200CLC, 230CLC, and 270CLC Repair TM1931 PDF

Return to INDEX
200CLC
230CLC
and
270CLC
Excavator
Repair
TECHNICAL MANUAL
200CLC, 230CLC, and 270CLC
Excavator Repair
TM1931 09JAN04 (ENGLISH)
For complete service information also see:

200CLC, 230CLC, and 270CLC Excavator
Operation and Tests . . . . . . . . . . . . . . . . . . . TM1930
POWERTECH 4.5 L & 6.8 L (4045 and 6068)
Diesel Engines, Base Engine . . . . . . . . . . . . CTM104
POWERTECH 4.5 L & 6.8 L (4045 and 6068)
Diesel Engines, Level 4 Electronic Fuel
Systems with Bosch VP44 Pump . . . . . . . . . CTM170
Alternators and Starting Motors . . . . . . . . . . CTM77
Undercarriage Appraisal Manual . . . . . . . . . SP326
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC –19–29SEP98–1/1
TM1931 (09JAN04) 200CLC, 230CLC & 270CLC Excavator Repair

010904
PN=2
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

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
Ideas, Comments (Please State Page Number):
OVERALL, how would you rate the quality of this publication? (Check one)
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THANK YOU!
TX,TM,FAX –19–19JUN00–1/1

010904
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Introduction

010904
PN=4
Contents
00
SECTION 00—General Information
Group 0001—Safety
Group 0003—Torque Values
SECTION 01—Tracks
01
Group 0130—Track System
SECTION 02—Axles and Suspension Systems

(Propel)
Group 0250—Axle Shaft, Bearings, and Reduction
Gears 02
Group 0260—Hydraulic System
SECTION 04—Engine
Group 0400—Removal and Installation
04
SECTION 05—Engine Auxiliary System
Group 0510—Cooling System
Group 0520—Intake System
Group 0560—External Fuel Supply System
SECTION 07—Dampener Drive (Flex Coupling) 05

Group 0752—Elements
SECTION 17—Frame or Supporting Structure

Group 1740—Frame Installation
Group 1749—Chassis Weights
07
SECTION 18—Operator’s Station

Group 1810—Operator Enclosure
Group 1821—Seat and Seat Belt
Group 1830—Heating and Air Conditioning 17
SECTION 33—Excavator
Group 3302—Buckets
Group 3340—Frames
18
SECTION 43—Swing or Pivoting System

Group 4350—Mechanical Drive Elements
SECTION 99—Dealer Fabricated Tools 33

Group 9900—Dealer Fabricated Tools
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 43
COPYRIGHT  2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2001
TM1931 (09JAN04) i 200CLC, 230CLC & 270CLC Excavator Repair

010904
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Contents
00
01
02
04
05
07
17
18
33
43
TM1931 (09JAN04) ii 200CLC, 230CLC & 270CLC Excavator Repair

010904
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Contents
99
INDX
TM1931 (09JAN04) iii 200CLC, 230CLC & 270CLC Excavator Repair

010904
PN=3
Contents
99
INDX
TM1931 (09JAN04) iv 200CLC, 230CLC & 270CLC Excavator Repair

010904
PN=4
00
Section 00
General Information
Contents
Page
Group 0001—Safety . . . . . . . . . . . . . . . . . .00-0001-1
Group 0003—Torque Values

Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3
Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-5
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Service Recommendations for Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-8
Service Recommendations for 37° Flare
and 30° Cone Seat Connectors . . . . . . . . .00-0003-9
Service Recommendations For Flared
Connections—Straight or Tapered
Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .00-0003-11
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .00-0003-12
TM1931 (09JAN04) 00-1 200CLC, 230CLC & 270CLC Excavator Repair

010904
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Contents
00

010904
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Group 0001
Safety
00
Recognize Safety Information 0001
1
This is the safety alert symbol. When you see this
–UN–28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
T133555
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
–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
T133588
labels.
TX03679,00016CC –19–21AUG00–1/1
Follow Safety Instructions
Read the safety messages in this manual and on the
–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently.
Be sure all operators of this machine understand every
T133556
safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 –19–28AUG00–1/1
Operate Only If Qualified
Do not operate this machine unless you have read the machine functions with the machine in an open area
operator’s manual carefully and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Familiarize yourself with the job site and your your work situation and your work site.
surroundings before operating. Try all controls and
TX03679,00016FA –19–30OCT00–1/1
TM1931 (09JAN04) 00-0001-1 200CLC, 230CLC & 270CLC Excavator Repair

010904
PN=9
Safety
00
0001 Wear Protective Equipment
2
Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
Wear close fitting clothing and safety equipment

appropriate to the job.
–UN–23AUG88
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
TS206
uncomfortable loud noises.
TX03679,00016D0 –19–30OCT00–1/1
Avoid Unauthorized Machine Modifications
Modifications of this machine, or addition of Always contact an authorized dealer before making
unapproved products or attachments, may affect machine modifications that change the intended use,
machine stability or reliability, and may create a hazard weight or balance of the machine, or that alter
for the operator or others near the machine. machine controls, performance or reliability.
TX03679,00016B7 –19–30OCT00–1/1
Add Cab Guarding For Special Uses
Special work situations or machine attachments may

–UN–15SEP00
create an environment with falling or flying objects.
Working near an overhead bank, doing demolition work,
using a hydraulic hammer, or working in a wooded area,
for example, may require added guarding to protect the
T133733
operator.
FOPS (falling object protective structures) and special

screens or guarding should be installed when falling or
flying objects may enter or damage the machine. Contact
your authorized dealer for information on devices intended
to provide protection in special work situations.
TX03679,00016CE –19–30OCT00–1/1

010904
PN=10
Safety
00
Inspect Machine 0001
3
Inspect machine carefully each day by walking around it

before starting.
Keep all guards and shields in good condition and
–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
T6607AQ
TX03679,0001734 –19–25SEP00–1/1
Stay Clear Of Moving Parts
–UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
T133592
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.
TX03679,00016D2 –19–30OCT00–1/1
Avoid High-Pressure Fluids
This machine uses a high-pressure hydraulic system.

Escaping fluid under pressure can penetrate the skin
–UN–31OCT00
causing serious injury.
Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping fluid.
T133509
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic fluid penetrates your skin, see a doctor

immediately. Injected fluid must be removed
surgically within hours or gangrene may result.
–UN–20SEP00
Contact a knowledgeable medical source or the Deere &

Company Medical Department in Moline, Illinois, U.S.A.
T133840
TX03679,00016D3 –19–30OCT00–1/1

010904
PN=11
Safety
00
0001 Beware Of Exhaust Fumes
4
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
T133546
outside air into the area.
TX03679,00016D4 –19–14SEP00–1/1
Prevent Fires
–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
T133553
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a

multi-purpose fire extinguisher on or near the machine.
–UN–07SEP00
Know how to use extinguisher properly.
T133554
TX03679,00016F5 –19–25SEP00–1/1
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TS204
TX03679,000174A –19–14SEP00–1/1

010904
PN=12
Safety
00
Handle Chemical Products Safely 0001
5
Exposure to hazardous chemicals can cause serious
–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS). The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 –19–14SEP00–1/1
Dispose Of Waste Properly
Improper disposal of waste can threaten the environment.
–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
T133567
any water source.
Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your authorized
dealer for more information.
TX03679,0001733 –19–14SEP00–1/1
Prepare For Emergencies
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
TX03679,000174B –19–14SEP00–1/1

010904
PN=13
Safety
00
0001 Use Steps And Handholds Correctly
6
Prevent falls by facing the machine when you get on and
–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2 –19–14SEP00–1/1
Start Only From Operator’s Seat
–UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799 –19–02MAY01–1/1
Use And Maintain Seat Belt
Use seat belt when operating machine. Remember to
–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced

every three years, regardless of appearance.
TX03679,00016DD –19–17OCT00–1/1

010904
PN=14
Safety
00
Prevent Unintended Machine Movement 0001
7
Be careful not to accidentally actuate control levers when
–UN–20SEP00
co-workers are present. Pull pilot control shut-off lever to
locked position during work interruptions. Pull pilot control
shut-off lever to locked position and stop engine before
allowing anyone to approach machine.
T133863
Always lower work equipment to the ground and pull pilot
control shut-off lever to locked position before standing up
or leaving the operator’s seat. Stop engine before exiting.
TX03679,0001746 –19–30OCT00–1/1
Avoid Work Site Hazards
Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
–UN–31OCT00
underground utilities before you dig.
Prepare work site properly. Avoid operating near

structures or objects that could fall onto the machine.
T134986
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
–UN–27SEP00
insulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or a

signal person to keep vehicles and pedestrians away. Use
T133650
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.
Operate only on solid footing with strength sufficient to

support machine. When working close to an excavation,
position propel motors away from the hole.
–UN–24AUG00
T133549
TX03679,0001748 –19–30OCT00–1/1

010904
PN=15
Safety
00
0001 Keep Riders Off Machine
8
Only allow operator on machine.
Riders are subject to injury. They may fall from machine,

be caught between machine parts, or be struck by foreign
–UN–08JUN90
objects.
Riders may obstruct operator’s view or impair his ability to

operate machine safely.
T7273AH
TX03679,0001726 –19–14SEP00–1/1
Avoid Backover Accidents
Before moving machine, be sure all persons are clear

of both travel and swing paths. Turn around and look
–UN–24AUG00
directly for best visibility. Use mirrors to assist in checking
all around machine. Keep windows and mirrors clean,
adjusted, and in good repair.
T133548
Be certain travel alarm is working properly.
Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03679,00016F3 –19–14SEP00–1/1

010904
PN=16
Safety
00
Avoid Machine Tip Over 0001
9
Use seat belt at all times.
–19–14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
T133716
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps. Properly attach ramps to truck bed. Avoid
trucks with steel beds because tracks slip more easily on
steel.
–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
T133545
bucket on uphill side and just above ground level.
Be careful with heavy loads. Using oversize buckets or

lifting heavy objects reduces machine stability. Extending
a heavy load or swinging it over side of undercarriage
may cause machine to tip.
–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.
T133803
TX03679,00016DF –19–12APR01–1/1
Use Special Care When Lifting Objects
Never use this machine to lift people.
Never lift a load above another person. Keep bystanders –UN–27SEP00
clear of all areas where a load might fall if it breaks free.

Do not leave the seat when there is a raised load.
T133839
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 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 –19–02OCT00–1/1

010904
PN=17
Safety
00
0001 Add And Operate Attachments Safely
10
Always verify compatibility of attachments by that all connections are secure and attachment
contacting your authorized dealer. Adding unapproved responds properly to controls.
attachments may affect machine stability or reliability,
and may create a hazard for others near the machine. Carefully read attachment manual and follow all
instructions and warnings. In an area free of
Ensure that a qualified person is involved in bystanders and obstructions, carefully operate
attachment installation. Add guards to machine if attachment to learn its characteristics and range of
operator protection is required or recommended. Verify motion.
TX03679,00016F0 –19–14SEP00–1/1
Park And Prepare For Service Safely
Warn others of service work. Always park and prepare

your machine for service or repair properly.
• Park machine on a level surface and lower equipment
–19–14DEC01
to the ground.
• Place pilot control shut-off lever in “lock” position. Stop
engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place in
T133332
the operator’s station.
Securely support machine or equipment before working

under it.
• Do not support machine with boom, arm, or other

hydraulically actuated attachments.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other
–UN–23AUG88
devices that may slip out of place.
Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people
whenever the engine must be running for service work. TS229
TX03679,00016E9 –19–12APR01–1/1

010904
PN=18
Safety
00
Service Cooling System Safely 0001
11
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP –19–04JUN90–1/1
Remove Paint Before Welding or Heating
Hazardous fumes can be generated when paint is heated

by welding or using a torch. Dust from sanding or grinding
–UN–24AUG00
paint can also be hazardous.
Remove paint to at least 76 mm (3 in.) from area to be

heated. Wear an approved respirator when sanding or
T133546
grinding paint. If a solvent or paint stripper is used, wash
area with soap and water. Remove solvent or paint
stripper containers from work area and allow fumes to
disperse at least 15 minutes before welding or heating.
Work outside or in a well-ventilated area. Dispose of

waste, paint and solvents properly.
TX03679,0001732 –19–06SEP00–1/1
Make Welding Repairs Safely
NOTE: Disable electrical power before welding. Turn off
–UN–31AUG00
main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors.
T133547
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.
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 –19–02OCT00–1/1

