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300GLC Excavator Repair (PIN: 1FF300GX_ _F710002— )

REPAIR TECHNICAL MANUAL 300GLC Excavator (PIN: 1FF300GX_ _F710002— ) TM13264X19 02FEB17

For complete service information also see: 300GLC Excavator Operation and Test .............

TM13263X19

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CTM120019

JDLink™ (MTG) Technical Manual.....................

TM114519

Undercarriage Appraisal Manual .......................

SP326VOL1

Test and Specifications Manual .........................

SP458VOL2

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

(ENGLISH)

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.

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.

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

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.

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

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. MM16284,0001A38 -19-01DEC15-1/1

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Introduction

Manual Identification—READ THIS FIRST!

TX1156411 —UN—27MAR14

IMPORTANT: Use only supporting manuals designated for your specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) when choosing the correct manual. Choosing the Correct Supporting Manuals John Deere excavators are available in different machine configurations based on the various markets into which they are sold. Different supporting manuals exist for different machine configurations. When necessary, product identification numbers are listed on the front covers of excavator manuals. These numbers are used to identify the correct supporting manual for your machine.

The product identification number (PIN) plate (1) is located on the front, right corner of the cab. Each machine has a 17-character PIN (2) shown on PIN plate.

JOHN DEERE Product Identification Number *1FF300GXCDF710002*

EXCAVATOR 300G DEERE & COMPANY, MOLINE, ILLINOIS, USA

TX1169347 —UN—30SEP14

Product Identification Number

PIN Plate Location

Example of PIN Plate 1— PIN Plate

Continued on next page

TM13264X19 (02FEB17)

2— 17-Character PIN

DJ54098,0000411 -19-30SEP14-1/2

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Introduction

The following is an example for a machine that meets Final Tier 4 and Stage IV emission levels:

The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number.

17-Character PIN Examples 1

• (1—3) World Code: Identifies location where machine is manufactured.

1FF .................. World Code (manufacturing location) 1DW ............. Davenport Works 1T8 ............... Thibodaux Works 1T0 ............... Dubuque Works 1FF ............... Deere—Hitachi (Kernersville, NC, USA) 1F9 ............... Deere—Hitachi (Indaiatuba, São Paulo, Brazil)

• (4—8) Machine Model Identifier: Identifies model number.

300G ................ Machine Model Identifier

9 _

10 _

_ ..................... Manufacturing Year Code (variable) D ................. 2013 E .................. 2014 F .................. 2015 G ................. 2016

• (11) Engine Emission Code: Represents engine emission certification.

F ..................... Engine Emission Code C ................. Tier 2 and Stage II D ................. Tier 3 and Stage III A E .................. Interim Tier 4 and Stage III B F .................. Final Tier 4 and Stage IV

X ..................... Machine Option Code X .................. Base Machine R ................. HYEX Military Excavators

• (9) Check Letter: Random character assigned by the factory. This is not used in machine identification. _ ..................... Check Letter (variable)

• (12—17) Machine Serial Number: Identifies machine serial number. This character will change from one machine to another.

710002 ............. Machine Serial Number

• (10) Manufacturing Year Code: Identifies year of machine manufacture.

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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:

John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA

FAX NUMBER: 1-563-589-5800 (USA) Publication Number: Page Number: Ideas, Comments:

Name: Phone: Email Address: THANK YOU! TX,TM,FAX -19-03JUL01-1/1

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Introduction

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Contents Section 00—General Information Group 0001—Safety Group 0003—Torque Values

Section 01—Tracks Group 0130—Track System

Section 02—Axles, Differentials, 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 0510—Cooling Systems Group 0530—External Exhaust Systems Group 0560—External Fuel Supply Systems

Section 07—Damper Drive (Flex Coupling) Group 0752—Elements

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

Section 19—Sheet Metal Group 1910—Hood and Engine Side Shields

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

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

Section 99—Dealer Fabricated Tools Group 9900—Dealer Fabricated Tools

Original Instructions. 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. COPYRIGHT © 2017 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2015

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Contents

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Section 00 General Information

Page Page

Group 0001—Safety Recognize Safety Information ................... 00-0001-1 Follow Safety Instructions.......................... 00-0001-1 Operate Only If Qualified ........................... 00-0001-1 Wear Protective Equipment....................... 00-0001-2 Avoid Unauthorized Machine Modifications.......................................... 00-0001-2 Control Pattern Selector—If Equipped ............................................... 00-0001-2 Add Cab Guarding for Special Uses ...................................................... 00-0001-2 Inspect Machine ........................................ 00-0001-3 Stay Clear of Moving Parts........................ 00-0001-3 Avoid High-Pressure Fluids ....................... 00-0001-3 Avoid High-Pressure Oils .......................... 00-0001-4 Work In Ventilated Area............................. 00-0001-4 Avoid Static Electricity Risk When Refueling ............................................... 00-0001-5 Prevent Fires ............................................. 00-0001-5 In Case of Machine Fire ............................ 00-0001-6 Prevent Battery Explosions ....................... 00-0001-6 Handle Chemical Products Safely.............. 00-0001-6 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................... 00-0001-7 Exhaust Filter Ash Handling and Disposal................................................. 00-0001-7 Prepare for Emergencies........................... 00-0001-7 Clean Debris from Machine ....................... 00-0001-8 Use Steps and Handholds Correctly ................................................ 00-0001-8 Start Only From Operator's Seat ............... 00-0001-8 Use and Maintain Seat Belt ....................... 00-0001-8 Prevent Unintended Machine Movement.............................................. 00-0001-9 Avoid Work Site Hazards........................... 00-0001-9 Keep Riders Off Machine ........................ 00-0001-10 Avoid Backover Accidents ....................... 00-0001-10 Inspect and Maintain ROPS .................... 00-0001-10 Avoid Machine Tip Over .......................... 00-0001-11 Use Special Care When Lifting Objects ................................................ 00-0001-11 Travel Safely............................................ 00-0001-12 Add and Operate Attachments Safely................................................... 00-0001-12 Park and Prepare for Service Safely................................................... 00-0001-12 Service Cooling System Safely ............... 00-0001-13 Remove Paint Before Welding or Heating ................................................ 00-0001-13 Make Welding Repairs Safely ................. 00-0001-13 Drive Metal Pins Safely ........................... 00-0001-14 Clean Exhaust Filter Safely ..................... 00-0001-15

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Group 0003—Torque Values Torque Value Metric Bolt and Cap Screw....................00-0003-1 Additional Metric Cap Screw Torque Values ........................................ 00-0003-2 Unified Inch Bolt and Cap Screw ..........00-0003-3 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ............................................ 00-0003-4 Service Recommendations for O-Ring Boss Fittings.............................. 00-0003-4 Service Recommendations for Flared Connections—Straight or Tapered Threads ................................... 00-0003-6 Service Recommendations for Flat Face O-Ring Seal Fittings ..................... 00-0003-7 Service Recommendation O-Ring Boss Fittings In Aluminum HousingExcavators.............................................................00-0003-8 O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure.......................00-0003-9 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure..............00-0003-11 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for High Pressure.....................00-0003-13 Service Recommendations for Metric Series Four Bolt Flange Fitting................................................... 00-0003-15 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 00-0003-16 Inch Series Four Bolt Flange For High Pressure ..................................................00-0003-17 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings............................. 00-0003-18 Service Recommendations For O-Ring Boss Fittings With Shoulder .............................................. 00-0003-19 Metric 24 O-Ring Seal DIN 20078.......00-0003-21

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Group 0001

Safety Recognize Safety Information T133555 —UN—15APR13

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

T133588 —19—28AUG00

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

TX,RECOGNIZE -19-28JUN10-1/1

Follow Safety Instructions

TS201 —UN—15APR13

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

TX,FOLLOW -19-20JAN11-1/1

Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction.

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

Operator should be familiar with the job site and surroundings before operating. Try all controls and TX,QUALIFIED -19-18JAN11-1/1

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Safety

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

TS206 —UN—15APR13

Wear close fitting clothing and safety equipment appropriate to the job. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use for hearing protection.

TX,WEAR,PE -19-22SEP10-1/1

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

reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability. AM40430,00000A9 -19-20AUG09-1/1

Control Pattern Selector—If Equipped This machine may be equipped with a control pattern selector valve. Ensure all bystanders are clear of machine

and area is large enough to operate machine functions. Verify the machine response to each control movement.

DB84312,00000A5 -19-07JUL15-1/1

Add Cab Guarding for Special Uses Special work situations or machine attachments could create an environment with falling or flying objects. Working near an overhead bank, demolition work, using a hydraulic hammer or winch, working in a forestry application or wooded area, or working in a waste management application, for example, could require added guarding to protect the operator.

Additional level II FOPS (falling object protective structure), forestry protection packages, and special screens or guarding should be installed when falling or flying objects could enter or damage the machine. A rear screen should always be used with a winch to protect against a snapping cable. Before operating in any special work environments, follow the operator protection recommendations of the manufacturer of any specialized attachment or equipment. Contact your authorized John Deere dealer for information on protective guarding. TX,CABGUARD -19-12FEB13-1/1

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Safety

Inspect Machine

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

T6607AQ —UN—15APR13

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

TX,INSPECT -19-08SEP10-1/1

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

T133592 —UN—15APR13

Stay Clear of Moving Parts

TX,MOVING,PARTS -19-20JAN11-1/1

Avoid High-Pressure Fluids

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. 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.

X9811 —UN—23AUG88

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

DX,FLUID -19-06OCT16-1/1

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Safety

Avoid High-Pressure Oils

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

T133840 —UN—20SEP00

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

T133509 —UN—15APR13

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

TX,HPOILS -19-20JAN11-1/1

Work In Ventilated Area

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

TS220 —UN—15APR13

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

DX,AIR -19-17FEB99-1/1

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Safety

Avoid Static Electricity Risk When Refueling The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge. RG22142 —UN—17MAR14

Refineries may have treated the fuel with a static dissipating additive. However, there are many factors that can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while it is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion.

RG21992 —UN—21AUG13

Therefore, it is important to ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

DX,FUEL,STATIC,ELEC -19-12JUL13-1/1

T133552 —UN—15APR13

Prevent Fires Handle Fluids Safely: All fuels, most lubricants, and some coolant mixtures are flammable. Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep flammable debris (trash, leaves, twigs, straw, and so forth), grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

T133553 —UN—07SEP00

Maintain Hoses, Tubes, and Wiring: Replace hoses and tubes immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use an extinguisher properly.

T133554 —UN—07SEP00

Be Aware of the Operating Environment: Airborne debris may contain sparks or embers. Do not operate near any flame.

TX,PREVENT,FIRE -19-09JUN16-1/1

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Safety

In Case of Machine Fire CAUTION: Avoid personal injury from exposed flames. Maintain safe distance.

TS227 —UN—15APR13

• Turn the engine off. • Turn the battery disconnect switch to the OFF position, if equipped.

• If possible, fight the fire using the portable fire

extinguisher or other fire suppression equipment, if equipped. • Ensure that the fire does not spread to the surrounding area. Do not risk injury. If a fire is too far advanced, do not try to extinguish fire. • Call for help.

In Case of Machine Fire

CN93077,00000B2 -19-09FEB16-1/1

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

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

TS204 —UN—15APR13

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

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.

TS1132 —UN—15APR13

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.

(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

Decommissioning — Proper Recycling and Disposal of Fluids and Components

TS1133 —UN—15APR13

Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:

• Use appropriate tools and personal protective

equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. • Follow instructions for specialized components. • Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. • Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. • Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. • Do not pour waste fluids onto the ground, down a drain, or into any water source. • Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);

filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. • Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. • Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. • Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste. DX,DRAIN -19-01JUN15-1/1

Exhaust Filter Ash Handling and Disposal CAUTION: Under federal, state, and local laws or regulations, exhaust filter ash can be classified as a hazardous waste. Hazardous waste must be disposed of in accordance with all applicable federal, state, and local laws or regulations

governing hazardous waste disposal. Only a qualified service provider should remove ash from the exhaust filter. Personal protective equipment and clothing, maintained in a sanitary and reliable condition, should be used when handling and cleaning exhaust filter. See your authorized dealer for exhaust filter ash handling and disposal. TX,ASH,DISP -19-20JAN11-1/1

Prepare for Emergencies Be prepared if a fire starts.

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

TS291 —UN—15APR13

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 -19-03MAR93-1/1

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Safety

Clean Debris from Machine

Clean any oil spills or fuel spills on machine surfaces. Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

T6669AG —UN—15APR13

Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator's station clean and free of debris.

TX,DEBRIS -19-20JAN11-1/1

Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

T133468 —UN—15APR13

Use Steps and Handholds Correctly

TX,STEPS -19-09FEB11-1/1

Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure that all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

T133715 —UN—15APR13

Start Only From Operator's Seat

TX,SOFOS -19-20JAN11-1/1

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

T133716 —19—17APR13

Use and Maintain Seat Belt

The complete seat belt assembly should be replaced every three years, regardless of appearance. TX,SEAT,BELT -19-20JAN11-1/1

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Safety

Prevent Unintended Machine Movement

T216779 —UN—22NOV05

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

VD76477,000036D -19-19APR11-1/1

Avoid Work Site Hazards T134986 —UN—31OCT00

Avoid contact with gas lines, buried cables, and water lines. Call utility line location services to identify all underground utilities before digging. Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

Work Site Hazards

T133650 —UN—27SEP00

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

Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position travel motors away from the hole. T133549 —UN—24AUG00

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc). At high speeds, hitting obstacles (rocks, uneven concrete, or manholes) can cause a sudden stop. Always wear seat belt.

Work Site Hazards TX03679,0001748 -19-08JUL15-1/1

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Safety

Keep Riders Off Machine Only allow operator on machine.

T7273AH —UN—08JUN90

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair the ability to operate machine safely.

Keep Riders Off Machine TX03679,0001726 -19-30JUN16-1/1

Avoid Backover Accidents

PC10857XW —UN—15APR13

Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Do not rely on the rear camera and radar object detection systems, if equipped, to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range.

TX,AVOID,BACKOVER -19-04MAR16-1/1

Inspect and Maintain ROPS

To maintain the ROPS:

A damaged rollover protective structure (ROPS) should be replaced, not reused.

• Replace missing hardware using correct grade

The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.

• Check hardware torque. • Check isolation mounts for damage, looseness, or

hardware.

wear; replace them if necessary.

• Check ROPS for cracks or physical damage.

If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. TX,ROPS -19-20JAN11-1/1

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Safety

Avoid Machine Tip Over T133716 —19—17APR13

Use seat belt at all times. Do not jump if the machine tips. Operator will be unlikely to jump clear and the machine may crush the operator. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.

Use Seat Belt

Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip.

T133545 —UN—15SEP00

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

Unloading Machine

T133803 —UN—27SEP00

Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.

Do Not Jump TX03679,00016DF -19-30JUN16-1/1

Use Special Care When Lifting Objects T133839 —UN—27SEP00

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

Use Special Care When Lifting Objects

Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use tether lines to guide loads and prearranged hand signals to communicate with co-workers. TX03679,00016E1 -19-08JUL15-1/1

TM13264X19 (02FEB17)

00-0001-11

300GLC Excavator 020217 PN=21

Safety

Travel Safely When working on steep slopes, travel as straight up and down as possible to prevent roll-over. T6964AD —UN—20DEC88

DO NOT PARK ON A HILLSIDE OR AN INCLINE. Always park the machine on level ground. Know the location of bystanders before moving the machine. Always keep the reverse warning alarm in working condition. The alarm warns bystanders when the machine starts to move in reverse.

Travel Safely

Use a signal person when moving the machine in congested areas. Coordinate hand signals before starting the machine. CN93077,00000B3 -19-01JUL15-1/1

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

is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion. TX,ATTACH -19-20JAN11-1/1

Park and Prepare for Service Safely Warn others of service work. Always park and prepare machine for service or repair properly.

• Park machine on a level surface and lower equipment T133332 —19—17APR13

to the ground.

• Place pilot shutoff lever in locked (UP) position. Stop engine and remove key.

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

Securely support machine or attachment before working under it.

• Do not support machine with any hydraulically actuated

Do Not Operate Tag

equipment.

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

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

TS229 —UN—23AUG88

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

Support Machine Properly OUT4001,000089A -19-02JUL15-1/1

TM13264X19 (02FEB17)

00-0001-12

300GLC Excavator 020217 PN=22

Safety

Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281 —UN—15APR13

Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.

TX,SURGE -19-19JAN11-1/1

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 —UN—15APR13

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area

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

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

Make Welding Repairs Safely T133547 —UN—15APR13

IMPORTANT: Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and negative (-) battery cables. Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic. Heating Near Pressurized Fluid Lines

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

Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. MB60223,0000212 -19-02JUL15-1/1

TM13264X19 (02FEB17)

00-0001-13

300GLC Excavator 020217 PN=23

Safety

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

T133738 —UN—15APR13

Drive Metal Pins Safely

TX,PINS -19-20JAN11-1/1

TM13264X19 (02FEB17)

00-0001-14

300GLC Excavator 020217 PN=24

Safety

During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials. Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode.

TS227 —UN—15APR13

Clean Exhaust Filter Safely

Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning.

Always make sure that engine is stopped while hauling machine on a truck or trailer. Contact with exhaust components while still hot can result in serious personal injury. Avoid contact with these components until cooled to safe temperatures.

TS271 —UN—23AUG88

Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel.

If service procedure requires engine to be running:

• Only engage power-driven parts required by service procedure

and machine

Keep hands, feet, and clothing away from power-driven parts. Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before leaving the operator’s station.

TS1693 —UN—09DEC09

• Ensure that other people are clear of operator station

TS1695 —UN—07DEC09

Shut off engine and remove key (if equipped) before leaving the machine unattended.

DX,EXHAUST,FILTER -19-12JAN11-1/1

TM13264X19 (02FEB17)

00-0001-15

300GLC Excavator 020217 PN=25

Safety

TM13264X19 (02FEB17)

00-0001-16

300GLC Excavator 020217 PN=26

Group 0003

Torque Values Metric Bolt and Cap Screw Torque Values

TORQ2 —UN—15APR13

METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified

Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings Class 4.8 Thread Size

Lubricateda N·m (lb·ft)

Class 8.8 or 9.8

Dryb N·m (lb·ft)

Class 10.9

Lubricateda N·m (lb·ft)

Dryb N·m (lb·ft)

Class 12.9

Lubricateda N·m (lb·ft)

Dryb N·m (lb·ft)

Lubricateda N·m (lb·ft)

Dryb N·m (lb·ft) 19.5 (14.5)

4.7 (3.5)

6 (4.4)

9 (6.6)

11.5 (8.5)

13 (9.5)

16.5 (12.2)

15.5 (11.5)

11.5 (8.5)

14.5 (10.7)

22 (16)

28 (20.5)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

M10

23 (17)

29 (21)

43 (32)

55 (40)

63 (46)

80 (59)

75 (55)

95 (70)

M12

40 (29.5)

50 (37)

75 (55)

95 (70)

110 (80)

140 (105)

130 (95)

165 (120)

M14

63 (46)

80 (59)

120 (88)

150 (110)

175 (130)

220 (165)

205 (150)

260 (190)

M16

100 (74)

125 (92)

190 (140)

240 (175)

275 (200)

350 (255)

320 (235)

400 (300)

M18

135 (100)

170 (125)

265 (195)

330 (245)

375 (275)

475 (350)

440 (325)

560 (410)

M20

190 (140)

245 (180)

375 (275)

475 (350)

530 (390)

675 (500)

625 (460)

790 (580)

M22

265 (195)

330 (245)

510 (375)

650 (480)

725 (535)

920 (680)

850 (625)

1080 (800)

M24

330 (245)

425 (315)

650 (480)

820 (600)

920 (680)

1150 (850)

1080 (800)

1350 (1000)

M27

490 (360)

625 (460)

950 (700)

1200 (885)

1350 (1000)

1700 (1250)

1580 (1160)

2000 (1475)

M30

660 (490)

850 (625)

1290 (950)

1630 (1200)

1850 (1350)

2300 (1700)

2140 (1580)

2700 (2000)

M33

900 (665)

1150 (850)

1750 (1300)

2200 (1625)

2500 (1850)

3150 (2325)

2900 (2150)

3700 (2730)

M36

1150 (850)

1450 (1075)

2250 (1650)

2850 (2100)

3200 (2350)

4050 (3000)

3750 (2770)

4750 (3500)

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

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

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

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

Make sure fastener threads are clean and that the thread engagement is properly started. This will prevent fasteners from failing when tightening. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for Tighten plastic insert or crimped steel-type lock nuts to approximately general use only. Check tightness of fasteners periodically. 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full Shear bolts are designed to fail under predetermined loads. Always torque value. replace shear bolts with identical property class. OUT3035,TORQUE2 -19-04MAR16-1/1

TM13264X19 (02FEB17)

00-0003-1

300GLC Excavator 020217 PN=27

Torque Values

T6873AA —UN—15APR13

Additional Metric Cap Screw Torque Values CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. 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.

T-Bolt

T6873AB —UN—18OCT88

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. 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. Make sure fastener threads are clean and that the thread engagement is properly started. This will prevent fasteners from failing when tightening.

H-Bolt

T6873AC —UN—18OCT88

Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart. METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

M-Bolt

Nominal Diameter

N·m

lb·ft

N·m

lb·ft

N·m

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

lb·ft M-Bolt

Torque tolerance is ±10%. 04T,90,M170 -19-29SEP99-1/1

TM13264X19 (02FEB17)

00-0003-2

300GLC Excavator 020217 PN=28

Torque Values

Unified Inch Bolt and Cap Screw Torque Values

TORQ1A —UN—15APR13

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified.

Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings Grade 2a (No Mark)

Grade 1 (No Mark) Thread Size

Lubricated N·m (lb·ft)

Dry N·m (lb·ft)

Lubricatedb N·m (lb·ft)

Dryc N·m (lb·ft)

Grade 5, 5.1, or 5.2 Lubricatedb N·m (lb·ft)

Grade 8 or 8.2

Dryc N·m (lb·ft)

Lubricatedb N·m (lb·ft)

Dryc N·m (lb·ft)

1/4

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165) 305 (225)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

285 (210)

360 (265)

285 (210)

360 (265)

730 (540)

920 (680)

1030 (760)

1300 (960)

1-1/8

400 (300)

510 (375)

400 (300)

510 (375)

910 (670)

1150 (850)

1450 (1075)

1850 (1350)

1-1/4

570 (420)

725 (535)

570 (420)

725 (535)

1280 (945)

1630 (1200)

2050 (1500)

2600 (1920)

1-3/8

750 (550)

950 (700)

750 (550)

950 (700)

1700 (1250)

2140 (1580)

2700 (2000)

3400 (2500)

1-1/2

990 (730)

1250 (930)

990 (730)

1250 (930)

2250 (1650)

2850 (2100)

3600 (2650)

4550 (3350)

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

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

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

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that the thread engagement is procedure is given for a specific application. Torque values listed are for properly started. This will prevent fasteners from failing when tightening. general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately Shear bolts are designed to fail under predetermined loads. Always 50 percent of the dry torque shown in the chart, applied to the nut, not replace shear bolts with identical grade. to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. OUT3035,TORQUE1 -19-04MAR16-1/1

TM13264X19 (02FEB17)

00-0003-3

300GLC Excavator 020217 PN=29

Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6234AC —UN—15APR13

2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align tube with fitting before attempting to start nut. 4. Lubricate male threads with hydraulic fluid or petroleum jelly. Cone Seat Connector

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

3/8 - 24 UNF

lb·ft 6

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

Service Recommendations for O-Ring Boss Fittings Straight Fitting T6243AE —UN—15APR13

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. 3. Tighten fitting to torque value shown on chart. Straight Fitting Continued on next page

TM13264X19 (02FEB17)

00-0003-4

04T,90,K66 -19-29SEP99-1/2

300GLC Excavator 020217 PN=30

Torque Values Angle Fitting 1. Back off lock nut (A) and backup washer (B) completely to head end (C) of fitting. T6520AB —UN—15APR13

2. Turn fitting into threaded boss until backup washer contacts face of boss. 3. Turn fitting head end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings. 4. Hold fitting head end with a wrench and tighten locknut and backup washer to proper torque value.

Angle Fitting

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART N·m

lb·ft

3/8-24 UNF

Thread Size

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

A—Lock Nut B—Backup Washer

C—Head End

NOTE: Torque tolerance is ± 10%. 04T,90,K66 -19-29SEP99-2/2

TM13264X19 (02FEB17)

00-0003-5

300GLC Excavator 020217 PN=31

Torque Values

Service Recommendations for Flared Connections—Straight or Tapered Threads 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6873AE —UN—15APR13

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. 4. Lubricate the male threads with hydraulic fluid or petroleum jelly.

Straight Thread

5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings. Straight Thread b

Tapered Thread

Thread Size

N·m

lb·ft

N·m

lb·ft

1/8

1/4

3/8

1/2

3/4

176

130

157

116

343

253

1-1/2

196

145

539

398

255

188

588

434

T6873AD —UN—15APR13

TORQUE CHARTa

Tapered Thread

Torque tolerance is ±10%. b With seat face.

NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately 10%. 04T,90,M171 -19-28JAN92-1/1

TM13264X19 (02FEB17)

00-0003-6

300GLC Excavator 020217 PN=32

Torque Values

Service Recommendations for Flat Face O-Ring Seal Fittings

4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.

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

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

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

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

3. Index angle fittings and tighten by hand pressing joint together to ensure O-ring remains in place.

FLAT FACE O-RING SEAL FITTING TORQUE* Nominal Tube OD mm in

Thread Size

Bulkhead Nut

Swivel Nut

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

Straight Fitting or Locknut Toque N·m

3/8-24

5/8

9/16

7/16-20

5/8

1/2-20

3/4

11/16

9/16-18

3/4

25 55

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. OUO6092,00010A4 -19-04MAR16-1/1

TM13264X19 (02FEB17)

00-0003-7

300GLC Excavator 020217 PN=33

Torque Values

T196315 —UN—17NOV03

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

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

5— Hex Nut 6— Backup Washer

3— Stud End 4— Adjustable Fitting

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

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

Thread Size mm

Hex Nut Size mm

Nm (lb-ft)

Thread Size in.

M12 x 1.5

39 (29)

1/8

7.8 (5.80)

M14 x 1.5

39 (29)

1/4

11.8 (8.70)

M16 x 1.5

55 (41)

3/8

23 (17)

M22 x 1.5

75 (55)

1/2

39 (29)

M27 x 2

110 (81)

3/4

55 (41)

M30 x 2

141 (104)

86 (64)

M33 x 2

165 (122)

1-1/4

126 (93)

M38 x 2

165 (122)

1-1/2

157 (116)

M42 x 2

275 (203)

204 (150)

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

Nm (lb-ft)

1/8

—

1/4

28 (20)

3/8

39 (29)

1/2

75 (55)

3/4

126 (93)

165 (122)

1-1/8

—

1-1/4

259 (191)

1-3/8

—

1-1/2

330 (243)

1-3/4

—

Nm (lb-ft)

1. Inspect fitting and O-ring boss sealing surfaces and the O-ring. They must be free of dirt, scratches, nicks, or burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. 2. Back the stud end hex nut (5) off as far as possible. Push backup washer (6) towards the nut to fully expose the turn down section of stud end. Washer must fit turned down section and not be too loose 3. Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape. Apply hydraulic oil to the threads of stud end, turned down section, and O-ring. 4. Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and contacts face of boss. Loosen an adjustable fitting no more than one turn for alignment. 5. Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when tightening hex nut. OUT3035,0000353 -19-28MAY09-1/1

TM13264X19 (02FEB17)

00-0003-8

300GLC Excavator 020217 PN=34

Torque Values

O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH-PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

H70406 —UN—15APR13

G E F

H F E

O-Ring Face Seal Fittings A—90° Swivel Elbow and Tube Nut B—90° Adjustable Stud Elbow

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

Nominal Tube OD or Hose ID

E—Stud End F— Tube Nut G—Swivel Nut H—Hex Nut Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Hex Size

Torque

Hex Size

Torque

in —

N·m (lb·ft) —

in —

N·m (lb·ft) —

9/16-18 —

11/16 —

24 (18) —

13/16 —

32 (24) —

Metric Tube OD mm

Dash Size

mm (in)

-3

4.78 (0.188)

-4

6.35 (0.250)

-5

7.92 (0.312)

-6

9.53 (0.375)

11/16-16

13/16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

15/16

75 (55)

1-1/8

93 (69)

-10

15.88 (0.625)

1-14

1-1/8

103 (76)

1-5/16

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

-14

22.23 (0.875)

1-3/16-12

152 (112)

1-1/2 —

175 (129)

1-3/8 —

-16

25.40 (1.000)

1-7/16-12

1-5/8

214 (158)

1-3/4

247 (182)

-20

31.75 (1.250)

1-11/16-12

1-7/8

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

2-1/4

326 (240)

2-3/8

374 (276)

175 (129)

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

Straight Hex Sizea

Adjustable Nut Hex Size

Steel or Gray Iron Torque

N·m (lb·ft)

3/8-24

5/8

9/16

18 (13)

7/16-20

5/8

24 (18)

1/2-20

3/4

11/16

30 (22)

9/16-18

3/4

37 (27)

3/4-16

7/8

15/16

75 (55)

7/8-14

1-1/16

103 (76)

1-1/16-12

1-1/4

1-3/8

177 (131)

1-3/16-12

1-3/8

1-1/2

231 (170)

1-5/16-12

1-1/2

1-5/8

270 (199)

1-5/8-12

1-3/4

1-7/8

286 (211)

1-7/8-12

2-1/8

326 (240)

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

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks,

and burrs. O-ring must be free of dirt, cuts, cracks, swelling, or flatten condition.

Continued on next page

TM13264X19 (02FEB17)

00-0003-9

OUT3035,0000420 -19-04MAR16-1/2

300GLC Excavator 020217 PN=35

Torque Values

2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose.

4. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment.

3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place.

Hold connections together while tightening nut to ensure O-ring remains in place.

Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut.

To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. OUT3035,0000420 -19-04MAR16-2/2

TM13264X19 (02FEB17)

00-0003-10

300GLC Excavator 020217 PN=36

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

T196337 —UN—15APR13

T196337

O-Ring Face Seal Fittings 1— 90° Swivel Elbow 2— 90° Adjustable Stud Elbow 3— Stud Straight

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

Nominal Tube OD or Hose ID Metric Tube OD mm

Inch Tube OD or Hose ID

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut Thread Size

Hex Size

Torque

Hex Size

Torque

N·m (lb·ft) —

—

N·m (lb·ft) —

-2

3.18 (0.125)

in —

-3

4.78 (0.188)

—

-4

6.35 (0.250)

-5

7.92 (0.312)

9/16-18 —

17 —

16 (12) —

22 —

32 (24) —

-6

9.53 (0.375)

11/16-16

24 (18)

42 (31)

-8

12.70 (0.500)

13/16-16

50 (37)

93 (69)

-10

15.88 (0.625

1-14

69 (51)

118 (87)

-12

19.05 (0.750)

1-3/16-12

102 (75)

175 (129)

-14

22.23 (0.875)

1-3/16-12

102 (75)

175 (129)

25 28

-16 —

25.40 (1.000) —

1-7/16-12 —

41 —

142 (105) —

46 —

247 (182) —

-20

31.75 (1.250)

1-11/16-12

190 (140)

328 (242)

-24

38.10 (1.500)

-32

50.80 (2.000)

2-12 —

60 —

217 (160) —

60 —

374 (276) —

Dash Size

mm (in)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

Aluminum or Brass Torque

N·m (lb·ft)

M8 x 1

8 (6)

5 (4)

M10 x 1

15 (11)

10 (7)

M12 x 1.5

25 (18)

17 (12)

M14 x 1.5

40 (30)

27 (20)

M16 x 1.5

45 (33)

30 (22)

M18 x 1.5

50 (37)

33 (25)

M22 x 1.5

69 (51)

46 (34)

M27 x 2

100 (74)

67 (49)

M30 x 2

130 (96)

87 (64)

M33 x 2

160 (118)

107 (79)

Continued on next page

TM13264X19 (02FEB17)

00-0003-11

OUT3035,0000366 -19-04MAR16-1/2

300GLC Excavator 020217 PN=37

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

Aluminum or Brass Torque

N·m (lb·ft)

M38 x 2

176 (130)

117 (87)

M42 x 2

210 (155)

140 (103)

M48 x 2

260 (192)

173 (128)

M60 x 2

315 (232)

210 (155)

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

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

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling, or flatten condition. 2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose.

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

3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place. Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000366 -19-04MAR16-2/2

TM13264X19 (02FEB17)

00-0003-12

300GLC Excavator 020217 PN=38

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH-PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

T196337 —UN—15APR13

10 T196337

O-Ring Face Seal Fittings 1— 90° Swivel Elbow 2— 90° Adjustable Stud Elbow 3— Stud Straight

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

Nominal Tube OD or Hose ID

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Torque

Hex Size mm

Torque

Metric Tube OD mm

Hex Size mm

Dash Size

mm (in)

-2

3.18 (0.125)

in —

—

N·m (lb·ft) —

—

N·m (lb·ft) —

—

17 —

24 (18) —

22 —

32 (24) —

-3

4.78 (0.188)

—

-4

6.35 (0.250)

-5

7.92 (0.312)

9/16-18 —

-6

9.53 (0.375)

11/16-16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

75 (55)

93 (69)

-10

15.88 (0.625)

1-14

103 (76)

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

175 (129)

-14

22.23 (0.875)

1-3/16-12

152 (112)

175 (129)

25 28

-16 —

25.40 (1.000) —

1-7/16-12 —

41 —

214 (158) —

46 —

247 (182) —

-20

31.75 (1.250)

1-11/16-12

—

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

—

326 (240)

374 (276)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

M8 x 1

8 (6)

M10 x 1

15 (11)

M12 x 1.5

35 (26)

M14 x 1.5

45 (33)

M16 x 1.5

55 (41)

M18 x 1.5

70 (52)

M22 x 1.5

100 (74)

M27 x 2

170 (125)

M30 x 2

215 159)

M33 x 2

260 (192)

M38 x 2

320 (236)

M42 x 2

360 (266)

Continued on next page

TM13264X19 (02FEB17)

00-0003-13

Steel or Gray Iron Torque N·m (lb·ft)

OUT3035,0000421 -19-04MAR16-1/2

300GLC Excavator 020217 PN=39

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

M48 x 2

420 (310)

N·m (lb·ft)

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

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

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000421 -19-04MAR16-2/2

TM13264X19 (02FEB17)

00-0003-14

300GLC Excavator 020217 PN=40

Torque Values

T6890BB —UN—15APR13

Service Recommendations for Metric Series Four Bolt Flange Fitting

Metric Series Four Bolt Flange Fitting A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

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. TORQUE CHARTa

2. Install the correct 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 the 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 four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, 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.

Thread

N·m

lb·ft 9

M10

M12

M14

157

116

M16

217

160

M18

334

246

M20

421

318

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. b Metric standard thread.

04T,90,K175 -19-29SEP99-1/1

TM13264X19 (02FEB17)

00-0003-15

300GLC Excavator 020217 PN=41

Torque Values

T6890BB —UN—15APR13

Service Recommendations For Inch Series Four Bolt Flange Fittings

Flange Fittings A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

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.

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

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.

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. 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.

5/8-11 UNC

158

264

117

195

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).

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

TM13264X19 (02FEB17)

00-0003-16

300GLC Excavator 020217 PN=42

Torque Values

T6890BB —UN—15APR13

Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations

Four Bolt Flange Fittings A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

If imperfection cannot be polished out, replace component.

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

Cap Screw Sizea

Min—Max Torque

N·m (lb·ft)b

1/2

5/16-18 UNC

20—31 (15—23)

3/4

3/8-16 UNC

34—54 (25—40)

7/16-14 UNC

57—85 (42—63)

1-1/4

1/2-13 UNC

85—131 (63—97)

1-1/2

5/8-11 UNC

159—264 (117—195)

3/4-10 UNC

271—468 (200—345)

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

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

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

1. Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat causes O-ring extrusion.

4. Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap screws within the specified torque values. OUT3035,0000422 -19-04MAR16-1/1

TM13264X19 (02FEB17)

00-0003-17

300GLC Excavator 020217 PN=43

Torque Values

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings 1. Inspect all fitting sealing surfaces. They must be free of dirt and defects. 2. Inspect O-ring (A). It must be free of damage or defects. 3. Inspect sealing ring (B) for damage or defects. 4. Hold body in desired position while tightening stud by hand. 5. Tighten stud (C) to torque value shown on the chart. Do not allow body to twist when tightening stud. T113948 —UN—06MAR98

NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting. Torque Value Tube Fitting O.D. Size

Metric Thread

N·m

lb·ft

6 L

M10 x 1

8 L

M12 x 1.5

10 L

M14 x 1.5

12 L

M16 x 1.5

100

15 L

M18 x 1.5

130

18 L

M22 x 1.5

22 L

M26 x 1.5

28 L

Non-Restricted Banjo Fitting Torque Value Inch Size

N·m

lb·ft

Tube Fitting O.D. Size

160

118

6 L

1/8

250

184

8 L

1/4

M33 x 2

400

295

10 L

1/4

35 L

M42 x 2

600

443

12 L

3/8

42 L

M48 x 2

800

590

15 L

1/2

130

6 S

M12 x 1.5

18 L

1/2

150

111

8 S

M14 x 1.5

22 L

3/4

250

184

400

295

10 S

M16 x 1.5

100

28 L

12 S

M18 x 1.5

130

35 L

1-1/4

600

443

118

42 L

1-1/2

800

590

118

6 S

1/4

184

8 S

1/4

3/8

100

14 S

1/2

130

16 S

1/2

150

111

20 S

3/4

250

184

25 S

400

295

30 S

1-1/4

600

443

38 S

1-1/2

800

590

14 S 16 S 20 S

M20 x 1.5 M22 x 1.5 M27 x 2

160 160 250

25 S

M33 x 2

400

295

10 S

30 S

M42 x 2

600

443

12 S

38 S

M48 x 2

800

590

CED,OUO1002,562 -19-09MAR98-1/1

TM13264X19 (02FEB17)

00-0003-18

300GLC Excavator 020217 PN=44

Torque Values

Service Recommendations For O-Ring Boss Fittings With Shoulder 1. Inspect component seal boss seat for dirt or defects. T113957 —UN—06MAR98

2. Inspect EOlastic seal (A) for damage. Replace seal or fitting as necessary. To replace seal, put electrical tape over threads to protect seal. Slide seal over tape and into seal groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. IMPORTANT: Do not allow hoses to twist when tightening fittings. NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting.

O-Ring Boss Fitting With Shoulder Torque Value Tube Fitting O.D. Size

Inch Size

N·m

lb·ft

6 L

1/8

Torque Value

8 L

1/4

N·m

10 L

1/4

12 L

3/8

59 103

Tube Fitting O.D. Size

Metric Thread

6 L

M10 x 1

15 L

1/2

140

1/2

100

74 133

lb·ft

8 L

M12 x 1.5

18 L

10 L

M14 x 1.5

22 L

3/4

180

12 L

M16 x 1.5

28 L

300

221

15 L

M18 x 1.5

35 L

1-1/4

600

443

18 L

M22 x 1.5

130

42 L

1-1/2

800

590

22 L

M26 x 1.5

190

140

6 S

1/4

28 L

M33 x 2

300

221

8 S

1/4

35 L

M42 x 2

600

443

10 S

3/8

42 L

M48 x 2

800

590

12 S

3/8

6 S

M12 x 1.5

14 S

1/2

160

118

8 S

M14 x 1.5

16 S

1/2

140

103

10 S

M16 x 1.5

20 S

3/4

250

184

12 S

M18 x 1.5

110

25 S

400

295

14 S

M20 x 1.5

140

103

30 S

1-1/4

650

479

16 S

M22 x 1.5

170

125

38 S

1-1/2

800

590

20 S

M27 x 2

250

184

25 S

M33 x 2

450

332

30 S

M42 x 2

600

443

38 S

M48 x 2

800

590

Continued on next page

TM13264X19 (02FEB17)

00-0003-19

CED,OUO1002,563 -19-09MAR98-1/2

300GLC Excavator 020217 PN=45

Torque Values Hex Socket Head Plugs Only Torque Value Thread Size

N·m

M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5

M22 x 1.5

100

M26 x 1.5

120

M27 x 2

150

111

M33 x 2

250

184

M42 x 2

400

295

M48 x 2

500

369

1/8

1/4

3/8

1/2

lb·ft

3/4

150

111

220

162

1-1/4

600

443

1-1/2

800

590 CED,OUO1002,563 -19-09MAR98-2/2

TM13264X19 (02FEB17)

00-0003-20

300GLC Excavator 020217 PN=46

Torque Values

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

Heavy Fitting Size mm

Light Fitting Size mm

—

M12 x 1.5

M16 x 1.5

M14 x 1.5

M18 x 1.5

M16 x 1.5

M20 x 1.5

M22 x 1.5 —

M18 x 1.5 —

15 16 18 20 22 25 28 30

M24 x 1.5 — M30 x 2 — M36 x 2 —

M42 x 2 —

M52 x 2

M22 x 1.5 — M26 x 1.5 —

Torque Turns

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

M30 x 2 — M36 x 2 — M45 x 2 —

NOTE: These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings. T113889 —UN—15APR13

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

Connection

2. Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition. 3. Lubricate O-rings using a thin film of clean hydraulic oil. 4. Align an adjustable fitting with the tube.

Hold connections together while tightening nut to ensure proper seal. 5. Tighten nut (A) hand tight so O-ring contacts seat and then an additional 1/4—1/3 turn using a wrench. CED,OUO1002,517 -19-14JAN04-1/1

TM13264X19 (02FEB17)

00-0003-21

300GLC Excavator 020217 PN=47

Torque Values

TM13264X19 (02FEB17)

00-0003-22

300GLC Excavator 020217 PN=48

Contents

Section 01 Tracks

Page

Group 0130—Track System Track Roller Remove and Install ............... 01-0130-1 Track Roller Disassemble and Assemble............................................... 01-0130-3 Track Roller Pressure Test ........................ 01-0130-5 Track Carrier Roller Remove and Install ..................................................... 01-0130-7 Metal Face Seals Repair ........................... 01-0130-9 Track Shoe Remove and Install .............. 01-0130-10 Track Chain Remove and Install ............. 01-0130-11 Track Chain Disassemble and Assemble............................................. 01-0130-16 Track Chain Repair to Replace Broken Part.......................................... 01-0130-18 Sprocket Remove and Install................... 01-0130-24 Front Idler Remove and Install ................ 01-0130-25 Front Idler Disassemble and Assemble............................................. 01-0130-26 Track Adjuster and Recoil Spring Remove and Install.............................. 01-0130-28 Track Adjuster and Recoil Spring Disassemble and Assemble ................ 01-0130-29

TM13264X19 (02FEB17)

01-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

01-2

300GLC Excavator

020217

PN=2

Group 0130

Track System Track Roller Remove and Install SPECIFICATIONS 300GLC Excavator Weight (approximate)

31 150 kg 68 674 lb.

Track Roller Weight (approximate) 57 kg 126 lb. Cap Screw Torque

840 N·m 620 lb.-ft.

Grease Fitting Torque

90 N·m 66 lb.-ft.

SERVICE EQUIPMENT AND TOOLS TX1089326A —UN—15MAR11

D01182AA 20-Ton Floor Stand (2 used)

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Personal injury may result from high-pressure grease. DO NOT remove grease fitting to release track tension. 2. Loosen grease fitting (1) counterclockwise 1—2 turns. Grease will escape through vent hole (2) in track adjuster cylinder.

Grease Fitting 1— Grease Fitting 2— Vent Hole

7— Track Frame

MM12851,00004B1 -19-05JAN15-1/4

3. Place wood block (3) in front of track to catch bar on grouser (4). CAUTION: Prevent possible injury from unexpected machine movement. Alert bystanders to stay clear before performing procedure. 4. To relieve track tension, start machine and slowly rotate track so grouser mounts wood block and idler retracts. 4— Grouser

TX1098609A —UN—23SEP11

3— Wood Block

Procedure for Retracting Idler Continued on next page

TM13264X19 (02FEB17)

01-0130-1

MM12851,00004B1 -19-05JAN15-2/4

300GLC Excavator 020217 PN=51

Track System

5. Swing upperstructure to the side as shown. Keeping the angle between boom and arm at 90—110°, lower boom to raise track off ground.

TX1098612 —UN—28SEP11

CAUTION: Avoid possible injury from machine sliding backwards. Keep angle between boom and arm 90—110°.

90˚-110˚

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate supporting equipment. 6. Using D01182AA 20-Ton Floor Stands, support the weight of the machine by lowering machine onto stands.

Machine Position

Specification 300GLC Excavator—Weight (approximate)........................................................................................ 31 150 kg 68 674 lb. MM12851,00004B1 -19-05JAN15-3/4

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

TX1089219A —UN—10MAR11

7. Remove cap screws (6) and track roller (5) using appropriate lifting device. Specification Track Roller—Weight (approximate).................................................................................. 57 kg 126 lb.

8. Inspect and repair as necessary. See Track Roller Disassemble and Assemble. (Group 0130.) Track Roller

9. Using appropriate lifting device, install track roller and tighten cap screws to specification. 5— Track Roller

Specification Cap Screw—Torque....................................................................840 N·m 620 lb.-ft.

6— Cap Screw (4 used)

12. Raise track and remove floor stands.

10. Tighten grease fitting to specification. Specification Grease Fitting—Torque.................................................................90 N·m 66 lb.-ft.

13. Lower machine to ground.

11. Adjust track tension. See Check and Adjust Track Sag. (Operator’s Manual.) MM12851,00004B1 -19-05JAN15-4/4

TM13264X19 (02FEB17)

01-0130-2

300GLC Excavator 020217 PN=52

Track System OTHER MATERIAL

Track Roller Disassemble and Assemble

NEVER-SEEZ® Anti-Seize Lubricant

SPECIFICATIONS

Loctite® Klean ‘N Prime™ Primer

Track Roller Weight (approximate) 57 kg 126 lb. Track Roller (engine oil SAE 30) Capacity

420 mL 14.2 oz.

Fill Plug Torque

30 N·m 22 lb.-ft.

Loctite® 592™ PST® Thread Sealant (slow cure)

4 1 2

1 4 5 4

3 TX1122883 —UN—27SEP12

3 4

7 6

8 TX1122883 Track Roller Components 1— Bushing (2 used) 2— Roller 3— Bracket (2 used)

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

6— O-Ring (2 used) 7— Fill Plug (2 used)

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

NOTE: 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.

1. Remove track roller using appropriate lifting device. See Track Roller Remove and Install. (Group 0130.)

For seals that are reused, use a piece of cardboard between seal rings to protect seal face.

Specification Track Roller—Weight (approximate).................................................................................. 57 kg 126 lb.

2. Remove fill plugs (7) and drain oil. Specification Track Roller (engine oil SAE 30)—Capacity...................................................................... 420 mL 14.2 oz.

3. Remove pins (5). 4. Remove brackets (3).

5. Remove metal face seals (4) from roller and bracket. Keep seal rings together as a matched set with seal ring faces together to protect surfaces. 6. Inspect metal face seals. See Metal Face Seals Repair. (Group 0130.) 7. Remove axle (8) and O-rings (6). NOTE: Bushings should only be removed if replacement is necessary. 8. If necessary, remove bushings (1) using a press.

Continued on next page

TM13264X19 (02FEB17)

8— Axle

01-0130-3

MM12851,00004B2 -19-14JAN15-1/2

300GLC Excavator 020217 PN=53

Track System

9. Inspect and replace parts as necessary. See 300GLC Track Roller Tread Diameter. (SP326VOL1 Undercarriage Appraisal Manual.)

16. Install O-rings onto axle.

10. Apply a thin film of oil to bushings and install.

17. Install brackets to axle.

IMPORTANT: Prevent possible machine damage due to improper seal. 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. Seat O-rings properly.

18. Apply NEVER-SEEZ® Anti-Seize Lubricant or equivalent to pins. Install pins.

NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. 11. Thoroughly clean O-rings and seat surfaces in brackets and in seal rings using volatile, non-petroleum base solvent and lint-free tissues. 12. Install metal face seals in brackets. Apply equal pressure with fingers at four equally spaced points on metal face seal. Metal face seal must “pop” down into place so the O-rings are tight against seal bore. 13. Install metal face seals in roller. Apply equal pressure with fingers at four equally spaced points on metal face seal. Metal face seal must “pop” down into place so O-ring is tight against seal bore. Repeat procedure for the other side. 14. Wipe fingerprints and foreign material off seal face using clean oil and lint-free tissues. Apply a thin film of oil to each seal ring face.

15. Install axle to roller.

19. Fill roller with oil to specification. Specification Track Roller (engine oil SAE 30)—Capacity...................................................................... 420 mL 14.2 oz.

20. Apply Loctite® Klean ‘N Prime™ Primer and Loctite® 592™ PST® Thread Sealant (slow cure) to threads of plug. Install and tighten fill plug to specification. Specification Fill Plug—Torque...........................................................................30 N·m 22 lb.-ft.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 21. Install track roller using appropriate lifting device. See Track Roller Remove and Install. (Group 0130.) Specification Track Roller—Weight (approximate).................................................................................. 57 kg 126 lb.

NEVER-SEEZ is a trademark of Emhart Chemical Group Loctite and its related brand marks are trademarks of Henkel Corporation MM12851,00004B2 -19-14JAN15-2/2

TM13264X19 (02FEB17)

01-0130-4

300GLC Excavator 020217 PN=54

Track System

Track Roller Pressure Test 420 mL 14.2 oz.

Track Roller Pressure

92—128 kPa 0.9—1.3 bar 13—19 psi

Oil Plug Torque

30 N·m 22 lb.-ft.

TX1098623A —UN—23SEP11

SPECIFICATIONS Track Roller (engine oil SAE 30) Capacity (approximate)

OTHER MATERIAL Loctite® Kleen ‘N Prime™ Primer Loctite® 592™ PST® Thread Sealant (slow cure)

Track Roller

1. Remove oil plug (7). 7— Oil Plug

2. Fill track roller to specification. Specification Track Roller (engine oil SAE 30)—Capacity (approximate)............................................................................... 420 mL 14.2 oz. Loctite and its related brand marks are trademarks of Henkel Corporation

Continued on next page

TM13264X19 (02FEB17)

01-0130-5

MM12851,00004B3 -19-05JAN15-1/2

300GLC Excavator 020217 PN=55

Track System

3. Install pressure test equipment (1—6) and connect to track roller. 4. Slowly pressurize track roller to specification. TX1094904A —UN—21JUL11

Specification Track Roller —Pressure...................................................... 92—128 kPa 0.9—1.3 bar 13—19 psi

5. Close valve. Wait for 30 seconds. Check for oil leaks or pressure decrease. 6. If leakage is found, disassemble roller and replace parts as necessary. See Track Roller Disassemble and Assemble. (Group 0130.)

Track Roller Pressure Test Equipment

7. Fill track roller to specification. Specification Track Roller (engine oil SAE 30)—Capacity (approximate)............................................................................... 420 mL 14.2 oz.

8. Apply Loctite® Kleen ‘N Prime™ Primer and Loctite® 592™ PST® Thread Sealant (slow cure) to threads of oil plug and install oil plug. Tighten oil plug to specification.

1— Air Pressure Regulator 2— Needle Valve 3— Pressure Gauge

TX1094902A —UN—25JUL11

Specification Oil Plug—Torque...........................................................................30 N·m 22 lb.-ft. 4— 1/4 in. Coupler Fitting 5— 1/4 in. Pipe Adapter 6— 1/4 in. Fitting Adapter

Track Roller With Pressure Test Equipment Loctite and its related brand marks are trademarks of Henkel Corporation MM12851,00004B3 -19-05JAN15-2/2

TM13264X19 (02FEB17)

01-0130-6

300GLC Excavator 020217 PN=56

Track System

Track Carrier Roller Remove and Install SPECIFICATIONS Carrier Roller Weight (approximate)

35 kg 77 lb.

Carrier Roller Cap Screw Torque

460 N·m 339 lb.-ft.

Grease Fitting Torque

90 N·m 66 lb.-ft.

Carrier Roller (engine oil SAE 30) Capacity

160 mL 5.4 oz.

Fill Plug Torque

30 N·m 22 lb.-ft. TX1114387A —UN—22MAY12

OTHER MATERIAL Loctite® Klean ‘N Prime™ Primer Loctite® 592™ PST® Thread Sealant (slow cure)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Personal injury may result from high-pressure grease. DO NOT remove grease fitting to release track tension.

Grease Fitting

2. Loosen grease fitting (1) counterclockwise 1—2 turns. Grease will escape through vent hole (2) in track adjuster (3).

1— Grease Fitting 2— Vent Hole

3— Track Adjuster 4— Track Frame

Loctite and its related brand marks are trademarks of Henkel Corporation MM12851,00004B4 -19-05JAN15-1/4

CAUTION: Prevent possible injury from accidental lowering of track by securely supporting track before attempting service procedure. TX1114388A —UN—22MAY12

3. Use appropriate jack to raise track chain (6) enough to permit carrier roller (5) removal. 4. Install wood block (7) between track chain and track frame (4). 4— Track Frame 5— Carrier Roller

6— Track Chain 7— Wood Block Carrier Roller and Track Chain Continued on next page

TM13264X19 (02FEB17)

01-0130-7

MM12851,00004B4 -19-05JAN15-2/4

300GLC Excavator 020217 PN=57

Track System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 5. Attach appropriate lifting device to carrier roller. Remove cap screws (8) and carrier roller.

TX1114389A —UN—22MAY12

Specification Carrier Roller—Weight (approximate).................................................................................. 35 kg 77 lb.

NOTE: Track carrier roller must be replaced as an assembly. 6. Inspect and replace as necessary. See 300GLC Carrier Roller Tread Diameter. (SP326VOL1 Undercarriage Appraisal Manual.)

Carrier Roller and Cap Screws

7. Using appropriate lifting device, install carrier roller and cap screws. Tighten cap screws to specification.

8— Cap Screw (4 used)

Specification Carrier Roller Cap Screw—Torque............................................................................460 N·m 339 lb.-ft.

8. Remove wood block and jack.

Specification Grease Fitting—Torque.................................................................90 N·m 66 lb.-ft.

9. Tighten grease fitting on track adjuster to specification. MM12851,00004B4 -19-05JAN15-3/4

10. Remove fill plug (9) and fill carrier roller with oil to specification.

TX1122936A —UN—20SEP12

Specification Carrier Roller (engine oil SAE 30)—Capacity...................................................................... 160 mL 5.4 oz.

11. Apply Loctite® Klean ‘N Prime™ Primer and Loctite® 592™ PST® Thread Sealant (slow cure) to threads of plug. Install and tighten fill plug to specification. Specification Fill Plug—Torque...........................................................................30 N·m 22 lb.-ft.

12. Adjust track tension. See Check and Adjust Track Sag. (Operator's Manual.)

Carrier Roller 9— Fill Plug

Loctite and its related brand marks are trademarks of Henkel Corporation MM12851,00004B4 -19-05JAN15-4/4

TM13264X19 (02FEB17)

01-0130-8

300GLC Excavator 020217 PN=58

Track System

Metal Face Seals Repair 1. Inspect for the following conditions to determine if seals can be reused: a. The narrow, highly polished sealing area (5) must be in the outer half of seal ring face (4). b. Sealing area must be uniform and concentric with the inside diameter and outside diameter of seal ring (1).

1— Seal Ring 2— Worn Area (shaded area) 3— Seal Ring Face

TX1008208 —UN—24MAY06

c. Sealing area must not be chipped, nicked, or scratched. 4— Outer Half of Seal Ring Face 5— Sealing Area (dark line)

Seal Inspection Areas TZ24494,0000E80 -19-19MAR13-1/3

2. Illustration shows examples of worn seal rings (1). I—Sealing area (4) is in inner half of seal ring face (3).

1— Seal Ring 2— Worn Area (shaded area)

TX1008209 —UN—31MAY06

II—Sealing area (4) not concentric with inside diameter and outside diameter of seal ring. 3— Inner Half of Seal Ring Face 4— Sealing Area (dark line)

Examples Of Worn Seal Rings TZ24494,0000E80 -19-19MAR13-2/3

3. Clean reusable seals by removing all foreign material from seal rings, except seal face (1), using a scraper or a stiff bristled fiber brush. TX1008335A —UN—26MAY06

4. Wash seal rings and O-rings using a volatile, non-petroleum base solvent to remove all oil. Thoroughly dry parts using a lint-free tissue. Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape. 1— Seal Face

Seal Face TZ24494,0000E80 -19-19MAR13-3/3

TM13264X19 (02FEB17)

01-0130-9

300GLC Excavator 020217 PN=59

Track System

Track Shoe Remove and Install

Shoe-to-Link Cap Screw Final Torque

407 N·m + 1/3 turn (120°) 300 lb·ft + 1/3 turn (120°)

IMPORTANT: Prevent possible machine damage. Operating a machine with loose shoes can cause wear to the cap screws, holes in the shoes, and links. The wear to components make it difficult to keep the shoes tight. Loose shoes can also cause hardware malfunction and loss of shoes.

Track Shoes

Improper track shoe cap screw torque results in serious damage to the undercarriage components, shorter life expectancy, and void the manufacturer's warranty on the undercarriage components. 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

5. Install cap screws. Install nut with rounded edge (3) against track link and chamfered edge (4) away from the link.

3. Inspect and replace parts as necessary. See 300GLC Three Bar Grouser Height. (SP326VOL1 Undercarriage Appraisal Manual.)

IMPORTANT: Prevent possible machine damage from improperly installing nut. Always install nut with rounded edge (3) against track link and chamfered edge (4) away from the link.

2. Remove cap screws (1), nuts (5), and track shoe (2).

4. Clean shoe and link contact surfaces of any dirt or paint. Do not alter or damage the component surface.

TX1132651 —UN—21MAR13

136 N·m 100 lb·ft TX1093550A —UN—15JUN11

SPECIFICATIONS Shoe-to-Link Cap Screw Initial Torque

Track Shoe Cap Screw and Nut 1— Cap Screw (4 used) 2— Track Shoe 3— Rounded Edge

4— Chamfered Edge 5— Nut (4 used)

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

TX04577,00000E3 -19-30JUL15-1/2

Specification Shoe-to-Link Cap Screw—Initial Torque..................................................................136 N·m 100 lb·ft

8. Tighten cap screws to specification in sequence shown.

Specification Shoe-to-Link Cap Screw—Final Torque........................................407 N·m + 1/3 turn (120°) 300 lb·ft + 1/3 turn (120°)

Torque Sequence

TX1093552 —UN—15JUN11

7. Tighten cap screws to specification in sequence shown.

TX04577,00000E3 -19-30JUL15-2/2

TM13264X19 (02FEB17)

01-0130-10

300GLC Excavator 020217 PN=60

Track System

Track Chain Remove and Install SPECIFICATIONS 300GLC Excavator Weight (approximate)

31 150 kg 68 674 lb.

Grease Fitting Torque

90 N·m 66 lb.-ft.

TX1098612 —UN—28SEP11

Track Chain Weight (approximate) 1440 kg 3175 lb.

90˚-110˚

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stand (2 used) D01030AA 50-Ton Master King Pin Pusher/Installer Machine Position

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Prevent possible injury from unexpected machine movement. Alert bystanders to stay clear before performing this procedure. CAUTION: Avoid possible injury from machine sliding backwards. Keep angle between boom and arm at 90—110°.

3. Using D01182AA 20-Ton Floor Stands, support machine weight by lowering machine onto stands. Specification 300GLC Excavator—Weight (approximate)........................................................................................ 31 150 kg 68 674 lb.

4. Rotate track in both directions to clear track chain of mud and debris.

2. Swing upperstructure to side as shown. Keeping angle between boom and arm at 90—110°, lower boom to raise track off ground. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate supporting equipment. MM12851,000049E -19-08JAN15-1/8

5. Rotate track until master pin (1) is just behind front idler (3). 6. With boom still at side of machine and keeping angle between boom and arm at 90—110°, lower boom to raise machine off floor stands.

1— Master Pin 2— Snap Ring

TX1089247A —UN—10MAR11

7. Remove floor stands and lower track to ground. 3— Front Idler

Master Pin Continued on next page

TM13264X19 (02FEB17)

01-0130-11

MM12851,000049E -19-08JAN15-2/8

300GLC Excavator 020217 PN=61

Track System

CAUTION: Personal injury may result from high-pressure grease. DO NOT remove grease fitting to release track tension. 8. Loosen grease fitting (4) counterclockwise 1—2 turns. Grease will escape through vent hole (5) in track adjuster cylinder. 8— Track Frame

TX1090275 —UN—04APR11

4— Grease Fitting 5— Vent Hole

Grease Fitting MM12851,000049E -19-08JAN15-3/8

9. Place wood block (6) in front of track to catch bar on grouser (7). CAUTION: Prevent possible injury from unexpected machine movement. Alert bystanders to stay clear before performing procedure. 10. To relieve track tension, start machine and slowly rotate track so grouser mounts wood block and idler retracts.

6— Wood Block

TX1098614A —UN—23SEP11

11. Remove track shoes on each side of track chain master pin. See Track Shoe Remove and Install. (Group 0130.) 7— Grouser

Blocking Track Grouser Continued on next page

TM13264X19 (02FEB17)

01-0130-12

MM12851,000049E -19-08JAN15-4/8

300GLC Excavator 020217 PN=62

Track System

12. Support track chain with wood block (9) so track chain does not fall when master pin is removed. 9— Wood Block

TX1098851A —UN—28SEP11

3— Front Idler

Wood Block Support Track Chain MM12851,000049E -19-08JAN15-5/8

13. Remove snap ring (2). 3— Front Idler

TX1089247A —UN—10MAR11

1— Master Pin 2— Snap Ring

Master Pin Continued on next page

TM13264X19 (02FEB17)

01-0130-13

MM12851,000049E -19-08JAN15-6/8

300GLC Excavator 020217 PN=63

Track System

14. Remove master pin (1) using D01030AA 50-Ton Master King Pin Pusher/Installer.

TX1098806A —UN—27SEP11

1— Master Pin

Master Pin Removal Using Track Press Continued on next page

TM13264X19 (02FEB17)

01-0130-14

MM12851,000049E -19-08JAN15-7/8

300GLC Excavator 020217 PN=64

Track System

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

TX1098615A —UN—27SEP11

15. Use appropriate lifting device to remove track from front idler (3) end. Specification Track Chain—Weight (approximate).............................................................................. 1440 kg 3175 lb.

CAUTION: Prevent possible injury from unexpected machine movement. Alert bystanders to stay clear before performing this procedure. CAUTION: Avoid possible injury from machine sliding backwards. Keep angle between boom and arm at 90—110°. 16. With boom still at side of machine and keeping angle between boom and arm at 90—110°, lower boom to raise track off ground. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate supporting equipment. 17. Using D01182AA 20-Ton Floor Stands, support machine weight by lowering machine onto stands. Specification 300GLC Excavator—Weight (approximate)........................................................................................ 31 150 kg 68 674 lb.

18. Using appropriate lifting device attached to track chain, slowly rotate travel motor in reverse direction to remove chain.

Front Idler 3— Front Idler

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 24. Using appropriate lifting device, lift and place leading edge of track chain on to sprocket. Specification Track Chain—Weight (approximate).............................................................................. 1440 kg 3175 lb.

25. Rotate sprocket in forward direction and guide track chain over carrier rollers until leading edge reaches front idler. 26. Pull the two ends of track chain together. Install master pin using D01030AA 50-Ton Master King Pin Pusher/Installer. 27. Install snap ring.

19. Remove track chain from underneath machine.

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

20. Inspect and repair as necessary. See Track Chain Disassemble and Assemble. (Group 0130.)

29. Tighten grease fitting on track tension cylinder to specification.

21. Using appropriate lifting device, move track under rollers, front idler, and sprocket.

Specification Grease Fitting—Torque.................................................................90 N·m 66 lb.-ft.

22. With boom still at side of machine and keeping angle between boom and arm at 90—110°, lower boom to raise machine off floor stands.

30. Adjust track tension. See Check and Adjust Track Sag. (Operator's Manual.)

23. Remove floor stands and lower machine onto track. MM12851,000049E -19-08JAN15-8/8

TM13264X19 (02FEB17)

01-0130-15

300GLC Excavator 020217 PN=65

Track System

Track Chain Disassemble and Assemble

1 2

12 13

4 12

10 4

12 3

4 3

11 TX1119881

TX1119881 —UN—07AUG12

Track Chain (exploded view) 1— Left Track Link (48 used) 2— Master Track Link 3— Track Pin (47 used) 4— Bushing (48 used) 5— Seal (88 used)

6— Master Track Pin 11— Cap Screw (192 used) 7— Master Track Bushing 12— Nut (192 used) 8— Master Track Spacer (2 used) 13— 600 mm Open Center 3 Bar 9— Snap Ring Shoe; 700 mm Open Center 10— Right Track Link (47 used) 3 Bar Shoe; 800 mm Open Center 3 Bar Shoe (48 used)

Continued on next page

TM13264X19 (02FEB17)

01-0130-16

MM12851,000049F -19-06JAN15-1/2

300GLC Excavator 020217 PN=66

Track System SPECIFICATIONS Track Chain Weight (approximate) 1980 kg 4365 lb. Track Chain Master Pin Outside Diameter (new)

45 mm 1.77 in.

Track Chain Master Pin Outside Diameter (limit of use)

41 mm 1.61 in.

Track Chain Master Bushing Inside Diameter (new)

45.45 mm 1.79 in.

Track Chain Master Bushing Inside Diameter (limit of use)

48.5 mm 1.91 in.

Track Chain Track Pin Outside Diameter (new)

44.69 mm 1.76 in.

Track Chain Track Pin Outside Diameter (limit of use)

41.7 mm 1.64 in.

Track Chain Bushing Inside Diameter (new)

45.45 mm 1.79 in.

Track Chain Bushing Inside Diameter (limit of use)

46.5 mm 1.83 in.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 1. Remove track chain using appropriate lifting device. See Track Chain Remove and Install. (Group 0130.) Specification Track Chain—Weight (approximate).............................................................................. 1980 kg 4365 lb.

2. Remove parts (1—13). 3. Inspect and replace parts as necessary. Specification Track Chain Master Pin—Outside Diameter (new)............................................................................................. 45 mm 1.77 in. Track Chain Master Pin—Outside Diameter (limit of use)................................................................................... 41 mm 1.61 in.

Track Chain Master Bushing—Inside Diameter (new)......................................................................... 45.45 mm 1.79 in. Track Chain Master Bushing—Inside Diameter (limit of use)................................................................ 48.5 mm 1.91 in. Track Chain Track Pin—Outside Diameter (new)........................................................................................ 44.69 mm 1.76 in. Track Chain Track Pin—Outside Diameter (limit of use)................................................................................ 41.7 mm 1.64 in. Track Chain Bushing—Inside Diameter (new)......................................................................... 45.45 mm 1.79 in. Track Chain Bushing—Inside Diameter (limit of use)................................................................ 46.5 mm 1.83 in.

4. Measure track chain link height. See 300GLC Track Chain Link Height. (SP326VOL1 Undercarriage Appraisal Manual.) 5. Measure track chain link bushing. See 300GLC Bushing Outer Diameter. (SP326VOL1 Undercarriage Appraisal Manual.) 6. Measure track chain link pitch. See 300GLC Track Chain Pitch. (SP326VOL1 Undercarriage Appraisal Manual.) 7. Install parts (1—13). 8. Install track chain. See Track Chain Remove and Install. (Group 0130.)

MM12851,000049F -19-06JAN15-2/2

TM13264X19 (02FEB17)

01-0130-17

300GLC Excavator 020217 PN=67

Track System

Track Chain Repair to Replace Broken Part

1. Remove three track shoes surrounding damaged area. See Track Shoe Remove and Install. (Group 0130.)

NOTE: This procedure is to address a broken track pin or broken track link. Broken Track Pin Replacement

6 5 9 3

8 1

TX1098001 —UN—16SEP11

11 10 2

TX1098001 Track Pin 1— Broken Track Pin 2— Bushing 3— Cut Point

7— Bushing 8— Grind Point 9— Track Link 10— Track Pin

4— Cut Point 5— Grind Point 6— Track Link

11— Track Link Assembly

NOTE: All track pins, bushing, and links will be discarded and replaced with new parts.

IMPORTANT: Avoid damage to good parts. Use care when operating cutting torch.

2. Remove broken track pin (1).

3. Cut bushing (2) and pin at cut points (3 and 4). Continued on next page

TM13264X19 (02FEB17)

01-0130-18

TZ24494,0000E84 -19-10JUN16-1/6

300GLC Excavator 020217 PN=68

Track System

6 5 9 7

8 11 2 TX1098002 —UN—21SEP11

TX1098002 Bushing 2— Bushing 5— Grind Point 6— Track Link

7— Bushing 8— Grind Point 9— Track Link

10— Track Pin 11— Track Link Assembly

4. Push remaining sections of bushing (2) and track pin (10) inward to remove and discard damaged parts.

6. Inspect and replace parts as necessary.

5. Grind bushing (7) at grind points (5 and 8) until flush with track links (6 and 9). Continued on next page

TM13264X19 (02FEB17)

01-0130-19

TZ24494,0000E84 -19-10JUN16-2/6

300GLC Excavator 020217 PN=69

Track System

TX1098003 —UN—16SEP11

TX1098003 Track Link Assembly 1— Replacement Track Pin 10— Replacement Track Pin

11— Replacement Track Link Assembly

12— Collar (4 used)

7. Install replacement track link assembly (11) and collars (12).

Broken Track Link Assembly Replacement

8. Install replacement track pin (10).

1. Remove three track shoes surrounding damaged area. See Track Shoe Remove and Install. (Group 0130.)

9. Install replacement track pin (1). 10. Install three track shoes surrounding damaged area. See Track Shoe Remove and Install. (Group 0130.) Continued on next page

TM13264X19 (02FEB17)

01-0130-20

TZ24494,0000E84 -19-10JUN16-3/6

300GLC Excavator 020217 PN=70

Track System

6 5 9 8 7

11 1

2 TX1098008 —UN—16SEP11

14 10

TX1098008 Track Pin 1— Track Pin 2— Bushing 3— Cut Point 4— Cut Point

9— Track Link 10— Track Pin 11— Track Link Assembly

5— Grind Point 6— Track Link 7— Bushing 8— Grind Point

13— Cut Point 14— Cut Point

IMPORTANT: Avoid damage to good parts. Use care when operating cutting torch.

NOTE: All track pins, bushing, and links will be discarded and replaced with new parts.

