5 Pin-up data . . . . . . . . . . . . . . . . . . . . . .33-3302-14 Remove and install . . . . . . . . . . . . . . . .33-3302-10 Repair cracked cutting edge . . . . . . . . . .33-3302-9 Replace welded cutting edge . . . . . . . . .33-3302-8 Tooth replacement . . . . . . . . . . . . . . . . .33-3302-1 Tooth tip, heavy-duty bucket . . . . . . . . . .33-3302-3 Bucket cylinder Assemble . . . . . . . . . . . . . . . . . . . . . . 33-3360-150 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-141 Disassemble . . . . . . . . . . . . . . . . . . . . 33-3360-142 Inspect pins and bushings. . . . . . . . . . .33-3340-13 Remove and install . . . . . . . . . . . . . . . 33-3360-137 Bucket flow control valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Bushing Track, measure wear . . . . . . . . . . . . . .01-0130-22 Bushings and seals Remove and install . . . . . . . . . . . . . . . .33-3340-16 Bypass valve Return filter, remove . . . . . . . . . . . . . . 33-3360-117

measure wear . . . . . . . . . . . . . . . . . . . .01-0130-13 Carrier roller oil specification . . . . . . . . . . .00-0004-6 Chain Track, disassemble and assemble . . . .01-0130-28 Track, disassemble and assemble to replace broken part . . . . . . . . . . . . . . . . . . . .01-0130-29 Track, install . . . . . . . . . . . . . . . . . . . . .01-0130-26 Track, remove. . . . . . . . . . . . . . . . . . . .01-0130-24 Charge air cooler Remove and install . . . . . . . . . . . . . . . . .05-0520-6 Charge air temperature switch Engine, remove and install . . . . . . . . . .16-1674-19 Check valve Arm II to arm I neutral passage, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Arm regenerative, remove poppet . . . . .33-3360-89 Propel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22 System relief valve isolation . . . . . . . . .33-3360-89 Circuit relief and anti-cavitation valve Disassemble and assemble . . . . . . . . 33-3360-109 Remove and install . . . . . . . . . . . . . . . .33-3360-89 Compressor Air conditioning, assemble . . . . . . . . . .18-1830-23 Air conditioning, disassemble and inspect. . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 Air conditioning, remove and install. . . .18-1830-14 Check and adjust belt tension . . . . . . . .18-1830-12 manifold, inspect air conditioning . . . . .18-1830-26 Oil charge check, R134a. . . . . . . . . . . . .18-1830-5 Oil removal, R134a . . . . . . . . . . . . . . . . .18-1830-6 Compressor, R134a, component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-32 Control lever pattern conversion . . . . . . . .33-3360-15 Control valve Arm II to arm I neutral passage check valve, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Arm in anti-drift valve, remove . . . . . . .33-3360-89 Arm regenerative check valve poppet, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Arm regenerative valve, remove . . . . . .33-3360-89 Boom anti-drift valve, remove . . . . . . . .33-3360-89 Boom regenerative valve, remove. . . . .33-3360-89 Bucket flow control valve, remove . . . . .33-3360-89 Check valve and orifice for propel flow control valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Circuit relief and anti-cavitation valve, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Disassemble and assemble . . . . . . . . .33-3360-89 Fitting with orifice and filter for front and rear pump control valves . . . . . . . . . . . . . . . . . .33-3360-89 Flow combiner valve, remove . . . . . . . .33-3360-89

C Cab Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Windowpane dimensions . . . . . . . . . . . .18-1810-4 Cable Engine speed control, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-5 Capacities Drain and refill . . . . . . . . . . . . . . . . . . . .00-0002-3 Carrier roller Disassemble and assemble . . . . . . . . .01-0130-15 TM1668 (28JAN09)

Index-2

270LC Excavator Repair 012809

PN=2

Index

Page

Front pump control valve, remove . . . . .33-3360-89 Left control valve spool, remove . . . . . .33-3360-89 Pilot pressure inlet fitting and filter, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Rear pump control valve, remove . . . . .33-3360-89 Remove and install . . . . . . . . . . . . . . . .33-3360-80 Right control valve spool, remove . . . . .33-3360-89 System relief valve isolation check valve poppet, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 System relief valve, remove . . . . . . . . .33-3360-89 Controller Dig function pilot, disassemble . . . . . . .33-3360-68 Dig function pilot, remove and install. . .33-3360-65 Engine and pump, harness connector installation . . . . . . . . . . . . . . . . . . . . . .16-1675-3 Engine and pump, remove and install. . . . . . . . . . . . . . . . 16-1674-25, 16-1675-4 Monitor, remove and install . . . . . . . . . . .16-1675-4 Propel pilot, disassemble . . . . . . . . . . .33-3360-73 Propel pilot, remove and install . . . . . . .33-3360-71 Coolant level switch Engine, remove and install . . . . . . . . . .16-1674-19 Coolant temperature gauge Remove and install . . . . . . . . . . . . . . . . .16-1676-2 Cooler Oil, remove and install . . . . . . . . . . . . 33-3360-127 Cooler, charge air Remove and install . . . . . . . . . . . . . . . . .05-0520-6 Counterbalance valve Propel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22 Counterweight Remove and install . . . . . . . . . . . . . . . . .17-1749-2 Crossover relief valve Swing motor, disassemble . . . . . . . . . .43-4360-15 Cutting edge Repair cracked . . . . . . . . . . . . . . . . . . . .33-3302-9 Replace welded bucket . . . . . . . . . . . . . .33-3302-8 Cylinder Arm, remove and install . . . . . . . . . . . 33-3360-134 Bleed procedure, hydraulic . . . . . . . . . 33-3360-141 Boom arm or bucket, assemble. . . . . . 33-3360-150 Boom, remove and install . . . . . . . . . . 33-3360-131 Bucket, remove and install . . . . . . . . . 33-3360-137 Disassemble boom, arm or bucket . . . 33-3360-142 Inspect pins and bushings. . . . . . . . . . .33-3340-13 Install bushings and seals . . . . . . . . . . .33-3340-16