010904
PN=19
Safety
00
0001 Drive Metal Pins Safely
12
–UN–14SEP00
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
T133738
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
TX03679,0001745 –19–25SEP00–1/1

010904
PN=20
Safety
00
Safety Signs 0001
13
–19–17APR01
T141213
TX14740,0001D0E –19–09APR01–1/1

010904
PN=21
Safety
00
0001
14

010904
PN=22
Group 0003
Torque Values
00
Unified Inch Bolt and Cap Screw Torque Values 0003
1
–UN–27SEP99
TORQ1A
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to 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.
DX,TORQ1 –19–01OCT99–1/1

010904
PN=23
Torque Values
00
0003 Metric Bolt and Cap Screw Torque Values
2
–UN–07SEP99
TORQ2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
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.
DX,TORQ2 –19–01OCT99–1/1

010904
PN=24
Torque Values
00
Additional Metric Cap Screw Torque Values 0003
3
–UN–18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
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.
–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
T6873AB
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 you properly

start thread engagement. This will prevent them from
failing when tightening.
–UN–18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page 04T,90,M170 –19–29SEP99–1/2

010904
PN=25
Torque Values
00
0003 METRIC CAP SCREW TORQUE VALUESa
4
T-Bolt H-Bolt M-Bolt
Nominal
Dia N•m lb-ft N•m lb-ft N•m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
Torque tolerance is ±10%.
a
04T,90,M170 –19–29SEP99–2/2

010904
PN=26
Torque Values
00
Check Oil Lines And Fittings 0003
5
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
Tubing with dents may cause the oil to overheat. If you

find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque

chart.
When you tighten connections, use two wrenches to

prevent bending or breaking tubing and fittings.
TX,90,DH1559 –19–01AUG94–1/1

010904
PN=27
Torque Values
00
0003 Service Recommendations for O-Ring Boss
6
Fittings
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
–UN–18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
Continued on next page 04T,90,K66 –19–29SEP99–1/2

010904
PN=28
Torque Values
00
Angle Fitting 0003
7
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
–UN–18OCT88
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is ± 10%.
04T,90,K66 –19–29SEP99–2/2

010904
PN=29
Torque Values
00
0003 Service Recommendations for Flat Face
8
O-Ring Seal Fittings
1. Inspect the fitting sealing surfaces. They must be free

of dirt or defects.
–UN–18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.
3. Lubricate O-rings and install into groove using
T6243AD
petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum

jelly so O-ring is not displaced during assembly.
5. Index angle fittings and tighten by hand pressing joint

together to insure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the

chart per dash size stamped on the fitting. Do not allow
hoses to twist when tightening fittings.
FLAT FACE O-RING SEAL FITTING TORQUE

Thread Size
Nominal Tube O.D. Dash Size in. Swivel Nut Bulkhead Nut
mm in. N•m lb-ft N•m lb-ft
6.35 0.250 -4 9/16-18 16 12 5.0 3.5
9.52 0.375 -6 11/16-16 24 18 9.0 6.5
12.70 0.500 -8 13/16-16 50 37 17.0 12.5
15.88 0.625 -10 1-14 69 51 17.0 12.5
19.05 0.750 -12 1 3/16-12 102 75 17.0 12.5
22.22 0.875 -14 1 3/16-12 102 75 17.0 12.5
25.40 1.000 -16 1 7/16-12 142 105 17.0 12.5
31.75 1.250 -20 1 11/16-12 190 140 17.0 12.5
38.10 1.500 -24 2-12 217 160 17.0 12.5
NOTE: Torque tolerance is +15 -20%.
04T,90,K67 –19–29SEP99–1/1

010904
PN=30
Torque Values
00
Service Recommendations for 37° Flare and 0003
9
30° Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
–UN–18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6234AC
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or petroleum

jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque

chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160
NOTE: Torque tolerance is ± 10%.
T82,BHMA,EL –19–29SEP99–1/1

010904
PN=31
Torque Values
00
0003 Service Recommendations For Flared
10
Connections—Straight or Tapered Threads
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
–UN–18OCT88
2. Defects in the tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6873AE
3. Align the tube with the fitting before attempting to start
the nut.
Straight Thread
4. Lubricate the male threads with hydraulic fluid or
petroleum jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on the

chart. Do not allow hoses to twist when tightening
–UN–18OCT88
fittings.
a
TORQUE CHART
T6873AD
b
Straight Thread Tapered Thread
Thread
Size N•m lb-ft N•m lb-ft
Tapered Thread
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
Torque tolerance is ±10%.
a
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

010904
PN=32
Torque Values
00
Service Recommendations For Inch Series Four Bolt Flange Fittings 0003
11
–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART

cause leaks. Roughness causes seal wear. N•m lb-ft
Out-of-flat causes seal extrusion. If defects cannot Nominal Cap Screw
be polished out, replace component. Flange Size
Size Min Max Min Max
2. Install O-ring (and backup washer if required) into 1/2 5/16-18 20 31 15 23
groove using petroleum jelly to hold it in place. UNC
3/4 3/8-16 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) 1 3/8-16 UNC 37 54 27 40
halves. Make sure split is centrally located and 1-1/4 7/16-14 47 85 35 63
perpendicular to port. Hand tighten cap screws to UNC
hold parts in place. Do not pinch O-ring (C). 1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange 2-1/2 1/2-13 UNC 107 131 79 97
must be centrally located on port. Hand tighten cap 3 5/8-11 UNC 158 264 117 195
screws to hold flange in place. Do not pinch O-ring. 3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.
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

010904
PN=33
Torque Values
00
0003 Service Recommendations for Metric Series Four Bolt Flange Fitting
12
–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
N•m lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
4. Single piece flange (D): Place hydraulic line in M12 95 70

center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance ± 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, 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

010904
PN=34
Section 01
Tracks
Contents 01
Page
Group 0130—Track System

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

010904
PN=1
Contents
01

010904
PN=2
Group 0130
Track System
Track Roller, Front Idler, and Carrier Roller
Oil
Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105E).

TX,45,DH5142 –19–06NOV01–1/1 01
0130
1
Track Roller Repair
Remove and Install Track Roller
1. Swing upperstructure 90° and lower bucket to raise

track off ground. Keep angle between boom and arm
90—110° and position round side of bucket on ground.
CAUTION: Prevent possible injury from

unexpected machine movement. Put shop
stands under frame to support machine while
removing lower track roller.
Track Roller—Specification
Machine (200CLC)—Weight.................................... 20 298 kg (44,750 lb)
approximate
approximate
approximate
2. Place shop stands under machine.
OUOE049,0000063 –19–19NOV01–1/6
CAUTION: Prevent possible injury from high

pressure grease. Do not remove grease fitting
(A) from valve (B).
3. Loosen valve (B) one to two turns to release grease

through bleed hole (C).
–UN–28NOV90
A—Grease Fitting
B—Valve
T7396DZ
C—Bleed Hole
Continued on next page OUOE049,0000063 –19–19NOV01–2/6

010904
PN=37
Track System
CAUTION: Heavy component; use a hoist.
Track Roller (200CLC and
230CLC)—Weight.............................................. 35 kg (77 lb) approximate
01
Track Roller (270CLC)—Weight...................... 54 kg (120 lb) approximate
0130
–UN–25OCT88
2
4. Attach hoist to track roller (B). Remove cap screws (A)
and track roller (B).
T6585TN
5. Measure track roller tread diameter. See 200CLC
Track Roller Tread Diameter, 230CLC Track Roller
Tread Diameter, or 270CLC Track Roller Tread
Diameter. (SP326 Undercarriage Appraisal Manual.) A—Cap Screw (4 used)
B—Track Roller
6. Repair or replace parts as necessary.
7. Tighten cap screws.
Roller-to-Frame Cap Screw
(200CLC and 230CLC)—Torque................................. 460 N•m (340 lb-ft)
Roller-to-Frame Cap Screw
(270CLC)—Torque ...................................................... 670 N•m (490 lb-ft)
8. If applicable, install rock guard and tighten cap screws.
Rock Guard Cap Screw (200CLC
and 230CLC)—Torque ................................................ 460 N•m (340 lb-ft)
Rock Guard Cap Screw
9. Check and Adjust Track Sag. (Operator’s Manual.)

010904
PN=38
Track System
01
0130
3
–UN–21SEP94
T8310AH
A—Plug (2 used) C—Pin (2 used) E—Metal Face Seal (2 used) G—Roller
B—Bracket (2 used) D—O-Ring (2 used) F—Bushing (2 used) H—Axle
Disassemble and Assemble Track Roller NOTE: Only remove bushing if replacement is
necessary.
1. Remove plug (A) and drain oil.
7. Remove bushing (F) using a 2 jaw puller and
2. Remove pin (C). adapters from puller set.
3. Remove bracket (B) using a bearing puller 8. Replace parts as necessary.

attachment and adapters from puller set.
Apply a thin film of oil to bushings (F) and install.
IMPORTANT: Metal face seals can be reused if
they are not worn or damaged. A IMPORTANT: O-rings and seat surfaces for
used seal must be kept together as a O-rings must be clean, dry, and oil
set because of wear patterns on seal free so O-rings do not slip when
ring face. roller is turning.
4. Remove metal face seal (E) from roller and bracket. 9. Thoroughly clean O-rings and seat surfaces in
Keep seal rings together as a matched set with seal brackets (B) and in seal rings using volatile,
ring faces together to protect surfaces. non-petroleum base solvent and lint-free tissues.
5. Inspect metal face seals. See Metal Face Seals 10. Install seals (E) in brackets (B) and in roller (G).
Repair. (See procedure in this group.) For seals Apply equal pressure with fingers at four equally
that will be reused, put a piece of cardboard spaced points on seal face. Seal must “pop” down
between seal rings to protect seal face. into place so O-ring is tight against seal bore. A
volatile, non-petroleum base solvent or talcum
6. Remove axle (H) from roller. powder may be used as a lubricant.

010904
PN=39
Track System
11. Wipe finger prints and foreign material off seal ring 15. Fill roller with 260 mL (8.8 oz) of oil.
face using clean oil and lint-free tissues. Apply a
thin film of oil to each seal ring face. 16. Apply cure primer and pipe sealant to threads of
plug. Install and tighten plug.
12. Apply a thin layer of NEVER-SEEZ anti-seize
01
lubricant or an equivalent to pin (C). Install pin Track Roller—Specification
0130
even with flat surface of bracket. Plug—Torque ......................................................... 20 N•m (177 lb-in.)
4
13. Install axle to bracket.
14. Apply NEVER-SEEZ anti-seize lubricant or

equivalent to pin (C). Install pin even with flat
surface of bracket.
NEVER-SEEZ is a trademark of Emhart Chemical Group. OUOE049,0000063 –19–19NOV01–5/6
Test Track Roller for Oil Leakage
1. Hold the shaft and turn shell several turns to seat

metal face seals.
2. Remove the plug.
–UN–02JUN97
3. Install parts (A—F). Plug, barbed adapter and
connector are from a leak detector kit such as the
D05361ST Rubber Stopper/Leak Detector Kit.
T109691B
4. Holding plug so it is not pushed out, slowly pressurize
oil cavity using air.
A—Plug, Barbed Adapter and Connector
Track Roller—Specification B—JT03001 Tee Fitting 7/16-20 M 37° x 7/16-20 F
Oil Cavity Air Test—Pressure ................ 110 ± 18 kPa (1.1 ± 0.3 bar) (16 37° SW x 7/16-20 M 37°
± 4 psi) C—Hose (2 used)
D—Pressure Gauge
E—Snubber (Needle) Valve
5. Close valve and wait for a minimum of 30 seconds. F—Air Pressure Regulator
Check for oil leakage. Check gauge to see if air
pressure has decreased.
6. If there is leakage, disassemble roller and replace

parts as necessary.
7. Apply cure primer and pipe sealant to threads. Install

plug.
OUOE049,0000063 –19–19NOV01–6/6

010904
PN=40
Track System
Track Carrier Roller Repair
Remove and Install Track Carrier Roller
CAUTION: Prevent possible injury from high 01

pressure grease. Do not remove grease fitting 0130
–UN–28NOV90
5
(A) from valve (B).