3. Cut track link assembly (11) at cut points (13 and 14).

2. Cut bushing (2) and pin at cut points (3 and 4).

4. Remove track pin (1) and remaining sections of track link assembly (11). Discard damaged parts. Continued on next page

TM13264X19 (02FEB17)

01-0130-21

TZ24494,0000E84 -19-10JUN16-4/6

300GLC Excavator 020217 PN=71

Track System

6 5 9

11 8

2 TX1098035 —UN—21SEP11

TX1098035 Bushing 2— Bushing 5— Grind Point 6— Track Link

7— Bushing 8— Grind Point 9— Track Link

10— Track Pin 11— Track Link Assembly

5. Push remaining sections of track pin (10) and track link assembly (11) inward to remove and discard damaged parts.

7. Inspect and replace parts as necessary.

6. Grind bushing (7) at grind points (5 and 8) until flush with track links (6 and 9). Continued on next page

TM13264X19 (02FEB17)

01-0130-22

TZ24494,0000E84 -19-10JUN16-5/6

300GLC Excavator 020217 PN=72

Track System

TX1098003 —UN—16SEP11

TX1098003 Track Link Assembly 1— Replacement Track Pin 10— Replacement Track Pin

11— Replacement Track Link Assembly

8. Install replacement track link assembly (11) and collars (12).

12— Collar (4 used)

11. Install three track shoes surrounding damaged area. See Track Shoe Remove and Install. (Group 0130.)

9. Install replacement track pin (10). 10. Install replacement track pin (1). TZ24494,0000E84 -19-10JUN16-6/6

TM13264X19 (02FEB17)

01-0130-23

300GLC Excavator 020217 PN=73

Track System

Sprocket Remove and Install 31 150 kg 68 674 lb.

Sprocket Weight (approximate)

69 kg 152 lb.

Sprocket Cap Screw Torque

500 N·m 369 lb.-ft.

TX1098612 —UN—28SEP11

SPECIFICATIONS 300GLC Excavator Weight (approximate)

90˚-110˚

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stand (2 used) OTHER MATERIAL Machine Position

Loctite® Klean ‘N Prime™ Primer Loctite® 271™ Threadlocker (high strength)

IMPORTANT: Prevent excessive wear to chain. Sprocket must be replaced when the tooth tips become excessively rounded, worn, or chipped. 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. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove track chain. See Track Chain Remove and Install. (Group 0130.)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate supporting equipment. 4. Using D01182AA 20-Ton Floor Stands, support machine weight by lowering machine onto stands. Specification 300GLC Excavator—Weight (approximate)........................................................................................ 31 150 kg 68 674 lb.

CAUTION: Prevent possible injury from unexpected machine movement. Alert bystanders to stay clear before performing procedure. CAUTION: Avoid possible injury from machine sliding backwards. Keep angle between boom and arm 90—110°. 3. Swing upperstructure to side as shown. Keeping angle between boom and arm at 90—110°, lower boom to raise sprocket off track. Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

01-0130-24

MM12851,00004A0 -19-08JAN15-1/2

300GLC Excavator 020217 PN=74

Track System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 5. Attach appropriate lifting device to support sprocket (1). Specification Sprocket—Weight (approximate).................................................................................. 69 kg 152 lb. TX1123246A —UN—26SEP12

6. Remove cap screws (2) and sprocket. 7. Repair or replace as necessary. 8. Apply Loctite® Klean ‘N Prime™ Primer and Loctite® 271™ Threadlocker (high strength) to threads of cap screws. 9. Using appropriate lifting device, install sprocket. Sprocket

10. Install cap screws and tighten to specification. Specification Sprocket Cap Screw—Torque............................................................................500 N·m 369 lb.-ft.

11. Remove floor stands and lower track chain onto sprocket.

1— Sprocket

2— Cap Screw (22 used)

12. Install track chain. See Track Chain Remove and Install. (Group 0130.) 13. Adjust track tension. See Check and Adjust Track Sag. (Operator’s Manual.)

Loctite and its related brand marks are trademarks of Henkel Corporation MM12851,00004A0 -19-08JAN15-2/2

Front Idler Remove and Install SPECIFICATIONS 187 kg 412 lb. TX1112232A —UN—12APR12

Front Idler Weight (approximate)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove track chain. See Track Chain Remove and Install. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Attach appropriate lifting device to support front idler (1).

Front Idler 1— Front Idler

Specification Front Idler—Weight (approximate)................................................................................ 187 kg 412 lb.

6. Repair or replace as necessary. See Front Idler Disassemble and Assemble. (Group 0130.)

4. Remove front idler from frame.

7. Using appropriate lifting device, install front idler.

5. Measure front idler wear. See 300GLC Front Idler Flange Height. (SP326VOL1 Undercarriage Appraisal Manual.)

8. Install track chain. See Track Chain Remove and Install. (Group 0130.) 9. Adjust track tension. See Check and Adjust Track Sag. (Operator’s Manual.) MM12851,00004A1 -19-08DEC14-1/1

TM13264X19 (02FEB17)

01-0130-25

300GLC Excavator 020217 PN=75

Track System OTHER MATERIAL

Front Idler Disassemble and Assemble

TY24811 NEVER-SEEZ® Anti-Seize Lubricant

SPECIFICATIONS Front Idler Weight (approximate)

170 kg 375 lb.

Front Idler (engine oil SAE 30) Capacity

380 mL 13 oz.

Front Idler Plug Torque

15 N·m 133 lb.-in.

Cap Screw Torque

270 N·m 200 lb.-ft.

7649 Loctite® Klean N Prime 242 Loctite® Thread Lock and Sealer (medium strength)

1 6

5 6

1 7

TX1129045 —UN—10JAN13

TX1129045

Front Idler 1— Pin (2 used) 2— Bushing (2 used) 3— Idler

4— Drain Plug (2 used) 5— Bracket (2 used) 6— Metal Face Seal (2 used)

7— O-Ring (2 used) 8— Axle 9— Yoke 10— Cap Screw (4 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 1. Remove front idler using appropriate lifting device. See Front Idler Remove and Install. (Group 0130.) Specification Front Idler—Weight (approximate)................................................................................ 170 kg 375 lb.

2. Remove cap screws (10) and yoke (9). 3. Remove drain plugs (4) and drain oil. Specification Front Idler (engine oil SAE 30)—Capacity...................................................................... 380 mL 13 oz.

NEVER-SEEZ is a trademark of Bostik Findley Inc. Loctite is a trademark of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

01-0130-26

TZ24494,0000E87 -19-19MAR13-1/3

300GLC Excavator 020217 PN=76

Track System

IMPORTANT: Avoid damage to metal face seals. Seals must be kept together as a set because of wear patterns. Metal face seals can be reused if they are not worn or damaged. 4. Remove pin (1), bracket (5), metal face seal (6), and O-ring (7) from axle. Repeat step for other side. 5. Inspect metal face seals. See Metal Face Seals Repair. (Group 0130.) 6. Remove axle from idler (3). 7. Inspect axle and bushings (2) for scoring or excessive wear. NOTE: Remove bushings only if replacement is necessary.

TX1119991A —UN—08AUG12

8. If necessary, remove bushings using bushing extracting tool. 9. Inspect and replace parts as necessary. 10. Apply a thin film of oil to new bushings. Install bushings so flange is tight against shoulder of idler. IMPORTANT: Avoid damage to metal face seals. Metal face seals and seat surfaces must be clean, dry, and oil free so they do not slip when roller is turning.

Front Idler

NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. 11. Thoroughly clean seat surfaces in idler, brackets, and metal face seals using volatile, non-petroleum base solvent and lint-free tissues.

1— Pin 5— Bracket 6— Metal Face Seal (2 used)

7— O-Ring 8— Axle

20. Apply PM37509 Klean N Prime and PM37418 Thread Lock and Sealer (medium strength) to threads of drain plugs.

12. Install metal face seals in brackets and idler. Apply equal pressure with fingers at four equally spaced points on metal face seal. Metal face seal must “pop” down into place so it is tight against seal bore.

21. Install drain plugs and tighten to specification.

13. Wipe fingerprints and foreign material off all metal face seals using clean oil and lint-free tissues. Apply a thin film of oil to each metal seal face. 14. Install axle into idler.

Specification Front Idler Plug—Torque.................................................................................15 N·m 133 lb.-in.

22. Install yoke. Tighten cap screws to specification.

15. Install O-rings onto axle. 16. Apply a thin layer of TY24811 NEVER-SEEZ® Anti-Seize Lubricant or equivalent to ends of axle and to bore in brackets.

Specification Cap Screw—Torque....................................................................270 N·m 200 lb.-ft.

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

17. Install brackets onto axle. 18. Apply NEVER-SEEZ® Anti-Seize Lubricant or equivalent to pins. Install pins.

23. Using appropriate lifting device, install front idler. See Front Idler Remove and Install. (Group 0130.)

19. Add oil through plug holes on bearing brackets to specification. Specification Front Idler (engine oil SAE 30)—Capacity...................................................................... 380 mL 13 oz.

Continued on next page

TM13264X19 (02FEB17)

01-0130-27

TZ24494,0000E87 -19-19MAR13-2/3

300GLC Excavator 020217 PN=77

Track System NEVER-SEEZ is a trademark of Bostik Findley Inc. TZ24494,0000E87 -19-19MAR13-3/3

Track Adjuster and Recoil Spring Remove and Install SPECIFICATIONS Track Adjuster and Recoil Spring Weight (approximate)

214 kg 472 lb.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) TX1090335A —UN—06APR11

2. Remove track chain. See Track Chain Remove and Install. (Group 0130.) 3. Remove front idler. See Front Idler Remove and Install. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Track Adjuster and Recoil Spring

4. Attach appropriate lifting device to support track adjuster and recoil spring. Specification Track Adjuster and Recoil Spring—Weight (approximate)................................................................................ 214 kg 472 lb.

5. Remove track adjuster and recoil spring (1) from track frame (2). 6. Repair or replace as necessary. See Track Adjuster and Recoil Spring Disassemble and Assemble. (Group 0130.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

1— Track Adjuster and Recoil Spring

2— Track Frame

Specification Track Adjuster and Recoil Spring—Weight (approximate)................................................................................ 214 kg 472 lb.

8. Install front idler. See Front Idler Remove and Install. (Group 0130.) 9. Install track chain. See Track Chain Remove and Install. (Group 0130.)

7. Using appropriate lifting device, install track adjuster and recoil spring in track frame. MM12851,00004A3 -19-11FEB15-1/1

TM13264X19 (02FEB17)

01-0130-28

300GLC Excavator 020217 PN=78

Track System

Track Adjuster and Recoil Spring Disassemble and Assemble 214 kg 472 lb.

Recoil Spring Set Length

575 mm 22.6 in.

Recoil Spring Free Length

691 mm 27.2 in.

Recoil Spring Weight (approximate)

104 kg 230 lb.

Plug Torque

15 N·m 133 lb.-in.

Grease Valve Torque

90 N·m 66 lb.-ft.

TX1123088 —UN—25SEP12

SPECIFICATIONS Track Adjuster and Recoil Spring Weight (approximate)

SERVICE EQUIPMENT AND TOOLS 30-Ton Hydraulic Jack

Track Adjuster

ST4920a Track Recoil Spring Disassembly and Assembly Tool DFT1110a Spacer DFT1087a Track Recoil Spring Disassembly and Assembly Guard Tool

1— Holder 2— Piston Rod

3— Dust Seal 4— U-Ring

Fabricated tool, dealer made. (See Group 9900 for instructions to make tool.)

CAUTION: Prevent possible injury. Recoil spring or rod may break if dropped while handling, transporting, or disassembling. Nicks or weld craters in recoil spring and rod can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual malfunction. Use heavy protective covering around spring assembly when handling, transporting, or disassembling track adjuster. To avoid personal injury from extreme preload on spring, a compression tool must be used for disassembly and assembly.

Specification Track Adjuster and Recoil Spring—Weight (approximate)................................................................................ 214 kg 472 lb.

NOTE: Removal of recoil spring is not necessary to replace dust seal (3) and U-ring (4). 2. Remove piston rod (2). 3. Remove holder (1) from piston rod using a press. 4. Remove dust seal (3) and U-ring (4).

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 1. Remove track adjuster and recoil spring using appropriate lifting device. See Track Adjuster and Recoil Spring Remove and Install. (Group 0130.) Continued on next page

TM13264X19 (02FEB17)

01-0130-29

MM12851,00004A4 -19-11FEB15-1/7

300GLC Excavator 020217 PN=79

Track System

5. Place 30-ton hydraulic jack (5) on bottom of ST4920 Track Recoil Spring Disassembly and Assembly Tool (6). See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.) 6. Remove nuts (7) and top plate (8).

7. Extend hydraulic jack ram to provide enough travel to release spring. Specification Recoil Spring—Set Length......................................................................................... 575 mm 22.6 in. Recoil Spring—Free Length......................................................................................... 691 mm 27.2 in. 5— 30-Ton Hydraulic Jack 6— ST4920 Track Recoil Spring Disassembly and Assembly Tool

7— Nut (8 used) 8— Top Plate

TX1123089 —UN—25SEP12

Track Recoil Spring Tool Continued on next page

TM13264X19 (02FEB17)

01-0130-30

MM12851,00004A4 -19-11FEB15-2/7

300GLC Excavator 020217 PN=80

Track System

8. Install DFT1110 Spacer (9) onto ST4920 Track Recoil Spring Disassembly and Assembly Tool. See DFT1110 Spacer. (Group 9900.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 9. Attach appropriate lifting strap (10) to track adjuster and recoil spring (11). Specification Track Adjuster and Recoil Spring—Weight (approximate)................................................................................ 214 kg 472 lb.

10. Position track adjuster and recoil spring in ST4920 Track Recoil Spring Disassembly and Assembly Tool with cylinder end on DFT1110 Spacer.

9— DFT1110 Spacer 10— Lifting Strap

TX1123090 —UN—25SEP12

11. Remove lifting strap. 11— Track Adjuster and Recoil Spring

Track Adjuster and Recoil Spring Continued on next page

TM13264X19 (02FEB17)

01-0130-31

MM12851,00004A4 -19-11FEB15-3/7

300GLC Excavator 020217 PN=81

Track System

12. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (12). See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. (Group 9900.) NOTE: The ST4920 Track Recoil Spring Disassembly and Assembly Tool is the same as used on other machines except the top plate. Use the top plate with the smallest opening that allows access to nut (13). 13. Install top plate and nuts (7). 14. Tighten nuts (7) so top plate is tight against retainer plate. 15. Remove grease valve (14) and plug (15). 13— Nut 14— Grease Valve 15— Plug

TX1123091 —UN—25SEP12

7— Nut (8 used) 8— Top Plate 12— DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

Track Recoil Spring Guard Tool Continued on next page

TM13264X19 (02FEB17)

01-0130-32

MM12851,00004A4 -19-11FEB15-4/7

300GLC Excavator 020217 PN=82

Track System

16. Raise upper half of DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool and tighten T-handles (16). 17. Extend hydraulic jack ram to release pressure on nut (13). 18. Remove nut (13). 19. Lower hydraulic jack ram to release recoil spring tension. 20. Remove nuts (7), top plate, and DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. 13— Nut 16— T-Handle (2 used)

TX1123092 —UN—25SEP12

7— Nut (8 used) 8— Top Plate 12— DFT1087 Track Recoil Spring Disassembly and Assembly Tool

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool Continued on next page

TM13264X19 (02FEB17)

01-0130-33

MM12851,00004A4 -19-11FEB15-5/7

300GLC Excavator 020217 PN=83

TX1123093 —UN—27SEP12

Track System

Track Adjuster and Recoil Spring 1— Holder 2— Piston Rod 3— Dust Seal 4— U-Ring

13— Nut 14— Grease Valve 15— Plug 17— Retainer Plate

18— Recoil Spring 19— Spacer 20— Cylinder

21. Remove retainer plate (17).

21— Rod

30. Using appropriate lifting device, install recoil spring.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 22. Using appropriate lifting device, remove recoil spring (18).

Specification Recoil Spring—Weight (approximate)................................................................................ 104 kg 230 lb.

31. Install retainer plate.

Specification Recoil Spring—Weight (approximate)................................................................................ 104 kg 230 lb.

23. Remove spacer (19).

32. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool, top plate, and nuts (7). 33. Raise upper half of DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool and tighten T-handles. 34. Extend hydraulic jack ram to compress recoil spring to compressed length.

24. Remove cylinder (20) from rod (21). 25. Inspect and replace parts as necessary.

Specification Recoil Spring—Free Length......................................................................................... 691 mm 27.2 in. Recoil Spring—Set Length......................................................................................... 575 mm 22.6 in.

26. Install DFT1110 Spacer onto ST4920 Track Recoil Spring Disassembly and Assembly Tool. 27. Install rod into DFT1110 Spacer. 28. Install cylinder onto rod. 29. Install spacer.

35. Install nut (13) so hole in nut is aligned with hole in rod. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Continued on next page

TM13264X19 (02FEB17)

01-0130-34

MM12851,00004A4 -19-11FEB15-6/7

300GLC Excavator 020217 PN=84

Track System 40. Attach appropriate lifting strap to track adjuster and recoil spring.

36. Install plug and tighten to specification. Specification Plug—Torque.................................................................................15 N·m 133 lb.-in.

37. Install grease valve and tighten to specification. Specification Grease Valve—Torque..................................................................90 N·m 66 lb.-ft.

38. Lower hydraulic jack ram to release recoil spring tension. 39. Remove nuts (7), top plate, and DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Specification Track Adjuster and Recoil Spring—Weight (approximate)................................................................................ 214 kg 472 lb.

41. Remove track adjuster and recoil spring from ST4920 Track Recoil Spring Disassembly and Assembly Tool. 42. Install U-ring and dust seal. 43. Install holder to piston rod. 44. Install piston rod. 45. Install track adjuster and recoil spring. See Track Adjuster and Recoil Spring Remove and Install. (Group 0130.) MM12851,00004A4 -19-11FEB15-7/7

TM13264X19 (02FEB17)

01-0130-35

300GLC Excavator 020217 PN=85

Track System

TM13264X19 (02FEB17)

01-0130-36

300GLC Excavator 020217 PN=86

Section 02 Axles, Differentials, and Suspension Systems Contents Page

Group 0250—Axle Shaft, Bearings, and Reduction Gears Travel Gear Case Remove and Install ..................................................... 02-0250-1 Travel Gear Case Disassemble and Assemble........................................ 02-0250-4 Group 0260—Hydraulic System Travel Motor and Park Brake Remove and Install................................ 02-0260-1 Travel Motor and Park Brake Disassemble and Assemble .................. 02-0260-2 Park Brake Valve Disassemble and Assemble............................................. 02-0260-10 Travel Motor and Park Brake Start-Up Procedure.............................. 02-0260-12

TM13264X19 (02FEB17)

02-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

02-2

300GLC Excavator

020217

PN=2

Group 0250

Axle Shaft, Bearings, and Reduction Gears Travel Gear Case Remove and Install 156 L 41 gal.

Travel Gear Case Assembly Weight (approximate)

483 kg 1065 lb.

Cap Screw Torque

630 N·m 465 lb.-ft.

Travel Gear Case Cover Cap Screw Torque

180 N·m 133 lb.-ft.

TX1089298A —UN—16MAR11

SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

ESSENTIAL TOOLS DF1063 Lifting Bracket DFT1130 Adapter

NOTE: Travel gear case, travel motor, and park brake are enclosed in same housing. All three components must be removed as an assembly. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

Travel Motor Cover 1— Cap Screw (6 used)

2— Travel Motor Access Panel

2. Remove track chain. See Track Chain Remove and Install. (Group 0130.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 3. Release hydraulic oil tank pressure by pressing pressure release button on top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 4. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

5. Remove cap screws (1) and travel motor access panel (2). Continued on next page

TM13264X19 (02FEB17)

02-0250-1

MM12851,00004B5 -19-06JAN15-1/3

300GLC Excavator 020217 PN=89

Axle Shaft, Bearings, and Reduction Gears

6. Install identification tags and disconnect hydraulic hoses (4 and 6—8). Close all openings using caps and plugs. See Travel Hydraulic System Line Connection. (Group 9025-15.) 6— Travel Motor Pressure Hose (forward) 7— Travel Motor Speed Change Valve Hose 8— Travel Motor Pressure Hose (reverse) TX1090334A —UN—06APR11

3— Cap Screw (24 used) 4— Travel Motor Drain Hose 5— Travel Gear Case Assembly

Travel Motor Continued on next page

TM13264X19 (02FEB17)

02-0250-2

MM12851,00004B5 -19-06JAN15-2/3

300GLC Excavator 020217 PN=90

Axle Shaft, Bearings, and Reduction Gears

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Support travel gear case assembly (5) with DF1063 Lift Bracket and DFT1130 Adapter. See DF1063 Lift Bracket and see DFT1130 Adapter. (Group 9900.)

TX1089304A —UN—16MAR11

Specification Travel Gear Case Assembly—Weight (approximate)................................................................................ 483 kg 1065 lb.

8. Apply alignment marks between travel gear case assembly and track frame to aid during installation. NOTE: Travel gear case assembly is shown removed with sprocket for balance. 9. Using appropriate lifting device, remove cap screws (3) and travel gear case assembly.

Travel Gear Case Assembly 5— Travel Gear Case Assembly

10. Remove sprocket. See Sprocket Remove and Install. (Group 0130.) 11. Clean, inspect, and replace parts as necessary.

• See Travel Gear Case Disassemble and Assemble. (Group 0250.)

• See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.)

• See Park Brake Valve Disassemble and Assemble. (Group 0260.)

12. Install sprocket. See Sprocket Remove and Install. (Group 0130.) 13. Using appropriate lifting device, install travel gear case assembly. 14. Align marks on travel gear case assembly to mark on track frame. Install cap screws and tighten to specification. Specification Cap Screw—Torque....................................................................630 N·m 465 lb.-ft.

NOTE: Travel motor drain hose (4) will remain capped and plugged until travel motor start-up procedure is performed. 15. Connect hydraulic hoses (6—8). See Travel Hydraulic System Line Connection. (Group 9025-15.) 16. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

17. Perform travel motor start-up procedure and connect travel motor drain hose (4). See Travel Motor and Park Brake Start-Up Procedure. (Group 0260.) IMPORTANT: Hydraulic pumps will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housings whenever oil has been drained from pumps or hydraulic oil tank. 18. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 19. Install track chain. See Track Chain Remove and Install. (Group 0130.) 20. Operate machine and check for leaks. 21. Install travel motor access panel and cap screws. Tighten to specification. Specification Travel Gear Case Cover Cap Screw—Torque....................................................................180 N·m 133 lb.-ft.

MM12851,00004B5 -19-06JAN15-3/3

TM13264X19 (02FEB17)

02-0250-3

300GLC Excavator 020217 PN=91

Axle Shaft, Bearings, and Reduction Gears

Travel Gear Case Disassemble and Assemble SPECIFICATIONS Travel Gear Case Assembly Weight (approximate)

490 kg 1080 lb.

Gear Oil Capacity

9.2 L 2.4 gal.

Ring Gear Weight (approximate)

53 kg 117 lb.

Third Stage Planetary Carrier Weight (approximate)

61 kg 135 lb.

Drum Weight (approximate)

71 kg 157 lb.

Sprocket Weight (approximate)

69 kg 152 lb.

Tapered Roller Bearing Temperature

50—70°C 122—158°F

Sprocket Weight (approximate)

69 kg 152 lb.

Sprocket-to-Drum Cap Screw Torque

680 N·m 502 lb.-ft.

Drum Weight (approximate)

71 kg 157 lb.

Bearing Nut Torque

800 N·m 590 lb.-ft.

Lock Plate Cap Screw Torque

90 N·m 66 lb.-ft.

Ring Gear-to-Drum Cap Screw Torque

270 N·m 199 lb.-ft.

Cover-to-Ring Gear Cap Screw Torque

110 N·m 81 lb.-ft.

ESSENTIAL TOOLS JT01748 Lifting Brackets DFT1305 Travel Gear Case Nut Wrench DFT1109 Holding Bar OTHER MATERIAL Loctite® 271™ Threadlocker (high strength) Loctite® 277™ Threadlocker (high strength) Loctite® 242® Threadlocker (medium strength)

Continued on next page

TM13264X19 (02FEB17)

02-0250-4

MM12851,00004E2 -19-14JAN15-1/8

300GLC Excavator 020217 PN=92

Axle Shaft, Bearings, and Reduction Gears

TX1165688 —UN—17JUL14

Disassemble Travel Gear Case

Travel Gear Case 1— Travel Motor 2— Metal Face Seal 3— Tapered Roller Bearing (2 used) 4— Drum 5— Sprocket 6— Cap Screw (24 used) 7— Lock Washer (24 used) 9— Bearing Nut 11— Needle Bearing (6 used) 12— Third Stage Planetary Carrier 13— Planetary Gear (3 used)

15— Thrust Plate (6 used) 16— Pin Fastener (3 used) 17— Spring Pin (3 used) 18— Third Stage Sun Gear 20— Ring Gear 21— Cap Screw (28 used) 23— Second Stage Planetary Carrier 25— Planetary Gear (3 used) 26— Needle Bearing (3 used)

27— Thrust Plate (6 used) 37— Pin Fastener (3 used) 28— Pin Fastener (3 used) 38— Spring Pin (3 used) 29— Spring Pin (3 used) 39— Shaft 30— Second Stage Sun Gear 41— Cover 32— First Stage Planetary Carrier 42— Stopper 33— Spacer (3 used) 43— Cap Screw (16 used) 34— Planetary Gear (3 used) 44— Plug (3 used) 35— Needle Bearing (3 used) 45— Ball Bearing 36— Thrust Plate (6 used) 46— Retaining Ring 47— Lock Plate 48— Cap Screw (2 used)

Continued on next page

TM13264X19 (02FEB17)

02-0250-5

MM12851,00004E2 -19-14JAN15-2/8

300GLC Excavator 020217 PN=93

Axle Shaft, Bearings, and Reduction Gears

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 1. Remove travel gear case assembly using appropriate lifting device. See Travel Gear Case Remove and Install. (Group 0250.) Specification Travel Gear Case Assembly—Weight (approximate)................................................................................ 490 kg 1080 lb.

2. Drain gear oil. See Drain and Refill Travel Gear Case Oil. (Operator’s Manual.) Specification Gear Oil—Capacity.......................................................................... 9.2 L 2.4 gal.

3. Place travel gear case assembly on workbench with travel motor (1) side facing down.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Using appropriate lifting device, remove third stage planetary carrier (12) from drum (4). Specification Third Stage Planetary Carrier—Weight (approximate).................................................................................. 61 kg 135 lb.

13. Apply alignment marks at mating positions and remove spring pins (17), pin fasteners (16), thrust plates (15), needle bearings (11), spacer (33), and planetary gears (13) from third stage planetary carrier (12). 14. Remove cap screws (48). Remove lock plate (47) from bearing nut (9). 15. Remove bearing nut (9) using DFT1305 Travel Gear Case Nut Wrench and DFT1109 Holding Bar.

4. Apply alignment marks at mating positions of cover (41), ring gear (20), and drum (4).

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

5. Remove cap screws (43) and cover. 6. Apply alignment marks at mating positions and remove shaft (39), spacer (33), and first stage planetary carrier (32) from ring gear (20). 7. Apply alignment marks at mating positions and remove spring pins (38), pin fasteners (37), thrust plates (36), needle bearings (35), and planetary gears (34) from first stage planetary carrier (32). 8. Apply alignment marks at mating positions and remove second stage sun gear (30), spacer (33), and second stage planetary carrier (23) from ring gear (20).

16. Remove drum using JT01748 Lifting Brackets. Specification Drum—Weight (approximate).................................................................................. 71 kg 157 lb.

IMPORTANT: Avoid damage to metal face seal. Seal must be kept together as a set because of wear patterns. Metal face seal can be reused if seal is not worn or damaged. 17. Remove and inspect metal face seal (2). See Metal Face Seals Repair. (Group 0130.)

9. Apply alignment marks at mating positions and remove spring pins (29), pin fasteners (28), thrust plates (27), needle bearings (26), and planetary gears (25) from second stage planetary carrier (23).

NOTE: Further disassembly is not necessary unless tapered roller bearing (3) replacement is required.

10. Apply alignment marks at mating positions and remove third stage sun gear (18) from third stage planetary carrier (12).

18. Inspect tapered roller bearings (3) and races inside drum (4). If replacement of tapered roller bearings is required, replace with new bearings.

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

11. Install JT01748 Lifting Brackets to ring gear. Apply alignment marks at mating positions. Remove cap screws (21) and ring gear.

19. Using appropriate lifting device, remove cap screws (6), lock washers (7), and sprocket (5).

Specification Ring Gear—Weight (approximate).................................................................................. 53 kg 117 lb.

Specification Sprocket—Weight (approximate).................................................................................. 69 kg 152 lb.

20. Clean, inspect, and replace parts as necessary. Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

02-0250-6

MM12851,00004E2 -19-14JAN15-3/8

300GLC Excavator 020217 PN=94

Axle Shaft, Bearings, and Reduction Gears

TX1165688 —UN—17JUL14

Assemble Travel Gear Case

Continued on next page

TM13264X19 (02FEB17)

02-0250-7

MM12851,00004E2 -19-14JAN15-4/8

300GLC Excavator 020217 PN=95

Axle Shaft, Bearings, and Reduction Gears 7. Using appropriate lifting device, install sprocket (5), lock washers (7), and cap screws (6). Tighten cap screws to specification.

IMPORTANT: Prevent possible machine damage. Apply clean gear oil onto parts to prevent parts from seizing.

Specification Sprocket—Weight (approximate).................................................................................. 69 kg 152 lb. Sprocket-to-Drum Cap Screw—Torque............................................................................680 N·m 502 lb.-ft.

IMPORTANT: When heating bearing cone, do not overheat parts. Heat bearing just enough to install. Overheating components can cause unnecessary damage to other components. 1. Heat inner race of tapered roller bearings (3) and install onto travel motor (1) tight against shoulder. Specification Tapered Roller Bearing—Temperature..............................................................50—70°C 122—158°F

IMPORTANT: Avoid damage to metal face seal. Metal face seal and seat surfaces must be clean, dry, and oil free so seal does not slip.

8. Heat inner race of tapered roller bearing (3) on cover side and install onto travel motor. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 9. Install drum using JT01748 Lifting Brackets from travel motor.

NOTE: A volatile, non-petroleum base solvent or talcum powder must be used as a lubricant. 2. Thoroughly clean seat surfaces on travel motor (1), drum (4), ring gear (20), and metal face seal (2) using non-petroleum base solvent and lint-free tissues. 3. Install metal face seals to travel motor and drum. Apply equal pressure with fingers at four equally spaced points on metal face seal. Metal face seal must “pop” down into place so it is tight against seal bore. NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant.

Specification Drum—Weight (approximate).................................................................................. 71 kg 157 lb.

10. Apply a thin coat of multipurpose grease to bearing nut (9). Install bearing nut using DFT1305 Travel Gear Case Nut Wrench and DFT1109 Holding Bar. Tighten bearing nut to specification. Specification Bearing Nut—Torque...................................................................800 N·m 590 lb.-ft.

11. To seat bearings, tap on drum using a plastic hammer. Then turn drum three times to the right and left to seat the bearings.

4. Wipe fingerprints and foreign material off metal face seal using volatile, non-petroleum base solvent and lint-free tissues. Apply a thin film of oil to metal seal face.

Repeat steps to ensure bearings are seated properly. 12. Apply Loctite® 271™ Threadlocker (high strength) to cap screws (48).

5. Install outer race of roller bearings to cover side of drum and travel motor side of drum.

13. Install lock plate (47) to bearing nut (9). Install cap screws (48). Tighten to specification.

6. Apply Loctite® 271™ Threadlocker (high strength) to cap screws (6). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Specification Lock Plate Cap Screw—Torque..............................................................................90 N·m 66 lb.-ft.

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

02-0250-8

MM12851,00004E2 -19-14JAN15-5/8

300GLC Excavator 020217 PN=96

Axle Shaft, Bearings, and Reduction Gears

NOTE: There is an identification groove on one side of planetary gears (13). Be sure this marked side faces the hole for the spring pin.

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

TX1164775

15. Using appropriate lifting device, install third stage planetary carrier (12) into spline of travel motor (1).

TX1164775 —UN—10JUL14

14. Using alignment marks, install thrust plates (15), needle bearings (11), spacer (33), planetary gears (13), spring pins (17), and pin fasteners (16) into third stage planetary carrier (12).

Spring Pin Installation

Specification Third Stage Planetary Carrier—Weight (approximate).................................................................................. 61 kg 135 lb.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 16. Using JT01748 Lifting Brackets, install ring gear. Specification Ring Gear—Weight (approximate).................................................................................. 53 kg 117 lb.

16— Pin Fastener (3 used)

17— Spring Pin (3 used)

17. Apply Loctite® 271™ Threadlocker (high strength) to cap screws (21). Install cap screws and tighten to specification. Specification Ring Gear-to-Drum Cap Screw—Torque............................................................................270 N·m 199 lb.-ft.

18. Using alignment marks, install third stage sun gear (18) into third stage planetary carrier (12).

Loctite and its related brand marks are trademarks of Henkel Corporation MM12851,00004E2 -19-14JAN15-6/8

NOTE: There is an identification groove on one side of planetary gears (25). Be sure this marked side faces the hole for the spring pin. 28

19. Using alignment marks, install thrust plates (27), needle bearings (26), planetary gears (25), spring pins (29), and pin fasteners (28) into second stage planetary carrier (23).

20. Using alignment marks at mating positions, install second stage planetary carrier (23), spacer (33), and second stage sun gear (30) into ring gear (20). 28— Pin Fastener (3 used) 29— Spring Pin (3 used)

51— Opening

Spring Pin

Continued on next page

TM13264X19 (02FEB17)

TX1114536 —UN—24MAY12

02-0250-9

MM12851,00004E2 -19-14JAN15-7/8

300GLC Excavator 020217 PN=97

Axle Shaft, Bearings, and Reduction Gears

NOTE: There is an identification groove on one side of planetary gears (34). Be sure this marked side faces the hole for the spring pin. 37

21. Using alignment marks, install thrust plates (36), needle bearings (35), planetary gears (34), spring pins (38), and pin fasteners (37) into first stage planetary carrier (32).

TX1114545 —UN—24MAY12

22. Using alignment marks, install shaft (39), spacer (33), and first stage planetary carrier (32) to ring gear (20). 23. Apply Loctite® 277™ Threadlocker (high strength) to flange surface of ring gear and cover. Spring Pin

24. Apply Loctite® 242® Threadlocker (medium strength) to thread of cap screws (43). Install cap screws and cover. Tighten to specification. Specification Cover-to-Ring Gear Cap Screw—Torque............................................................................ 110 N·m 81 lb.-ft.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 25. Install travel gear case assembly using appropriate lifting device. See Travel Gear Case Remove and Install. (Group 0250.)

37— Pin Fastener (3 used) 38— Spring Pin (3 used)

52— Opening

26. Refill gear oil. See Drain and Refill Travel Gear Case Oil. (Operator’s Manual.) Specification Gear Oil—Capacity.......................................................................... 9.2 L 2.4 gal.

27. Perform travel motor and park brake start-up procedure. See Travel Motor and Park Brake Start-Up Procedure. (Group 0260.)

Specification Travel Gear Case Assembly—Weight (approximate)................................................................................ 490 kg 1080 lb. Loctite and its related brand marks are trademarks of Henkel Corporation MM12851,00004E2 -19-14JAN15-8/8

TM13264X19 (02FEB17)

02-0250-10

300GLC Excavator 020217 PN=98

Group 0260

Hydraulic System Travel Motor and Park Brake Remove and Install NOTE: The travel gear case, travel motor, and park brake are enclosed in the same housing. All three components must be removed as an assembly.

See Travel Gear Case Remove and Install. (Group 0250.) To access travel motor, travel gear case must be disassembled. See Travel Gear Case Disassemble and Assemble. (Group 0250.) TZ24494,0000E8C -19-19MAR13-1/1

TM13264X19 (02FEB17)

02-0260-1

300GLC Excavator 020217 PN=99

Hydraulic System

Travel Motor and Park Brake Disassemble and Assemble

OTHER MATERIAL 277 Loctite® Rigid Form-In-Place Gasket

SPECIFICATIONS Travel Gear Case Assembly Weight (approximate)

490 kg 1090 lb.

Park Brake Valve Weight (approximate)

23 kg 51 lb.

Disk Spring Height

7.6—7.2 mm 0.300—0.283 in.

Friction Plate Height

2.75—2.70 mm 0.108—0.106 in.

Plate Height

1.80—1.75 mm 0.071—0.069 in.

Housing Weight (approximate)

110 kg 245 lb.

Cap Screw Torque

400 N·m 300 lb.-ft.

SERVICE EQUIPMENT AND TOOLS D01044AA Bushing, Bearing, and Seal Driver Set

Continued on next page

TM13264X19 (02FEB17)

02-0260-2

TZ24494,0000E8D -19-27MAR13-1/9

300GLC Excavator 020217 PN=100

Hydraulic System

Disassemble Travel Motor and Park Brake

27 27

25 27

24 23 23 22

11 13

14 15 16 12

9 20

9 9

21 9 7 5

8 8

2 8

TX1114730 —UN—25MAY12

1 6 4

TX1114730

1 Travel Motor and Park Brake

1— Cap Screw (8 used) 2— Park Brake Valve 3— Needle Bearing 4— Disk Spring 5— O-Ring 6— Brake Piston 7— O-Ring 8— Plate (4 used)

16— Retainer 17— Bushing 18— Spring (6 used) 19— Rotor 20— Valve Plate 21— Dowel Pin (2 used) 22— Shaft 23— Snap Ring (2 used)

9— Friction Plate (4 used) 10— Pin 11— Inner Ring Plate 12— Pin (2 used) 13— Piston (2 used) 14— Swash Plate 15— Piston (9 used)

24— Roller Bearing 25— Oil Seal 26— O-Ring 27— O-Ring (3 used) 28— Housing

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Continued on next page

TM13264X19 (02FEB17)

02-0260-3

TZ24494,0000E8D -19-27MAR13-2/9

300GLC Excavator 020217 PN=101

Hydraulic System 1. Remove travel gear case assembly using appropriate lifting device. See Travel Gear Case Remove and Install. (Group 0250.) Specification Travel Gear Case Assembly—Weight (approximate)................................................................................ 490 kg 1090 lb.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Using appropriate lifting device, support park brake valve (2). Specification Park Brake Valve—Weight (approximate).................................................................................. 23 kg 51 lb.

IMPORTANT: Prevent possible damage to needle bearing (3). Remove needle bearing only if replacement is necessary. Needle bearing must be replaced if removed. 4. Remove needle bearing (3) if necessary. NOTE: Dowel pins (21) are not removable. 5. Remove valve plate (20). 6. Apply tape to thrust surface of shaft (22) to protect needle bearing seating surface. 7. Remove disk spring (4) from housing. Inspect part for wear or damage. Compare to specification. Specification Disk Spring—Height.............................................................7.6—7.2 mm 0.300—0.283 in.

8. Remove O-rings (26 and 27) from housing.

3. Remove cap screws (1) and park brake valve (2) from housing (28). Loctite is a trademark of Henkel Corporation TZ24494,0000E8D -19-27MAR13-3/9

CAUTION: Prevent possible injury from components under pressure. Park brake piston may come out quickly with considerable force. Use only regulated air pressure and stand clear of park brake piston when removing. 9. Carefully apply 100—300 kPa (14—43 psi) air pressure to brake release passage (29) to remove brake piston (6). 28— Housing 29— Brake Release Passage

30— Piston Oil Passage

TX1114748 —UN—25MAY12

Travel Motor and Park Brake Housing Continued on next page

TM13264X19 (02FEB17)

02-0260-4

TZ24494,0000E8D -19-27MAR13-4/9

300GLC Excavator 020217 PN=102

Hydraulic System

IMPORTANT: Prevent possible damage due to improper handling. Position brake piston with seating surface facing up on bench.

TX1114847 —UN—25MAY12

10. Position brake piston with seating surface facing up on bench. 11. Remove O-rings (5 and 7) from brake piston. 12. Remove friction plates (9) and plates (8) from housing. 13. Inspect parts for wear or damage. Specification Friction Plate—Height......................................................2.75—2.70 mm 0.108—0.106 in. Plate—Height...................................................................1.80—1.75 mm 0.071—0.069 in.

Brake Piston 6— Brake Piston

14. Remove rotor (19), springs (18), bushing (17), retainer (16), and pistons (15). TZ24494,0000E8D -19-27MAR13-5/9

IMPORTANT: Prevent possible damage due to handling. Prevent swash plate from falling out while housing is positioned horizontally.

TX1114748 —UN—25MAY12

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

15. Using appropriate lifting device, position housing with brake release passage (29) facing down. Specification Housing—Weight (approximate).................................................................................110 kg 245 lb.

Travel Motor and Park Brake Housing

NOTE: When swash plate cannot be removed, apply 100—300 kPa (14—43 psi) air pressure to piston oil passage (30). Cover pistons (13) with a cloth to prevent ejection.

28— Housing 29— Brake Release Passage

30— Piston Oil Passage

20. Remove and discard oil seal (25) from housing.

16. Remove swash plate (14) from housing. 17. Remove pistons (13) and pins (12) using a magnet.

21. Remove snap rings (23) from shaft (22).

18. Remove inner ring plate (11).

IMPORTANT: Prevent roller bearing damage due to falling during shaft removal. Handle with care.

19. Remove shaft (22) and attached roller bearing (24) through motor side of housing.

22. Remove roller bearing (24) from shaft (22).

NOTE: Oil seal (25) must be replaced after removal.

23. Repair or replace parts as necessary. Continued on next page

TM13264X19 (02FEB17)

02-0260-5

TZ24494,0000E8D -19-27MAR13-6/9

300GLC Excavator 020217 PN=103

Hydraulic System Assemble Travel Motor and Park Brake

27 27

25 27

24 23 23 22

11 13

14 15 16 12

9 20

9 9

21 9 7 5

8 8

2 8

TX1114730 —UN—25MAY12

1 6 4

TX1114730

1 Travel Motor and Park Brake

1— Cap Screw (8 used) 2— Park Brake Valve 3— Needle Bearing 4— Disk Spring 5— O-Ring 6— Brake Piston 7— O-Ring 8— Plate (4 used)

16— Retainer 17— Bushing 18— Spring (6 used) 19— Rotor 20— Valve Plate 21— Dowel Pin (2 used) 22— Shaft 23— Snap Ring (2 used)

9— Friction Plate (4 used) 10— Pin 11— Inner Ring Plate 12— Pin (2 used) 13— Piston (2 used) 14— Swash Plate 15— Piston (9 used)

24— Roller Bearing 25— Oil Seal 26— O-Ring 27— O-Ring (3 used) 28— Housing

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

Continued on next page

TM13264X19 (02FEB17)

02-0260-6

TZ24494,0000E8D -19-27MAR13-7/9

300GLC Excavator 020217 PN=104

Hydraulic System 1. Hoist and place housing (28) with park brake valve (2) mounting surface facing up. Specification Housing—Weight (approximate).................................................................................110 kg 245 lb.

6. Install snap rings (23) to shaft. 7. Install pistons (13) to housing with stepped side facing inside. IMPORTANT: Prevent damage to surface of shaft during installation. Surface damage may cause damage to needle bearing (3) inner race.

2. Apply multipurpose grease to lip of new oil seal (25) and apply PM38655 Rigid Form-In-Place Gasket to outer surface of oil seal.

8. Install shaft into housing.

3. Install oil seal.

9. Install pins (12) into housing.

4. Install inner ring plate (11) to roller bearing with stamped mark facing outside.

10. Apply grease to pin alignment holes of swash plate (14). Align holes with positions of pins (12) and install into housing.

5. Install roller bearing (24) to shaft (22) using D01044AA Bushing, Bearing, and Seal Driver Set. TZ24494,0000E8D -19-27MAR13-8/9

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

11. Hoist and place housing with brake release passage (29) facing down. Specification Housing—Weight (approximate).................................................................................110 kg 245 lb. 28— Housing 29— Brake Release Passage

29 30

TX1114748 —UN—25MAY12

IMPORTANT: Prevent possible damage due to handling. Prevent swash plate from falling out while housing is positioned horizontally.

Travel Motor and Park Brake Housing

30— Piston Oil Passage

TZ24494,0000E8D -19-27MAR13-9/9

TM13264X19 (02FEB17)

02-0260-7

300GLC Excavator 020217 PN=105

Hydraulic System

NOTE: Chamfered side of retainer (16) must face towards bushing (17) side.

TX1114781 —UN—25MAY12

12. Lubricate with clean hydraulic oil and install springs (18), bushing (17), retainer (16), and pistons (15) to rotor (19).

13. Install rotor to housing. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 14. Hoist and place housing with park brake valve (2) mounting surface facing up.

Travel Motor Retainer and Bushing

Specification Housing—Weight (approximate).................................................................................110 kg 245 lb.

NOTE: Friction plates (9) and plates (8) are installed alternately. Follow proper installation sequence. 15. Starting with a friction plate, lubricate with clean hydraulic oil and install plates (8) and friction plates (9) alternately into housing. 16. Apply grease to O-rings (5 and 7). Install O-rings to brake piston (6). IMPORTANT: Prevent damage to brake piston seating surface during installation. Handle with care. NOTE: Brake piston will be fully installed during installation of brake valve. 17. Position brake piston so notch on disk spring mounting surface is located opposite brake releasing oil passage on housing. Tap brake piston into housing.

16— Retainer

24. Install valve plate aligning to installed dowel pins (21) in backside of park brake valve (2). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 25. Using appropriate lifting device, install park brake valve and cap screws (1) to housing. Tighten to specification. See Park Brake Valve Disassemble and Assemble. (Group 0260.) Specification Park Brake Valve—Weight (approximate).................................................................................. 23 kg 51 lb. Specification Cap Screw—Torque....................................................................400 N·m 300 lb.-ft.

18. Install disk spring (4) on brake piston with inner diameter surface facing brake piston.

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

19. Install O-rings (26 and 27) onto housing. 20. Add clean hydraulic oil into housing until plate (8) is submerged. 21. If removed, install outer race of needle bearing (3) into park brake valve (2). 22. Install outer race of roller bearing (24) to brake valve with stamped mark facing outside. IMPORTANT: Prevent damage to valve plate (20) due to falling. If damaged, valve plate will cause oil leakage. Handle with care.

17— Bushing

26. Install travel gear case assembly using appropriate lifting device. See Travel Gear Case Remove and Install. (Group 0250.) Specification Travel Gear Case Assembly—Weight (approximate)................................................................................ 490 kg 1090 lb.

27. Perform travel motor and park brake start-up procedure. See Travel Motor and Park Brake Start-Up Procedure. (Group 0260).

23. Apply petroleum jelly to mating surface of valve plate (20) to adhere it to travel motor cover during assembly. TZ24494,0000E8D -19-27MAR13-10/9

TM13264X19 (02FEB17)

02-0260-8

300GLC Excavator 020217 PN=106

Hydraulic System

TM13264X19 (02FEB17)

02-0260-9

300GLC Excavator 020217 PN=107

Hydraulic System

TX1124325 —UN—17OCT12

Park Brake Valve Disassemble and Assemble

Parking Brake Assembly

Continued on next page

TM13264X19 (02FEB17)

02-0260-10

TZ24494,0000E8E -19-19MAR13-1/2

300GLC Excavator 020217 PN=108

Hydraulic System 1— Travel Motor Manifold Cover 7— Poppet (2 used) 2— Counterbalance Valve Spool 8— Spring (2 used) 3— Spool (2 used) 9— Relief Valve (2 used) 4— Spring (2 used) 10— Valve Spool 5— O-Ring (2 used) 11— Compression Spring 6— Counterbalance Valve Plug (2 12— O-Ring used) 13— Travel Speed Change Plug

SPECIFICATIONS

24— O-Ring 25— Pipe Plug 26— O-Ring 27— Fitting Plug 28— Pipe Plug (3 used)

9. Inspect poppets for wear.

Counterbalance Valve Plug Torque 350 N·m 260 lb.-ft. Relief Valve Torque

14— Ball 15— Seat 16— O-Ring 17— Pipe Plug 18— O-Ring 19— Pipe Plug 20— O-Ring (2 used) 21— Drain Plug (2 used) 22— O-Ring 23— Pipe Plug

10. Repair or replace parts as necessary.

450 N·m 330 lb.-ft.

11. Apply a film of clean hydraulic oil to parts.

Travel Speed Change Plug Torque 35 N·m 26 lb.-ft.

12. Install poppets, springs, and relief valves. Tighten relief valves to specification.

NOTE: Valves may be removed with travel motor in machine.

Specification Relief Valve—Torque...................................................................450 N·m 330 lb.-ft.

1. Remove park brake. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) 2. Remove counterbalance valve plugs (6). NOTE: Remove counterbalance valve while rotating, if resistance is felt do not try to force, return to original position and try again. 3. Push, rotate, and remove O-rings (5), springs (4), spools (3), and counterbalance valve spool (2). 4. Inspect counterbalance valve spool (2) for wear.

13. Remove and inspect travel speed change plug (13) and O-ring (12). 14. Remove compression spring (11) and valve spool (10) from travel motor manifold cover (1) using a magnet. 15. Repair or replace parts as necessary. 16. Apply a film of clean hydraulic oil to parts. 17. Install valve spool (10) with shoulder facing compression spring (11). 18. Install O-ring (12) onto travel speed change plug (13).

5. Repair or replace parts as necessary.

19. Install compression spring (11) and travel speed change plug (13). Tighten plug to specification.

6. Apply a film of clean hydraulic oil to parts. NOTE: Install counterbalance valve while rotating, if resistance is felt do not try to force, return to original position and try again. 7. Install counterbalance valve spool (2), spools (3), springs, O-rings, and counterbalance valve plugs. Tighten counterbalance valve plug to specification. Specification Counterbalance Valve Plug—Torque...............................................................................350 N·m 260 lb.-ft.

Specification Travel Speed Change Plug—Torque.................................................................................35 N·m 26 lb.-ft.

20. Install park brake. See Travel Motor and Park Brake Disassemble and Assemble. (Group 0260.) 21. Perform travel motor and park brake start-up procedure. See Travel Motor and Park Brake Start-Up Procedure. (Group 0260).

8. Remove relief valves (9), springs (8), and poppets (7). TZ24494,0000E8E -19-19MAR13-2/2

TM13264X19 (02FEB17)

02-0260-11

300GLC Excavator 020217 PN=109

Hydraulic System

Travel Motor and Park Brake Start-Up Procedure SPECIFICATIONS 156 L 41 gal.

TX1092057A —UN—12MAY11

Hydraulic Oil Tank Capacity

IMPORTANT: To avoid component damage from insufficient lubrication, this procedure must be performed whenever the travel motor is replaced, disassembled, or the case has been drained. 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 2. Release hydraulic oil tank pressure by pressing the pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity............................................................................... 156 L 41 gal.

4. Disconnect travel motor drain hose (1). 5. Fill travel motor case with hydraulic oil through case drain port until full. For approved hydraulic oils, see Hydraulic Oil. (Operator’s Manual.)

Travel Motor Drain Hose 1— Travel Motor Drain Hose

6. Connect travel motor drain hose. 7. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) IMPORTANT: Hydraulic pumps will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housings whenever oil has been drained from the pumps or hydraulic oil tank. 8. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 9. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 10. Operate machine and check for leaks. JL58967,000019D -19-01DEC14-1/1

TM13264X19 (02FEB17)

02-0260-12

300GLC Excavator 020217 PN=110

Section 04 Engine Contents Page

Group 0400—Removal and Installation Engine Remove ......................................... 04-0400-1 Engine Install ............................................. 04-0400-7

TM13264X19 (02FEB17)

04-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

04-2

300GLC Excavator

020217

PN=2

Group 0400

Removal and Installation Engine Remove

Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Cooling System Capacity (approximate)

36 L 9.5 gal.

Pump 1 and 2 Weight (approximate)

210 kg 463 lb.

Engine Weight (approximate)

832 kg 1835 lb.

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

SERVICE EQUIPMENT AND TOOLS DFT1119 Pump Support JDG11260 Lifting Strap

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates. 2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable. 3. Remove hood and engine side shields. See Hood and Engine Side Shields Remove and Install. (Group 1910.) 4. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing.

6. Drain coolant from radiator. See Drain Cooling System. (Operator’s Manual.) Specification Cooling System—Capacity (approximate)................................................................................ 36 L 9.5 gal.

7. Remove exhaust aftertreatment assembly. See Exhaust Aftertreatment Assembly Remove and Install. (Group 0530.) 8. Remove coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.) 9. Install identification tags and disconnect upper charge air cooler tube (1) and upper radiator hose (2). Close all openings using caps and plugs. 10. Install identification tags and disconnect deaeration hose (3). Close all openings using caps and plugs. NOTE: It is not necessary to disconnect upper hydraulic oil cooler hose during engine removal. 11. Remove air intake tube (4). Close all openings using caps and plugs.

5. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See

Continued on next page

TM13264X19 (02FEB17)

04-0400-1

DV53278,00008D8 -19-10FEB15-1/15

300GLC Excavator 020217 PN=113

Removal and Installation 3— Deaeration Hose 4— Air Intake Tube

TX1183607A —UN—28JAN15

1— Upper Charge Air Cooler Tube 2— Upper Radiator Hose

Cooling System (upper) DV53278,00008D8 -19-10FEB15-2/15

12. Install identification tags and disconnect electrical connections from alternator (G3).

TX1166683A —UN—30JUL14

G3—Alternator

Alternator DV53278,00008D8 -19-10FEB15-3/15

13. Install identification tags and disconnect surge tank-to-coolant pump hose (5). Close all openings using caps and plugs.

5— Surge Tank-to-Coolant Pump Hose 6— Diesel Exhaust Fluid (DEF) Return Hose

TX1183620A —UN—28JAN15

14. Install identification tags and disconnect diesel exhaust fluid (DEF) return hose (6) and coolant pump-to-cab heater hose (7). Close all openings using caps and plugs. 7— Coolant Pump-to-Cab Heater Hose

Coolant Hoses Continued on next page

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04-0400-2

DV53278,00008D8 -19-10FEB15-4/15

300GLC Excavator 020217 PN=114

Removal and Installation

IMPORTANT: Prevent possible fuel spill. On machines without a fuel shutoff valve, install clamp on fuel hose to prevent the release of fuel.

8— Final Fuel Filter-to-HighPressure Fuel Pump Line

TX1183622A —UN—28JAN15

15. Install identification tags and disconnect fuel lines (8 and 9). Close all openings using caps and plugs. 9— Fuel Return Manifold-toFuel Cooler Line

Fuel Lines DV53278,00008D8 -19-10FEB15-5/15

16. Install identification tags and disconnect starter motor (M1).

10— Oil Filter Manifold-to-Oil Filter Hose 11— Oil Filter-to-Oil Filter Manifold Hose

TX1183624A —UN—28JAN15

17. Install identification tags and disconnect oil filter hoses (10 and 11). Close all openings using caps and plugs. M1—Starter Motor

Starter Motor DV53278,00008D8 -19-10FEB15-6/15

18. Install identification tags and disconnect electrical connectors (X5015, X5016, and X5068). X5068—Engine Interface Harness-to-Engine Harness Connector 3

TX1183609A —UN—28JAN15

X5015—Engine Interface Harness-to-Engine Harness Connector 1 X5016—Engine Interface Harness-to-Engine Harness Connector 2

Electrical Connectors Continued on next page

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04-0400-3

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300GLC Excavator 020217 PN=115

Removal and Installation

NOTE: It is not necessary to evacuate air conditioning system during engine removal.

TX1183625A —UN—28JAN15

19. Install identification tags and disconnect air conditioner compressor clutch (Y11). 20. Remove serpentine belt (12). See Inspect Serpentine Belt. (Operator’s Manual.) 21. Remove cap screws (13) and set air conditioner compressor aside. 12— Serpentine Belt 13— Cap Screw (4 used)

Y11— Air Conditioner Compressor Clutch Air Conditioner Compressor

DV53278,00008D8 -19-10FEB15-8/15

22. Install identification tags and disconnect hydraulic fan pump hoses (14 and 15). Close all openings using caps and plugs. 15— Supply Pressure Hose (fan pump to fan speed control valve)

TX1183626A —UN—28JAN15

14— Sump Hose (hydraulic oil tank to fan drive pump)

Hydraulic Fan Pump DV53278,00008D8 -19-10FEB15-9/15

NOTE: It is not necessary to remove lower hydraulic oil cooler hose during engine removal.

TX1183627A —UN—28JAN15

23. Remove lower charge air cooler tube (16). Close all openings using caps and plugs. 24. Disconnect lower radiator hose (17). Close all openings using caps and plugs. 16— Lower Charge Air Cooler Tube

17— Lower Radiator Hose

Cooling System (lower) Continued on next page

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04-0400-4

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300GLC Excavator 020217 PN=116

Removal and Installation

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

TX1183628A —UN—28JAN15

25. Support pumps 1 and 2 by installing DFT1119 Pump Support to pump lifting points (18). See DFT1119 Pump Support. (Group 9900.) Specification Pump 1 and 2—Weight (approximate)................................................................................ 210 kg 463 lb. 18— Pump Lifting Point (2 used)

Pump Support Lifting Points DV53278,00008D8 -19-10FEB15-11/15

26. Remove cap screws (19 and 20). 20— Cap Screw (4 used)

TX1183629A —UN—28JAN15

19— Cap Screw (4 used)

TX1183630A —UN—28JAN15

Hydraulic Pump (upper)

Hydraulic Pump (lower) Continued on next page

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04-0400-5

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300GLC Excavator 020217 PN=117

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 27. Support engine by attaching appropriate lifting device to JDG11260 Lifting Strap (21) and front lifting strap (22).

21— JDG11260 Lifting Strap

TX1183611A —UN—28JAN15

Specification Engine—Weight (approximate)................................................................................ 832 kg 1835 lb. 22— Front Lifting Strap

Engine Lifting Points DV53278,00008D8 -19-10FEB15-13/15

28. Remove cap screws (23). 24— Engine Mount (2 used)

TX1183632A —UN—28JAN15

23— Cap Screw (2 used)

Rear Engine Mount Continued on next page

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04-0400-6

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300GLC Excavator 020217 PN=118

Removal and Installation

29. Remove cap screws (25). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 30. Using appropriate lifting device, remove engine. Specification Engine—Weight (approximate)................................................................................ 832 kg 1835 lb.

25— Cap Screw (2 used)

TX1183634A —UN—30JAN15

31. Repair or replace parts as necessary. For additional information on John Deere PowerTech™ engines and components for engine model 6068HT107, see PowerTech™ 6068 OEM Diesel Engines (Final Tier 4/Stage IV Platform). (CTM120019.) 26— Engine Mount (2 used)

Front Engine Mount PowerTech is a trademark of Deere & Company DV53278,00008D8 -19-10FEB15-15/15

Engine Install Installation is reverse of removal procedure.

Engine—Weight (approximate)................................................................................ 832 kg 1835 lb.

Tools

Fluid Specifications

• DFT1119 Pump Support

- Used to support hydraulic pump 1 and 2. For instructions to make tool, see DFT1119 Pump Support. (Group 9900.) • JDG11260 Lifting Strap - Attach to rear lifting point on engine.

Weight Specifications

Specification Hydraulic Oil Tank—Capacity............................................................................... 156 L 41 gal. Cooling System—Capacity....................................................................................................... 36 L 9.5 gal.

Additional Information CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Pump 1 and 2—Weight (approximate)................................................................................ 210 kg 463 lb.

IMPORTANT: Prevent damage to diesel exhaust fluid (DEF) system hoses. DEF system hoses are fragile and can easily be damaged if proper care is not used. Avoid bending, twisting, or kinking DEF system hoses. DV53278,00008D9 -19-15JAN15-1/1

TM13264X19 (02FEB17)

04-0400-7

300GLC Excavator 020217 PN=119

Removal and Installation

TM13264X19 (02FEB17)

04-0400-8

300GLC Excavator 020217 PN=120

Section 05 Engine Auxiliary System Contents Page

Group 0510—Cooling Systems Radiator Remove and Install ..................... 05-0510-1 Hydraulic Oil Cooler Remove and Install ..................................................... 05-0510-2 Charge Air Cooler Remove and Install ..................................................... 05-0510-4 Fuel Cooler Remove and Install ................ 05-0510-5 Cooling Package Remove and Install ..................................................... 05-0510-6 Fan and Fan Guard Remove and Install ................................................... 05-0510-11 Coolant Surge Tank Remove and Install ................................................... 05-0510-14 Group 0530—External Exhaust Systems Exhaust Tube Remove and Install.............. 05-0530-1 JDG11335 Bellows Alignment Fixture.................................................... 05-0530-2 Exhaust Bellows Alignment Procedure .............................................. 05-0530-7 Diesel Particulate Filter (DPF) Remove and Install.............................. 05-0530-10 Selective Catalyst Reduction (SCR) Remove and Install................... 05-0530-13 Diesel Oxidation Catalyst (DOC) Remove and Install.............................. 05-0530-16 Exhaust Aftertreatment Assembly Remove and Install.............................. 05-0530-19 Diesel Exhaust Fluid (DEF) Tank Remove and Install.............................. 05-0530-21 Diesel Exhaust Fluid (DEF) Header Remove and Install.............................. 05-0530-23 Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble............................................. 05-0530-30 Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure............................. 05-0530-31 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install ...................... 05-0530-32 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install ................. 05-0530-41 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install ............................................ 05-0530-42 Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install ................... 05-0560-1

TM13264X19 (02FEB17)

05-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

05-2

300GLC Excavator

020217

PN=2

Group 0510

Cooling Systems Radiator Remove and Install 43 kg 95 lb.

Radiator Weight (approximate)

47 kg 104 lb.

TX1170409A —UN—02SEP14

SPECIFICATIONS Hydraulic Fan Motor Bracket Weight (approximate)

Fan Guard and Hydraulic Fan Motor Bracket

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

1— Cap Screw 2— Cap Screw (5 used)

3. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.)

3— Cap Screw (6 used) 4— Hydraulic Fan Motor Bracket

6. Using appropriate lifting device, remove cap screws (3) and hydraulic fan motor bracket (4) with fan guard.

4. Remove cap screw (1) and set electrical connector aside. 5. Remove cap screws (2). CAUTION: Prevent Possible crushing injury from heavy component. Use appropriate lifting device.

Specification Hydraulic Fan Motor Bracket—Weight (approximate).................................................................................. 43 kg 95 lb. JB42225,000006A -19-30SEP14-1/3

7. Remove cap screws (5) and fan shroud (6). 6— Fan Shroud

TX1170411A —UN—02SEP14

5— Cap Screw (3 used)

Fan Shroud Continued on next page

TM13264X19 (02FEB17)

05-0510-1

JB42225,000006A -19-30SEP14-2/3

300GLC Excavator 020217 PN=123

Cooling Systems

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

TX1170413A —UN—02SEP14

8. Using appropriate lifting device, remove cap screws (10, 11) and radiator (8). Specification Radiator—Weight (approximate).................................................................................. 47 kg 104 lb.

9. Repair or replace parts as necessary. 10. Install radiator and cap screws (10, 11). Cooling Package

11. Install fan shroud and cap screws (5). 12. Install hydraulic fan motor bracket, fan guard, and cap screws (3).

7— Hydraulic Oil Cooler 8— Radiator 9— Charge Air Cooler

10— Cap Screw (6 used) 11— Cap Screw (8 used)

13. Install cap screws (2). 14. Install electrical connector and cap screw (1).

17. Operate machine and check for leaks.

15. Install cooling package. See Cooling Package Remove and Install. (Group 0510.) 16. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) JB42225,000006A -19-30SEP14-3/3

Hydraulic Oil Cooler Remove and Install Hydraulic Fan Motor Bracket Weight (approximate)

43 kg 95 lb.

Hydraulic Oil Cooler Weight (approximate)

72 kg 158 lb.

TX1170409A —UN—02SEP14

SPECIFICATIONS

Fan Guard and Hydraulic Fan Motor Bracket

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

1— Cap Screw 2— Cap Screw (5 used)

3. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.)

6. Using appropriate lifting device, remove cap screws (3) and hydraulic fan motor bracket (4) with fan guard.

4. Remove cap screw (1) and set electrical connector aside. 5. Remove cap screws (2). CAUTION: Prevent Possible crushing injury from heavy component. Use appropriate lifting device.

Specification Hydraulic Fan Motor Bracket—Weight (approximate).................................................................................. 43 kg 95 lb.

Continued on next page

TM13264X19 (02FEB17)

3— Cap Screw (6 used) 4— Hydraulic Fan Motor Bracket

05-0510-2

JB42225,000006B -19-30SEP14-1/3

300GLC Excavator 020217 PN=124

Cooling Systems

7. Remove cap screws (5) and fan shroud (6). 6— Fan Shroud

TX1170411A —UN—02SEP14

5— Cap Screw (3 used)

Fan Shroud JB42225,000006B -19-30SEP14-2/3

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

TX1170480A —UN—28AUG14

8. Using appropriate lifting device, remove cap screws (10, 11) and hydraulic oil cooler (7). Specification Hydraulic Oil Cooler—Weight (approximate).................................................................................. 72 kg 158 lb.

9. Repair or replace parts as necessary. Hydraulic Oil Cooler

10. Install hydraulic oil cooler and cap screws (10, 11). 11. Install fan shroud and cap screws (5).

7— Hydraulic Oil Cooler 8— Radiator 9— Charge Air Cooler

12. Install hydraulic fan motor bracket, fan guard, and cap screws (3).

10— Cap Screw (8 used) 11— Cap Screw (6 used)

13. Install cap screws (2). 14. Install electrical connector and cap screw (1). 15. Install cooling package. See Cooling Package Remove and Install. (Group 0510.)

16. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 17. Operate machine and check for leaks. JB42225,000006B -19-30SEP14-3/3

TM13264X19 (02FEB17)

05-0510-3

300GLC Excavator 020217 PN=125

Cooling Systems

Charge Air Cooler Remove and Install 43 kg 95 lb.

Charge Air Cooler Weight (approximate)

32 kg 69 lb.

TX1170409A —UN—02SEP14

SPECIFICATIONS Hydraulic Fan Motor Bracket Weight (approximate)

Fan Guard and Hydraulic Fan Motor Bracket

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

1— Cap Screw 2— Cap Screw (5 used)

3. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.)

3— Cap Screw (6 used) 4— Hydraulic Fan Motor Bracket

6. Using appropriate lifting device, remove cap screws (3) and hydraulic fan motor bracket (4) with fan guard.

4. Remove cap screw (1) and set electrical connector aside. 5. Remove cap screws (2). CAUTION: Prevent Possible crushing injury from heavy component. Use appropriate lifting device.

Specification Hydraulic Fan Motor Bracket—Weight (approximate).................................................................................. 43 kg 95 lb. JB42225,000006C -19-30SEP14-1/3

7. Remove cap screws (5) and fan shroud (6). 6— Fan Shroud

TX1170411A —UN—02SEP14

5— Cap Screw (3 used)

Fan Shroud Continued on next page

TM13264X19 (02FEB17)

05-0510-4

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300GLC Excavator 020217 PN=126

Cooling Systems

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

TX1170478A —UN—28AUG14

8. Using appropriate lifting device, remove cap screws (10, 11) and charge air cooler (9). Specification Charge Air Cooler—Weight (approximate).................................................................................. 32 kg 69 lb.

9. Repair or replace parts as necessary. Charge Air Cooler

10. Install charge air cooler and cap screws (10, 11). 11. Install fan shroud and cap screws (5).

7— Hydraulic Oil Cooler 8— Radiator 9— Charge Air Cooler

12. Install hydraulic fan motor bracket, fan guard, and cap screws (3).

10— Cap Screw (8 used) 11— Cap Screw (8 used)

13. Install cap screws (2). 14. Install electrical connector and cap screw (1). 15. Install cooling package. See Cooling Package Remove and Install. (Group 0510.)

Fuel Cooler Remove and Install 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) TX1170267A —UN—27AUG14

IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates. 2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable. IMPORTANT: Prevent possible fuel spill. On machines without a fuel shutoff valve, install clamps on fuel hoses to prevent the release of fuel.

Fuel Cooler 1— Cap Screw (4 used) 2— Fuel Cooler

3. Install clamps on fuel hoses (3, 4) to minimize fuel spills. 4. Install identification tags and disconnect fuel cooler hoses (3, 4). Close all openings using caps and plugs. 5. Remove cap screws (1) and fuel cooler (2). 6. Inspect and replace parts as necessary. 7. Install fuel cooler and cap screws (1). 8. Connect fuel cooler hoses (3, 4) to fuel cooler.

3— Fuel Cooler-to-Fuel Tank Hose 4— Fuel Return Manifold-toFuel Cooler Hose

9. Release clamps from fuel hoses. 10. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 11. Operate machine and check for leaks.

NOTE: It is not necessary to bleed fuel system when replacing fuel cooler. JB42225,000006D -19-30SEP14-1/1

TM13264X19 (02FEB17)

05-0510-5

300GLC Excavator 020217 PN=127

Cooling Systems

Cooling Package Remove and Install 36 L 9.5 gal.

Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Cooling Package Weight (approximate)

261 kg 575 lb.

TX1170340A —UN—28AUG14

SPECIFICATIONS Cooling System Capacity (approximate)

Condenser 1— Nut (2 used) 2— Cap Screw (2 used)

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

3— Cap Screw (2 used)

7. Remove cap screws (3).

CAUTION: Prevent possible injury. Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to relieve the pressure, then remove. 3. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) Specification Cooling System—Capacity (approximate)................................................................................ 36 L 9.5 gal.

CAUTION: High-pressure release of oil from pressurized system can cause serious burns of penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button. 4. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 5. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

NOTE: Air conditioning system does not require evacuation to remove cooling package. Air conditioner lines remain connected. 6. Remove nuts (1) and cap screws (2). Continued on next page

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05-0510-6

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Cooling Systems MM12851,00004CE -19-29JAN15-2/10

8. Remove cap screws (4) and support bracket (5). 5— Support Bracket

TX1170342A —UN—28AUG14

4— Cap Screw (2 used)

Support Bracket MM12851,00004CE -19-29JAN15-3/10

9. Remove cap screws (6) and mounting bracket (7). 7— Mounting Bracket

TX1183614A —UN—28JAN15

6— Cap Screw (4 used)

TX1183615A —UN—28JAN15

Mounting Bracket

Lower Cap Screws Continued on next page

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05-0510-7

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300GLC Excavator 020217 PN=129

Cooling Systems

10. Remove clamp (10).

TX1183612A —UN—28JAN15

11. Install identification tags and disconnect upper charge air cooler tube (8). Close all openings using caps and plugs. 12. Install identification tags and disconnect upper radiator hose (9). Close all openings using caps and plugs. 13. Install identification tags and disconnect upper hydraulic oil cooler hose (13). Close all openings using caps and plugs. 14. Install identification tags and disconnect deaeration hose (11) and cap screw (12).