Dealer fabricated tools DFT1087 track recoil spring disassembly and assembly guard tool . . . . . . . . . . . . . .99-9900-5 DFT1089 barrel support . . . . . . . . . . . .99-9900-14 DFT1109 holding bar . . . . . . . . . . . . . . .99-9900-8 DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-6 DFT1114 guide pin . . . . . . . . . . . . . . . .99-9900-15 DFT1119 pump support . . . . . . . . . . . .99-9900-13 DFT1130 adapter . . . . . . . . . . . . . . . . .99-9900-10 DF1036A propel gearbox nut wrench . . .99-9900-7 DF1038 torque adapter . . . . . . . . . . . . .99-9900-11 DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-8 Rotary manifold lifting tool. . . . . . . . . . .99-9900-12 ST4920 track recoil spring disassembly and assembly tool . . . . . . . . . . . . . . . . . . .99-9900-1 Diesel engine oil. . . . . . . . . . . . . . . . . . . . .00-0004-4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Lubricity . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Diesel fuel storage . . . . . . . . . . . . . . . . . . .00-0004-2 Dig function pilot controller Disassemble and assemble . . . . . . . . .33-3360-68 Remove and install . . . . . . . . . . . . . . . .33-3360-65 Dig function pressure switch Remove and install . . . . . . . . . . . . . . . .16-1674-21 Dome light Remove and install switch. . . . . . . . . . .16-1674-16 Drain and refill Capacities . . . . . . . . . . . . . . . . . . . . . . . .00-0002-3

D Dampener drive Remove and install . . . . . . . . . . . . . . . . .07-0752-2 TM1668 (28JAN09)

E Electrical Connect engine and pump controller (EPC) harness . . . . . . . . . . . . . . . . . . . . . . . .16-1675-3 Fuse specifications . . . . . . . . . . . . . . . . .16-1674-3 Precautions before welding . . . . . . . . . . 16-1675-1, 17-1740-1, 33-3302-3 Spring wire retainer connector . . . . . . .16-1674-25 Electrical component identification Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-10 Front chassis . . . . . . . . . . . . . . . . . . . . .16-1674-4 Hydraulic. . . . . . . . . . . . . . . . . . . . . . . .16-1674-12 Electrolyte specific gravity Checking. . . . . . . . . . . . . . . . . . . . . . . . .16-1671-5 Element Final fuel filter, remove and install. . . . . .05-0560-9 Primary fuel filter, remove and install . . .05-0560-6 Engine Charge air temperature switch, remove . . . . . . . . . . . . . . . . . . . . . . .16-1674-19 Control motor adjustment . . . . . . . . . . . .05-0515-7

Index-3

270LC Excavator Repair 012809

PN=3

Indx 3

Index

Page

Coolant heater, remove and install . . . . .05-0505-1 Coolant level switch, remove. . . . . . . . .16-1674-19 Coolant temperature sensor . . . . . . . . .16-1674-20 Crankcase ventilation tube . . . . . . . . . .04-0400-16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-8 Oil level switch . . . . . . . . . . . . . . . . . . .16-1674-19 Oil pressure switch . . . . . . . . . . . . . . . .16-1674-19 Overheat alarm switch, remove. . . . . . .16-1674-18 Remove . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-5 Speed calibration . . . . . . . . 16-1675-1, 17-1740-1, 33-3302-3 Speed learning procedure . . . . . . . . . . . 05-0515-8, Indx 16-1671-12, 16-1675-2 4 Stopped, lower boom . . . . . . . . . . . . . .33-3360-17 Valve lash (clearance) adjustment . . . .04-0400-17 Engine and pump controller Harness connector installation . . . . . . . .16-1675-3 Remove and install . . . . . . . 16-1674-25, 16-1675-4 Engine control motor Adjustment . . . . . . . . . . . . . . . . . . . . . . .05-0515-7 Engine control motor and sensor Remove and install . . . . . . . . . . . . . . . . .05-0515-6 Engine coolant heater Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Engine coolant temperature sensor Engine, remove and install . . . . . . . . . .16-1674-20 Engine hour meter switch Remove and install . . . . . . . . . . . . . . . . .16-1676-3 Engine oil Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-4 Engine oil level switch Engine, remove and install . . . . . . . . . .16-1674-19 Engine oil pressure switch Engine, remove and install . . . . . . . . . .16-1674-19 Engine speed Fast and slow idle, adjust . . . . . . . . . . . .05-0515-2 Engine speed control cable Remove and install . . . . . . . . . . . . . . . . .05-0515-5 Engine speed learning Switch, engine learning . . . 05-0515-8, 16-1671-12, 16-1675-2 Engine speed sensor Remove and install . . . . . . . . . . . . . . . .16-1674-23 EPC Harness connector installation . . . . . . . .16-1675-3 Remove and install . . . . . . . 16-1674-25, 16-1675-4 Evaporator Remove and install . . . . . . . . . . . . . . . .18-1830-30

Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Fan belt Remove and install . . . . . . . . . . . . . . . . .05-0510-5 Fan guard Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Fan shroud Remove and install . . . . . . . . . . . . . . . . .05-0510-2 Fast idle Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2 Filter Final fuel, remove and install . . . . . . . . .05-0560-8 Final fuel, remove and install element . . .05-0560-9 Hydraulic oil tank breather, disassemble . . . . . . . . . . . . . . . . . . 33-3360-122 Hydraulic return, remove and install. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-117 Pilot pressure inlet fitting, remove . . . . .33-3360-89 Pilot, disassemble and assemble . . . . .33-3360-54 Pilot, remove and install . . . . . . . . . . . .33-3360-52 Primary fuel, remove and install . . . . . . .05-0560-4 Primary fuel, remove and install element . . . . . . . . . . . . . . . . . . . . . . . .05-0560-6 Suction strainer, remove and install . . 33-3360-120 Final fuel filter Element, remove and install . . . . . . . . . .05-0560-9 Remove and install . . . . . . . . . . . . . . . . .05-0560-8 Flow combiner valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Flow regulator valve Disassemble and assemble . . . . . . . . .33-3360-79 Remove and install . . . . . . . . . . . . . . . .33-3360-77 Front idler Assemble . . . . . . . . . . . . . . . . . . . . . . .01-0130-37 Disassemble . . . . . . . . . . . . . . . . . . . . .01-0130-36 Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-34 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-6 Remove and install . . . . . . . . . . . . . . . .01-0130-35 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-39 Front pump control valve Fitting with orifice and filter, remove . . .33-3360-89 Remove and install . . . . . . . . . . . . . . . .33-3360-89 Front pump pressure sensor Remove and install . . . . . . . . . . . . . . . .16-1674-22 Fuel Bleed system . . . . . . . . . . . . . . . . . . . .05-0560-11 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Fuel filter Element, remove and install final . . . . . .05-0560-9 Final, remove and install . . . . . . . . . . . . .05-0560-8 Primary element, remove and install . . . .05-0560-6 Primary, remove and install. . . . . . . . . . .05-0560-4 Fuel injection pump Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-13

F Fan Belt, remove and install. . . . . . . . . . . . . .05-0510-5 TM1668 (28JAN09)

Index-4

270LC Excavator Repair 012809

PN=4

Index

Page

Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-11 Repair . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-12 Fuel level gauge Remove and install . . . . . . . . . . . . . . . . .16-1676-2 Fuel level switch. . . . . . . . . . . . . . . . . . . .16-1674-20 Engine, remove and install . . . . . . . . . .16-1674-20 Remove and install . . . . . . . . . . . . . . . .16-1674-20 Fuel shut-off solenoid Check and adjust linkage . . . . . . . . . . .05-0515-11 Fuel shut-off solenoid linkage Remove and install . . . . . . . . . . . . . . . .05-0515-10 Fuel system Bleed . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-16 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-2 Fuel, diesel storage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2 Functional Schematic and component location Legend . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-6 Fuse Color codes . . . . . . . . . . . . . . . . . . . . .16-1674-15 Replacing . . . . . . . . . . . . . . . . . . . . . . .16-1674-14 Specification . . . . . . . . . . . . . . . . . . . . . .16-1674-3

G Gauge Coolant temperature . . . . . . . . . . . . . . . .16-1676-2 Fuel level . . . . . . . . . . . . . . . . . . . . . . . .16-1676-2 Hour meter . . . . . . . . . . . . . . . . . . . . . . .16-1676-2 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6 Gearbox Hydraulic pump drive, assemble . . . . . .33-3360-37 Hydraulic pump drive, disassemble . . . .33-3360-22 Hydraulic pump drive, remove. . . . . . . .33-3360-19 Propel, assemble . . . . . . . . . . . . . . . . .02-0250-18 Propel, disassemble . . . . . . . . . . . . . . . .02-0250-8 Propel, remove and install. . . . . . . . . . . .02-0250-4 Pump drive, pilot pump drive shaft . . . .33-3360-36 Swing, disassemble and assemble . . . . .43-4350-8 Swing, remove and install . . . . . . . . . . . .43-4350-4 Swing, start-up procedure . . . . . . . . . . . .43-4350-6 Grease Extreme pressure and multipurpose . . . .00-0004-7 Specification . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Ground strap, cab Remove and install . . . . . . . . . . . . . . . .16-1674-18 Grouser Track shoe, measure wear . . . . . . . . . .01-0130-19 Track shoe, remove and install . . . . . . .01-0130-20 TM1668 (28JAN09)