T7396DZ
2. Raise track link, using a jack, enough to permit carrier
roller removal. A—Grease Fitting
B—Valve
C—Bleed Hole
CAUTION: Prevent accidental lowering of track
by securely supporting track before attempting
service procedure.
3. Install wooden blocks between track link and frame.
OUOE049,0000064 –19–19NOV01–1/4
4. Remove cap screws (B) and carrier roller (A).
5. Measure track carrier roller tread diameter. See

200CLC Carrier Roller Tread Diameter, 230CLC
Carrier Roller Tread Diameter, or 270CLC Carrier
Roller Tread Diameter. (SP326 Undercarriage
–UN–25OCT88
Appraisal Manual.)
T6557DK
7. Install carrier roller and tighten cap screws (B).
Track Carrier Roller—Specification

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

010904
PN=41
Track System
01
0130
6
–UN–30APR98
T114725
A—Plug C—Cap Screw (2 used) E—Bushing G—Metal Face Seal

B—Cover D—Thrust Washer F—Roller H—Support
Disassemble and Assemble Track Carrier Roller IMPORTANT: Replace entire roller assembly if
bushing (E) and shaft surfaces are
1. Remove plug (A) and drain oil. damaged. Bushing (E) is no longer
serviceable because cover (B)
2. Remove cap screws (C) through oil plug drain hole. cannot be removed.
3. Remove roller (F) from support (H). 4. Inspect bushing (E) and shaft on support (H).

010904
PN=42
Track System
IMPORTANT: Metal face seals can be reused if A volatile, non-petroleum base solvent or
they are not worn or damaged. A talcum power may be used as a lubricant.
used seal must be kept together as a
set because of wear patterns on seal 10. Install one half of metal face seal into support (H).
ring face.
01
11. Apply a thin coat of oil to the metal faces on each 0130
5. Remove metal face seal (G). half of the seal. 7
6. Inspect metal face seal. See Metal Face Seals 12. Install the other half of metal face seal on the half
Repair. (See procedure in this group.) For seals already in place in support (H).
that will be reused, put a piece of cardboard
between seal rings to protect seal face. 13. Install roller (F) over shaft on support (H) being
sure to keep cap screws (C) in alignment with
7. Replace parts as necessary. holes on shaft.
IMPORTANT: O-rings may slip when roller is 14. Tighten cap screws (C).
turning if O-rings and seat surfaces
are not clean, dry and oil free. Track Carrier Roller—Specification
Thrust Washer-to-Support Shaft
Cap Screw—Torque ................................................. 64 N•m (47 lb-ft)
8. Thoroughly clean the O-rings and seat surfaces in
roller, support, and seal bushings using a volatile,
15. For 200CLC and 230CLC, fill carrier roller with 70
non-petroleum base solvent and lint-free tissue.
mL (0.018 gal) of clean oil through plug (A) hole.
For 270CLC, fill carrier roller with 75 mL (0.020
9. Install O-ring on seal rings.
gal) of oil.
NOTE: Current carrier roller metal face seals use a
16. Apply cure primer and pipe sealant to threads of
tapered fit. There is no longer the “pop” into
plug. Install plug.
place fit previously used.
OUOE049,0000064 –19–19NOV01–4/4

010904
PN=43
Track System
Metal Face Seals Repair
Inspect Metal Face Seals
1. Inspect for the following conditions to determine if

01
0130 seals can be reused:
8
a. The narrow, highly polished sealing area (E) must
be in the outer half of seal ring face (D).
b. Sealing area must be uniform and concentric with

the ID and OD of seal ring (A).
c. Sealing area must not be chipped, nicked, or

scratched.
A—Seal Ring
–UN–24AUG93
B—Worn Area (Shaded Area)
C—Seal Ring Face
D—Outer Half of Seal Ring Face
E—Sealing Area (Dark Line)
T85079
T47,0130,5939HQ –19–19NOV01–1/3
2. Illustration shows examples of worn seal rings (A).
I—Sealing area (D) is in inner half of seal ring face (C).
II—Sealing area (D) not concentric with ID and OD of

seal ring.
–UN–05DEC96
A—Seal Ring
B—Worn area (Shaded Area)
C—Inner Half of Seal Ring Face
T85080
D—Sealing Area (Dark Line)
Continued on next page T47,0130,5939HQ –19–19NOV01–2/3

010904
PN=44
Track System
3. Clean reusable seals by removing all foreign material

from seal rings, except seal face (A), using a scraper
or a stiff bristled fiber brush.
4. Wash seal rings and O-rings using a volatile,

01
non-petroleum base solvent to remove all oil.
–UN–23FEB89
0130
Thoroughly dry parts using a lint-free tissue. 9
Apply a thin film of oil to seal ring face. Put face of seal
rings together and hold using tape.
T82840
A—Seal Face
T47,0130,5939HQ –19–19NOV01–3/3
Track Shoe Repair
Remove and Install Track Shoe
1. Measure grouser height. See 200CLC Three Bar

Grouser Height, 230CLC Three Bar Grouser Height, or
–UN–23FEB89
270CLC Three Bar Grouser Height 800 mm (31.5 in.)
Width. (SP326 Undercarriage Appraisal Manual.)
2. Apply a light coat of oil to cap screw threads and install
T6794AM
shoe.
3. Install all track shoe nuts with rounded corners (A)

against the link and chamfered edges (B) away from
the link. Be sure nut is properly positioned in the link
so there is full contact between the nut and the link.
4. Tighten cap screws in pattern shown.

–UN–23FEB89
Track Shoe—Specification
Shoe-to-Link Cap Screw (18 mm)
(200CLC)—Torque Turn.............................. 210 ± 21 N•m (155 ± 16 lb-ft)
plus 1/2 (180°) turn
T6352AH
Track Shoe—Specification
Shoe-to-Link Cap Screw (20, 22
mm) (230CLC and 270CLC)—
Torque Turn ................................................... 298 N•m (220 lb-ft) plus 1/2 A—Rounded Edge
(180°) turn B—Chamfered Edge
TX,01,SB384 –19–19SEP00–1/1

010904
PN=45
Track System
Track Chain Repair
Remove and Install Track Chain
1. Swing upperstructure to side. Lower boom to raise

01
0130 track off the ground.
10
Keep the angle between boom and arm at 90—110°
with the round side of bucket on the ground.

unexpected machine movement. Put blocks or
shop stands under machine frame to support
machine while measuring track sag.
Track Chain—Specification
approximate
approximate
approximate
2. Place blocks or shop stands under the machine to

support machine.
OUOE049,0000065 –19–20JUN01–1/5
CAUTION: Prevent possible injury from high

pressure grease. Do not remove grease fitting
(A) from valve (B).

–UN–28NOV90
A—Grease Fitting
B—Valve
T7396DZ
C—Bleed Hole
Continued on next page OUOE049,0000065 –19–20JUN01–2/5

010904
PN=46
Track System
NOTE: The master pin (2) can be identified by the large

dimple (3) on the pin’s end.
4. Move track chain so master pin (2) is over front idler or

sprocket.
01
0130
5. Remove the track shoe on each side of master pin. 11
6. If removing chain at idler, put wooden blocks in front of

idler and under chain so chain does not fall when
master pin is removed.
–UN–20JUL01
7. Remove master pin using a 50-Ton Master Pin Pusher
Installer. Remove bushings (1).
T143215B
Track Chain—Specification 1—Bushing (2 used)

Tracks with 800 mm (32 in.) 2—Master Pin
Shoes (200CLC)—Weight ......................... 1293 kg (2850 lb) approximate 3—Dimple
Tracks with 800 mm (32 in.)
Shoes (230CLC)—Weight ......................... 1395 kg (3075 lb) approximate
Tracks with 800 mm (32 in.)
Shoes (270CLC)—Weight ......................... 1814 kg (4000 lb) approximate
8. Remove track chain.
9. Measure track chain link, bushing, and pitch. (See

SP326 Undercarriage Appraisal Manual.)
10. Replace parts as necessary.
11. Position track chain so section on ground has pin

boss on links toward rear of machine.
12. Install end of chain on sprocket and slowly turn

sprocket in forward direction to pull chain across top
of frame to front idler.
13. Pull ends of chain together. Install bushings and

master pin (2) using 50-Ton Master Pin Pusher
Installer.
14. Install track shoe. See Track Shoe Repair. (See

procedure in this group.)

010904
PN=47
Track System
01
0130
12
–UN–09SEP98
T117027
A—Track Link (49 used) D—Snap Ring G—Track Link (48 used) J—Shoe (49 used)
B—Master Track Link E—Master Bushing H—Seal (96 used) K—Pin (48 used)
C—Master Pin F—Spacer (2 used) I—Bushing (48 used)
Disassemble and Assemble Track Chain
1. Measure track components (A—K). See Track

Chain. (SP326 Undercarriage Appraisal Manual.)

010904
PN=48
Track System
NOTE: Wear on pins and bushings does not extend 4. Apply grease to the counterbore in track links, the
over the entire surface. Turning pins and seals, and the ends of bushings.
bushing is determined by the amount of wear.
5. For each joint, fill the clearance between the pin
2. Turn pins (C and K) and bushings (E and I) as OD and bushing ID with grease.
01
required. 0130
6. Install seal (H) so tapered side (L) is toward 13
3. Clean any dust or rust from the surfaces of track bushing.
link pin bores and counterbores and the ends of
bushings.
OUOE049,0000065 –19–20JUN01–5/5
Broken Track Chain Part Repair
Disassemble and Assemble Track Chain to Replace

Broken Part
1. Remove track shoes from each side of broken link
–UN–26OCT88
assembly. See Track Shoe Repair. (See procedure in
this group.)
IMPORTANT: When making cuts using cutting torch,
T5821AG
be careful not to cut or gouge good
parts.
2. Cut links, bushing, and pin at points (A) to remove A—Cut Locations
broken link (B). B—Broken Link
OUOE003,0000008 –19–28OCT01–1/4
3. Grind the ends of bushing (A) even with links to make

it into a master bushing.
A—Bushing
–UN–26OCT88
T5821AH
Continued on next page OUOE003,0000008 –19–28OCT01–2/4

010904
PN=49
Track System
4. Burn holes through center of pin stubs (A).
5. Hold a heavy hammer (B) against the link while pin

stub is being driven out.
01
0130 A—Pin Stub
–UN–26OCT88
14 B—Hammer
T5821AI
OUOE003,0000008 –19–28OCT01–3/4
6. Install links (C and E) on master bushing (D). Check

cap screw hole spacing using a track shoe.
7. Instal spacers (B) into counterbore of links.
8. Install link assembly. Install master pins (A).
–UN–24MAY89
9. Install track shoes. See Track Shoe Repair. (See
T5821AJ
A—Master Pin
B—Spacer
C—Right Link
D—Master Bushing
E—Left Link
OUOE003,0000008 –19–28OCT01–4/4
Sprocket Repair
Remove and Install Sprocket

010904
PN=50
Track System
IMPORTANT: Sprocket must be replaced when the

tooth tips become excessively rounded,
worn, or chipped to prevent excessive
wear to chain. If machine is driven in
one direction a majority of the time,
01
wear will be on one side of teeth. To 0130
extend service life, change sprockets 15
from one side of machine to the other.
1. Disconnect track chain. See Track Chain Repair. (See

–UN–20JUL01
2. Lift side of machine so sprocket teeth clear chain.
T143369B
Sprocket—Specification
Sprocket (200CLC and 1—Cap Screw (16 used)
230CLC)—Weight............................................ 46 kg (101 lb) approximate
Sprocket (270CLC)—Weight ........................... 70 kg (150 lb) approximate
3. Remove cap screws (1) and sprocket.
4. Apply cure primer and thread lock and sealer (high

strength) to threads of cap screws (B).
5. Install sprocket and tighten cap screws (1).
Sprocket—Specification
Sprocket-to-Propel Gearbox Cap
Screw—Torque ............................................................ 490 N•m (360 lb-ft)
6. Lower machine.
7. Install track chain. See Track Chain Repair. (See