Cooling Package

15. Remove clamps (14 and 16) and air filter-to-turbo air tube (15).

8— Upper Charge Air Cooler Tube 9— Upper Radiator Hose 10— Clamp 11— Deaeration Hose 12— Cap Screw

13— Upper Hydraulic Oil Cooler Hose 14— Clamp 15— Air Filter-to-Turbo Air Tube 16— Clamp MM12851,00004CE -19-29JAN15-5/10

16. Install identification tags and disconnect hydraulic hoses (17—19) from fan motor. Close all openings using caps and plugs. 19— Supply Pressure Hose TX1170348A —UN—28AUG14

17— Hydraulic Return Hose 18— Case Drain Hose

Fan Motor Hydraulic Hoses MM12851,00004CE -19-29JAN15-6/10

17. Install identification tags and disconnect lower radiator hose (20). Close all openings using caps and plugs.

20— Lower Radiator Hose

TX1170349A —UN—28AUG14

18. Install identification tags and disconnect lower hydraulic oil cooler hose (21). Close all openings using caps and plugs. 21— Lower Hydraulic Oil Cooler Hose

Lower Cooling Package Hoses Continued on next page

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05-0510-8

MM12851,00004CE -19-29JAN15-7/10

300GLC Excavator 020217 PN=130

Cooling Systems

19. Install identification tags and disconnect lower charge air cooler tube (22). Close all openings using caps and plugs. TX1170351A —UN—28AUG14

22— Lower Charge Air Cooler Tube

Lower Charge Air Cooler Tube MM12851,00004CE -19-29JAN15-8/10

20. Disconnect engine interface harness-to-fan harness connector (X5040) and remove cap screw (23). X5040—Engine Interface Harness-to-Fan Harness Connector

TX1170354A —UN—28AUG14

23— Cap Screw

Electrical Connector Continued on next page

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Cooling Systems

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

TX1170355A —UN—28AUG14

21. Using appropriate lifting device, remove cap screws (24) and cooling package. Specification Cooling Package—Weight (approximate)............................................................................................ 261 kg 575 lb.

22. Repair or replace parts as necessary. Lower Cooling Package Cap Screws

23. Using appropriate lifting device, install cooling package and cap screws (24).

24— Cap Screw (8 used)

24. Connect electrical connector (X5040). 25. Connect lower charge air cooler tube.

39. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.)

26. Connect lower hydraulic oil cooler hose. 27. Connect lower radiator hose.

Specification Cooling System—Capacity (approximate)................................................................................ 36 L 9.5 gal.

28. Connect hydraulic lines to fan motor. 29. Install air filter-to-turbo air tube and clamps. 30. Install deaeration line and cap screw (12).

IMPORTANT: Prevent possible hydraulic pump damage. Perform hydraulic pump start-up procedure whenever oil has been drained from hydraulic pump or hydraulic oil tank.

31. Connect upper hydraulic oil cooler hose. 32. Connect upper radiator hose. 33. Connect upper charge air cooler tube.

40. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)

34. Install cap screws (6) and mounting bracket.

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

35. Install cap screws (4) and support bracket. 36. Install cap screws (3). 37. Install cap screws (2) and nuts (1). 38. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

42. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 43. Operate machine and check for leaks.

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal. MM12851,00004CE -19-29JAN15-10/10

TM13264X19 (02FEB17)

05-0510-10

300GLC Excavator 020217 PN=132

Cooling Systems

Fan and Fan Guard Remove and Install 36 L 9.5 gal.

Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Hydraulic Fan Motor Bracket Weight (approximate)

43 kg 95 lb.

Lock Nut Torque

80 N·m 59 lb.-ft.

TX1183612A —UN—28JAN15

SPECIFICATIONS Cooling System Capacity (approximate)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

Cooling Package

IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates.

8— Upper Charge Air Cooler Tube 9— Upper Radiator Hose 10— Clamp 11— Deaeration Hose 12— Cap Screw

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

13— Upper Hydraulic Oil Cooler Hose 14— Clamp 15— Air Filter-to-Turbo Air Tube 16— Clamp

7. Install identification tags and disconnect upper charge air cooler tube (8). Close all openings using caps and plugs.

8. Install identification tags and disconnect upper radiator hose (9). Close all openings using caps and plugs. 9. Install identification tags and disconnect upper hydraulic oil cooler hose (13). Close all openings using caps and plugs.

3. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) Specification Cooling System—Capacity (approximate)................................................................................ 36 L 9.5 gal.

10. Install identification tags and disconnect deaeration hose (11) and cap screw (12). 11. Remove clamps (14 and 16) and air filter-to-turbo air tube (15).

6. Remove clamp (10). Continued on next page

TM13264X19 (02FEB17)

05-0510-11

MM12851,00004CF -19-29JAN15-1/5

300GLC Excavator 020217 PN=133

Cooling Systems

12. Remove hydraulic hoses (17—19) from fan motor. 19— Supply Pressure Hose

TX1170348A —UN—28AUG14

17— Return Hose 18— Case Drain Hose

Fan Motor Hydraulic Hoses MM12851,00004CF -19-29JAN15-2/5

13. Remove cap screws (20) and fan guard (21). 14. Remove cap screw (22) and set electrical connector aside. TX1183275A —UN—23JAN15

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 15. Using appropriate lifting device, remove cap screws (23) and hydraulic fan motor bracket (24). Specification Hydraulic Fan Motor Bracket—Weight (approximate).................................................................................. 43 kg 95 lb.

Hydraulic Fan Motor Bracket 20— Cap Screw (7 used) 21— Fan Guard 22— Cap Screw

Continued on next page

TM13264X19 (02FEB17)

05-0510-12

23— Cap Screw (6 used) 24— Hydraulic Fan Motor Bracket MM12851,00004CF -19-29JAN15-3/5

300GLC Excavator 020217 PN=134

Cooling Systems

16. Remove lock nut (25). 17. Remove fan (26) using an appropriate puller.

TX1171383A —UN—10SEP14

18. Repair or replace parts as necessary. IMPORTANT: Avoid possible machine damage from worn component. Always install new lock nut when installing fan. 19. Install fan and lock nut (25). Specification Lock Nut—Torque..........................................................................80 N·m 59 lb.-ft.

20. Using appropriate lifting device, install hydraulic fan motor mounting bracket and cap screws (23).

Fan Lock Nut 25— Lock Nut

26— Fan

21. Install cap screw (22) and electrical connector. 22. Install fan guard and cap screws (20). 23. Connect hydraulic hoses to fan motor. 24. Install air filter-to-turbo air tube and clamps. 25. Connect deaeration hose and cap screw (12).

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

30. Fill cooling system. See Drain Cooling System. (Operator’s Manual.)

26. Connect upper hydraulic oil cooler hose. 27. Connect upper radiator hose. 28. Connect upper charge air cooler tube and clamp. 29. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

Specification Cooling System—Capacity (approximate)................................................................................ 36 L 9.5 gal.

31. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 32. Operate machine and check for leaks. Continued on next page

TM13264X19 (02FEB17)

05-0510-13

MM12851,00004CF -19-29JAN15-4/5

300GLC Excavator 020217 PN=135

Cooling Systems

Coolant Surge Tank Remove and Install SPECIFICATIONS 36 L 9.5 gal. TX1182662A —UN—16JAN15

Cooling System Capacity (approximate)

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

1— Coolant Surge Tank 2— Coolant Hose 3— Coolant Hose

4— Coolant Overflow Hose 5— Filler Cap

5. Install identification tags and disconnect coolant overflow hose (4). Close all openings using caps and plugs.

4. Install identification tags and disconnect coolant hoses (2 and 3). Close all openings using caps and plugs. Continued on next page

TM13264X19 (02FEB17)

05-0510-14

MM12851,00004D0 -19-23JAN15-1/2

300GLC Excavator 020217 PN=136

Cooling Systems

6. Install identification tags and disconnect coolant hose (7). Close all openings using caps and plugs.

TX1182664A —UN—16JAN15

7. Install identification tags and disconnect electrical connectors (B5009 and B5010). 8. Remove cap screw (8) and clamp (9). 9. Remove cap screws (6) and coolant surge tank (1). 10. Repair or replace parts as necessary. 11. Install coolant surge tank and cap screws (6). 12. Install clamp and cap screw (8). Coolant Surge Tank (bottom)

13. Connect electrical connectors. 14. Connect coolant hose (7).

1— Coolant Surge Tank 4— Coolant Overflow Hose 6— Cap Screw (4 used) 7— Coolant Hose

15. Connect coolant overflow hose (4). 16. Connect coolant hoses (2 and 3). 17. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.) Specification Cooling System—Capacity (approximate)................................................................................ 36 L 9.5 gal.

8— Cap Screw 9— Clamp B5009—Engine Coolant Loss Level Sensor B5010—Engine Coolant Service Level Sensor

19. Operate machine and check for leaks.

18. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) MM12851,00004D0 -19-23JAN15-2/2

TM13264X19 (02FEB17)

05-0510-15

300GLC Excavator 020217 PN=137

Cooling Systems

TM13264X19 (02FEB17)

05-0510-16

300GLC Excavator 020217 PN=138

Group 0530

External Exhaust Systems Exhaust Tube Remove and Install 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) TX1180585A —UN—15DEC14

IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates. 2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable. 3. Remove turbocharger-to-exhaust tube clamp (2) and exhaust filter-to-exhaust tube clamp (3).

Exhaust Tube 1— Exhaust Tube 2— Turbocharger-to-Exhaust Tube Clamp

4. Remove exhaust tube (1). 5. Inspect and replace parts as necessary.

3— Exhaust Filter-to-Exhaust Tube Clamp

6. Install exhaust tube assembly and clamps. IMPORTANT: The life of the exhaust bellows is dependant on being properly aligned. If not aligned correctly, the life of the exhaust bellows will significantly decrease and may risk unfiltered exhaust into the atmosphere.

Specification Exhaust Tube Clamp—Torque.............................................................................20 N·m 177 lb.-in.

7. Perform exhaust bellows alignment procedure. See Exhaust Bellows Alignment Procedure. (Group 0530.)

9. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.)

8. Tighten exhaust tube clamps to specification.

10. Operate machine and check for leaks. MM12851,00004C5 -19-13JAN15-1/1

TM13264X19 (02FEB17)

05-0530-1

300GLC Excavator 020217 PN=139

External Exhaust Systems

JDG11335 Bellows Alignment Fixture The table below lists the model and series of machine with the required configuration of JDG11335 Bellows Alignment Fixture. Articulated Dump Truck Model/Series

Configuration

250D Series II

300D Series II

A Crawlers

Model/Series

Configuration

750K (S.N. F271593— )

750K

755K

850K

850K (S.N. F271510— )

D Excavators

Model/Series

Configuration

250G

290G

300G

350G

380G

B 4WD Loaders

Model/Series

Configuration

624K (S.N. —676685)

644K (S.N. —675480)

724K (S.N. —675480)

744K (S.N. —675480)

A Motor Graders

Model/Series

Configuration

600, 700, and 800 G and GP

B Skidders

Model/Series

Configuration

640L

648L

748L

848L

948L

A Tracked Feller Bunchers

Model/Series

Configuration

803M

853M

859M

B Tracked Harvesters

Model/Series

Configuration

803MH

853MH

859MH

Continued on next page

TM13264X19 (02FEB17)

05-0530-2

VD76477,000059B -19-17NOV16-1/5

300GLC Excavator 020217 PN=140

External Exhaust Systems Wheeled Feller Bunchers Configuration

643L

843L

TX1087788 —UN—10FEB11

Model/Series

JDG11335 Bellows Alignment Fixture Components 1— JDG11335P5P1 Insert (4 used) 5— JDG11335P6P2 Collar 2— JDG11335P4P1 Insert (4 used) 6— JDG11335P1P1 Bar (2 used) 3— Cap Screw (2 used) 7— JDG11335P2P1 Bar (2 used) 4— JDG11335P7P2 Collar 8— JDG11335P3P1 Bar (2 used)

9— Cap Screw (8 used) 10— JDG11335P7P1 Collar 11— Cap Screw (6 used) 12— Latch (2 used) 13— Cap Screw (16 used)

NOTE: All fixture parts are common except the inserts and bars. Refer to the tables below for configurations and part numbers for the inserts and bars. Using the tables below, construct tool with proper configuration.

14— JDG11335P6P1 Collar

Configuration B Insert

JDG11335P4P1

Bar 269 mm (10.6 in)

JDG11335P2P1

Center of Groove-to-Center of Groove Measurement

243.5 mm 9.59 in

Configuration C

Configuration A Insert

JDG11335P4P1

Bar 310 mm (12.2 in)

JDG11335P1P1

Center of Groove-to-Center of Groove Measurement

284.5 mm 11.20 in

Insert

JDG11335P5P1

Bar 278.1 mm (10.9 in)

JDG11335P3P1

Center of Groove-to-Center of Groove Measurement

247.5 mm 9.74 in

Configuration D (utilize inner holes or modify bar) Insert

JDG11335P5P1

Bar 278.1 mm (10.9 in)

JDG11335P3P1

Center of Groove-to-Center of Groove Measurement

222.0 mm 8.74 in

Continued on next page

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External Exhaust Systems

For assembly of all inserts, install inserts with groove (15) closest to the bar. 16— Cap Screw (3 used) 17— Cap Screw (2 used)

TX1088673 —UN—03MAR11

1— JDG11335P5P1 Insert (4 used) 2— JDG11335P4P1 Insert (4 used) 15— Groove

16 15

JDG11335P4P1 Insert Installation

17 1

TX1088674 —UN—02MAR11

JDG11335P5P1 Insert Installation Continued on next page

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External Exhaust Systems

TX1091780 —UN—06MAY11

TX1091780 Center of Groove-to-Center of Groove Measurement 18— Center of Groove-to-Center of Groove Measurement Configuration C

To verify the fixture is built correctly, measure center of groove-to-center of groove (18) for the required configuration. Configuration A Insert

JDG11335P4P1

Bar 310 mm (12.2 in)

JDG11335P1P1

Center of Groove-to-Center of Groove Measurement

284.5 mm 11.20 in

Insert

JDG11335P4P1 JDG11335P2P1

Center of Groove-to-Center of Groove Measurement

243.5 mm 9.59 in

JDG11335P5P1

Bar 278.1 mm (10.9 in)

JDG11335P3P1

Center of Groove-to-Center of Groove Measurement

247.5 mm 9.74 in

Configuration D (utilize inner holes or modify bar)

Configuration B Bar 269 mm (10.6 in)

Insert

JDG11335P5P1

Bar 278.1 mm (10.9 in)

JDG11335P3P1

Center of Groove-to-Center of Groove Measurement

222.0 mm 8.74 in

Continued on next page

TM13264X19 (02FEB17)

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VD76477,000059B -19-17NOV16-4/5

300GLC Excavator 020217 PN=143

External Exhaust Systems Bar Modification Configuration D

278.1 mm (10.9 in) 259.0 mm (10-13/64 in)

14.0 mm (35/64 in)

4X Ø 5.4 mm (7/32 in)

20 230.0 mm (9-1/16 in)

TX1212063

5.7 mm (15/64 in)

TX1212063 —UN—04MAR16

JDG11335P3P1 Configuration D 8— JDG11335P3P1 Bar (2 used)

19— Existing Drilling (4 used)

20— Configuration D Drilling (4 used)

To modify JDG11335P3P1 Bars (8) for machines requiring configuration D, measure and drill (20) as indicated. VD76477,000059B -19-17NOV16-5/5

TM13264X19 (02FEB17)

05-0530-6

300GLC Excavator 020217 PN=144

External Exhaust Systems

Exhaust Bellows Alignment Procedure

IMPORTANT: The life of the exhaust bellows is dependant on being properly aligned. If not aligned correctly, the life of the exhaust bellows will significantly decrease and may risk unfiltered exhaust into the atmosphere.

SPECIFICATIONS Turbocharger-to-Exhaust Tube Clamp Torque

20 N·m 177 lb.-in.

DOC-to-Exhaust Tube Clamp Torque

20 N·m 177 lb.-in.

NOTE: Graphic is for reference only.

ESSENTIAL TOOLS

TX1080155 —UN—26JUL10

JDG11335 Bellows Alignment Fixture

TX1080155 Axial, Angular, and Lateral Specifications 24— Axial

25— Angular

26— Lateral

This procedure is to be performed whenever the exhaust tube or exhaust bellows is disconnected. The JDG11335 Bellows Alignment Fixture is used to hold the exhaust bellows at nominal alignment. While the exhaust bellows is held at nominal alignment, it allows the technician to visually see and measure to verify that the exhaust bellows is in alignment with the exhaust filter. The life of the bellows depends on how well the exhaust bellows is aligned axially (24), angularly (25), and laterally (26). Axial tolerance is ±6.4 mm (±0.252 in.), angular tolerance is 2°, and lateral tolerance is ±8.5 mm. (±0.335 in.). Use

the adjustable frame with the adjustment points to align the exhaust bellows with the exhaust filter inlet. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Assemble JDG11335 Bellows Alignment Fixture. See JDG11335 Bellows Alignment Fixture. (Group 0530.) 3. Remove selective catalyst reduction (SCR) assembly. See Selective Catalyst Reduction (SCR) Remove and Install. (Group 0530.)

Continued on next page

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External Exhaust Systems

4. Install JDG11335 Bellows Alignment Fixture (5). 5. Disconnect turbocharger-to-exhaust tube clamp (6). TX1183670A —UN—28JAN15

NOTE: The gap between the exhaust tube and turbocharger has to remain consistent throughout the circumference of the joint. 6. Verify exhaust tube is in position by checking that diesel oxidation catalyst (DOC)-to-exhaust tube clamp is secure. NOTE: Loosening cap screws (7) allows for adjustment of DOC and diesel particulate filter (DPF) assembly (8) if needed.

JDG11335 Bellows Alignment Fixture

7. Adjust DOC and DPF assembly (8) to maintain consistent gap between exhaust tube and turbocharger. TX1183671A —UN—28JAN15

NOTE: A new seal is required during installation of clamp. 8. Connect turbocharger-to-exhaust tube clamp. Tighten clamp to specification. Specification Turbocharger-to-Exhaust Tube Clamp—Torque....................................................................20 N·m 177 lb.-in.

DOC and DPF Housing

9. Remove JDG11335 Bellows Alignment Fixture. 5— JDG11335 Bellows Alignment Fixture 6— Turbocharger-to-Exhaust Tube Clamp

10. Install SCR assembly. See Selective Catalyst Reduction (SCR) Remove and Install. (Group 0530.) 11. Operate machine and check for leaks. Exhaust Bellows Alignment Procedure—Adjusting Diesel Oxidation Catalyst (DOC) NOTE: This procedure is to be used when adjustment of the diesel exhaust catalyst (DOC) is required while aligning exhaust bellows.

7— Cap Screw (4 used) 8— DOC and DPF Assembly

2. Assemble JDG11335 Bellows Alignment Fixture. See JDG11335 Bellows Alignment Fixture. (Group 0530.) 3. Remove selective catalyst reduction (SCR) assembly. See Selective Catalyst Reduction (SCR) Remove and Install. (Group 0530.)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) MM12851,00004DE -19-30JAN15-2/4

4. Remove cap screws (9 and 10) and panel (11). 11— Panel TX1183676A —UN—28JAN15

9— Cap Screw (5 used) 10— Cap Screw (2 used)

Panel Continued on next page

TM13264X19 (02FEB17)

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MM12851,00004DE -19-30JAN15-3/4

300GLC Excavator 020217 PN=146

External Exhaust Systems

5. Install JDG11335 Bellows Alignment Fixture (5). 6. Disconnect DOC-to-exhaust tube clamp (14). TX1183677A —UN—28JAN15

NOTE: The gap between the exhaust tube and DOC has to remain consistent throughout the circumference of the joint. 7. Verify exhaust tube is in position by checking that turbocharger-to-exhaust tube clamp is secure. NOTE: Loosening cap screws (7) allows for adjustment of DOC and diesel particulate filter (DPF) assembly (8) if needed. JDG11335 Bellows Alignment Fixture

8. Adjust DOC and DPF assembly (8) to maintain consistent gap between exhaust tube and DOC.

TX1183672A —UN—28JAN15

9. Install identification tags and disconnect electrical sensors (B5201, B5202, and B5214). See Exhaust Aftertreatment Harness (W53) Component Location. (Group 9015-10.) 10. Loosen nut (15) and clamp (16). 11. Discard seal (17). 12. Adjust DOC (18) as necessary to attain proper alignment between exhaust tube and DOC mating surfaces.

Electrical Connectors

13. Install DOC-to-exhaust tube clamp. Tighten to specification.

5— JDG11335 Bellows Alignment Fixture 7— Cap Screw (4 used) 8— DOC and DPF Assembly 14— DOC-to-Exhaust Tube Clamp 15— Nut 16— Clamp

Specification DOC-to-Exhaust Tube Clamp—Torque.............................................................................20 N·m 177 lb.-in.

14. Install new seal (17). 15. Tighten nut and clamp. 16. Connect electrical sensors (B5201, B5202, and B5214). See Exhaust Aftertreatment Harness (W53) Component Location. (Group 9015-10.)

17— Seal 18— Diesel Oxidation Catalyst (DOC) B5201—Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor B5202—Diesel Oxiidation Catalyst (DOC) Outlet Temperature Sensor B5214—Diesel Particulate Filter (DPF) Inlet Pressure Sensor

17. Remove JDG11335 Bellows Alignment Fixture.

19. Install SCR assembly. See Selective Catalyst Reduction (SCR) Remove and Install. (Group 0530.)

18. Install panel and cap screws (9 and 10).

20. Operate machine and check for leaks. MM12851,00004DE -19-30JAN15-4/4

TM13264X19 (02FEB17)

05-0530-9

300GLC Excavator 020217 PN=147

External Exhaust Systems

Diesel Particulate Filter (DPF) Remove and Install SPECIFICATIONS Selective Catalytic Reduction (SCR) Assembly Weight (approximate)

91 kg 200 lb.

TX1172603A —UN—25SEP14

3. Remove diesel exhaust fluid (DEF) dosing injector. See Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install. (Group 0530.) 4. Remove exhaust aftertreatment assembly. See Exhaust Aftertreatment Assembly Remove and Install. (Group 0530.)

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

5. Install identification tags and disconnect sensors (B5109, B5204, B5502). Remove cap screw (1, 4).

B5109—Exhaust Pressure Delta Pressure Sensor B5204—Exhaust Filter Temperature Module B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor

6. Remove cap screws (2) and bracket (3). JB42225,0000074 -19-30SEP14-1/5

7. Remove cap screws (5) and set bracket, dosing control line (6), and exhaust temperature sensor line (7) aside. 7— Exhaust Temperature Sensor Line TX1167849A —UN—19SEP14

5— Cap Screw (3 used) 6— Dosing Control Line

Exhaust Aftertreatment Assembly Continued on next page

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=148

External Exhaust Systems

8. Remove clamp (8) from diesel exhaust fluid (DEF) decomposition tube (9). 9. Remove cap screws (10). TX1172964A —UN—26SEP14

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 10. Using appropriate lifting device, remove selective catalytic reduction (SCR) assembly (11) and DEF decomposition tube. Specification Selective Catalytic Reduction (SCR) Assembly—Weight (approximate).................................................................................. 91 kg 200 lb.

Selective Catalytic Reduction (SCR) Assembly 8— Clamp 9— Diesel Exhaust Fluid (DEF) Decomposition Tube

10— Cap Screw (4 used) 11— Selective Catalytic Reduction (SCR) Assembly JB42225,0000074 -19-30SEP14-3/5

11. Install identification tags and disconnect sensors (B5203, B5213, B5217) and set aside. B5217—Aftertreatment Inlet NOx Sensor TX1172966A —UN—26SEP14

B5203—Diesel Particulate Filter (DPF) Outlet Temperature Sensor B5213—Diesel Particulate Filter (DPF) Outlet Pressure Sensor

TX1172965A —UN—26SEP14

Exhaust Aftertreatment Sensors

Exhaust Aftertreatment Sensors Continued on next page

TM13264X19 (02FEB17)

05-0530-11

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300GLC Excavator 020217 PN=149

External Exhaust Systems

12. Remove nuts (12) and mounting band (13). 13. Remove clamp (14) and exhaust tube (15).

TX1172968A —UN—26SEP14

IMPORTANT: Diesel particulate filter (DPF) must be installed in the same direction as it was removed. Install direction marks to assist in assembly. 14. Remove clamp (16) and diesel particulate filter (DPF) (17). 15. Inspect and replace parts as necessary. IMPORTANT: Gaskets between diesel particulate filter (DPF) and diesel oxidation catalyst (DOC) is not reusable. New gasket is required.

Diesel Particulate Filter (DPF) (bottom view)

16. Install DPF and clamp.

TX1172967A —UN—26SEP14

IMPORTANT: Gasket between diesel particulate filter (DPF) and exhaust tube is not reusable. New gasket is required. NOTE: To assist in DEF decomposition tube alignment, leave mounting band, nuts, and clamp loose. 17. Install exhaust tube and clamp. 18. Install mounting band and nuts (12). Diesel Particulate Filter (DPF)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. IMPORTANT: Gasket between DEF decomposition tube and exhaust tube is not reusable. New gasket is required. 19. Using appropriate lifting device, align SCR assembly and DEF decomposition tube to exhaust tube. Specification Selective Catalytic Reduction (SCR) Assembly—Weight (approximate).................................................................................. 91 kg 200 lb.

20. Install clamp. 21. Tighten clamp and nuts.

12— Nut (2 used) 13— Mounting Band 14— Clamp

15— Exhaust Tube 16— Clamp 17— Diesel Particulate Filter (DPF)

25. Install bracket and cap screws (2). 26. Install sensors (B5502, B5204, B5109) and cap screws (1, 4). 27. Install exhaust aftertreatment assembly. See Exhaust Aftertreatment Assembly Remove and Install. (Group 0530.) 28. Install DEF dosing injector. See Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install. (Group 0530.) 29. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.)

22. Install cap screws (10). 23. Install sensors (B5217, B5213, B5203). 24. Install exhaust temperature sensor line, dosing control line, and cap screws (5).

30. Operate machine and check for leaks. JB42225,0000074 -19-30SEP14-5/5

TM13264X19 (02FEB17)

05-0530-12

300GLC Excavator 020217 PN=150

External Exhaust Systems

Selective Catalyst Reduction (SCR) Remove and Install SPECIFICATIONS Selective Catalytic Reduction (SCR) Assembly Weight (approximate)

91 kg 200 lb.

Selective Catalytic Reduction (SCR) Weight (approximate)

46 kg 101 lb. TX1172603A —UN—25SEP14

Exhaust Aftertreatment Assembly 1— Cap Screw 2— Cap Screw (2 used) 3— Bracket 4— Cap Screw

3. Install identification tags and disconnect sensors (B5109, B5204, B5502). Remove cap screw (1, 4). 4. Remove cap screws (2) and bracket (3).

B5109—Exhaust Pressure Delta Pressure Sensor B5204—Exhaust Filter Temperature Module B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor JL58967,000074F -19-23JAN17-1/5

5. Remove cap screws (5) and set bracket, dosing control line (6), and exhaust temperature sensor line (7) aside. 7— Exhaust Temperature Sensor Line TX1167849A —UN—19SEP14

5— Cap Screw (3 used) 6— Dosing Control Line

Exhaust Aftertreatment Assembly Continued on next page

TM13264X19 (02FEB17)

05-0530-13

JL58967,000074F -19-23JAN17-2/5

300GLC Excavator 020217 PN=151

External Exhaust Systems

6. Install identification tags and remove sensors (B5215, B5218) and set aside. B5218—Aftertreatment Outlet NOx Sensor

TX1172006A —UN—19SEP14

B5215—Selective Catalytic Reduction (SCR) Outlet Temperature Sensor (S.N. —730487)

Selective Catalytic Reduction (SCR) Sensors JL58967,000074F -19-23JAN17-3/5

7. Install identification tags and remove sensor (B5216). 8. Remove clamp (8) from diesel exhaust fluid (DEF) decomposition tube (9). 9. Remove cap screws (10). CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. TX1172604A —UN—25SEP14

10. Using appropriate lifting device, remove selective catalytic reduction (SCR) assembly (11). Specification Selective Catalytic Reduction (SCR) Assembly—Weight (approximate).................................................................................. 91 kg 200 lb. Selective Catalytic Reduction (SCR) Assembly 8— Clamp 9— Diesel Exhaust Fluid (DEF) Decomposition Tube 10— Cap Screw (4 used)

11— Selective Catalytic Reduction (SCR) Assembly B5216—Selective Catalytic Reduction (SCR) Inlet Temperature Sensor (S.N. —730487) Continued on next page

TM13264X19 (02FEB17)

05-0530-14

JL58967,000074F -19-23JAN17-4/5

300GLC Excavator 020217 PN=152

External Exhaust Systems

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

TX1172605A —UN—25SEP14

11. Remove nuts (12) and SCR (13). Specification Selective Catalytic Reduction (SCR)—Weight (approximate).................................................................................. 46 kg 101 lb.

12. Inspect and replace parts as necessary. Selective Catalytic Reduction (SCR)

13. Install SCR and nuts (12). CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 14. Install selective catalytic reduction (SCR) assembly and cap screws (10). Specification Selective Catalytic Reduction (SCR) Assembly —Weight (approximate).................................................................................. 91 kg 200 lb.

IMPORTANT: Gasket between DEF decomposition tube and SCR is not reusable. New gasket is required. 15. Install clamp to DEF decomposition tube.

12— Nut (4 used)

13— Selective Catalytic Reduction (SCR)

16. Install sensors (B5215, B5218, B5216). 17. Install cap screws (5), dosing control line, and exhaust temperature sensor line. 18. Install bracket and cap screws (2). 19. Install sensors (B5109, B5204, B5502) and cap screws (1, 4). 20. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 21. Operate machine and check for leaks. JL58967,000074F -19-23JAN17-5/5

TM13264X19 (02FEB17)

05-0530-15

300GLC Excavator 020217 PN=153

External Exhaust Systems

Diesel Oxidation Catalyst (DOC) Remove and Install SPECIFICATIONS Seleective Catalytic Reduction (SCR) Assembly Weight (approximate)

91 kg 200 lb.

TX1172603A —UN—25SEP14

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

5. Install identification tags and disconnect sensors (B5109, B5204, B5502). Remove cap screws (1, 4).

B5109—Exhaust Pressure Delta Pressure Sensor B5204—Exhaust Filter Temperature Module B5502—Selective Catalytic Reduction (SCR) Inlet NOx Sensor

6. Remove cap screws (2) and bracket (3). JB42225,0000075 -19-29SEP14-1/4

7. Remove cap screws (5) and set bracket, dosing control line (6), and exhaust temperature sensor line (7) aside. 7— Exhaust Temperature Sensor Line TX1167849A —UN—19SEP14

5— Cap Screw (3 used) 6— Dosing Control Line

Exhaust Aftertreatment Assembly Continued on next page

TM13264X19 (02FEB17)

05-0530-16

JB42225,0000075 -19-29SEP14-2/4

300GLC Excavator 020217 PN=154

External Exhaust Systems

8. Remove clamp (8) from diesel exhaust fluid (DEF) decomposition tube (9). 9. Remove cap screws (10). TX1172964A —UN—26SEP14

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 10. Using appropriate lifting device, remove selective catalytic reduction (SCR) assembly (11) and DEF decomposition tube. Specification Seleective Catalytic Reduction (SCR) Assembly—Weight (approximate).................................................................................. 91 kg 200 lb.

Selective Catalytic Reduction (SCR) Assembly 8— Clamp 9— Diesel Exhaust Fluid (DEF) Decomposition Tube

Continued on next page

TM13264X19 (02FEB17)

05-0530-17

10— Cap Screw (4 used) 11— Selective Catalytic Reduction (SCR) Assembly JB42225,0000075 -19-29SEP14-3/4

300GLC Excavator 020217 PN=155

External Exhaust Systems

11. Install identification tags and remove sensors (B5201, B5202, B5214) and set aside. 12. Remove nuts (15) and mounting band (13). TX1172699A —UN—25SEP14

13. Remove clamp (12). 14. Remove DOC (14). 15. Inspect and replace parts as necessary. NOTE: To assist in diesel oxidation catalyst (DOC) alignment, leave mounting band, nuts, and clamp loose. Diesel Oxidation Catalyst (DOC) (bottom view)

IMPORTANT: Gasket between diesel oxidation catalyst (DOC) and diesel particulate filter (DPF) is not reusable. New gasket is required. 16. Install DOC. 17. Install clamp. 18. Install mounting band and nuts (4).

TX1172698A —UN—25SEP14

19. Align DOC to exhaust tube. See Exhaust Bellows Alignment Procedure. (Group 0530.) 20. Install sensors (B5214, B5202, B5201). CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 21. Using appropriate lifting device, install selective catalytic reduction (SCR) assembly and DEF decomposition tube.

Diesel Oxidation Catalyst (DOC)

Specification Selective Catalytic Reduction (SCR) Assembly—Weight (approximate).................................................................................. 91 kg 200 lb.

12— Clamp 13— Mounting Band 14— Diesel Oxidation Catalyst (DOC) 15— Nut (2 used)

IMPORTANT: Gasket between decomposition tube and exhaust tube is not reusable. New gasket is required. 22. Install clamp.

B5201—Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor B5202—Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor B5214—Diesel Particulate Filter (DPF) Inlet Pressure Sensor

29. Align DOC to exhaust tube. See Exhaust Bellows Alignment Procedure. (Group 0530.)

23. Install cap screws (10). 24. Install sensors (B5217, B5213, B5203). 25. Install exhaust temperature sensor line, dosing control line, and cap screws (5). 26. Install bracket and cap screws (2). 27. Install sensors (B5502, B5204, B5109) and cap screws (1, 4).

30. Install diesel exhaust fluid (DEF) dosing injector. See Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install. (Group 0530.) 31. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 32. Operate machine and check for leaks.

28. Install exhaust aftertreatment assembly. See Exhaust Aftertreatment Assembly Remove and Install. (Group 0530.) JB42225,0000075 -19-29SEP14-4/4

TM13264X19 (02FEB17)

05-0530-18

300GLC Excavator 020217 PN=156

External Exhaust Systems

Exhaust Aftertreatment Assembly Remove and Install SPECIFICATIONS 215 kg 475 lb.

TX1169769A —UN—27AUG14

Exhaust Aftertreatment Assembly Weight (approximate)

Exhaust Aftertreatment

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

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

4— Bracket 5— Exhaust Aftertreatment Assembly

3. Remove exhaust tube. See Exhaust Tube Remove and Install. (Group 0530.) 6. Remove cap screws (3) and set bracket (4) aside.

4. Remove cap screws (1) and bracket (2). 5. Remove diesel exhaust fluid (DEF) dosing injector. See Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install. (Group 0530.)

JB42225,0000064 -19-30SEP14-1/3

7. Disconnect engine interface harness-to-exhaust aftertreatment harness connector (X5039) and remove cap screw (6). X5039—Engine Harness-toExhaust Aftertreatment Harness

TX1169771A —UN—27AUG14

6— Cap Screw

Exhaust Aftertreatment Harness Continued on next page

TM13264X19 (02FEB17)

05-0530-19

JB42225,0000064 -19-30SEP14-2/3

300GLC Excavator 020217 PN=157

External Exhaust Systems

8. Remove cap screws (7).

TX1169772A —UN—27AUG14

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 9. Using appropriate lifting device, remove exhaust aftertreatment assembly (5). Specification Exhaust Aftertreatment Assembly—Weight (approximate)................................................................................ 215 kg 475 lb. Exhaust Aftertreatment Assembly

10. Repair and replace parts as necessary. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Using appropriate lifting device, install exhaust aftertreatment assembly and cap screws (7). 12. Connect engine interface harness-to-exhaust aftertreatment harness connector and install cap screw (6). 13. Install cap screws (3) and bracket. 14. Install DEF dosing injector. See Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install. (Group 0530.)

7— Cap Screw (4 used)

15. Install bracket and cap screws (1). 16. Install exhaust tube. See Exhaust Tube Remove and Install. (Group 0530.) 17. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 18. Operate machine and check for leaks.

JB42225,0000064 -19-30SEP14-3/3

TM13264X19 (02FEB17)

05-0530-20

300GLC Excavator 020217 PN=158

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Tank Remove and Install 35 L 9.3 gal

Diesel Exhaust Fluid (DEF) Tank Capacity (S.N. 730488— )

35.6 L 9.4 gal

Toolbox Weight (approximate)

32 kg 71 lb.

Diesel Exhaust Fluid (DEF) Tank Cover Weight (approximate)

34 kg 75 lb.

TX1165844A —UN—22JUL14

SPECIFICATIONS Diesel Exhaust Fluid (DEF) Tank Capacity (S.N. —730487)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

Top Cover

2. Drain or pump diesel exhaust fluid (DEF) from DEF tank into approved container.

1— Cap Screw (4 used)

2— Top Cover

Specification Diesel Exhaust Fluid (DEF) Tank—Capacity (S.N. —730487)................................................................................ 35 L 9.3 gal Diesel Exhaust Fluid (DEF) Tank—Capacity (S.N. 730488— )............................................................................ 35.6 L 9.4 gal

3. Remove cap screws (1) and top cover (2). JL58967,0000760 -19-24JAN17-1/6

4. Remove cap screws (3) and side cover (4). 4— Side Cover

TX1165845A —UN—18AUG14

3— Cap Screw (4 used)

Side Cover Continued on next page

TM13264X19 (02FEB17)

05-0530-21

JL58967,0000760 -19-24JAN17-2/6

300GLC Excavator 020217 PN=159

External Exhaust Systems

5. Remove cap screws (5).

TX1230900A —UN—16DEC16

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 6. Using appropriate lifting device, remove toolbox (6). Specification Toolbox—Weight (approximate).................................................................................. 32 kg 71 lb. 5— Cap Screw (8 used)

6— Toolbox Toolbox

JL58967,0000760 -19-24JAN17-3/6

7. Loosen cap screws (7) and remove work light (E1). 8. Remove filler cap (10), cap screw (8), and deflector (9). 10— Filler Cap E1— Work Light

TX1165897A —UN—22JUL14

7— Cap Screw (2 used) 8— Cap Screw 9— Deflector

Work Light JL58967,0000760 -19-24JAN17-4/6

9. Remove cap screws (11).

TX1165901A —UN—22JUL14

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 10. Using appropriate lifting device, remove DEF tank cover (12). Specification Diesel Exhaust Fluid (DEF) Tank Cover—Weight (approximate).................................................................................. 34 kg 75 lb. 11— Cap Screw (5 used)

12— DEF Tank Cover Continued on next page

TM13264X19 (02FEB17)

Diesel Exhaust Fluid (DEF) Tank Cover

05-0530-22

JL58967,0000760 -19-24JAN17-5/6

300GLC Excavator 020217 PN=160

External Exhaust Systems

11. Loosen nuts (13) and disconnect straps (14). Remove DEF tank (15.) 12. Repair or replace parts as necessary. TX1165903A —UN—19AUG14

13. Install DEF tank. Connect straps and tighten nuts. 14. Using appropriate lifting device, install DEF tank cover and cap screws (11). 15. Install filler cap, cap screw (8), and deflector. 16. Install work light and tighten cap screws (7). 17. Using appropriate lifting device, install toolbox and cap screws (5).

DEF Tank Mount

18. Install side cover and cap screws (3). 13— Nut (2 used) 14— Strap (2 used)

19. Install top cover and cap screws (1).

15— Diesel Exhaust Fluid (DEF) Tank

20. Fill DEF tank. Specification Diesel Exhaust Fluid (DEF) Tank—Capacity (S.N. —730487)................................................................................ 35 L 9.3 gal

Diesel Exhaust Fluid (DEF) Tank—Capacity (S.N. 730488— )............................................................................ 35.6 L 9.4 gal

21. Operate machine and check for leaks. JL58967,0000760 -19-24JAN17-6/6

Diesel Exhaust Fluid (DEF) Header Remove and Install

TX1165844A —UN—22JUL14

Diesel Exhaust Fluid (DEF) Header Remove and Install (S.N. —730488) SPECIFICATIONS Diesel Exhaust Fluid (DEF) Tank Capacity (approximate)

35 L 9.3 gal.

Toolbox Weight (approximate)

32 kg 71 lb.

Diesel Exhaust Fluid (DEF) Tank Cover Weight (approximate)

34 kg 75 lb. Top Cover

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 1— Cap Screw (4 used)

2. Drain or pump diesel exhaust fluid (DEF) from DEF tank into approved container.

2— Top Cover

Specification Diesel Exhaust Fluid (DEF) Tank—Capacity (approximate).................................................................................... 35 L 9.3 gal.

3. Remove cap screws (1) and top cover (2). Continued on next page

TM13264X19 (02FEB17)

05-0530-23

JL58967,0000781 -19-31JAN17-1/13

300GLC Excavator 020217 PN=161

External Exhaust Systems

4. Remove cap screws (3) and side cover (4). 4— Side Cover

TX1165845A —UN—18AUG14

3— Cap Screw (4 used)

Side Cover JL58967,0000781 -19-31JAN17-2/13

5. Remove cap screws (5).

TX1230900A —UN—16DEC16

6— Toolbox Toolbox

JL58967,0000781 -19-31JAN17-3/13

7. Loosen cap screws (7) and remove work light (E1). 8. Remove filler cap (10), cap screw (8), and deflector (9). 10— Filler Cap E1— Work Light

TX1165897A —UN—22JUL14

7— Cap Screw (2 used) 8— Cap Screw 9— Deflector

Work Light Continued on next page

TM13264X19 (02FEB17)

05-0530-24

JL58967,0000781 -19-31JAN17-4/13

300GLC Excavator 020217 PN=162

External Exhaust Systems

9. Remove cap screws (11).

TX1165901A —UN—22JUL14

12— DEF Tank Cover Continued on next page

TM13264X19 (02FEB17)

Diesel Exhaust Fluid (DEF) Tank Cover

05-0530-25

JL58967,0000781 -19-31JAN17-5/13

300GLC Excavator 020217 PN=163

External Exhaust Systems

11. Install identification tags and disconnect DEF dosing unit supply hose (16) and DEF dosing unit return hose (17). Close all openings using caps and plugs. 12. Install identification tags and disconnect DEF coolant supply hose (15) and DEF coolant return hose (18). Close all openings using caps and plugs. 13. Disconnect DEF tank breather (14). 14. Remove cap screws (13). 15. Disconnect and remove DEF tank header assembly A (A5507A). TX1232790A —UN—24JAN17

16. Inspect and replace parts as necessary. 17. Connect DEF tank header assembly A and install cap screws (13). 18. Connect DEF tank breather. 19. Connect DEF dosing supply hose and DEF dosing return hose. 20. Connect DEF coolant supply hose and DEF coolant return hose.

Diesel Exhaust Fluid (DEF) Tank Header A

21. Using appropriate lifting device, install DEF tank cover and cap screws (11). 22. Install filler cap, cap screw (8), and deflector. 23. Install work light and tighten cap screws (7). CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 24. Using appropriate lifting device, install toolbox and cap screws (5). Toolbox—Weight (approximate).................................................................................. 32 kg 71 lb.

25. Install side cover and cap screws (3). 26. Install top cover and cap screws (1).

Diesel Exhaust Fluid (DEF) Header Remove and Install (S.N. 730488— ) Diesel Exhaust Fluid (DEF) Tank Capacity (approximate)

35.6 L 9.4 gal.

Toolbox Weight (approximate)

32 kg 71 lb.

Diesel Exhaust Fluid (DEF) Tank Cover Weight (approximate)

34 kg 75 lb.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

27. Fill DEF system. Specification Diesel Exhaust Fluid (DEF) Tank—Capacity (approximate).................................................................................... 35 L 9.3 gal.

2. Drain or pump diesel exhaust fluid (DEF) from DEF tank into approved container. Specification Diesel Exhaust Fluid (DEF) Tank—Capacity (approximate)................................................................................. 35.6 L 9.4 gal.

Continued on next page

TM13264X19 (02FEB17)

17— Diesel Exhaust Fluid (DEF) Dosing Unit Return Hose 18— Diesel Exhaust Fluid (DEF) Coolant Return Hose A5507A—Diesel Exhaust Fluid (DEF) Tank Header Assembly A

SPECIFICATIONS

Specification

28. Operate machine and check for leaks.

13— Cap Screw (3 used) 14— Diesel Exhaust Fluid (DEF) Tank Breather 15— Diesel Exhaust Fluid (DEF) Coolant Supply Hose 16— Diesel Exhaust Fluid (DEF) Dosing Unit Supply Hose

05-0530-26

JL58967,0000781 -19-31JAN17-6/13

300GLC Excavator 020217 PN=164

External Exhaust Systems

3. Remove cap screws (1) and top cover (2). 2— Top Cover

TX1165844A —UN—22JUL14

1— Cap Screw (4 used)

Top Cover JL58967,0000781 -19-31JAN17-7/13

4. Remove cap screws (3) and side cover (4). 4— Side Cover

TX1165845A —UN—18AUG14

3— Cap Screw (4 used)

Side Cover JL58967,0000781 -19-31JAN17-8/13

5. Remove cap screws (5).

TX1230900A —UN—16DEC16

6— Toolbox Toolbox Continued on next page

TM13264X19 (02FEB17)

05-0530-27

JL58967,0000781 -19-31JAN17-9/13

300GLC Excavator 020217 PN=165

External Exhaust Systems

7. Loosen cap screws (7) and remove work light (E1). 8. Remove filler cap (10), cap screw (8), and deflector (9). 10— Filler Cap E1— Work Light

TX1165897A —UN—22JUL14

7— Cap Screw (2 used) 8— Cap Screw 9— Deflector

Work Light JL58967,0000781 -19-31JAN17-10/13

9. Remove cap screws (11).

TX1165901A —UN—22JUL14

Diesel Exhaust Fluid (DEF) Tank Cover

12— DEF Tank Cover JL58967,0000781 -19-31JAN17-11/13

11. Install identification tags and disconnect DEF dosing unit supply hose (16) and DEF dosing unit return hose (17). Close all openings using caps and plugs. 12. Install identification tags and disconnect DEF tank heater supply hose (15) and DEF tank heater return hose (18). Close all openings using caps and plugs. 13. Disconnect DEF tank breather (14). TX1232711A —UN—24JAN17

14. Remove cap screws (13). 15. Disconnect and remove DEF tank header assembly B (A5507B). 16. Inspect and replace parts as necessary. 13— Cap Screw (6 used) 14— Diesel Exhaust Fluid (DEF) Tank Breather 15— Diesel Exhaust Fluid (DEF) Tank Heater Supply Hose 16— Diesel Exhaust Fluid (DEF) Dosing Unit Supply Hose

17— Diesel Exhaust Fluid (DEF) Dosing Unit Return Hose 18— Diesel Exhaust Fluid (DEF) Tank Heater Return Hose A5507B—Diesel Exhaust Fluid (DEF) Tank Header Assembly B

Diesel Exhaust Fluid (DEF) Tank Header B

Continued on next page

TM13264X19 (02FEB17)

05-0530-28

JL58967,0000781 -19-31JAN17-12/13

300GLC Excavator 020217 PN=166

External Exhaust Systems

17. Align DEF tank header recess (19), gasket alignment tab (20), and DEF tank alignment mark (21). 18. Connect DEF tank header assembly B and install cap screws (13). 19. Connect DEF tank breather. 20. Connect DEF dosing supply hose and DEF dosing return hose. TX1232723A —UN—24JAN17

21. Connect DEF tank heater supply hose and DEF tank heater return hose. 22. Using appropriate lifting device, install DEF tank cover and cap screws (11). 23. Install filler cap, cap screw (8), and deflector. 24. Install work light and tighten cap screws (7). Diesel Exhaust Fluid (DEF) Tank Header Gasket Alignment

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 25. Using appropriate lifting device, install toolbox and cap screws (5). Specification Toolbox—Weight (approximate).................................................................................. 32 kg 71 lb.

26. Install side cover and cap screws (3). 27. Install top cover and cap screws (1).

19— Diesel Exhaust Fluid (DEF) Tank Header Recess 20— Gasket Alignment Tab

21— Diesel Exhaust Fluid (DEF) Tank Alignment Mark

Specification Diesel Exhaust Fluid (DEF) Tank—Capacity (approximate)................................................................................. 35.6 L 9.4 gal.

29. Operate machine and check for leaks.

28. Fill DEF system. JL58967,0000781 -19-31JAN17-13/13

TM13264X19 (02FEB17)

05-0530-29

300GLC Excavator 020217 PN=167

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble SPECIFICATIONS Cap Screw Torque

2 N·m 18 lb·in

TX1227375A —UN—31OCT16

IMPORTANT: Prevent machine damage and inaccurate readings from diesel exhaust fluid (DEF) tank concentration sensor. Oils on skin may cause inaccurate readings and set false diagnostic trouble codes (DTCs). Avoid contacting DEF tank concentration sensor with hands or fingers. Diesel Exhaust Fluid (DEF) Tank Header Suction Screen Remove and Install (S.N. —730487) 1. Remove DEF tank header suction screen. See DEF Tank Header Suction Screen — Removal. (CTM120019.) 2. Install DEF tank header suction screen. See DEF Tank Header Suction Screen — Installation. (CTM120019.)

DEF Baffle 3— Diesel Exhaust Fluid (DEF) Baffle

4— Cap Screw (2 used)

Diesel Exhaust Fluid (DEF) Baffle Inspection (S.N. 730488— ) 1. Remove cap screws (4) and DEF baffle (3). 2. Inspect DEF baffle for debris, tears, or any deformities. Replace if necessary.

Specification Cap Screw—Torque........................................................................2 N·m 18 lb·in

3. Install DEF baffle and cap screws. Tighten to specification. JL58967,0000788 -19-31JAN17-1/2

Diesel Exhaust Fluid (DEF) Tank Header Suction Filter Remove and Install (S.N. 730488— ) 1. Remove DEF baffle. See Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble—Diesel Exhaust Fluid (DEF) Baffle Inspection. 2. Remove retaining clip (2) and suction filter (1). 3. Repair or replace parts as necessary. 4. Install suction filter and retaining clip. 2— Retaining Clip TX1226670A —UN—24OCT16

1— Suction Filter

DEF Suction Filter JL58967,0000788 -19-31JAN17-2/2

TM13264X19 (02FEB17)

05-0530-30

300GLC Excavator 020217 PN=168

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure

11. Fill DEF tank. See Refilling Diesel Exhaust Fluid (DEF) Tank. (Operator’s Manual.)

Cleaning Procedure—DEF Tank Removed

12. Operate machine and check for leaks.

IMPORTANT: Diesel exhaust fluid (DEF) tank must be fully flushed to prevent machine damage from contaminants. Perform flushing procedure 3 or more times.

Cleaning Procedure—DEF Tank Installed

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove DEF tank. See Diesel Exhaust Fluid (DEF) Tank Remove and Install. (Group 0530.) 3. Remove DEF header. See Diesel Exhaust Fluid (DEF) Header Remove and Install. (Group 0530.)

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove DEF header. See Diesel Exhaust Fluid (DEF) Tank Remove and Install. (Group 0530.) 3. Drain DEF tank. See Disposal of Diesel Exhaust Fluid (DEF). (Operator’s Manual.) 4. Using a garden hose with a twist type spray nozzle, rinse top and sides of DEF tank for approximately 30 seconds.

IMPORTANT: If DEF tank is flushed with a fluid other than distilled water or clean DEF, a final rinse with clean DEF must be performed before installing DEF tank or components.

6. Repeat steps 4 and 5 a total of three times.

NOTE: If distilled water is not available, clean DEF can be used.

8. Add approximately 3.8 L (1 gal) of clean, unused DEF to DEF tank to dilute and absorb any residual water.

4. Partially fill DEF tank with clean distilled water.

9. Using a vacuum with a clean length of bulk hose attached, vacuum DEF from DEF tank. Be sure to remove DEF from all corners and low spots.

5. Agitate liquid inside of DEF tank to remove built-up contaminants from bottom of tank. 6. Drain DEF tank through filler neck. See Disposal of Diesel Exhaust Fluid (DEF). (Operator’s Manual.) 7. Thoroughly dry inside of DEF tank. 8. Using distilled water or clean DEF, rinse DEF header assembly and thoroughly dry. 9. Install DEF header. See Diesel Exhaust Fluid (DEF) Header Remove and Install. (Group 0530.) 10. Install DEF tank. See Diesel Exhaust Fluid (DEF) Tank Remove and Install. (Group 0530.)

5. Allow tank to drain completely.

7. Install DEF tank drain plug.

10. Replace DEF header suction screen. See Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble. (Group 0530.) 11. Install DEF header. See Diesel Exhaust Fluid (DEF) Header Remove and Install. (Group 0530.) NOTE: For DEF tank capacity, see Drain and Refill Capacities. (Operator’s Manual.) 12. Fill DEF tank. See Refilling Diesel Exhaust Fluid (DEF) Tank. (Operator’s Manual.) 13. Operate machine and check for leaks.

NOTE: For DEF tank capacity, see Drain and Refill Capacities. (Operator’s Manual.) JL58967,0000779 -19-30JAN17-1/1

TM13264X19 (02FEB17)

05-0530-31

300GLC Excavator 020217 PN=169

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install

TX1165844A —UN—22JUL14

Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install (S.N. —730487) SPECIFICATIONS Toolbox Weight (approximate)

32 kg 71 lb.

Diesel Exhaust Fluid (DEF) Tank Cover Weight (approximate)

34 kg 75 lb.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

Top Cover

2. Remove cap screws (1) and top cover (2). 1— Cap Screw (4 used)

2— Top Cover JL58967,0000766 -19-30JAN17-1/23

3. Remove cap screws (3) and side cover (4). 4— Side Cover

TX1165845A —UN—18AUG14

3— Cap Screw (4 used)

Side Cover JL58967,0000766 -19-30JAN17-2/23

4. Remove cap screws (5).

TX1230900A —UN—16DEC16

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 5. Using appropriate lifting device, remove toolbox (6). Specification Toolbox—Weight (approximate).................................................................................. 32 kg 71 lb. 5— Cap Screw (8 used)

6— Toolbox Toolbox Continued on next page

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05-0530-32

JL58967,0000766 -19-30JAN17-3/23

300GLC Excavator 020217 PN=170

External Exhaust Systems

6. Loosen cap screws (7) and remove work light (E1). 7. Remove filler cap (10), cap screw (8), and deflector (9). 10— Filler Cap E1— Work Light

TX1165897A —UN—22JUL14

7— Cap Screw (2 used) 8— Cap Screw 9— Deflector

Work Light JL58967,0000766 -19-30JAN17-4/23

8. Remove cap screws (11).

TX1165901A —UN—22JUL14

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 9. Using appropriate lifting device, remove DEF tank cover (12). Specification Diesel Exhaust Fluid (DEF) Tank Cover—Weight (approximate).................................................................................. 34 kg 75 lb. 11— Cap Screw (5 used)

Diesel Exhaust Fluid (DEF) Tank Cover

12— Diesel Exhaust Fluid (DEF) Tank Cover JL58967,0000766 -19-30JAN17-5/23

10. Remove cap screws (14) and bracket (13). 11. Disconnect electrical connectors (E5601—E5603). E5602—Diesel Exhaust Fluid (DEF) Unit Supply Line Heater E5603—Diesel Exhaust Fluid (DEF) Unit Return Line Heater TX1166563A —UN—29JUL14

13— Bracket 14— Cap Screw (3 used) E5601—Diesel Exhaust Fluid (DEF) Unit Pressure Line Heater

Diesel Exhaust Fluid (DEF) Dosing Unit Continued on next page

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05-0530-33

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300GLC Excavator 020217 PN=171

External Exhaust Systems

12. Remove cap screws (15) and electrical connectors. 13. Remove cap screw (16) and set coolant lines (17, 18) aside. 17— Coolant Line 18— Coolant Line

TX1166566A —UN—29JUL14

15— Cap Screw (3 used) 16— Cap Screw

Diesel Exhaust Fluid (DEF) Dosing Unit Bracket JL58967,0000766 -19-30JAN17-7/23

14. Disconnect electrical connector (19).

TX1166569A —UN—29JUL14

19— Electrical Connector

Electrical Connector (bottom) JL58967,0000766 -19-30JAN17-8/23

15. Attach identification tags and disconnect DEF lines (20—22) from dosing unit (B5501). Close all openings using caps and plugs. 22— Diesel Exhaust Fluid (DEF) Line B5501—Diesel Exhaust Fluid (DEF) Dosing Unit

TX1166570A —UN—29JUL14

20— Diesel Exhaust Fluid (DEF) Line 21— Diesel Exhaust Fluid (DEF) Line

Diesel Exhaust Fluid (DEF) Lines Continued on next page

TM13264X19 (02FEB17)

05-0530-34

JL58967,0000766 -19-30JAN17-9/23

300GLC Excavator 020217 PN=172

External Exhaust Systems

16. Remove cap screws (23) to remove DEF dosing unit bracket (24). 24— Diesel Exhaust Fluid (DEF) Dosing Unit Bracket TX1166571A —UN—29JUL14

23— Cap Screw (4 used)

Diesel Exhaust Fluid (DEF) Dosing Unit Bracket JL58967,0000766 -19-30JAN17-10/23

17. Remove cap screws (25) and DEF dosing unit (B5501). 18. Repair or replace parts as necessary.

TX1166572A —UN—18AUG14

19. Install cap screws (25) and attach DEF dosing unit to bracket. 20. Install cap screws (23) and DEF dosing unit bracket. 21. Connect DEF lines. 22. Connect electrical connector (19) to bottom. 23. Install cap screws (15) and connect electrical connectors (E5601—E5603). Diesel Exhaust Fluid (DEF) Dosing Unit

24. Install coolant lines and cap screw (16) 25. Install bracket and cap screws (14).

25— Cap Screw (3 used)

26. Using appropriate lifting device, install DEF tank cover and cap screws (11). 27. Install filler cap, cap screw (8), and deflector.

B5501—Diesel Exhaust Fluid (DEF) Dosing Unit

28. Install work light and tighten cap screws (7).

Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install (S.N. 730488— )

29. Using appropriate lifting device, install toolbox and cap screws (5).

Toolbox Weight (approximate)

32 kg 71 lb.

Diesel Exhaust Fluid (DEF) Tank Cover Weight (approximate)

34 kg 75 lb.

30. Install side cover and cap screws (3). 31. Install top cover and cap screws (1). 32. Operate machine and check for leaks.

SPECIFICATIONS

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) Continued on next page

TM13264X19 (02FEB17)

05-0530-35

JL58967,0000766 -19-30JAN17-11/23

300GLC Excavator 020217 PN=173

External Exhaust Systems

2. Remove cap screws (1) and top cover (2). 2— Top Cover

TX1165844A —UN—22JUL14

1— Cap Screw (4 used)

Top Cover JL58967,0000766 -19-30JAN17-12/23

3. Remove cap screws (3) and side cover (4). 4— Side Cover

TX1165845A —UN—18AUG14

3— Cap Screw (4 used)

Side Cover JL58967,0000766 -19-30JAN17-13/23

4. Remove cap screws (5).

TX1230900A —UN—16DEC16

6— Toolbox Toolbox Continued on next page

TM13264X19 (02FEB17)

05-0530-36

JL58967,0000766 -19-30JAN17-14/23

300GLC Excavator 020217 PN=174

External Exhaust Systems

6. Loosen cap screws (7) and remove work light (E1). 7. Remove filler cap (10), cap screw (8), and deflector (9). 10— Filler Cap E1— Work Light

TX1165897A —UN—22JUL14

7— Cap Screw (2 used) 8— Cap Screw 9— Deflector

Work Light JL58967,0000766 -19-30JAN17-15/23

8. Remove cap screws (11).

TX1165901A —UN—22JUL14

Diesel Exhaust Fluid (DEF) Tank Cover

12— Diesel Exhaust Fluid (DEF) Tank Cover JL58967,0000766 -19-30JAN17-16/23

10. Remove cap screws (14) and bracket (13). E5602—Diesel Exhaust Fluid (DEF) Unit Supply Line Heater E5603—Diesel Exhaust Fluid (DEF) Unit Return Line Heater

TX1232714A —UN—24JAN17

13— Bracket 14— Cap Screw (3 used) E5601—Diesel Exhaust Fluid (DEF) Unit Pressure Line Heater

Diesel Exhaust Fluid (DEF) Dosing Unit Continued on next page

TM13264X19 (02FEB17)

05-0530-37

JL58967,0000766 -19-30JAN17-17/23

300GLC Excavator 020217 PN=175

External Exhaust Systems

11. Install identification tags and disconnect hoses (27 and 28) and electrical connector (26) from coolant control valve (Y5019). Close all openings using caps and plugs. TX1232854A —UN—26JAN17

12. Remove cap screw (29). 13. Disconnect electrical connectors (E5601—E5603). 26— Electrical Connector 27— Diesel Exhaust Fluid (DEF) Tank Heater Supply Hose 28— Diesel Exhaust Fluid (DEF) Tank Heater Return Hose

29— Cap Screw Y5019—Coolant Control Valve

Coolant Control Valve JL58967,0000766 -19-30JAN17-18/23

14. Remove cap screws (15) and set aside electrical connectors.

TX1232857A —UN—24JAN17

15— Cap Screw (3 used)

JL58967,0000766 -19-30JAN17-19/23

15. Disconnect electrical connector (19).

TX1166569A —UN—29JUL14

19— Electrical Connector

Electrical Connector (bottom) Continued on next page

TM13264X19 (02FEB17)

05-0530-38

JL58967,0000766 -19-30JAN17-20/23

300GLC Excavator 020217 PN=176

External Exhaust Systems

16. Install identification tags and disconnect DEF lines (20—22) from dosing unit (B5501). Close all openings using caps and plugs. 22— Diesel Exhaust Fluid (DEF) Line B5501—Diesel Exhaust Fluid (DEF) Dosing Unit

TX1166570A —UN—29JUL14

20— Diesel Exhaust Fluid (DEF) Line 21— Diesel Exhaust Fluid (DEF) Line

Diesel Exhaust Fluid (DEF) Lines JL58967,0000766 -19-30JAN17-21/23

17. Remove cap screws (23) to remove DEF dosing unit bracket (24). 24— Diesel Exhaust Fluid (DEF) Dosing Unit Bracket TX1166571A —UN—29JUL14

23— Cap Screw (4 used)

Diesel Exhaust Fluid (DEF) Dosing Unit Bracket Continued on next page

TM13264X19 (02FEB17)

05-0530-39

JL58967,0000766 -19-30JAN17-22/23

300GLC Excavator 020217 PN=177

External Exhaust Systems

18. Remove cap screws (25) and DEF dosing unit (B5501). 19. Repair or replace parts as necessary.

TX1166572A —UN—18AUG14

20. Install cap screws (25) and attach DEF dosing unit to bracket. 21. Install cap screws (23) and DEF dosing unit bracket. 22. Connect DEF lines. 23. Connect electrical connector (19) to bottom. 24. Install cap screw (29). 25. Connect DEF tank heater hoses and electrical connector (26) to coolant control valve (Y5019). 26. Install cap screws (15) and connect electrical connectors (E5601—E5603).

Diesel Exhaust Fluid (DEF) Dosing Unit 25— Cap Screw (3 used)

B5501—Diesel Exhaust Fluid (DEF) Dosing Unit

27. Install bracket and cap screws (14). 28. Using appropriate lifting device, install DEF tank cover and cap screws (11).

32. Install side cover and cap screws (3). 33. Install top cover and cap screws (1).

29. Install filler cap, cap screw (8), and deflector.

34. Operate machine and check for leaks.

30. Install work light and tighten cap screws (7). 31. Using appropriate lifting device, install toolbox and cap screws (5).

JL58967,0000766 -19-30JAN17-23/23

TM13264X19 (02FEB17)

05-0530-40

300GLC Excavator 020217 PN=178

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install TX1168573A —UN—08AUG14

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates. 2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable. 3. Tag and disconnect coolant return line (2) and coolant supply line (3). IMPORTANT: Prevent damage to diesel exhaust fluid (DEF) system hoses. DEF system hoses are fragile and can be easily damaged if proper care is not used. Avoid bending, twisting, or kinking DEF system hoses. 4. Tag and disconnect diesel exhaust fluid (DEF) injector pressure hose (4). 5. Remove cap screws (1).

Diesel Exhaust Fluid (DEF) Dosing Injector 1— Cap Screw (3 used) 2— Coolant Return Line 3— Coolant Supply Line

4— Diesel Exhaust Fluid (DEF) Injector Pressure Hose Y5020—Diesel Exhaust Fluid (DEF) Dosing Injector

9. Connect electrical connector. 10. Connect DEF injector pressure hose. 11. Connect coolant return line and coolant supply line.

6. Tag and disconnect electrical connector and remove DEF dosing injector (Y5020).

12. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.)

7. Inspect and replace parts as necessary.

13. Operate machine and check for leaks.

8. Install DEF dosing injector and cap screws (1). JB42225,0000066 -19-30SEP14-1/1

TM13264X19 (02FEB17)

05-0530-41

300GLC Excavator 020217 PN=179

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install SPECIFICATIONS 91 kg 201 lb.

TX1173129A —UN—29SEP14

Selective Catalytic Reduction (SCR) Assembly Weight

Decomposition Tube 1— Clamp 2— Decomposition Tube 3— Clamp

4— Cap Screw (4 used) 5— Selective Catalytic Reduction (SCR) Assembly

3. Remove diesel exhaust fluid (DEF) dosing injector. See Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install. (Group 0530.)

8. Repair and replace parts as necessary.

4. Remove clamp (1).

9. Install decomposition tube and clamp.

5. Loosen cap screws (4).

10. Using appropriate lifting device, slide SCR assembly in place.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 6. Using appropriate lifting device, slide selective catalytic reduction (SCR) assembly (5) forward. Specification Selective Catalytic Reduction (SCR) Assembly—Weight.......................................................................... 91 kg 201 lb.

7. Remove clamp (3) and decomposition tube (2).

11. Tighten cap screws (4). 12. Install clamp. 13. Install DEF dosing injector. See Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install. (Group 0530.) 14. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) 15. Operate machine and check for leaks. JL58967,000018B -19-29SEP14-1/1

TM13264X19 (02FEB17)

05-0530-42

300GLC Excavator 020217 PN=180

Group 0560

External Fuel Supply Systems Fuel Tank Remove and Install 514 L 136 gal.

Fuel Tank Weight (approximate without fuel)

246 kg 542 lb.

TX1165183A —UN—12AUG14

SPECIFICATIONS Fuel Tank Capacity

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Rotate upperstructure 90 degrees. 3. Remove access panels below fuel and hydraulic oil tanks.

Handrails

4. Drain fuel from fuel tank into suitable container. See Drain Water and Sediment from Fuel Tank Sump. (Operator’s Manual.)

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

3— Handrail 4— Handrail

Specification Fuel Tank—Capacity....................................................................... 514 L 136 gal.

5. Remove cap screws (1 and 2) and handrails (3 and 4). Continued on next page

TM13264X19 (02FEB17)

05-0560-1

MM12851,00004C8 -19-22JAN15-1/6

300GLC Excavator 020217 PN=181

External Fuel Supply Systems

6. Remove cap screws (5) and cover (6). 7. Open toolbox and remove cap screws (7) on side of toolbox. Remove side panel (8).

5— Cap Screw (4 used) 6— Cover 7— Cap Screw (4 used)

TX1165184A —UN—12AUG14

8. Remove cap screws (9) and tilt toolbox forward. 8— Side Panel 9— Cap Screw (4 used)

TX1165185A —UN—12AUG14

Cover

TX1168861A —UN—14AUG14

Side Panel

Toolbox Cap Screws (inside view) MM12851,00004C8 -19-22JAN15-2/6

9. Remove cap screws (10).

TX1165187A —UN—12AUG14

10— Cap Screw (3 used)

Diesel Exhaust Fluid (DEF) Tank Breather Filter Cap Screws Continued on next page

TM13264X19 (02FEB17)

05-0560-2

MM12851,00004C8 -19-22JAN15-3/6

300GLC Excavator 020217 PN=182

External Fuel Supply Systems

10. Install identification tags and disconnect connector (11) from fuel level sensor (B18). See Machine Harness (W2) Component Location. (Group 9015-10.) B18— Fuel Level Sensor TX1164583A —UN—30JUL14

11— Connector

Fuel Level Sensor MM12851,00004C8 -19-22JAN15-4/6

11. Remove cap screws (12) and cover (13).

12— Cap Screw (2 used) 13— Cover

TX1164582A —UN—30JUL14

12. Install identification tags and disconnect fuel cooler hose (15). Close all openings using caps and plugs. See Engine Fuel System Component Location. (Group 9010-05.) 15— Fuel Cooler Hose 16— Clamp

TX1164850A —UN—26AUG14

Cover

Fuel Cooler Hose Continued on next page

TM13264X19 (02FEB17)

05-0560-3

MM12851,00004C8 -19-22JAN15-5/6

300GLC Excavator 020217 PN=183

External Fuel Supply Systems

TX1164852A —UN—12AUG14

13. Install identification tags and disconnect fuel supply hose (18) and fuel drain hose (20). Close all openings using caps and plugs. See Engine Fuel System Component Location. (Group 9010-05.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 14. Support fuel tank by attaching appropriate lifting device. Specification Fuel Tank—Weight (approximate without fuel)............................................................................................... 246 kg 542 lb.

IMPORTANT: Avoid damage to diesel exhaust fluid (DEF) breather and line when removing fuel tank. Fuel tank may damage DEF breather and line. Use care when removing fuel tank. 15. Remove mounting cap screws (21) and fuel tank. 16. Repair or replace as necessary. 17. Using appropriate lifting device, install fuel tank and mounting cap screws. 18. Connect fuel hoses (18 and 20). See Engine Fuel System Component Location. (Group 9010-05.) 19. Connect fuel cooler hose (15) and tighten clamp. See Engine Fuel System Component Location. (Group 9010-05.) 20. Install cap screw (12) and cover (13). 21. Connect connector to fuel level sensor (B18). See Machine Harness (W2) Component Location. (Group 9015-10.)

Fuel Tank (bottom view) 18— Fuel Supply Hose 20— Fuel Drain Hose

21— Mounting Cap Screw (6 used)

22. Install cap screws (10). 23. Tilt toolbox to resting position and install cap screws (9). 24. Install side panel (8) and cap screws (7). 25. Install cover (6) and cap screws (5). 26. Install handrails and cap screws (1 and 2). 27. Install access panels below fuel and hydraulic oil tanks. 28. Fill fuel tank. See Fuel Tank. (Operator’s Manual.) 29. Bleed fuel system. See Bleed Fuel System. (Operator’s Manual.) 30. Operate machine and check for leaks.