Page

H Heater Engine coolant, remove and install . . . . .05-0505-1 Heater core and blower motor Remove and install . . . . . . . . . . . . . . . .18-1830-35 Heater core (machine with air conditioning) Remove and install . . . . . . . . . . . . . . . .18-1830-34 Hoses Heater, remove and install . . . . . . . . . .18-1830-37 Hour meter Remove and install . . . . . . . . . . . . . . . . .16-1676-2 Hour Meter Switch, remove and install . . . . . . . . . . .16-1676-3 Hydraulic Fittings, 30&deg; cone seat. . . . . . . . . . .00-0003-9 Fittings, 37&deg; flare . . . . . . . . . . . . . . .00-0003-9 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-5 Hydraulic cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-141 Hydraulic fitting Flared connections . . . . . . . . . . . . . . . .00-0003-10 Hydraulic oil Cleanup procedure using portable filter caddy . . . . . . . . . . . . . . . . . . . . . . . .33-3360-18 Hydraulic oil tank Disassemble and assemble . . . . . . . . 33-3360-116 Relief valve and breather filter, disassemble . . . . . . . . . . . . . . . . . . 33-3360-122 Remove and install . . . . . . . . . . . . . . . 33-3360-110 Hydraulic pump Assemble . . . . . . . . . . . . . . . . . . . . . . .33-3360-37 Disassemble . . . . . . . . . . . . . . . . . . . . .33-3360-22 Regulator, disassemble. . . . . . . . . . . . .33-3360-46 Remove and install . . . . . . . . . . . . . . . .33-3360-19 Start-up procedure . . . . . . . . . . . . . . . .33-3360-21 Hydraulic pump drive gearbox Assemble . . . . . . . . . . . . . . . . . . . . . . .33-3360-37

I Idler Front, assemble . . . . . . . . . . . . . . . . . .01-0130-37 Front, disassemble . . . . . . . . . . . . . . . .01-0130-36 Front, measure wear. . . . . . . . . . . . . . .01-0130-34 Front, remove and install . . . . . . . . . . .01-0130-35 Front, test for oil leakage . . . . . . . . . . .01-0130-39 Isolation check valve poppet System relief valve, remove . . . . . . . . .33-3360-89

Index-5

270LC Excavator Repair 012809

PN=5

Indx 5

Index

Page

L Legend Functional schematic and component location . . . . . . . . . . . . . . . . . . . . . . . .16-1674-6 Link Bucket, remove and install . . . . . . . . . . .33-3340-5 Track, measure wear . . . . . . . . . . . . . .01-0130-21 Linkage Fuel shut-off solenoid, check and adjust . . . . . . . . . . . . . . . . . . . . . . . .05-0515-11 Fuel shut-off solenoid, remove and Indx install. . . . . . . . . . . . . . . . . . . . . . . . .05-0515-10 6 Lubricant Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-8 Storage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-8

M Machine Towing . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Make-up valve Swing motor, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .43-4360-15 Manifold Air conditioning compressor, inspect . . .18-1830-26 Rotary, air test . . . . . . . . . . . . . . . . . . .02-0260-32 Rotary, disassemble and assemble. . . .02-0260-30 Rotary, remove and install . . . . . . . . . .02-0260-26 Metal face seal Inspect . . . . . . . . . . . . . . . 01-0130-17, 02-0250-16 Mixing lubricants. . . . . . . . . . . . . . . . . . . . .00-0004-8 Monitor controller Remove and install . . . . . . . . . . . . . . . . .16-1675-4 Motor Engine control, adjustment . . . . . . . . . . .05-0515-7 Engine control, remove and install . . . . .05-0515-6 Propel, assemble . . . . . . . . . . . . . . . . .02-0260-14 Propel, disassemble . . . . . . . . . . . . . . . .02-0260-8 Propel, remove and install. . . . . . . . . . . .02-0260-5 Swing, assemble. . . . . . . . . . . . . . . . . . .43-4360-9 Swing, disassemble . . . . . . . . . . . . . . . .43-4360-4 Swing, remove and install . . . . . . . . . . . .43-4360-1 Swing, start-up procedure . . . . . . . . . . . .43-4360-3 Motor, propel, brake valve housing Disassemble . . . . . . . . . . . . . . . . . . . . .02-0260-22

O O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6 TM1668 (28JAN09)