OUOE003,0000009 –19–09NOV01–2/2

010904
PN=51
Track System
Front Idler Repair
Remove and Install Front Idler
1. Disconnect track chain. See Track Chain Repair. (See

01
0130 procedure in this group.)
–UN–25OCT88
16
2. Slide front idler (A) forward, using pry bar.
T6876BU
Front Idler—Specification
Front Idler (200CLC and
230CLC)—Weight.......................................... 100 kg (240 lb) approximate A—Front Idler
Front Idler (270CLC)—Weight....................... 160 kg (350 lb) approximate
3. Attach front idler to hoist and remove from frame.
4. Measure front idler wear. See Front Idler Flange

Height. (SP326 Undercarriage Appraisal Manual.)
5. Repair or replace idler as necessary.
6. Install front idler.
7. Connect track chain. See Track Chain Repair. (See

Continued on next page TX,01,SB395 –19–15NOV01–1/4

010904
PN=52
Track System
01
0130
17
–UN–21SEP94
T8312AA
A—Pin (2 used) D—Plug (2 used) G—O-Ring (2 used) I—Yoke
B—Bushing (2 used) E—Bracket (Bearing) (2 used) H—Axle J—Cap Screw (4 used)
C—Idler F—Metal Face Seal (2 used)
Disassemble and Assemble Front Idler 5. Remove axle (H). Inspect axle and bushing for
scoring or excessive wear.
1. Remove cap screws (J) and yoke (I).
NOTE: Remove bushings only if replacement is
2. Remove drain plug (D) and drain oil. necessary.
IMPORTANT: Metal face seals can be reused if 6. Remove bushing using a 2-jaw puller and adapters
they are not worn or damaged. A from 17-1/2 and 30-ton puller set.
used seal must be kept together as a
set because of wear patterns on seal 7. Replace parts as necessary.
ring face.
8. Apply a thin film of oil to bushings (B). Install
3. Remove pins (A), brackets (E), O-rings (G) and bushings so flange is tight against shoulder of idler.
metal face seals (F).
9. Install O-rings (G) on axle.
4. Inspect metal face seals. See Metal Face Seals
Repair. (See procedure in this group.) Keep seal 10. Apply a thin layer of NEVER-SEEZ anti-seize
rings together as a matched set with seal ring faces lubricant or equivalent to end of axle from O-ring
together to protect surfaces. to end of axle and to bore in bracket (E).
NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page TX,01,SB395 –19–15NOV01–2/4

010904
PN=53
Track System
11. Install axle into bracket. 16. Wipe finger prints and foreign material off seal ring
face using clean oil and lint-free tissues. Apply a
12. Apply NEVER-SEEZ anti-seize lubricant or thin film of oil to each seal face.
equivalent to pin (A). Install pin.
17. For 200CLC and 230CLC, fill front idler with 265
01
0130 IMPORTANT: Metal face seal O-rings and seat mL (8.96 oz) of oil. For 270CLC, fill front idler with
18 surfaces for O-rings must be clean, 300 mL (10.14 oz) of oil.
dry, and oil free so O-rings do not
slip when idler is turning. 18. Install axle (H) into idler.
13. Thoroughly clean the metal face seal (F) O-rings 19. Apply cure primer to threads of drain plug (D).
and seat surfaces in idler, brackets, and seal rings
using volatile, non-petroleum base solvent and 20. Apply thread lock and sealer (medium strength) to
lint-free tissues. threads of plug. Install and tighten plug.
14. Install metal face seal O-ring on seal rings. 21. Install yoke (I). Tighten cap screws (J).
NOTE: A volatile, non-petroleum base solvent or Front Idler—Specification

Yoke-to-Bracket Cap Screw—
talcum powder may be used as a lubricant.
Torque................................................................... 210 N•m (156 lb-ft)
15. Install metal face seals (F) in bracket and idler.

Apply equal pressure with fingers at four equally
spaced points on seal face. Seal must "pop" down
into place so O-ring is tight against seal bore.
NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page TX,01,SB395 –19–15NOV01–3/4

010904
PN=54
Track System
Test Front Idler for Oil Leakage
1. Turn the shaft several turns to seat metal face seals.
2. Remove the plug (G).

01
0130
3. Install parts (A—F) as shown. Plug barbed adapter, 19
and connector are from a leak detector kit such as the
D05361ST Rubber Stopper/Leak Detector Kit.
4. Holding plug so it is not pushed out, slowly pressurize

oil cavity using air.
Front Idler—Specification
Oil Cavity Air Test—Pressure ................ 110 ± 28 kPa (1.1 ± 0.3 bar) (16
± 4 psi)
5. Close valve and wait for a minimum of 30 seconds to

check for oil leakage. Check gauge to see if air
pressure has decreased.
–UN–13JUN97
6. If there is external leakage, disassemble idler and
replace parts as necessary.
7. Check oil level in idler. If the oil level is down and there
T109791B
is no external leakage, check for a leak from oil cavity
to interior of idler wheel.
A—Plug, Adapter and Connector
8. Apply cure primer to threads of plug.
B—Connector 1/8 M NPT x 7/16-20 M 37°
C—Hose
9. Apply thread lock and sealer (medium strength) to D—Pressure Gauge
threads of plug. Install and tighten plug. E—Snubber (Needle) Valve
F—Air Pressure Regulator
G—Drain Plug
TX,01,SB395 –19–15NOV01–4/4
Track Adjuster and Recoil Spring Repair
Remove and Install Track Adjuster and Recoil Spring
1. Remove track chain. See Track Chain Repair. (See

2. Remove front idler. See Front Idler Repair. (See

Continued on next page OUOE003,000000A –19–09NOV01–1/6

010904
PN=55
Track System
CAUTION: Spring or rod may break if dropped

while handling, transporting or disassembling.
Nicks or weld craters in spring and rod
assembly can cause stress concentration
01 resulting in a weak spot. Weak spots may result
0130
–UN–25OCT88
in immediate or eventual failure creating a risk
20
of personal injury. Put a heavy protective
covering around spring assembly when
handling, transporting, or disassembling track
T6557CX
adjuster.
A compression tool must be used for

disassembly and assembly because of the A—Track Adjuster
extreme preload on spring.
3. Slide track adjuster (A) forward, using a pry bar.
Track Adjuster and Recoil Spring—Specification

Track Adjuster Cylinder and
Recoil Spring (200CLC and
230CLC)—Weight.......................................... 129 kg (280 lb) approximate
Recoil Spring (270CLC)—Weight.................. 180 kg (400 lb) approximate
4. Attach track adjuster to hoist and remove from frame.
6. Install front idler. See Front Idler Repair. (See

7. Install track chain. See Track Chain Repair. (See


010904
PN=56
Track System
Disassemble and Assemble Track Adjuster and Recoil

Spring
CAUTION: Spring or rod may break if dropped

while handling, transporting or disassembling. 01
Nicks or weld craters in spring and rod 0130
21
resulting in a weak spot. Weak spots may result
in immediate or eventual failure creating a risk
of personal injury. Put a heavy protective
covering around spring assembly when
handling, transporting, or disassembling track
adjuster.

disassembly and assembly because of the
–UN–25OCT88
Track Recoil Spring Disassembly
and Assembly Tool—Weight ......................... 225 kg (496 lb) approximate
T6557DY
1. Place an 18-t (20-ton) jack on bottom of ST4920 Track
Recoil Spring Disassembly and Assembly Tool (A).
Remove nuts (B) and top plate (C). (Group 9900.)
A—ST4920 Track Recoil Spring Disassembly and
Assembly Tool
NOTE: It is not necessary to remove the recoil spring to B—Nut
replace wear ring and U-ring packing on piston. C—Top Plate
To replace O-ring in the cylinder, remove recoil
spring and rod.
2. Remove nuts (B). Remove top plate (C).

010904
PN=57
Track System

01
230CLC)—Weight.......................................... 129 kg (280 lb) approximate
0130
22
Recoil Spring (270CLC)—Weight.................. 180 kg (400 lb) approximate
3. Connect track adjuster (B) to a hoist using a lifting

strap (A).
4. Put track adjuster in assembly tool with cylinder end on

DFT1110 Spacer (C). (Group 9900.)
5. Remove lifting strap.
A—Lifting Strap
B—Track Adjuster
C—DFT1110 Spacer
–UN–28APR92
T7720AF

010904
PN=58
Track System
6. Install DFT1087 Track Recoil Spring Disassembly and

Assembly Guard Tool (F). (Group 9900.)
7. Install plate top (A) and nuts (B) with smallest opening
to allow access to nut (D).
01
0130
8. Extend jack ram to provide enough travel to release 23
spring to the approximate free length.

230CLC)—Free Length .......................... 626 mm (24.64 in.) approximate
Recoil Spring (270CLC)—Free
Length ..................................................... 679 mm (26.73 in.) approximate
9. Tighten nuts (B) so plate is tight against retainer plate.
10. Remove valve (C) and special plug (E).
A—Top Plate
B—Nut (8 used)
–UN–28APR92
C—Valve
D—Nut
E—Special Plug
F—DFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool
T7720AG

010904
PN=59
Track System
11. Raise upper half of guard tool (F). Tighten T-handles.
12. Operate jack to compress spring just enough so nut

(D) can be removed.
01
0130 13. Lower jack ram to release spring force.
24
15. If disassembly of track adjuster cylinder is necessary,

seeTrack Adjuster Cylinder Repair. (See procedure in
this group.)
16. Put track adjuster cylinder in assembly tool with

cylinder end on spacer.
17. Install spacer on rod.
18. Install spring using a hoist and lifting strap.
–UN–28APR92
19. Install retainer plate.
20. Install guard tool.
T7720AH
21. Install top plate. Install nuts.
22. Raise upper half of guard tool. Tighten T-handles.

A—Top Plate
23. Operate jack to compress spring to the compressed B—Nut (8 used)
length. D—Nut
F—DFT1087 Track Recoil Spring Disassembly and
Track Adjuster and Recoil Spring—Specification Assembly Guard Tool
230CLC)—Compressed Length .................................. 521 mm (20.51 in.)
Recoil Spring (270CLC)—
Compressed Length .................................................... 557 mm (21.92 in.)
24. Install nut (D) so hole is aligned with hole in rod.

Install special plug.
25. Tighten valve.

Valve—Torque ................................................................. 88 N•m (65 lb-ft)
OUOE003,000000A –19–09NOV01–6/6

010904
PN=60
Track System
Track Adjuster Cylinder Repair
Disassemble and Assemble Track Adjuster Cylinder
CAUTION: Spring or rod may break if dropped 01

while handling, transporting or disassembling. 0130
25
Nicks or weld craters in spring and rod
resulting in a weak spot. Weak spots can result
in immediate or eventual failure of spring or rod
creating a risk of personal injury. Put a heavy
protective covering around spring assembly
when handling, transporting, or disassembling.

disassembly and assembly because of the
NOTE: It is not necessary to remove the recoil spring to

replace wear ring (4) and U-ring packing (5). It is
necessary to remove the recoil spring to replace
O-ring (8).
1. Remove recoil spring if necessary. See Track Adjuster

and Recoil Spring Repair. (See procedure in this
group.)
Continued on next page TX,01,SB407 –19–25JUN01–1/2

010904
PN=61
Track System
2. If necessary, remove rod (7) from cylinder (9) using a

press.
1 2
3
01
0130 4. Apply multi-purpose grease to U-ring packing (5), wear
26 ring (4) and O-ring (8). Fill grooves inside flange (2) 4
with grease. 5
6
5. Install U-ring packing (5) with lip towards inside of
cylinder.
6. Tighten cap screws (1).
Track Adjuster Cylinder—Specification

Flange-to-Cylinder Cap Screw— 7
Torque ............................................................................. 50 N•m (37 lb-ft)
8
1—Cap Screw (3 used)
2—Flange 9
3—Piston Rod
–UN–20JUL01
4—Wear Ring
5—U-Ring
6—Retaining Ring
7—Rod
T143380
8—O-Ring T143380
9—Cylinder
TX,01,SB407 –19–25JUN01–2/2

010904
PN=62
Section 02
Axles and Suspension Systems (Propel)
Contents
Page
Group 0250—Axle Shaft, Bearings, and Reduction

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

Propel Motor . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1
Start-Up Procedure . . . . . . . . . . . . . . . . .02-0260-22
Rotary Manifold . . . . . . . . . . . . . . . . . . . . . .02-0260-22

010904
PN=1
Contents
02

010904
PN=2
Group 0250
Axle Shaft, Bearings, and Reduction Gears
Propel Gearbox Repair
Remove and Install Propel Gearbox
1. Disconnect track chain. See Track Chain Repair.