MM12851,00004C8 -19-22JAN15-6/6

TM13264X19 (02FEB17)

05-0560-4

300GLC Excavator 020217 PN=184

Section 07 Damper Drive (Flex Coupling) Contents Page

Group 0752—Elements Damper Drive (Flex Coupling) Remove and Install................................ 07-0752-1

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PN=1

Contents

TM13264X19 (02FEB17)

07-2

300GLC Excavator

020217

PN=2

Group 0752

Elements OTHER MATERIAL

Damper Drive (Flex Coupling) Remove and Install

Loctite® 242® Threadlocker (medium strength)

SPECIFICATIONS Coupling-to-Flywheel Cap Screw Torque

320 N·m 236 lb.-ft.

Spline Hub-to-Pump Shaft Set Screw Torque

110 N·m 81 lb.-ft.

Coupling-to-Cylinder Hub Cap Screw Torque

320 N·m 236 lb.-ft.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

2 5 1

7 A

8 1

TX1167019 —UN—30JUL14

3 A

TX1167019 Damper Drive (flex coupling) 1— Spline Hub 2— Set Screw (2 used) 3— Coupling 4— Cap Screw (4 used) 5— Flywheel Insert (4 used)

6— Flywheel Guide Pin (4 used) 7— Cap Screw (4 used) 8— Hub Insert (4 used)

NOTE: Coupling (3) may come off with pump or stay on flywheel.

9— Groove Mark 10— Hydraulic Pump 11— Flywheel Housing 12— Hub Guide Pin (8 used)

A—Damper Drive (flex coupling)

2. Remove hydraulic pump (10). See Pump 1 and 2 Remove and Install. (Group 3360.)

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

07-0752-1

JL58967,0000145 -19-24JUL14-1/2

300GLC Excavator 020217 PN=187

Elements

3. Remove cap screws (7) and hub inserts (8) from spline hub (1). 4. Loosen set screws (2) and remove spline hub from hydraulic pump shaft. 5. Remove coupling (3), cap screws (4), and flywheel inserts (5) from flywheel. 6. Inspect and replace parts as necessary. TX1167021A —UN—30JUL14

IMPORTANT: Prevent possible damage to guide pins. Do not use steel hammer to install guide pins (6 and 12). Use only a rubber or plastic mallet. 7. Remove and replace damaged flywheel guide pins (6) and hub guide pins (12). 8. Apply Loctite® 242® Threadlocker (medium strength) to cap screws (4). Damper Drive (flex coupling, pump side)

9. Align and install flywheel inserts on flywheel guide pins. Install cap screws (4) and tighten to specification. Specification Coupling-to-Flywheel Cap Screw—Torque....................................................................320 N·m 236 lb.-ft.

10. Install coupling onto flywheel.

TX1167020A —UN—30JUL14

IMPORTANT: Prevent possible damage to pump shaft. Install hub assembly onto pump shaft with groove mark (9) facing flywheel housing (11). 11. Install spline hub onto hydraulic pump shaft. 12. Apply Loctite® 242® Threadlocker (medium strength) to set screws. Tighten set screws to specification. Specification Spline Hub-toPump Shaft Set Screw—Torque............................................................................ 110 N·m 81 lb.-ft.

Damper Drive (flex coupling, engine side) 1— Spline Hub 2— Set Screw (2 used) 3— Coupling 4— Cap Screw (4 used) 5— Flywheel Insert (4 used)

13. Apply Loctite® 242® Threadlocker (medium strength) to cap screws (7). 14. Align and install hub inserts on hub guide pins. Install cap screws (7) and tighten to specification. Specification Coupling-to-Cylinder Hub Cap Screw—Torque....................................................................320 N·m 236 lb.-ft.

7— Cap Screw (4 used) 8— Hub Insert (4 used) 9— Groove Mark 10— Hydraulic Pump 11— Flywheel Housing

15. Install hydraulic pump. See Pump 1 and 2 Remove and Install. (Group 3360.)

Loctite and its related brand marks are trademarks of Henkel Corporation JL58967,0000145 -19-24JUL14-2/2

TM13264X19 (02FEB17)

07-0752-2

300GLC Excavator 020217 PN=188

Section 17 Frame or Supporting Structure Contents Page

Group 1740—Frame Installation Welding on Machine .................................. 17-1740-1 Group 1749—Chassis Weights Counterweight Remove and Install ..................................................... 17-1749-1

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TM13264X19 (02FEB17)

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300GLC Excavator

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Group 1740

Frame Installation Welding on Machine CAUTION: Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic. Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. 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. When sanding or grinding painted surfaces, avoid breathing the dust. Wear an approved respirator. If using solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 1. Remove paint before welding or heating.

• When sanding or grinding paint, avoid breathing the dust.

• Wear an approved respirator. When using 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.

IMPORTANT: Avoid machine damage to diesel exhaust fluid (DEF) system. After key switch is switched to OFF position, wait at least 10 minutes before turning battery disconnect switch to OFF position or disconnecting battery cables. During cold-weather exposure, if adequate time is not allowed for lines to be purged, residual DEF can freeze and possibly damage components of the DEF system. IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery and control units. Disconnect battery positive and negative cables before welding on machine. 2. Disconnect the negative (-) battery cable(s).

3. Disconnect the positive (+) battery cable(s). 4. Cover, protect, or move any wiring harness sections away from welding area. IMPORTANT: Have only a qualified welder perform this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings, articulation joints, or pivot points. Remove or protect all parts that can be damaged by heat or weld splatter. 5. Connect welder ground close to welding point and away from control units. 6. 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.

Welding Repair of Major Structure—Specification Weld Metal—Tensile Strength...................................................................................482.6 MPa 70 000 psi Yield Strength .........................................................................413.7 MPa 60 000 psi Elongation......................................................................................... 22%

IMPORTANT: Avoid poor weld penetration. Preheat area that will be repaired to allow better weld penetration. Poor weld penetration can lead to further damage. 7. To repair weld metal failure, remove failed weld metal using arc gouging or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). Welding Repair of Major Structure—Specification Structural Assemblies—Preheat Temperature..................................................................................... 38°C 100°F Ground Engaging Tools—Preheat Temperature................................................................................... 177°C 350°F TP97644,000011E -19-04MAR16-1/1

TM13264X19 (02FEB17)

17-1740-1

300GLC Excavator 020217 PN=191

Frame Installation

TM13264X19 (02FEB17)

17-1740-2

300GLC Excavator 020217 PN=192

Group 1749

Chassis Weights Counterweight Remove and Install SPECIFICATIONS Counterweight Weight (approximate)

5300 kg 11 685 lb.

Counterweight Cap Screw Torque

1950 N·m 1438 lb.-ft.

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) TX1116643A —UN—27JUN12

2. Remove hood and engine side shields. See Hood and Engine Side Shields Remove and Install. (Group 1910.) 3. Install identification tags and disconnect rear camera (A12) connector. See Rear Camera Harness (W19) Component Location. (Group 9015-10.) 4. Remove caps (1) to gain access to lifting brackets. 1— Cap (2 used) 2— Counterweight

Counterweight (top view)

A12— Rear Camera

MM12851,00004D4 -19-09FEB15-1/3

CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device. 5. Support counterweight (2) by attaching appropriate lifting device to lifting brackets (3).

2— Counterweight

TX1116644A —UN—26JUN12

Specification Counterweight—Weight (approximate).............................................................................. 5300 kg 11 685 lb. 3— Lifting Bracket (2 used)

Lifting Points Continued on next page

TM13264X19 (02FEB17)

17-1749-1

MM12851,00004D4 -19-09FEB15-2/3

300GLC Excavator 020217 PN=193

Chassis Weights

6. Remove counterweight cap screws (4) and counterweight. 7. Repair or replace as necessary. TX1181335A —UN—19DEC14

CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device. 8. Install counterweight using appropriate lifting device. Specification Counterweight—Weight (approximate).............................................................................. 5300 kg 11 685 lb.

Counterweight (bottom view)

9. Install counterweight cap screws and tighten to specification.

2— Counterweight

Specification Counterweight Cap Screw—Torque..........................................................................1950 N·m 1438 lb.-ft.

10. Install caps.

4— Counterweight Cap Screw (4 used)

12. Install hood and engine side shields. See Hood and Engine Side Shields Remove and Install. (Group 1910.)

11. Connect rear camera (A12) connector. See Rear Camera Harness (W19) Component Location. (Group 9015-10.) MM12851,00004D4 -19-09FEB15-3/3

TM13264X19 (02FEB17)

17-1749-2

300GLC Excavator 020217 PN=194

Contents

Section 18 Operator's Station

Page

Group 1800—Removal and Installation Cab Remove and Install ............................ 18-1800-1 Group 1810—Operator Enclosure Windshield Remove and Install ................. 18-1810-1 Windshield Disassemble and Assemble............................................... 18-1810-2 Sliding Windows Remove and Install ..................................................... 18-1810-7 Windowpanes Remove and Install ..................................................... 18-1810-7 Windowpanes Dimensions ........................ 18-1810-8 Group 1821—Seat and Seat Belt Seat Remove and Install ........................... 18-1821-1 Seat Belt Remove and Install .................... 18-1821-2 Mechanical Suspension Seat Disassemble and Assemble .................. 18-1821-3 Air Suspension Seat Disassemble and Assemble........................................ 18-1821-8 Group 1830—Heating and Air Conditioning R134a Refrigerant Cautions and Proper Handling..................................... 18-1830-1 R134a Refrigerant Oil Information.............. 18-1830-2 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure............................ 18-1830-3 Recover R134a Refrigerant....................... 18-1830-3 Flush and Purge Air Conditioning System................................................... 18-1830-4 Evacuate R134a System ........................... 18-1830-6 Charge R134a System .............................. 18-1830-7 Air Conditioner Compressor Remove and Install................................ 18-1830-8 Condenser Remove and Install ................. 18-1830-9 Heater and Air Conditioner Remove and Install ............................................ 18-1830-10 Receiver-Dryer Remove and Install ................................................... 18-1830-13

TM13264X19 (02FEB17)

18-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

18-2

300GLC Excavator

020217

PN=2

Group 1800

Removal and Installation Cab Remove and Install 36 L 9.5 gal

Hydraulic Oil Tank Capacity

156 L 41.0 gal

Cab Weight (approximate)

658 kg 1451 lb

Cab Isolator Lock Nut Torque

206 N·m 152 lb·ft

Cab Mount Cap Screw Torque

550 N·m 406 lb·ft

100-Pin Connector (X3) Cap Screw Torque

10 N·m 89 lb·in

TX1091639A —UN—13MAY11

SPECIFICATIONS Cooling System Capacity

Electrical Connectors

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

6— Electrical Connector (4 used)

IMPORTANT: Avoid machine damage. After turning key switch to OFF position, only turn battery disconnect switch to OFF position when indicator light no longer illuminates.

hydraulic oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing.

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

4. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

5. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Replace Hydraulic Tank Oil Filter. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity............................................................................... 156 L 41.0 gal

3. Drain coolant from radiator. See Drain Cooling System. (Operator’s Manual.)

6. Remove lower cab panels.

Specification Cooling System—Capacity....................................................................................................... 36 L 9.5 gal

CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of

7. Disconnect electrical connectors (6) from each corner of the lower side of cab, located by cab mounting isolators (7). 8. Recover refrigerant from air conditioning system. See Recover R134a Refrigerant. (Group 1830.)

Continued on next page

TM13264X19 (02FEB17)

7— Cab Mounting Isolator (4 used)

18-1800-1

MM12851,00004C3 -19-14SEP15-1/11

300GLC Excavator 020217 PN=197

Removal and Installation

8— Air Conditioner Hose (2 used) 9— Cap Screw

TX1167516A —UN—31JUL14

9. Install identification tags and disconnect air conditioner hoses (8) and heater hoses (10) from bottom of cab. Close all openings using caps and plugs. See Heater and Air Conditioner Component Location. (Group 9031-15.) 10— Heater Hose (2 used) 11— Clamp (2 used)

Air Conditioner and Heater Hoses MM12851,00004C3 -19-14SEP15-2/11

10. Remove windshield washer hose (13) from windshield washer bottle (12). Close all openings using caps and plugs. 13— Windshield Washer Hose

TX1181441A —UN—22DEC14

12— Windshield Washer Bottle

Windshield Washer Hose MM12851,00004C3 -19-14SEP15-3/11

IMPORTANT: Avoid possible component damage. Ensure electrical connections are dry and free of contamination. TX1091648A —UN—13MAY11

11. Disconnect main cab electrical connector (14) from right rear of cab. 12. Disconnect JDLink™ cable port connection point (15). Position cable on top of cab and out of the way. 14— Main Cab Electrical Connector

15— JDLink™ Cable Port Connection Point Electrical Connector Outside Right Rear on Cab

JDLink is a trademark of Deere & Company Continued on next page

TM13264X19 (02FEB17)

18-1800-2

MM12851,00004C3 -19-14SEP15-4/11

300GLC Excavator 020217 PN=198

Removal and Installation

13. Install identification tags and disconnect hydraulic hoses on pilot control valve side of pilot signal manifold (16). Close all openings using caps and plugs.

• See Pilot Control Valve-to-Pilot Signal Manifold

Component Location—Excavator Pattern. (Group 9025-15.) • See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.) • See Travel Hydraulic System Line Connection. (Group 9025-15.) TX1091669A —UN—08JUN11

16— Pilot Signal Manifold

Pilot Signal Manifold Connections MM12851,00004C3 -19-14SEP15-5/11

14. Install identification tags and disconnect hydraulic hoses from pattern changer (17) (if equipped). Close all openings using caps and plugs. TX1167518A —UN—31JUL14

17— Pattern Changer (if equipped)

Pattern Changer (if equipped) MM12851,00004C3 -19-14SEP15-6/11

15. Remove cap screw (18).

TX1181440A —UN—22DEC14

18— Cap Screw

Cap Screw (under cab) Continued on next page

TM13264X19 (02FEB17)

18-1800-3

MM12851,00004C3 -19-14SEP15-7/11

300GLC Excavator 020217 PN=199

Removal and Installation

TX1091694

TX1091694 —UN—13MAY11

Cab Isolator Lock Nut 20— Cab Isolator Lock Nut (4 used)

21— Cap Screw (2 used)

22— Spacer (2 used)

Continued on next page

TM13264X19 (02FEB17)

18-1800-4

MM12851,00004C3 -19-14SEP15-8/11

300GLC Excavator 020217 PN=200

Removal and Installation 16. Remove cab isolator lock nuts (20) and washers from all four corners of cab.

17. Remove cap screws (21) and spacers (22) from frame to cab plate.

Continued on next page

TM13264X19 (02FEB17)

18-1800-5

MM12851,00004C3 -19-14SEP15-9/11

300GLC Excavator 020217 PN=201

Removal and Installation

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

TX1091708A —UN—14MAY11

18. Using appropriate lifting device, connect cab lifting devices (24) to cab lifting points (23). Specification Cab—Weight (approximate)................................................................................ 658 kg 1451 lb

IMPORTANT: Prevent possible damage to cab door. Close and lock cab door before removing cab. Cab Lifting Points

IMPORTANT: Avoid possible component damage. Before removing cab, verify all wiring connectors and hydraulic hoses are disconnected and secured to cab. 19. Remove cab.

TX1091709A —UN—14MAY11

20. Repair or replace parts as necessary. CAUTION: Prevent possible crushing injury from heavy object. Use appropriate lifting device. IMPORTANT: Prevent possible damage to cab door. Close and lock cab door before installing cab. IMPORTANT: Avoid possible component damage. Ensure all wiring harnesses and other components are out of the way before installing cab.

Cab Lifting Devices 23— Cab Lifting Point (4 used)

24— Cab Lifting Device (4 used)

21. Using appropriate lifting device, install cab.

• See Travel Hydraulic System Line Connection.

NOTE: Isolator lock nuts should not be reused. Replace with new lock nuts when installing cab.

(Group 9025-15.)

22. Install washers and new cab isolator lock nuts (20). Tighten to specifications. Specification Cab Isolator Lock Nut—Torque................................................................................206 N·m 152 lb·ft

23. Install cap screws (21) and spacers (22). Tighten to specification. Cab Mount Cap Screw—Torque............................................................................550 N·m 406 lb·ft

• See Pilot Control Valve-to-Pilot Signal Manifold

Component Location—Excavator Pattern. (Group 9025-15.) • See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.)

Specification 100-Pin Connector (X3) Cap Screw—Torque......................................................................10 N·m 89 lb·in

25. Connect electrical connectors. See Cab Harness (W1) Component Location. (Group 9015-10.)

Specification

24. Connect hydraulic hoses to pilot signal manifold and pattern changer (if equipped).

IMPORTANT: Avoid connector damage. Do not install connector with impact wrench or power tools. Over torquing will result in permanent damage to connector. Torque only to specification.

26. Connect heater and air conditioner hoses. See Heater and Air Conditioner Component Location. (Group 9031-15.) 27. Install cap screws (18). 28. Install windshield washer hose to windshield washer bottle. 29. Install lower cab panels. 30. Fill cooling system with coolant. See Cooling System Fill and Deaeration Procedure. (Operator's Manual.)

Continued on next page

TM13264X19 (02FEB17)

18-1800-6

MM12851,00004C3 -19-14SEP15-10/11

300GLC Excavator 020217 PN=202

Removal and Installation

31. Remove vacuum pump or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) 32. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.)

performed to fill pump housing whenever oil has been drained from pump or hydraulic oil tank. 33. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 34. Charge air conditioning system. See Charge R134a System. (Group 1830.)

IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be MM12851,00004C3 -19-14SEP15-11/11

TM13264X19 (02FEB17)

18-1800-7

300GLC Excavator 020217 PN=203

Removal and Installation

TM13264X19 (02FEB17)

18-1800-8

300GLC Excavator 020217 PN=204

Group 1810

Operator Enclosure Windshield Remove and Install 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove cap screws (1) and covers (2—5). 4— Cover 5— Cover 6— Front Window Handle

TX1127297A —UN—04DEC12

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

Windshield Interior JN86345,00000E0 -19-10JAN13-1/2

IMPORTANT: Avoid damage to window. Use two technicians during window removal to prevent window from falling out of machine. TX1098000A —UN—16SEP11

3. Remove cap screws (7) and rollers (8). 4. Tilt front window handle (6) into interior until horizontal. 5. Holding windshield horizontally, tilt one lower corner up until it releases. 6. Lift entire windshield to release remaining corner to remove. 7. Repair or replace as necessary. See Windshield Disassemble and Assemble. (Group 1810.)

Windshield Rollers

8. Holding windshield horizontally, insert one lower corner until it latches into place.

7— Cap Screw (4 used)

8— Roller (2 used)

9. Holding latched corner, tilt opposite corner until it latches.

11. Install rollers and cap screws (7).

10. Tilt front window handle to a vertical position.

12. Install covers and cap screws. JN86345,00000E0 -19-10JAN13-2/2

TM13264X19 (02FEB17)

18-1810-1

300GLC Excavator 020217 PN=205

Operator Enclosure

Windshield Disassemble and Assemble 1. Remove nut (2) and windshield wiper arm (1). 2— Nut

TX1097950 —UN—16SEP11

1— Windshield Wiper Arm

Wiper Arm CW08338,0000F35 -19-04JUN13-1/9

2. Remove cap screws (4) and cover (3). 3— Cover

4— Cap Screw (2 used)

3 TX1097952 —UN—16SEP11

Cover Continued on next page

TM13264X19 (02FEB17)

18-1810-2

CW08338,0000F35 -19-04JUN13-2/9

300GLC Excavator 020217 PN=206

Operator Enclosure

3. Remove cap screws (5) and windshield wiper motor (M5). 5— Cap Screw (2 used)

M5—Windshield Wiper Motor

M5 TX1097953 —UN—16SEP11

Windshield Wiper Motor CW08338,0000F35 -19-04JUN13-3/9

IMPORTANT: Avoid windshield damage. Isolator (7) is attached to windshield with adhesive. Avoid too much pressure to windshield when removing isolator from windshield. 4. Remove cap screws (6) and isolator (7). 7— Isolator

TX1097954 —UN—16SEP11

6— Cap Screw (4 used)

Isolator Continued on next page

TM13264X19 (02FEB17)

18-1810-3

CW08338,0000F35 -19-04JUN13-4/9

300GLC Excavator 020217 PN=207

Operator Enclosure

NOTE: Mark orientation of front windshield seal (8) when removing. Front windshield seal must be installed in same orientation for proper installation.

9 8 10

5. Apply soapy water to windshield (10) and windshield frame (9). Slide front windshield seal (8) out of windshield frame. 10— Windshield

TX1097956 —UN—16SEP11

8— Front Windshield Seal 9— Windshield Frame

Front Seal CW08338,0000F35 -19-04JUN13-5/9

6. Slide windshield (10) out of windshield frame (9).

NOTE: Mark orientation of rear windshield seal (11) when removing. Rear windshield seal must be installed in same orientation for proper installation.

11 10

7. Remove rear windshield seal (11). 11— Rear Windshield Seal

TX1097955 —UN—16SEP11

9— Windshield Frame 10— Windshield

Windshield Continued on next page

TM13264X19 (02FEB17)

18-1810-4

CW08338,0000F35 -19-04JUN13-6/9

300GLC Excavator 020217 PN=208

Operator Enclosure

38 20 17 19

16 21

14 S28 22 9

13 12

16 15 14

30 TX1097962 —UN—16SEP11

30 32

39 35

33 34

TX1097962

Windshield 9— Windshield Frame 12— Spring (2 used) 13— Roller (2 used) 14— Cap Screw (4 used) 15— Bracket 16— Roller (2 used) 17— Spring (2 used)

18— Screw (2 used) 19— Cover 20— Cap Screw (4 used) 21— Bracket 22— Cover 23— Spring 24— Cover 25— Washer (2 used) 26— Cap Screw (2 used)

27— Cover 28— Lever 29— Shaft 30— Cap Screw (4 used) 31— Lock 32— Cap Screw (6 used) 33— Cover 34— Cap Screw (4 used)

35— Handle 36— Cap Screw (2 used) 37— Lock 38— Cover 39— Cover S28— Window Switch

8. Remove springs (12) and rollers (13).

22. Install spring (23).

9. Remove cap screws (20) and covers (19 and 38).

23. Install cover (22).

10. Remove cap screws (34) and covers (33 and 39).

24. Install window switch (S28) and screws (18).

11. Remove cap screws (32 and 36) and handle (35).

25. Install cover (24), washers (25), and cap screws (26).

12. Remove cap screws (30) and locks (31 and 37).

26. Install rollers (16) and springs (17) onto brackets (15 and 21).

13. Remove cap screws (14) and remove brackets (15 and 21).

27. Install brackets and cap screws (14).

14. Remove springs (17) and rollers (16) from brackets.

28. Install locks (31 and 37) and cap screws (30).

15. Remove cap screws (26), washers (25), and cover (24).

29. Install handle (35) and cap screws (32 and 36).

16. Remove screws (18) and window switch (S28). 17. Remove cover (22). 18. Remove spring (23). 19. Remove cover (27), lever (28), and shaft (29). 20. Inspect and repair as necessary. 21. Install shaft (29), lever (28), and cover (27).

30. Install covers (33 and 39) and cap screws (34). 31. Install covers (19 and 38) and cap screws (20). 32. Install rollers (13) and springs (12). NOTE: Install front windshield seal (8) in correct orientation from disassembly. 33. Install front windshield seal (8). Continued on next page

TM13264X19 (02FEB17)

18-1810-5

CW08338,0000F35 -19-04JUN13-7/9

300GLC Excavator 020217 PN=209

Operator Enclosure

34. Slide windshield (10) into windshield frame (9).

35. Apply soapy water to windshield and windshield frame. Install rear windshield seal (11).

NOTE: Install rear windshield seal (11) in correct orientation from disassembly. CW08338,0000F35 -19-04JUN13-8/9

36. Apply Loctite® 5572 Adhesive to mating surfaces (40—45.) 37. Install isolator (7) and cap screws (6).

TX1097981 —UN—16SEP11

38. Install windshield wiper motor (M5) and cap screws (5). 39. Install covers (3) and cap screws (4). 40. Install windshield wiper arm (1) and nut (2). 7— Isolator 40— Mating Surface 41— Mating Surface 42— Mating Surface

43— Mating Surface 44— Mating Surface 45— Mating Surface

7 7 Isolator (inside view)

TX1097982 —UN—16SEP11

Isolator (outside view) Loctite is a trademark of Henkel Corporation CW08338,0000F35 -19-04JUN13-9/9

TM13264X19 (02FEB17)

18-1810-6

300GLC Excavator 020217 PN=210

Operator Enclosure

Sliding Windows Remove and Install 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove molding (1) from inside of sliding window assembly (2). IMPORTANT: Avoid damage to window, use two technicians during window removal to prevent window from falling out of machine.

TX1089899A —UN—06APR11

3. Cut adhesive between sliding window assembly and cab door (3). 4. Remove sliding window assembly. 5. Repair or replace as necessary. 6. Gently lift sliding window frame in the middle from the top of frame to remove and install glass panes. 7. Apply LOCTITE® 37532 Weatherstrip Adhesive to cab door. Sliding Window

8. Install sliding window assembly. 9. Push window assembly tight against cab door.

1— Molding 2— Sliding Window Assembly

10. Install molding.

3— Cab Door

LOCTITE is a trademark of Henkel Corporation OUO1020,0001DD1 -19-25JAN12-1/1

Windowpanes Remove and Install

NOTE: Adhesive will not stick to bare metal.

Adhesive used to hold the windowpanes in place is a urethane adhesive that is used on most automobile windshields. Urethane adhesive manufactured by Loctite Corporation or equivalent is recommended. Do not use any other type of adhesive. It is recommended that an auto glass dealer install windowpanes. IMPORTANT: Windowpanes must have an ultraviolet barrier around edge of glass since ultraviolet rays will deteriorate adhesive. Windowpanes ordered through John Deere Parts have the ultraviolet barrier. If windowpane is purchased through a glass dealer, dealer must put an ultraviolet barrier on glass. Do not apply paint to border of glass. If an auto glass dealer is not installing windowpanes, use following procedure: 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

NOTE: Paint must be fully cured before installing windowpane. 3. If existing adhesive is removed from frame and paint is scraped off window frame, paint window frame. Paint must be fully cured before installing windowpane. 4. Trim existing adhesive so it has a smooth surface. 5. Follow manufacturer’s instructions for using adhesive. 6. Apply 6 mm (1/4 in.) bead of adhesive on top of the existing adhesive. 7. Install new windowpane. Use hand pressure to force windowpane down around the edges. 8. Apply duct tape to hold windowpane in place while adhesive cures. 9. Allow adhesive to cure for 24 hours before operating machine.

2. Scrape broken glass off existing adhesive. Do not remove adhesive from window frame or cab. JN86345,00000E3 -19-10JAN13-1/1

TM13264X19 (02FEB17)

18-1810-7

300GLC Excavator 020217 PN=211

Operator Enclosure

Windowpanes Dimensions

Use tempered safety glass to make windowpanes.

CAUTION: Use caution handling glass to prevent breakage and possible injury. UNIT: mm 84.0 mm 71.0 mm (3.3 in.) (2.8 in.) 4.0 mm 22.0 mm (0.2 in.) (0.9 in.) 2R120.0 mm 71.0 mm (2R4.7 in.) (2.8 in.) a

84.0 mm (3.3 in.)

b 2R30.0 mm (2R1.2 in.) 2R20.0 mm (2R0.8 in.)

64.5 mm (2.5 in.) 2R15 mm (2R0.6 in.)

R2970.0 mm (R116.9 in.) 1098.0 mm (43.2 in.) R28.0mm (R1.1 in.)

47.0 mm (1.9 in.) 19.5 mm (0.8 in.) 268.0 mm (10.6 in.) 36.0 mm (1.4 in.)

51.2 mm (2.0 in.) 53.0 mm (2.1 in.)

R75.0 mm (R3.0 in.)

123.5 mm (4.9 in.)

190.0 mm (7.5 in.) 217.0 mm (8.5 in.)

40.5 mm (1.6 in.)

28 mm (1.1 in.)

R800.0 mm (R31.5 in.) 270.75 mm (10.7 in.)

56.0 mm (2.2 in.)

30.0 mm (1.2 in.) R120.0 mm (R4.7in.) 47.0 mm 2R5.0 mm (2R0.2 in.) (1.9 in.) 19.5 mm R5.0 mm (0.8 in.) (R0.2 in.) 4R5.0 mm (4R0.2 in.)

40.0 mm (1.6 in.)

36.0 mm (1.4 in.)

264.0 mm (10.4 in.)

40.0 mm (1.6 in.)

45.0 mm (1.8 in.)

53.0 mm (2.1 in.) 12.0 mm (0.5 in.)

832.0 mm (32.8 in.)

12.0 mm (0.5 in.) SECTION A C0.5 mm (C0.2 in.)

SECTION B C0.5 mm (C0.2 in.)

R3.0 mm (R0.1 in.) R3.0 mm (R0.1 in.) 30.0 mm (1.2 in.)

C0.5 mm (C0.2 in.)

211.0 mm (8.3 in.) R3.0 mm (R0.1 in.) R3.0 mm (R0.1 in.)

TX1089907 Continued on next page

TM13264X19 (02FEB17)

DETAIL C

18-1810-8

R3.0 mm (R0.1 in.)

TX1089907 —UN—08JUN11

C0.5 mm (C0.2 in.)

DJ54098,0000208 -19-26NOV12-1/9

300GLC Excavator 020217 PN=212

Operator Enclosure

Upper Front Glass 1— Upper Front Glass a— Black Ceramic Painted Surface

b— Black Ceramic Painted Range

DJ54098,0000208 -19-26NOV12-2/9

UNIT: mm 4.0 mm (0.2 in.)

D R1075.0 mm (R42.3 in.)

372.9 mm (14.7 in.)

2 50.0 mm (2.0 in.)

22.0 mm (0.9 in.)

25.0 mm (1.0 in.) 25.0 mm (1.0 in.)

84.0 mm (3.3 in.) 865.0 mm (34.1 in.)

SECTION A

TX1089909

R2.0 mm (R0.1 in.)

TX1089909 —UN—08JUN11

54.1 mm (2.1 in.)

Lower Front Glass 2— Lower Front Glass

a— Black Ceramic Painted Surface Continued on next page

TM13264X19 (02FEB17)

18-1810-9

DJ54098,0000208 -19-26NOV12-3/9

300GLC Excavator 020217 PN=213

Operator Enclosure

UNIT:mm 370.5 mm (14.6 in.)

5.0 mm (0.2 in.)

R151.4 mm (R6.0 in.)

796.4 mm (31.4 in.)

R2853.0 mm (R112.3 in.)

3R4.0 mm (3R0.2 in.)

SECTION A

R3.0 mm (R0.1in.) TX1092088

TX1092088 —UN—08JUN11

480.9 mm (18.9 in.)

139.2 mm (5.5 in.)

Cab Door Front Sliding Glass 3— Cab Door Front Sliding Glass a— Chamfer Along Periphery Continued on next page

TM13264X19 (02FEB17)

18-1810-10

DJ54098,0000208 -19-26NOV12-4/9

300GLC Excavator 020217 PN=214

Operator Enclosure

UNIT:mm 308.5 mm (12.1 in.) 50.0 mm (2.0 in.)

R10.0 mm (R0.4 in.)

R128.0 mm (R5.0 in.)

11.0 mm (0.4 in.)

a 4 796.4 mm (31.4 in.)

2 2

40.0 mm (1.6 in.)

12.2 mm (0.5 in.)

3R4.0 mm (3R0.2 in.)

290.4 mm (11.4 in.) 433.8 mm (17.1 in.) SECTION A

R3.0 mm (R0.1in.) TX1092089

TX1092089 —UN—08JUN11

13.9 mm (0.5 in.)

34.4 mm (1.4 in.)

Cab Door Rear Sliding Glass 4— Cab Door Rear Sliding Glass

a— Chamfer Along Periphery Continued on next page

TM13264X19 (02FEB17)

18-1810-11

DJ54098,0000208 -19-26NOV12-5/9

300GLC Excavator 020217 PN=215

Operator Enclosure

UNIT: mm 610.3 mm (24.0 in.)

56.0 mm (2.2 in.)

468.5 mm (18.4 in.)

1011.5 mm (39.8 in.) 983.0 mm (78.1 in.)

213.0 mm (8.4 in.)

74.0 mm (2.9 in.)

480.0 mm (18.9 in.)

204.0 mm (8.0 in.)

265.0 mm (10.4 in.)

50.0 mm (2.0 in.) 2 21 mm 2 (0.8 in.)

7R5.0 mm (7R0.2 in.)

25.0 mm (1.0 in.)

113.0 mm (4.4 in.) 74.0 mm (2.9 in.) b

67.0 mm 74.0 mm (2.6 in.) (2.9 in.)

A R2867.0 mm (R112.9 in.) 221.0 mm (8.7 in.)

54.3 mm (2.1 in.) R967.0 mm (R38.1 in.) R10.0 mm (R0.4 in.) R60.0 mm (R2.4 in.)

R412.0 mm (R16.2 in.)

R25.0 mm (R1.0 in.) R50.0 mm R452.0 mm (R2.0 in.) (R17.8 in.) 227.0 mm (8.9 in.) R55.0 mm R95.0 mm (R2.2 in.) (R3.7 in.)

R25.0 mm C (R1.0 in.) 4R20.0 mm R150.0 mm (4R0.8 in.) (R5.9 in.) 5 220.0 mm (8.7 in.) R1075.0 mm B (R42.3 in.) 41.0 mm (1.6 in.)

R412.0 mm (R16.2 in.) R1035.0 mm (R40.7 in.) R50.0 mm (R2.0 in.)

33.0 mm (1.3 in.)

133.0 mm (5.2 in.)

76.0 mm (3.0 in.) 193.0 mm (7.6 in.)

235.0 mm (9.3 in.)

255.0 mm (10.0 in.)

R78.0 mm (R3.1 in.)

127.0 mm (5.0 in.)

68.0 mm (2.7 in.)

227.0 mm (8.9 in.) 278.5 mm (11.0 in.) R462.0 mm (R18.2 in.) R85.0 mm (R3.3 in.)

55.5 mm (2.2 in.)

c 283.0 mm (11.1 in.)

117.0 mm (4.6 in.)

380.0 mm (15.0 in.)

Section A d

C0.5 mm (C0.2 in.)

Section B

Section C C0.5 mm (C0.2 in.)

C0.5 mm (C0.2 in.)

R3.0 mm (R0.1 in.)

TX1092090

C0.5 mm (C0.2 in.) TX1092090 —UN—08JUN11

5.0 mm (0.2 in.)

Lower Cab Door Glass 5— Lower Cab Door Glass a— Black Ceramic Painted Surface

b— Black Ceramic Painted Range d— Shaded Paint Along Periphery c— Chamfer Here Continued on next page

TM13264X19 (02FEB17)

18-1810-12

DJ54098,0000208 -19-26NOV12-6/9

300GLC Excavator 020217 PN=216

Operator Enclosure 496.0 mm (19.5 in.) 448.0 mm (17.6 in.) 319.0 mm (12.6 in.) 190.0 mm (7.5 in.) 35.0 mm 30.0 mm (1.4 in.) (1.2 in.)

UNIT: mm

196.5 mm (7.7 in.) 1097 mm (43.2 in.) 1101.5 mm (43.4 in.)

103.0 mm (4.1 in.) 3R5.0 mm (3R0.2 in.)

683.0 mm (26.9 in.) R20.0 mm (R0.8 in.)

3.0 mm (0.1 in.)

4R5.0 mm (4R0.2 in.)

Section A d 5.0 mm (0.2 in.)

C0.5 mm (C0.2 in.)

3.0 mm (0.1 in.)

R4055.0 mm (R159.6 in.) R4026.0 mm (R158.5 in.)

3.0 mm (0.1 in.)

C0.5 mm (C0.2 in.)

632.0 mm (24.9 in.)

30.5mm (1.2 in.)

R80.0 mm (R3.1 in.) R86.0 mm (R3.4 in.) R74.0 mm (R2.9 in.)

Section B

R90.0 mm (R3.5 in.) 3R10.0 mm (3R0.4 in.) R20.0 mm (R0.8 in.)

156.0 mm (6.1 in.)

R110.0 mm (R4.3 in.)

R610.0 mm (R24.0 in.) R638.0 mm (R25.1 in.)

297.0 mm (11.7 in.)

63.0 mm (2.5 in.)

50.0 mm (2.0 in.) R1035.0 mm (R40.7 in.) R3035.0 mm (R119.5 in.)

119.5 mm (4.7 in.)

267.0 mm (10.5 in.)

Section C C0.5 mm (C0.2 in.)

TX1092091

C0.5 mm (C0.2 in.)

TX1092091 —UN—08JUN11

R50.0 mm R3078.0 mm (R2.0 in.) (R121.2 in.) 42.0 mm (1.7 in.) 40.0 mm (1.6 in.) 319.0 mm c (12.6 in.) 128.0 mm (5.0 in.) B

R3.0 mm (R0.1 in.)

Rear Left Side Glass 6— Rear Left Side Glass a— Black Ceramic Painted Surface

b— Black Ceramic Painted Range d— Shaded Paint Along Periphery c— Chamfer Here Continued on next page

TM13264X19 (02FEB17)

18-1810-13

DJ54098,0000208 -19-26NOV12-7/9

300GLC Excavator 020217 PN=217

Operator Enclosure

UNIT: mm 869.8 mm (34.2 in.) 710.0 mm (20.8 in.)

206.0 mm (8.1 in.)

104.0 mm (4.1 in.)

39.0 mm (1.5 in.)

102.0 mm (4.0 in.)

2R25.0 mm (2R1.0 in.)

R30.0 mm (R2.1 in.)

R3000.0 mm (R118.1 in.) 37.0 mm (1.5 in.) R4000.0 mm (R157.5 in.)

R45.0 mm (R1.8 in.)

107˚

1205.0 mm (47.4 in.)

1591.0 mm (62.6 in.)

1287.9 mm (50.7 in.)

313.6 mm (12.3 in.)

1304.8 mm (51.4 in.)

50.0 mm (2.0 in.)

1396.3 mm (55.0 in.) 5.0 mm (0.2 in.)

R240.0 mm (R9.4 in.)

R2145.0 mm R90.0 mm (R84.4 in.) R2940.0 mm (R3.5 in.) R30.0 mm (R115.7 in.) (R1.2 in.) R10.0 mm 7 (R0.4 in.) R370.0 mm R1100.0 mm (R14.6 in.) (R43.8 in.) R700.0 mm (R27.6 in.)

1643.1 mm (64.7 in.)

50.0 mm (2.0 in.) A

856.0 mm (33.7 in.)

130.0 mm (5.1 in.) 125.0 mm (4.9 in.) 148.5 mm (5.8 in.)

R30.0 mm (R1.2 in.)

R710.0 mm (R28.0 in.) 40.0 mm (1.6 in.) R200.0 mm (R7.9 in.) R50.0 mm (R2.0 in.)

2R5.0 mm (2R0.2 in.)

R5000.0 mm (R196.9 in.)

R50.0 mm (R2.0 in.) R1040.0 mm (R40.9 in.)

213.0 mm (8.4 in.) R1200.0 mm (R47.2 in.)

54.0 mm (2.1 in.)

142.5 mm (5.6 in.) 536.8 mm (21.1 in.)

R70.0 mm (R2.8 in.)

1379.5 mm (54.3 in.)

SECTION A

1603.8 mm (63.1 in.) 5.0 mm (0.2 in.)

TX1089919 —UN—08JUN11

d C0.5 mm (C0.2 in.) C0.5 mm (C0.2 in.)

TX1089919 Right Side Cab Glass 7— Right Side Cab Glass a— Black Ceramic Painted Surface

b— Black Ceramic Painted Range c— Shaded Paint Along Periphery

Continued on next page

TM13264X19 (02FEB17)

18-1810-14

DJ54098,0000208 -19-26NOV12-8/9

300GLC Excavator 020217 PN=218

Operator Enclosure

844 mm (33.2 in.) 97 mm (3.8 in.)

4-R5 mm (R0.5 in.)

590 mm (23.2 in.)

4 mm (0.2 in.)

22 mm (0.9 in.)

72 mm (2.8 in.)

76 mm (3.0 in.) a

4-R30 mm (R1.2 in.) 288.5 mm (11.4 in.) 645.5 mm (25.4 in.) 70 mm (2.8 in.)

26 mm (1.0 in.)

215 mm (8.5 in.)

15 mm (0.6 in.) 2-R100 mm (R3.9 in.)

2-R1000 mm (R39.4 in.) 2-R450 mm (R17.7 in.) 2-R58 mm (R2.8 in.)

26 mm (1.0 in.) A 220 mm (8.7 in.)

45 mm (1.8 in.) 126 mm (5.0 in.)

590 mm (23.2 in.)

2-R200 mm (R7.9 in.)

5 mm (0.2 in.) CO.0.5 mm (CO.0.5 in.) CO.0.5 mm (CO.0.5 in.) TX1089920

TX1089920 —UN—05APR11

Rear Cab Glass 8— Rear Cab Glass DJ54098,0000208 -19-26NOV12-9/9

TM13264X19 (02FEB17)

18-1810-15

300GLC Excavator 020217 PN=219

Operator Enclosure

TM13264X19 (02FEB17)

18-1810-16

300GLC Excavator 020217 PN=220

Group 1821

Seat and Seat Belt Seat Remove and Install SPECIFICATIONS Seat Weight (approximate)

42 kg 93 lb

Cap Screw Torque

20 N·m 180 lb·in OTHER MATERIAL

Loctite® 242® Threadlocker (medium strength)

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) TX1090007 —UN—07JUN11

NOTE: Sliding seat to different positions may aid in the removal of cap screws. CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device. 2. Attach appropriate lifting device to seat (2). Remove cap screws (1) and seat. Seat Remove and Install

Specification Seat—Weight (approximate).................................................................................. 42 kg 93 lb

1— Cap Screw (4 used)

2— Seat

3. Repair or replace parts as necessary. 4. Apply Loctite® 242® Threadlocker (medium strength) on cap screws (1).

Specification Cap Screw—Torque......................................................................20 N·m 180 lb·in

5. Install seat and cap screws. Tighten to specification. Loctite and its related brand marks are trademarks of Henkel Corporation JB42225,000004A -19-05NOV15-1/1

TM13264X19 (02FEB17)

18-1821-1

300GLC Excavator 020217 PN=221

Seat and Seat Belt

Seat Belt Remove and Install

1 2 4

3 4 5

4 7 2

TX1093260 —UN—14JUN11

TX1093260 Seat Belt 1— Cap Screw (2 used) 2— Washer (2 used)

3— Seat Belt Buckle 4— Spacer (4 used)

5— Tether (2 used) 6— Seat Belt 7— Seat Belt Cover Continued on next page

TM13264X19 (02FEB17)

18-1821-2

JB42225,000004B -19-05NOV15-1/2

300GLC Excavator 020217 PN=222

Seat and Seat Belt SPECIFICATIONS

a. Install spacer (4).

210 N·m 155 lb·ft

Cap Screw Torque

b. Install tether (5). c. Install spacer (4).

OTHER MATERIAL Loctite® 242® Threadlocker (medium strength)

d. Install seat belt buckle (3).

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

e. Install washer (2).

2. Remove seat belt buckle (3):

f. Apply Loctite® 242® Threadlocker (medium strength) to cap screws (1).

a. Remove cap screw (1).

g. Install cap screw (1) and tighten to specification.

b. Remove washer (2). c. Remove seat belt buckle (3).

Specification Cap Screw—Torque....................................................................210 N·m 155 lb·ft

d. Remove spacer (4).

6. Install seat belt (6):

e. Remove tether (5).

a. Install spacer (4).

f. Remove spacer (4).

b. Install tether (5).

3. Remove seat belt (6):

c. Install spacer (4).

a. Slide seat belt cover (7) up to access hardware.

d. Install seat belt (6).

b. Remove cap screw (1).

e. Install washer (2).

c. Remove washer (2). d. Remove seat belt (6).

f. Apply Loctite® 242® Threadlocker (medium strength) to cap screws (1).

e. Remove spacer (4).

g. Install cap screw (1) and tighten to specification.

f. Remove tether (5).

Specification Cap Screw—Torque....................................................................210 N·m 155 lb·ft

g. Remove spacer (4).

h. Slide seat belt cover (7) down to cover hardware.

4. Repair or replace parts as necessary. 5. Install seat belt buckle (3): Loctite and its related brand marks are trademarks of Henkel Corporation

JB42225,000004B -19-05NOV15-2/2

Mechanical Suspension Seat Disassemble and Assemble 1. Remove seat from machine. See Seat Remove and Install. (Group 1821.) NOTE: New cap screws (1) are required when they are removed.

TX1172382A —UN—23SEP14

2. Remove cap screws (1) and discard. 3. Remove zip tie (2) and discard. 4. Remove fasteners (3). 1— Cap Screw (2 used) 2— Zip Tie

3— Fastener (24 used) 4— Seat Suspension Boot

Fasteners Continued on next page

TM13264X19 (02FEB17)

18-1821-3

JL58967,0000188 -19-24SEP14-1/7

300GLC Excavator 020217 PN=223

Seat and Seat Belt

5. Disconnect fore-and-aft adjustment cable (5).

TX1172383A —UN—23SEP14

5— Fore-and-Aft Adjustment Cable

Fore-and-Aft Adjustment Cable JL58967,0000188 -19-24SEP14-2/7

IMPORTANT: Prevent possible damage to seat suspension boot (4). Use care when pulling seat suspension boot over weight adjustment knob (6). 6. Pull seat suspension boot over weight adjustment knob (6) as shown. 6— Weight Adjustment Knob TX1172384A —UN—23SEP14

4— Seat Suspension Boot

Weight Adjustment Knob Continued on next page

TM13264X19 (02FEB17)

18-1821-4

JL58967,0000188 -19-24SEP14-3/7

300GLC Excavator 020217 PN=224

Seat and Seat Belt

7. Remove cap screws (7).

TX1172385A —UN—23SEP14

7— Cap Screw (4 used)

Frame Cap Screws JL58967,0000188 -19-24SEP14-4/7

CAUTION: Prevent possible injury due to springs (8, 9) under tension. Adjust seat accordingly to relieve spring tension. 8. Remove springs (8, 9), cap screws (10), brackets (11), and upper frame (12). 11— Bracket (2 used) 12— Upper Frame TX1172386A —UN—23SEP14

8— Spring (4 used) 9— Spring (2 used) 10— Cap Screw (4 used)

Springs Continued on next page

TM13264X19 (02FEB17)

18-1821-5

JL58967,0000188 -19-24SEP14-5/7

300GLC Excavator 020217 PN=225

Seat and Seat Belt

NOTE: Adjustment knobs (13, 14) are pressed onto levers. 9. Remove knobs (13, 14) and seat suspension boot from upper frame. 14— Up-and-Down Adjustment Knob

TX1172076A —UN—23SEP14

4— Seat Suspension Boot 13— Fore-and-Aft Adjustment Knob

Upper Frame Continued on next page

TM13264X19 (02FEB17)

18-1821-6

JL58967,0000188 -19-24SEP14-6/7

300GLC Excavator 020217 PN=226

Seat and Seat Belt

CAUTION: Prevent possible injury due to springs (19) under tension. Turn weight adjustment knob (6) until springs are relieved of pressure prior to disconnecting cylinder (18). 10. Remove clip (15), pin (16), and bushings (17). Disconnect barrel end of cylinder (18).

TX1172310A —UN—23SEP14

11. Remove springs (19), washers (20), and weight adjustment knob assembly (21). 12. Repair or replace parts as necessary. 13. Lubricate threads of weight adjustment knob assembly with grease. 14. Install weight adjustment knob assembly, washers, and springs (19). 15. Install bushings, pin, and clip.

Cylinder

16. Install seat suspension boot and knobs (13, 14) to upper frame. 17. Install upper frame, brackets, cap screws (10), and springs (8, 9). 18. Install cap screws (7).

TX1172309A —UN—23SEP14

IMPORTANT: Prevent possible damage to seat suspension boot (4). Use care when pulling seat suspension boot over weight adjustment knob (6). 19. Pull seat suspension boot over weight adjustment knob. 20. Connect fore-and-aft adjustment cable. 21. Install fasteners. 22. Install zip tie.

Weight Adjustment Knob Assembly

23. Install new cap screws (1). 24. Install seat. See Seat Remove and Install. (Group 1821.)

15— Clip 16— Pin 17— Bushing (2 used) 18— Cylinder

19— Spring (2 used) 20— Washer (2 used) 21— Weight Adjustment Knob Assembly JL58967,0000188 -19-24SEP14-7/7

TM13264X19 (02FEB17)

18-1821-7

300GLC Excavator 020217 PN=227

Seat and Seat Belt

Air Suspension Seat Disassemble and Assemble 1. Remove cap screws (1). 2. Remove zip tie (2). 3. Remove plastic fasteners (3). 3— Plastic Fastener (24 used) 4— Suspension Boot TX1172369A —UN—20SEP14

1— Cap Screw (2 used) 2— Zip Tie

Air Suspension Seat JL58967,0000189 -19-29SEP14-1/8

4. Remove pin (5), nut (6), and air compressor control valve (7). 7— Air Compressor Control Valve TX1172370A —UN—20SEP14

5— Pin 6— Nut

Air Compressor Valve Assembly JL58967,0000189 -19-29SEP14-2/8

5. Install identification tags and disconnect air lines (8, 9) and electrical connectors (10, 11). 10— Electrical Connector 11— Electrical Connector TX1172371A —UN—20SEP14

8— Air Line 9— Air Line

Air Compressor Valve Connection Continued on next page

TM13264X19 (02FEB17)

18-1821-8

JL58967,0000189 -19-29SEP14-3/8

300GLC Excavator 020217 PN=228

Seat and Seat Belt

NOTE: Seat adjustment knobs are pressed on to levers. 6. Remove seat adjustment knobs (12, 13). 7. Remove seat suspension boot (4). 13— Seat Adjustment Knob

TX1172372A —UN—20SEP14

12— Seat Adjustment Knob

Seat Adjustment Knobs JL58967,0000189 -19-29SEP14-4/8

8. Remove cap screws (14) and seat suspension (15). 15— Seat Suspension

TX1172373A —UN—20SEP14

14— Cap Screw (4 used)

Seat Suspension Continued on next page

TM13264X19 (02FEB17)

18-1821-9

JL58967,0000189 -19-29SEP14-5/8

300GLC Excavator 020217 PN=229

Seat and Seat Belt

9. Remove cap screw (16) and air line (17). 17— Air Line

TX1172375A —UN—22SEP14

16— Cap Screw

Seat Suspension Continued on next page

TM13264X19 (02FEB17)

18-1821-10

JL58967,0000189 -19-29SEP14-6/8

300GLC Excavator 020217 PN=230

Seat and Seat Belt

10. Remove C-clip (18) and air bag (19). 23— Cap Screw (2 used)

TX1172377A —UN—20SEP14

18— C-Clip 19— Air Bag

TX1172378A —UN—20SEP14

Seat Suspension (bottom view)

Air Bag JL58967,0000189 -19-29SEP14-7/8

11. Install identification tags and disconnect electrical connectors (20, 21) and air line (22). 12. Remove cap screws (23) and air compressor (24). TX1172379A —UN—20SEP14

13. Repair or replace parts as necessary. 14. Assembly is reverse of disassembly procedure. 20— Electrical Connector 21— Electrical Connector

22— Air Line 24— Air Compressor

Air Compressor JL58967,0000189 -19-29SEP14-8/8

TM13264X19 (02FEB17)

18-1821-11

300GLC Excavator 020217 PN=231

Seat and Seat Belt

TM13264X19 (02FEB17)

18-1821-12

300GLC Excavator 020217 PN=232

Group 1830

Heating and Air Conditioning R134a Refrigerant Cautions and Proper Handling

If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.

SERVICE EQUIPMENT AND TOOLS Refrigerant Identifier

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

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. Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerants, hoses, fittings, components, or refrigerant oils.

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

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

DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with bare hands. Skin may freeze to container. Wear gloves.

AS79221,00005A0 -19-03MAR16-1/2

Refrigerant Identifier

Used to safely and correctly identify type and check purity of refrigerant prior to recovery, recycling, and charging of air conditioning systems. AS79221,00005A0 -19-03MAR16-2/2

TM13264X19 (02FEB17)

18-1830-1

300GLC Excavator 020217 PN=233

Heating and Air Conditioning

R134a Refrigerant Oil Information

a. Determine if R134a leakage was detected. See R134a Refrigerant Leak Test. (Group 9031-25.)

SPECIFICATIONS Compressor Oil Volume

160 mL 5.4 fl. oz.

System Oil Volume

160 mL 5.4 fl. oz.

b. Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) c. Flush complete system, if needed. See Flush and Purge Air Conditioning System. (Group 1830.)

OTHER MATERIAL KJD10575 R134a Compressor Oil

d. If compressor is serviceable, pour flushing solvent in manifold ports and internally wash out old oil.

If installing a new compressor, make sure oil level is visible through suction port. Oil level is normally below drive shaft.

e. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

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

6. Install compressor. See Air Conditioner Compressor Remove and Install. (Group 1830.)

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

IMPORTANT: Prevent possible air conditioning system damage. Do not add any more oil than required or maximum cooling will be reduced.

• New compressor • Used compressor removed from operation • Compressor internally washed with flushing solvent CAUTION: Avoid possible injury. All new compressors are charged with a mixture of nitrogen, R134a refrigerant, and R134a refrigerant oil. Wear safety goggles and discharge compressor slowly. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 3. Remove and repair or replace compressor. See Air Conditioner Compressor Remove and Install. (Group 1830.) 4. Drain oil into graduated container while rotating compressor shaft if a new compressor is required. 5. Record measured oil and discard oil properly. If oil drained from a compressor removed from operation is very black or amount of oil is less than specification, perform the following:

Do not leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture. Do not spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils. 7. Add required amount of R134a compressor oil. If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl. oz. per ft.) to determine correct amount of oil to be added. Specification Compressor Oil—Volume................................................................................. 160 mL 5.4 fl. oz. System Oil—Volume.................................................................... 160 mL 5.4 fl. oz.

8. Connect all components. 9. Evacuate air conditioning system. See Evacuate R134a System. (Group 1830.) 10. Charge R134a air conditioning system. See Charge R134a System. (Group 1830.)

Specification Compressor Oil—Volume................................................................................. 160 mL 5.4 fl. oz. JL58967,000014B -19-26AUG14-1/1

TM13264X19 (02FEB17)

18-1830-2

300GLC Excavator 020217 PN=234

Heating and Air Conditioning

R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure

CAUTION: Avoid possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) IMPORTANT: Prevent possible air conditioning system contamination. Use correct refrigerant recovery, recycling, and charging station. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils.

CAUTION: Avoid possible injury. Do not remove high-pressure relief valve. Air conditioning system will discharge.

Refrigerant Recovery, Recycling, and Charging Station

3. Close both high and low pressure valves on refrigerant recovery, recycling, and charging station (5).

1— Cap (2 used) 2— Low Side Pressure (blue) Hose 3— High Side Pressure (red) Hose

4. Remove caps (1) from test ports. 5. Connect low side pressure (blue) hose (2) from refrigerant recovery, recycling, and charging station to low pressure test port on compressor. 6. Connect high side pressure (red) hose (3) to high pressure test port on compressor.

TX1153908 —UN—18FEB14

4— Air Conditioner Compressor 5— Refrigerant Recovery, Recycling, and Charging Station

7. Follow manufacturer’s instructions when using refrigerant recovery, recycling, and charging station. JL58967,000014C -19-30SEP14-1/1

Recover R134a Refrigerant

high-pressure relief valve. Air conditioning system will discharge rapidly.

CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 3. Run air conditioning system for 3 minutes to help in recovery process. 4. Turn air conditioning system off before proceeding with recovery steps.

IMPORTANT: Prevent possible air conditioning system damage. Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils. 5. With engine OFF, connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure. (Group 1830.) 6. Follow manufacturer’s instructions when using refrigerant recovery, recycling, and charging station.

CAUTION: Avoid possible injury from air conditioning system refrigerant. Do not remove AS79221,0000598 -19-08DEC16-1/1

TM13264X19 (02FEB17)

18-1830-3

300GLC Excavator 020217 PN=235

Heating and Air Conditioning

Flush and Purge Air Conditioning System SPECIFICATIONS Flushing Solvent in Suction Port Volume

2. Turn compressor end-for-end and roll compressor side-to-side.

240 mL 8 fl. oz.

Flushing Solvent in Discharge Port 120 mL 4 fl. oz. Volume Air Pressure Minimum Pressure (for flushing and purging)

3. Remove both plugs from manifold ports and drain solvent from compressor.

620 kPa 6.2 bar 90 psi

4. Connect battery power and ground to engage compressor clutch solenoid. Rotate pulley at least five revolutions to move cooling system cleaner out of cylinders.

ESSENTIAL TOOLS TY25601 Cooling System Cleaner

5. Invert compressor. Roll end-for-end and side-to-side. Drain thoroughly.

JT02099 Cap JT03194 Cap JT02075 Air Conditioner Flusher

6. Repeat previous two steps at least three times.

Procedure Set-Up

Condenser Flush and Purge IMPORTANT: Determine if condenser is continuous loop or parallel flow style.

CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.

Continuous loop style has either multiple round tubes or an extruded serpentine construction.

1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.)

If condenser is parallel flow style, do not flush, it should be replaced. Potential blockages in parallel flow style condenser will not flush completely and could result in system malfunction.

2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 3. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.) IMPORTANT: Air conditioner compressor is serviceable. Do not attempt to flush through receiver-dryer. Flushing solution may not be completely removed from component and could cause system malfunction.

1. Determine if condenser is continuous loop or parallel flow style. 2. Add TY25601 Cooling System Cleaner and connect JT02075 Air Conditioner Flusher outlet hose to inlet end of compressor discharge line using appropriate adapter. 3. Attach return hose and aerator nozzle to end of receiver/dryer inlet hose using appropriate adapter. Put nozzle in container to collect cooling system cleaner.

4. Remove air conditioner compressor. See Air Conditioner Compressor Remove and Install. (Group 1830.) NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed.

4. Open air valve to force cooling system cleaner into condenser circuit. Air pressure must be at least to specification for flushing and purging.

5. Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) Compressor Cleaning 1. Pour TY25601 Cooling System Cleaner into suction port and discharge port. Plug both ports in compressor manifold, using JT02099 and JT03194 Caps. Specification Flushing Solvent in Suction Port—Volume.................................................................. 240 mL 8 fl. oz. Flushing Solvent in Discharge Port—Volume............................................................................... 120 mL 4 fl. oz.

Specification Air Pressure—Minimum Pressure (for flushing and purging)....................................................................................... 620 kPa 6.2 bar 90 psi

NOTE: Purging condenser circuit takes 10—12 minutes to thoroughly remove solvent. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. 5. Disconnect hose from aeration nozzle to check circuit for cooling system cleaner. Hold hose close to piece of cardboard; continue purging until cardboard is dry.

Continued on next page

TM13264X19 (02FEB17)

18-1830-4

JL58967,000014E -19-25JUL14-1/2

300GLC Excavator 020217 PN=236

Heating and Air Conditioning

6. Dispose of cooling system cleaner properly.

Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

Evaporator Flush and Purge 1. Add TY25601 Cooling System Cleaner and connect JT02075 Air Conditioner Flusher outlet hose to inlet end of evaporator inlet line using appropriate adapter. 2. Attach hose and aerator nozzle to compressor inlet line using appropriate adapter. Put nozzle in container to collect cooling system cleaner.

4. Disconnect hose from aeration nozzle to check circuit for cooling system cleaner. Hold hose close to piece of cardboard; continue purging until cardboard is dry. 5. Dispose of cooling system cleaner properly. Procedure Wrap-Up

3. Open air valve to force cooling system cleaner into condenser circuit. Air pressure must be at least to specification for flushing and purging.

1. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

Specification

2. Add required oil. See R134a Refrigerant Oil Information. (Group 1830.)

Air Pressure—Minimum Pressure (for flushing and purging)....................................................................................... 620 kPa 6.2 bar 90 psi

NOTE: Purging condenser circuit takes 10—12 minutes to thoroughly remove solvent.

3. Install air conditioner compressor. See Air Conditioner Compressor Remove and Install. (Group 1830.) 4. Charge system. See Charge R134a System. (Group 1830.)

JL58967,000014E -19-25JUL14-2/2

TM13264X19 (02FEB17)

18-1830-5

300GLC Excavator 020217 PN=237

Heating and Air Conditioning

Evacuate R134a System

from 98 kPa (980 mbar) (29 in Hg) for each 300 m (1000 ft) elevation above sea level.

SPECIFICATIONS Vacuum Pressure at Sea Level

98 kPa 980 mbar 29 in Hg

Vacuum Pressure Above Sea Level

Subtract 3.4 kPa from 98 kPa for each 300 m elevation Subtract 34 mbar from 980 mbar for each 300 m elevation Subtract 1 in Hg from 29 in Hg for each 1000 ft elevation

6. Evacuate system until low-pressure gauge registers specified vacuum. If specified vacuum cannot be obtained in 15 minutes, a leak may be present. Locate and repair leak. See R134a Refrigerant Leak Test. (Group 9031-25.)

1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.)

Specification Vacuum—Pressure at Sea Level...................................................................................... 98 kPa 980 mbar 29 in Hg Pressure Above Sea Level ..................................................................... Subtract 3.4 kPa from 98 kPa for each 300 m elevation Subtract 34 mbar from 980 mbar for each 300 m elevation Subtract 1 in Hg from 29 in Hg for each 1000 ft elevation

2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

7. When vacuum reaches specified level, close low side and high side valves. Turn vacuum pump off.

CAUTION: Avoid possible injury from air conditioning system refrigerant. Do not remove high-pressure relief valve. Air conditioning system will discharge rapidly.

8. If vacuum decreases more than specified amount in 5 minutes, there is a leak in system.

Leak Present Decrease in Vacuum 3.4 kPa 34 mbar 1 in Hg

CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.

IMPORTANT: Prevent possible air conditioning system damage. Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils. 3. Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure. (Group 1830.) 4. Open low and high-pressure valves on refrigerant recovery, recycling, and charging station.

Specification Leak Present—Decrease in Vacuum..................................................................................... 3.4 kPa 34 mbar 1 in Hg

9. Locate and repair leak. See R134a Refrigerant Leak Test. (Group 9031-25.) 10. Start evacuation. Open low side and high side valves. 11. Evacuate system for 30 minutes after initial specified vacuum is reached. 12. Stop evacuation. Close low side and high side valves. 13. Charge system. See Charge R134a System. (Group 1830.)

5. Follow manufacturer’s instructions and evacuate system. NOTE: Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in Hg) AS79221,000059A -19-08DEC16-1/1

TM13264X19 (02FEB17)

18-1830-6

300GLC Excavator 020217 PN=238

Heating and Air Conditioning

Charge R134a System

and Charging Station Installation Procedure. (Group 1830.)

SPECIFICATIONS Evacuate System Vacuum

Air Conditioning System Refrigerant Charge Weight

Subtract 3.4 kPa from 98 kPa for each 300 m elevation above sea level Subtract 34 mbar from 980 mbar for each 300 m elevation above sea level Subtract 1 in. Hg from 29 in. Hg for each 1000 ft. elevation above sea level 0.85—0.95 kg 1.87—2.09 lb.

CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) IMPORTANT: Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils. CAUTION: Avoid possible injury from air conditioning system refrigerant. Do not remove high-pressure relief valve. Air conditioning system will discharge rapidly.

4. Evacuate system. See Evacuate R134a System. (Group 1830.) NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft.) elevation above sea level. Specification Evacuate System—Vacuum........................ Subtract 3.4 kPa from 98 kPa for each 300 m elevation above sea level Subtract 34 mbar from 980 mbar for each 300 m elevation above sea level Subtract 1 in. Hg from 29 in. Hg for each 1000 ft. elevation above sea level

5. Follow manufacturer’s instructions and charge system. 6. Add refrigerant until system is charged to specification. Specification Air Conditioning System Refrigerant—Charge Weight................................................................................0.85—0.95 kg 1.87—2.09 lb.

7. Perform air conditioner check. See Operational Checkout. (Group 9005-10.)

3. Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, MM12851,00004C1 -19-10DEC14-1/1

TM13264X19 (02FEB17)

18-1830-7

300GLC Excavator 020217 PN=239

Heating and Air Conditioning

Air Conditioner Compressor Remove and Install SPECIFICATIONS 28 N·m 21 lb.-ft.

TX1165429A —UN—30JUL14

Pressure Line Cap Screw Torque

4. Remove serpentine belt (6). See Inspect Serpentine Belt. (Operator’s Manual.) 2— Cap Screw (2 used) 3— High-Pressure Line 4— Low-Pressure Line 5— Cap Screw (4 used)

5. Install identification tags and disconnect high-pressure line (3) and low-pressure line (4) by removing cap screws (2). Close all openings using caps and plugs.

6— Belt 7— Air Conditioner Compressor Y11— Air Conditioner Compressor Clutch

6. Remove cap screws (5) and air conditioner compressor (7). NOTE: When replacing with a new compressor, flush and purge each component in the air conditioning system individually. See Flush and Purge Air Conditioning System. (Group 1830.)

Specification Pressure Line Cap Screw—Torque..............................................................................28 N·m 21 lb.-ft.

10. Connect air conditioner compressor clutch.

7. Repair or replace parts as necessary. 8. Install air conditioner compressor and cap screws.

11. Install serpentine belt. See Inspect Serpentine Belt. (Operator’s Manual.)

9. Connect high-pressure line and low-pressure line. Install and tighten cap screws to specification.

12. Evacuate and charge system. See Evacuate R134a System and see Charge R134a System. (Group 1830.) JL58967,0000165 -19-30JUL14-1/1

TM13264X19 (02FEB17)

18-1830-8

300GLC Excavator 020217 PN=240

Heating and Air Conditioning

Condenser Remove and Install 23 N·m 17 lb.-ft.

Condenser-to-Evaporator Line Cap Screw Torque

23 N·m 17 lb.-ft.

TX1165430A —UN—16JUL14

SPECIFICATIONS Compressor-to-Condenser Line Cap Screw Torque

Condenser Mounting 1— Condenser 2— Cap Screw (2 used) 4— Compressor-to-Condenser Line

4. Install identification tags and disconnect compressor-to-condenser line (4) and condenser-to-evaporator line (5). Close all openings using caps and plugs. NOTE: Condenser can be removed without removing receiver-dryer. If removing receiver-dryer, see Receiver-Dryer Remove and Install. (Group 1830.) 5. Remove cap screws (6) and condenser (1).

5— Condenser-to-Evaporator Line 6— Cap Screw (4 used) B20— Air Conditioner High/Low Pressure Switch

Condenser-toEvaporator Line Cap Screw—Torque..............................................................................23 N·m 17 lb.-ft.

6. Repair or replace parts as necessary.

9. Connect air conditioner high/low pressure switch (B20).

7. Install condenser and cap screws.

10. Evacuate and charge system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

8. Connect compressor-to-condenser line and condenser-to-evaporator line. Install cap screws and tighten to specification. Specification Compressor-toCondenser Line Cap Screw—Torque..............................................................................23 N·m 17 lb.-ft.

JL58967,0000166 -19-14JUL14-1/1

TM13264X19 (02FEB17)

18-1830-9

300GLC Excavator 020217 PN=241

Heating and Air Conditioning

Heater and Air Conditioner Remove and Install SPECIFICATIONS Cooling System Capacity

36 L 9.5 gal.

TX1093026A —UN—06JUN11

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.) 3. Drain cooling system. See Drain Cooling System. (Operator’s Manual.) Specification Cooling System—Capacity....................................................................................................... 36 L 9.5 gal.

4. Remove seat. See Seat Remove and Install. (Group 1821.) 5. Remove cap screws (1 and 2) and center panel (3).

Rear Seat Panels 1— Cap Screw (2 used) 2— Cap Screw (3 used) 3— Center Panel 4— Cap Screw (2 used)

5— Back Panel 6— Cap Screw (3 used) 7— Right Side Panel

6. Remove cap screws (4) and back panel (5). 7. Remove cap screws (6) and right side panel (7). MM12851,00004C2 -19-13JAN15-1/6

8. Install identification tags and disconnect electrical connectors (8) from monitor controller (DSZ) (A4). See Cab Harness (W1) Component Location and see Monitor Harness (W3) Wiring Diagram. (Group 9015-10.) 9. Remove cap screws (10) to release cab wiring harness (11). 11— Cab Wiring Harness A4—Monitor Controller (DSZ)

TX1094553A —UN—12JUL11

8— Electrical Connector (5 used) 10— Cap Screw (3 used)

Monitor Control Electrical Connections Continued on next page

TM13264X19 (02FEB17)

18-1830-10

MM12851,00004C2 -19-13JAN15-2/6

300GLC Excavator 020217 PN=242

Heating and Air Conditioning

10. Remove screws (12) and move 12-volt power converter (A8) aside. 11. Remove screws (15). Lift up relay block (16), install identification tags, and disconnect electrical connectors (14). 12. Remove wiring clamp (17). 16— Relay Block 17— Wiring Clamp A8—12-Volt Power Converter

TX1094554A —UN—12JUL11

12— Screw (2 used) 14— Electrical Connector (4 used) 15— Screw (4 used)

Left Side Air Conditioner and Heater Connections MM12851,00004C2 -19-13JAN15-3/6

13. Remove screws (18), install identification tags, disconnect electrical connector (20), and remove air conditioner controller (ACF) (A7). See Heater and Air Conditioner Harness (W41) Component Location. (Group 9015-10.) 14. Remove cap screws (21), cover (22), and panel (23). 22— Cover 23— Panel A7—Air Conditioner Controller (ACF)

TX1094557A —UN—12JUL11

18— Screw (4 used) 20— Electrical Connector 21— Cap Screw (7 used)

Air Conditioner and Heater Panel MM12851,00004C2 -19-13JAN15-4/6

15. Remove cap screws (25) and fresh air inlet duct (24). 25— Cap Screw (2 used)

TX1093041A —UN—07JUN11

24— Fresh Air Inlet Duct

Fresh Air Inlet Duct Continued on next page

TM13264X19 (02FEB17)

18-1830-11

MM12851,00004C2 -19-13JAN15-5/6

300GLC Excavator 020217 PN=243

Heating and Air Conditioning

16. Install identification tags and disconnect engine coolant hoses (28) from heater and evaporator case (26). Close all openings using caps and plugs. 17. Install identification tags and disconnect air conditioner refrigerant lines (29) from heater and evaporator case. Close all openings using caps and plugs. 18. Remove cap screws (32) and air duct (30). 19. Remove cap screws (31). Separate air filter from air duct and remove. TX1093039A —UN—08JUN11

20. Remove heater-air conditioner. 21. Repair or replace parts as necessary. 22. Install heater-air conditioner. 23. Connect air filter to air duct (30). Install cap screws (31). 24. Install air duct (30) and cap screws (32).