Page

Oil Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-5 Specification carrier roller . . . . . . . . . . . .00-0004-6 Specification front idler . . . . . . . . . . . . . .00-0004-6 Specification hydraulic. . . . . . . . . . . . . . .00-0004-5 Specification track roller . . . . . . . . . . . . .00-0004-6 Oil cooler Bypass valve, remove and install . . . . 33-3360-125 Remove and install . . . . . . 05-0510-2, 33-3360-127 Oil cooler bypass valve Remove and install . . . . . . . . . . . . . . . 33-3360-125 Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Oil Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6 Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-5 Oil pan Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-10 Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-10 Oil, component, R134a air conditioning Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Overheat alarm switch Engine, remove and install . . . . . . . . . .16-1674-18

P Park brake Propel motor, assemble . . . . . . . . . . . .02-0260-14 Propel motor, disassemble . . . . . . . . . . .02-0260-8 Propel motor, remove and install. . . . . . .02-0260-5 Swing motor, assemble. . . . . . . . . . . . . .43-4360-9 Swing motor, disassemble . . . . . . . . . . .43-4360-4 Swing motor, remove and install . . . . . . .43-4360-1 Park brake release valve Swing motor, disassemble . . . . . . . . . .43-4360-17 Pattern conversion Control levers . . . . . . . . . . . . . . . . . . . .33-3360-15 Pilot controller Dig function, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-68 Dig function, remove and install . . . . . .33-3360-65 Propel, disassemble and assemble . . . .33-3360-73 Propel, remove and install. . . . . . . . . . .33-3360-71 Pilot filter Disassemble and assemble . . . . . . . . .33-3360-54 Remove and install . . . . . . . . . . . . . . . .33-3360-52 Pilot pressure inlet fitting and filter Remove and install . . . . . . . . . . . . . . . .33-3360-89 Pilot pressure regulating valve Disassemble and assemble . . . . . . . . .33-3360-54 Remove and install . . . . . . . . . . . . . . . .33-3360-52 Pilot pump Disassemble and assemble . . . . . . . . .33-3360-50

Index-6

270LC Excavator Repair 012809

PN=6

Index

Page

Drive shaft and gear, disassemble . . . .33-3360-36 Remove and install . . . . . . . . . . . . . . . .33-3360-49 Pilot shut-off valve Disassemble and assemble . . . . . . . . .33-3360-57 Linkage adjustment . . . . . . . . . . . . . . . .33-3360-56 Remove and install . . . . . . . . . . . . . . . .33-3360-54 Pitch Track, measure . . . . . . . . . . . . . . . . . . .01-0130-23 Portable filter caddy Hydraulic oil cleanup procedure . . . . . .33-3360-18 Power boost System relief valve, disassemble . . . . 33-3360-107 Primary fuel filter Element, remove and install . . . . . . . . . .05-0560-6 Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Propel flow control valve Check valve and orifice, remove . . . . . .33-3360-89 Propel function pressure sensor Remove and install . . . . . . . . . . . . . . . .16-1674-22 Propel gearbox Assemble . . . . . . . . . . . . . . . . . . . . . . .02-0250-18 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-0250-8 Remove and install . . . . . . . . . . . . . . . . .02-0250-4 Propel motor Brake pressure reducing valve . . . . . . .02-0260-22 Check valve . . . . . . . . . . . . . . . . . . . . .02-0260-22 Counterbalance valve . . . . . . . . . . . . . .02-0260-22 Relief valve . . . . . . . . . . . . . . . . . . . . . .02-0260-22 Shuttle valve, park brake release . . . . .02-0260-22 Shuttle valve, servo piston . . . . . . . . . .02-0260-22 Propel motor and park brake Assemble . . . . . . . . . . . . . . . . . . . . . . .02-0260-14 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-0260-8 Remove and install . . . . . . . . . . . . . . . . .02-0260-5 Start-up procedure . . . . . . . . . . . . . . . . .02-0260-7 Propel motor brake valve housing Disassemble . . . . . . . . . . . . . . . . . . . . .02-0260-22 Propel pilot controller Disassemble and assemble . . . . . . . . .33-3360-73 Remove and install . . . . . . . . . . . . . . . .33-3360-71 Proportional solenoid valve Disassemble and assemble . . . . . . . . .33-3360-62 Remove and install . . . . . . . . . . . . . . . .33-3360-59 Proportional solenoids Remove and install . . . . . . . . . . . . . . . .16-1674-23 Pump Hydraulic, assemble . . . . . . . . . . . . . . .33-3360-37 Hydraulic, disassemble . . . . . . . . . . . . .33-3360-22 Pilot, disassemble and assemble . . . . .33-3360-50 Pilot, disassemble drive shaft and gear. . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-36 Pilot, remove and install . . . . . . . . . . . .33-3360-49 Regulator, disassemble. . . . . . . . . . . . .33-3360-46