(Group 0130.)
2. Remove sprocket. See Sprocket Repair. (Group 0130.)
CAUTION: The hydraulic oil tank is pressurized.

02
High pressure release of oil from pressurized 0250
system can cause serious burns or penetrating 1
injury.
3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.)
4. Disconnect hydraulic lines.

010904
PN=65
5. Attach JDG909 Lifting Bracket to gearbox as shown.
Propel Gearbox—Specification
Propel Gearbox (200CLC)—
Weight............................................................ 310 kg (680 lb) approximate
Weight.......................................................... 480 kg (1060 lb) approximate
02
0250
2 NOTE: Make alignment marks between propel gearbox
and undercarriage to aid in installation.
–UN–15JUN01
6. Remove cap screws (1). Remove propel gearbox and
propel motor.
T142702B
NOTE: Align marks made during removal. 200CLC Machine Shown
8. Install gearbox. Tighten cap screws (1). 1—Cap Screw (14 used)—200CLC and 230CLC
—Cap Screw (17 used)—270CLC
Gearbox-to-Frame Cap Screw—
Torque ......................................................................... 630 N•m (460 lb-ft)
9. Connect lines. See Propel System Component

Location. (Group 9025-15.)
10. Fill propel gearbox with oil. See Check Propel

Gearbox Oil Level. (Operator’s Manual.)
11. Do Propel Motor Start-Up Procedure. (Group 0260.)

010904
PN=66
02
0250
3

010904
PN=67
14
13 15
7
02 12
0250 6
4 3 11 9 16
5
4
10 17
3
9
8
2 18
1
19
20
21
22
20
33
23
24
25
26
27 30
26 29 32
25
28
30
31
–UN–15JUN01
T142270
T142270

010904
PN=68
1—Third Planet Carrier 9—Spacer (2 used) 18—Spring Pin (3 used) 26—Needle Bearing (6 used)
2—Third Planet Sun Gear 10—Second Planet Sun Gear 19—Pin (3 used) 27—Third Planet Gear
3—Thrust Plate (6 used) 11—First Planet Carrier 20—Thrust Plate (6 used) 28—Propel Motor
4—Second Planet Gear (3 12—Shaft 21—Needle Bearing (3 used) 29—Metal Face Seal
used) 13—Ring Gear 22—First Planet Gear (3 used) 30—Bearing (2 used)
5—Needle Bearing (3 used) 14—Thrust Pad 23—Spring Pin (3 used) 31—Drum
6—Pin (3 used) 15—Cap Screw (12 used) 24—Pin (3 used) 32—Bearing Nut
7—Spring Pin (3 used) 16—Cover 25—Thrust Plate (6 used) 33—Dowel Pin
8—Second Planet Carrier 17—Cap Screw (24 used)
Disassemble and Assemble Propel Gearbox— 5. Remove third planet sun gear (2) and third planet
200CLC and 230CLC carrier (1).
02
0250
1. Remove cap screws (15) and cover (16). NOTE: Disassembly of first, second, and third planet 5
carriers are similar. Repeat procedure as
2. Remove shaft (12) and first planet carrier (11). required.
3. Remove second planet sun gear (10) and second 6. Remove spring pins, pins, thrust plates, needle
planet carrier (8). bearings, and planetary gears.
Clean and inspect parts, replace as necessary. Oil

parts with gear oil prior to assembly.
Ring Gear (200CLC and
230CLC)—Weight ....................................... 41 kg (90 lb) approximate
4. Install JT01748 Lifting Brackets to ring gear (13).

Remove cap screws (17) and ring gear.
Third Planet Carrier (200CLC
and 230CLC)—Weight................................ 39 kg (85 lb) approximate
OUOE049,0001000 –19–19NOV01–4/14
7. Install spring pins with slit (1) toward end of pin.
8. Install third planet gear (27) in third planet carrier (1)

with marked side towards hole for spring.
–UN–22JUN01
1—Slit
T142429

010904
PN=69
9. Remove bearing nut (32) from propel motor (28) using

DF1036A Propel Gearbox Nut Wrench (35) and
DFT1109 Holding Bar (34). Fasten holding bar to ring
gear. (Group 9900.)
Drum (200CLC and 230CLC)—
Weight................................................................ 44 kg (97 lb) approximate
02
–UN–15JUN01
0250 10. Remove drum (31) using JT01748 Lifting Brackets.
6
IMPORTANT: Metal face seals can be reused if they

are not worn or damaged. A used seal
T142380
must be kept together as a set because
of wear patterns on seal ring face.
32—Bearing Nut
11. Remove metal face seal (29). See Metal Face Seals 34—DFT1109 Holding Bar
Repair. (Group 0130.) 35— DF1036A Propel Gearbox Nut Wrench
NOTE: Further disassembly is not necessary unless

bearing replacement is required. Bearing will be
destroyed during removal, replace with new
bearing.
12. Inspect bearing (30) and race inside housing (31).
CAUTION: DO NOT heat oil over 182°C (260°F).

Oil fumes or oil can ignite above 193°C (380°F).
Use a thermometer. DO NOT allow a flame or
heating element to come in direct contact with
the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.
14. Heat inner bearing cone. Install cone tight against

shoulder.
Bearing Cone (200CLC and
230CLC)—Temperature ....................................... 50—70°C (122—158°F)

010904
PN=70
IMPORTANT: Metal face seal O-rings and seat

surfaces for O-rings must be clean, dry,
and oil free so O-ring does not slip.
15. Thoroughly clean metal face seal O-rings and seat

surfaces in propel motor housing, drum, and seal ring
using volatile, non-petroleum base solvent and
lint-free tissues.
NOTE: A volatile, non-petroleum base solvent or talcum

powder can be used as a lubricant. Solvent must 02
not damage the O-ring or leave an oil residue. 0250
7
16. Install O-ring and metal face seal on propel motor

housing and drum. Apply equal pressure with fingers
at four equally spaced points on seal face. Seal must
“pop” down into place so O-ring is tight against seal
bore and seal ring is installed squarely.
17. Clean seal ring face. Apply a thin film of clean oil.
18. Apply a thin coat of multi-purpose grease to threads

of bearing nut (32). Install bearing nut with machined
surface towards bearing.
19. Tighten bearing nut using DF1036A Propel Gearbox

Nut Wrench and DFT1109 Holding Bar. Fasten
holding bar to ring gear. (Group 9900.) Seat bearings.
Bearing Nut (200CLC and
230CLC)—Torque .................................... 790 N•m (580 lb-ft) then tap on
drum using a plastic hammer,
turn drum 4—5 turns to the right
and left to seat the bearings.
20. Repeat steps to ensure bearings are seated.

010904
PN=71
21. Ensure center of dowel pin (33) is aligned with center

of spline on propel motor shaft. If centers are not
aligned tighten bearing nut until dowel pin center
aligns with center of the next spline.
22. Install third planet carrier so dowel pin (33) enters

hole (35) on third planet carrier.
23. Apply rigid from-in-place gasket to flange surface on

ring gear.
02
–UN–15JUN01
0250 24. Apply thread lock and sealer (high strength) to cap
8
screws (17). Tighten cap screws.
T142422
Ring Gear-to-Drum Cap Screw
25. Install second and first planet carriers, sun gears and
shaft. 35

cover.
–UN–15JUN01
27. Apply thread lock and sealer (medium strength) to
thread of cap screws (15). Tighten cap screws.
T142944
Cover-to-Ring Gear Cap Screw
(200CLC and 230CLC)—Torque................................... 110 N•m (83 lb-ft)
28—Propel Motor
32—Bearing Nut
33—Dowel Pin
35—Hole

010904
PN=72
02
0250
9

010904
PN=73
02
0250
10
–UN–25APR97
T109286

010904
PN=74
00—Propel Motor 17—Thrust Washer (6 used) 31—Thrust Washer (6 used) 44—Cover

02—Propel Gearbox Housing 18—Pin (3 used) 32—Pin (3 used) 45—Pin
03—Seal 19—Spring Pin (3 used) 33—Spring Pin (3 used) 46—Roller Bearing
05—Drum 20—Third Planet Sun Gear 34—Second Planet Sun Gear 47—Snap Ring
06—Sprocket 21—Needle Bearing (6 used) 35—Thrust Washer 48—Cap Screw and Lock
07—Lock Washer (20 used) 23—Ring Gear 36—First Planet Carrier Washer (12 used)
08—Cap Screw (20 used) 25—Cap Screw (24 used) 37—First Planet Gear (3 used) 49—Plug (3 used)
09—Roller Bearing (2 used) 27—Second Planet Carrier 38—Needle Bearing (3 used) 51—O-Ring
10—Nut 28—Thrust Washer (2 used) 39—Thrust Washer (6 used) 52—Cap Screw (4 used)
11—Lock Plate 29—Second Planet Sun Gear 40—Pin (3 used) 53—Lock Washer (4 used)
12—Cap Screw (2 used) (3 used) 41—Spring Pin (3 used) 55—Name Plate
14—Third Planet Carrier 30—Needle Bearing (3 used) 42—Propel Shaft 56—Cap Screw (2 used)
15—Third Planet Gear (3 used) 02
0250
Disassemble and Assemble Propel Gearbox— 11
270CLC
1. Make alignment marks between cover (44), ring Third Planet Carrier
gear (23) and drum (05). (270CLC)—Weight.................................... 52 kg (120 lb) approximate
2. Remove cap screws and lock washers (48) and 6. Remove third planet sun gear (20) and third planet
cover (44). carrier (14).
3. Remove shaft (42) and first planet carrier (36). NOTE: Disassembly of first, second, and third planet
carriers are similar. Repeat procedure as
4. Remove second planet sun gear (34) and second required.
planet carrier (27).
7. Remove spring pins, pins, thrust plates, needle
bearings, and planetary gears.
Propel Gearbox—Specification Clean and inspect parts, replace as necessary. Oil

Ring Gear (270CLC)—Weight .................. 55 kg (120 lb) approximate parts with gear oil prior to assembly.
5. Install JT01748 Lifting Brackets to ring gear (23).

Remove cap screws (25) and ring gear.
OUOE049,0001000 –19–19NOV01–10/14
IMPORTANT: There is a mark on one side of third

planet gear (15). Be sure that this
marked side faces the hole for the
spring pin.
8. Install spring pins with slit (1) toward end of pin.

–UN–22JUN01
9. Remove cap screws (12) and lock plate (11).

T142429
1—Slit

010904
PN=75
10. Remove bearing nut (10) using DF1036A Propel

Gearbox Nut Wrench (35) and DFT1109 Holding Bar
(34). Fasten holding bar to ring gear. (Group 9900.)
Drum (270CLC)—Weight ................................ 65 kg (140 lb) approximate
11. Remove drum (05) using JT01748 Lifting Brackets.

02
–UN–15JUN01
0250
IMPORTANT: Metal face seals can be reused if they
12
are not worn or damaged. A used seal
must be kept together as a set because
T142380
of wear patterns on seal ring face.
12. Remove metal face seal (03). See Metal Face Seals
Repair. (Group 0130.)
NOTE: Further disassembly is not necessary unless

bearing replacement is required. Bearing will be
destroyed during removal, replace with new
bearing.
13. Inspect bearings (09) and races inside housing.