Air Conditioner Component Location

25. Connect engine coolant hoses and refrigerant lines. 26. Install fresh air inlet duct (24) and cap screws (25). 27. Install panel (23), cover (22), and cap screws (21). 28. Connect air conditioner controller (ACF) (A7). Install screws (18) and electrical connector (20). See Cab Harness (W1) Component Location. (Group 9015-10.)

26— Heater and Evaporator Case 27— Air Duct 28— Engine Coolant Hose (2 used) 29— Air Conditioner Refrigerant Line (2 used)

30— Air Duct 31— Cap Screw (6 used) 32— Cap Screw (2 used)

29. Install wiring clamp (17). 30. Connect electrical connectors (14) to relay block (16).

38. Install seat. See Seat Remove and Install. (Group 1821.)

31. Install relay block and screws (15). 32. Install 12-volt power converter and screws (12). 33. Install cap screws (10) to clamp down cab wiring harness (11). 34. Connect electrical connectors (8) to monitor controller. See Cab Harness (W1) Component Location and see Monitor Harness (W3) Component Location. (Group 9015-10.) 35. Install right side panel and cap screws (6).

37. Install center panel and cap screws (1 and 2).

39. Evacuate and charge system. See Evacuate R134a System and see Charge R134a System. (Group 1830.) 40. Fill cooling system. See Drain Cooling System. (Operator’s Manual.) Specification Cooling System—Capacity....................................................................................................... 36 L 9.5 gal.

36. Install back panel and cap screws (4). MM12851,00004C2 -19-13JAN15-6/6

TM13264X19 (02FEB17)

18-1830-12

300GLC Excavator 020217 PN=244

Heating and Air Conditioning

Receiver-Dryer Remove and Install SPECIFICATIONS Condenser-to-Receiver-Dryer Line 5 N·m 44 lb.-in. Cap Screw Torque TX1165431A —UN—05AUG14

Receiver-Dryer-to-Evaporator Line 5 N·m Cap Screw Torque 44 lb.-in.

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.) 3. Install identification tags and disconnect condenser-to-receiver-dryer line (2) and receiver-dryer-to-evaporator line (4) by removing cap screws (1). Close all openings using caps and plugs. 4. Remove cap screws (5) and receiver-dryer (6). 5. Repair or replace parts as necessary.

Receiver-Dryer 1— Cap Screw (2 used) 2— Condenser-to-ReceiverDryer Line 4— Receiver-Dryer-toEvaporator Line

5— Cap Screw (2 used) 6— Receiver-Dryer B20— Air Conditioner High/Low Pressure Switch

6. Install receiver-dryer and cap screws. 7. Connect condenser-to-receiver-dryer line and receiver-dryer-to-evaporator line. Install cap screws and tighten to specification. Specification Condenser-to-ReceiverDryer Line Cap Screw—Torque................................................................................5 N·m 44 lb.-in.

Receiver-Dryer-toEvaporator Line Cap Screw—Torque................................................................................5 N·m 44 lb.-in.

8. Evacuate and charge system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

JL58967,0000168 -19-25JUL14-1/1

TM13264X19 (02FEB17)

18-1830-13

300GLC Excavator 020217 PN=245

Heating and Air Conditioning

TM13264X19 (02FEB17)

18-1830-14

300GLC Excavator 020217 PN=246

Contents

Section 19 Sheet Metal

Page

Group 1910—Hood and Engine Side Shields Hood and Engine Side Shields Remove and Install................................ 19-1910-1

TM13264X19 (02FEB17)

19-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

19-2

300GLC Excavator

020217

PN=2

Group 1910

Hood and Engine Side Shields Hood and Engine Side Shields Remove and Install 126 kg 277 lb.

Right Engine Side Shield Weight (approximate)

98 kg 217 lb.

Left Engine Shield Weight (approximate)

70 kg 155 lb. TX1182771A —UN—20JAN15

SPECIFICATIONS Hood Weight (approximate)

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Open hood (1). Install identification tags and disconnect electrical connector (X5041). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Electrical Connector

3. Using appropriate lifting device, support hood. Specification Hood—Weight (approximate)................................................................................ 126 kg 277 lb.

1— Hood 2— Pin (2 used) 3— Washer (2 used)

4— Prop Rod X5041—Fan Harness-to-Engine Light Harness Connector

4. Remove pins (2), washers (3), and disconnect prop rod (4). MM12851,00004E1 -19-23JAN15-1/5

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 5. Using appropriate lifting device, remove cap screws (5) and hood.

1— Hood

TX1169843A —UN—27AUG14

Specification Hood—Weight (approximate)................................................................................ 126 kg 277 lb. 5— Cap Screw (4 used)

Hood Hinge Cap Screws Continued on next page

TM13264X19 (02FEB17)

19-1910-1

MM12851,00004E1 -19-23JAN15-2/5

300GLC Excavator 020217 PN=249

Hood and Engine Side Shields

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 6. Using appropriate lifting device, remove cap screws (7) and right engine side shield (6).

6— Right Engine Side Shield

TX1170843A —UN—05SEP14

Specification Right Engine Side Shield—Weight (approximate).................................................................................. 98 kg 217 lb. 7— Cap Screw (4 used)

Right Engine Side Shield MM12851,00004E1 -19-23JAN15-3/5

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Using appropriate lifting device, remove cap screws (9) and left engine side shield (8).

TX1182770A —UN—19JAN15

Specification Left Engine Shield—Weight (approximate).................................................................................. 70 kg 155 lb.

8. Repair or replace parts as necessary. 9. Using appropriate lifting device, install left engine side shield and cap screws (9). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Left Engine Side Shield

10. Using appropriate lifting device, install right engine side shield and cap screws (7). Do not fully tighten yet.

8— Left Engine Side Shield

9— Cap Screw (6 used)

Specification Right Engine Side Shield—Weight (approximate).................................................................................. 98 kg 217 lb.

Specification Hood—Weight (approximate)................................................................................ 126 kg 277 lb.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Using appropriate lifting device, install hood and cap screws (5). Do not fully tighten yet. Continued on next page

TM13264X19 (02FEB17)

19-1910-2

MM12851,00004E1 -19-23JAN15-4/5

300GLC Excavator 020217 PN=250

Hood and Engine Side Shields

TX1182882 —UN—23JAN15

13 10

TX1182882 Hood and Engine Side Shields Gap 1— Hood 6— Right Engine Side Shield 8— Left Engine Side Shield

10— Hood-to-Left Engine Side Shield Gap 11— Front Gap

IMPORTANT: Avoid damage to hood and engine shields due to improper gap. Hood and engine shields may come in contact with each other if an even gap is not attained. Attain even gap between hood and engine shields. 12. Adjust hood (1) as needed to attain even hood-to-left engine shield gap (10). Maintain even space between front and rear gaps (11 and 12). 13. Tighten cap screws (5) once proper gap is attained.

12— Rear Gap 13— Hood-to-Right Engine Side Shield Gap

14— Front Gap 15— Rear Gap

14. Adjust right engine shield (6) as needed to attain even hood-to-right engine shield gap (13). Maintain even space between front and rear gaps (14 and 15). 15. Tighten cap screws (7) once proper gap is attained. 16. Connect prop rod and install washers and pins. 17. Connect electrical connector (X5041). 18. Adjust hood latches as needed to attain proper fit. MM12851,00004E1 -19-23JAN15-5/5

TM13264X19 (02FEB17)

19-1910-3

300GLC Excavator 020217 PN=251

Hood and Engine Side Shields

TM13264X19 (02FEB17)

19-1910-4

300GLC Excavator 020217 PN=252

Contents

Section 33 Excavator

Page Page

Group 3302—Buckets Bucket Remove and Install........................ 33-3302-1 Adjust Bucket Pivot End Play .................... 33-3302-2 Bucket Pin-Up Data ................................... 33-3302-3

Solenoid Valve Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves .................................................. 33-3360-39 Pilot Valve (Left and Right) Remove and Install ............................................ 33-3360-40 Pilot Valve (Left and Right) Disassemble and Assemble ................ 33-3360-42 Travel Pilot Valve Remove and Install ................................................... 33-3360-48 Travel Pilot Valve Disassemble and Assemble............................................. 33-3360-50 Pilot Signal Manifold Remove and Install ................................................... 33-3360-53 Pilot Signal Manifold Disassemble and Assemble...................................... 33-3360-55 Control Valve Remove and Install............ 33-3360-58 Control Valve Halves Disassemble and Assemble...................................... 33-3360-62 Control Valve (5-Spool) Disassemble and Assemble ................ 33-3360-64 Control Valve (4-Spool) Disassemble and Assemble ................ 33-3360-78 Hydraulic Oil Tank Remove and Install ................................................... 33-3360-90 Restriction Valve Remove and Install ................................................... 33-3360-94 Hydraulic Oil Cooler Bypass Valve Remove and Install.............................. 33-3360-95 Boom Cylinder Remove and Install ................................................... 33-3360-96 Boom Cylinder Disassemble and Assemble............................................. 33-3360-99 Arm Cylinder Remove and Install .......... 33-3360-102 Arm Cylinder Disassemble and Assemble........................................... 33-3360-104 Bucket Cylinder Remove and Install ................................................. 33-3360-107 Bucket Cylinder Disassemble and Assemble........................................... 33-3360-109 Hydraulic Cylinder Bleed Procedure .......................................... 33-3360-112

Group 3340—Frames Bucket Links Remove and Install .............. 33-3340-1 Arm Remove and Install ............................ 33-3340-3 Boom Remove and Install ......................... 33-3340-5 Inspect Pins, Bushings, and Bosses—Front Attachment.................. 33-3340-11 Bushings and Seal Remove and Install ................................................... 33-3340-13 Group 3360—Hydraulic System Apply Vacuum to Hydraulic Oil Tank ....................................................... 33-3360-1 Pump 1 and 2 Remove and Install.............. 33-3360-2 Pump 1 and 2 Disassemble and Assemble............................................... 33-3360-5 Pump Gear Case Disassemble and Assemble............................................. 33-3360-12 Pump 1 and 2 Inspection......................... 33-3360-14 Pump 1 and 2 Start-Up Procedure............ 33-3360-17 Pump 1 and 2 Regulator Remove and Install ............................................ 33-3360-18 Pump 1 and 2 Regulator Disassemble and Assemble ................ 33-3360-20 Pilot Pump Remove and Install ............... 33-3360-22 Pilot Pump Disassemble and Assemble............................................. 33-3360-24 Pilot Pressure Regulating Valve and Filter Remove and Install.............. 33-3360-26 Pilot Pressure Regulating Valve and Filter Disassemble and Assemble............................................. 33-3360-27 Pilot Shutoff Solenoid Valve Remove and Install.............................. 33-3360-28 Pilot Shutoff Solenoid Valve Disassemble and Assemble ................ 33-3360-29 Fan Drive Pump Remove and Install ................................................... 33-3360-31 Fan Drive Motor Remove and Install ................................................... 33-3360-32 Fan Drive Motor Disassemble and Assemble............................................. 33-3360-33 Fan Drive Motor Solenoid Valves Remove and Install.............................. 33-3360-36 Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves .................................................. 33-3360-37

TM13264X19 (02FEB17)

33-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

33-2

300GLC Excavator

020217

PN=2

Group 3302

Buckets Bucket Remove and Install SPECIFICATIONS Link Pin Weight (approximate)

33 kg 73 lb.

Arm Pin Weight (approximate)

31 kg 68 lb.

TX1114612A —UN—25MAY12

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Lower bucket to ground and roll bucket so that flat surface is touching ground. CAUTION: Prevent possible crushing injury from heavy component. Bucket could possibly roll. Secure bucket position with appropriate blocking. 3. Using appropriate blocking, remove nuts (4 and 7) and cap screws (3 and 6).

Bucket Pins 1— Bucket 2— Link Pin 3— Cap Screw 4— Nut (2 used) 5— Arm Pin

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Using appropriate lifting device, remove link pin (2) and arm pin (5). Specification Link Pin—Weight (approximate).................................................................................. 33 kg 73 lb. Arm Pin—Weight (approximate).................................................................................. 31 kg 68 lb.

5. Separate bucket (1) from arm and remove dust seals (8 and 9). 6. Inspect dust seals for damage. Replace as necessary. 7. Check pins and bushings for wear. See Inspect Pins, Bushings, and Bosses—Front Attachment. (Group 3340.) 8. Repair or replace parts as necessary.

6— Cap Screw 7— Nut (2 used) 8— Dust Seal (2 used) 9— Dust Seal (2 used)

10. Align machine arm with bucket. 11. Install dust seals, link pin, and arm pin. 12. Adjust bucket pivot end play. See Adjust Bucket Pivot End Play. (Group 3302.) IMPORTANT: Avoid possible damage to pins. Cap screws must be free to turn in hole to allow movement of pins. Tighten nuts against each other, not against retainer. 13. Install cap screws (3 and 6) and tighten nuts (4 and 7) against each other. 14. Grease front attachment. See Lubricate Front End Pin Joints. (Operator’s Manual.)

9. Apply grease to pins and bores. DV53278,0000889 -19-07JAN15-1/1

TM13264X19 (02FEB17)

33-3302-1

300GLC Excavator 020217 PN=255

Buckets

Adjust Bucket Pivot End Play SPECIFICATIONS Bucket Pivot Bushing-to-Arm Clearance (as close to but not less than)

0.5 mm 0.020 in.

TX1113143A —UN—27APR12

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove nuts (2) and cap screw (1). 3. Measure clearance between bushing and arm. Adjust clearance to specification. Specification Bucket Pivot Bushingto-Arm—Clearance (as close to but not less than)............................................................................................. 0.5 mm 0.020 in.

Bucket Pivot Shims

NOTE: Alternate buckets may have different adjustment procedures. 4. Slide pin (5) out of bucket to edge of seal (4). TX1113142A —UN—27APR12

5. Inspect bushings and seals. See Inspect Pins, Bushings, and Bosses—Front Attachment and see Bushings and Seal Remove and Install. (Group 3340.) 6. Remove or add shims (3) on each side of joint to get a minimal amount of clearance. There must be some clearance in the joint. 7. Push pin back into place. Align pin bores and install cap screw. Measuring Bushing to Arm Clearance

IMPORTANT: Avoid possible damage to pins. Cap screws must be free to turn in hole to allow movement of pins. Tighten nuts against each other, not against retainer.

1— Cap Screw 2— Nut (2 used) 3— Shim (as needed)

4— Seal 5— Pin

8. Install cap screw and tighten nuts against each other. JL58967,0000137 -19-14JAN15-1/1

TM13264X19 (02FEB17)

33-3302-2

300GLC Excavator 020217 PN=256

Buckets

Bucket Pin-Up Data

2 1 10

15 9 8 7 17 Section A

TX1003797

14 13 12 Section B

TX1003797 —UN—07MAR06

Excavator Bucket Pin-Up Data

NOTE: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine. Bucket Pin-Up Data Item 1

478 mm 18.7 in.

0 mm 0 in.

622 mm 24.5 in.

600 mm 23.6 in.

475 mm 18.7 in.

1560 mm 61.4 in.

549 mm 21.6 in.

409 mm 16.1 in.

90 mm 3.5 in.

470 mm 18.5 in.

69 mm 2.7 in.

549 mm 21.6 in.

Continued on next page

TM13264X19 (02FEB17)

33-3302-3

DV53278,000088A -19-16DEC14-1/2

300GLC Excavator 020217 PN=257

Buckets Bucket Pin-Up Data 13

410 mm 16.1 in.

90 mm 3.5 in.

45°

565 mm 22.2 in. DV53278,000088A -19-16DEC14-2/2

TM13264X19 (02FEB17)

33-3302-4

300GLC Excavator 020217 PN=258

Group 3340

Frames Bucket Links Remove and Install 53 kg 117 lb.

Left Arm Link Weight (approximate)

26 kg 57 lb.

Bucket Link Pin Weight (approximate)

33 kg 73 lb.

Bucket Cylinder Pin Weight (approximate)

26 kg 57 lb.

TX1180626A —UN—15DEC14

SPECIFICATIONS Bucket Link Weight (approximate)

Arm Link Pin Weight (approximate) 27 kg 59 lb. Right Arm Link Weight (approximate)

26 kg 57 lb.

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Lower bucket so bottom of bucket is resting on ground. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Bucket and Arm Links 1— Left Bucket Link 2— Right Bucket Link

3— Left Arm Link 4— Right Arm Link

3. Using appropriate lifting device, support bucket links (1 and 2). Specification Bucket Link—Weight (approximate).................................................................................. 53 kg 117 lb. Continued on next page

TM13264X19 (02FEB17)

33-3340-1

DV53278,000088B -19-08JAN15-1/2

300GLC Excavator 020217 PN=259

Frames

4. Insert wooden block between bucket cylinder (10) and arm to hold cylinder up when bucket cylinder pin (8) is removed. 5. Remove nuts (12) and cap screw (14). 6. Remove nuts (7) and cap screw (9).

TX1180624A —UN—15DEC14

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Using appropriate lifting device, remove left arm link (3). Specification Left Arm Link—Weight (approximate).................................................................................. 26 kg 57 lb.

8. Remove nuts (5) and cap screw (11).

Bucket Links and Cylinders

CAUTION: Prevent possible crushing injury from heavy component. Support right arm link with appropriate lifting device while removing bucket cylinder pin.

1— Left Bucket Link 2— Right Bucket Link 3— Left Arm Link 4— Right Arm Link 5— Nut (2 used) 6— Bucket Link Pin 7— Nut (2 used) 8— Bucket Cylinder Pin

9. Using appropriate lifting device, remove bucket link pin (6) and bucket cylinder pin (8). Specification Bucket Link Pin—Weight (approximate).................................................................................. 33 kg 73 lb. Bucket Cylinder Pin—Weight (approximate).................................................................................. 26 kg 57 lb.

10. Remove bucket links (1 and 2). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Using appropriate lifting device, remove arm link pin (13) and right arm link (4).

9— Cap Screw 10— Bucket Cylinder 11— Cap Screw 12— Nut (2 used) 13— Arm Link Pin 14— Cap Screw 15— Bucket

14. Using appropriate lifting device, install right arm link and arm link pin. 15. Using appropriate lifting device, install bucket links. 16. Align right arm link, bucket links, and bucket cylinder so that bucket cylinder pin can be installed. 17. Using appropriate lifting device, install bucket cylinder pin and bucket link pin. IMPORTANT: Avoid possible damage to pins. Cap screws must be free to turn in hole to allow movement of pins. Tighten nuts against each other, not against retainer.

Specification Arm Link Pin—Weight (approximate).................................................................................. 27 kg 59 lb. Right Arm Link—Weight (approximate).................................................................................. 26 kg 57 lb.

18. Install cap screw (11) and tighten nuts (5) against each other.

12. Clean, inspect, and replace parts as necessary.

21. Install cap screw (14) and tighten nuts (12) against each other.

19. Using appropriate lifting device, install left arm link. 20. Install cap screw (9) and tighten nuts (7) against each other.

13. Inspect pins and bushings. See Inspect Pins, Bushings, and Bosses—Front Attachment. (Group 3340.) DV53278,000088B -19-08JAN15-2/2

TM13264X19 (02FEB17)

33-3340-2

300GLC Excavator 020217 PN=260

Frames

Arm Remove and Install 156 L 41 gal.

3.11 m (10 ft. 2 in.) Arm With Bucket Cylinder and Linkage Weight (approximate)

1288 kg 2840 lb.

3.76 m (12 ft. 4 in.) Arm With Bucket Cylinder and Linkage Weight (approximate)

1377 kg 3036 lb.

Arm Thrust Plate Clearance

0—1.5 mm 0—0.06 in.

T106031 —UN—10JAN97

SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

Machine Position

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove bucket. See Bucket Remove and Install. (Group 3302.)

See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

3. Retract arm cylinder and lower front attachment to ground.

5. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

4. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. DV53278,000088C -19-08JAN15-1/3

6. Remove cap screws (1). Install identification tags and disconnect hydraulic lines (2). Close all openings using caps and plugs. 2— Bucket Cylinder Hydraulic Line (2 used)

TX1166020A —UN—21JUL14

1— Cap Screw (4 used)

Bucket Cylinder Continued on next page

TM13264X19 (02FEB17)

33-3340-3

DV53278,000088C -19-08JAN15-2/3

300GLC Excavator 020217 PN=261

Frames

7. Install wooden block between arm cylinder and boom to hold cylinder up when arm cylinder pin (5) is removed. 8. Remove cap screw (4), spacer (3), and arm cylinder pin. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 9. Support arm using appropriate lifting device.

TX1181852A —UN—07JAN15

Specification 3.11 m (10 ft. 2 in.) Arm With Bucket Cylinder and Linkage—Weight (approximate).............................................................................. 1288 kg 2840 lb. 3.76 m (12 ft. 4 in.) Arm With Bucket Cylinder and Linkage—Weight (approximate).............................................................................. 1377 kg 3036 lb. Boom-to-Arm Pin and Arm Cylinder

10. Remove cap screw (6), spacer (7), washer (8), boom-to-arm pin (9), and thrust plates (10). Record location of thrust plates to aid in assembly procedure.

3— Spacer 4— Cap Screw 5— Arm Cylinder Pin 6— Cap Screw

11. Remove arm. 12. Inspect pins and bushings for wear. See Inspect Pins, Bushings, and Bosses—Front Attachment. (Group 3340.) 13. Clean pins and bores.

7— Spacer 8— Washer 9— Boom-to-Arm Pin 10— Thrust Plate (as needed)

19. Connect hydraulic lines.

15. Support arm using appropriate lifting device.

20. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

16. Install arm and boom-to-arm pin. Install thrust plates as needed to attain specified arm thrust plate clearance.

21. Bleed air from bucket cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.)

14. Apply grease to pins and bores.

Specification Arm Thrust Plate—Clearance....................................................................0—1.5 mm 0—0.06 in.

22. Install bucket. See Bucket Remove and Install. (Group 3302.)

17. Install washer, spacer, and cap screw.

23. Grease arm and arm cylinder pin joints. See Lubricate Front End Pin Joints. (Operator’s Manual.)

18. Install arm cylinder pin, spacer, and cap screw.

24. Operate machine and check for leaks. DV53278,000088C -19-08JAN15-3/3

TM13264X19 (02FEB17)

33-3340-4

300GLC Excavator 020217 PN=262

Frames

Boom Remove and Install 156 L 41 gal.

Boom Cylinder Weight (approximate)

245 kg 540 lb.

Boom Cylinder Pin Weight (approximate)

52 kg 115 lb.

Boom With Arm Cylinder Weight (approximate)

2322 kg 5119 lb.

Boom Foot Pin Weight (approximate)

68 kg 150 lb.

Boom Thrust Plate Clearance

0—1 mm 0—0.04 in.

TX1165220A —UN—15JUL14

SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

Boom Hydraulic Lines

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

1— Hydraulic Line (4 used)

2. Remove bucket. See Bucket Remove and Install. (Group 3302.) 3. Remove arm. See Arm Remove and Install. (Group 3340.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 4. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 5. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil (Operator’s Manual). Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

6. Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. Continued on next page

TM13264X19 (02FEB17)

33-3340-5

DV53278,000088D -19-14JAN15-1/7

300GLC Excavator 020217 PN=263

Frames

7. Remove cap screws (5) and cover (2). 8. Remove cap screws (23) on side of toolbox. Remove side panel (3).

2— Cover 3— Side Panel 5— Cap Screw (4 used)

TX1165208A —UN—15JUL14

9. Remove cap screws (22) and tilt toolbox forward. 22— Cap Screw (4 used) 23— Cap Screw (4 used)

TX1165213A —UN—30JUL14

Cover

TX1165214A —UN—15JUL14

Side Panel

Toolbox (inside view) Continued on next page

TM13264X19 (02FEB17)

33-3340-6

DV53278,000088D -19-14JAN15-2/7

300GLC Excavator 020217 PN=264

Frames

10. Install identification tags and disconnect boom light (E2) on left side of boom foot pin.

TX1115302A —UN—07JUN12

E2— Boom Light

Boom Light DV53278,000088D -19-14JAN15-3/7

11. Install identification tags and disconnect lubrication hoses (6). Close all openings using caps and plugs. 7— Boom Cylinder (2 used)

TX1115303A —UN—07JUN12

6— Lubrication Hose (2 used)

Lubrication Hose Continued on next page

TM13264X19 (02FEB17)

33-3340-7

DV53278,000088D -19-14JAN15-4/7

300GLC Excavator 020217 PN=265

Frames

12. Remove nuts (8), cap screw (9), and collar (10). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. NOTE: Boom cylinder pin (12) can be pushed out of boom to lower one cylinder at a time. 13. Support boom cylinder with appropriate lifting device.

TX1115304 —UN—07JUN12

Specification Boom Cylinder—Weight (approximate)................................................................................ 245 kg 540 lb. Boom Cylinder Pin—Weight (approximate).................................................................................. 52 kg 115 lb.

14. Remove boom cylinder pin (12) and shims (11). Record location of shims to aid in assembly procedure. 15. Lower boom cylinder.

Boom Cylinder

16. Repeat steps for other boom cylinder. 7— Boom Cylinder (2 used) 8— Nut (4 used) 9— Cap Screw (2 used) Continued on next page

TM13264X19 (02FEB17)

33-3340-8

10— Collar (2 used) 11— Shim (4 used) 12— Boom Cylinder Pin DV53278,000088D -19-14JAN15-5/7

300GLC Excavator 020217 PN=266

Frames

TX1164409 —UN—10JUL14

15 14

TX1164409 Boom Foot Pin 13— Cap Screw 14— Washer 15— Retaining Plate

16— Boom Foot Pin 17— Thrust Plate

18— Thrust Plate 19— Shim (2 used)

17. Remove cap screw (13), washer (14), and retaining plate (15).

24. Apply grease to pins and bores. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 18. Support boom with appropriate lifting device. Specification Boom With Arm Cylinder—Weight (approximate).............................................................................. 2322 kg 5119 lb. Boom Foot Pin—Weight (approximate).................................................................................. 68 kg 150 lb.

19. Remove boom foot pin (16), thrust plates (17 and 18), and shims (19). Record location of thrust plates and shims to aid in assembly procedure. 20. Remove boom.

25. Support boom with appropriate lifting device. Install boom foot pin and thrust plates equally on each side. Add shims to attain specified boom thrust plate clearance. Specification Boom Thrust Plate—Clearance.......................................................................0—1 mm 0—0.04 in.

26. Install retaining plate, washer, and cap screw (13). Tighten cap screw to specification. Specification Boom Foot Pin Cap Screw—Torque............................................................................746 N·m 550 lb.-ft.

21. Inspect pins and bushings for wear. See Inspect Pins, Bushings, and Bosses—Front Attachment. (Group 3340.) 22. Repair or replace parts as necessary. 23. Clean pins and bores.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. NOTE: Boom cylinder pin can be pushed in boom to raise one cylinder at a time.

Continued on next page

TM13264X19 (02FEB17)

33-3340-9

DV53278,000088D -19-14JAN15-6/7

300GLC Excavator 020217 PN=267

Frames 27. Using appropriate lifting device, raise boom cylinder. Install boom cylinder pin and shims. Specification Boom Cylinder—Weight (approximate)................................................................................ 245 kg 540 lb. Boom Cylinder Pin—Weight (approximate).................................................................................. 52 kg 115 lb.

IMPORTANT: Avoid possible damage to pins. Cap screws must be free to turn in hole to allow movement of pins. Tighten nuts against each other, not against retainer. 28. Install collar, cap screw (9), and tighten nuts (8) against each other. 29. Repeat steps for other boom cylinder.

32. Tilt toolbox to resting position and install cap screws. 33. Install side panel and cap screws (23). 34. Install cover and cap screws (5). 35. Connect hydraulic lines. 36. Install arm. See Arm Remove and Install. (Group 3340.) 37. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) 38. Bleed air from boom and arm cylinders. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 39. Install bucket. See Bucket Remove and Install. (Group 3302.)

30. Connect lubrication hoses.

40. Grease boom pin joints. See Lubricate Front End Pin Joints. (Operator’s Manual.)

31. Connect boom light (E2) on left side of boom foot pin.

41. Operate machine and check for leaks. DV53278,000088D -19-14JAN15-7/7

TM13264X19 (02FEB17)

33-3340-10

300GLC Excavator 020217 PN=268

Frames

1— Boom-to-Frame Joint 2— Boom Cylinder Head End-to-Frame Joint 3— Boom Cylinder Rod End-to-Boom Joint 4— Boom-to-Arm Joint 5— Arm Cylinder Rod End-to-Arm Joint 6— Arm Cylinder Head End-to-Boom Joint

7— Bucket Cylinder Head End-to-Arm Joint 8— Bucket Cylinder Rod End-to-Side and Bucket Links Joint 9— Side Links-to-Arm Joint 10— Bucket Link-to-Bucket Joint 11— Bucket-to-Arm Joint

4 9 2 TX1004442

TX1004442 —UN—06MAR06

Inspect Pins, Bushings, and Bosses—Front Attachment

Boom, Bucket, and Arm Pins, Bushings, and Bosses 1

Item

Standard

Allowable Limit

Remedy

100 mm 3.94 in.

99.0 mm 3.90 in.

Replace

Bushing (main frame)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

Bushing (boom)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

100 mm 3.94 in.

99.0 mm 3.90 in.

Replace

Boss (main frame)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

Bushing (boom cylinder)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

100 mm 3.94 in.

99.0 mm 3.90 in.

Replace

Bushing (boom cylinder)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

Boss (boom)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

100 mm 3.94 in.

99.0 mm 3.90 in.

Replace

Bushing (boom)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

Bushing (arm)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

100 mm 3.94 in.

99.0 mm 3.90 in.

Replace

Boss (arm)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

Bushing (arm cylinder)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

100 mm 3.94 in.

99.0 mm 3.90 in.

Replace

Boss (boom)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

Bushing (arm cylinder)

100 mm 3.94 in.

101.5 mm 4.00 in.

Replace

80 mm 3.15 in.

79.0 mm 3.11 in.

Replace

Boss (arm)

80 mm 3.15 in.

81.5 mm 3.21 in.

Replace

Bushing (bucket cylinder)

80 mm 3.15 in.

81.5 mm 3.21 in.

Replace

90 mm 3.54 in.

89.0 mm 3.50 in.

Replace

Continued on next page

TM13264X19 (02FEB17)

33-3340-11

DV53278,000088E -19-09FEB15-1/2

300GLC Excavator 020217 PN=269

Frames Pins, Bushings, and Bosses

Item

Standard

Allowable Limit

Remedy

Boss (left arm link)

90 mm 3.54 in.

91.5 mm 3.60 in.

Replace

Bushing (left bucket link)

90 mm 3.54 in.

91.5 mm 3.60 in.

Replace

Bushing (bucket cylinder)

90 mm 3.54 in.

91.5 mm 3.60 in.

Replace

80 mm 3.15 in.

79.0 mm 3.11 in.

Replace

Boss (left arm link)

80 mm 3.15 in.

81.5 mm 3.21 in.

Replace

Bushing (arm)

80 mm 3.15 in.

81.5 mm 3.21 in.

Replace

90 mm 3.54 in.

89.0 mm 3.50 in.

Replace

Boss (bucket)

90 mm 3.54 in.

91.5 mm 3.60 in.

Replace

Bushing (left arm link)

90 mm 3.54 in.

91.5 mm 3.60 in.

Replace

90 mm 3.54 in.

89.0 mm 3.50 in.

Replace

Boss (bucket)

90 mm 3.54 in.

91.5 mm 3.60 in.

Replace

Bushing (arm)

90 mm 3.54 in.

91.5 mm 3.60 in.

Replace DV53278,000088E -19-09FEB15-2/2

TM13264X19 (02FEB17)

33-3340-12

300GLC Excavator 020217 PN=270

Frames

Bushings and Seal Remove and Install NOTE: Bushings 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 (5) and dust seals using bushing, bearing, and seal driver set. IMPORTANT: Bushings will be damaged if installed with driver. Only install bushings using press.

2. Install bushings with lubrication hole aligned with lubrication passage in pivot. 3. Install bushings to a depth equal to thickness of dust seal (10). 4. Install dust seals with lip toward outside of component.

1 7

9 6

6— Disk 7— Bushing Stop (disk) 8— Pilot (disk) 9— Ram Stop (disk) 10— Thickness of Dust Seal

TX1113406 —UN—08MAY12

1— Hydraulic Ram 2— Pipe—Minimum Inner Diameter to Clear Bushing Outer Diameter 3— Pipe—Maximum Outer Diameter 4— Pipe—Length of Bushing 5— Bushing (2 used)

TX1092651 —UN—26MAY11

Pipe Dimensions

Dust Seal Thickness DP27668,00004E7 -19-10DEC12-1/1

TM13264X19 (02FEB17)

33-3340-13

300GLC Excavator 020217 PN=271

Frames

TM13264X19 (02FEB17)

33-3340-14

300GLC Excavator 020217 PN=272

Group 3360

Hydraulic System Apply Vacuum to Hydraulic Oil Tank ESSENTIAL TOOLS D15032NU Vacuum Pump Kit TX1087267A —UN—24JAN11

JT07085A Vacuum Pump Adapter Set

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 2. Release hydraulic oil tank pressure by pressing pressure release button (1) at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

Hydraulic Oil Tank Cover 1— Pressure Release Button 2— Hydraulic Oil Tank Cover

3— Cap Screw (4 used)

3. Remove cap screws (3) and hydraulic oil tank cover (2). TZ24494,0000EBE -19-27JAN16-1/2

4. Assemble fittings and hydraulic oil tank adapter from D15032NU Vacuum Pump Kit (4) and JT07085A Vacuum Pump Adapter Set. Install in hydraulic tank opening as shown. Refer to manufacturer’s instructions for operating pump.

TX1090390A —UN—05APR11

4— D15032NU Vacuum Pump Kit

D15032NU Vacuum Pump Kit TZ24494,0000EBE -19-27JAN16-2/2

TM13264X19 (02FEB17)

33-3360-1

300GLC Excavator 020217 PN=273

Hydraulic System

Pump 1 and 2 Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Pump Assembly Weight (approximate)

210 kg 463 lb.

TX1170025A —UN—25AUG14

B35— Pump 1 Delivery Pressure Sensor B36— Pump 1 Control Pressure Sensor B37— Pump 2 Delivery Pressure Sensor

3. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

B38— Pump 2 Control Pressure Sensor Y20— Pump 2 Flow Rate Limit Solenoid Y21— Torque Control Solenoid

4. Drain hydraulic oil tank. See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

5. Remove exhaust aftertreatment assembly. See Exhaust Aftertreatment Assembly Remove and Install. (Group 0530.) 6. Install identification tags and disconnect sensors (B35—B38) and solenoids (Y20 and Y21). See Pump Harness (W8) Component Location. (Group 9015-10.) Continued on next page

TM13264X19 (02FEB17)

33-3360-2

DV53278,0000896 -19-05JAN15-1/3

300GLC Excavator 020217 PN=274

Hydraulic System

7. Remove cap screws (1), install identification tags and disconnect hydraulic return lines (2). Close all openings using caps and plugs. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.)

8. Remove cap screws (3), install identification tags and disconnect pump supply lines (4) from hydraulic oil tank supply line (5). Close all openings using caps and plugs.

4— Pump Supply Line (2 used) 5— Hydraulic Oil Tank Supply Line

3 1

2 5

TX1170068 —UN—25AUG14

1— Cap Screw (8 used) 2— Hydraulic Return Line (2 used) 3— Cap Screw (8 used)

Pump 1 and 2 Continued on next page

TM13264X19 (02FEB17)

33-3360-3

DV53278,0000896 -19-05JAN15-2/3

300GLC Excavator 020217 PN=275

Hydraulic System

9. Install identification tags and disconnect hydraulic lines (6—9). Close all openings using caps and plugs.

10. Install identification tags and disconnect pilot pump supply line (10). Close all openings using caps and plugs.

11. Install identification tags and disconnect attenuator lines (11). Close all openings using caps and plugs.

7 9

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

TX1170067 —UN—25AUG14

12. Support pump assembly by attaching appropriate lifting device. Specification Pump Assembly—Weight (approximate)................................................................................ 210 kg 463 lb.

5 Pump 1 and 2

13. Remove cap screws (12) and pump assembly. 5— Hydraulic Oil Tank Supply Line 6— Hydraulic Line 7— Hydraulic Line 8— Hydraulic Line

14. Inspect damper drive (flex coupling). See Damper Drive (Flex Coupling) Remove and Install. (Group 0752.) IMPORTANT: Prevent possible machine damage from oil loss of pump gear case. Ensure spring washers are used for outside mounting holes and seal washers are used for inside mounting holes. 15. Repair or replace as necessary. See Pump 1 and 2 Disassemble and Assemble and see Pump Gear Case Disassemble and Assemble. (Group 3360.) 16. Using appropriate lifting device, align damper drive (flex coupling) and install pump assembly.

9— Hydraulic Line 10— Pilot Pump Supply Line 11— Attenuator Line (2 used) 12— Cap Screw (8 used)

26. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) Connect negative (-) battery cable. 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. 27. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)

17. Install cap screws (12). 18. Connect attenuator lines (11).

CAUTION: Prevent possible injury from unexpected machine movement. Clear all personnel from area before operating machine.

19. Connect pilot pump supply line (10). See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.) 20. Connect hydraulic lines (6—9). 21. Connect pump supply lines (4) and install cap screws (3). 22. Connect hydraulic return lines (2) and install cap screws (1). 23. Connect sensors (B35—B38) and solenoids (Y20 and Y21). See Pump Harness (W8) Component Location. (Group 9015-10.) 24. Install exhaust aftertreatment assembly. See Exhaust Aftertreatment Assembly Remove and Install. (Group 0530.)

28. Operate machine and check for leaks. Verify all machine functions operate correctly. See Operational Checkout. (Group 9005-10.) 29. Check pump regulator adjustments. For minimum flow: • See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.) For maximum flow: • See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)

25. Fill hydraulic oil tank. See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) DV53278,0000896 -19-05JAN15-3/3

TM13264X19 (02FEB17)

33-3360-4

300GLC Excavator 020217 PN=276

Hydraulic System ESSENTIAL TOOLS

Pump 1 and 2 Disassemble and Assemble SPECIFICATIONS Pump Gear Case Oil Capacity Pump Weight (approximate)

1.4 L 1.5 qt. 67 kg 148 lb.

Servo Piston Set Screw and Pin Torque

35 N·m 26 lb.-ft.

Stop-to-Cover Cap Screw Torque

20 N·m 177 lb.-in.

Drive Shaft Bearing Inner Race Temperature

50—80°C 122—176°F

Drive Shaft Starting Torque

2.5—3.5 N·m 22—31 lb.-in.

Pump Housing Temperature

50—80°C 122—176°F

Cover-to-Pump Housing Cap Screw Torque

110 N·m 81 lb.-ft.

Pump Gear Case-to-Pump 1 or 2 Torque

150 N·m 111 lb.-ft.

JDG911 Spanner Wrench SERVICE EQUIPMENT AND TOOLS Ring Compressor DF1037a Hydraulic Pump Torque Adapter a

Fabricated tool, dealer made. (See Section 99 for instructions to make tool.) OTHER MATERIAL Loctite® Klean ‘N Prime™ Primer Loctite® 242® Threadlocker (medium strength)

Continued on next page

TM13264X19 (02FEB17)

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DV53278,0000757 -19-12FEB15-1/8

300GLC Excavator 020217 PN=277

TX1131039 —UN—18FEB13

Hydraulic System

Main Hydraulic Pump

Continued on next page

TM13264X19 (02FEB17)

33-3360-6

DV53278,0000757 -19-12FEB15-2/8

300GLC Excavator 020217 PN=278

Hydraulic System 1— Snap Ring 2— Drive Gear 3— O-Ring 4— Regulator 5— Cap Screw (4 used) 7— Snap Ring 8— Seal Cover 9— Oil Seal 10— O-Ring 11— Pump Housing 12— O-Ring (10 used) 13— Spring Pin (2 used) 14— Bearing Nut 15— Bearing

16— Bearing 17— Spacer 18— Gasket 19— Spring Pin (2 used) 20— Drain Plug 21— Pin 22— Piston (7 used) 23— Pin (2 used) 24— Pin 25— Snap Ring (6 used) 26— Pin 27— Link 28— Pin (2 used) 29— Lever (2 used) 30— Pin

31— Cover 32— Plug 33— Lock Washer (8 used) 34— Cap Screw (8 used) 35— Stop 36— O-Ring 37— Name Plate 38— Screw (2 used) 39— Cap Screw (8 used) 40— Lock Washer (8 used) 41— Set Screw 42— Servo Piston 43— O-Ring

44— Stop 45— Valve Plate 46— Cylinder Block 47— Spring 48— Center Shaft 49— Drive Shaft 50— Delivery Pressure Sensor 51— Cap Screw (4 used) 52— Spring Washer (2 used) 53— Seal Washer (2 used)

1. Remove pilot pump and hydraulic pump 1 and 2 assembly. See Pump 1 and 2 Remove and Install. (Group 3360.)

10. Remove pin (24) and link (27) assembly.

NOTE: Procedure is the same for pump 1 or pump 2.

11. Remove snap rings (25) from pins (23 and 28).

2. Remove regulator (4). See Pump 1 and 2 Regulator Remove and Install. (Group 3360.)

12. Remove pins (23) and levers (29).

NOTE: Do not remove pins (28) unless necessary.

3. Remove fill plug, drain plug, and O-ring from pump gear case (not shown) to drain engine oil. See Pump Gear Case Disassemble and Assemble. (Group 3360.)

IMPORTANT: Prevent possible damage to hydraulic pump valve plates. Valve plates have highly-machined surfaces. Use care when removing valve plates.

Specification Pump Gear Case Oil—Capacity................................................................................... 1.4 L 1.5 qt.

NOTE: Do not lose pin (21) when removing center shaft.

4. Remove drain plug (20) with O-ring.

14. Remove spring (47), pin (21), and center shaft (48) from drive shaft.

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

13. Remove valve plate (45) and cylinder block (46).

NOTE: Pistons are matched to bores. Use identification tags to identify pistons to ensure proper assembly. 15. Incline or tip pistons (22) toward center of drive shaft and remove pistons.

5. Support pump 1 or pump 2 with appropriate lifting device to remove separately. Specification Pump—Weight (approximate).................................................................................. 67 kg 148 lb.

IMPORTANT: Prevent possible machine damage from oil loss of pump gear case. Ensure spring washers (52) are used for outside holes and seal washers (53) are used for inside holes.

16. Remove snap ring (7), seal cover (8), oil seal (9), and O-ring (10) from pump housing. 17. Remove oil seal from seal cover. 18. Place pump housing with drive shaft side down. Using a press, remove drive shaft with bearings attached. 19. Remove bearing nut (14) using JDG911 Spanner Wrench. 20. Remove bearing (15) and spacer (17) using a puller.

6. Remove cap screws (51), spring washers (52), and seal washers (53).

21. Remove bearing from spacer.

7. Remove snap ring (1) and drive gear (2) from drive shaft (49).

22. Remove outer race of bearing (16). 23. Remove bearing from drive shaft.

8. Remove cap screws (39), lock washers (40), and cover (31) from pump housing (11).

24. Remove delivery pressure sensor (50). 25. Remove cap screws (34) and lock washers (33).

9. Remove O-rings (3 and 12), spring pins (13), and gasket (18) from pump housing. IMPORTANT: Prevent possible damage to hydraulic pump and remove feedback link only if damaged or deformed. Damaged or deformed feedback link may alter pump performance.

26. Remove stops (35 and 44) and O-rings (12, 36, and 43). 27. Remove servo piston (42) only if replacement is necessary.

Continued on next page

TM13264X19 (02FEB17)

33-3360-7

DV53278,0000757 -19-12FEB15-3/8

300GLC Excavator 020217 PN=279

Hydraulic System

Disassemble servo piston using following procedure:

34. Install delivery pressure sensor.

• Heat set screw (41) to loosen thread lock and sealer

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 oil in a well-ventilated area. Plan a safe handling procedure to avoid burns.

(medium strength used).

• Remove set screw using a 6 mm hex key wrench. • Remove pin (30). • Remove servo piston. 28. Clean and inspect parts. Repair or replace parts as necessary. See Pump 1 and 2 Inspection. (Group 3360.)

35. In well-ventilated area, heat inner races of bearings (15 and 16) to specification.

29. Assemble hydraulic pump in reverse order.

Specification Drive Shaft Bearing Inner Race—Temperature..................................................................50—80°C 122—176°F

IMPORTANT: Ensure that all components are clean during assembly to prevent hydraulic system contamination. 30. Install servo piston (42) into cover. If set screw or pin (30) was removed, install using following procedure:

36. Apply clean hydraulic oil to bearings.

• Clean threads of set screw (41) using Klean N Prime. • Apply242® Thread Lock and Sealer (medium strength) to threads of set screw.

37. Position drive shaft on workbench with spline side facing upward. Install bearing (16) onto drive shaft. Apply clean hydraulic oil to bearing races. 38. Install outer race onto bearing (16).

• Install pin (30). • Tighten set screw and pin to specification.

39. Install outer race of bearing (15) into spacer (17).

Specification Servo Piston Set Screw and Pin—Torque............................................................................35 N·m 26 lb.-ft.

31. Install O-rings (36 and 43) and stops (35 and 44).

40. Install bearing (15) and spacer (17) onto drive shaft. 41. Verify that bearings (15 and 16) are secure when cooled down. 42. Apply clean hydraulic oil to bearing race surfaces and install inner race of bearing (15).

32. Install O-rings (12) in cover (31). 33. Install lock washers (33) and cap screws (34). Tighten cap screws to specification.

43. Apply clean hydraulic oil to threads of bearing nut (14) and install onto drive shaft. Tighten bearing nut until it contacts bearing (15).

Specification Stop-to-Cover Cap Screw—Torque..............................................................................20 N·m 177 lb.-in. Loctite and its related brand marks are trademarks of Henkel Corporation DV53278,0000757 -19-12FEB15-4/8

44. Install a ring compressor to align bearings on drive shaft (49). 49— Drive Shaft TX1005435A —UN—30MAR06

14— Bearing Nut

Drive Shaft Nut Installation Continued on next page

TM13264X19 (02FEB17)

33-3360-8

DV53278,0000757 -19-12FEB15-5/8

300GLC Excavator 020217 PN=280

Hydraulic System

45. Place drive shaft with attached parts on knife-edged puller. Be sure ring compressor holds weight of assembly. 46. Install hydraulic pump torque adapter on spline of drive shaft and turn 2—3 times before recording. Make a record of the starting torque. Starting torque must be as specified. Specification Drive Shaft—Starting Torque................................................................................. 2.5—3.5 N·m 22—31 lb.-in.

T146158B —UN—01NOV01

47. Adjust bearing nut to reach starting torque specification. CAUTION: Prevent possible burn injury from hot components by wearing proper protection while heating and installing drive shafts. Allow sufficient time for housing to cool before handling. 48. To aid in installation of drive shaft, heat pump housing (11). Apply multipurpose grease to inside of housing and to O-ring groove and O-ring (10). Specification Pump Housing—Temperature..........................................................................................50—80°C 122—176°F

Torque Adapter on Drive Shaft

IMPORTANT: Prevent possible pump valve plate damage. Install valve plates so inlet port is toward the center and top of pump housing. 57. Install valve plate using the following procedure:

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

• Apply oil to valve plate. • Install pins (28) into holes of levers (29) and install

49. Using appropriate lifting device and press, install drive shaft.

• Install valve plate so inlet port is toward the center

snap rings (25).

and top of pump housing.

• Align levers-to-link holes and install pins (23) and

Specification Pump—Weight (approximate).................................................................................. 67 kg 148 lb.

snap rings.

58. Install link (27) assembly and pin (24). 59. Install center shaft (48) into valve plate (45).

50. Verify that drive shaft is secure when cooled down.

60. Install O-rings (3 and 12), spring pins (13), and gasket (18) to pump housing.

51. Install oil seal (9) into seal cover (8). 52. Install seal cover (8) and oil seal, snap ring (7), and O-ring (10). Make sure snap ring is seated in groove.

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

NOTE: Pistons must be installed in the bores they were removed from. 53. Apply clean hydraulic oil to pistons (22) and install into drive shaft. 54. Apply multipurpose grease to pin (21) and install into center shaft.

61. Using appropriate lifting device, place pump face down on wood blocks. Specification Pump—Weight (approximate).................................................................................. 67 kg 148 lb.

55. Install center shaft (48) and spring (47) into drive shaft. 56. Align pin (21) with groove in cylinder block (46) and install pistons and center shaft. Continued on next page

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=281

Hydraulic System

62. Position valve plate (45) and cylinder block (46) as shown. Be sure outlet port (55) is positioned as shown.

19— Spring Pin (2 used) 30— Pin 31— Cover

TX1131378A —UN—19FEB13

63. Install cover (31), aligning pin (30) with center shaft bore in valve plate (45) and holes with spring pins (19). 45— Valve Plate 46— Cylinder Block 55— Outlet Port

Valve Plate and Rotor Installation DV53278,0000757 -19-12FEB15-7/8

64. Install lock washers (40) and cap screws (39). Tighten cap screws to specification.

T6557FO —UN—18OCT88

Specification Cover-to-Pump Housing Cap Screw—Torque.................................................................... 110 N·m 81 lb.-ft.

65. Install drive gear (2) and snap ring (1) to drive shaft.

Cover-to-Housing Installation DV53278,0000757 -19-12FEB15-8/8

TM13264X19 (02FEB17)

33-3360-10

300GLC Excavator 020217 PN=282

Hydraulic System

IMPORTANT: Prevent possible machine damage from oil loss of pump gear case. Ensure spring washers (52) are used for outside holes and seal washers (53) are used for inside holes. 66. Align pump 1 or pump 2 to pump gear case and install spring washers (52), seal washers (53), and cap screws (51). Tighten cap screws to specification. Specification Pump Gear Case-toPump 1 or 2—Torque..................................................................150 N·m 111 lb.-ft.

TX1131896 —UN—27FEB13

67. Install drain plug (20) with O-ring. 68. Install drain plug and O-ring to pump gear case. 69. Install regulator. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.) 70. Install pilot pump and hydraulic pump 1 and 2 assembly. See Pump 1 and 2 Remove and Install. (Group 3360.) Spring and Seal Washer Placement 51— Cap Screw (8 used) 52— Spring Washer (4 used)

53— Seal Washer (4 used)

DV53278,0000757 -19-12FEB15-9/8

TM13264X19 (02FEB17)

33-3360-11

300GLC Excavator 020217 PN=283

Hydraulic System

TX1134178 —UN—02APR13

Pump Gear Case Disassemble and Assemble

Pump Gear Case 1— Snap Ring 2— O-Ring 3— Seal Cover 4— Oil Seal 5— Snap Ring 6— Bearing 7— Center Gear

8— Center Shaft 9— Bearing 10— Pump Gear Case 12— Fill Plug 18— Cap Screw (2 used) 19— Pilot Pump

20— Spring Washer (2 used) 22— Washer (2 used) 23— Adapter 24— O-Ring 25— Drain Plug 26— O-Ring

SPECIFICATIONS Pump Gear Case Weight (approximate)

42 kg 93 lb.

Dipstick Cap Screw Torque

20 N·m 177 lb.-in.

27— Cap Screw (2 used) 28— Dipstick Tube 29— Gasket 30— Dipstick

8. Remove snap ring (5). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

1. Remove pilot pump and hydraulic pump 1 and 2 assembly. See Pump 1 and 2 Remove and Install. (Group 3360.)

9. Using appropriate lifting device and press, remove center shaft (8) and bearing (6) from pump gear case (10).

2. Remove damper drive coupling. See Damper Drive (Flex Coupling) Remove and Install. (Group 0752.)

Specification Pump Gear Case—Weight (approximate).................................................................................. 42 kg 93 lb.

IMPORTANT: Prevent possible machine damage from oil loss of pump gear case. Ensure spring washers are used for outside mounting holes and seal washers are used for inside mounting holes. 3. Remove pump 1 and pump 2 separately. See Pump 1 and 2 Disassemble and Assemble. (Group 3360.)

10. Remove center gear (7) and bearing (9) from pump gear case. 11. Remove bearing (6) from center shaft using a press. 12. Clean and inspect parts. Repair or replace parts as necessary.

4. Remove pilot pump (19). See Pilot Pump Remove and Install. (Group 3360.)

13. Install bearing (6) to center shaft using a press.

5. Remove cap screws (27), dipstick (30), dipstick tube (28), and gasket (29). 6. Remove snap ring (1), seal cover (3), oil seal (4), and O-ring (2).

14. Install bearing (9) and center gear (7) to pump gear case.

7. Remove oil seal from seal cover.

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

Continued on next page

TM13264X19 (02FEB17)

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MM12851,00004E9 -19-10FEB15-1/2

300GLC Excavator 020217 PN=284

Hydraulic System 15. Using appropriate lifting device and press, install center shaft and bearing into pump gear case. Specification Pump Gear Case—Weight (approximate).................................................................................. 42 kg 93 lb.

16. Install snap ring (5).

20. Install pilot pump. See Pilot Pump Remove and Install. (Group 3360.) IMPORTANT: Prevent possible machine damage from oil loss of pump gear case. Ensure spring washers are used for outside mounting holes and seal washers are used for inside mounting holes. 21. Install pump 1 and pump 2 to gear case. See Pump 1 and 2 Disassemble and Assemble. (Group 3360.)

17. Install oil seal into seal cover. 18. Install O-ring (2), seal cover (3), oil seal (4), and snap ring (1). 19. Install gasket, dipstick tube, dipstick, and cap screw. Tighten cap screws to specification.

22. Install damper drive coupling. See Damper Drive (Flex Coupling) Remove and Install. (Group 0752.) 23. Install pilot pump and hydraulic pump 1 and 2 assembly. See Pump 1 and 2 Remove and Install. (Group 3360.)

Specification Dipstick Cap Screw—Torque..............................................................................20 N·m 177 lb.-in. MM12851,00004E9 -19-10FEB15-2/2

TM13264X19 (02FEB17)

33-3360-13

300GLC Excavator 020217 PN=285

Hydraulic System

Pump 1 and 2 Inspection

SPECIFICATIONS 55 mm nominal 2.17 in. nominal 54.8 mm limit of use 2.16 in. limit of use

Pump 1 (front) Drive Shaft Oil Seal Contact Surface (4) Outside Diameter

60 mm nominal 2.36 in. nominal 59.8 mm limit of use 2.35 in. limit of use

Pump 1 and 2 (front and rear) Drive Shaft Spline Tooth Surface (2) Thickness

4.9 mm nominal 0.193 in. nominal 3.5 mm limit of use 0.138 in. limit of use

Piston-to-Drive Shaft Socket Play

0.060 mm nominal 0.002 in. nominal 0.400 mm limit of use 0.016 in. limit of use

Cylinder Block Bore-to-Piston Clearance

0.044 mm nominal 0.002 in. nominal 0.080 mm limit of use 0.003 in. limit of use

Piston-to-Connecting Rod Play

0.150 mm nominal 0.006 in. nominal 0.400 mm limit of use 0.016 in. limit of use

Servo Piston-to-Cylinder Head Bore Clearance

0.090 mm nominal 0.004 in. nominal 0.200 mm limit of use 0.008 in. limit of use

Servo Piston Pin-to-Valve Plate Bore Clearance

0.051 mm nominal 0.002 in. nominal 0.300 mm limit of use 0.012 in. limit of use

Center Shaft-to-Valve Plate Bore Clearance

0.081 mm nominal 0.003 in. nominal 0.300 mm limit of use 0.012 in. limit of use

1 4 TX1129493 —UN—18JAN13

Pump 2 (rear) Drive Shaft Oil Seal Contact Surface (1) Outside Diameter

2 3 5

Oil Seal Contact and Spline Tooth Surfaces 1— Oil Seal Contact Surface 2— Spline Tooth Surface 3— Pump 2 (rear) Drive Shaft

1. Measure diameter of oil seal contact surfaces (1 and 4) and spline tooth surface (2) thickness on pump 1 (front) drive shaft (5) and pump 2 (rear) drive shaft (3). Compare to specification.

4— Oil Seal Contact Surface 5— Pump 1 (front) Drive Shaft

Specification Pump 2 (rear) Drive Shaft Oil Seal Contact Surface (1)—Outside Diameter.....................................................55 mm nominal 2.17 in. nominal 54.8 mm limit of use 2.16 in. limit of use Pump 1 (front) Drive Shaft Oil Seal Contact Surface (4)—Outside Diameter.....................................................60 mm nominal 2.36 in. nominal 59.8 mm limit of use 2.35 in. limit of use Pump 1 and 2 (front and rear) Drive Shaft Spline Tooth Surface (2)—Thickness................................................................4.9 mm nominal 0.193 in. nominal 3.5 mm limit of use 0.138 in. limit of use TZ24494,0000EC4 -19-20MAR13-1/6

2. Measure play (8) between piston connecting rod (6) and socket in rear drive shaft (7). Compare to specification.

6— Piston Connecting Rod 7— Rear Drive Shaft

TX1092962 —UN—06JUN11

Specification Piston-to-Drive Shaft Socket—Play...............................................................0.060 mm nominal 0.002 in. nominal 0.400 mm limit of use 0.016 in. limit of use 8— Play Piston-to-Socket Play Continued on next page

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300GLC Excavator 020217 PN=286

Hydraulic System

3. Measure inside diameter of cylinder block (9) piston bore. Measure outside diameter of piston (10). Subtract outside diameter from inside diameter for clearance. Compare to specification.

9— Cylinder Block

TX1092965A —UN—06JUN11

Specification Cylinder Block Bore-toPiston—Clearance......................................................0.044 mm nominal 0.002 in. nominal 0.080 mm limit of use 0.003 in. limit of use 10— Piston

TX1092966A —UN—06JUN11

Cylinder Block Piston Bore

Piston TZ24494,0000EC4 -19-20MAR13-3/6

4. Clamp connecting rod end of piston in a vise (11) with soft-jaw faces. Measure connecting rod-to-piston play (12). Compare to specification.

11— Vise

TX1092968 —UN—06JUN11

Specification Piston-to-Connecting Rod—Play...................................................................0.150 mm nominal 0.006 in. nominal 0.400 mm limit of use 0.016 in. limit of use 12— Connecting Rod-to-Piston Play Piston-to-Connecting Rod Play Continued on next page

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TZ24494,0000EC4 -19-20MAR13-4/6

300GLC Excavator 020217 PN=287

Hydraulic System

5. Measure outside diameter (OD)—small end (14) and outside diameter (OD)—large end (17) of servo piston (16). Measure inside diameter (ID)—small end (15) and inside diameter (ID)—large end (18) of bore in cylinder head (13). Subtract outside diameter from inside diameter for clearance. Compare to specification.

13— Cylinder Head 14— OD—Small End 15— ID—Small End

TX1092970 —UN—06JUN11

Specification Servo Piston-to-Cylinder Head Bore—Clearance...............................................0.090 mm nominal 0.004 in. nominal 0.200 mm limit of use 0.008 in. limit of use 16— Servo Piston 17— OD—Large End 18— ID—Large End

Servo Piston-to-Bore Clearance TZ24494,0000EC4 -19-20MAR13-5/6

6. Measure outside diameter—servo piston pin (21). Measure inside diameter—valve plate bore (20). Subtract outside diameter from inside diameter for the clearance. Compare to specification. Specification Servo Piston Pin-to-Valve Plate Bore—Clearance................................................0.051 mm nominal 0.002 in. nominal 0.300 mm limit of use 0.012 in. limit of use

7. Measure outside diameter—center shaft (22). Measure inside diameter—valve plate bore (20). Subtract outside diameter from inside diameter for the clearance. Compare to specification. Specification Center Shaft-to-Valve Plate Bore—Clearance................................................0.081 mm nominal 0.003 in. nominal 0.300 mm limit of use 0.012 in. limit of use

20 21

TX1129512 —UN—18JAN13

20 22

Center Shaft and Servo Piston Pin-to-Bore Pin Clearance 19— Valve Plate 20— Inside Diameter—Valve Plate Bore

21— Outside Diameter—Servo Piston Pin 22— Outside Diameter—Center Shaft

TZ24494,0000EC4 -19-20MAR13-6/6

TM13264X19 (02FEB17)

33-3360-16

300GLC Excavator 020217 PN=288

Hydraulic System

Pump 1 and 2 Start-Up Procedure 1.4 L 1.5 qt.

Pump Drive Gear Case Oil Fill Plug Torque

40 N·m 30 lb.-ft.

TX1131452A —UN—19FEB13

SPECIFICATIONS Pump Drive Gear Case Oil Capacity

Pump 1 and 2 start-up procedure is to ensure the pumps and pump drive gear case are filled with oil and air is bled from suction side of pumps to prevent cavitation. 1— Dipstick 2— Fill Plug 3— Pump 2 Air Bleed Plug

4— Pump 2 Regulator 5— Pump 1 Air Bleed Plug 6— Pump 1 Regulator

Fill and Air Bleed Plugs

TZ24494,0000EC5 -19-28JAN15-1/2

IMPORTANT: Prevent possible pump drive gear case and pump damage. Pump drive gear case and pump 1 and 2 must be filled with oil before starting engine. T145092 —UN—31AUG01

1. Remove fill plug (2). 2. Fill pump drive gear case with engine oil until level is at “H” mark on dipstick (1). See Check Pump Drive Gear Case Oil Level. (Operator’s Manual.) Specification Pump Drive Gear Case Oil—Capacity................................................................................... 1.4 L 1.5 qt.

3. Install fill plug and tighten to specification.

Dipstick 1— Dipstick

Specification Pump Drive Gear Case Oil Fill Plug—Torque......................................................................40 N·m 30 lb.-ft.

8. Start engine and run at slow idle. 9. Slowly loosen air bleed plugs and bleed air from pump until oil starts to come out of gap.

4. Remove pump 1 air bleed plug (5) and pump 2 air bleed plug (3) from the top of pump 1 regulator (6) and pump 2 regulator (4).

10. After bleeding all air, tighten air bleed plugs securely.

5. Slowly add clean hydraulic oil to pump drive gear case through air bleed holes.

11. Slowly raise boom to full height and then lower to pressurize hydraulic oil tank.

6. When pump housing is full of oil, temporarily tighten air bleed plugs.

NOTE: Air in pilot circuits is purged automatically.

7. Check hydraulic oil tank level. See Maintenance—Hydraulic System—Change Hydraulic Oil in operator’s manual.

12. Purge air from the hydraulic system by slowly operating each function several times. TZ24494,0000EC5 -19-28JAN15-2/2

TM13264X19 (02FEB17)

33-3360-17

300GLC Excavator 020217 PN=289

Hydraulic System

Pump 1 and 2 Regulator Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

NOTE: Pump 1 regulator (5) and pump 2 regulator (1) are similar in design. Removal of pump 2 regulator is used in this procedure. TX1131259A —UN—15FEB13

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

4. Install identification tags and disconnect pilot hose (3) and hydraulic lines (4). Close all openings using caps and plugs. 5. Remove cap screws (2) and pump 2 regulator (1). 6. Repair or replace parts as necessary. See Pump 1 and 2 Regulator Disassemble and Assemble. (Group 3360.) 7. Install pump 2 regulator, making sure groove in remote control sleeve and load sleeve engage dowel pin in feedback link. 8. Install and tighten cap screws.

Pump 2 Regulator 1— Pump 2 Regulator 2— Cap Screw (4 used) 3— Pilot Hose

4— Hydraulic Line (4 used) 5— Pump 1 Regulator

10. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) IMPORTANT: Prevent possible pump drive gear case and pump damage. Pump drive gear case and pump 1 and 2 must be filled with oil before starting engine. 11. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 12. Operate machine and check for leaks. Check pump regulator for adjustments. For minimum flow: • See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.) For maximum flow: • See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)

9. Connect pilot hose and hydraulic lines. DV53278,0000897 -19-16DEC14-1/1

TM13264X19 (02FEB17)

33-3360-18

300GLC Excavator 020217 PN=290

Hydraulic System

TM13264X19 (02FEB17)

33-3360-19

300GLC Excavator 020217 PN=291

Hydraulic System

TX1131447 —UN—19FEB13

Pump 1 and 2 Regulator Disassemble and Assemble

Pump 1 Regulator (front)

Continued on next page

TM13264X19 (02FEB17)

33-3360-20

TZ24494,0000EC7 -19-20MAR13-1/2

300GLC Excavator 020217 PN=292

Hydraulic System 1— Housing 2— Sleeve B 3— Spool B 5— Cylinder B 6— Load Piston 7— O-Ring 8— Backup Ring 9— O-Ring 10— Stop B 12— Stop (2 used)

14— O-Ring (3 used) 15— O-Ring (2 used) 16— Nut (2 used) 17— Nut (2 used) 20— Piston A 22— Cylinder A 24— Stop A 27— Sleeve A

28— Spool A 29— Set Screw 34— Nut 35— Cover 37— Cap Screw (8 used) 38— Cover 39— Pipe Plug 41— O-Ring 43— Cap Screw (4 used)

SPECIFICATIONS Pump 1 (front) and Pump 2 (rear) Cover-to-Housing Cap Screw Torque

47— Outer Compression Spring 48— Inner Compression Spring 49— Compression Spring

NOTE: Note direction of piston A, sleeve A, and spool A.

20 N·m 177 lb.-in.

11. Insert spool A into sleeve A and install into center of housing.

NOTE: Pump 1 (front) and pump 2 (rear) regulators are similar. Pump 1 (front) regulator is used in this procedure. 1. Remove pump 1 and 2 regulator. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.) IMPORTANT: Avoid possible housing damage. Some parts from housing port A are different from port B. Parts for each port must be kept together and installed into the same port from which they were removed. NOTE: Removal of stops (10, 12, and 24) and set screw (29) from covers (35 and 38) will require the adjustment of pump regulators. Only remove parts from covers if replacement is necessary. 2. Remove cap screws (37) and covers (35 and 38) with set screw (29) and stops (10, 12, and 24) attached. 3. Remove O-rings (15) and compression springs (47—49). NOTE: Note direction of sleeve B (2) and spool B (3). 4. Remove cylinder B (5), load piston (6), sleeve B (2), and spool B (3) from housing (1). 5. Remove load piston, O-rings (7 and 9), and backup ring (8) from cylinder B.

12. Install O-rings (14) and piston A into cylinder A. 13. Install cylinder A into housing. NOTE: Note direction of sleeve B and spool B. 14. Insert spool B into sleeve B and install into center of housing. 15. Install O-rings (7 and 9), backup ring, and load piston into cylinder B. 16. Install cylinder B into housing. 17. Install O-rings (15) and compression springs (47—49). 18. Install covers with set screw and stops attached. 19. Install cap screws (37) and tighten to specification. Specification Pump 1 (front) and Pump 2 (rear) Cover-to-Housing Cap Screw—Torque......................................................................20 N·m 177 lb.-in.

20. Install pump 1 and 2 regulator. See Pump 1 and 2 Regulator Remove and Install. (Group 3360.) IMPORTANT: Prevent possible pump 1 and 2 damage. Fill hydraulic pumps with oil before starting engine.

NOTE: Note direction of piston A (20), sleeve A (27), and spool A (28).

21. After installing regulator, perform pump 1 and pump 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)

6. Remove cylinder A (22), piston A (20), sleeve A (27), and spool A (28) from housing.

22. Operate machine and check for leaks. Check pump regulator for adjustments.

7. Remove piston A and O-rings (14) from cylinder.

For minimum flow: • See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)

8. Remove pipe plug (39) and O-ring (41). 9. Repair or replace parts as necessary.

For maximum flow: • See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)

10. Install pipe plug and O-ring (41). IMPORTANT: Avoid possible regulator damage. Apply clean hydraulic oil to parts prior to installation.

TZ24494,0000EC7 -19-20MAR13-2/2

TM13264X19 (02FEB17)

33-3360-21

300GLC Excavator 020217 PN=293

Hydraulic System

Pilot Pump Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Pump Drive Gear Case Capacity

1.1 L 1.2 qt.

OTHER MATERIAL

TX1168498A —UN—14AUG14

Loctite® 277™ Threadlocker (high strength)

4. Drain pump drive gear case. See Drain and Refill Pump Drive Gear Case Oil. (Operator's Manual.) Specification Pump Drive Gear Case—Capacity............................................................................... 1.1 L 1.2 qt.

5. Install identification tags and disconnect hydraulic lines (5) and hoses (1 and 3). Close all openings using caps and plugs. 6. Remove cap screws (2) and pilot pump (4). 7. Repair or replace parts as necessary. See Pilot Pump Disassemble and Assemble. (Group 3360.)

Pilot Pump 1— Pressure Hose 2— Cap Screw (2 used) 3— Suction Hose

4— Pilot Pump 5— Hydraulic Line (2 used)

8. Apply Loctite® 277™ Threadlocker (high strength) to mounting surface for pilot pump. 9. Install pilot pump and cap screws. 10. Connect hydraulic lines and hoses. 11. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) 12. Fill pump drive gear case. See Drain and Refill Pump Drive Gear Case Oil. (Operator's Manual.) IMPORTANT: Prevent possible pilot pump damage. Perform pump 1 and 2 start-up procedure before starting engine. 13. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 14. Operate machine and check for leaks. Verify pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

Loctite and its related brand marks are trademarks of Henkel Corporation DV53278,0000898 -19-16DEC14-1/1

TM13264X19 (02FEB17)

33-3360-22

300GLC Excavator 020217 PN=294

Hydraulic System

TM13264X19 (02FEB17)

33-3360-23

300GLC Excavator 020217 PN=295

Hydraulic System

TX1091469 —UN—02MAY11

Pilot Pump Disassemble and Assemble

Pilot Pump Components

Continued on next page

TM13264X19 (02FEB17)

33-3360-24

TZ24494,0000EC9 -19-20MAR13-1/2

300GLC Excavator 020217 PN=296

Hydraulic System 1— Housing 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) 13— Driven Gear 14— Drive Gear 15— Washer (4 used)

16— Cap Screw (4 used) 17— End Cover 26— Bushing (2 used) 27— Bushing (2 used)

SPECIFICATIONS Cover-to-Flange Cap Screw Torque

28— Pin (4 used)

IMPORTANT: Prevent possible pilot pump malfunction. Apply clean hydraulic oil to all parts during assembly.

37 N·m 27 lb·ft

1. Remove pilot pump. See Pilot Pump Remove and Install. (Group 3360.)

10. Install bushings and gears.

NOTE: Be careful not to lose keys (10).

11. Install seals (6) and backup retainers (9).

2. Remove cap screws (16), end cover (17), and O-ring (12). 3. Remove snap ring (5) and flange (2). 4. Remove O-ring (12) and oil seal (3) from flange. 5. Remove seals (6) and backup retainers (9). 6. Remove bushings (26 and 27) and gears (13 and 14). 7. Inspect bushings. If inside diameter and surface toward gear are rough or worn, replace pump. 8. Inspect gears and housing (1). If gear teeth, shaft, and inside of housing is rough or worn, replace pump.