Remove and install . . . . . . . . . . . . . . . .33-3360-19 Start-up procedure . . . . . . . . . . . . . . . .33-3360-21 Pump control pressure sensor Remove and install . . . . . . . . . . . . . . . .16-1674-23 Pump drive gearbox Disassemble . . . . . . . . . . . . . . . . . . . . .33-3360-22 Remove and install . . . . . . . . . . . . . . . .33-3360-19

TM1668 (28JAN09)

R Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-2 Rear pump control valve Remove and install . . . . . . . . . . . . . . . .33-3360-89 Rear pump pressure sensor Remove and install . . . . . . . . . . . . . . . .16-1674-22 Reciever dryer Remove and install . . . . . . . . . . . . . . . .18-1830-28 Recoil spring Track, disassemble and assemble . . . .01-0130-41 Track, remove and install . . . . . . . . . . .01-0130-40 Refrigerant Charge R134a system . . . . . . . . . . . . .18-1830-11 Evacuate R134a system . . . . . . . . . . . .18-1830-10 Recover R134a system. . . . . . . . . . . . . .18-1830-9 R134a recovery, recycling and charging . . . . . . . . . . . . . . . . . . . . . . .18-1830-8 Refrigerant cautions, air conditioning R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 Refrigerant, air conditioning Proper handling. . . . . . . . . . . . . . . . . . . .18-1830-4 Regulator Hydraulic pump, disassemble . . . . . . . .33-3360-46 Relay Battery, remove and install . . . . . . . . . .16-1674-26 Relief valve Propel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22 Restriction Switch, air filter . . . . . . . . . . . . . . . . . . .16-1674-24 Restriction switch Air filter, remove and install. . . . . . . . . .16-1674-24 Restriction valve Swing motor make-up oil, remove. . . . 33-3360-123 Return filter Remove and install . . . . . . . . . . . . . . . 33-3360-117 Roller Track carrier, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-15 Track carrier, measure wear . . . . . . . . .01-0130-13 Track carrier, remove and install . . . . . .01-0130-13 Track, disassemble and assemble . . . .01-0130-10

Index-7

270LC Excavator Repair 012809

PN=7

Indx 7

Index

Page

Track, measure wear . . . . . . . . . . . . . . .01-0130-7 Track, remove and install . . . . . . . . . . . .01-0130-8 Track, test for oil leakage . . . . . . . . . . .01-0130-12 Rotary manifold Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-32 Disassemble and assemble . . . . . . . . .02-0260-30 Remove and install . . . . . . . . . . . . . . . .02-0260-26 R134a compressor oil Charge check . . . . . . . . . . . . . . . . . . . . .18-1830-5

Specific gravity, electrolyte . . . . . . . . . . . . .16-1671-5 Specification Carrier roller oil . . . . . . . . . . . . . . . . . . . .00-0004-6 Front idler oil. . . . . . . . . . . . . . . . . . . . . .00-0004-6 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-3 Grease . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .00-0004-5 Track roller oil . . . . . . . . . . . . . . . . . . . . .00-0004-6 270LC . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-1 Speed control cable Remove and install . . . . . . . . . . . . . . . . .05-0515-5 Spring Track adjuster, disassemble . . . . . . . . .01-0130-41 Track recoil, remove and install. . . . . . .01-0130-40 Spring wire retainer connectors Disconnect . . . . . . . . . . . . . . . . . . . . . .16-1674-25 Sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-33 Start aid switch. . . . . . . . . . . . . . . . . . . . .16-1674-17 Start-up procedure Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-21 Propel motor and park brake. . . . . . . . . .02-0260-7 Swing motor and park brake . . . . . . . . . .43-4360-3 Starter Remove and install . . . . . . . . . . . . . . . .04-0400-20 Switch, remove and install . . . . . . . . . .16-1674-17 Starter solenoid Remove and install . . . . . . . . . . . . . . . .16-1674-26 Starter switch Remove and install . . . . . . . . . . . . . . . .16-1674-17 Storing lubricants . . . . . . . . . . . . . . . . . . . .00-0004-8 Strainer Remove and install suction . . . . . . . . . 33-3360-120 Structure Welding repair of major. . . . . . . . . . . . . .17-1740-3 Suction strainer Remove and install . . . . . . . . . . . . . . . 33-3360-120 Swing bearing Disassemble and assemble . . . . . . . . .43-4350-25 Install lower seal . . . . . . . . . . . . . . . . . .43-4350-29 Install upper seal. . . . . . . . . . . . . . . . . .43-4350-28 Remove and install . . . . . . . . . . . . . . . .43-4350-23 Swing gearbox Disassemble and assemble . . . . . . . . . .43-4350-8 Remove and install . . . . . . . . . . . . . . . . .43-4350-4 Start-up procedure . . . . . . . . . . . . . . . . .43-4350-6 Swing motor Crossover relief valve, disassemble . . .43-4360-15 Make-up oil restriction valve, remove . . . . . . . . . . . . . . . . . . . . . . 33-3360-123 Make-up valve, disassemble . . . . . . . . .43-4360-15 Park brake release valve, disassemble . . . . . . . . . . . . . . . . . . .43-4360-17