15. Heat inner bearing cone. Install cone tight against

shoulder.
Bearing Cone (270CLC)—
Temperature ......................................................... 50—70°C (122—158°F)

010904
PN=76
IMPORTANT: Metal face seal O-rings and seat

surfaces for O-rings must be clean, dry,
and oil free so O-ring does not slip.
16. Thoroughly clean metal face seal O-rings and seat

surfaces in propel motor housing, drum, and seal ring
using volatile, non-petroleum base solvent and
lint-free tissues.
NOTE: A volatile, non-petroleum base solvent or talcum

powder can be used as a lubricant. Solvent must 02
not damage the O-ring or leave an oil residue. 0250
13
17. Install O-ring and metal face seal on propel motor

housing and drum. Apply equal pressure with fingers
at four equally spaced points on seal face. Seal must
“pop” down into place so O-ring is tight against seal
bore and seal ring is installed squarely.
18. Clean seal ring face. Apply a thin film of clean oil.
IMPORTANT: Install bearing nut with stepped surface

towards bearing.
19. Apply a thin coat of multi-purpose grease to bearing

nut. Tighten bearing nut using DF1036A Propel
Gearbox Nut Wrench and DFT1109 Holding Bar.
Fasten holding bar to ring gear. (Group 9900.)
Bearing Nut (270CLC)—Torque .............. 790 N•m (580 lb-ft) Then tap on
drum using a plastic hammer.
Then turn drum four-to-five times
to the right and left to seat the
bearings.
20. To seat bearings, tap on drum using a plastic

hammer. Then turn drum three times to the right and
left to seat the bearings.
Repeat steps to ensure bearings are seated properly.

010904
PN=77
NOTE: If lock plate (11) will not engage with spline of

housing tighten bearing nut until lock plate
engages.
21. Install lock plate (11). Apply thread lock and sealer
(high strength) to threads of cap screws (12). Tighten
cap screws.
Lock Plate-to-Bearing Nut Cap
Screw (270CLC)—Torque ............................................... 88 N•m (65 lb-ft)
02
0250
14 22. Apply rigid from-in-place gasket to flange surface on
ring gear.
Apply thread lock and sealer (high strength) to cap

screws (25). Tighten cap screws.
Ring Gear-to-Drum Cap Screw
23. Install second and first planet carriers, sun gears and
shaft.

cover.
Apply thread lock and sealer (medium strength) to

thread of cap screws (48). Tighten cap screws.
Cover-to-Ring Gear Cap Screw
(270CLC)—Torque ........................................................ 110 N•m (83 lb-ft)
OUOE049,0001000 –19–19NOV01–14/14

010904
PN=78
Group 0260
Hydraulic System
Propel Motor Repair
Remove and Install Propel Motor—200CLC and

230CLC
NOTE: Propel motor is an integral part of propel gearbox.
If removal is required. See Propel Gearbox Repair. (Group

0250.)
Remove and Install Propel Motor—270CLC 02

0260
1
unexpected machine movement. Block both
tracks when removing propel motors. When
propel motors are removed, machine has no
brakes and can move. The machine will roll free
on a slope or while being towed.
1. Block tracks.
2. Drain oil from propel gearbox. Approximate capacity is

6.0 L (6.5 qt).

High pressure release of oil can cause serious
burns or penetrating injury.
4. Pull a vacuum in hydraulic oil tank using a vacuum

pump or drain hydraulic oil tank. See 270CLC Drain
and Refill Capacities. (Operator’s Manual.)
Continued on next page ouoe049,0001010 –19–19NOV01–1/26

010904
PN=79
Hydraulic System
5. Disconnect lines.
Propel Motor—Specification
Propel Motor Cover (270CLC)—
Weight.............................................................. 90 kg (200 lb) approximate
NOTE: Cap screws (1) used to hold propel motor and

park brake to propel gearbox have heads longer
–UN–19NOV01
02 than those holding propel motor cover to housing.
0260
2
6. Loosen cap screws and lock washers (1).
T147509B
7. Connect propel motor and park brake to a hoist using
lifting straps or chains and DF1063 Lift Bracket and
DFT1130 Adapter. (Group 9900.)
8. Remove cap screws (1) and remove propel motor, park

brake and remove O-ring.
10. Install O-ring.
Install propel motor and park brake.
11. Install and tighten cap screws (1).
–UN–20SEP94
Propel Motor Cover-to-Propel
Gearbox Cap Screw (270CLC)—
Torque ......................................................................... 265 N•m (195 lb-ft)
T8318AC
Location. (Group 9025-15.) Right Side Shown
1—Cap Screw and Lock Washer (4 used)

13. Fill propel gearbox with oil. See Check Propel
Gearbox Oil Level. (Operator’s Manual.)
14. Do Propel Motor Start-Up Procedure. (See procedure

in this group.)

010904
PN=80
Hydraulic System
7
8
6
5
9
4
2
02
6 0260
3
1
3
17
16 18
15 19
20
14
13 21
12 29
11
29
10
28
27
26 30
25
24
30
23
22
–UN–20JUL01
T142484
T142484
1—Shaft 9—Housing 17—Swash Plate 24—Needle Bearing

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

010904
PN=81
Hydraulic System
Disassemble and Assemble Propel Motor—200CLC 6. Remove friction plates (29) and plates (30).
and 230CLC
7. Inspect parts for wear or damage.
1. If required, remove propel gearbox. See Propel
Gearbox Repair. (Group 0250.) Propel Motor—Specification
Friction Plate (200CLC and
230CLC)—Height................................ 2.75—2.70 mm (0.108—0.106
CAUTION: Heavy component; use a hoist. in.)
Plate (200CLC and 230CLC)—
Propel Motor—Specification Height.................................................. 1.80—1.75 mm (0.071—0.069
Propel Motor (200CLC and in.)
02 230CLC)—Weight ..................................... 92 kg (203 lb) approximate
0260 IMPORTANT: Pistons must be installed into the
4 same bores because of wear
IMPORTANT: Use care when removing propel
motor cover (23), valve plate (11) is patterns. Mark location of pistons
easily damaged. with respect to bores to aid in
assembly.
2. Remove propel motor cover (23), and valve plate
(11). 8. Remove parts (12—18).
IMPORTANT: Remove needle bearing (24) only if 9. Remove parts (1—4) through motor side of housing
replacement is necessary. Do not (9).
re-use needle bearing as it may have
been damaged during removal. 10. Replace parts as necessary.
3. Remove needle bearing (24) as required. 11. Apply multi-purpose grease to lip of seal (4) and
apply rigid form-in-place gasket to outer surface of
4. Remove disc spring (25). seal.
Inspect part for wear or damage. 12. Install parts (1—4) using D01044AA Bushing,
Bearing and Seal Driver Set.
Disc Spring (200CLC and
230CLC)—Height.............................. 7.0—6.9 mm (0.276—0.272 in.)
5. Apply 100—300 kPa (14—43 psi) air pressure to

brake release passage (7) to remove brake piston
(27).

010904
PN=82
Hydraulic System
13. Lubricate parts (12—18) with hydraulic oil and install.

Insure that pistons (16) are installed in their original 15
bores. Install bushing (14) and retainer (15) as
shown.
14. Install parts (25—30).
–UN–20JUL01
14
15. Install needle bearing (24) into propel motor cover
(23).
T142996
NOTE: Apply petroleum jelly to mating surface of valve 02
plate to adhere it to propel motor cover during 0260
5
assembly.
14—Bushing
15—Retainer
16. Install pins (10) then valve plate (11).
17. Assemble propel motor cover (23) to housing (9).
18. Install cap screws (22) and tighten.
Propel Motor Cover-to-Propel
Motor Housing Cap Screw

010904
PN=83
Hydraulic System
18
17
8 16
02 6
0260
6 6 13
5 12 15
4 11 14
10
3 9
2
1
7
7 31
32
33
28
34
30
35
36
29
37
27
19 28
26
25 38
20 21 39
22
23
24
–UN–01NOV01
42 40
T146684
T146684 41
Propel Motor and Park Brake Components—270CLC

010904
PN=84
Hydraulic System
1—O-Ring 12—Roller Bearing 22—Piston Seal 33—Spring

2—Disk Spring 13—Nut 23—Piston Seal 34—Piston (7 used)
3—Brake Piston 14—Propel Motor Housing 24—Servo Piston 35—Rotor
4—O-Ring 15—O-Ring 25—Cap Screw (4 used) 36—Bushing
5—O-Ring 16—Brake Releasing Oil 26—O-Ring 37—Valve Plate
6—Plate (5 used) Passage 27—Plug 38—Plate
7—Friction Plate (4 used) 17—Lip Seal 28—Pivot Plug (2 used) 39—Pin (2 used)
8—Spacer 18—Snap Ring 29—Shoulder Bolt 40—Propel Motor Cover
9—Motor Drive Shaft 19—Cap Screw (4 used) 30—Link 41—Plug
10—Roller Bearing 20—Cover 31—Pin 42—O-Ring
11—Spacer 21—O-Ring 32—Center Shaft
Disassemble and Assemble Propel Motor—270CLC 5. Apply 100—300 kPa (14—43 psi) air pressure to 02
0260
brake release passage (16) to remove brake piston
7
IMPORTANT: Valve plate and pistons have (3).
machined surfaces. Do not let valve
plate and pistons drop. 6. Remove brake parts (3—8).
1. Remove propel motor cover (40) from propel motor NOTE: If parts are not within specification, replace
housing (14). Make sure valve plate in valve parts.
housing is not damaged.
7. Inspect brake parts for wear or damage.
IMPORTANT: Pistons must be installed into the
same bores because of wear pattern. Propel Motor—Specification
Disk Spring (270CLC)—Height......... 7.2—7.6 mm (0.283—0.300 in.)
Friction Plate (270CLC)—
2. Mark pistons and bores in rotor (35) so pistons are Thickness ............................................ 3.25—3.30 mm (0.128—0.130
installed into same bores during assembly. in.)
Plate (270CLC)—Thickness ............... 1.75—1.80 mm (0.069—0.071
3. Remove parts (32, 33, and 35). in.)
NOTE: Remove pin (31) only if necessary. 8. Remove parts (17 and 18).
4. Remove pistons (34).
NOTE: Remove piston evenly from bore. Do not

scratch or damage piston or bore.

010904
PN=85
Hydraulic System
9. Remove nut (B) using JDG911 Spanner Wrench.
10. Use a puller and a press to remove parts (C—E) from

shaft (A).
A—Motor Drive Shaft

B—Nut
C—Roller Bearing
D—Spacer
E—Roller Bearing
02
0260
8
–UN–11OCT94
T8320AE
ouoe049,0001010 –19–19NOV01–8/26
IMPORTANT: Valve plate and slide plate have

machined surfaces. Do not let plates
drop.
11. Remove parts (A—D).
A—Cover
B—Plug and O-Ring
C—Shoulder Bolt
D—Valve Plate and Link Assembly
–UN–20SEP94
T8321AF

010904
PN=86
Hydraulic System
12. Disassemble servo piston parts (A—E) if necessary.
A—Plug
B—O-Ring
C—Spool
D—Spring
–UN–27APR92
E—Piston Ring (2 used)
T7685IE
02
0260
ouoe049,0001010 –19–19NOV01–10/26 9
13. Inspect bushing (B) and replace if necessary.
IMPORTANT: Thread lock and sealer (high strength)

is used on pivot plugs (A).
NOTE: Remove pivot plugs (A) only if necessary to
–UN–20SEP94
remove valve plate (C).
T8321AH
A—Pivot Plug
B—Bushing
C—Valve Plate
ouoe049,0001010 –19–19NOV01–11/26
NOTE: If removed install bushing (B) with chamfered side

of bushing facing inside of valve plate (C).
15. Install bushing (B) using disk drivers, until bushing is

even with valve plate (C). –UN–20SEP94
16. If removed, apply thread lock and sealer (high

strength) to threads of pivot plugs (A).
IMPORTANT: DO NOT allow thread lock and sealer on

T8321AH
smooth portion of pivot plugs.
17. Install valve plate and pivot plugs (A) in link. Tighten
pivot plugs. A—Pivot Plug (2 used)
B—Bushing
Propel Motor—Specification C—Valve Plate
Pivot Plug (270CLC)—Torque......................................... 49 N•m (36 lb-ft)