12. Apply multipurpose grease to lip of oil seal (3). Install oil seal with lip (spring side) towards inside of housing. 13. Install O-ring to flange. 14. Install flange and snap ring. 15. Install O-ring, end cover, and cap screws. Tighten to specification. Specification Cover-to-Flange Cap Screw—Torque..............................................................................37 N·m 27 lb·ft

16. Install pilot pump. See Pilot Pump Remove and Install. (Group 3360.)

9. Clean and replace parts as necessary. TZ24494,0000EC9 -19-20MAR13-2/2

TM13264X19 (02FEB17)

33-3360-25

300GLC Excavator 020217 PN=297

Hydraulic System

Pilot Pressure Regulating Valve and Filter Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) TX1180987A —UN—16DEC14

CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

Pilot Pressure Regulating Valve and Filter 1— Cap Screw (2 used) 2— Pilot Pressure Regulating Valve and Filter Housing 3— Pilot-to-Pump 2 Regulator Hose

4— Return Hose 5— Pilot-to-Solenoid Valve Manifold Hose 6— Pressure Hose

8. Connect hoses. See Hydraulic System Line Connections. (Group 9025-15.)

4. Install identification tags and disconnect hoses (3—6). Close all openings using caps and plugs. See Hydraulic System Line Connections. (Group 9025-15.)

9. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

5. Remove cap screws (1) and pilot pressure regulating valve and filter housing (2).

10. Operate machine and check for leaks.

6. Repair or replace parts as necessary. See Pilot Pressure Regulating Valve and Filter Disassemble and Assemble. (Group 3360.)

11. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

7. Install pilot pressure regulating valve and filter housing. Install cap screws. DV53278,0000899 -19-16DEC14-1/1

TM13264X19 (02FEB17)

33-3360-26

300GLC Excavator 020217 PN=298

Hydraulic System

Pilot Pressure Regulating Valve and Filter Disassemble and Assemble

1 2

SPECIFICATIONS 25 N·m 221 lb·in

4 5 6

1. Remove pilot pressure regulating valve and filter. See Pilot Pressure Regulating Valve and Filter Remove and Install. (Group 3360.)

TX1003402 —UN—07FEB06

Plug-to-Housing Torque

2. Remove plug (6) and O-ring (5). 3. Remove spring (4), shim (3), and poppet (2). 4. Inspect and replace parts as necessary.

Pilot Pressure Regulating Valve Housing

5. Check that poppet slides smoothly in pilot pressure regulating valve housing (1). 6. Install poppet, shim, and spring. 7. Inspect O-ring for damage and replace if needed.

1— Pilot Pressure Regulating Valve Housing 2— Poppet 3— Shim (as required)

4— Spring 5— O-Ring 6— Plug

8. Install plug and O-ring. Tighten plug to specification. Specification Plug-to-Housing—Torque...................................................................................25 N·m 221 lb·in

9. Install pilot pressure regulating valve and filter. See Pilot Pressure Regulating Valve and Filter Remove and Install. (Group 3360.) TZ24494,0000ECB -19-20MAR13-1/1

TM13264X19 (02FEB17)

33-3360-27

300GLC Excavator 020217 PN=299

Hydraulic System

Pilot Shutoff Solenoid Valve Remove and Install SPECIFICATIONS 156 L 41 gal.

TX1092277A —UN—16MAY11

Hydraulic Oil Tank Capacity (approximate)

1. Turn upperstructure 90 degrees to tracks. 2. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing.

Access Panel

TX1113388A —UN—07MAY12

3. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 4. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

Pilot Shutoff Solenoid Valve

TX1003406A —UN—07FEB06

5. Remove cap screws (6) and access panel (7) on underside of cab. 6. Install identification tags and disconnect pilot shutoff solenoid (Y10). See Pilot Shutoff Valve Harness (W21) Component Location. (Group 9015-10.) 7. Install identifications tags and disconnect pilot lines (2). See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.) Close all openings using caps and plugs. 8. Lift up floor mat.

Cap Screws 1— Cap Screw (2 used) 2— Pilot Line (9 used) 3— Pilot Shutoff Solenoid Valve

9. Remove cap screws (1) and pilot shutoff solenoid valve (3).

Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

10. Repair or replace parts as necessary. See Pilot Shutoff Solenoid Valve Disassemble and Assemble. (Group 3360.)

CAUTION: Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine.

11. Install pilot shutoff solenoid valve and cap screws. 12. Connect pilot lines. 13. Connect pilot shutoff solenoid. 14. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See

6— Cap Screw (6 used) 7— Access Panel Y10— Pilot Shutoff Solenoid

15. Operate machine and check for leaks. Verify correct operation of pilot shutoff circuit. See Operational Checkout. (Group 9005-10.) 16. Install access panel and cap screws. DV53278,000089A -19-16DEC14-1/1

TM13264X19 (02FEB17)

33-3360-28

300GLC Excavator 020217 PN=300

Hydraulic System

Pilot Shutoff Solenoid Valve Disassemble and Assemble 1. Remove pilot shutoff solenoid valve. See Pilot Shutoff Solenoid Valve Remove and Install. (Group 3360.)

11 10 10 2

12 8 4

TX1092021 —UN—19MAY16

1 12 8 TX1092021 Continued on next page

TM13264X19 (02FEB17)

33-3360-29

TZ24494,0000ECD -19-20MAR13-1/2

300GLC Excavator 020217 PN=301

Hydraulic System

Pilot Shutoff Solenoid Valve 1— Spring 2— Plate 3— Pilot Shutoff Solenoid Valve

4— Spool 5— Screen 6— Solenoid 8— Plug (2 used)

9— Cap Screw (2 used) 10— Cap Screw (2 used)

6. Install spool, spring, O-rings (12), and plugs (8). Tighten plugs to specification.

SPECIFICATIONS Plug Torque

27 N·m 20 lb·ft

Solenoid-to-Pilot Shutoff Valve Cap Screw Torque

4 N·m 36 lb·in

11— O-Ring 12— O-Ring (2 used)

Specification Plug—Torque.................................................................................27 N·m 20 lb·ft

NOTE: Screen (5) cannot be removed.

7. Install O-ring (11) to solenoid.

2. Apply alignment marks on pilot shutoff solenoid valve (3) and solenoid (6) to aid in assembly.

8. Install solenoid and align marks made during disassembly. Install cap screws and tighten to specification.

3. Remove cap screws (9), solenoid, and O-ring (11). 4. Remove plugs (8), O-rings (12), spring (1), and spool (4). 5. Clean and inspect all parts. Replace worn or damaged parts as necessary. Use new O-rings when assembling. IMPORTANT: To prevent seizing, apply clean hydraulic oil to parts before assembling.

Specification Solenoid-to-Pilot Shutoff Valve Cap Screw—Torque................................................................................4 N·m 36 lb·in

9. Install pilot shutoff solenoid valve. See Pilot Shutoff Solenoid Valve Remove and Install. (Group 3360.) TZ24494,0000ECD -19-20MAR13-2/2

TM13264X19 (02FEB17)

33-3360-30

300GLC Excavator 020217 PN=302

Hydraulic System

Fan Drive Pump Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Fan Drive Pump Weight (approximate)

28 kg 62 lb.

TX1091434A —UN—06JUN11

2. Relieve hydraulic oil pressure. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

4. Install identification tags and disconnect return line (2) and supply pressure line (3). Close all openings using caps and plugs. CAUTION: Prevent possible crushing injury from heavy object. Use appropriate lifting device. 5. Attach appropriate lifting straps to fan pump.

1— Fan Pump 2— Return Line

3— Supply Pressure Line 4— Cap Screw (2 used)

7. Inspect and repair as necessary. 8. Install fan pump with new gasket and cap screws (4). 9. Connect supply pressure line and return line. 10. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 11. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)

Specification Fan Drive Pump—Weight (approximate).................................................................................. 28 kg 62 lb.

12. Operate machine and check for leaks.

6. Remove cap screws (4), fan pump (1), and gasket. DV53278,000089B -19-13JAN15-1/1

TM13264X19 (02FEB17)

33-3360-31

300GLC Excavator 020217 PN=303

Hydraulic System

Fan Drive Motor Remove and Install SPECIFICATIONS 43 kg 95 lb. TX1182436A —UN—13JAN15

Fan Drive Motor Weight (approximate)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove fan and fan guard. See Fan and Fan Guard Remove and Install. (Group 0510.) 3. Install identification tags and disconnect fan speed sensor (B5503), variable speed fan solenoid (Y5014), and reversing fan solenoid (Y5015).

Fan Motor

4. Remove cap screw (2). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting devices.

1— Cap Screw (2 used) 2— Cap Screw 3— Fan Drive Motor

B5503—Fan Speed Sensor Y5014—Variable Speed Fan Solenoid Y5015—Reversing Fan Solenoid

5. Using appropriate lifting device remove cap screws (1) and fan drive motor (3). Specification Fan Drive Motor—Weight (approximate).................................................................................. 43 kg 95 lb.

8. Install cap screw (2). 9. Connect fan speed sensor (B5503), variable speed fan solenoid (Y5014), and reversing fan solenoid (Y5015).

6. Inspect and repair as necessary.

10. Install fan and fan guard. See Fan and Fan Guard Remove and Install. (Group 0510.)

7. Using appropriate lifting device install fan drive motor and cap screws (1).

11. Operate machine and check for leaks. DV53278,000089C -19-16DEC14-1/1

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33-3360-32

300GLC Excavator 020217 PN=304

Hydraulic System

TX1186793 —UN—13MAR15

Fan Drive Motor Disassemble and Assemble

Fan Drive Motor Components 1— End Cap 2— Cartridge Assembly 3— Shaft Seal

4— Housing 5— Shaft and Bearing Assembly

6— Retaining Ring 7— Socket Head Cap Screw (4 used)

Continued on next page

TM13264X19 (02FEB17)

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MB00333,000025D -19-27APR15-1/3

300GLC Excavator 020217 PN=305

TX1186795 —UN—13MAR15

Hydraulic System

Fan Drive Motor Cartridge Components 8— Cam Ring 9— Rotor 10— Dowel Pin (2 used)

13— Pressure Port Plate 14— Seal

11— Vane (12 used) 12— Spring (24 used)

15— Seal

1. Remove socket head cap screws (7).

13. Install shaft seal.

2. Remove end cap (1).

14. Install shaft and bearing assembly.

3. Make a note of the location of dowel pins (10) as motor is disassembled. Dowel pins must be installed in correct location for motor to run properly.

15. Install retaining ring. 16. Install seal (15) on pressure port plate.

4. Install 10-24 UNC x 3 in. long cap screws in two threaded holes in cam ring (8) and slowly pull up on cap screws to remove cam ring and rotor (9) assembly.

17. Install seal (14) in housing.

5. Remove rotor from cam ring.

NOTE: Pressure port plate and cam ring must be installed so that dowel pins are in same location as previously noted.

6. Remove vanes (11) and springs (12) from rotor.

18. Install pressure port plate in housing.

7. Install 10-24 UNC x 3 in. long cap screws in two threaded holes in pressure port plate, and slowly pull pressure port plate straight out of housing (4).

19. Install dowel pin into pressure port plate. 20. Install vanes and springs in rotor.

8. Remove dowel pins (10).

21. Install rotor in cam ring.

9. Remove retaining ring (6).

22. Align cam ring and rotor assembly with dowel pin and install.

10. Remove shaft and bearing assembly (5).

23. Install dowel pin into cam ring.

11. Remove shaft seal (3).

24. Align end cap with dowel pin and install end cap.

12. Inspect, clean, and replace parts as necessary. IMPORTANT: Avoid possible fan drive motor damage from running motor dry. Apply clean hydraulic oil to parts prior to installation. Continued on next page

TM13264X19 (02FEB17)

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MB00333,000025D -19-27APR15-2/3

300GLC Excavator 020217 PN=306

Hydraulic System

25. Install socket head cap screws (7). Tighten to specification evenly and in proper sequence as shown. Specification End Cap (1) Cap Screw—Torque............................................................................100 N·m 74 lb.-ft. 7— Socket Head Cap Screw (4 used)

TX1187471 —UN—13MAR15

1— End Cap

Socket Head Cap Screw Tightening Sequence MB00333,000025D -19-27APR15-3/3

TM13264X19 (02FEB17)

33-3360-35

300GLC Excavator 020217 PN=307

Hydraulic System

Fan Drive Motor Solenoid Valves Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) TX1166949A —UN—25JUL14

4. Install identification tags and disconnect variable speed fan solenoid (Y5014) and reversing fan solenoid (Y5015) connectors.

Fan Drive Motor 1— Locking Nut (2 used) 2— O-Ring (2 used)

Y5014—Variable Speed Fan Solenoid Y5015—Reversing Fan Solenoid

9. Install O-rings onto variable speed fan solenoid and reversing fan solenoid. 10. Install variable speed fan solenoid and reversing fan solenoid. 11. Connect variable speed fan solenoid (Y5014) and reversing fan solenoid (Y5015) connectors.

6. Remove variable speed fan solenoid and O-ring (2).

12. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

7. Remove reversing fan solenoid and O-ring.

13. Operate machine and check for leaks.

5. Loosen locking nuts (1) on variable speed fan solenoid (Y5014) and reversing fan solenoid (Y5015).

8. Replace parts as necessary. DV53278,000089D -19-05JAN15-1/1

TM13264X19 (02FEB17)

33-3360-36

300GLC Excavator 020217 PN=308

Hydraulic System

Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves

SPECIFICATIONS Power Dig/Travel Speed Solenoid-to-Manifold Cap Screw Torque

6 N·m 53 lb·in

2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

TX1113681A —UN—17MAY12

NOTE: Power Dig/Travel Speed solenoid, arm regenerative solenoid, and dig regenerative solenoid are all removed and installed similarly. Power Dig/Travel Speed solenoid (marked SG) (Y24) is shown.

Power Dig/Travel Speed Solenoid 1— Electrical Connector

2— Cap Screw (2 used) Y24— Power Dig/Travel Speed Solenoid (marked SG)

3. Install identification tags and disconnect electrical connector (1) from power dig/travel speed solenoid (marked SG) (Y24). See Machine Harness (W2) Component Location. (Group 9015-10.) NOTE: If removing more than one solenoid, keep parts for each individual solenoid valve together.

NOTE: Be careful not to lose O-ring when removing solenoid. 4. Remove cap screws (2) and remove power dig/travel speed solenoid. Continued on next page

TM13264X19 (02FEB17)

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JL58967,0000175 -19-27JUL15-1/2

300GLC Excavator 020217 PN=309

Hydraulic System

5. Repair or replace parts as needed. See Solenoid Valve Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves. (Group 3360.)

7. Connect electrical connector. See Machine Harness (W2) Component Location. (Group 9015-10.) 8. Check pressure setting of solenoid valves:

NOTE: Inspect O-ring for damage. Replace if necessary.

• See Power Dig/Travel Speed Solenoid Valve Test

6. Install power dig/travel speed solenoid with O-ring. Install cap screws and tighten to specification.

• See Arm Regenerative Solenoid Valve Test and

Specification Power Dig/Travel Speed Solenoid-to-Manifold Cap Screw—Torque................................................................................6 N·m 53 lb·in

and Adjustment. (Group 9025-25.) Adjustment. (Group 9025-25.)

• See Dig Regenerative Solenoid Valve Test and Adjustment. (Group 9025-25.)

JL58967,0000175 -19-27JUL15-2/2

TM13264X19 (02FEB17)

33-3360-38

300GLC Excavator 020217 PN=310

Hydraulic System

Solenoid Valve Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves

1. Remove solenoid valve manifold.

NOTE: Do not loosen adjusting screw and lock nut (2) unless disassembling. If disassembled, pressure setting of proportional solenoid valve will need to be adjusted.

2. Remove solenoid valve (3) and O-ring (4). See Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves. (Group 3360.)

NOTE: O-rings (7—9) will be removed as an assembly with sleeve (6).

4. Remove O-rings (7—9) from sleeve.

5. Clean and inspect parts. Replace solenoid as necessary.

IMPORTANT: Avoid possible component damage. Apply clean hydraulic oil to components during assembly. 6. Install O-rings (7—9) on to sleeve. 7. Install spring washer, plate, sleeve, and spool into solenoid valve manifold. 8. Install solenoid valve and O-ring. See Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves. (Group 3360.)

TX1113657 —UN—10MAY12

3. Remove spool (5), sleeve (6), plate (10), and spring washer (11) from solenoid valve manifold.

11 Solenoid Valve 1— Screw (2 used) 2— Adjusting Screw and Lock Nut 3— Solenoid Valve 4— O-Ring 5— Spool 6— Sleeve

7— O-Ring 8— O-Ring 9— O-Ring 10— Plate 11— Spring Washer

9. Install solenoid valve manifold.

• See Arm Regenerative Solenoid Valve Test and

10. Check pressure setting of solenoid valves:

• See Dig Regenerative Solenoid Valve Test and

Adjustment. (Group 9025-25.)

• See Power Dig/Travel Speed Solenoid Valve Test

Adjustment. (Group 9025-25.)

and Adjustment. (Group 9025-25.)

RH60123,0001E80 -19-30SEP14-1/1

TM13264X19 (02FEB17)

33-3360-39

300GLC Excavator 020217 PN=311

Hydraulic System

Pilot Valve (Left and Right) Remove and Install 20 N·m 177 lb·in

Lock Nut Torque

55 N·m 41 lb·ft

TX1096358A —UN—19AUG11

SPECIFICATIONS Cap Screw Torque

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) NOTE: Right and left pilot valves are identical. Remove and install procedure is the same.

Pilot Valve 1— Boot 2— Lock Nut (2 used) 3— Shaft 4— Cap Screw (4 used)

5— Boot 6— Pilot Valve S5— Horn Switch

5. Loosen lock nuts (2) and remove lever from threaded shaft (3). 6. Remove cap screws (4) and remove boot (5).

3. Raise boot (1) and remove tie bands on horn switch (S5). 4. Install identification tags and disconnect horn switch (S5). See Cab Harness (W1) Component Location. (Group 9015-10.) Continued on next page

TM13264X19 (02FEB17)

33-3360-40

JL58967,000078C -19-02FEB17-1/2

300GLC Excavator 020217 PN=312

Hydraulic System

TX1096360A —UN—19AUG11

7. Install identification tags and disconnect pilot valve hydraulic hoses (7). Close all openings using caps and plugs. Remove pilot valve (6). See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.) 8. Repair or replace parts as necessary. See Pilot Valve (Left and Right) Disassemble and Assemble. (Group 3360.) 9. Connect pilot valve hydraulic hoses. See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern or see Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.)

Pilot Valve Hoses 6— Pilot Valve

10. Install pilot valve and boot (5).

7— Pilot Valve Hydraulic Hose (6 used)

11. Install cap screws and tighten to specification. Specification Cap Screw—Torque......................................................................20 N·m 177 lb·in

14. Slide boot (1) in to place. CAUTION: Prevent possible injury from unexpected machine movement. Clear all personnel from area before operating machine.

12. Install lever by threading onto shaft and tighten lock nuts to specification. Specification Lock Nut—Torque..........................................................................55 N·m 41 lb·ft

15. Operate machine and check for leaks. Verify all pilot control functions operate correctly. See Operational Checkout. (Group 9005-10.)

13. Connect horn switch and install tie bands. See Cab Harness (W1) Component Location. (Group 9015-10.) JL58967,000078C -19-02FEB17-2/2

TM13264X19 (02FEB17)

33-3360-41

300GLC Excavator 020217 PN=313

Hydraulic System

Pilot Valve (Left and Right) Disassemble and Assemble SPECIFICATIONS Plug Torque

20 N·m 177 lb·in

Universal Joint Torque

25 N·m 221 lb·in

Cam-to-Pushers Clearance

0—0.2 mm 0—0.008 in

Coupling-to-Cam and Universal Joint Torque

70 N·m 52 lb·ft

ESSENTIAL TOOLS ST4145 Spool Holder ST4146 Spring Compressor ST4144 Snap Ring Holder OTHER MATERIAL TY6341 Multipurpose SD Polyurea Grease Loctite® 271™ Threadlocker (high strength)

Continued on next page

TM13264X19 (02FEB17)

33-3360-42

JL58967,0000177 -19-04AUG14-1/7

300GLC Excavator 020217 PN=314

TX1096302 —UN—18AUG11

Hydraulic System

Pilot Control Valve

Continued on next page

TM13264X19 (02FEB17)

33-3360-43

JL58967,0000177 -19-04AUG14-2/7

300GLC Excavator 020217 PN=315

Hydraulic System 1— Housing 2— Coupling 3— Cam 4— Universal Joint 5— Plate 6— O-Ring (4 used) 7— Sleeve (4 used) 8— Oil Seal (4 used)

9— Pusher (2 used) 10— Pusher (2 used) 11— Snap Ring (4 used) 12— Spring Guide (4 used) 13— Return Spring (2 used)

14— Return Spring (2 used) 15— Balance Spring (2 used) 16— Balance Spring (2 used) 17— Shim (4 used) 18— Spacer (4 used)

1. Remove pilot valve (left and right). See Pilot Valve (Left and Right) Remove and Install. (Group 3360.)

19— Spool (4 used) 20— O-Ring 21— Plug 22— Snap Ring 23— Plug

5. Remove O-rings (6) from sleeves. IMPORTANT: Avoid possible housing damage. Some parts from housing ports 1 and 3 are different than parts from housing ports 2 and 4. Parts for each port must be kept together and installed into the same port from which they were removed. Port numbers are stamped on the housing.

2. Remove cam (3) from universal joint (4). NOTE: Do not remove universal joint (4) unless worn or damaged. 3. Remove universal joint if replacement is needed. IMPORTANT: Avoid possible component damage. Do not attempt to remove oil seals (8) from sleeves (7).

6. Remove pushers (9 and 10) and install identification tags.

4. Remove sleeves (7) and O-rings (6). Loctite and its related brand marks are trademarks of Henkel Corporation JL58967,0000177 -19-04AUG14-3/7

IMPORTANT: Avoid possible component damage. Do not lower spool (19) when compressing return springs (13 and 14).

25 7. Install ST4145 Spool Holder (24) into the port hole on housing.

8. Install ST4146 Spring Compressor (25) into the pusher hole on housing.

TX1096325 —UN—24AUG11

9. Push tool to compress return springs and tighten tool by using an M14 x 2.0 mm pitch cap screw. 10. Remove snap rings (11) from spools. 11. Remove ST4146 Spring Compressor. 12. Remove spring guides (12), return springs (13 and 14), and balance springs (15 and 16) from spools and install identification tags. IMPORTANT: Avoid possible spool damage. Keep shims (17) in order during removal. Quantity of shims has been determined for each port during the performance testing.

24 Spring Removal Tools 1— Housing 24— ST4145 Spool Holder

25— ST4146 Spring Compressor

13. Remove shims (17) and spacers (18). 19. Remove plug (23).

14. Remove spool holder.

16. Remove snap ring (22).

NOTE: Spools have been selected to match the holes of housing. Spools and housing must be replaced as an assembly.

17. Install an M8 x 1.25 mm pitch cap screw to plug (21) to remove from housing.

20. Clean and inspect parts. Repair or replace as necessary.

15. Remove spools (19).

18. Remove O-ring (20) from plug. Continued on next page

TM13264X19 (02FEB17)

33-3360-44

JL58967,0000177 -19-04AUG14-4/7

300GLC Excavator 020217 PN=316

TX1096302 —UN—18AUG11

Hydraulic System

Pilot Control Valve

Continued on next page

TM13264X19 (02FEB17)

33-3360-45

JL58967,0000177 -19-04AUG14-5/7

300GLC Excavator 020217 PN=317

Hydraulic System 1— Housing 2— Coupling 3— Cam 4— Universal Joint 5— Plate 6— O-Ring (4 used) 7— Sleeve (4 used) 8— Oil Seal (4 used)

9— Pusher (2 used) 10— Pusher (2 used) 11— Snap Ring (4 used) 12— Spring Guide (4 used) 13— Return Spring (2 used)

IMPORTANT: Avoid possible valve damage. Apply clean hydraulic oil to parts prior to installation. 21. Install plug (23) and tighten to specification. Specification Plug—Torque.................................................................................20 N·m 177 lb·in

14— Return Spring (2 used) 15— Balance Spring (2 used) 16— Balance Spring (2 used) 17— Shim (4 used) 18— Spacer (4 used)

19— Spool (4 used) 20— O-Ring 21— Plug 22— Snap Ring 23— Plug

23. Install plug (21) and snap ring (22). IMPORTANT: Avoid possible component damage. Components are select fit to bores. Install components in the same bore that they were removed from otherwise leaks will occur. 24. Install spools to their correct port holes in housing.

22. Install O-ring (20) onto plug (21). JL58967,0000177 -19-04AUG14-6/7

25. Install ST4145 Spool Holder to the port hole on housing. 26. Install shims and spacers to spools using same amount of shims as disassembly.

IMPORTANT: Avoid possible component damage. Ports 1 and 3 use short balance springs. Ports 2 and 4 use long balance springs.

TX1096325 —UN—24AUG11

27. Install balance springs to spools. IMPORTANT: Avoid possible component damage. Ports 1 and 3 use short return springs. Ports 2 and 4 use long return springs. 28. Install return springs to spools.

29. Install ST4146 Spring Compressor into pusher holes in housing. Tighten spring compressor with M14 x 2.00 mm pitch cap screw. 30. Install spring guides with protrusion facing upward.

Spring Removal Tools 1— Housing 24— ST4145 Spool Holder

25— ST4146 Spring Compressor JL58967,0000177 -19-04AUG14-7/7

TM13264X19 (02FEB17)

33-3360-46

300GLC Excavator 020217 PN=318

Hydraulic System

31. Install snap rings (11) to ST4144 Snap Ring Holder (26). 32. Install snap rings (11) into groove on head of spools remaining out of spring compressor.

25 26

IMPORTANT: Avoid possible component damage. Ports 1 and 3 use pushers with one outer groove. Ports 2 and 4 use pushers with two outer grooves.

TX1096326 —UN—24AUG11

33. Install pushers into housing by hand. 34. Verify snap rings (11) and balance springs are installed correctly. 35. Install pushers to housing.

36. Apply TY6341 Multipurpose SD Polyurea Grease to ball at ends of pushers. 37. Apply TY6341 Multipurpose SD Polyurea Grease to joint of universal joint and to inner surface of sleeve seals.

Snap Ring Installation Tool 1— Housing 24— ST4145 Spool Holder

38. Apply TY6341 Multipurpose SD Polyurea Grease to inner surface of oil seals. 39. Install O-rings (6) and sleeves. 40. Apply Loctite® 271™ Threadlocker (high strength) to the threads of universal joint. 41. Secure plate by aligning cap screw holes in plate with cap screw holes in housing and install universal joint. Tighten universal joint to specification.

25— ST4146 Spring Compressor 26— ST4144 Snap Ring Holder

Specification Cam-to-Pusher—Clearance.........................................................................................0—0.2 mm 0—0.008 in

43. Hold cam and tighten coupling to specification.

Specification Universal Joint—Torque................................................................25 N·m 221 lb·in

Specification Coupling-to-Cam and Universal Joint—Torque................................................................70 N·m 52 lb·ft

42. Install cam onto universal joint. Check clearance between cam and pushers.

44. Install pilot valve (left and right). See Pilot Valve (Left and Right) Remove and Install. (Group 3360.)

Loctite and its related brand marks are trademarks of Henkel Corporation JL58967,0000177 -19-04AUG14-8/7

TM13264X19 (02FEB17)

33-3360-47

300GLC Excavator 020217 PN=319

Hydraulic System

Travel Pilot Valve Remove and Install 1. Turn upperstructure 90 degrees to tracks.

TX1092277A —UN—16MAY11

2. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 3. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

Access Panel 6— Cap Screw (6 used)

7— Access Panel

4. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) 5. Remove cap screws (6) and access panel (7) from underside of cab. JL58967,0000179 -19-05JAN15-1/3

6. Install identification tags and disconnect pilot lines (8). Close all openings using caps and plugs. See Travel Hydraulic System Line Connection. (Group 9025-15.)

3— Travel Pilot Valve

TX1113835A —UN—16MAY12

7. Remove floor mat from cab. 8— Pilot Line (6 used)

Travel Pilot Valve (bottom view) Continued on next page

TM13264X19 (02FEB17)

33-3360-48

JL58967,0000179 -19-05JAN15-2/3

300GLC Excavator 020217 PN=320

Hydraulic System

8. Remove cap screws (1), pedals (4), and levers (5). 9. Remove cap screws (2) and travel pilot valve (3).

TX1091034A —UN—10JUN11

10. Repair or replace parts as necessary. See Travel Pilot Valve Disassemble and Assemble. (Group 3360.) 11. Install travel pilot valve and cap screws (2). 12. Install levers, pedals, and cap screws (1). 13. Connect pilot lines. See Travel Hydraulic System Line Connection. (Group 9025-15.) 14. Install access panel and cap screws (6). Travel Pilot Valve

15. Install floor mat in cab. 16. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) CAUTION: Prevent possible injury from unexpected machine movement. Clear all personnel from area before operating machine.

1— Cap Screw (4 used) 2— Cap Screw (2 used) 3— Travel Pilot Valve

4— Pedal (2 used) 5— Lever (2 used)

17. Operate machine and check for leaks. Verify all travel functions for correct operation. See Operational Checkout. (Group 9005-10.) JL58967,0000179 -19-05JAN15-3/3

TM13264X19 (02FEB17)

33-3360-49

300GLC Excavator 020217 PN=321

Hydraulic System

Travel Pilot Valve Disassemble and Assemble 1

35 35

26 3

32 5 29

6 7 10 29

28 27 6 26

5 4

25 31 30

24 23 22 21 20

18 17

36 15

TX1131400

TX1131400 —UN—19FEB13

Travel Pilot Valve Components

Continued on next page

TM13264X19 (02FEB17)

33-3360-50

TZ24494,0000ED7 -19-20MAR13-1/3

300GLC Excavator 020217 PN=322

Hydraulic System 1— Cap Screw (2 used) 2— Cover 3— Pin (2 used) 4— O-Ring (2 used) 5— O-Ring (2 used) 6— Damper (2 used) 7— Rubber Seat (2 used) 8— Cap Screw (2 used) 9— Lock Washer (2 used) 10— Holder

11— Oil Seal (4 used) 12— O-Ring (4 used) 13— Bushing (4 used) 14— Casing 15— O-Ring (2 used) 16— Plug (2 used) 17— Plug (2 used) 18— O-Ring (2 used) 19— Spool (4 used) 20— Spring (4 used)

21— Spacer (4 used) 22— Shim (12 used) 23— Balance Spring (4 used) 24— Spring Guide (16 used) 25— Pusher (4 used) 26— Bracket (2 used) 27— Spring Pin (2 used) 28— Cap Screw (4 used) 29— Lock Washer (4 used)

SPECIFICATIONS Damper-to-Holder Cap Screw Torque

7 N·m 62 lb·in

Plug (small) Torque

10 N·m 89 lb·in

Plug (large) Torque

20 N·m 177 lb·in

Holder-to-Casing Cap Screw Torque

50 N·m 37 lb·ft

Cover-to-Holder Cap Screw Torque

5 N·m 44 lb·in

30— Spring Pin (2 used) 31— Spring Pin (2 used) 32— Bushing (4 used) 33— Cam (2 used) 34— Spring Pin (2 used) 35— Spring Pin (2 used) 36— Filter

NOTE: Spring pins (27) should only be removed if necessary. NOTE: Spring pins (30 and 31) are stepped and can only be removed from one direction. Marks should be installed on brackets to show installation direction of spring pins. 12. Remove spring pins and brackets. 13. Remove cap screws (28) and lock washers (29).

1. Remove travel pilot valve. See Travel Pilot Valve Remove and Install. (Group 3360.)

14. Remove rubber seats (7), dampers (6), and O-rings (4) from pins (3).

NOTE: The casing (14) and spools (19) are replaced as an assembly because the spools are select-fitted to bores in housing.

NOTE: Spring pins (34 and 35) are stepped and can only be removed from one direction. 15. Remove spring pins from cams (33) and pins.

Note port location and quantity of shims (22) when removing. Same number of shims must be used when installing.

16. Remove pins and cams. 17. Remove O-rings (5).

2. Remove cover (2) and cap screws (1). Remember to keep parts removed from each port together. Identify each group of parts by port numbers stamped on casing.

18. Remove bushings (32) only if necessary. 19. Remove filter (36). 20. Repair or replace parts as necessary.

3. Remove cap screws (8), lock washers (9), and holder (10) from casing (14). 4. Remove pushers (25) as assemblies from casing.

IMPORTANT: To prevent seizing, apply clean hydraulic oil to parts before assembling. 21. Install filter.

5. Remove pushers, oil seals (11), and O-rings (12) from bushings (13).

NOTE: Bushings must be flush with hole end in holder.

NOTE: Note port location of spools (19) when removing. Spool must be installed in same port.

22. Install bushings if removed.

6. Remove spools (19), spring guides (24), balance springs (23), shims (22), and spacers (21) from casing by rotating. 7. Record number of shims removed. 8. Compress balance spring and remove spring guide, balance spring, shims, and spacer from spool. 9. Remove springs (20). 10. Remove O-ring (15) and plug (16).

23. Apply multipurpose grease to O-rings (5) and install on pins (3). NOTE: Note direction of insertion for spring pins (34 and 35). 24. Assemble cams (33) in holder (10) with spring pins and pins. Install spring pins with slits 90° apart. 25. Lock spring pins in position by displacing the bore above spring pin using a punch and hammer. 26. Install rubber seats (7) and dampers (6) on pins with lever facing upward.

11. Remove O-ring (18) and plug (17). IMPORTANT: Avoid pin (3) damage. Place a stand under bracket (26) for support.

Continued on next page

TM13264X19 (02FEB17)

33-3360-51

TZ24494,0000ED7 -19-20MAR13-2/3

300GLC Excavator 020217 PN=323

Hydraulic System

27. Install cap screws (28) and lock washers (29). Tighten to specification. Specification Damper-to-Holder Cap Screw—Torque................................................................................7 N·m 62 lb·in

28. Apply multipurpose grease to O-rings (4) and install on pins.

34. Using the same number of shims (22) as removed, install spacers (21), shims, and balance springs (23) onto spool. 35. Compress balance springs and install spring guides (24) with stepped end facing down. NOTE: Note port location of spools when installing. Spool must be installed in same port. 36. Install spools, spring guides, balance springs, shims, and spacers into casing by rotating.

NOTE: Note direction of insertion for spring pins (30 and 31). Spring pins must be positioned with slits 90° apart.

37. Install oil seals (11), O-rings (12), and pushers (25) to bushings (13).

IMPORTANT: Avoid pin damage. Place a stand under bracket (26) for support.

38. Apply multipurpose grease to end of each pusher and oil seals.

29. Align brackets with marks made during disassembly and install with spring pins.

39. Install pusher assemblies into casing.

30. Lock spring pins in position by slightly displacing the bore above spring pin using a punch and hammer.

40. Install holder (10) to casing (14) with cap screws (8) and lock washers (9). Tighten to specification.

31. Install O-ring (18) and plug (17). Tighten plug to specification.

Specification Holder-to-Casing Cap Screw—Torque..............................................................................50 N·m 37 lb·ft

Specification Plug (small)—Torque.....................................................................10 N·m 89 lb·in

41. Install cover (2) and cap screws (1). Tighten to specification.

32. Install O-ring (15) and plug (16). Tighten plug to specification. Specification Plug (large)—Torque.....................................................................20 N·m 177 lb·in

33. Install springs (20).

Specification Cover-to-Holder Cap Screw—Torque................................................................................5 N·m 44 lb·in

42. Apply multipurpose grease to spring pins (27). 43. Install travel pilot valve. See Travel Pilot Valve Remove and Install. (Group 3360.) TZ24494,0000ED7 -19-20MAR13-3/3

TM13264X19 (02FEB17)

33-3360-52

300GLC Excavator 020217 PN=324

Hydraulic System

Pilot Signal Manifold Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1131796A —UN—25FEB13

Pilot Signal Manifold

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

1— Pilot Signal Manifold 2— Pilot Line (34 used) 3— Cap Screw (4 used) 4— Bracket

B33— Swing Pressure Sensor B34— Travel Pressure Sensor B60— Attachment Pressure Sensor

• See Pilot Control Valve-to-Pilot Signal Manifold

4. Install identification tags and disconnect swing pressure sensor (B33) and travel pressure sensor (B34). See Machine Harness (W2) Component Location. (Group 9015-10.)

Component Location—Backhoe Pattern. (Group 9025-15.) • See Pilot Signal Manifold-to-Control Valve Line Connection. (Group 9025-15.)

5. Install identification tags and disconnect attachment pressure sensor (B60). See Attachment Harness (W17) Component Location. (Group 9015-10.) 6. Install identification tags and disconnect pilot lines (2). Close all openings using caps and plugs.

• See Pilot Control Valve-to-Pilot Signal Manifold

Component Location—Excavator Pattern. (Group 9025-15.) • See Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern. (Group 9025-15.) • See Pilot Signal Manifold-to-Control Valve Line Connection. (Group 9025-15.)

11. Connect swing pressure sensor and travel pressure sensor. See Machine Harness (W2) Component Location. (Group 9015-10.) 12. Connect attachment pressure sensor. See Attachment Harness (W17) Component Location. (Group 9015-10.) 13. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

7. Remove cap screws (3) and pilot signal manifold (1). 8. Repair or replace parts as necessary. See Pilot Signal Manifold Disassemble and Assemble. (Group 3360.) 9. Position pilot signal manifold on bracket (4) and install cap screws.

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. 14. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) CAUTION: Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine.

10. Connect pilot lines.

• See Pilot Control Valve-to-Pilot Signal Manifold

Component Location—Excavator Pattern. (Group 9025-15.) Continued on next page

TM13264X19 (02FEB17)

33-3360-53

DV53278,000089E -19-16DEC14-1/2

300GLC Excavator 020217 PN=325

Hydraulic System 15. Operate machine and check for leaks. Verify all pilot control functions operate correctly. See Operational Checkout. (Group 9005-10.) DV53278,000089E -19-16DEC14-2/2

TM13264X19 (02FEB17)

33-3360-54

300GLC Excavator 020217 PN=326

Hydraulic System

Pilot Signal Manifold Disassemble and Assemble 14

21 15

16 17 13

19 20

11 6

18 19 16

4 20

17 3 2

C B

25 26

19 27

16 15 20

14 17

28 19 17 16 T143485

T143485 —UN—17JUL01

Pilot Signal Manifold (1 of 2) Continued on next page

TM13264X19 (02FEB17)

33-3360-55

JB42225,000004D -19-23JUL14-1/3

300GLC Excavator 020217 PN=327

Hydraulic System

31 32 31

C T143486

T143486 —UN—17JUL01

Pilot Signal Manifold (2 of 2)

Continued on next page

TM13264X19 (02FEB17)

33-3360-56

JB42225,000004D -19-23JUL14-2/3

300GLC Excavator 020217 PN=328

Hydraulic System 1— Cap Screw (10 used) 2— Body 3— Gasket 4— Body 5— Gasket 6— Body 7— Gasket 8— Body 9— Gasket 10— Body 11— Name Plate

12— Screw (4 used) 13— Plate 14— Cap Screw (11 used) 15— Plug (7 used) 16— O-Ring (7 used) 17— Spring (4 used) 18— Spring

1. Remove cap screws (14) and plates (13, 21, and 29) as needed.

19— Spring Seat (7 used) 20— Spool (6 used) 21— Plate 22— O-Ring 23— Valve 24— O-Ring 25— Spring 26— Spool 27— Spring

28— Spring 29— Plate 30— Filter (17 used) 31— Shuttle Valve (21 used) 32— Spring (4 used)

4. Clean, inspect, and replace parts as necessary. 5. Assemble components (2—10) and tighten cap screws (1).

IMPORTANT: To prevent manifold damage, parts from each port must be kept together and installed into same port from which it was removed.

NOTE: Apply clean hydraulic oil to spools before installing.

2. Remove parts (15—20 and 22—28) as needed.

6. Install parts (15—20 and 22—28).

NOTE: Note order of body (2, 4, 6, 8, and 10) and gaskets (3, 5, 7, and 9) for assembly.

7. Install plates and cap screws.

3. Remove cap screws (1) and separate components (2—10) as needed. JB42225,000004D -19-23JUL14-3/3

TM13264X19 (02FEB17)

33-3360-57

300GLC Excavator 020217 PN=329

Hydraulic System

Control Valve Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Control Valve Weight (approximate)

218 kg 481 lb.

Mounting Bracket-to-Control Valve 270 N·m 200 lb.-ft. Cap Screw Torque 140 N·m 103 lb.-ft.

TX1124553A —UN—25OCT12

Pilot Signal Manifold Mounting Bracket-to-Control Valve Cap Screw Torque

Control Valve

2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) Disconnect negative (-) battery cable.

1— Control Valve 2— Hydraulic Hose (52 used) 3— Solenoid Valve Manifold

4— Pilot Signal Manifold 5— Bracket 6— Cap Screw (3 used)

CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 3. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 4. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

NOTE: It is not necessary to disconnect hydraulic hoses from pilot signal manifold. 5. Remove cap screws (6) and secure pilot signal manifold (4) and bracket (5) aside. 6. Install identification tags and disconnect hydraulic hoses (2) from control valve. Close all openings using caps and plugs. See Control Valve Line Identification. (Group 9025-15.) Continued on next page

TM13264X19 (02FEB17)

33-3360-58

DV53278,000089F -19-16DEC14-1/5

300GLC Excavator 020217 PN=330

Hydraulic System

7. Install identification tags and disconnect boom up pressure sensor (B30) and arm in pressure sensor (B31). See Machine Harness (W2) Component Location. (Group 9015-10.) B31— Arm In Pressure Sensor

TX1124590 —UN—25OCT12

B30— Boom Up Pressure Sensor

Pressure Sensors DV53278,000089F -19-16DEC14-2/5

8. Install identification tags and disconnect solenoids (Y22—Y24). See Machine Harness (W2) Component Location. (Group 9015-10.) Y23— Arm Regenerative Solenoid (marked SC) Y24— Power Dig/Travel Speed Solenoid (marked SG)

TX1124617A —UN—25OCT12

3— Solenoid Valve Manifold Y22— Dig Regenerative Solenoid (marked SF)

Solenoid Valve Manifold Continued on next page

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300GLC Excavator 020217 PN=331

Hydraulic System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 9. Install M10 eyebolts (14) and attach appropriate lifting device to support control valve (1). Specification Control Valve—Weight (approximate)................................................................................ 218 kg 481 lb. 14— M10 Eyebolt (2 used)

TX1124644A —UN—25OCT12

1— Control Valve

M10 Eyebolts Continued on next page

TM13264X19 (02FEB17)

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Hydraulic System

10. Remove cap screws (11) and remove control valve. 11. Repair or replace parts as needed. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.) 12. Install control valve and cap screws (11). Tighten cap screws to specification. TX1097297A —UN—07SEP11

Specification Mounting Bracket-toControl Valve Cap Screw—Torque............................................................................270 N·m 200 lb.-ft.

13. Connect solenoids (Y22—Y24). See Machine Harness (W2) Component Location. (Group 9015-10.) 14. Connect sensors (B30 and B31). See Machine Harness (W2) Component Location. (Group 9015-10.) 15. Connect hydraulic hoses to control valve. See Control Valve Line Identification. (Group 9025-15.)

Mount 1— Control Valve 11— Cap Screw (4 used)

12— Mount

16. Install pilot signal manifold and bracket. Install cap screws (6) and tighten to specification. Specification Pilot Signal Manifold Mounting Bracketto-Control Valve Cap Screw—Torque............................................................................140 N·m 103 lb.-ft.

17. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

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. 19. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) CAUTION: Prevent possible injury from unexpected machine movement. Clear all personnel from area before operating machine. 20. Operate machine and check for leaks. Verify all machine functions operate correctly. See Operational Checkout. (Group 9005-10.)

18. Connect negative (-) battery cable. Turn battery disconnect switch to ON position. See Battery Disconnect Switch. (Operator’s Manual.) DV53278,000089F -19-16DEC14-5/5

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33-3360-61

300GLC Excavator 020217 PN=333

Hydraulic System

Control Valve Halves Disassemble and Assemble SPECIFICATIONS Control Valve Cap Screw Torque

210 N·m 155 lb·ft

3 3

14 13

13 13

14 13

13 11 13 14

13 14 14 14

TX1124954 —UN—10MAR15

TX1124954 Control Valve Halves Continued on next page

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=334

Hydraulic System 1— Control Valve (5-spool side) 2— Control Valve (4-spool side)

3— Cap Screw (9 used) 11— O-Ring (3 used)

1. Remove control valve. See Control Valve Remove and Install. (Group 3360.)

13— O-Ring (16 used) 14— O-Ring (12 used)

NOTE: Control valve halves are notched and can only be assembled one way.

2. Place control valve on a clean, flat surface. 3. Remove cap screws (3) and control valve (5-spool side) (1) from control valve (4-spool side) (2). 4. Remove O-rings (11, 13, 14). 5. Inspect and replace parts as needed. See Control Valve (5-Spool) Disassemble and Assemble and see Control Valve (4-Spool) Disassemble and Assemble. (Group 3360.)

7. Install control valve halves together and install cap screws. Tighten to specification. Specification Control Valve Cap Screw—Torque............................................................................210 N·m 155 lb·ft

8. Install control valve. See Control Valve Remove and Install. (Group 3360.)

6. Apply clean hydraulic oil to O-rings and install to control valve. JB42225,0000051 -19-13JUL15-2/2

TM13264X19 (02FEB17)

33-3360-63

300GLC Excavator 020217 PN=335

Hydraulic System

Control Valve (5-Spool) Disassemble and Assemble SPECIFICATIONS Arm Circuit Relief and Anticavitation Valve Torque

85 N·m 63 lb·ft

Main Relief and Power Digging Valve Torque

60 N·m 44 lb·ft

Pilot Cap Screw Torque

42 N·m 31 lb·ft

Cap Screw Torque

62 N·m 46 lb·ft

Continued on next page

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=336

TX1004777 —UN—26APR06

Hydraulic System

Control Valve End Caps (5-spool side)

Continued on next page

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300GLC Excavator 020217 PN=337

Hydraulic System

56 56

104 58

20 60 61

121

62 63

20 H

C 99 A

85 J 10 9

98 52

51 K D

116

E F

86 J

10 9

98 51

TX1124829 —UN—29OCT12

100

117

123

118

115 6

6 93 96

G 13

119

61 62

65 75

120

65 66

114

104

122

TX1124829 5-Spool (bottom side)

Continued on next page

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300GLC Excavator 020217 PN=338

Hydraulic System 1— Housing 41— Left Travel Spool 2— O-Ring 42— Spring Seat (10 used) 3— Plug 43— Spring (5 used) 4— Poppet 44— Spool Cap Screw (5 used) 5— Spring 45— Auxiliary Spool 6— O-Ring (3 used) 46— Boom 2 Spool 7— Flange 47— Arm 1 Spool 8— Cap Screw (22 used) 48— Spring Seat (2 used) 9— O-Ring (4 used) 49— Spring 10— Plug (4 used) 50— Swing Spool 11— Poppet 51— O-Ring (10 used) 12— Spring (2 used) 52— Pilot Cap Screw (16 used) 13— O-Ring (5 used) 53— O-Ring 14— O-Ring 54— Plug 15— Backup Ring 55— Top Pilot Cap 16— Plug 56— Plug (2 used) 17— Main Relief and Power 57— O-Ring (2 used) Digging Valve 58— Cap Screw (8 used) 18— O-Ring 59— Arm 1 Flow Rate Spool 19— Arm Out Circuit Relief and 60— Spring Anticavitation Valve (2 used) 61— Spring Seat (2 used) 20— O-Ring (11 used) 62— O-Ring (2 used) 21— O-Ring 63— Plug (2 used) 22— Spring 64— Sleeve (2 used) 23— Seat 65— Spring (2 used) 24— Poppet 66— Plug 25— Backup Ring 67— Spring 26— O-Ring 68— Poppet 27— O-Ring 69— Poppet 28— Backup Ring 70— Plug 29— Sleeve 71— O-Ring 30— Spool 72— Flange 31— O-Ring 73— Spring 32— Body 74— Poppet 33— Spring 34— Piston 35— O-Ring 36— Plug 37— Poppet 38— Spring 39— O-Ring 40— Spacer

75— Flange (2 used) 76— Poppet (2 used) 77— Auxiliary Flow Rate Spool 78— Spring 79— Plug 80— Spring 81— Poppet 82— Poppet 83— Poppet 84— Cover (2 used) 85— O-Ring (2 used) 86— Poppet 87— Plug 88— O-Ring 89— Spring 90— Poppet 91— Cap Screw (4 used) 92— Cap (2 used) 93— Spring Seat (2 used) 94— Spring 95— Auxiliary Flow Combiner Spool 96— Spring 97— Dig Regenerative Spool 98— Bottom Pilot Cap (4 used) 99— Arm In Circuit Relief and Anticavitation Valve 100— O-Ring 104— Body (2 used) 105— Main Relief Valve Isolation Check Valve 106— Check Valve (lift check) Left Travel Neutral Passage

107— Arm Reduced Leakage Valve 108— Left Travel Spool Assembly 109— Auxiliary Spool Assembly 110— Boom 2 Spool Assembly 111— Arm 1 Spool Assembly 112— Swing Spool Assembly 113— Check Valve 114— Auxiliary Flow Rate Control Valve 115— Auxiliary Flow Combiner Valve Check Valve 116— Load Check Valve (left travel parallel circuit) 117— Dig Regenerative Check Valve 118— Auxiliary Flow Combiner Valve 119— Dig Regenerative Valve 120— Arm Reduced Leakage Valve 121— Lift Check (boom 2 power passage) 122— Arm 1 Flow Rate Control Valve 123— Lift Check (swing neutral passage)

1. Remove control valve. See Control Valve Remove and Install. (Group 3360.)

7. Inspect parts and replace as needed.

2. Separate control valve halves. See Control Valve Halves Disassemble and Assemble. (Group 3360.)

NOTE: Pilot caps and cover should be installed last if inspection of other parts in this section are needed. If no other parts in this section are being inspected, install pilot caps and cover.

NOTE: Parts listed below are shown on main graphics above.

8. Install O-rings (18 and 100) and arm circuit relief and anticavitation valves (19 and 99). Tighten to specification.

3. Remove pilot cap screws (52), top pilot cap (55), and bottom pilot caps (98). 4. Remove O-rings (20, 21, and 51) from housing (1). IMPORTANT: Do not disassemble the circuit relief and anticavitation valves. If the circuit relief and anticavitation valves have been disassembled, adjust circuit relief valve pressure. 5. Remove arm out circuit relief and anticavitation valves (19), O-ring (18), arm in circuit relief and anticavitation valve (99), and O-ring (100) from housing (1). NOTE: Main relief and power digging valve (17) is serviceable as an assembly.

Specification Arm Circuit Relief and Anticavitation Valve—Torque...............................................................................85 N·m 63 lb·ft

9. Install main relief and power digging valve (17). Tighten to specification. Specification Main Relief and Power Digging Valve—Torque..................................................................60 N·m 44 lb·ft

6. Remove main relief and power digging valve (17).

Continued on next page

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JB42225,0000052 -19-20OCT16-4/22

300GLC Excavator 020217 PN=339

Hydraulic System

10. Install O-rings (20, 21, and 51), pilot caps (55 and 98), and pilot cap screws (52). Tighten to specification.

Specification Pilot Cap Screw—Torque..............................................................................42 N·m 31 lb·ft JB42225,0000052 -19-20OCT16-5/22

Main Relief Valve Isolation Check Valve (105) Disassemble and Assemble

105

1. Remove cap screws (8) and flange (7).

3. Inspect parts and replace as needed.

8 TX1124782 —UN—29OCT12

2. Remove O-ring (6), spring (5), and poppet (4).

4. Install poppet, spring, and O-ring. 5. Install flange and cap screws. Tighten to specification. Specification Cap Screw—Torque......................................................................62 N·m 46 lb·ft 4— Poppet 5— Spring 6— O-Ring

Main Relief Valve Isolation Check Valve

7— Flange 8— Cap Screw (2 used) 105— Main Relief Valve Isolation Check Valve JB42225,0000052 -19-20OCT16-6/22

Check Valve (Lift Check) Left Travel Neutral Passage (106) Disassemble and Assemble

106

1. Remove cap screws (8) and flange (7).

7 11

3. Inspect parts and replace as needed.

8 TX1124783 —UN—29OCT12

2. Remove O-ring (13), spring (12), and poppet (11).

Check Valve (lift check) Left Travel Neutral Passage

12— Spring 13— O-Ring 106— Check Valve (lift check) Left Travel Neutral Passage Continued on next page

TM13264X19 (02FEB17)

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JB42225,0000052 -19-20OCT16-7/22

300GLC Excavator 020217 PN=340

Hydraulic System Arm Reduced Leakage Valve (107) Disassembly

1. Remove plug (36), O-ring (35), piston (34), and spring (33).

22 24

27 28 29 31

TX1124784 —UN—29OCT12

107

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

33 34 35 36

2. Remove cap screws (8) and body (32). 3. Remove O-ring (31), sleeve (29), and backup ring (28).

4. Remove O-rings (26 and 27), backup ring (25), spool (30), and poppet (24).

25 26

Arm Reduced Leakage Valve

5. Remove seat (23) and spring (22). 6. Inspect parts for wear and damage.

8— Cap Screw (2 used) 22— Spring 23— Seat 24— Poppet 25— Backup Ring 26— O-Ring 27— O-Ring 28— Backup Ring 29— Sleeve

30— Spool 31— O-Ring 32— Body 33— Spring 34— Piston 35— O-Ring 36— Plug 107— Arm Reduced Leakage Valve JB42225,0000052 -19-20OCT16-8/22

Left Travel Spool Assembly (108) Disassembly

108

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove left travel spool assembly (108) by slowly rotating as it is being removed.

2. Secure left travel spool (41) in a vise using wood blocks. Remove spool cap screw (44), spring seats (42), and spring (43). 3. Inspect parts for wear and damage. 41— Left Travel Spool 42— Spring Seat (2 used) 43— Spring

Left Travel Spool

44— Spool Cap Screw 108— Left Travel Spool Assembly Continued on next page

TM13264X19 (02FEB17)

TX1124785 —UN—29OCT12

IMPORTANT: The spools are select fitted to the bores in control valve and are a different design for each function. The spools need to be installed into same bores from which they were removed. Spools must be installed into proper bores for proper operation of machine.

33-3360-69

JB42225,0000052 -19-20OCT16-9/22

300GLC Excavator 020217 PN=341

Hydraulic System Auxiliary Spool Assembly (109) Disassembly

109

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove auxiliary spool assembly (109) by slowly rotating as it is being removed.

2. Secure auxiliary spool (45) in a vise using wood blocks. Remove spool cap screw (44), spring seats (42), and spring (43). 3. Inspect parts for wear and damage. 42— Spring Seat (2 used) 43— Spring 44— Spool Cap Screw

TX1124786 —UN—29OCT12

Auxiliary Spool

45— Auxiliary Spool 109— Auxiliary Spool Assembly JB42225,0000052 -19-20OCT16-10/22

Boom 2 Spool Assembly (110) Disassembly

110

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove boom 2 spool assembly (110) by slowly rotating as it is being removed.

2. Secure boom 2 spool (46) in a vise using wood blocks. Remove spool cap screw (44), spring seats (42), and spring (43). 3. Inspect parts for wear and damage. 42— Spring Seat (2 used) 43— Spring 44— Spool Cap Screw

Boom 2 Spool

46— Boom 2 Spool 110— Boom 2 Spool Assembly

Continued on next page

TM13264X19 (02FEB17)

TX1124787 —UN—29OCT12

33-3360-70

JB42225,0000052 -19-20OCT16-11/22

300GLC Excavator 020217 PN=342

Hydraulic System Arm 1 Spool Assembly (111) Disassembly

111

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove arm 1 spool assembly (111) by slowly rotating as it is being removed.

42 48

43 48

2. Secure arm 1 spool (47) in a vise using wood blocks. Remove spool cap screw (44), spring seats (42 and 48), and springs (43 and 49). 3. Inspect parts for wear and damage. 42— Spring Seat (2 used) 43— Spring 44— Spool Cap Screw 47— Arm 1 Spool

TX1124788 —UN—29OCT12

Arm 1 Spool

48— Spring Seat (2 used) 49— Spring 111— Arm 1 Spool Assembly

JB42225,0000052 -19-20OCT16-12/22

Swing Spool Assembly (112) Disassembly

112

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove swing spool assembly (112) by slowly rotating as it is being removed.

2. Secure swing spool (50) in a vise using wood blocks. Remove spool cap screw (44), spring seats (42), and spring (43). 3. Inspect parts for wear and damage. 42— Spring Seat (2 used) 43— Spring 44— Spool Cap Screw

Swing Spool

50— Swing Spool 112— Swing Spool Assembly

Continued on next page

TM13264X19 (02FEB17)

TX1124789 —UN—29OCT12

33-3360-71

JB42225,0000052 -19-20OCT16-13/22

300GLC Excavator 020217 PN=343

Hydraulic System Check Valve (113) Disassemble and Assemble 1. Remove spacer (40), backup ring (28), and O-ring (39).

113

2. Remove spring (38) and poppet (37). 3. Inspect parts and replace as needed.

4. Install poppet, spring, O-ring, and backup ring.

5. Install spacer. 39— O-Ring 40— Spacer 113— Check Valve

TX1124790 —UN—29OCT12

28— Backup Ring 37— Poppet 38— Spring

Check Valve JB42225,0000052 -19-20OCT16-14/22

Auxiliary Flow Rate Control Valve (114) Disassemble and Assemble

114 56

1. Remove cap screws (58) and body (104).

104

2. Remove plug (56) and O-ring (57). 3. Remove plug (63), O-ring (62), spring seat (61), spring (78), and auxiliary flow rate spool (77).

78 61 62

4. Remove O-rings (13 and 20).

63 20

5. Remove sleeve (64), spring (65), plug (79), spring (80), and poppet (81).

13 65

7. Inspect parts and replace as needed.

79 81

8. Install poppets (81 and 82), spring (80), plug (79), spring (65), and sleeve (64).

9. Install O-rings (13 and 20).

10. Install body (104) and cap screws (58). Tighten to specification.

Auxiliary Flow Rate Control Valve

Specification Cap Screw—Torque......................................................................62 N·m 46 lb·ft

11. Install O-ring (57) and plug (56). 12. Install auxiliary flow rate spool (77), spring (78), spring seat (61), O-ring (62), and plug (63).

13— O-Ring 20— O-Ring 56— Plug 57— O-Ring 58— Cap Screw (4 used) 61— Spring Seat 62— O-Ring 63— Plug 64— Sleeve

Continued on next page

TM13264X19 (02FEB17)

TX1124813 —UN—31OCT12

6. Remove poppet (82).

33-3360-72

65— Spring 77— Auxiliary Flow Rate Spool 78— Spring 79— Plug 80— Spring 81— Poppet 82— Poppet 104— Body 114— Auxiliary Flow Rate Control Valve JB42225,0000052 -19-20OCT16-15/22

300GLC Excavator 020217 PN=344

Hydraulic System Auxiliary Flow Combiner Valve Check Valve (115) Disassemble and Assemble

1. Remove cap screws (8) and flange (7). 2. Remove O-ring (6), spring (5), and poppet (83).

3. Inspect parts and replace as needed. 4. Install poppet, spring, O-ring, flange, and cap screws. Tighten to specification.

115

Specification Cap Screw—Torque......................................................................62 N·m 46 lb·ft 5— Spring 6— O-Ring 7— Flange

TX1124814 —UN—29OCT12

6 5 83

8— Cap Screw (2 used) 83— Poppet 115— Auxiliary Flow Combiner Valve Check Valve

Auxiliary Flow Combiner Valve Check Valve JB42225,0000052 -19-20OCT16-16/22

Load Check Valve (Left Travel Parallel Circuit) (116) Disassemble and Assemble 1. Remove plug (10) and O-ring (9).

2. Remove spring (38) and poppet (86). 3. Inspect parts and replace as needed.

9 38

9— O-Ring 10— Plug 38— Spring

86— Poppet 116— Load Check Valve (left travel parallel circuit)

116 TX1124816 —UN—29OCT12

4. Install poppet, spring, O-ring, and plug.

Load Check Valve (left travel parallel circuit) Continued on next page

TM13264X19 (02FEB17)

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Hydraulic System Dig Regenerative Check Valve (117) Disassemble and Assemble 1. Remove plug (87), O-ring (88), spring (89), and poppet (90).

2. Inspect parts and replace as needed.

3. Install poppet, spring, O-ring, and plug.

89 90— Poppet 117— Dig Regenerative Check Valve

117

TX1124817 —UN—30OCT12

87— Plug 88— O-Ring 89— Spring

Dig Regenerative Check Valve JB42225,0000052 -19-20OCT16-18/22

Auxiliary Flow Combiner Valve (118) Disassembly

118

NOTE: Not all parts are serviceable. Disassembly is for inspection only. 1. Remove cap screws (91) and cap (92).

91 92

3. Remove spring (94) and auxiliary flow combiner spool (95).

93 94

4. Inspect parts for wear and damage. 6— O-Ring 91— Cap Screw (2 used) 92— Cap 93— Spring Seat

94— Spring 95— Auxiliary Flow Combiner Spool 118— Auxiliary Flow Combiner Valve

TX1124818 —UN—29OCT12

2. Remove O-ring (6) and spring seat (93).

Auxiliary Flow Combiner Valve Continued on next page

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300GLC Excavator 020217 PN=346

Hydraulic System Dig Regenerative Valve (119) Disassembly

119

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove cap screws (91) and cap (92). 2. Remove O-ring (6) and spring seat (93).

3. Remove spring (96) and dig regenerative spool (97). 4. Inspect parts for wear and damage. 96— Spring 97— Dig Regenerative Spool 119— Dig Regenerative Valve

TX1124820 —UN—29OCT12

6— O-Ring 91— Cap Screw (2 used) 92— Cap 93— Spring Seat

Dig Regenerative Valve JB42225,0000052 -19-20OCT16-20/22

Arm Reduced Leakage Valve (120) Disassemble and Assemble

120

1. Remove plug (70) and O-ring (71). 2. Remove cap screws (8) and flange (72).

70 71

3. Remove O-rings (13 and 20). 4. Remove spring (73) and poppet (74). 5. Inspect parts and replace as needed.

TX1124822 —UN—29OCT12

6. Install poppet, spring, and O-rings (13 and 20). 7. Install flange and cap screws. Tighten to specification.

Specification Cap Screw—Torque......................................................................62 N·m 46 lb·ft

8. Install O-ring (71) and plug (70). 8— Cap Screw (4 used) 13— O-Ring 20— O-Ring (3 used) 70— Plug 71— O-Ring

Arm Reduced Leakage Valve

72— Flange 73— Spring 74— Poppet 120— Arm Reduced Leakage Valve Continued on next page

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300GLC Excavator 020217 PN=347

Hydraulic System Lift Checks (Boom 2 Power Passage and Swing Neutral Passage) (121 and 123) Disassemble and Assemble 1. Remove cap screws (8) and flanges (75).

2. Remove O-rings (13), springs (12), and poppets (76). 3. Inspect parts and replace as needed.

Specification Cap Screw—Torque......................................................................62 N·m 46 lb·ft 8— Cap Screw (8 used) 12— Spring (2 used) 13— O-Ring (2 used) 75— Flange (2 used)

76— Poppet (2 used) 121— Lift Check (boom 2 power passage) 123— Lift Check (swing neutral passage)

121

TX1124823 —UN—29OCT12

4. Install poppets, springs, O-rings, flanges, and cap screws. Tighten to specification.

12 76 G Lift Check (boom 2 power passage)

75 TX1124826 —UN—29OCT12

123

13 12 76

L Lift Check (swing neutral passage)

JB42225,0000052 -19-20OCT16-22/22

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=348

Hydraulic System Arm 1 Flow Rate Control Valve (122) Disassemble and Assemble

1. Remove plug (56) and O-ring (57). 2. Remove plug (63), O-ring (62), spring seat (61), spring (60), and arm 1 flow rate spool (59).

122 57

104

62 63

4. Remove sleeve (64), spring (65), plug (66), spring (67), and poppets (68 and 69).

5. Inspect parts and replace as needed.

6. Install poppets, spring (67), plug (66), spring (65), and sleeve.

60 61

TX1124825 —UN—29OCT12

3. Remove cap screws (58), body (104), and O-rings (13 and 20).

7. Install O-rings (13 and 20). 8. Install body and cap screws. Tighten to specification.

Specification Cap Screw—Torque......................................................................62 N·m 46 lb·ft

9. Install plug (56) and O-ring (57). 10. Install arm 1 flow rate control spool, spring (60), spring seat, O-ring (62), and plug (63). 11. Assemble control valve halves. See Control Valve Halves Disassemble and Assemble. (Group 3360.) 12. Install control valve. See Control Valve Remove and Install. (Group 3360.)

Arm 1 Flow Rate Control Valve 13— O-Ring 20— O-Ring 56— Plug 57— O-Ring 58— Cap Screw (4 used) 59— Arm 1 Flow Rate Spool 60— Spring 61— Spring Seat 62— O-Ring

63— Plug 64— Sleeve 65— Spring 66— Plug 67— Spring 68— Poppet 69— Poppet 104— Body 122— Arm 1 Flow Rate Control Valve

13. Operate machine and test appropriate functions for proper operation. JB42225,0000052 -19-20OCT16-23/22

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=349

Hydraulic System

Control Valve (4-Spool) Disassemble and Assemble SPECIFICATIONS Circuit Relief and Anticavitation Valve Torque

85 N·m 63 lb·ft

Pilot Cap Screw Torque

42 N·m 31 lb·ft

Cap Screw Torque

42 N·m 31 lb·ft

Flow Rate Cap Screw Torque

62 N·m 46 lb·ft

Continued on next page

TM13264X19 (02FEB17)

33-3360-78

DP27668,0000470 -19-11APR16-1/19

300GLC Excavator 020217 PN=350

Hydraulic System

6 5

12 11

2 9

1 8 7

A B 19 13

21 22 23

19 8

15 20

30 24

43 44

A 45

37 38

47 49

131

39 38

41 38 41

39 38

130

52 54 55 56

132

133

35 36

43 44

31 32

128

45 D

25 26 28

59 41

57 59

58 134

63 4 62 60 TX1124883

TX1124883 —UN—29OCT12

E 7

4-Spool (top pilot caps)

Continued on next page

TM13264X19 (02FEB17)

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Hydraulic System

69 4

135

71 72

63 63

71 73

67 67

59 74

59 B

19 1

A 65

64 102

103 105 106

7 4

129

107 6

101

100

108 138

111

116 118

114

113

110

85 86 87

77 13 78 139

115 117

120 121

126 123

89 13

79 80

90 116

125

122

120 119

115

77 13

127

119 114

76 136

124 120 119

93 116 115 114

95 137

TX1133471

109 112

TX1133471 —UN—10APR13

104

4-Spool (bottom caps)

Continued on next page

TM13264X19 (02FEB17)

33-3360-80

DP27668,0000470 -19-11APR16-3/19

300GLC Excavator 020217 PN=352

Hydraulic System 1— Housing 36— Plug 2— Poppet 37— Right Travel Spool 3— Spring (2 used) 38— Spring Seat (8 used) 4— O-Ring (3 used) 39— Spring (4 used) 5— Flange 40— Body 6— Cap Screw (13 used) 41— Cap Screw (4 used) 7— O-Ring (3 used) 42— Plug 8— Plug (3 used) 43— Backup Ring (2 used) 9— O-Ring (5 used) 44— O-Ring (2 used) 10— Plug (3 used) 45— Spring (2 used) 11— Poppet 46— Poppet 12— Spring 47— Bucket Spool 13— O-Ring (3 used) 48— Plug 14— O-Ring 49— Poppet 15— Poppet 50— Boom 1 Spool 16— Flange 51— Arm 2 Spool 17— Main Relief Valve Isolation 52— Spring Seat (2 used) Check Valve 53— Spring 18— Right Travel and Bucket 54— Arm Regenerative Spool Combined Function Check 55— O-Ring Valve 56— Backup Ring 19— O-Ring (2 used) 57— Spool 20— Circuit Relief and 58— Spring Anticavitation Valve (2 used) 59— O-Ring (8 used) 21— Spring 60— O-Ring 22— Washer 61— Plug 23— Poppet 62— Top Pilot Cap 24— Backup Ring 63— Pilot Cap Screw (14 used) 25— O-Ring 64— Bottom Pilot Cap 26— O-Ring 65— O-Ring 27— Arm Regenerative Circuit 66— Plug Check Valve 67— Bottom Pilot Cap (3 used) 28— Backup Ring 68— Cap Screw (2 used) 29— Sleeve 69— Cap 30— Spool 70— Cap Screw 31— O-Ring 71— Spring Seat (2 used) 32— Body 72— Spring 33— Spring 34— Piston 35— O-Ring

73— Travel Flow Combiner Spool 113— Spring 74— Circuit Relief and 114— Plug (3 used) Anticavitation Valve (2 used) 115— O-Ring (3 used) 75— Poppet 116— Spring Seat (3 used) 76— Spring 117— Spring 77— O-Ring (5 used) 118— Arm 2 Flow Rate Spool 78— O-Ring (2 used) 119— Plug (3 used) 79— O-Ring 120— O-Ring (3 used) 80— Manual Boom Lower Screw 121— Spring 81— O-Ring 122— Arm 2 Flow Rate Spool 82— Plug 123— Body 83— Poppet 124— Arm 2 Flow Rate Spool 84— Poppet 125— Spring 85— Spring 126— O-Ring 86— Plug 127— Plug 87— Spring (3 used) 128— Boom Reduced Leakage 88— Sleeve Valve 89— Plug 129— Bypass Shutoff Valve 90— O-Ring 130— Right Travel Spool 91— Body Assembly 92— Bucket Flow Rate Spool 131— Bucket Spool Assembly 93— Spring 132— Boom 1 Spool Assembly 94— Spring Seat 133— Arm 2 Spool Assembly 95— O-Ring 134— Arm Regenerative Valve 96— Plug 135— Travel Flow Combiner 97— Flow Rate Cap Screw (12 Valve used) 136— Boom Reduced Leakage 98— Poppet Valve 99— Poppet 137— Bucket Flow Rate Control 100— Spring Valve 101— Plug 138— Arm 2 Flow Rate Control 102— O-Ring Valve 103— Cap 139— Orifice 104— Cap Screw (4 used) 105— Bypass Shutoff Spool 106— Spring 107— Flange 108— Poppet 109— Poppet 110— Spring 111— Plug 112— Poppet

1. Remove control valve. See Control Valve Remove and Install. (Group 3360.) 2. Separate control valve halves. See Control Valve Halves Disassemble and Assemble. (Group 3360.)