Indx 8

S Sag Track, adjust . . . . . . . . . . . . . . . . . . . . .01-0130-31 Seal Metal face, inspect . . . . . . 01-0130-17, 02-0250-16 Seat Check adjustment . . . . . . . . . . . . . . . . . .18-1821-1 Remove and install . . . . . . . . . . . . . . . . .18-1821-2 Seat belt Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9 Remove and install . . . . . . . . . . . . . . . . .18-1821-8 Sensor Engine control, remove and install . . . . .05-0515-6 Engine coolant temperature . . . . . . . . .16-1674-20 Engine speed . . . . . . . . . . . . . . . . . . . .16-1674-23 Front pump pressure, remove . . . . . . . .16-1674-22 Fuel level switch . . . . . . . . . . . . . . . . . .16-1674-20 Propel function pressure, remove . . . . .16-1674-22 Pump Control Pressure. . . . . . . . . . . . .16-1674-23 Rear pump pressure, remove . . . . . . . .16-1674-22 Shut-off valve Pilot, linkage adjustment . . . . . . . . . . . .33-3360-56 Pilot, remove and install . . . . . . . . . . . .33-3360-54 Shut-off valve, pilot, Disassemble and assemble . . . . . . . . .33-3360-57 Shuttle valve Propel motor, park brake release . . . . .02-0260-22 Propel motor, servo piston . . . . . . . . . .02-0260-22 Sliding window Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Slow idle Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2 Solenoid Fuel shut-off linkage, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .05-0515-10 Fuel shut-off, check and adjust linkage. . . . . . . . . . . . . . . . . . . . . . . .05-0515-11 Starter, remove and install . . . . . . . . . .16-1674-26 Valve, proportional, disassemble. . . . . .33-3360-62 Valve, proportional, remove . . . . . . . . .33-3360-59 TM1668 (28JAN09)

Index-8

270LC Excavator Repair 012809

PN=8

Index

Page

Swing motor and park brake Assemble . . . . . . . . . . . . . . . . . . . . . . . .43-4360-9 Disassemble . . . . . . . . . . . . . . . . . . . . . .43-4360-4 Remove and install . . . . . . . . . . . . . . . . .43-4360-1 Start-up procedure . . . . . . . . . . . . . . . . .43-4360-3 Switch Air filter restriction, remove . . . . . . . . . .16-1674-24 Charge air temperature switch, remove . . . . . . . . . . . . . . . . . . . . . . .16-1674-19 Dig function pressure, remove . . . . . . .16-1674-21 Dome light, remove and install . . . . . . .16-1674-16 Engine coolant switch, remove . . . . . . .16-1674-19 Engine hour meter, remove. . . . . . . . . . .16-1676-3 Engine oil level, remove . . . . . . . . . . . .16-1674-19 Engine oil pressure, remove . . . . . . . . .16-1674-19 Engine overheat alarm, remove . . . . . .16-1674-18 Engine speed learning procedure . . . . . 05-0515-8, 16-1671-12, 16-1675-2 Remove and install control panel . . . . .16-1674-16 Start aid . . . . . . . . . . . . . . . . . . . . . . . .16-1674-17 Starter, remove and install . . . . . . . . . .16-1674-17 Travel alarm cancel. . . . . . . . . . . . . . . .16-1674-17 Windshield wiper enable switch. . . . . . .16-1674-24 System relief valve Disassemble and assemble . . . . . . . . 33-3360-107 Isolation check valve poppet . . . . . . . . .33-3360-89 Remove and install . . . . . . . . . . . . . . . .33-3360-89

Track Roller oil specification . . . . . . . . . . . . . . .00-0004-6 Track adjuster Disassemble and assemble . . . . . . . . .01-0130-41 Remove and install . . . . . . . . . . . . . . . .01-0130-40 Track adjuster cylinder Disassemble and assemble . . . . . . . . .01-0130-46 Track bushing Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-22 Track carrier roller Disassemble and assemble . . . . . . . . .01-0130-15 Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-13 Remove and install . . . . . . . . . . . . . . . .01-0130-13 Track chain Disassemble and assemble . . . . . . . . .01-0130-28 Disassemble and assemble to replace broken part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-29 Install . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-26 Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-24 Track link Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-21 Track pitch Measure . . . . . . . . . . . . . . . . . . . . . . . .01-0130-23 Track roller Disassemble and assemble . . . . . . . . .01-0130-10 Measure wear . . . . . . . . . . . . . . . . . . . . .01-0130-7 Remove and install . . . . . . . . . . . . . . . . .01-0130-8 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-12 Track sag Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-31 Track shoe grouser Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-19 Remove and install . . . . . . . . . . . . . . . .01-0130-20 Travel alarm Remove and install . . . . . . . . . . . . . . . .16-1674-21 Travel alarm cancel switch . . . . . . . . . . . .16-1674-17 Travel alarm volume Change . . . . . . . . . . . . . . . . . . . . . . . . . .16-1676-3