010904
PN=87
Hydraulic System
IMPORTANT: Piston seals are brittle. Use care not to

chip, crack or break seals.
18. Assemble servo piston parts (A—E).
A—Plug
–UN–27APR92
B—O-Ring
C—Spool
D—Spring
E—Piston Ring (2 used)
T7685IE
02
0260
10 ouoe049,0001010 –19–19NOV01–13/26
19. Apply clean oil to all internal parts.
20. Install parts (D and E).
IMPORTANT: Valve plate and slide plate have

machined surfaces. Use care not
damage or scratch machined surfaces.
21. Apply petroleum jelly to both sides of plate (B).
22. Install parts (A—C). Align link assembly with servo

piston.
A—Valve Plate and Link Assembly
–UN–20SEP94
B—Plate
C—Pin (2 used)
D—Servo Piston
E—Piston Seal (2 used)
T8321AG

010904
PN=88
Hydraulic System
23. Install shoulder bolt (C) through link assembly (D) at

end of servo piston. Install plug and O-Ring . Tighten
shoulder bolt (C) and plug (B).
Shoulder Bolt (270CLC)—Torque ................................... 49 N•m (36 lb-ft)
24. Install O-ring and cover (A). Tighten cover cap

screws.
02
Servo Piston Cover Cap Screw
0260
(270CLC)—Torque .......................................................... 88 N•m (65 lb-ft)
11
A—Cover
–UN–20SEP94
B—Plug and O-Ring
C—Shoulder Bolt
D—Valve Plate and Link Assembly
T8321AF

010904
PN=89
Hydraulic System

–UN–23AUG88
25. Heat bearing cones (C and E).
02
TS227
Bearing Cone (270CLC)—
0260 Temperature ......................................................... 50—70°C (122—158°F)
12
26. Install parts (C—E) on motor drive shaft (A).
Install race and spacer with spacer notches towards

larger bearing.
27. Apply clean oil to threads of nut (B).
Install nut with thin shoulder away from bearing.
A—Motor Drive Shaft

B—Nut
C—Roller Bearing
D—Spacer
E—Roller Bearing
–UN–11OCT94
T8320AE

010904
PN=90
Hydraulic System
02
0260
13
–UN–26SEP94
–UN–11OCT94
T8320AO
T8320AP
A—Nut B—DF1038 Torque Adapter C—JDG911 Spanner Wrench
28. Tighten nut (A) using JDG911 Spanner Wrench 29. Check rolling drag torque using DF1038 Torque
(C) until rolling drag torque is to specification. Adapter (B). (Group 9900.)
Propel Motor—Specification 30. Stake nut in one place on the thin shoulder.
Motor Drive Shaft (270CLC)—
Rolling Drag Torque .............................. 3.0—4.0 N•m (27—35 lb-in.)

010904
PN=91
Hydraulic System
31. Apply rigid form-in-place gasket to outer diameter of

oil seal (B).
32. Install seal with spring side into bore first. Use a disk
driver to push seal to bottom of bore.
–UN–20SEP94
33. Apply multi-purpose grease to seal lips.
34. Install snap ring (A).
T8319BY
02 NOTE: Use a soft faced hammer to make sure bearings
0260 are tight against bottom of bore.
14
35. Install motor drive shaft assembly into housing, using A—Snap Ring
care not to damage seal lips. B—Oil Seal
ouoe049,0001010 –19–19NOV01–18/26
36. Install spacer (G) with notches to bottom of bore and

aligned with notches in housing.
37. Install friction plates (F) and plates (E):
• Begin with one friction plate and align notches in

friction plate with notches in gear.
• Install one plate.
• Repeat step, alternating friction plates and plates.
Keep notches of plates aligned with one another.
38. Apply petroleum jelly to O-rings (C and D). Install

O-rings on piston (B) with rounded side out.
–UN–20SEP94
IMPORTANT: Make sure brake port (A) is clear to
allow air to exit as piston is installed.
NOTE: To ease installation of piston apply petroleum jelly T8319BR

to outer diameter of piston.
39. Install piston (B) evenly into bore.

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

010904
PN=92
Hydraulic System
40. Install pistons into same bores as they were removed.

Make sure pistons move freely.
41. Assemble parts (32) and (33) and align pin (31) with
slot in rotor (35).
–UN–20SEP94
42. Install rotor (35).
43. Install disk spring (2) so inner diameter contacts the

brake piston.
T8319BP
02
44. Install O-rings (1 and 15). 0260
15

010904
PN=93
Hydraulic System
45. Remove parts (A—C) from alignment port (E) of

propel motor cover (D).
46. Move valve plate and servo piston to align pivot plug
with port. Install a 6 mm hex key wrench in pivot plug
to hold valve plate and link in position.
–UN–20SEP94
47. Install a 4.8 mm (3/16 in.) wooden dowel or soft rod
(F) through reducing valve port and center of valve
plate.
T8322BC
02
0260 48. Lift propel motor cover into position over propel motor
16
housing. Align cover to housing and install dowel into
bore of center shaft (G).
49. Install and tighten four housing cap screws.
Propel Motor Cover-to-Motor
Housing Cap Screw (270CLC)—
Torque ......................................................................... 390 N•m (290 lb-ft)
50. Remove dowel (F) and install parts (A—C). Tighten

plug.
Brake Pressure Reducing Valve
Plug (270CLC)—Torque .................................................. 69 N•m (51 lb-ft)
51. Install and tighten plug and O-ring (A).
Alignment Port Plug (270CLC)—
Torque ............................................................................. 90 N•m (65 lb-ft)
–UN–20SEP94
A—Plug and O-Ring
B—Pressure Reducing Valve
C—Spring
D— Propel Motor Cover
T8322BD
E—Alignment Port
F—Wooden Dowel or Rod
G—Center Shaft

010904
PN=94
Hydraulic System
1
2
3
4
5
7
1
6 02
12 0260
17
16 5
15 4
14
13 3
2
–UN–20JUL01
10
11
8
T143007
T143007
1—Counterbalance Valve 5—Spring Seat (2 used) 9—Poppet (2 used) 13—Propel Speed Change
2—Counterbalance Valve Plug 6—Spool 10—Spring (2 used) Plug
(2 used) 7—Propel Motor Cover 11—Relief Valve (2 used) 14—O-Ring
3—O-Ring (2 used) 8—Crossover Relief Valve (2 12—Propel Speed Change 15—Spring
4—Spring (2 used) used) Valve 16—Spool
Disassemble and Assemble Propel Motor Cover— Propel Motor Cover—Specification

Counterbalance Valve Plug
200CLC and 230CLC
(200CLC and 230CLC)—
Torque................................................................... 440 N•m (325 lb-ft)
NOTE: Valves may be removed with propel motor in Relief Valve (200CLC and
machine. 230CLC)—Torque ................................................. 310 N•m (230 lb-ft)
Propel Speed Change Plug
• Apply a film of clean hydraulic oil to parts before (200CLC and 230CLC)—
Torque....................................................................... 34 N•m (25 lb-ft)
assembly.

010904
PN=95
Hydraulic System
02
0260
18
–UN–26SEP94
T8322BE
A—Plug (2 used) G—O-Ring (4 used) M—Check Valve Poppet (2 R—O-Ring (10 used)
B—O-Ring (2 used) H—Ball Seat (2 used) used) S—Plug
C—Counterbalance Spring (2 I—Ball (2 used) N—Relief Valve (2 used) T—O-Ring
used) J—Plug (2 used) O—Propel Motor Cover U—Brake Pressure Reducing
D—Spool Plug (2 used) K—O-Ring (2 used) P—O-Ring (2 used) Valve Spool
E—Counterbalance Spool L—Check Valve Spring (2 Q—Plug (10 used) V—Pressure Reducing Spring
F—Plug (4 used) used)
Disassemble and Assemble Propel Motor Cover—

270CLC

010904
PN=96
Hydraulic System
1. Park Brake Release Shuttle Valve
NOTE: Valve can be removed with propel motor on

machine.
a. Clean threads of seat (B). Apply cure primer and
–UN–20SEP94
thread lock and sealer (high strength).
b. Install ball (C) and tighten seat (B).
T8323AB
Propel Motor—Specification 02
Ball Seat (270CLC)—Torque .................................... 14.5 N•m (128 lb-in.) 0260
19
A—Plug with O-Ring
B—Ball Seat
c. Install and tighten plug (A). C—Ball
Park Brake Release Shuttle Valve

010904
PN=97
Hydraulic System
2. Servo Piston Operating Shuttle Valve

machine.
a. Clean threads of seat (B). Apply cure primer and
–UN–20SEP94
thread lock and sealer (high strength).
b. Install ball (C) and tighten seat (B).
T8323AJ
02 Propel Motor—Specification
0260 Ball Seat (270CLC)—Torque .................................... 14.5 N•m (128 lb-in.)
20
A—Plug with O-Ring
B—Ball Seat
c. Install and tighten plug (A). C—Ball
Servo Piston Operating Shuttle
Valve Plug (270CLC)—Torque ....................................... 34 N•m (25 lb-ft)

machine.
3. Counterbalance Valve (E)
a. Apply clean oil to spool.
b. Install O-ring and tighten plug.
Counterbalance Valve Plug
NOTE: Valves can be removed with propel motor on

machine.
4. Relief Valves (N)
Tighten relief valve.
Relief Valve (270CLC)—Torque.................................. 540 N•m (398 lb-ft)

010904
PN=98
Hydraulic System
NOTE: Valves can be removed with propel motor on

machine.
5. Check Valves (M)
Install parts and tighten plug.
Check Valve Plug (270CLC)—
Torque ......................................................................... 235 N•m (173 lb-ft)
02
NOTE: Valve can be removed with propel motor on 0260
machine. 21
6. Brake Pressure Reducing Valve (U)
Install parts and tighten plug.
Brake Pressure Reducing Valve
ouoe049,0001010 –19–19NOV01–26/26

010904
PN=99
Hydraulic System
Propel Motor Start-Up Procedure
IMPORTANT: Propel motor will be damaged if not

filled with oil before operating propel
function. Procedure must be performed
whenever a new propel motor is
installed or oil has been drained from
the motor.
1. Disconnect drain line (1).
–UN–01NOV01
02
0260 2. Fill motor with hydraulic oil until oil reaches top of drain
22
port.
T146686C
NOTE: Use a funnel with suitable diameter neck to allow
air to escape while filling.
200CLC and 230CLC Propel Motor Drain Line
3. Connect drain line (1).
1—Propel Motor Drain Line
–UN–03MAY01
T139271D
270CLC Propel Motor Drain Line
CED,OUOE023,169 –19–19NOV01–1/1
Rotary Manifold Repair
Remove and Install Rotary Manifold

High pressure release of oil from pressurized
system can cause serious burns or penetrating
injury.
2. Disconnect upper hydraulic lines.

010904
PN=100
Hydraulic System
3. Remove cap screws (2) and bracket (1).
4. Attach the rotary manifold to a hoist using a lifting strap

and two Rotary Manifold Lifting Tool. (Group 9900.)
5. Disconnect lower hydraulic lines.
1—Bracket
–UN–20JUL01
02
0260
23
T143108B
OUOE049,0000051 –19–19NOV01–2/5
Rotary Manifold—Specification
Rotary Manifold—Weight................................... 27 kg (60 lb) approximate
6. Remove four mounting cap screws. Lower rotary
–UN–27APR92
manifold.
T7685JC
8. Install rotary manifold. Tighten four mounting cap
screws.
Manifold-to-Frame Cap Screw—
Torque ............................................................................. 34 N•m (25 ft-lb)
9. Install stop bracket. Tighten cap screws.
Stop Bracket-to-Frame Cap
Screw—Torque ................................................................ 40 N•m (30 lb-ft)
10. Connect upper and lower hydraulic lines. See Propel

System Component Location. (Group 9025-15.)

010904
PN=101
Hydraulic System
Disassemble and Assemble Rotary Manifold
1. Make alignment marks on spindle (B), housing (G) and

cover (K) to aid in assembly.
2. Remove parts (H—L). Carefully remove spindle

assembly (B) from housing (G).
3. Remove plugs in spindle and clean ports.
02 4. Remove parts (C—F).