NOTE: Pilot caps should be installed last if inspection of other parts in this section are needed. If no other parts in this section are being inspected, install pilot caps.

NOTE: Parts listed below are shown on main graphics above.

7. Install O-rings (19) and circuit relief and anticavitation valves (20 and 74). Tighten to specification.

3. Remove pilot cap screws (63), top pilot cap (62), and bottom pilot caps (67).

Specification Circuit Relief and Anticavitation Valve—Torque...............................................................................85 N·m 63 lb·ft

4. Remove O-rings (4, 13, 14, and 59). IMPORTANT: Do not disassemble the circuit relief and anticavitation valves (20 and 74). If the circuit relief and anticavitation valves have been disassembled, adjust circuit relief valve pressure. See Circuit Relief Valve Test and Adjustment. (Group 9025-25.)

8. Install O-rings (4, 13, 14, and 59). 9. Install top pilot cap, bottom pilot caps, and pilot cap screws. Tighten to specification.

5. Remove circuit relief and anticavitation valves (20 and 74) and O-rings (19).

Specification Pilot Cap Screw—Torque..............................................................................42 N·m 31 lb·ft

6. Inspect parts and replace as needed. Continued on next page

TM13264X19 (02FEB17)

33-3360-81

DP27668,0000470 -19-11APR16-4/19

300GLC Excavator 020217 PN=353

Hydraulic System Main Relief Valve Isolation Check Valve (17) Disassemble and Assemble

1. Remove cap screws (6) and flange (16).

3. Inspect parts and replace as needed.

6 TX1124875 —UN—29OCT12

2. Remove O-ring (4), spring (3), and poppet (15).

4. Install poppet, spring, and O-ring. 5. Install flange and cap screws (6). Tighten to specification. Specification Cap Screw—Torque......................................................................42 N·m 31 lb·ft

Main Relief Valve Isolation Check Valve 15— Poppet 16— Flange 17— Main Relief Valve Isolation Check Valve

3— Spring 4— O-Ring 6— Cap Screw (2 used)

DP27668,0000470 -19-11APR16-5/19

Right Travel and Bucket Combined Function Check Valve (18) Disassemble and Assemble

1. Remove cap screws (6) and flange (5).

3. Inspect parts and replace as needed.

6 TX1124876 —UN—29OCT12

2. Remove O-ring (4), spring (3), and poppet (2).

4. Install poppet, spring, and O-ring. 5. Install flange and cap screws. Tighten to specification. Specification Cap Screw—Torque......................................................................42 N·m 31 lb·ft 2— Poppet 3— Spring 4— O-Ring

Right Travel and Bucket Combined Function Check Valve

5— Flange 6— Cap Screw (2 used) 18— Right Travel and Bucket Combined Function Check Valve Continued on next page

TM13264X19 (02FEB17)

33-3360-82

DP27668,0000470 -19-11APR16-6/19

300GLC Excavator 020217 PN=354

Hydraulic System Arm Regenerative Circuit Check Valve (27) Disassemble and Assemble

1. Remove plug (8), O-ring (7), spring (12), and poppet (11). 2. Inspect parts and replace as needed.

7— O-Ring 8— Plug 11— Poppet

12— Spring 27— Arm Regenerative Circuit Check Valve

TX1124899 —UN—29OCT12

3. Install poppet, spring, O-ring, and plug.

Arm Regenerative Circuit Check Valve DP27668,0000470 -19-11APR16-7/19

Boom Reduced Leakage Valve (128) Disassembly

1. Remove plug (36), O-ring (35), piston (34), and spring (33).

21 23

26 28 29 31

33 34 35 36

2. Remove cap screws (6) and body (32). 3. Remove O-ring (31), sleeve (29), backup ring (28), and O-ring (26).

4. Remove O-ring (25), backup ring (24), spool (30), poppet (23), washer (22), and spring (21). 6— Cap Screw (4 used) 21— Spring 22— Washer 23— Poppet 24— Backup Ring 25— O-Ring 26— O-Ring 28— Backup Ring 29— Sleeve

Boom Reduced Leakage Valve

30— Spool 31— O-Ring 32— Body 33— Spring 34— Piston 35— O-Ring 36— Plug 128— Boom Reduced Leakage Valve Continued on next page

TM13264X19 (02FEB17)

24 25

TX1124877 —UN—29OCT12

128

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

33-3360-83

DP27668,0000470 -19-11APR16-8/19

300GLC Excavator 020217 PN=355

Hydraulic System Right Travel Spool Assembly (130) Disassembly

130

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove right travel spool assembly (130) by slowly rotating as it is being removed.

TX1124878 —UN—29OCT12

2. Secure right travel spool (37) in a vise using wood blocks. Remove spool cap screw (41), spring seats (38), and spring (39). 3. Inspect parts for wear and damage. 37— Right Travel Spool 38— Spring Seat (2 used) 39— Spring

Right Travel Spool

41— Cap Screw 130— Right Travel Spool Assembly DP27668,0000470 -19-11APR16-9/19

Bucket Spool Assembly (131) Disassembly

131

42 43 44 45 46

1. Remove bucket spool assembly (131) by slowly rotating as it is being removed.

TX1124879 —UN—29OCT12

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

2. Secure bucket spool (47) in a vise using wood blocks. Remove spool cap screw (41), spring seats (38), and spring (39). 3. Remove plug (42), backup ring (43), O-ring (44), spring (45), and poppet (46). 4. Inspect parts for wear and damage.

Bucket Spool 38— Spring Seat (2 used) 39— Spring 41— Cap Screw 42— Plug 43— Backup Ring Continued on next page

TM13264X19 (02FEB17)

33-3360-84

44— O-Ring 45— Spring 46— Poppet 47— Bucket Spool 131— Bucket Spool Assembly DP27668,0000470 -19-11APR16-10/19

300GLC Excavator 020217 PN=356

Hydraulic System Boom 1 Spool Assembly (132) Disassembly

132

48 43 44 45 49

1. Remove boom 1 spool assembly (132) by slowly rotating as it is being removed.

TX1124880 —UN—29OCT12

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

2. Secure boom 1 spool (50) in a vise using wood blocks. Remove spool cap screw (41), spring seats (38), and spring (39). 3. Remove plug (48), backup ring (43), O-ring (44), spring (45), and poppet (49).

Boom 1 Spool

4. Inspect parts for wear and damage.

38— Spring Seat (2 used) 39— Spring 41— Cap Screw 43— Backup Ring 44— O-Ring

45— Spring 48— Plug 49— Poppet 50— Boom 1 Spool 132— Boom 1 Spool Assembly DP27668,0000470 -19-11APR16-11/19

Arm 2 Spool Assembly (133) Disassembly

133

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove arm 2 spool assembly (133) by slowly rotating as it is being removed.

38 52

39 52

2. Secure arm 2 spool (51) in a vise using wood blocks. Remove cap screw (41), spring seats (38 and 52), and springs (39 and 53). 3. Inspect parts for wear and damage. 38— Spring Seat (2 used) 39— Spring 41— Cap Screw 51— Arm 2 Spool

Arm 2 Spool

52— Spring Seat (2 used) 53— Spring 133— Arm 2 Spool Assembly

Continued on next page

TM13264X19 (02FEB17)

TX1124881 —UN—29OCT12

33-3360-85

DP27668,0000470 -19-11APR16-12/19

300GLC Excavator 020217 PN=357

Hydraulic System Arm Regenerative Valve (134) Disassembly

134

NOTE: Not all parts are serviceable. Disassembly is for inspection only.

1. Remove arm regenerative valve (134) and secure it in a vise using wood blocks. 2. Remove spring (58), spool (57), backup ring (56), and O-ring (55).

55 54— Arm Regenerative Spool 55— O-Ring 56— Backup Ring

TX1124882 —UN—29OCT12

3. Inspect parts for wear and damage.

57— Spool 58— Spring 134— Arm Regenerative Valve

Arm Regenerative Valve DP27668,0000470 -19-11APR16-13/19

Travel Flow Combiner Valve (135) Disassembly NOTE: Not all parts are serviceable. Disassembly is for inspection only. 1. Remove cap screws (68) and cap (69). 2. Remove O-ring (4), cap screw (70), spring seats (71), and spring (72) from travel flow combiner spool (73).

4— O-Ring 68— Cap Screw (2 used) 69— Cap 70— Cap Screw

TX1124885 —UN—30OCT12

3. Inspect parts for wear and damage. 71— Spring Seat (2 used) 72— Spring 73— Travel Flow Combiner Spool 135— Travel Flow Combiner Valve

Travel Flow Combiner Valve Continued on next page

TM13264X19 (02FEB17)

33-3360-86

DP27668,0000470 -19-11APR16-14/19

300GLC Excavator 020217 PN=358

Hydraulic System Bypass Shutoff Valve (129) Disassembly NOTE: Not all parts are serviceable. Disassembly is for inspection only. 1. Remove cap screws (6) and flange (107). 2. Remove bypass shutoff spool (105), spring (106), and O-ring (4).

4— O-Ring 6— Cap Screw (2 used) 105— Bypass Shutoff Spool

TX1124886 —UN—30OCT12

3. Inspect parts for wear and damage. 106— Spring 107— Flange 129— Bypass Shutoff Valve

Bypass Shutoff Valve DP27668,0000470 -19-11APR16-15/19

Boom Reduced Leakage Valve (136) Disassemble and Assemble 1. Remove manual boom lower screw (80), plug (82), and O-rings (79 and 81). 2. Remove cap screws (6) and body (40). 3. Remove O-rings (13, 77, and 78). 4. Remove spring (76) and poppet (75). 5. Inspect parts and replace as needed. 6. Install poppet and spring. TX1124887 —UN—30OCT12

7. Install O-rings (13, 77, and 78). 8. Install body and cap screws. Tighten to specification. Specification Cap Screw—Torque......................................................................42 N·m 31 lb·ft

9. Install O-rings (79 and 81), plug, and manual boom lower screw. 6— Cap Screw (4 used) 13— O-Ring (3 used) 40— Body 75— Poppet 76— Spring 77— O-Ring

Boom Reduced Leakage Valve

78— O-Ring 79— O-Ring 80— Manual Boom Lower Screw 81— O-Ring 82— Plug 136— Boom Reduced Leakage Valve Continued on next page

TM13264X19 (02FEB17)

33-3360-87

DP27668,0000470 -19-11APR16-16/19

300GLC Excavator 020217 PN=359

Hydraulic System Bucket Flow Rate Control Valve (137) Disassemble and Assemble 1. Remove plugs (89 and 96) and O-rings (90 and 95). 2. Remove spring seat (94), spring (93), and bucket flow rate spool (92). 3. Remove flow rate cap screws (97) and body (91). 4. Remove O-rings (13 and 77). 5. Remove sleeve (88), spring (87), plug (86), spring (85), and poppets (83 and 84). TX1124888 —UN—30OCT12

6. Inspect parts and replace as needed. 7. Install O-ring (90) and plug (89). 8. Install bucket flow rate spool, spring (93), spring seat, O-ring (95), and plug (96) into body. 9. Install O-rings (13 and 77). 10. Install poppets (83 and 84), spring (85), and plug (86). Bucket Flow Rate Control Valve

11. Install spring (87), body, and flow rate cap screws. Tighten to specification. Specification Flow Rate Cap Screw—Torque..............................................................................62 N·m 46 lb·ft

13— O-Ring 77— O-Ring 83— Poppet 84— Poppet 85— Spring 86— Plug 87— Spring 88— Sleeve 89— Plug

Continued on next page

TM13264X19 (02FEB17)

33-3360-88

90— O-Ring 91— Body 92— Bucket Flow Rate Spool 93— Spring 94— Spring Seat 95— O-Ring 96— Plug 97— Flow Rate Cap Screw (4 used) 137— Bucket Flow Rate Control Valve DP27668,0000470 -19-11APR16-17/19

300GLC Excavator 020217 PN=360

Hydraulic System Arm 2 Flow Rate Control Valve (138) Disassemble and Assemble

138

98 108

99 100

109

101 87

110 112

111 87 113 114

77 78

139

115 117 116

127

118 119 120

120

126 119 124

114 115 121 116

125

120 122

TX1133473 —UN—10APR13

123

119

116

115 114

TX1133473 Arm 2 Flow Rate Control Valve 13— O-Ring (2 used) 77— O-Ring (3 used) 78— O-Ring 87— Spring (2 used) 97— Flow Rate Cap Screw (8 used) 98— Poppet 99— Poppet 100— Spring

101— Plug 108— Poppet 109— Poppet 110— Spring 111— Plug 112— Poppet 113— Spring 114— Plug (3 used) 115— O-Ring (3 used) 116— Spring Seat (3 used)

117— Spring 118— Arm 2 Flow Rate Spool 119— Plug (3 used) 120— O-Ring (3 used) 121— Spring 122— Arm 2 Flow Rate Spool 123— Body 124— Arm 2 Flow Rate Spool

125— Spring 126— O-Ring 127— Plug 138— Arm 2 Flow Rate Control Valve 139— Orifice

1. Remove plugs (119) and O-rings (120).

7. Remove orifice (139).

2. Remove plugs (114) and O-rings (115).

8. Remove springs (87), plugs (101 and 111), springs (100 and 110), and poppets (98, 99, 108, and 109).

3. Remove spring seats (116), springs (117, 121, and 125), and arm 2 flow rate spools (118, 122, and 124). 4. Remove flow rate cap screws (97) and body (123).

9. Inspect parts and replace as needed.

5. Remove O-rings (13, 77, and 78).

10. Install poppets (98, 99, 108, and 109), springs (100 and 110), plugs (101 and 111), and springs (87).

6. Remove spring (113) and poppet (112).

11. Install orifice. Continued on next page

TM13264X19 (02FEB17)

33-3360-89

DP27668,0000470 -19-11APR16-18/19

300GLC Excavator 020217 PN=361

Hydraulic System

12. Install poppet (112) and spring (113).

16. Install O-rings (120) and plugs (119).

13. Install O-rings (13, 77, and 78).

17. Install O-rings (115) and plugs (114).

14. Install body and flow rate cap screws. Tighten to specification.

18. Assemble control valve halves. See Control Valve Halves Disassemble and Assemble. (Group 3360.)

Specification Flow Rate Cap Screw—Torque..............................................................................62 N·m 46 lb·ft

19. Install control valve. See Control Valve Remove and Install. (Group 3360.) 20. Operate machine and test appropriate functions for proper operation.

15. Install arm 2 flow rate spools (118, 122, and 124), springs (117, 121, and 125), and spring seats. DP27668,0000470 -19-11APR16-19/19

Hydraulic Oil Tank Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Hydraulic Oil Tank Weight (approximate)

163 kg 360 lb.

Hydraulic Oil Tank-to-Frame Cap Screw Torque

400 N·m 295 lb.-ft.

TX1167469A —UN—31JUL14

Handrail 1— Hydraulic Oil Tank 2— Cap Screw (4 used)

4. Remove cap screws (2) and handrail (3). 5. Remove cap screws (4).

Continued on next page

TM13264X19 (02FEB17)

3— Handrail 4— Cap Screw (5 used)

33-3360-90

DV53278,00008A0 -19-16DEC14-1/6

300GLC Excavator 020217 PN=362

Hydraulic System

6. Install identification tag and disconnect hydraulic oil temperature sensor (B40). See Machine Harness (W2) Component Location. (Group 9015-10.) B40— Hydraulic Oil Temperature Sensor

TX1167471A —UN—31JUL14

1— Hydraulic Oil Tank

Hydraulic Oil Temperature Sensor DV53278,00008A0 -19-16DEC14-2/6

7. Install identification tags and disconnect return lines (5). Close all openings using caps and plugs. See Hydraulic System Line Connections. (Group 9025-15.) 8. Remove clamps (6 and 7) and return line couplers (8 and 9). Close all openings using caps and plugs. 8— Return Line Coupler 9— Return Line Coupler

TX1167472A —UN—31JUL14

5— Return Line (5 used) 6— Clamp (2 used) 7— Clamp (2 used)

Return Lines and Couplers Continued on next page

TM13264X19 (02FEB17)

33-3360-91

DV53278,00008A0 -19-16DEC14-3/6

300GLC Excavator 020217 PN=363

Hydraulic System

9. Loosen clamps (10) and disconnect supply line (11). Close all openings using caps and plugs. See Hydraulic System Line Connections. (Group 9025-15.) 10. Install identification tag and disconnect fan drive pump supply line (12). Close all openings using caps and plugs. See Fan Drive Hydraulic System Component Location. (Group 9025-15.) 12— Fan Drive Pump Supply Line

TX1167477A —UN—31JUL14

10— Clamp (2 used) 11— Supply Line

Supply Lines (bottom) DV53278,00008A0 -19-16DEC14-4/6

NOTE: To remove hydraulic oil tank, disconnecting fuel lines is not necessary.

TX1181015A —UN—16DEC14

11. Remove cap screws (14) and set fuel filter housing (15) aside. 12. Remove cap screws (16) and set engine oil filter housing (13) aside. 13— Engine Oil Filter Housing 14— Cap Screw (2 used)

15— Fuel Filter Housing 16— Cap Screw (2 used)

Fuel Filter Housings Continued on next page

TM13264X19 (02FEB17)

33-3360-92

DV53278,00008A0 -19-16DEC14-5/6

300GLC Excavator 020217 PN=364

Hydraulic System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 13. Attach appropriate lifting device to hydraulic oil tank (1). Specification Hydraulic Oil Tank—Weight (approximate)................................................................................ 163 kg 360 lb.

14. Remove cap screws (17), washers (18), and spacers (19).

16. Repair or replace parts as necessary.

19 18 19

17. Attach appropriate lifting device to hydraulic oil tank.

18. Install hydraulic oil tank, spacers, washers, and cap screws (17). Tighten cap screws to specification.

TX1167482 —UN—05AUG14

15. Remove hydraulic oil tank.

18 17

Specification Hydraulic Oil Tank-to-Frame Cap Screw—Torque............................................................................400 N·m 295 lb.-ft.

Hydraulic Oil Tank 1— Hydraulic Oil Tank 17— Cap Screw (4 used)

18— Washer (4 used) 19— Spacer (4 used)

19. Install engine oil filter housing (13) and cap screws (16). 20. Install fuel filter housing (15) and cap screws (14). 21. Connect supply line and fan drive pump supply line. Tighten clamps (10). See Hydraulic System Line Connections. (Group 9025-15.) See Fan Drive Hydraulic System Component Location. (Group 9025-15.) 22. Install return line couplers and clamps. 23. Connect return lines. See Hydraulic System Line Connections. (Group 9025-15.) 24. Connect hydraulic oil temperature sensor (B40). See Machine Harness (W2) Component Location. (Group 9015-10.)

25. Install cap screws (4). 26. Install handrail (3) and cap screws (2). 27. Fill hydraulic oil tank. See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 28. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 29. Operate machine and check for leaks. DV53278,00008A0 -19-16DEC14-6/6

TM13264X19 (02FEB17)

33-3360-93

300GLC Excavator 020217 PN=365

Hydraulic System

Restriction Valve Remove and Install

2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

6 1 7

3 4

8 9

TX1166871 —UN—25JUL14

TX1166871 Restriction Valve 1— Return Line 2— Return Line 3— Flange (4 used)

4— Cap Screw (8 used) 5— Clamp (2 used) 6— Return Line Coupler

4. Remove cap screws (4) and flanges (3). 5. Remove clamps (5), return line coupler (6), and return line (1). Close all openings using caps and plugs. 6. Remove snap ring (7), restriction valve (8) and O-rings (9). 7. Repair or replace parts as necessary. 8. Install O-rings, restriction valve, and snap ring. 9. Install return line, return line coupler, and clamps. 10. Install flanges and cap screws.

7— Snap Ring 8— Restriction Valve 9— O-Ring (2 used)

11. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 12. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 13. Operate machine and check for leaks. DV53278,00008A1 -19-14JAN15-1/1

TM13264X19 (02FEB17)

33-3360-94

300GLC Excavator 020217 PN=366

Hydraulic System

Hydraulic Oil Cooler Bypass Valve Remove and Install

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

SPECIFICATIONS 156 L 41 gal.

Return Line Flange-to-Control Valve Socket Head Cap Screw Torque

62 N·m 46 lb.-ft.

Control Valve-to-Hydraulic Oil Tank Return Line Coupling Cap Screw Torque

11 N·m 97 lb.-in.

1— Control Valve 2— O-Ring 3— Oil Cooler Bypass Valve

4— Socket Head Cap Screw (2 used) 5— Hydraulic Return Line

TX1092942 —UN—07JUN11

Hydraulic Oil Tank Capacity (approximate)

Oil Cooler Bypass Valve 6— Coupling 7— Cap Screw (2 used) 8— Hydraulic Oil Tank

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank (8). See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

4. Loosen cap screws (7) on coupling (6). 5. Remove socket head cap screws (4) and hydraulic return line (5) from control valve (1). 6. Remove oil cooler bypass valve (3) and O-ring (2). 7. Repair or replace parts as necessary. 8. Install oil cooler bypass valve and O-ring. 9. Install hydraulic return line.

Continued on next page

TM13264X19 (02FEB17)

33-3360-95

DV53278,00008A2 -19-16DEC14-1/2

300GLC Excavator 020217 PN=367

Hydraulic System

10. Install socket head cap screws. Tighten to specification. Specification Return Line Flange-to-Control Valve Socket Head Cap Screw—Torque..............................................................................62 N·m 46 lb.-ft.

11. Tighten cap screws on coupling to specification.

12. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 13. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)

Specification Control Valve-toHydraulic Oil Tank Return Line Coupling Cap Screw—Torque.............................................................................. 11 N·m 97 lb.-in.

14. Operate machine and check for leaks.

DV53278,00008A2 -19-16DEC14-2/2

Boom Cylinder Remove and Install SPECIFICATIONS 245 kg 540 lb.

Upper Pin Weight (approximate)

52 kg 115 lb.

TX1098619 —UN—23SEP11

Boom Cylinder Weight (approximate)

3 NOTE: Procedure is same for both boom cylinders. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Position machine as shown. Fully retract bucket cylinder (1) and arm cylinder (2). Lower bucket to ground. CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 3. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

Machine Position 1— Bucket Cylinder 2— Arm Cylinder

4. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

Continued on next page

TM13264X19 (02FEB17)

3— Boom Cylinder (2 used)

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Hydraulic System

5. Install identification tags and disconnect lubrication line (13). Close openings using caps or plugs. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1122939A —UN—20SEP12

6. Support boom cylinder (3) using appropriate lifting device. Specification Boom Cylinder—Weight (approximate)................................................................................ 245 kg 540 lb.

7. Remove nuts (12) and cap screw (5). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 8. Using appropriate lifting device support upper pin (4). Specification Upper Pin—Weight (approximate).................................................................................. 52 kg 115 lb.

Boom Cylinder 3— Boom Cylinder (2 used) 4— Upper Pin 5— Cap Screw

12— Nut (2 used) 13— Lubrication Line

9. Record location of shims upon removal of upper pin and shims to aid in assembly procedure. Continued on next page

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=369

Hydraulic System

10. Install identification tags and disconnect hydraulic lines (9 and 10). Close all openings using caps and plugs. 11. Remove cap screw (6) and nuts (7). 12. Record location of shims upon removal of lower pin (8) and shims to aid in assembly procedure. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 13. Using appropriate lifting device, remove boom cylinder.

TX1182347A —UN—13JAN15

Specification Boom Cylinder—Weight (approximate)................................................................................ 245 kg 540 lb.

14. Repair or replace parts as necessary. See Boom Cylinder Disassemble and Assemble. (Group 3360.) 15. Attach appropriate lifting device to boom cylinder and align head end of boom cylinder with lower pin holes. Boom Cylinder

16. Install boom cylinder. IMPORTANT: Avoid possible damage to pins. Cap screws must be free to turn in hole to allow movement of pins. Tighten nuts against each other, not against retainer. 17. Install shims as needed, lower pin (8), cap screw (6), and tighten nuts (7) against each other. 18. Connect hydraulic lines. 19. Align rod end of boom cylinder with upper pin holes.

3— Boom Cylinder (2 used) 6— Cap Screw 7— Nut (2 used)

23. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 20. Using appropriate lifting device, install shims as needed, upper pin (4), cap screw (5), and tighten nuts (12) against each other. Specification Upper Pin—Weight (approximate).................................................................................. 52 kg 115 lb.

21. Connect lubrication line. 22. Lubricate all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operator's Manual.)

8— Lower Pin 9— Hydraulic Line (to head end) 10— Hydraulic Line (to rod end)

CAUTION: Avoid personal injury from unexpected machine movement. Bleed air from hydraulic cylinders. IMPORTANT: Avoid component damage from cavitation. Bleed air from hydraulic cylinders. 24. Bleed air out of boom cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 25. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator's Manual.) 26. Operate machine and check for leaks.

DV53278,00008A3 -19-15JAN15-3/3

TM13264X19 (02FEB17)

33-3360-98

300GLC Excavator 020217 PN=370

Hydraulic System SERVICE EQUIPMENT AND TOOLS

Boom Cylinder Disassemble and Assemble SPECIFICATIONS 245 kg 540 lb.

Boom Cylinder Rod Weight (approximate)

105 kg 232 lb.

Boom Rod Curvature

0.5 mm per 1 m 0.020 in. per 3.25 ft.

Boom Cylinder Piston Torque

980 N·m 723 lb.-ft.

Boom Cylinder Piston Nut Torque

1850 N·m 1364 lb.-ft.

Set Screw Torque

65 N·m 48 lb.-ft.

Boom Cylinder Socket Head Cap Screw Torque

520 N·m 384 lb.-ft.

ST3318 Piston Nut Tool ST3353 Piston Tool ST8027 Cylinder Head Maintenance Tool ST2979 Installation Tool

TX1134229 —UN—04APR13

Boom Cylinder Weight (approximate)

ST5908 Hydraulic Cylinder Disassembly/Assembly Device

Boom Cylinder Components

Continued on next page

TM13264X19 (02FEB17)

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Hydraulic System

5 1

6 13

24 25 23

22 21 22 23 15 14

9 10 16

TX1134243 —UN—04APR13

TX1134243 Boom Cylinder Seal Identification 1— Rod 2— Dust Seal 3— Backup Ring 4— U-Ring 5— Seal 6— Cylinder Head 7— Bushing 8— Retaining Ring

9— O-Ring 10— Backup Ring 11— O-Ring 12— Socket Head Cap Screw (12 used) 13— Barrel 14— Steel Ball

CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device. 1. Using appropriate lifting device, secure cylinder horizontally on a work bench. Drain hydraulic oil from cylinder. Specification Boom Cylinder—Weight (approximate)................................................................................ 245 kg 540 lb.

2. Pull rod (1) out so piston (25) is against cylinder head (6).

15— Set Screw 16— Piston Nut 19— O-Ring 20— Backup Ring (2 used) 21— Piston Seal 22— Wear Ring (2 used)

23— Dust Ring (2 used) 24— Cushion Bearing 25— Piston

Specification Boom Cylinder Rod—Weight (approximate)................................................................................ 105 kg 232 lb.

4. Remove socket head cap screws (12) from cylinder head. 5. Remove rod, cylinder head, and piston from barrel (13). 6. Secure rod in ST5908 Hydraulic Cylinder Disassembly/Assembly Device. 7. Apply alignment mark on piston nut and rod. 8. Remove staked material from set screw (15) hole using a small air grinder or a drill and bit.

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

9. Remove set screw and steel ball (14). 10. Remove piston nut using ST3318 Piston Nut Tool.

3. Connect rod to appropriate lifting device using a lifting strap.

11. Remove piston using ST3353 Piston Tool. NOTE: Note direction of oil groove in cushion bearing (24) for assembly.

Continued on next page

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=372

Hydraulic System 12. Remove cushion bearing (24) from rod. Note direction of oil groove in cushion bearing for assembly. 13. Remove wear rings (22), dust rings (23), piston seal (21), backup rings (20), and O-ring (19) from piston. 14. Remove cylinder head from rod. NOTE: Note direction of U-ring for assembly. 15. Remove components (2—5, 7—11). Note direction of U-ring (4) for assembly. 16. Inspect dust seals and bushings in rod and barrel for wear or damage. Repair or replace parts as necessary. See Inspect Pins, Bushings, and Bosses—Front Attachment. (Group 3340.) 17. Check for rod curvature on V-blocks using dial indicator. Specification Boom Rod—Curvature.................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft.

18. Repair or replace parts as necessary. 19. Install bushing (7) into cylinder head using ST8027 Cylinder Head Maintenance Tool. NOTE: Note direction of U-ring during installation. 20. Install U-ring (4), backup ring (3), seal (5), and retaining ring (8) to cylinder head.

NOTE: Note direction of oil groove in cushion bearing during installation. 26. Install cushion bearing. Check direction of oil groove in cushion bearing. 27. Align marks made during disassembly and install piston. Tighten to specification using ST3353 Piston Tool. Specification Boom Cylinder Piston—Torque............................................................................980 N·m 723 lb.-ft.

28. Install piston nut. Tighten to specification using ST3318 Piston Nut Tool. Specification Boom Cylinder Piston Nut—Torque..............................................................................1850 N·m 1364 lb.-ft.

29. Install steel ball and set screw. Tighten set screw to specification. Specification Set Screw—Torque.......................................................................65 N·m 48 lb.-ft.

30. Stake set screw in two places 90° from previous stake marks.

21. Install dust seal (2) to cylinder head using ST8027 Cylinder Head Maintenance Tool.

31. Apply clean oil to piston and seals. Attach appropriate lifting device to rod using a lifting strap. Carefully install piston, rod, and cylinder head into barrel.

22. Install O-ring (9), backup ring (10), and O-ring (11) to cylinder head.

32. Install socket head cap screws (12). Tighten to specification.

23. Install piston seal (21) to piston and adjust piston seal using ST2979 Installation Tool.

Specification Boom Cylinder Socket Head Cap Screw—Torque............................................................................520 N·m 384 lb.-ft.

24. Install wear rings (22), dust rings (23), O-ring (19), and backup rings (20) to piston. 25. Install assembled cylinder head on rod using ST8027 Cylinder Head Maintenance Tool.

DV53278,00008A4 -19-16DEC14-3/3

TM13264X19 (02FEB17)

33-3360-101

300GLC Excavator 020217 PN=373

Hydraulic System

Arm Cylinder Remove and Install SPECIFICATIONS

348 kg 767 lb.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

2. Position machine as shown. Fully retract bucket cylinder (1) and arm cylinder (2). Lower bucket to ground. CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing.

TX1098619 —UN—23SEP11

Arm Cylinder Weight (approximate)

Machine Position 1— Bucket Cylinder 2— Arm Cylinder

3. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

3— Boom Cylinder

Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

4. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Continued on next page

TM13264X19 (02FEB17)

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Hydraulic System

5. Install identification tags and disconnect hydraulic lines (5) and lubrication line (11) from arm cylinder (2). Close all openings using caps and plugs. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 6. Support arm cylinder using appropriate lifting device. TX1129209A —UN—17JAN13

Specification Arm Cylinder—Weight (approximate)................................................................................ 348 kg 767 lb.

7. Remove cap screw (6), washer (7), and pin (8). Record location of shims upon removal of pin to aid in assembly procedure. 8. Remove cap screw (13), washer (14), and pin (15). Record location of shims upon removal of pin to aid in assembly procedure.

Arm Cylinder

9. Remove arm cylinder.

TX1126860A —UN—05DEC12

10. Repair or replace parts as necessary. See Arm Cylinder Disassemble and Assemble. (Group 3360.) 11. Using appropriate lifting device, install arm cylinder and align with pin holes. 12. Install shims (9), pin (15), washer (14), and cap screw (6). 13. Install shims (9), pin (8), washer (7), and cap screw (13). Arm Cylinder

14. Connect hydraulic lines and lubrication line. 15. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) CAUTION: Avoid personal injury from unexpected machine movement. Bleed air from hydraulic cylinders. IMPORTANT: Avoid component damage from cavitation. Bleed air from hydraulic cylinders.

2— Arm Cylinder 5— Hydraulic Line (2 used) 6— Cap Screw 7— Washer 8— Pin (head end) 9— Shim (as needed)

10— Boom 11— Lubrication Line 12— Arm 13— Cap Screw 14— Washer 15— Pin (rod end)

17. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator's Manual.) 18. Operate machine and check for leaks.

16. Bleed air out of arm cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) DV53278,00008A5 -19-15JAN15-2/2

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=375

Hydraulic System SERVICE EQUIPMENT AND TOOLS

Arm Cylinder Disassemble and Assemble SPECIFICATIONS 348 kg 767 lb.

Arm Cylinder Rod Weight (approximate)

105 kg 232 lb.

Arm Cylinder Rod Curvature

0.5 mm per 1 m 0.020 in. per 3.25 ft.

Arm Cylinder Piston Torque

980 N·m 723 lb.-ft.

Arm Cylinder Piston Nut Torque

1850 N·m 1364 lb.-ft.

Set Screw Torque

65 N·m 48 lb.-ft.

Arm Cylinder Socket Head Cap Screw Torque

710 N·m 525 lb.-ft.

ST3276 Piston Nut Tool ST3351 Piston Tool ST8022 Cylinder Head Maintenance Tool ST2970 Installation Tool

TX1134231 —UN—11APR13

Arm Cylinder Weight (approximate)

ST5908 Hydraulic Cylinder Disassembly/Assembly Device

Arm Cylinder Components

Continued on next page

TM13264X19 (02FEB17)

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Hydraulic System

5 1

6 13

24 25 23

22 21 22 23 15 14

9 10 19

20 17 18

TX1134244

TX1134244 —UN—04APR13

Arm Cylinder Seal Identification 1— Rod 2— Dust Seal 3— Backup Ring 4— U-Ring 5— Seal 6— Cylinder Head 7— Bushing 8— Retaining Ring

9— O-Ring 10— Backup Ring 11— O-Ring 12— Socket Head Cap Screw (14 used) 13— Barrel 14— Steel Ball

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

15— Set Screw 16— Piston Nut 17— Ring 18— Cushion Plunger 19— O-Ring 20— Backup Ring (2 used) 21— Piston Seal

4. Remove socket head cap screws (12) from cylinder head. 5. Remove rod, cylinder head, and piston from barrel (13).

1. Using appropriate lifting device, secure cylinder on a work bench. Drain hydraulic oil from cylinder.

6. Secure rod in ST5908 Hydraulic Cylinder Disassembly/Assembly Device.

Specification Arm Cylinder—Weight (approximate)................................................................................ 348 kg 767 lb.

2. Pull rod (1) out so piston (25) is against cylinder head (6). CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device.

7. Apply alignment mark on piston nut and end of rod. 8. Remove staked material from set screw (15) hole using a small air grinder or a drill and bit. 9. Remove set screw and steel ball (14). 10. Remove piston nut using ST3276 Piston Nut Tool. 11. Remove piston using ST3351 Piston Tool. NOTE: Note direction of oil groove in cushion bearing (24) for assembly.

3. Connect rod to appropriate lifting device using a lifting strap. Specification Arm Cylinder Rod—Weight (approximate)................................................................................ 105 kg 232 lb.

12. Remove cushion bearing (24) from rod. Note direction of oil groove in cushion bearing for assembly. 13. Remove wear rings (22), dust rings (23), piston seal (21), backup rings (20), and O-ring (19) from piston. 14. Remove cylinder head (6) from rod.

Continued on next page

TM13264X19 (02FEB17)

22— Wear Ring (2 used) 23— Dust Ring (2 used) 24— Cushion Bearing 25— Piston

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300GLC Excavator 020217 PN=377

Hydraulic System

NOTE: Ring (17) and cushion plunger (18) cannot be removed from cylinder head.

NOTE: Cushion bearing must be installed with groove in direction noted during removal.

NOTE: Note direction of U-ring for assembly.

26. Install cushion bearing. Check direction of oil groove in cushion bearing.

15. Remove components (2—5, 7—11). Note direction of U-ring (4) for assembly. Ring (17) and cushion plunger (18) cannot be removed from cylinder head. 16. Inspect dust seals and bushings in rod and barrel for wear or damage. Repair or replace parts as necessary. See Inspect Pins, Bushings, and Bosses—Front Attachment. (Group 3340.) 17. Check for rod curvature on V-blocks using dial indicator. Specification Arm Cylinder Rod—Curvature.............................................................. 0.5 mm per 1 m 0.020 in. per 3.25 ft.

18. Repair or replace parts as necessary. 19. Install bushing (7) into cylinder head using ST8022 Cylinder Head Maintenance Tool. NOTE: U-ring (4) must be installed as noted during removal. 20. Install U-ring (4), backup ring (3), seal (5), and retaining ring (8) to cylinder head. 21. Install dust seal (2) to cylinder head. 22. Install O-ring (9), backup ring (10), and O-ring (11) to cylinder head. 23. Install piston seal (21) to piston and adjust piston seal using ST2970 Installation Tool. 24. Install wear rings (22), dust rings (23), O-ring (19), and backup rings (20) to piston. 25. Install assembled cylinder head on rod using ST8022 Cylinder Head Maintenance Tool.

27. Align marks made during disassembly and install piston. Tighten to specification using ST3351 Piston Tool. Specification Arm Cylinder Piston—Torque............................................................................980 N·m 723 lb.-ft.

28. Install piston nut. Tighten to specification using ST3276 Piston Nut Tool. Specification Arm Cylinder Piston Nut—Torque..............................................................................1850 N·m 1364 lb.-ft.

29. Install steel ball and set screw. Tighten set screw to specification. Specification Set Screw—Torque.......................................................................65 N·m 48 lb.-ft.

30. Stake set screw in two places 90° from previous stake marks. 31. Apply clean oil to piston and seals. Attach appropriate lifting device to rod using a lifting strap. Carefully install piston, rod, and cylinder head into barrel. 32. Install socket head cap screws (12). Tighten to specification. Specification Arm Cylinder Socket Head Cap Screw—Torque............................................................................710 N·m 525 lb.-ft. DV53278,00008A6 -19-06JAN15-3/3

TM13264X19 (02FEB17)

33-3360-106

300GLC Excavator 020217 PN=378

Hydraulic System

Bucket Cylinder Remove and Install SPECIFICATIONS 211 kg 465 lb.

Lower Pin Weight (approximate)

27 kg 60 lb.

1 3

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Position the machine as shown. Fully retract the bucket cylinder (1) and arm cylinder (2). Lower bucket to ground.

TX1098619 —UN—23SEP11

Bucket Cylinder Weight (approximate)

Machine Position

1— Bucket Cylinder 2— Arm Cylinder

3— Boom Cylinder

Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

3. Release hydraulic oil tank pressure by pressing button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 4. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See

DV53278,00008A7 -19-15JAN15-1/3

5. Remove nuts (15) and cap screw (13) from rod end of bucket cylinder. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 6. Support bucket cylinder (1) using appropriate lifting device.

TX1180984A —UN—16DEC14

Specification Bucket Cylinder—Weight (approximate).................................................................................211 kg 465 lb.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Support lower pin (14) using appropriate lifting device. Specification Lower Pin—Weight (approximate).................................................................................. 27 kg 60 lb.

8. Remove lower pin. Record location of shims (16) upon removal of lower pin to aid in assembly procedure.

Bucket Cylinder 1— Bucket Cylinder 4— Right Bucket Link 5— Left Bucket Link 13— Cap Screw

Continued on next page

TM13264X19 (02FEB17)

33-3360-107

14— Lower Pin 15— Nut (2 used) 16— Shim (4 used)

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300GLC Excavator 020217 PN=379

Hydraulic System

9. Install identification tags and disconnect hydraulic lines (9 and 11). Close all openings using caps and plugs. 10. Remove nuts (8) and cap screw (7). 11. Remove upper pin (12) and bucket cylinder (1). Record location of shims (16) upon removal of upper pin to aid in assembly procedure. TX1170973A —UN—05SEP14

12. Repair or replace parts as necessary. See Bucket Cylinder Disassemble and Assemble. (Group 3360.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 13. Using appropriate lifting device, install head end of bucket cylinder, upper pin (12), and shims (16). Bucket Cylinder

Specification Bucket Cylinder—Weight (approximate).................................................................................211 kg 465 lb.

IMPORTANT: Avoid possible damage to pins. Cap screws must be free to turn in hole to allow movement of pins. Tighten nuts against each other, not against retainer.

1— Bucket Cylinder 6— Arm 7— Cap Screw 8— Nut (2 used)

Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

14. Install cap screw (7) and tighten nuts (8) against each other.

CAUTION: Avoid personal injury from unexpected machine movement. Bleed air from hydraulic cylinders.

15. Connect hydraulic lines. 16. Align rod end of bucket cylinder with pin holes, right bucket link (4), and left bucket link (5). 17. Using appropriate lifting device, install rod end of bucket cylinder, lower pin (14), and shims (16). IMPORTANT: Avoid possible damage to pins. Cap screws must be free to turn in hole to allow movement of pins. Tighten nuts against each other, not against retainer. 18. Install cap screw (13) and tighten nuts (15) against each other.

9— Hydraulic Line (to rod end) 11— Hydraulic Line (to head end) 12— Upper Pin 16— Shim (2 used)

IMPORTANT: Avoid component damage from cavitation. Bleed air from hydraulic cylinders. 20. Bleed air out of bucket cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 21. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator's Manual.) 22. Operate machine and check for leaks.

19. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See DV53278,00008A7 -19-15JAN15-3/3

TM13264X19 (02FEB17)

33-3360-108

300GLC Excavator 020217 PN=380

Hydraulic System SERVICE EQUIPMENT AND TOOLS

Bucket Cylinder Disassemble and Assemble SPECIFICATIONS Bucket Cylinder Weight (approximate)

211 kg 465 lb.

Bucket Cylinder Rod Weight (approximate)

88 kg 194 lb.

Bucket Cylinder Rod Curvature

0.5 mm per 1 m 0.020 in. per 3.25 ft.

Bucket Cylinder Piston Torque

980 N·m 723 lb.-ft.

ST5908 Hydraulic Cylinder Disassembly/Assembly Device ST3318 Piston Nut Tool ST3353 Piston Tool ST8021 Cylinder Head Maintenance Tool ST2967 Installation Tool

Bucket Cylinder Piston Nut Torque 1850 N·m 1364 lb.-ft. 65 N·m 48 lb.-ft.

Bucket Cylinder Head-to-Barrel Socket Head Cap Screw Torque

375 N·m 277 lb.-ft.

TX1134233 —UN—04APR13

Set Screw Torque

Bucket Cylinder Components

Continued on next page

TM13264X19 (02FEB17)

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300GLC Excavator 020217 PN=381

Hydraulic System

5 1

6 13

22 21 22 23 15

24 25 23

14 2

9 10 20

TX1134245 —UN—04APR13

TX1134245 Bucket Cylinder Seal Identification 1— Rod 2— Dust Seal 3— Backup Ring 4— U-Ring 5— Seal 6— Cylinder Head 7— Bushing 8— Retaining Ring

9— O-Ring 10— Backup Ring 11— O-Ring 12— Socket Head Cap Screw (14 used) 13— Barrel 14— Steel Ball

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

15— Set Screw 16— Piston Nut 19— O-Ring 20— Backup Ring (2 used) 21— Piston Seal 22— Wear Ring (2 used)

4. Remove socket head cap screws (12) from cylinder head. 5. Remove rod, cylinder head, and piston from barrel (13).

1. Using appropriate lifting device, secure cylinder to a work bench. Drain hydraulic oil from cylinder.

6. Secure rod in ST5908 Hydraulic Cylinder Disassembly/Assembly Device.

Specification Bucket Cylinder—Weight (approximate).................................................................................211 kg 465 lb.

2. Pull rod (1) out so piston (25) is against cylinder head (6). CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device.

7. Apply alignment marks on piston nut and rod. 8. Remove staked material from set screw (15) hole using a small air grinder or a drill and bit. 9. Remove set screw and steel ball (14). 10. Remove piston nut using ST3318 Piston Nut Tool. 11. Remove piston using ST3353 Piston Tool. NOTE: Note direction of oil groove in cushion bearing (24) for assembly.

3. Connect rod to appropriate lifting device using a lifting strap. Specification Bucket Cylinder Rod—Weight (approximate).................................................................................. 88 kg 194 lb.

Continued on next page

TM13264X19 (02FEB17)

23— Dust Ring (2 used) 24— Cushion Bearing 25— Piston

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300GLC Excavator 020217 PN=382

Hydraulic System

NOTE: Note direction of U-ring for assembly.

26. Install cushion bearing. Check direction of oil groove in cushion bearing.

15. Remove components (2—5, 7—11) from cylinder head. Note direction of U-ring (4) for assembly.

27. Align marks made during disassembly and install piston. Tighten to specification using ST3353 Piston Tool.

16. Inspect dust seals and bushings in rod and barrel for wear or damage. Repair or replace parts as necessary. See Inspect Pins, Bushings, and Bosses—Front Attachment. (Group 3340.) 17. Check for rod curvature on V-blocks using dial indicator. Specification Bucket Cylinder Rod—Curvature.............................................................. 0.5 mm per 1 m 0.020 in. per 3.25 ft.

18. Repair or replace parts as necessary. 19. Install bushing (7) into cylinder head using ST8021 Cylinder Head Maintenance Tool.

Specification Bucket Cylinder Piston—Torque............................................................................980 N·m 723 lb.-ft.

28. Install piston nut. Tighten to specification using ST3318 Piston Nut Tool. Specification Bucket Cylinder Piston Nut—Torque..............................................................................1850 N·m 1364 lb.-ft.

29. Install steel ball and set screw. Tighten set screw to specification.

NOTE: U-ring (4) must be installed as noted during removal.

Specification Set Screw—Torque.......................................................................65 N·m 48 lb.-ft.

20. Install U-ring (4), backup ring (3), seal (5), and retaining ring (8) to cylinder head.

30. Stake set screw in two places 90° from previous stake marks.

21. Install dust seal (2) to cylinder head using ST8021 Cylinder Head Maintenance Tool.

31. Apply clean oil to piston and seals. Attach appropriate lifting device to rod using a lifting strap. Carefully install piston, rod, and cylinder head into barrel.

22. Install O-ring (9), backup ring (10), and O-ring (11) to cylinder head. 23. Install piston seal (21) to piston and adjust piston seal using ST2967 Installation Tool. 24. Install wear rings (22), dust rings (23), O-ring (19), and backup rings (20) to piston. 25. Install assembled cylinder head on rod using ST8021 Cylinder Head Maintenance Tool.

32. Install socket head cap screws (12). Tighten to specification. Specification Bucket Cylinder Head-to-Barrel Socket Head Cap Screw—Torque............................................................................375 N·m 277 lb.-ft.

NOTE: Cushion bearing must be installed with groove in direction noted during removal. DV53278,00008A8 -19-06JAN15-3/3

TM13264X19 (02FEB17)

33-3360-111

300GLC Excavator 020217 PN=383

Hydraulic System

Hydraulic Cylinder Bleed Procedure

hydraulic system, or when machine has been in storage for a period of time.

SPECIFICATIONS Engine Speed

Slow Idle

CAUTION: Prevent injury from unexpected machine movement. Perform this procedure when repairs or maintenance is done on hydraulic system, or when machine has been stored for a period of time. 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.

IMPORTANT: Prevent component damage from cavitation. Perform this procedure when repairs or maintenance is done on hydraulic system, or when machine has been stored for a period of time. 1. Operate engine to specification. Specification Engine—Speed..........................................................................Slow Idle

2. Slowly extend and retract cylinder several times to approximately 100 mm (4 in) from end of stroke. 3. Operate cylinder several times to full stroke. 4. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.)

NOTE: Bleed air at initial start-up, whenever major repairs or maintenance (oil change) is done on JL58967,00002B2 -19-12MAY15-1/1

TM13264X19 (02FEB17)

33-3360-112

300GLC Excavator 020217 PN=384

Section 43 Swing or Pivoting System Contents Page

Group 4350—Mechanical Drive Elements Swing Gear Case Remove and Install ..................................................... 43-4350-1 Swing Gear Case Disassemble and Assemble........................................ 43-4350-3 Swing Gear Case Start-Up Procedure ............................................ 43-4350-14 Upperstructure Remove and Install ................................................... 43-4350-15 Swing Bearing Remove and Install ................................................... 43-4350-18 Swing Bearing Disassemble and Assemble............................................. 43-4350-20 Swing Bearing Upper Seal Install ............ 43-4350-24 Swing Bearing Lower Seal Install ............ 43-4350-25 Group 4360—Hydraulic System Center Joint Remove and Install ............... 43-4360-1 Center Joint Disassemble and Assemble............................................... 43-4360-3 Center Joint Air Test .................................. 43-4360-4 Swing Motor and Park Brake Remove and Install................................ 43-4360-5 Swing Motor and Park Brake Disassemble .......................................... 43-4360-7 Swing Motor and Park Brake Inspection .............................................. 43-4360-9 Swing Motor and Park Brake Assemble............................................. 43-4360-12 Swing Motor and Park Brake Start-Up Procedure.............................. 43-4360-14 Crossover Relief Valve and Make-Up Check Valve Remove and Install ............................................ 43-4360-15 Make-Up Check Valve Disassemble and Assemble ................ 43-4360-17 Swing Park Brake Check Valve and Orifice Remove and Install .................. 43-4360-18

TM13264X19 (02FEB17)

43-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

43-2

300GLC Excavator

020217

PN=2

Group 4350

Mechanical Drive Elements Swing Gear Case Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Swing Gear Case Oil Capacity (approximate)

12.0 L 12.7 qt.

Swing Gear Case Assembly Weight (approximate)

360 kg 794 lb.

Swing Gear Case Cap Screw Torque

640 N·m 470 lb.-ft.

OTHER MATERIAL Loctite® 277™ Threadlocker (high strength)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1130692A —UN—06FEB13

Swing Device

3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

4. Drain swing gear case oil. See Drain and Refill Swing Gear Case Oil. (Operator’s Manual.) Specification Swing Gear Case Oil—Capacity (approximate)................................................................................. 12.0 L 12.7 qt.

5. Install identification tags and disconnect hydraulic lines (2—5). Close all openings using caps and plugs. See Swing Motor Line Identification. (Group 9025-15.) 6. Remove swing park brake check valve (6). See Swing Park Brake Check Valve and Orifice Remove and Install. (Group 4360.)

1— Cap Screw (14 used) 2— Swing Left Supply Line 3— Swing Right Supply Line 4— Return Line to Return Manifold

5— Return Line to Control Valve 6— Swing Park Brake Check Valve 7— Swing Gear Case Assembly

8. Attach appropriate lifting device to swing gear case assembly (7). Remove cap screws (1) and swing gear case assembly. Specification Swing Gear Case Assembly—Weight (approximate)................................................................................ 360 kg 794 lb.

9. Repair or replace parts as necessary. See Swing Gear Case Disassemble and Assemble. (Group 4350.) 10. Apply Loctite® 277™ Threadlocker (high strength) to mating surfaces of swing gear case housing and upperstructure. CAUTION: Prevent possible crushing injury from heavy components. Use appropriate lifting device.

7. Apply alignment marks on swing gear case housing and upperstructure to aid in installation. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Continued on next page

TM13264X19 (02FEB17)

43-4350-1

DV53278,00008BB -19-17DEC14-1/2

300GLC Excavator 020217 PN=387

Mechanical Drive Elements 11. Using appropriate lifting device, install swing gear case assembly. Specification Swing Gear Case Assembly—Weight (approximate)................................................................................ 360 kg 794 lb.

12. Align swing gear case assembly mark with mark on upperstructure. 13. Install cap screws and tighten to specification. Specification Swing Gear Case Cap Screw—Torque............................................................................640 N·m 470 lb.-ft.

14. Install swing park brake check valve. See Swing Park Brake Check Valve and Orifice Remove and Install. (Group 4360.) NOTE: Return line to return manifold (4) will remain capped and plugged until swing motor and park brake start-up procedure is performed. 15. Install hydraulic lines (2, 3, and 5). See Swing Motor Line Identification. (Group 9025-15.) 16. Fill swing gear case oil. See Drain and Refill Swing Gear Case Oil. (Operator’s Manual.)

Specification Swing Gear Case Oil—Capacity (approximate)................................................................................. 12.0 L 12.7 qt.

17. Perform swing motor and park brake start-up procedure and connect return line to return manifold (4). See Swing Motor and Park Brake Start-Up Procedure. (Group 4360.) 18. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

IMPORTANT: To prevent possible hydraulic pump damage, pump 1 and 2 start-up procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 19. If hydraulic oil tank was drained, perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 20. Operate machine and check for leaks.

Loctite and its related brand marks are trademarks of Henkel Corporation DV53278,00008BB -19-17DEC14-2/2

TM13264X19 (02FEB17)

43-4350-2

300GLC Excavator 020217 PN=388

Mechanical Drive Elements ESSENTIAL TOOLS

Swing Gear Case Disassemble and Assemble SPECIFICATIONS Swing Gear Case Assembly Weight (approximate)

360 kg 794 lb.

Swing Gear Case Oil Capacity

12.0 L 12.7 qt.

Swing Motor and Park Brake Weight (approximate)

71 kg 157 lb.

Ring Gear Weight (approximate)

39 kg 86 lb.

Housing Assembly Weight (approximate)

178 kg 393 lb.

Shaft Assembly Weight (approximate)

60 kg 132 lb.

Bearing Nut Torque

600 N·m 443 lb.-ft.

Lock Plate-to-Bearing Nut Cap Screw Torque

50 N·m 37 lb.-ft.

Ring Gear Housing Cap Screw Torque

300 N·m 221 lb.-ft.

Drain Plug Torque

50 N·m 37 lb.-ft.

ST5100 Stand DFT1351 Swing Gear Case Nut Spanner Wrench OTHER MATERIAL Loctite® 277™ Threadlocker (high strength)

Continued on next page

TM13264X19 (02FEB17)

43-4350-3

DV53278,00008BC -19-21JAN15-1/11

300GLC Excavator 020217 PN=389

Mechanical Drive Elements

23 24

1 25

2 3 33 21

4 32 5 6

7 19

10 17 16

11 30

15 13

TX1129133 —UN—15JAN13

TX1129133 Swing Gear Case Disassemble and Assemble

Continued on next page

TM13264X19 (02FEB17)

43-4350-4

DV53278,00008BC -19-21JAN15-2/11

300GLC Excavator 020217 PN=390

Mechanical Drive Elements 1— Swing Motor 2— First Stage Sun Gear 3— Thrust Plate 4— Pin (3 used) 5— Spring Pin (3 used) 6— Needle Bearing (3 used) 7— First Stage Planetary Gear (3 used) 8— Thrust Plate (3 used)

16— Lock Plate 17— Cap Screw (2 used) 18— Second Stage Carrier 19— Thrust Plate 20— Second Stage Sun Gear 21— First Stage Carrier 23— Cap Screw (8 used) 24— Ring Gear Cap Screw (12 used)

9— Pin (3 used) 10— Spring Pin (3 used) 11— Needle Bearing (6 used) 12— Second Stage Planetary Gear (3 used) 13— Thrust Plate (6 used) 14— Upper Roller Bearing 15— Bearing Nut

25— Ring Gear 26— Housing 27— Lower Roller Bearing 28— Seal 29— Sleeve 30— O-Ring 31— Shaft 32— Drain Plug 33— Drain Line

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

43-4350-5

DV53278,00008BC -19-21JAN15-3/11

300GLC Excavator 020217 PN=391

Mechanical Drive Elements Disassemble Swing Gear Case CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 1. Attach appropriate lifting device, remove swing gear case assembly. See Swing Gear Case Remove and Install. (Group 4350.) Specification Swing Gear Case Assembly—Weight (approximate)................................................................................ 360 kg 794 lb.

2. Install ST5100 Stand using M20 x 2.5 cap screws. 3. Remove drain plug (32) and drain oil from swing gear case. See Drain and Refill Swing Gear Case Oil. (Operator’s Manual.)

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 11. Support ring gear (25) by attaching appropriate lifting device. Remove cap screws (24). Specification Ring Gear—Weight (approximate).................................................................................. 39 kg 86 lb.

12. Using appropriate lifting device, remove ring gear. NOTE: Second stage sun gear (20) may be removed separately or with second stage carrier (18). 13. Remove second stage sun gear (20). 14. Remove second stage carrier (18) from shaft (31). 15. Remove spring pins (10) from second stage carrier.

Specification Swing Gear Case Oil—Capacity................................................................................. 12.0 L 12.7 qt.

16. Remove pins (9), second stage planetary gears (12), needle bearings (11), and thrust plates (13 and 19) from second stage carrier.

4. Disconnect drain line (33) from housing (26). 5. Apply alignment marks to swing motor (1), ring gear (25), and housing to aid during assembly. CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 6. Using appropriate lifting device, remove swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.)

17. Remove cap screws (17) and lock plate (16) from bearing nut (15). 18. Remove bearing nut from shaft (31) using DFT1351 Swing Gear Case Nut Spanner Wrench (37). See DFT1351 Swing Gear Case Nut Spanner Wrench. (Group 9900.) NOTE: Roller bearings (14 and 27) and sleeve (29) are pressed onto shaft (31).

Specification Swing Motor and Park Brake—Weight (approximate).................................................................................. 71 kg 157 lb.

NOTE: First stage sun gear (2) may be removed separately or with swing motor (1).

NOTE: Each second stage planetary gear (12) uses two needle bearings (11).

19. Remove upper roller bearing (14) from shaft (31). CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 20. Support housing (26) assembly using appropriate lifting device and remove ST5100 Stand.

7. Remove first stage sun gear (2). 8. Remove first stage carrier (21) from ring gear (25). 9. Remove spring pins (5) from first stage carrier. 10. Remove pins (4), first stage planetary gears (7), needle bearings (6), and thrust plates (3 and 8) from first stage carrier.

Specification Housing Assembly—Weight (approximate)............................................................................................. 178 kg 393 lb.

Continued on next page

TM13264X19 (02FEB17)

43-4350-6

DV53278,00008BC -19-21JAN15-4/11

300GLC Excavator 020217 PN=392

Mechanical Drive Elements 15— Bearing Nut

37— DFT1351 Swing Gear Case Nut Spanner Wrench

TX1129006 —UN—07JAN13

Bearing Nut Continued on next page

TM13264X19 (02FEB17)

43-4350-7

DV53278,00008BC -19-21JAN15-5/11

300GLC Excavator 020217 PN=393

Mechanical Drive Elements

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

21. Support shaft (31) by attaching appropriate lifting device. Push on spline side of shaft using a press (34) to remove shaft from housing (26).

Specification Shaft Assembly—Weight (approximate).................................................................................. 60 kg 132 lb.

22. Inspect shaft (31), lower roller bearing (27), and sleeve (29) for damage. 23. Remove lower roller bearing (27) and sleeve (29) from shaft using a press. 24. Remove seal (28) from housing and discard.

TX1129007 —UN—07JAN13

Shaft and Housing 26— Housing 31— Shaft

34— Press

25. Remove O-ring (30) from sleeve. 26. Repair or replace parts as necessary.

Continued on next page

TM13264X19 (02FEB17)

43-4350-8

DV53278,00008BC -19-21JAN15-6/11

300GLC Excavator 020217 PN=394

Mechanical Drive Elements

23 24

1 25

2 3 33 21

4 32 5 6

7 19

10 17 16

11 30

15 13

TX1129133 —UN—15JAN13

TX1129133 Swing Gear Assembly

Continued on next page

TM13264X19 (02FEB17)

43-4350-9

DV53278,00008BC -19-21JAN15-7/11

300GLC Excavator 020217 PN=395

9— Pin (3 used) 10— Spring Pin (3 used) 11— Needle Bearing (6 used) 12— Second Stage Planetary Gear (3 used) 13— Thrust Plate (6 used) 14— Upper Roller Bearing 15— Bearing Nut

25— Ring Gear 26— Housing 27— Lower Roller Bearing 28— Seal 29— Sleeve 30— O-Ring 31— Shaft 32— Drain Plug 33— Drain Line DV53278,00008BC -19-21JAN15-8/11

Assemble Swing Gear Case 1. Install O-ring (30) in sleeve (29). CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device.

TX1128932A —UN—04JAN13

2. Support shaft (31) using appropriate lifting device. Install sleeve and lower roller bearing (27) onto shaft using a press. Specification Shaft Assembly—Weight (approximate).................................................................................. 60 kg 132 lb.

3. Apply Loctite® 277™ Threadlocker (high strength) to outer surface of new seal (28). 4. Install new seal so lip (spring side) is toward bottom of housing (26).

Bearing Nut

5. Apply grease to inner surface of new seal.

15— Bearing Nut

6. Apply grease to outer surface of sleeve (29) and shaft (31). CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 7. Using appropriate lifting device, install shaft assembly into housing. Specification Shaft Assembly—Weight (approximate).................................................................................. 60 kg 132 lb.

NOTE: The fitting between the inner race of upper roller bearing (14) and shaft (31) is tight. 8. Install upper roller bearing (14) until two threads of shaft (31) are visible. 9. Apply grease to thread part of bearing nut (15). Install and tighten bearing nut hand tight to secure shaft in housing (26). Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

43-4350-10

DV53278,00008BC -19-21JAN15-9/11

300GLC Excavator 020217 PN=396

Mechanical Drive Elements

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 10. Using appropriate lifting device, install housing (26) assembly to ST5100 Stand (36) with M20 x 2.5 cap screws (22). Specification Housing Assembly—Weight (approximate)............................................................................................. 178 kg 393 lb.

TX1128930A —UN—16JAN13

IMPORTANT: Avoid possible bearing and shaft damage. Properly seat bearings (14 and 27) by tapping on housing assembly with plastic hammer then tightening bearing nut. Procedure will be done multiple times to ensure bearings are properly seated. 11. Position pinion gear against stopper (35) to prevent shaft (31) rotation. Housing Assembly 22— Cap Screw (2 used) 26— Housing 31— Shaft

35— Stopper 36— ST5100 Stand

DV53278,00008BC -19-21JAN15-10/11

12. Tighten bearing nut (15) to specification using DFT1351 Swing Gear Case Nut Spanner Wrench (37). See DFT1351 Swing Gear Case Nut Spanner Wrench. (Group 9900.)

37 15 TX1129006 —UN—07JAN13

Specification Bearing Nut—Torque ..................................................................600 N·m 443 lb.-ft.

13. Remove the M20 x 2.5 cap screws used to secure housing (26) to ST5100 Stand. 14. Rotate housing five times in both directions while tapping with a plastic hammer. 15. Install housing assembly to ST5100 Stand using M20 x 2.5 cap screws.

Bearing Nut 15— Bearing Nut

37— DFT1351 Swing Gear Case Nut Spanner Wrench

16. Tighten bearing nut (15) to specification using DFT1351 Swing Gear Case Nut Spanner Wrench. See DFT1351 Swing Gear Case Nut Spanner Wrench. (Group 9900.)

(15). Procedure will be done multiple times to ensure bearings are properly seated.

Specification Bearing Nut—Torque ..................................................................600 N·m 443 lb.-ft.

17. To properly seat roller bearings (14 and 27), repeat procedures to tap on housing (26) assembly with plastic hammer and tightening bearing nut (15) multiple times.

IMPORTANT: Avoid possible bearing and shaft damage, properly seat bearings (14 and 27) by tapping on housing (26) assembly with plastic hammer then tightening bearing nut

18. Remove the M20 x 2.5 cap screws that are securing the housing to ST5100 Stand. DV53278,00008BC -19-21JAN15-11/11

TM13264X19 (02FEB17)

43-4350-11

300GLC Excavator 020217 PN=397

Mechanical Drive Elements

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. IMPORTANT: Avoid possible swing system component damage. Verify that sleeve (29) does not move in axial direction. Perform procedures to tap on housing (26) assembly with plastic hammer and tightening bearing nut (15) multiple times to properly seat bearings (14 and 27).

TX1128979A —UN—07JAN13

19. Using appropriate lifting device, position housing (26) assembly on flat work bench and check that sleeve (29) does not move on its axis. Specification Housing Assembly—Weight (approximate)............................................................................................. 178 kg 393 lb.

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. 20. Using appropriate lifting device, install housing assembly to ST5100 Stand (36) with M20 x 2.5 cap screws.

Housing Assembly 26— Housing 29— Sleeve

31— Shaft

Specification Housing Assembly—Weight (approximate)............................................................................................. 178 kg 393 lb. DV53278,00008BC -19-21JAN15-12/11

TM13264X19 (02FEB17)

43-4350-12

300GLC Excavator 020217 PN=398

Mechanical Drive Elements

21. Install lock plate (16). If lock plate does not engage with splines of shaft (31), tighten bearing nut (15) until lock plate engages. 22. Install cap screws (17) and tighten to specification. Specification Lock Plate-to-Bearing Nut Cap Screw—Torque .....................................................................50 N·m 37 lb.-ft. TX1165457A —UN—16JUL14

CAUTION: Avoid possible crushing injury from heavy object. Use appropriate lifting device. 23. Attach appropriate lifting device to ring gear (25). Specification Ring Gear—Weight (approximate).................................................................................. 39 kg 86 lb.

24. Align marks on ring gear and housing (26). Install ring gear. 25. Apply Loctite® 277™ Threadlocker (high strength) to motor mounting surface of ring gear (25). Tighten cap screws (24) to specification. Specification Ring Gear Housing Cap Screw—Torque ...........................................................................300 N·m 221 lb.-ft.

NOTE: Procedure for assembly of first and second stage carrier assemblies are identical. 26. Install thrust plate (19) into second stage carrier (18). 27. Install needle bearings (11) into second stage planetary gears (12). 28. Install second stage planetary gears and thrust plate (13) into second stage carrier. 29. Install pins (9) into second stage carrier. 30. Install spring pins (10) with slit of spring pins towards end of pin (9). 31. Install second stage carrier into ring gear (25). 32. Install second stage sun gear (20). 33. Install thrust plate (3) into first stage carrier (21).

Lock Plate 16— Lock Plate 17— Cap Screw (2 used)

31— Shaft

35. Install first stage planetary gears (7) and thrust plate (8) into first stage carrier. 36. Install pins (4) into first stage carrier. 37. Install spring pins (5) with slit of spring pins towards end of pin (4). 38. Install first stage sun gear (2) to swing motor (1). 39. Apply Loctite® 277™ Threadlocker (high strength) to motor mounting surface of ring gear (25). 40. Remove the M20 x 2.5 cap screws used to secure housing (26) to ST5100 Stand. 41. Install swing motor and park brake. See Swing Motor and Park Brake Remove and Install. (Group 4360.) 42. Install drain line (33) and drain plug (32). Specification Drain Plug—Torque ......................................................................50 N·m 37 lb.-ft.

43. Fill swing gear case. See Drain and Refill Swing Gear Case Oil. (Operator’s Manual.)

34. Install needle bearings (6) into first stage planetary gears (7). Loctite and its related brand marks are trademarks of Henkel Corporation DV53278,00008BC -19-21JAN15-13/11

TM13264X19 (02FEB17)

43-4350-13

300GLC Excavator 020217 PN=399

Mechanical Drive Elements

Swing Gear Case Start-Up Procedure SPECIFICATIONS 12.0 L 12.7 qt. TX1164327A —UN—02JUL14

Swing Gear Case Oil Capacity (approximate)

IMPORTANT: Swing gear case will be damaged if not filled with oil before operating swing function. Procedure must be performed whenever a new swing gear case is installed or oil has been drained from the gear case. 1. Check swing gear case oil level. See Check Swing Gear Case Oil Level. (Operator’s Manual.) 2. If necessary, remove fill cap (2) and add oil. For information on oil types, see Swing Gear Case and Travel Gear Case Oils. (Operator’s Manual.)

Swing Gear Case 1— Dipstick

2— Fill Cap

Specification Swing Gear Case Oil—Capacity (approximate)................................................................................. 12.0 L 12.7 qt. DV53278,00008BD -19-17DEC14-1/1

TM13264X19 (02FEB17)

43-4350-14

300GLC Excavator 020217 PN=400

Mechanical Drive Elements

Upperstructure Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Upperstructure Weight (approximate)

6975 kg 15 380 lb.

Stop Bracket Cap Screw Torque

TX1121913A —UN—06SEP12

Upperstructure Cap Screw Torque 637 N·m 470 lb.-ft. 140 N·m 103 lb.-ft.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing.

Center Joint 1— Right Forward Travel Supply Line 2— Right Reverse Travel Supply Line 3— Left Reverse Travel Supply Line 4— Left Forward Travel Supply Line

2. Relieve hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

5— Pilot Line 6— Return Line 7— Cap Screw (2 used) 8— Stop Bracket

NOTE: Center joint remains attached to undercarriage when upperstructure is removed.

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

8. Remove cap screws (7) and stop bracket (8).

4. Remove boom. See Boom Remove and Install. (Group 3340.) 5. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) 6. Remove cab. See Cab Remove and Install. (Group 1800.) 7. Install identification tags and disconnect hydraulic lines (1—6). Close all openings using caps and plugs. See Travel Hydraulic System Line Connection. (Group 9025-15.) Continued on next page

TM13264X19 (02FEB17)

43-4350-15

DV53278,00008BE -19-25JUN15-1/3

300GLC Excavator 020217 PN=401

Mechanical Drive Elements

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 9. Support upperstructure (9) by attaching appropriate lifting device (12) to counterweight mounting frames (10) and boom mounting holes (11). 11— Boom Mounting Hole (2 used) 12— Lifting Device

9 10

TX1121915 —UN—06SEP12

9— Upperstructure 10— Counterweight Mounting Frame (2 used)

Upperstructure Lifting Continued on next page

TM13264X19 (02FEB17)

43-4350-16

DV53278,00008BE -19-25JUN15-2/3

300GLC Excavator 020217 PN=402

Mechanical Drive Elements

10. Install alignment marks on upperstructure and outer race on swing bearing (14) to aid during installation.

TX1121916A —UN—07SEP12

11. Remove upperstructure cap screws (13). Record location of cap screws to aid during installation. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Using appropriate lifting device, remove upperstructure from undercarriage. Specification Upperstructure—Weight (approximate).............................................................................. 6975 kg 15 380 lb.

Upperstructure Cap Screws 9— Upperstructure 13— Upperstructure Cap Screw (36 used)

13. Repair or replace parts as necessary.

14— Swing Bearing

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 14. Attach appropriate lifting device to boom mounting holes and counterweight mounting frames. Install upperstructure. Specification Upperstructure—Weight (approximate).............................................................................. 6975 kg 15 380 lb.

15. Align upperstructure and swing bearing using alignment marks. 16. Install uppperstructure cap screws and tighten to specification. Specification Upperstructure Cap Screw—Torque............................................................................637 N·m 470 lb.-ft.

17. Install stop bracket and cap screws. Tighten to specification. Specification Stop Bracket Cap Screw—Torque............................................................................140 N·m 103 lb.-ft.