T Tank Fuel, remove and install . . . . . . . . . . . . .05-0560-2 Hydraulic oil, disassemble. . . . . . . . . . 33-3360-116 Hydrulic oil, remove and install . . . . . . 33-3360-110 Thermostats Remove and install . . . . . . . . . . . . . . . . .05-0510-5 Tooth Replacement, bucket . . . . . . . . . . . . . . .33-3302-1 Tip replacement, heavy-duty bucket . . . .33-3302-3 Tooth shank Remove and install . . . . . . . . . . . . . . . . .33-3302-4 Torque value Flared connections . . . . . . . . . . . . . . . .00-0003-10 Flat face O-ring seal fitting . . . . . . . . . . .00-0003-8 Inch SAE four bolt flange fitting. . . . . . .00-0003-11 Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3 Metric four bolt flange fitting . . . . . . . . .00-0003-12 O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6 30&deg; cone seat hydraulic fittings . . . .00-0003-9 37&deg; flare hydraulic fittings . . . . . . . .00-0003-9 Towing machine . . . . . . . . . . . . . . . . . . . . .02-0250-3 TM1668 (28JAN09)

U Upperstructure Install . . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-20 Remove . . . . . . . . . . . . . . . . . . . . . . . .43-4350-15

V Valve Arm II to arm I neutral passage check, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89

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Indx 9

Index

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Arm in anti-drift, remove . . . . . . . . . . . .33-3360-89 Arm regenerative check valve poppet, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Arm regenerative, remove. . . . . . . . . . .33-3360-89 Boom anti-drift, remove. . . . . . . . . . . . .33-3360-89 Boom regenerative, remove . . . . . . . . .33-3360-89 Bucket flow control, remove . . . . . . . . .33-3360-89 Circuit relief and anti-cavitation, disassemble . . . . . . . . . . . . . . . . . . 33-3360-109 Circuit relief and anti-cavitation, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Control, disassemble and assemble . . .33-3360-89 Indx Control, remove and install . . . . . . . . . .33-3360-80 10 Flow combiner, remove. . . . . . . . . . . . .33-3360-89 Flow regulator, disassemble . . . . . . . . .33-3360-79 Flow regulator, remove and install . . . .33-3360-77 Front pump control, remove . . . . . . . . .33-3360-89 Hydraulic oil tank relief, disassemble . . . . . . . . . . . . . . . . . . 33-3360-122 Oil cooler bypass, remove. . . . . . . . . . 33-3360-125 Pilot pressure regulating, disassemble . . . . . . . . . . . . . . . . . . .33-3360-54 Pilot pressure regulating, remove . . . . .33-3360-52 Pilot shut-off, linkage adjustment. . . . . .33-3360-56 Pilot shut-off, remove and install . . . . . .33-3360-54 Propel motor brake pressure reducing . . . . . . . . . . . . . . . . . . . . . .02-0260-22 Propel motor check . . . . . . . . . . . . . . . .02-0260-22 Propel motor counterbalance . . . . . . . .02-0260-22 Propel motor relief . . . . . . . . . . . . . . . .02-0260-22 Propel motor, park brake shuttle . . . . . .02-0260-22 Propel motor, servo piston shuttle . . . . .02-0260-22 Proportional solenoid, disassemble . . . .33-3360-62 Proportional solenoid, remove. . . . . . . .33-3360-59 Rear pump control, remove. . . . . . . . . .33-3360-89 Return filter bypass, remove . . . . . . . . 33-3360-117 Swing motor crossover relief, disassemble . . . . . . . . . . . . . . . . . . .43-4360-15 Swing motor make-up oil restriction, remove . . . . . . . . . . . . . . . . . . . . . . 33-3360-123 Swing motor make-up, disassemble . . .43-4360-15 Swing motor park brake release, disassemble . . . . . . . . . . . . . . . . . . .43-4360-17 System relief valve isolation check valve poppet, remove . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 System relief, disassemble . . . . . . . . . 33-3360-107 System relief, remove and install . . . . .33-3360-89 Valve spool Remove and install . . . . . . . . . . . . . . . .33-3360-89 Right control valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Valve, pilot shut-off Disassemble and assemble . . . . . . . . .33-3360-57

Vent Tube engine crankcase. . . . . . . . . . . . .04-0400-16

TM1668 (28JAN09)

W Water separator Primary fuel filter element, remove . . . . .05-0560-6 Primary fuel filter, remove and install . . .05-0560-4 Welding on machine . . . . . . . . 16-1675-1, 17-1740-1, 33-3302-3 Welding repair of major structure . . . . . . . .17-1740-3 Window Sliding, remove and install . . . . . . . . . . .18-1810-3 Windowpane Dimensions . . . . . . . . . . . . . . . . . . . . . . .18-1810-4 Install one piece molding . . . . . . . . . . . .18-1810-2 Install two piece molding . . . . . . . . . . . . .18-1810-1 Windshield wiper enable switch Remove and install . . . . . . . . . . . . . . . .16-1674-24

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