20. Install counterweight. See Counterweight Remove and Install. (Group 1749.) 21. Install boom. See Boom Remove and Install. (Group 3340.) 22. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

IMPORTANT: To prevent possible hydraulic pump damage, pump 1 and 2 start-up procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 23. When hydraulic oil tank is drained, perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 24. Operate machine and check for leaks.

18. Connect hydraulic lines. See Travel Hydraulic System Line Connection. (Group 9025-15.) 19. Install cab. See Cab Remove and Install. (Group 1800.) DV53278,00008BE -19-25JUN15-3/3

TM13264X19 (02FEB17)

43-4350-17

300GLC Excavator 020217 PN=403

Mechanical Drive Elements

Swing Bearing Remove and Install SPECIFICATIONS Swing Bearing Weight (approximate)

324 kg 715 lb.

Cap Screw Torque

650 N·m 480 lb.-ft.

Swing Bearing Grease Capacity (approximate)

17 L 4.5 gal.

SERVICE EQUIPMENT AND TOOLS JT01748 Lifting Bracket OTHER MATERIAL TX1122064 —UN—12SEP12

Loctite® 277™ Threadlocker (high strength)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Position machine so upperstructure and tracks face forward and are aligned. 3. Remove upperstructure. See Upperstructure Remove and Install. (Group 4350.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Lifting Brackets 1— Lifting Bracket (3 used)

2— Swing Bearing

4. Install JT01748 Lifting Brackets (1) to swing bearing (2). Support swing bearing by attaching appropriate lifting device to lifting brackets. Specification Swing Bearing—Weight (approximate)................................................................................ 324 kg 715 lb. Loctite and its related brand marks are trademarks of Henkel Corporation DV53278,00008BF -19-17DEC14-1/3

5. Apply alignment marks on inner race of swing bearing and track frame (3). 6. Remove cap screws (4) and remove swing bearing. TX1122068 —UN—12SEP12

7. Inspect and replace swing bearing upper and lower seals if necessary. See Swing Bearing Upper Seal Install or see Swing Bearing Lower Seal Install. (Group 4350.) 8. Repair or replace parts as necessary. See Swing Bearing Disassemble and Assemble. (Group 4350.) 9. Clean mating surfaces of swing bearing and track frame (3).

Swing Bearing Cap Screws

10. Apply Loctite® 277™ Threadlocker (high strength) to mating surfaces of swing bearing and track frame.

2— Swing Bearing 3— Track Frame

4— Cap Screw (36 used)

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM13264X19 (02FEB17)

43-4350-18

DV53278,00008BF -19-17DEC14-2/3

300GLC Excavator 020217 PN=404

Mechanical Drive Elements

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

TX1122615A —UN—18SEP12

11. Attach appropriate lifting device to swing bearing. Specification Swing Bearing—Weight (approximate)................................................................................ 324 kg 715 lb.

IMPORTANT: Prevent possible damage to swing bearing. Tooth and bearing loading plug must be installed on left rear side of machine so use of that portion of swing bearing is minimized. Tooth marked with letter G, S, or equivalent is starting and stopping point for hardening process.

Tooth and Bearing Loading Plug

12. Install swing bearing on track frame. Position swing bearing so tooth (5) marked G, S, or equivalent and bearing loading plug (6) are towards left rear side of machine.

13. Install cap screws and tighten to specification.

14. Apply grease to swing bearing teeth and pinion shaft. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operator’s Manual.)

TX1122659 —UN—18SEP12

Specification Cap Screw—Torque....................................................................650 N·m 480 lb.-ft.

Specification Swing Bearing Grease—Capacity (approximate).................................................................................... 17 L 4.5 gal.

6 7 Swing Bearing Install Position

15. Install upperstructure. See Upperstructure Remove and Install. (Group 4350.)

5— Tooth 6— Bearing Loading Plug

7— Grease Fitting (2 used)

DV53278,00008BF -19-17DEC14-3/3

TM13264X19 (02FEB17)

43-4350-19

300GLC Excavator 020217 PN=405

Mechanical Drive Elements SERVICE EQUIPMENT AND TOOLS

Swing Bearing Disassemble and Assemble SPECIFICATIONS Swing Bearing Weight (approximate)

324 kg 715 lb.

Swing Bearing Grease Capacity

0.4 L 13.6 oz.

M8-1.25 Cap Screw JT01748 Lifting Bracket

Continued on next page

TM13264X19 (02FEB17)

43-4350-20

DV53278,00008C0 -19-17DEC14-1/4

300GLC Excavator 020217 PN=406

Mechanical Drive Elements

4 1

7 3

TX1113415 —UN—18MAR15

TX1113415 Swing Bearing (exploded view) 1— Outer Race 2— Inner Race 3— Steel Ball (95 used)

4— Plug (2 used) 5— Lower Seal

6— Upper Seal 7— Spacer (95 used)

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

Continued on next page

TM13264X19 (02FEB17)

43-4350-21

DV53278,00008C0 -19-17DEC14-2/4

300GLC Excavator 020217 PN=407

Mechanical Drive Elements 1. Remove swing bearing. See Swing Bearing Remove and Install. (Group 4350.)

Specification Swing Bearing—Weight (approximate)................................................................................ 324 kg 715 lb. DV53278,00008C0 -19-17DEC14-3/4

2. Grind tack weld (9) off top of taper pin (11). 3. Drive taper pin out from bottom side of bearing.

9— Tack Weld 10— Loading Plug

TX1092921 —UN—06JUN11

4. Remove loading plug (10) using M8-1.25 cap screw. 11— Taper Pin

Swing Bearing Cross Section DV53278,00008C0 -19-17DEC14-4/4

TM13264X19 (02FEB17)

43-4350-22

300GLC Excavator 020217 PN=408

Mechanical Drive Elements

5. Using a magnet and wire, remove steel balls (3) and spacers (7) by rotating outer race.

TX1124992 —UN—31OCT12

NOTE: Upper and lower swing bearing seals should only be removed if damaged. 6. If damaged, remove upper and lower seals using a scraper. See Swing Bearing Upper Seal Install and see Swing Bearing Lower Seal Install. (Group 4350.) 7. Replace parts as necessary. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Swing Bearing Cross Section

8. Using JT01748 Lifting Brackets, align outer race and inner race of swing bearing.

TX1124993 —UN—31OCT12

Specification Swing Bearing—Weight (approximate)................................................................................ 324 kg 715 lb.

9. Install steel balls and spacers alternately through plug hole while turning outer race. 10. Install loading plug. 11. Install taper pin even with top of swing bearing. Swing Bearing Cross Section

12. Tack weld pin to swing bearing. See Welding On Machine. (Group 1740.) 13. While turning outer race, add multipurpose grease to swing bearing through lubrication fittings. See Lubricate Swing Bearing. (Operator’s Manual.) Specification Swing Bearing Grease—Capacity............................................................................ 0.4 L 13.6 oz.

3— Steel Ball (95 used)

7— Spacer (95 used)

14. Install swing bearing. See Swing Bearing Remove and Install. (Group 4350.)

DV53278,00008C0 -19-17DEC14-5/4

TM13264X19 (02FEB17)

43-4350-23

300GLC Excavator 020217 PN=409

Mechanical Drive Elements

Swing Bearing Upper Seal Install OTHER MATERIAL Loctite® 7649™ Klean ‘N Prime™ Primer TX1092915A —UN—06JUN11

Loctite® 454™ Quick Gel® Super Glue

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove upperstructure. See Upperstructure Remove and Install. (Group 4350.) 3. Remove seal (1). Scrape and clean old adhesive from seal groove. 4. Thoroughly clean seal groove and new seal using Loctite® 7649™ Klean ‘N Prime™ Primer.

Seal 1— Seal

5. Apply Loctite® 454™ Quick Gel® Super Glue sparingly to seal groove. 6. Install seal with lip against inner bearing race. Start 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 7. Before bringing ends of seal together, cut off excess length. Be careful not to cut seal too short.

IMPORTANT: Prevent possible damage to seal. Avoid pulling seal out of groove. Adhesive must cure for at least 24 hours before using swing function. 9. Install upperstructure. See Upperstructure Remove and Install. (Group 4350.)

8. Apply Loctite® 454™ Quick Gel® Super Glue to both ends of seal. Push ends into seal groove to insure a proper seal. Loctite and its related brand marks are trademarks of Henkel Corporation JB42225,0000033 -19-21JUL14-1/1

TM13264X19 (02FEB17)

43-4350-24

300GLC Excavator 020217 PN=410

Mechanical Drive Elements

Swing Bearing Lower Seal Install OTHER MATERIAL Loctite® 7649™ Klean ‘N Prime™ Primer TX1113412 —UN—07MAY12

Loctite® 454™ Quick Gel® Super Glue

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) NOTE: It is not necessary to remove upperstructure to replace swing bearing lower seal. Part of swing bearing shown is cut away to show lower seal in groove. Swing Bearing Lower Seal

2. Remove old seal (1). 3. Scrape old adhesive from seal groove (2). Thoroughly clean seal groove and new seal using Loctite® 7649™ Klean ‘N Prime™ Primer. 4. Apply Loctite® 454™ Quick Gel® Super Glue sparingly to seal groove. 5. Install seal with seal lip against outer race. Start approximately 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 6. Before bringing ends of seal together, cut off excess length.

1— Seal

2— Seal Groove

7. Apply Loctite® 454™ Quick Gel® Super Glue to both ends of seal. Push ends into seal groove to insure a proper seal. IMPORTANT: Prevent possible damage to seal. 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.

Loctite and its related brand marks are trademarks of Henkel Corporation JB42225,0000034 -19-17JUL14-1/1

TM13264X19 (02FEB17)

43-4350-25

300GLC Excavator 020217 PN=411

Mechanical Drive Elements

TM13264X19 (02FEB17)

43-4350-26

300GLC Excavator 020217 PN=412

Group 4360

Hydraulic System Center Joint Remove and Install SPECIFICATIONS 156 L 41 gal. TX1020553A —UN—19MAR07

Hydraulic Oil Tank Capacity (approximate)

Center Joint Weight (approximate) 27 kg 60 lb. Center Joint Manifold-to-Frame Cap Screw Torque

90 N·m 66 lb.-ft.

Center Joint Stop Bracket-toManifold Cap Screw Torque

140 N·m 103 lb.-ft.

SERVICE EQUIPMENT AND TOOLS Center Joint Lifting Tool (2 used)

Center Joint

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

1— Stop Bracket 2— Cap Screw (2 used)

3— Hydraulic Hose (4 used) 4— Small Hydraulic Hose (2 used)

2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

4. Install identification tags and disconnect hydraulic hoses (3 and 4). Close all openings using caps and plugs. 5. Remove cap screws (2) and remove stop bracket (1). Continued on next page

TM13264X19 (02FEB17)

43-4360-1

DV53278,00008C1 -19-20JAN15-1/2

300GLC Excavator 020217 PN=413

Hydraulic System

6. Install identification tags and disconnect hydraulic hoses (7). Close all openings using caps and plugs.

5 6

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

7. Support center joint (5) using appropriate lifting device. For instructions to make tool, see Center Joint (Rotary Manifold) Lifting Tool. (Group 9900.)

TX1113221 —UN—07MAY12

Specification Center Joint—Weight (approximate).................................................................................. 27 kg 60 lb.

8. Remove cap screws (6) and lower center joint. 9. Inspect and replace parts as necessary. See Center Joint Air Test and see Center Joint Disassemble and Assemble. (Group 4360.) 10. Raise center joint into position. Install cap screws and tighten to specification. Center Joint (underside)

Specification Center Joint Manifold-to-Frame Cap Screw—Torque..............................................................................90 N·m 66 lb.-ft.

11. Connect hydraulic hoses. See Travel Hydraulic System Line Connection. (Group 9025-15.) 12. Install stop bracket and cap screws. Tighten to specification. Specification Center Joint Stop Bracket-to-Manifold Cap Screw—Torque............................................................................140 N·m 103 lb.-ft.

13. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

5— Center Joint 6— Cap Screw (4 used)

7— Hydraulic Hose (8 used)

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

IMPORTANT: To prevent possible hydraulic pump damage, pump 1 and 2 start-up procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 14. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 15. Operate machine and check for leaks. DV53278,00008C1 -19-20JAN15-2/2

TM13264X19 (02FEB17)

43-4360-2

300GLC Excavator 020217 PN=414

Hydraulic System

Center Joint Disassemble and Assemble

SPECIFICATIONS Center Joint Weight (approximate)

27 kg 60 lb.

Press Force

4895—14 680 N 1100—3300 lb.-force

Cover-to-Housing Cap Screw Torque

50 N·m 37 lb.-ft.

2 3 4

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

5 6

1. Using appropriate lifting device, remove center joint. See Center Joint Remove and Install. (Group 4360.)

Specification Center Joint—Weight (approximate).................................................................................. 27 kg 60 lb.

2. Place center joint on a flat, clean work area.

3. Install alignment marks on spindle (2), housing (7), and cover (11) to aid in assembly.

TX1182242 —UN—12JAN15

4. Remove cap screws (12).

5. Remove cover, O-ring (10), snap ring (9), and ring (8) from housing.

Center Joint Components

IMPORTANT: Avoid damage to internal components of center joint. Do not damage the seal sliding surface of spindle.

1— Plug 2— Spindle 3— Dust Seal 4— O-Ring 5— Bushing 6— Oil Seal (6 used)

6. Remove the housing from the spindle.

7— Housing 8— Ring 9— Snap Ring 10— O-Ring 11— Cover 12— Cap Screw (4 used)

7. Remove oil seals (6) from housing. 8. Remove dust seal (3) and O-ring (4) from housing. NOTE: Sliding surfaces with seals that are heavily damaged by seizure or foreign matter should be replaced.

IMPORTANT: Prevent possible component damage from installing dust seal incorrectly. Install dust seal with lip side toward housing.

9. Inspect housing and spindle for wear and damage.

14. Install dust seal and O-ring (4).

IMPORTANT: Prevent possible machine damage from weld spatter. Cover the seal surface when welding.

15. Install oil seals to housing. IMPORTANT: Prevent possible component damage. Install spindle assembly slowly into housing so oil seals are not damaged.

10. Remove bushing (5) if surface shows wear, scores, or damage.

16. Lubricate spindle assembly with clean hydraulic oil and install into housing. Align reference marks made during disassembly.

11. Remove bushing by welding on bushing inner diameter in four places at 90°. Let bushing cool and shrink, remove from housing. 12. If bushing is removed clean housing and new bushing. Apply clean hydraulic oil to housing and new bushing to prevent seizing of parts. 13. Install bushing into housing using a press.

IMPORTANT: Prevent possible component damage from installing ring incorrectly. Install ring with chamfered side facing spindle assembly. 17. Install ring and O-ring (10) to housing. 18. Install snap ring to spindle.

Specification Press Force—Force....................................................... 4895—14 680 N 1100—3300 lb.-force Continued on next page

TM13264X19 (02FEB17)

43-4360-3

DV53278,00008C2 -19-21JAN15-1/2

300GLC Excavator 020217 PN=415

Hydraulic System

19. Install cover and cap screws to housing. Tighten cap screws to specification. Specification

20. Install center joint. See Center Joint Remove and Install. (Group 4360.)

Cover-to-Housing Cap Screw—Torque..............................................................................50 N·m 37 lb.-ft. DV53278,00008C2 -19-21JAN15-2/2

Center Joint Air Test SERVICE EQUIPMENT AND TOOLS JDG185 Air Test Plug

T6557JB —UN—01NOV88

1. Install a plug in one port. 2. Apply air pressure, using JDG185 Air Test Plug and regulated air pressure through the other port in that passage. 3. Listen for air leaks at ports on either side of pressurized port. 4. Repair or replace if air leaks are found. See Center Joint Disassemble and Assemble. (Group 4360.)

Center Joint Air Test TZ24494,0000EF2 -19-20MAR13-1/1

TM13264X19 (02FEB17)

43-4360-4

300GLC Excavator 020217 PN=416

Hydraulic System

Swing Motor and Park Brake Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Swing Motor and Park Brake Weight (approximate)

77 kg 170 lb.

Swing Motor-to-Ring Gear Cap Screw Torque

90 N·m 67 lb.-ft.

Cap Screw Torque

58 N·m 43 lb.-ft.

TX1113463A —UN—08MAY12

2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

7— Cap Screw (6 used)

8— Swing Motor and Park Brake Cover

4. Remove cap screws (7). 5. Remove swing motor and park brake cover (8). Continued on next page

TM13264X19 (02FEB17)

43-4360-5

DV53278,00008C3 -19-17DEC14-1/2

300GLC Excavator 020217 PN=417

Hydraulic System

6. Install identification tags and disconnect hydraulic lines (1, 2, and 3). Close all openings using caps and plugs. See Hydraulic System Line Connections. (Group 9025-15.) TX1128545A —UN—02JAN13

7. Remove cap screws (9) and flanges (10). 8. Install identification tags and disconnect swing damper valve hydraulic lines (5). Close all openings using caps and plugs. See Hydraulic System Line Connections. (Group 9025-15.) 9. Disconnect front attachment pressure sensor (B32). See Machine Harness (W2) Component Location. (Group 9015-10.)

Swing Motor and Park Brake

10. Remove cap screws (4). 1— Pilot Signal Manifold Hydraulic Line 2— Hydraulic Oil Tank Return Line 3— Control Valve Hydraulic Line 4— Cap Screw (12 used) 5— Swing Damper Valve Hydraulic Line (2 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Using appropriate lifting device, remove swing motor and park brake (6). Specification Swing Motor and Park Brake—Weight (approximate).................................................................................. 77 kg 170 lb.

12. Inspect and replace parts as necessary. See Swing Motor and Park Brake Disassemble. (Group 4360.) 13. Using appropriate lifting device, install swing motor and park brake. 14. Install cap screws and tighten to specification. Specification Swing Motor-toRing Gear Cap Screw—Torque..............................................................................90 N·m 67 lb.-ft.

15. Connect front attachment pressure sensor (B32). See Machine Harness (W2) Component Location. (Group 9015-10.) 16. Connect swing damper valve hydraulic lines (5). See Hydraulic System Line Connections. (Group 9025-15.) 17. Install flanges (10) and cap screws (9). Tighten cap screws to specification. Specification Cap Screw—Torque......................................................................58 N·m 43 lb.-ft.

NOTE: Control valve hydraulic line (3) will remain capped and plugged until swing motor and park brake start-up procedure is performed.

6— Swing Motor and Park Brake 9— Cap Screw (8 used) 10— Flange (4 used) B32— Front Attachment Pressure Sensor

18. Connect hydraulic lines (1 and 2). See Hydraulic System Line Connections. (Group 9025-15.) 19. Perform swing motor and park brake start-up procedure. See Swing Motor and Park Brake Start-Up Procedure. (Group 4360.) 20. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

IMPORTANT: To prevent possible hydraulic pump damage, pump 1 and 2 start-up procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 21. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 22. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operator’s Manual.) 23. Operate machine and check for leaks. DV53278,00008C3 -19-17DEC14-2/2

TM13264X19 (02FEB17)

43-4360-6

300GLC Excavator 020217 PN=418

Hydraulic System ESSENTIAL TOOLS

Swing Motor and Park Brake Disassemble ST1468 Extracting Tool

SPECIFICATIONS 48 kg 106 lb.

Swing Motor and Park Brake Weight

6 7 8

2 3 4

11 5 12

3 2

1 17 13

18 18 18

15 16 19 19

23 20 21 22 24

25 26

28 29

32 30 31 TX1138130 Continued on next page

TM13264X19 (02FEB17)

43-4360-7

TX1138130 —UN—05JUN13

DV53278,00008C4 -19-20JAN15-1/2

300GLC Excavator 020217 PN=419

Hydraulic System

Swing Motor and Park Brake 1— Crossover Relief Valve (2 used) 2— Make-Up Check Valve Plug (2 used) 3— O-Ring (2 used) 4— Spring (2 used) 5— Poppet (2 used) 6— Damper Valve (2 used)

7— Back-Up Ring (2 used) 8— Packing (2 used) 9— Cap Screw (4 used) 10— Park Brake Valve Casing 11— O-Ring 12— Roller Bearing 13— Valve Plate 14— Spring (24 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 1. Using appropriate lifting device, place swing motor on clean, flat surface. Specification Swing Motor and Park Brake—Weight................................................................................ 48 kg 106 lb.

15— Brake Piston 16— O-Ring 17— O-Ring 18— Plate (4 used) 19— Friction Plate (3 used) 20— Rotor 21— Retainer 22— Plate 23— Plunger (9 used) 24— Shoe Plate

25— Shaft 26— Roller Bearing 27— Oil Seal 28— O-Ring 29— Piston 30— Spring 31— Ball 32— Swing Motor Gear Case

8. Using ST1468 Extracting Tool, remove brake piston (15). 9. Remove O-rings (16 and 17) from swing motor gear case (32). 10. Remove rotor, retainer (21), plate (22), and plungers (23) from shaft (25). 11. Remove plates (18) and friction plates (19). 12. Remove shoe plate (24) from swing motor gear case.

2. Remove crossover relief valves (1). Crossover relief valves are not serviceable. Do not disassemble crossover relief valves.

13. Remove oil seal (27) and outer race of roller bearing (26) from swing motor gear case.

3. Remove make-up check valve plugs (2), O-rings (3), springs (4), and poppets (5).

14. Remove inner race of roller bearing from shaft using a press.

4. Remove damper valves (6), back-up rings (7), and packings (8).

IMPORTANT: Prevent possible machine damage. Filter and orifice are mounted inside of piston (29). Unless absolutely necessary, do not disassemble. If the inner parts need to be replaced, replace them as an assembly.

5. Remove cap screws (9), park brake valve casing (10), and O-ring (11). NOTE: Do not remove roller bearing (12) unless necessary.

15. Remove piston (29), O-ring (28), spring (30), and ball (31).

6. If necessary, remove roller bearing (12).

16. Inspect and replace parts as necessary.

7. Remove valve plate (13) and springs (14) from rotor (20). DV53278,00008C4 -19-20JAN15-2/2

TM13264X19 (02FEB17)

43-4360-8

300GLC Excavator 020217 PN=420

Hydraulic System

Swing Motor and Park Brake Inspection SPECIFICATIONS Plunger-to-Cylinder Clearance

0.027 mm new 0.001 in. new 0.052 mm maximum used 0.0020 in. maximum used

Plunger-to-Shoe Clearance

0.0 mm new 0.0 in. new 0.3 mm maximum used 0.012 in. maximum used

Shoe Thickness

5.5 mm new 0.22 in. new 5.3 mm minimum 0.21 in. minimum

Friction Plate Thickness

2.0 mm new 0.08 in. new 1.8 mm minimum 0.07 in. minimum

1. Measure clearance between outer diameter of plunger and inner bore of cylinder. T142067 —UN—22JUN01

Specification Plunger-toCylinder—Clearance.........................................................0.027 mm new 0.001 in. new 0.052 mm maximum used 0.0020 in. maximum used

Plunger and Bore Continued on next page

TM13264X19 (02FEB17)

43-4360-9

TZ24494,0000EF5 -19-20MAR13-1/4

300GLC Excavator 020217 PN=421

Hydraulic System

2. Measure clearance between plunger and shoe.

T142069 —UN—22JUN01

Specification Plunger-toShoe—Clearance..................................................................0.0 mm new 0.0 in. new 0.3 mm maximum used 0.012 in. maximum used

Plunger and Shoe TZ24494,0000EF5 -19-20MAR13-2/4

3. Measure thickness of shoe.

T142072 —UN—22JUN01

Specification Shoe—Thickness..................................................................5.5 mm new 0.22 in. new 5.3 mm minimum 0.21 in. minimum

Shoe Thickness Continued on next page

TM13264X19 (02FEB17)

43-4360-10

TZ24494,0000EF5 -19-20MAR13-3/4

300GLC Excavator 020217 PN=422

Hydraulic System

4. Measure thickness of friction plate. Specification Friction Plate—Thickness.......................................................................................2.0 mm new 0.08 in. new 1.8 mm minimum 0.07 in. minimum

T142073 —UN—22JUN01

5. Inspect and replace parts as necessary.

Friction Plate Thickness TZ24494,0000EF5 -19-20MAR13-4/4

TM13264X19 (02FEB17)

43-4360-11

300GLC Excavator 020217 PN=423

Hydraulic System

Swing Motor and Park Brake Assemble 6 7 8

2 3 4

11 5 12

3 2

1 17 13

18 18 18

15 16 19 19

23 20 21 22 24

25 26

28 29

32 30 31 TX1138130

TX1138130 —UN—05JUN13

Swing Motor and Park Brake

Continued on next page

TM13264X19 (02FEB17)

43-4360-12

TZ24494,0000EF6 -19-29JUN16-1/2

300GLC Excavator 020217 PN=424

Hydraulic System 1— Crossover Relief Valve (2 used) 2— Make-Up Check Valve Plug (2 used) 3— O-Ring (2 used) 4— Spring (2 used) 5— Poppet (2 used) 6— Damper Valve (2 used)

7— Back-Up Ring (2 used) 8— Packing (2 used) 9— Cap Screw (4 used) 10— Park Brake Valve Casing 11— O-Ring 12— Roller Bearing 13— Valve Plate 14— Spring (24 used)

SPECIFICATIONS Valve Casing Cap Screw Torque

431 N·m 318 lb·ft

Damper Valve Torque

70 N·m 52 lb·ft

25— Shaft 26— Roller Bearing 27— Oil Seal 28— O-Ring 29— Piston 30— Spring 31— Ball 32— Swing Motor gear Case

14. Install ball (31), spring (30), and piston (29) to swing motor gear case. 15. Install the outer race of bearing (12) to park brake valve casing (10).

Make-Up Check Valve Plug Torque 334 N·m 246 lb·ft Crossover Relief Valve Torque

15— Brake Piston 16— O-Ring 17— O-Ring 18— Plate (4 used) 19— Friction Plate (3 used) 20— Rotor 21— Retainer 22— Plate 23— Plunger (9 used) 24— Shoe Plate

16. Apply grease to valve plate (13). Install plate to valve casing with the notch on port facing toward the rotor.

177 N·m 131 lb·ft

17. Apply grease to needle part of bearing (12).

1. Install inner race of bearings (26 and 12) to shaft (25) using press.

18. Install park brake valve casing to swing motor gear case.

2. Install oil seal (27) to swing motor gear case (32).

19. Install cap screws (9). Tighten to specification.

3. Install outer race of bearing (26) to case.

Specification Valve Casing Cap Screw—Torque............................................................................431 N·m 318 lb·ft

IMPORTANT: Prevent possible oil seal damage. Wrap tape around shaft splines during installation. 4. Install shaft to swing motor gear case. 5. Install shoe plate (24) to swing motor gear case with the chamfered side toward case. 6. Install retainer (21) to plungers (23) with the notch on retainer facing the shoe plate side. 7. Align the notch and install retainer to plate (22). 8. Install the plungers to rotor (20). 9. Install the rotor to shaft. 10. Starting with a plate (18), alternately install plates and friction plates (19) to swing motor gear case and rotor aligning the four notches on the outer side of friction plates and on the spline side of plates respectively. 11. Install O-rings (16 and 17) to case. 12. Align the matching mark and install brake piston (15) into case.

20. Install damper valves (6), with back-up rings (7), and packings (8) attached. Tighten to specification. Specification Damper Valve—Torque.................................................................70 N·m 52 lb·ft

21. Install poppets (5), springs (4), and make-up check valve plugs (2). Tighten plugs with O-rings (3) attached to specification. Specification Make-Up Check Valve Plug—Torque...............................................................................334 N·m 246 lb·ft

22. Install crossover relief valves (1) into park brake valve casing. Tighten to specification. Specification Crossover Relief Valve—Torque.............................................................................177 N·m 131 lb·ft

13. Install springs (14) and O-ring (11) to brake piston. TZ24494,0000EF6 -19-29JUN16-2/2

TM13264X19 (02FEB17)

43-4360-13

300GLC Excavator 020217 PN=425

Hydraulic System

Swing Motor and Park Brake Start-Up Procedure SPECIFICATIONS Swing Motor Oil Capacity (approximate)

1.5 L 1.6 qt.

Return Line to Return Manifold Torque

80 N·m 59 lb.-ft.

TX1129148A —UN—10JAN13

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 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. 2. Install identification tag and disconnect return line to return manifold (1). Close opening using cap or plug. NOTE: Air must be allowed to escape from the swing motor while filling.

Swing Motor Main Hydraulic Line 1— Return Line to Return Manifold

3. Fill motor with hydraulic oil through port until oil reaches level of port. Specification Swing Motor Oil—Capacity (approximate)................................................................................... 1.5 L 1.6 qt.

Specification Return Line to Return Manifold—Torque..........................................................................80 N·m 59 lb.-ft.

4. Connect return line to return manifold. Tighten to specification. JB42225,0000041 -19-24JUL14-1/1

TM13264X19 (02FEB17)

43-4360-14

300GLC Excavator 020217 PN=426

Hydraulic System

Crossover Relief Valve and Make-Up Check Valve Remove and Install SPECIFICATIONS Hydraulic Oil Tank Capacity (approximate)

156 L 41 gal.

Crossover Relief Valve Torque

177 N·m 130 lb.-ft.

Make-Up Check Valve Torque

334 N·m 245 lb.-ft.

Swing Damper Valve Torque

70 N·m 51 lb.-ft.

TX1138150A —UN—05JUN13

Remove and Install Crossover Relief Valve 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 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.

Swing Motor Relief Valves

2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

1— Crossover Relief Valve (2 used) 2— Swing Motor Make-Up Check Valve (2 used)

3. Apply vacuum or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

Specification Hydraulic Oil Tank—Capacity (approximate).................................................................................. 156 L 41 gal.

4. Remove crossover relief valves (1). Crossover relief valves are not serviceable. Do not disassemble crossover relief valves.

6. Install crossover relief valves. Tighten to specification. Specification Crossover Relief Valve—Torque.............................................................................177 N·m 130 lb.-ft.

8. Perform swing motor crossover relief valve test and adjustment. See Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.) Remove and Install Make-Up Check Valve

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

5. Inspect and replace as necessary.

7. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.)

4. Remove swing motor make-up check valves (2). 5. Inspect and replace parts as necessary. See Make-Up Check Valve Disassemble and Assemble. (Group 4360.)

Continued on next page

TM13264X19 (02FEB17)

3— Swing Damper Valve (2 used)

43-4360-15

DV53278,00008C6 -19-20JAN15-1/2

300GLC Excavator 020217 PN=427

Hydraulic System

6. Install make-up check valves. Tighten to specification. Specification Make-Up Check Valve—Torque.............................................................................334 N·m 245 lb.-ft.

7. Remove vacuum or fill hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See Drain and Refill Hydraulic Tank Oil. (Operator’s Manual.) 8. Perform swing motor crossover relief valve test and adjustment. See Swing Motor Crossover Relief Valve Test and Adjustment. (Group 9025-25.) Remove and Install Swing Damper Valve 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.)

4. Remove swing damper valves (3). 5. Inspect and replace parts as necessary. 6. Install swing damper valves. Tighten to specification. Specification Swing Damper Valve—Torque...............................................................................70 N·m 51 lb.-ft.

DV53278,00008C6 -19-20JAN15-2/2

TM13264X19 (02FEB17)

43-4360-16

300GLC Excavator 020217 PN=428

Hydraulic System

Make-Up Check Valve Disassemble and Assemble SPECIFICATIONS Make-Up Check Valve Torque

550 N·m 410 lb.-ft.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1113765 —UN—15MAY12

2. Remove make-up check valves from swing motor and park brake (5). See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) 3. Inspect O-rings (2), springs (3), and poppets (4) for wear and damage. 4. Replace parts as necessary. 5. Install O-rings, springs, poppets, and make-up check valve plugs (1). 6. Tighten make-up check valve plugs to specification. See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.) Specification Make-Up Check Valve—Torque.............................................................................550 N·m 410 lb.-ft.

Make-Up Check Valve 1— Make-Up Check Valve Plug (2 used) 2— O-Ring (2 used) 3— Spring (2 used)

4— Poppet (2 used) 5— Swing Motor and Park Brake

TZ24494,0000EF9 -19-02APR13-1/1

TM13264X19 (02FEB17)

43-4360-17

300GLC Excavator 020217 PN=429

Hydraulic System

Swing Park Brake Check Valve and Orifice Remove and Install SPECIFICATIONS Cap Screw Torque

12 N·m 106 lb.-in.

TX1128552A —UN—03JAN13

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid personal injury from high-pressure fluid. High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure from hydraulic system before servicing. 2. Release hydraulic oil tank pressure by pressing pressure release button at top of hydraulic oil tank. See Hydraulic Oil Tank Pressure Release Procedure. (Group 9025-25.) 3. Install identification tags and disconnect hydraulic oil line (2) and front attachment pressure sensor (B32) from swing park brake check valve (1). See Swing Motor Line Identification. (Group 9025-15.) See Machine Harness (W2) Component Location. (Group 9015-10.) Close all openings using caps and plugs. 4. Remove cap screws (3) and swing park brake check valve from housing. 5. Repair or replace parts as necessary. 6. Install swing park brake check valve and cap screws. Tighten to specification. Specification Cap Screw—Torque......................................................................12 N·m 106 lb.-in.

Swing Park Brake Check Valve 1— Swing Park Brake Check Valve 2— Hydraulic Oil Line

3— Cap Screw (3 used) B32— Front Attachment Pressure Sensor

7. Connect hydraulic oil line and front attachment pressure sensor to swing park brake check valve. See Swing Motor Line Identification. (Group 9025-15.) See Machine Harness (W2) Component Location. (Group 9015-10.) 8. Perform swing motor and park brake start-up procedure. See Swing Motor and Park Brake Start-Up Procedure. (Group 4360.) 9. Operate machine and check for leaks. TZ24494,0000EFA -19-02APR13-1/1

TM13264X19 (02FEB17)

43-4360-18

300GLC Excavator 020217 PN=430

Contents

Section 99 Dealer Fabricated Tools

Page

Group 9900—Dealer Fabricated Tools DF1037 Hydraulic Pump Torque Adapter .................................................. 99-9900-1 DF1063 Lift Bracket................................... 99-9900-2 ST4920 Track Recoil Spring Disassembly and Assembly Tool ........................................................ 99-9900-4 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool ............................................. 99-9900-8 DFT1110 Spacer........................................ 99-9900-9 DFT1130 Adapter .................................... 99-9900-10 DFT1036A Travel Gearbox Nut Wrench ................................................ 99-9900-11 DFT1109 Holding Bar .............................. 99-9900-12 DFT1119 Pump Support .......................... 99-9900-13 DFT1351 Swing Gear Case Nut Spanner Wrench.................................. 99-9900-14 Center Joint (Rotary Manifold) Lifting Tool ........................................... 99-9900-15 DF1038 Torque Adapter .......................... 99-9900-16 DFT1144 Guide Pin ................................. 99-9900-16

TM13264X19 (02FEB17)

99-1

300GLC Excavator

020217

PN=1

Contents

TM13264X19 (02FEB17)

99-2

300GLC Excavator

020217

PN=2

Group 9900

Dealer Fabricated Tools

TX1073189 —UN—16APR10

DF1037 Hydraulic Pump Torque Adapter

DF1037 Hydraulic Pump Torque Adapter 1— Nut Welded 3— I.D. 2— Drilled and Tapped Hole (thru 4— Bar Welded to Top of Pipe both sides)

Hydraulic Pump Torque Adapter is used to check rolling drag torque on hydraulic pump shaft. Material required

• 1/4 in. flat steel stock • 1/2 in. nut • 1/8 in. adjusting screws (2 used)

• 2.25 in. inside diameter (I.D.) pipe TZ24494,0000EFB -19-20MAR13-1/1

TM13264X19 (02FEB17)

99-9900-1

300GLC Excavator 020217 PN=433

Dealer Fabricated Tools

DF1063 Lift Bracket Tool is the same as used on other machines. Only the lift bracket of the tool is used for this machine with DFT1130 Adapter. DF1063 Lift Bracket is used to remove and install travel motor. Material required:

• 38.1 mm x 76.2 mm x 0.48 mm (1-1/2 in. x 3 in. x 3/16 T8318AC —UN—20SEP94

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)

DF1063 Lift Bracket Continued on next page

TM13264X19 (02FEB17)

99-9900-2

TZ24494,0000EFC -19-20MAR13-1/2

300GLC Excavator 020217 PN=434

T7247BW —19—25APR90

Dealer Fabricated Tools

1063 Specifications TZ24494,0000EFC -19-20MAR13-2/2

TM13264X19 (02FEB17)

99-9900-3

300GLC Excavator 020217 PN=435

Dealer Fabricated Tools

ST4920 Track Recoil Spring Disassembly and Assembly Tool NOTE: It is recommended that DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool be used with track recoil spring disassembly and assembly tool. See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. (Group 9900.) 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.

T6585UY —UN—24MAR98

Material required: • 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G). • “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H). • “F” Grade (SAE Grade 8) for Studs (B). Print Numbers: • A-ST4050 Nut • B-ST4045 Stud • C-ST4035 Holder (Plate) • C-ST4036 Holder (Plate) • C-ST4037 Holder (Plate) • D-ST4047 Eyebolt • E-ST4040 Supporting Plate • F-ST4042 Base Plate • G-ST4041 Base • H-ST4046 Cap Screw • I-ST4049 Lock Washer

Track Recoil Spring Disassembly and Assembly Tool 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)

TZ24494,0000EFD -19-20MAR13-1/5

Track Recoil Spring Tool........................................ ST4920

Used with hydraulic jack to compress recoil spring in track adjuster repair.

Continued on next page

TM13264X19 (02FEB17)

99-9900-4

TZ24494,0000EFD -19-20MAR13-2/5

300GLC Excavator 020217 PN=436

T7029CI —UN—06JUL89

Dealer Fabricated Tools

ST4920 Dimensions Continued on next page

TM13264X19 (02FEB17)

99-9900-5

TZ24494,0000EFD -19-20MAR13-3/5

300GLC Excavator 020217 PN=437

T7029CH —UN—06JUL89

Dealer Fabricated Tools

ST4920 Dimensions Continued on next page

TM13264X19 (02FEB17)

99-9900-6

TZ24494,0000EFD -19-20MAR13-4/5

300GLC Excavator 020217 PN=438

T7029CG —UN—06JUL89

Dealer Fabricated Tools

ST4920 Dimensions TZ24494,0000EFD -19-20MAR13-5/5

TM13264X19 (02FEB17)

99-9900-7

300GLC Excavator 020217 PN=439

Dealer Fabricated Tools

T7162AF —UN—17OCT89

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

DFT1087 Dimensions A—3/16 in. 1020 CR Steel Plate B—9/16 in. Hole (2 places)

C—1/2 in. Nut (2 used) E—1/2 x 3 in. Steel Round Stock D—1/2 x 2 in. Cap Screw (2 used) (2 used)

Track Recoil Spring Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.) Material required:

• 3/16 in. 1020 CR Steel Plate (A) • 9/16 in. Hole (2 places) (B) • 1/2 in. Nut (2 used) (C) • 1/2 x 2 in. Cap Screw (D) (2 used) • 1/2 x 3 in. Steel Round Stock (E) (2 used) TZ24494,0000EFE -19-20MAR13-1/2

Track Recoil Spring Guard Tool...........................DFT1087

Used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. TZ24494,0000EFE -19-20MAR13-2/2

TM13264X19 (02FEB17)

99-9900-8

300GLC Excavator 020217 PN=440

Dealer Fabricated Tools

T7708AC —UN—23FEB92

DFT1110 Spacer

Spacer is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. Spacer is installed on the bottom plate so force is applied to spring flange on cylinder and not to the piston. See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.)

Material required:

• 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy Wall Steel Pipe

Cut the ends of spacer so they are parallel to each other. TZ24494,0000EFF -19-20MAR13-1/2

Spacer ................................................................. DFT1110

Spacer is used to apply force to spring flange on cylinder and not to the piston. TZ24494,0000EFF -19-20MAR13-2/2

TM13264X19 (02FEB17)

99-9900-9

300GLC Excavator 020217 PN=441

Dealer Fabricated Tools

T8319BN —UN—20SEP94

DFT1130 Adapter

DFT1130 Adapter Specifications A—Steel Plate

B—Square Tube

C—Steel Plate

Adapter is used with DF1063 Lift Bracket to remove and install travel motor. Material required:

• 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)

• 1.3 mm (1/2 in.) 1020 Steel Plate (A) TZ24494,0000F00 -19-20MAR13-1/2

Adapter ................................................................DFT1130

Used to remove and install travel motor. TZ24494,0000F00 -19-20MAR13-2/2

TM13264X19 (02FEB17)

99-9900-10

300GLC Excavator 020217 PN=442

Dealer Fabricated Tools

T7681FZ —UN—28FEB92

DFT1036A Travel Gearbox Nut Wrench

DFT1036A Dimension Drawing

Travel Gearbox Nut Wrench is used to remove and install the hub-to-housing nut in the travel gearbox. Material required: • 16 mm (5/8 in.) Flat Bar Stock

• M24 (1 in.) Nut • M10-1.5 x 60 mm Cap Screw (2 used) • M10-1.5 Nut (2 used) JB35873,0000220 -19-16JUN11-1/1

TM13264X19 (02FEB17)

99-9900-11

300GLC Excavator 020217 PN=443

Dealer Fabricated Tools

T7690AA —UN—27FEB92

DFT1109 Holding Bar

DFT1109 Dimension Drawing

Holding Bar is used with the see DFT1036A Travel Gearbox Nut Wrench as a guide when loosening the hub-to-housing nut in the travel gearbox. (Group 9900.)

Material required: • 16 mm (5/8 in.) Flat Bar Stock JB35873,0000222 -19-16JUN11-1/1

TM13264X19 (02FEB17)

99-9900-12

300GLC Excavator 020217 PN=444

Dealer Fabricated Tools

DFT1119 Pump Support Ø38 mm (1.5 in.) 13 mm (0.5 in.) 76 mm (3 in.)

13 mm (0.5 in.) 76.2 x 76.2 x 6.35 mm 610 mm (3 x 3 x 0.250 in.) (24 in.) 9.5 mm 76 mm (0.375 in.) (3 in.) 9.5 mm (0.375 in.) Ø11 mm (0.438 in.)

19 mm (0.750 in.)

89 mm (3.5 in.) 102 mm (4 in.) 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.)

38 mm (1.5 in.) 76 mm (3 in.) 114 mm (4.5 in.)

457 mm (18 in.)

Ø12 mm (0.472 in.) 5 Places

Ø11 mm (0.438 in.) 12 PLACES

38 mm (1.5 in.) 76 mm (3 in.) 152 mm (6 in.) 229 mm (9 in.) 305 mm (12 in.) 380 mm (15 in.) 457 mm (18 in.) 533 mm (21 in.) 610 mm (24 in.)

9.5 mm (0.375 in.)

1524 mm (60 in.)

104.8 mm (4.125 in.) 165 mm (6.5 in.) 376 mm (14.8 in.)

TX1022920 —UN—11JAN08

9.5 mm (0.375 in.)

88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.)

233 mm (9.2 in.) TX1022920

335 mm (13.2 in.) DFT1119 Pump Support

Pump support is used with a hand hoist to support a pump(s) when an engine is removed. Two end stands are needed.

• 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

Drill the holes through the square steel tubing so they are centered.

• 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)

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

• M10 or 3/8 in. D Grade (SAE Grade 5) Nut (2 used)

Cap Screw (2 used)

TZ24494,0000F03 -19-20MAR13-1/2

Pump Support...................................................... DFT1119

Used with a hand hoist to support a pump. TZ24494,0000F03 -19-20MAR13-2/2

TM13264X19 (02FEB17)

99-9900-13

300GLC Excavator 020217 PN=445

Dealer Fabricated Tools

DFT1351 Swing Gear Case Nut Spanner Wrench

151 mm (5.945 in.)

19 mm (.75 in.)

(

31.75 mm (1.25 in.) 178 mm (7.0 in.)

159 mm 6.25 in.)

63.5 mm (2.5 in.)

8 mm

178 mm (7.0 in.) 2 38.1 mm (1.5 in.) 6.35 mm (.25 in.)

32 mm 4 3

TX1129339 —UN—15JAN13

2 1 1 2

TX1129339 DFT1351 Swing Gear Case Nut Spanner Wrench

1. 178 x 63.5 mm (7.0 x 2.5 in.) Steel Tubing 2. 178 x 38.1 x 6.35 mm (7.0 x 1.5 x .25 in.) Steel Plate

3. M8 class 8.8 Cap Screw (with head removed) 4. 32 mm Hex Nut (head of cap screw may also be used) Continued on next page

TM13264X19 (02FEB17)

99-9900-14

TZ24494,0000F04 -19-20MAR13-1/2

300GLC Excavator 020217 PN=446

Dealer Fabricated Tools

Swing Gear Case Nut Spanner Wrench..............DFT1351

Used to remove and install the bearing nut in swing gear case assembly. TZ24494,0000F04 -19-20MAR13-2/2

Center Joint (Rotary Manifold) Lifting Tool Tool is used to remove and install center joint. Drill and tap disk in fitting cap to M8-1.25 mm threads (A). Material required: • 38H1416 Cap (—12) • M8-1.25 Lifting Eyebolt such as JT05548 Metric Lifting Eyebolt

T6641DO —UN—24OCT88

A—Threads

Center Joint Lifting Tool JB35873,0000223 -19-16JUN11-1/1

TM13264X19 (02FEB17)

99-9900-15

300GLC Excavator 020217 PN=447

Dealer Fabricated Tools

T6557CH —UN—25OCT95

DF1038 Torque Adapter

Torque Adapter is used to check rolling drag torque on rotor drive shaft.

• 17 mm (0.125 in.) Hex Head Driver

Material required: JB35873,0000221 -19-16JUN11-1/1

DFT1144 Guide Pin Guide pin is used to align cap screw holes in swing bearing and upperstructure. T6641EK —UN—24OCT88

Remove threads for a distance (B) and then grind a taper on same end. Material Required:

• M20-2.5 x 230 mm (9 in.) Threaded Rod A—230 mm (9 in.)

B—100 mm (4 in.) DFT1144 Guide Pin

JB35873,0000224 -19-16JUN11-1/1

TM13264X19 (02FEB17)

99-9900-16

300GLC Excavator 020217 PN=448

Index Page Page

A Air conditioner Compressor, remove and install .................... 18-1830-8 Condenser, remove and install ...................... 18-1830-9 Receiver-dryer, remove and install .............. 18-1830-13 Air conditioner and heater Remove and install ...................................... 18-1830-10 Air conditioner system Flush and purge ............................................. 18-1830-4 Air conditioning Charge ........................................................... 18-1830-7 R134a refrigerant oil information.................... 18-1830-2 Refrigerant cautions and proper handling........................................................ 18-1830-1 Air seat Disassemble and assemble ........................... 18-1821-8 Air suspension Seat disassemble and assemble ................... 18-1821-8 Alignment procedure Exhaust bellows ............................................. 05-0530-7 Arm Remove and install ........................................ 33-3340-3 Arm cylinder Bleed procedure......................................... 33-3360-112 Disassemble and assemble ....................... 33-3360-104 Inspect pins and bushings ........................... 33-3340-11 Remove and install .................................... 33-3360-102 Arm pins and bushings Inspect ......................................................... 33-3340-11 Arm regenerative solenoid valve Remove and install ...................................... 33-3360-37 Attachments Adding safely ............................................... 00-0001-12 Operating safely........................................... 00-0001-12 Avoid static electricity risk when fueling ............ 00-0001-5

B Backover Accidents ......................................... 00-0001-10 Bearing Swing, disassemble and assemble.............. 43-4350-20 Swing, remove and install ............................ 43-4350-18 Bellows alignment JDG11335 bellows alignment fixture.............. 05-0530-2 Bleed procedure Hydraulic cylinder....................................... 33-3360-112 Boom Remove and install ........................................ 33-3340-5 Boom cylinder Bleed procedure......................................... 33-3360-112 Dissassemble and assemble ....................... 33-3360-99 Inspect pins and bushings ........................... 33-3340-11 Remove and install ...................................... 33-3360-96 Boom pins and bushings Inspect ......................................................... 33-3340-11

Boom, arm, and bucket bushings and bosses Inspect ......................................................... 33-3340-11 Boom, arm, and bucket pins Inspect ......................................................... 33-3340-11 Brake Swing park, inspection ................................... 43-4360-9 Swing park, remove and install ...................... 43-4360-5 Broken track chain Repair .......................................................... 01-0130-18 Broken track pin Repair .......................................................... 01-0130-18 Bucket Adjust pivot end play...................................... 33-3302-2 Pin-up data 250GLC ...................................................... 33-3302-3 Remove and install ........................................ 33-3302-1 Bucket cylinder Bleed procedure......................................... 33-3360-112 Disassemble and assemble ....................... 33-3360-109 Inspect pins and bushings ........................... 33-3340-11 Remove and Install .................................... 33-3360-107 Bucket links Remove and install ........................................ 33-3340-1 Bucket pins Inspect ......................................................... 33-3340-11 Bushings Remove and install ...................................... 33-3340-13 Bypass valve Remove and install ...................................... 33-3360-95

C Cab Remove and Install ........................................ 18-1800-1 Center joint Air test............................................................ 43-4360-4 Disassemble and assemble ........................... 43-4360-3 Remove and install ........................................ 43-4360-1 Chain Track, repair................................................. 01-0130-18 Charge air cooler Remove and install ........................................ 05-0510-4 Cleaning procedure Diesel exhaust fluid tank .............................. 05-0530-31 Compressor Remove and install ........................................ 18-1830-8 Condenser, air conditioner Remove and install ........................................ 18-1830-9 Control pattern................................................... 00-0001-2 Control valve 4-spool ......................................................... 33-3360-78 5-spool ......................................................... 33-3360-64 Arm reduced leakage valve ......................... 33-3360-64 Arm regenerative valve ................................ 33-3360-78 Auxiliary flow combiner valve check valve........................................................... 33-3360-64 Auxiliary flow rate valve ............................... 33-3360-64 Continued on next page

TM13264X19 (02FEB17)

Index-1

300GLC Excavator 020217 PN=1

Index

Page

Auxiliary function flow combiner valve ......... 33-3360-64 Boom reduced leakage valve....................... 33-3360-78 Bucket flow rate valve .................................. 33-3360-78 Bypass shut-off valve................................... 33-3360-78 Lift check (arm I power passage)................. 33-3360-64 Lift check (boom II power passage) ............. 33-3360-64 Lift check (left travel neutral passage) ......... 33-3360-64 Lift check (swing neutral passage)............... 33-3360-64 Lift check and orifice (left travel power passage) .................................................... 33-3360-64 Remove and install ...................................... 33-3360-58 Spool assemblies (4-spool).......................... 33-3360-78 Spool assemblies (5 spool).......................... 33-3360-64 System relief and power boost valve ........... 33-3360-64 Travel function flow combiner valve ............. 33-3360-78 Control Valve Halves Control Valve Halves ................................ 33-3360-62 Coolant surge tank Remove and install ...................................... 05-0510-14 Cooler bypass valve Remove and install ...................................... 33-3360-95 Cooling package Remove and install ........................................ 05-0510-6 Cooling system Service safely............................................... 00-0001-13 Counterbalance valve, travel motor Disassemble and assemble ......................... 02-0260-10 Counterweight Remove and install ........................................ 17-1749-1 Crossover relief valve Remove and install ...................................... 43-4360-15 Cylinder Arm, disassemble and assemble ............... 33-3360-104 Arm, remove and install ............................. 33-3360-102 Bleed procedure......................................... 33-3360-112 Boom, disassemble and assemble .............. 33-3360-99 Boom, remove and install ............................ 33-3360-96 Bucket, disassemble and asemble ............ 33-3360-109 Bucket, remove and install......................... 33-3360-107

DFT1119 pump support ............................... 99-9900-13 DFT1130 adapter ......................................... 99-9900-10 DFT1144 guide pin....................................... 99-9900-16 DFT1351 swing gear case nut spanner wrench........................................................ 99-9900-14 Holding bar................................................... 99-9900-12 ST4920 track recoil spring disassembly and assembly tool ........................................ 99-9900-4 Diesel exhaust fluid decomposition tube Remove and install ...................................... 05-0530-42 Diesel exhaust fluid dosing injector Remove and install ...................................... 05-0530-41 Diesel exhaust fluid dosing unit Remove and install ...................................... 05-0530-32 Diesel exhaust fluid header Remove and install ...................................... 05-0530-23 Diesel exhaust fluid tank Remove and install ..................05-0530-21, 05-0530-31 Diesel exhaust fluid tank header suction screen Remove and install ...................................... 05-0530-30 Diesel oxidation catalyst Remove and install ...................................... 05-0530-16 Diesel particulate filter Remove and install ...................................... 05-0530-10 Dig regenerative solenoid valve Remove and install ...................................... 33-3360-37 Dimensions Windowpanes (windshield) ............................ 18-1810-8 Disassemble and assemble Pump gear case........................................... 33-3360-12 Travel gear case ............................................ 02-0250-4 Drive gear case Start-up procedure ....................................... 33-3360-17

D Damper drive (flex coupling) Remove and install ........................................ 07-0752-1 Damper valve Remove and install ...................................... 43-4360-15 Dealer fabricated tools Center joint (rotary manifold) lifting tool ............................................................. 99-9900-15 DF1037 hydraulic pump torque adapter ......................................................... 99-9900-1 DF1038 torque adapter................................ 99-9900-16 DF1063 lift bracket......................................... 99-9900-2 DFT1036A travel gearbox nut wrench ......... 99-9900-11 DFT1087 track recoil spring disassembly and assembly guard tool .............................. 99-9900-8 DFT1110 spacer............................................. 99-9900-9

E End play, bucket pivot Adjust ............................................................. 33-3302-2 Engine .............................................04-0400-1, 04-0400-7 Install.............................................................. 04-0400-7 Remove.......................................................... 04-0400-1 Engine side shields Remove and install ........................................ 19-1910-1 Exhast tube Remove and install ........................................ 05-0530-1 Exhaust aftertreatment assembly Remove and install ...................................... 05-0530-19 Exhaust bellows Alignment procedure...................................... 05-0530-7 Exhaust filter...................................................... 00-0001-7 Exhaust Filter, Safety Safety, Exhaust Filter ................................... 00-0001-15

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TM13264X19 (02FEB17)

Index-2

300GLC Excavator 020217 PN=2

Index

Page

F Fan and fan guard remove and install........................................ 05-0510-11 Fan drive motor Remove and install ...................................... 33-3360-32 Fan drive motor solenoid valves Remove and install ...................................... 33-3360-36 Fan drive pump Remove and install ...................................... 33-3360-31 Filter, pilot Remove and install ...................................... 33-3360-26 Fire prevention................................................... 00-0001-5 Front idler Disassemble and assemble ......................... 01-0130-26 Remove and install ...................................... 01-0130-25 Fuel cool Remove and install ........................................ 05-0510-5 Fuel tank Remove and install ........................................ 05-0560-1

G Grouser Remove and install ...................................... 01-0130-10

H Hazards Avoiding ......................................................... 00-0001-9 Heater and air conditioner Remove and install ...................................... 18-1830-10 Hood Remove and install ........................................ 19-1910-1 Hood and engine side shields Remove and install ........................................ 19-1910-1 HVAC Charge ........................................................... 18-1830-7 Hydraulic Fittings, 30° cone seat ................................... 00-0003-4 Fittings, 37° flare ............................................ 00-0003-4 Hydraulic cylinder bleed procedure ............... 33-3360-112 Hydraulic fan motor Disassemble and assemble ......................... 33-3360-33 Hydraulic fitting Flared connections......................................... 00-0003-6 Non-restricted banjo (adjustable)................. 00-0003-18 O-ring boss with shoulder ............................ 00-0003-19 Hydraulic oil cooler Remove and install ........................................ 05-0510-2 Hydraulic oil cooler bypass valve Remove and install ...................................... 33-3360-95 Hydraulic oil tank Apply vacuum ................................................ 33-3360-1 Remove and install ...................................... 33-3360-90 Hydraulic pump Disassemble and assemble ........................... 33-3360-5

Inspection..................................................... 33-3360-14 Remove and install ........................................ 33-3360-2 Start-up procedure ....................................... 33-3360-17 Hydraulic pump regulator Disassemble and assemble ......................... 33-3360-20 Remove and install ...................................... 33-3360-18

I Identification Manual ....................................................................... --3 Inch bolt and cap screw Torque value .................................................. 00-0003-3 Inch series four bolt flange fitting Service recommendation, torque value for high pressure ............................................. 00-0003-17 Inspection Hydraulic pump ............................................ 33-3360-14

J JDG11335 bellows alignment fixture ................. 05-0530-2 Joint Center, remove and install ............................. 43-4360-1

L Leakage test Track roller ..................................................... 01-0130-5 Left and right pilot valve Disassemble and assemble ......................... 33-3360-42 Remove and install ...................................... 33-3360-40 Lifting objects Special care ................................................. 00-0001-11

M Machine Welding .......................................................... 17-1740-1 Machine modifications Avoid .............................................................. 00-0001-2 Machine movement Unintended..................................................... 00-0001-9 Machine tip over Avoiding ....................................................... 00-0001-11 Machine,inspect................................................. 00-0001-3 Make-up check valve Disassemble and assemble ......................... 43-4360-17 Remove and install ...................................... 43-4360-15 Manifold, pilot signal Disassemble and assemble ......................... 33-3360-55 Remove and install ...................................... 33-3360-53 Manual Identification............................................................... --3 Mechanical seat Disassemble and assemble ........................... 18-1821-3

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TM13264X19 (02FEB17)

Index-3

300GLC Excavator 020217 PN=3

Index

Page

Mechanical suspension Seat disassmble and assemble ..................... 18-1821-3 Metal face seals Inspect ........................................................... 01-0130-9 Metric bolt and cap screw Torque value .................................................. 00-0003-1 Motor Swing, assemble.......................................... 43-4360-12 Swing, disassemble ....................................... 43-4360-7 Swing, inspection ........................................... 43-4360-9 Swing, remove and install .............................. 43-4360-5 Motor cover, travel Disassemble and assemble ......................... 02-0260-10 Motor, fan drive Remove and install ...................................... 33-3360-32 Motor, hydraulic fan Disassemble and assemble ......................... 33-3360-33

Pilot pressure regulating valve Disassemble and assemble ......................... 33-3360-27 Pilot pressure regulating valve and filter Remove and install ...................................... 33-3360-26 Pilot pump Disassemble and assemble ......................... 33-3360-24 Remove and install ...................................... 33-3360-22 Pilot shutoff lever ............................................... 00-0001-9 Pilot shutoff solenoid valve Disassemble and assemble ......................... 33-3360-29 Remove and install ...................................... 33-3360-28 Pilot signal manifold Disassemble and assemble ......................... 33-3360-55 Remove and install ...................................... 33-3360-53 Pilot valve Disassemble and assemble ......................... 33-3360-42 Remove and install ...................................... 33-3360-40 Pilot valve, travel Disassemble and assemble ......................... 33-3360-50 Remove and install ...................................... 33-3360-48 Pins, metal Drive safely .................................................. 00-0001-14 Power dig solenoid valve Remove and install ...................................... 33-3360-37 Pressure test Track roller ..................................................... 01-0130-5 Pump Disassemble and assemble ........................... 33-3360-5 Remove and install ........................................ 33-3360-2 Start-up procedure ....................................... 33-3360-17 Pump gear case Disassemble and Assemble......................... 33-3360-12 Pump regulator, hydraulic Disassemble and assemble ......................... 33-3360-20 Remove and install ...................................... 33-3360-18 Pump, fan drive Remove and install ...................................... 33-3360-31 Pump, pilot Disassemble and assemble ......................... 33-3360-24 Remove and install ...................................... 33-3360-22

O O-ring boss fitting in aluminum housingexcavators Torque value, service recommendation ............................................................... 00-0003-8 O-ring boss fittings............................................. 00-0003-4 O-ring face seal fitting Inch hex nut and stud end for high pressure torque values................................. 00-0003-9 Metric hex nut and stud end for high pressure torque values............................... 00-0003-13 Metric hex nut and stud end for standard pressure torque values............................... 00-0003-11 O-ring seal, metric 24 Service recommendation ............................. 00-0003-21 Oil cooler bypass valve Remove and install ...................................... 33-3360-95 Oil information R134a refrigerant ........................................... 18-1830-2 Oil tank Remove and install ...................................... 33-3360-90 Operation qualification....................................... 00-0001-1

R P Park brake Disassemble and assemble ........................... 02-0260-2 Remove and install ........................................ 02-0260-1 Swing, disassemble ....................................... 43-4360-7 Swing, inspection ........................................... 43-4360-9 Swing, remove and install .............................. 43-4360-5 Swing, start-up procedure............................ 43-4360-14 Parts, moving Stay clear ....................................................... 00-0001-3 Pilot filter Remove and install ...................................... 33-3360-26 Pilot filter and pilot pressure regulating valve Remove and install ...................................... 33-3360-26

R134a refrigerant Recover.......................................................... 18-1830-3 R134a system Charge ........................................................... 18-1830-7 Evacuate ........................................................ 18-1830-6 Radiator Remove and install ........................................ 05-0510-1 Receiver-dryer Remove and install ...................................... 18-1830-13 Recognize Safety, information ......................................... 00-0001-1 Recovery/charging station Installation procedure..................................... 18-1830-3 Refrigerant cautions and proper handling Air conditioning .............................................. 18-1830-1 Continued on next page

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Index-4

300GLC Excavator 020217 PN=4

Index

Page

Refrigerant oil information R134a ............................................................ 18-1830-2 Refueling, avoid static electricity risk................. 00-0001-5 Regulating valve, pilot pressure Disassemble and assemble ......................... 33-3360-27 Regulator, hydraulic pump Disassemble and assemble ......................... 33-3360-20 Remove and install ...................................... 33-3360-18 Remove and install Arm ................................................................ 33-3340-3 Boom.............................................................. 33-3340-5 Cab ................................................................ 18-1800-1 Charge air cooler ........................................... 05-0510-4 Coolant surge tank....................................... 05-0510-14 Cooling package ............................................ 05-0510-6 Damper drive (flex coupling) .......................... 07-0752-1 Diesel exhaust fluid decomposition tube ............................................................ 05-0530-42 Diesel exhaust fluid dosing injector.............. 05-0530-41 Diesel exhaust fluid dosing unit ................... 05-0530-32 Diesel exhaust fluid header.......................... 05-0530-23 Diesel exhaust fluid tank header suction screen ........................................................ 05-0530-30 Diesel exhaust fuild tank .............................. 05-0530-21 Diesel oxidation catalyst .............................. 05-0530-16 Diesel particulate filter.................................. 05-0530-10 Exhaust aftertreatment assembly ................ 05-0530-19 Exhaust tube .................................................. 05-0530-1 Fan and fan guard........................................ 05-0510-11 Fuel cooler ..................................................... 05-0510-5 Hydraulic oil cooler......................................... 05-0510-2 Radiator ......................................................... 05-0510-1 Restriction valve........................................... 33-3360-94 Selective catalyst reduction ......................... 05-0530-13 Travel gear case ............................................ 02-0250-1 Upperstructure ............................................. 43-4350-15 Restriction valve Remove and install ...................................... 33-3360-94 Riding machine................................................ 00-0001-10 Roller, track Pressure test.................................................. 01-0130-5 ROPS Inspect ......................................................... 00-0001-10 Maintain ....................................................... 00-0001-10

Safety, information Recognize ...................................................... 00-0001-1 Seal, Swing bearing upper, install ......................... 43-4350-24 Seals Remove and install ...................................... 33-3340-13 Seals, metal face Inspect ........................................................... 01-0130-9 Seat Air suspension remove and install ................. 18-1821-1 Disassemble and assemble .....18-1821-3, 18-1821-8 Mechanical suspension remove and install ............................................................ 18-1821-1 Remove and install ........................................ 18-1821-1 Seat belt Remove and install ........................................ 18-1821-2 Selective catalyst reduction Remove and install ...................................... 05-0530-13 Service recommendation Inch series four bolt flange fitting for high pressure ..................................................... 00-0003-17 O-ring boss fitting in aluminum housingexcavators ....................................... 00-0003-8 O-ring face seal fittings with inch hex nut and stud end for high pressure .................... 00-0003-9 O-ring face seal fittings with metric hex nut and stud end for high pressure ............ 00-0003-13 O-ring face seal fittings with metric hex nut and stud end for standard pressure ........... 00-0003-11 O-ring seal, metric 24................................... 00-0003-21 Shutoff solenoid valve, pilot Remove and install ...................................... 33-3360-28 Sliding window Remove and install ......................18-1810-1, 18-1810-7 Solenoid valve Arm regenerative, disassemble and assemble.................................................... 33-3360-39 Arm regenerative, remove and install .......... 33-3360-37 Dig regenerative, disassemble and assemble.................................................... 33-3360-39 Dig regenerative, remove and install ........... 33-3360-37 Power dig, disassemble and assemble.................................................... 33-3360-39 Power dig, remove and install...................... 33-3360-37 Solenoid valve, fan drive motor Remove and install ...................................... 33-3360-36 Sprocket Remove and install ...................................... 01-0130-24 Start-up procedure Drive gear case............................................ 33-3360-17 Hydraulic pump ............................................ 33-3360-17 Swing gear case .......................................... 43-4350-14 Steps Use correctly Handholds .................................................. 00-0001-8 Swing bearing Disassemble and assemble ......................... 43-4350-20

S Safety Add cab guarding for special uses............................................00-0001-1, 00-0001-2 Clean debris from machine ............................ 00-0001-8 Fire................................................................. 00-0001-6 Operator's seat .............................................. 00-0001-8 Protective equipment ..................................... 00-0001-2 Safety hazards Travel ........................................................... 00-0001-12 Safety, high-pressure fluids Avoid high-pressure fluids.............................. 00-0001-3

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TM13264X19 (02FEB17)

Index-5

300GLC Excavator 020217 PN=5

Index

Page

Lower seal install ......................................... 43-4350-25 Remove and install ...................................... 43-4350-18 Upper seal, install ........................................ 43-4350-24 Swing gear case Disassemble and assemble ........................... 43-4350-3 Remove and install ........................................ 43-4350-1 Start-up procedure ....................................... 43-4350-14 Swing motor Assemble ..................................................... 43-4360-12 Disassemble .................................................. 43-4360-7 Inspection....................................................... 43-4360-9 Remove and install ........................................ 43-4360-5 Start-up procedure ....................................... 43-4360-14 Swing park brake check valve and orifice Remove and install ...................................... 43-4360-18

Track carrier roller Remove and install ........................................ 01-0130-7 Track chain Disassemble and assemble ......................... 01-0130-16 Remove and install ...................................... 01-0130-11 Track link Repair .......................................................... 01-0130-18 Track Pin Repair .......................................................... 01-0130-18 Track roller Disassemble and assemble ........................... 01-0130-3 Pressure test.................................................. 01-0130-5 Remove and install ........................................ 01-0130-1 Track shoe Remove and install ...................................... 01-0130-10 Tracks, front idler Remove and install ...................................... 01-0130-25 Travel gear case Assemble ....................................................... 02-0250-7 Disassemble .................................................. 02-0250-5 Disassemble and assemble ........................... 02-0250-4 Remove and install ........................................ 02-0250-1 Travel motor Disassemble and assemble ........................... 02-0260-2 Remove and install ........................................ 02-0260-1 Start-up procedure ....................................... 02-0260-12 Travel motor and park brake Disassemble and assemble ........................... 02-0260-2 Remove and install ........................................ 02-0260-1 Start-up procedure ....................................... 02-0260-12 Travel motor cover Disassemble and assemble ......................... 02-0260-10 Travel motor, counterbalance valve Disassemble and assemble ......................... 02-0260-10 Travel pilot valve Disassemble and assemble ......................... 33-3360-50 Remove and install ...................................... 33-3360-48

T Tank Remove and install ...................................... 33-3360-90 Tank, hydraulic oil Apply vacuum ................................................ 33-3360-1 Tip over Avoiding ....................................................... 00-0001-11 Tool JDG11335 bellows alignment fixture.............. 05-0530-2 Torque value 30° cone seat hydraulic fittings ...................... 00-0003-4 37° flare hydraulic fittings............................... 00-0003-4 Flared connections......................................... 00-0003-6 Flat face O-ring seal fitting ............................. 00-0003-7 Inch SAE four bolt flange fitting.................... 00-0003-16 Inch series four bolt flange fitting for high pressure ..................................................... 00-0003-17 Metric bolt and cap screw .............................. 00-0003-1 Metric cap screw ............................................ 00-0003-2 Metric four bolt flange fitting......................... 00-0003-15 Non-restricted banjo fittings ......................... 00-0003-18 O-Ring boss fitting ......................................... 00-0003-4 O-ring boss fitting in aluminum housingexcavators ....................................... 00-0003-8 O-ring boss fittings with shoulder................. 00-0003-19 O-ring face seal fittings with inch hex nut and stud end for high pressure .................... 00-0003-9 O-ring face seal fittings with metric hex nut and stud end for high pressure ............ 00-0003-13 O-ring face seal fittings with metric hex nut and stud end for standard pressure ........... 00-0003-11 O-ring seal, metric 24................................... 00-0003-21 Unified inch bolt and cap screw ..................... 00-0003-3 Track Chain repair ................................................. 01-0130-18 Track adjuster Recoil spring, disassemble and assemble.................................................... 01-0130-29 Recoil spring, remove and install ................. 01-0130-28 Track Bushing Repair .......................................................... 01-0130-18

U Upperstructure Remove and install ...................................... 43-4350-15

V Valve Crossover relief, remove and install............. 43-4360-15 Damper, remove and install ......................... 43-4360-15 Make-up check, disassemble....................... 43-4360-17 Make-up check, remove and install ............. 43-4360-15 Valve, control Remove and install ...................................... 33-3360-58 Valve, pilot pressure regulating Disassemble and assemble ......................... 33-3360-27 Remove and install ...................................... 33-3360-26 Valve, pilot shutoff solenoid Disassemble and assemble ......................... 33-3360-29 Continued on next page

TM13264X19 (02FEB17)

Index-6

300GLC Excavator 020217 PN=6

Index

Page

Remove and install ...................................... 33-3360-28 Valve, solenoid Fan drive motor, remove and install............. 33-3360-36 Valve, travel pilot Disassemble and assemble ......................... 33-3360-50 Remove and install ...................................... 33-3360-48

Window glass Dimensions .................................................... 18-1810-8 Windowpane Dimensions .................................................... 18-1810-8 Windowpanes Remove and install ........................................ 18-1810-7 Windshield Disassemble and assemble ........................... 18-1810-2 Work site hazards Avoid .............................................................. 00-0001-9

W Welding on machine .......................................... 17-1740-1 Welding repairs................................................ 00-0001-13 Window Remove and install ........................................ 18-1810-7

TM13264X19 (02FEB17)

Index-7

300GLC Excavator 020217 PN=7

Index

TM13264X19 (02FEB17)

Index-8

300GLC Excavator 020217 PN=8