0260
24
5. Inspect and repair as necessary.
6. Install parts (C—F).
7. Install spindle assembly (B) in housing (G), aligning

marks made during disassembly.
8. Install parts (H—L), aligning marks made during

disassembly and tighten cap screws.
Cover-to-Housing Cap Screw—
Torque ............................................................................. 49 N•m (36 lb-ft)
9. Install plugs.
A—Plug
B—Spindle Assembly
C—Oil Seal
D—O-Ring
E—Bushing
F—Oil Seal Rings (6 used)
G—Housing
H—Ring
I—Snap Ring
J—O-Ring
K—Cover
L—Cap Screw (4 used)
–UN–17JUN98
T115530

010904
PN=102
Hydraulic System
Rotary Manifold Air Test
1. Install a plug in one port.
2. Apply air pressure using JDG185 Air Test Plug and

shop air pressure through the other port in that
–UN–01NOV88
passage.
3. Listen for air leaks at ports on either side of

pressurized port.
T6557JB
02
0260
OUOE049,0000051 –19–19NOV01–5/5 25

010904
PN=103
Hydraulic System
02
0260
26

010904
PN=104
Section 04
Engine
Contents
Page

Engine Repair . . . . . . . . . . . . . . . . . . . . . . .04-0400-1
Fuel Injection Pump Repair . . . . . . . . . . . . . .04-0400-4
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-5
04

010904
PN=1
Contents
04

010904
PN=2
Group 0400
Removal and Installation
Engine Repair
Remove and Install Engine
CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
–UN–23AUG88
burns.
Shut off engine. Remove filler cap when cool to

touch. Slowly loosen filler cap to first stop to
TS281
relieve pressure, then remove.
1. Disconnect battery ground (negative) cable.
2. Drain coolant. Approximate capacity of cooling system

is 23.0 L (24.3 qt). See Drain Cooling System. 04
(Operator’s Manual.) 0400
1
3. Remove fan guard, radiator shroud, fan blade and

spacer. See Fan, Fan Guard, and Fan Shroud Repair.
(Group 0510.)
4. Disconnect charge air cooler hoses.
5. Remove upper and lower radiator hoses.
6. Disconnect air intake hose.
7. Remove muffler and muffler bracket.
NOTE: Label wiring to aid installation.
8. Disconnect engine wiring. See Machine Harness (W2)

Component Location. (Group 9015-10.)
NOTE: It is not necessary to discharge the air

conditioning system.
9. Disconnect air conditioner compressor bracket from

engine. Secure compressor and bracket so it will not
interfere with engine removal.
10. Relieve Fuel System Pressure. (CTM170.)
11. Disconnect fuel filter input line, fuel filter overflow

tube, and fuel pump overflow tube.
12. Disconnect heater hoses.
Continued on next page TX,04,DH5305 –19–19NOV01–1/4

010904
PN=107
Engine—Specification
Hydraulic Pump and Drive
Gearbox—Weight .......................................... 170 kg (375 lb) approximate
13. Support main hydraulic pump and drive gearbox using

DFT1119 Pump Support (A) and a small hoist winch
(B). (Group 9900.)
A—DFT1119 Pump Support

B—Hoist Winch
04
0400
2
–UN–17OCT96
T104491
TX,04,DH5305 –19–19NOV01–2/4
Engine—Weight ........................................... 954 kg (2100 lb) approximate
IMPORTANT: The recommended method for lifting the

engine is using the JDG23 Lifting Sling.
The lifting force must be at 90° at the
lifting points.
14. Attach JDG23 Lifting Sling (1) to engine as shown.
15. Remove cap screws securing main hydraulic pump

and drive gearbox to engine flywheel housing.
1—Engine Lifting Sling

–UN–20JUL01
T143006B

010904
PN=108
5
4
1
5
4
2 3
04
4 0400
5 3
–UN–19NOV01
4
T143012
T143012 3
1—Bracket, Right Front 3—Bracket, Rear (2 used) 4—Cap Screw (14 used) 5—Washer (14 used)
2—Bracket, Left Front
16. Remove cap screws (4) and washers (5) from Tighten cap screws.
engine mounts.
Engine Mount Cap Screw—
17. Raise engine slightly. Move engine away from
Torque................................................................... 350 N•m (260 lb-ft)
hydraulic pump and drive gearbox. Lift and
remove engine when disengaged from hydraulic
20. Align hydraulic pump and drive gearbox to engine
pump drive coupling.
and tighten cap screws.
18. Repair or replace parts as necessary. If Engine—Specification
disassembly is necessary, see Engine Drive Gearbox-to-Flywheel
Disassembly Sequence. (CTM104.) Housing Cap Screw—Torque ................................... 50 N•m (37 lb-ft)
21. Connect engine wiring. See Machine Harness

CAUTION: Heavy component; lift engine
(W2) Component Location Diagram. (Group
using JDG23 Lifting Sling. Lifting force must
9015-10.)
be 90° to engine lift points.
Engine—Specification 22. Fill radiator and reservoir with coolant. See

Engine—Weight .................................... 954 kg (2100 lb) approximate Cooling System Fill and Deaeration Procedure.
(Operator’s Manual.)
19. Use JDG23 Lifting Sling to install engine. Install
engine mount cap screws (5) and washers (4). 23. Bleed Fuel System. (Operator’s Manual.)
TX,04,DH5305 –19–19NOV01–4/4

010904
PN=109
Fuel Injection Pump Repair
Remove and Install Fuel Injection Pump
IMPORTANT: Never steam clean or pour cold water

on injection pump while pump is
running or still warm to prevent pump
seizure.
For replacement of fuel injection pump, see the following:
• 200CLC (S.N. —504000), 230CLC and 270CLC See

Remove Bosch VP44 Fuel Injection Pump. (CTM170.)
• 200CLC (S.N. 504001—) Perform Remove Injection
Pump. (CTM331.)
04
0400
4
TX,04,DH5307 –19–10NOV03–1/1

010904
PN=110
Starter Repair
Remove and Install Starter
IMPORTANT: Always disconnect battery ground
–UN–15AUG01
(negative) cable before removing starter
to prevent short circuits.
1. Disconnect battery ground (negative) cable.
T144796B
2. Disconnect ground strap and electrical connectors.
CAUTION: Heavy component; use a hoist. 1—Starter
Starter—Specification
Starter—Weight ................................................. 23 kg (50 lb) approximate 04
0400
3. Remove starter (1). 5
5. Install starter (1).
Starter—Specification
Starter Mounting Cap Screw—
Torque ............................................................................. 47 N•m (35 lb-ft)
7. Connect ground strap and electrical connectors. See

System Functional Schematic, Component Location,
and Wiring Diagram Master Legend. (Group 9015-10.)
8. Connect battery ground (negative) cable.
TX,04,DH5312 –19–19NOV01–1/1

010904
PN=111
04
0400
6

010904
PN=112
Section 05
Engine Auxiliary System
Contents
Page
Group 0510—Cooling System

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1
Fan, Fan Guard and Fan Shroud . . . . . . . . .05-0510-1
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-2
Group 0520—Intake System

Air Intake System Leakage Test . . . . . . . . . .05-0520-1
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-2
Group 0560—External Fuel Supply System

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1
Primary Fuel Filter (Water Separator) . . . . . .05-0560-3
Final Fuel Filter . . . . . . . . . . . . . . . . . . . . . . .05-0560-4 05

010904
PN=1
Contents
05

010904
PN=2
Group 0510
Cooling System
Radiator Repair
Remove and Install Radiator

–UN–23AUG88
burns.
Shut off engine. Only remove filler cap when

cool enough to touch with bare hands. Slowly
TS281
loosen cap to first stop to relieve pressure
before removing completely.
1. Drain coolant from radiator. Approximate capacity is

28.4 L (30 qt).
2. Remove upper and lower radiator hoses and overflow

hose.
3. Remove cap screws (1—3).

05
CAUTION: Heavy component; use a hoist. 0510
1
Radiator—Specification
Radiator—Weight .............................................. 39 kg (85 lb) approximate
–UN–02AUG01
4. Attach radiator to hoist and remove.
5. Repair or replace as necessary.
T142681
6. Install radiator and tighten cap screws (1—3).
7. Fill radiator and reservoir with coolant. See Cooling

System Fill and Deaeration Procedure. (See Operator’s 1—Cap Screw (9 used)
Manual.) 2—Cap Screw (6 used)
8. Start engine and check for leaks.
TX,05,DH5317 –19–19NOV01–1/1
Fan, Fan Guard, and Fan Shroud Repair
Remove and Install Fan, Fan Guard, and Fan Shroud

010904
PN=115
Cooling System

burns.
Shut off engine. Only remove filler cap when

cool enough to touch with bare hands. Slowly
–UN–23AUG88
loosen cap to first stop to relieve pressure
before removing completely.
1. Remove cap screws (1). Remove fan guard.
TS281
2. Remove cap screws (3). Slide fan shroud toward
engine.
3. Remove cap screws (2). Remove fan, and fan shroud.
–UN–02AUG01
5. Install fan. Tighten cap screws.
Fan—Specification
05 Engine Fan-to-Pulley Cap
T142994B
0510 Screw—Torque ................................................................ 70 N•m (50 lb-ft)
2
1—Cap Screw (4 used) Fan Guard—200CLC and 230CLC

–UN–19NOV01
T147134B
Fan Guard—270CLC
TX,05,DH5318 –19–19NOV01–2/2
Fan Belt Repair
Remove and Install Fan Belt

010904
PN=116
Cooling System
1. Remove fan guard. See Fan, Fan Guard, and Fan

Shroud Repair. (See procedure in this group.)
2. Remove air conditioning compressor belt.
3. Place a 15 mm wrench on hex head of cap screw (A)

in center of tension adjuster idler.
4. Pull idler away from belt to release belt tension.
5. Remove fan belt.
6. Inspect belt for wear or cracks. Replace as necessary.
7. Install fan belt.
A—Hex Head of Cap Screw
–UN–25MAR97
05
0510
3
T108219
TX,05,DH5319 –19–19NOV01–2/2

010904
PN=117
Cooling System
05
0510
4

010904
PN=118
Group 0520
Intake System
Air Intake System Leakage Test
1. Remove air cleaner cover. Remove primary filter

element.
2. Put a large plastic bag inside and over end of element
–UN–23FEB89
as shown. Install element and cover.
3. Remove fitting for start aid nozzle from intake manifold.
T5906AP
4. Install the JDG51 Inlet Air Adapter (A).
5. Connect air pressure regulator to adapter using hose

and fitting.
IMPORTANT: Plastic bag could be drawn into the

engine causing damage if engine starts.
Do not start the engine when turning
the engine crankshaft to close valves.
–UN–25OCT88
6. Pressurize air intake system to 14—21 kPa (0.14—
0.21 bar) (2—3 psi). If intake system cannot be 05
pressurized, turn engine crankshaft slightly to close 0520
T6089AR
1
valves.
Air Intake System—Specification

Leakage Test—Pressure .............................. 14—21 kPa (0.14—0.21 bar) A—JDG51 Inlet Air Adapter
(2—3 psi)
7. Spray a soap solution over all connections from the air

cleaner to turbocharger and intake manifold. Check for
leaks. Correct all leaks
8. When installing start aid nozzle, be certain arrow on

nozzle is pointing against intake air flow.
TX,05,GG2309 –19–19NOV01–1/1

010904
PN=119
Intake System
Air Cleaner Repair
05
0520
2
–UN–19NOV01
T144782
1—Valve 5—Hose 8—Inner Filter Element 11—Gasket
2—Air Cleaner 6—Hose 9—Wing Nut (3 used) 12—Clip
3—Indicator 7—Cap Screw (4 used) 10—Outer Filter Element 13—Cover
4—Clamp (3 used)
Remove and Install Air Cleaner
NOTE: Tighten hose clamps until rubber hose begins

to deform.
OUOE027,0000040 –19–19NOV01–1/1

010904
PN=120
Group 0560
External Fuel Supply System
Fuel Tank Repair
05
0560
1
–UN–19NOV96
T105203
1—Fuel Strainer 10—Cap Screw 15—Switch 22—Cap Screw (4 used)

2—Filler Cap 11—Float (Fuel Level Sender) 16—Sealing Washer 23—Lock Washer (4 used)
3—Fuel Tank 12—Cap Screw (5 used) 18—Drain Valve 25—Washer (4 used)
4—Plug 13—Gasket 19—Fitting 26—Wiring Connector
9—Bracket 14—Lock Washer 20—Plug
Continued on next page TX,05,GG2307 –19–19NOV01–1/2

010904
PN=121
Remove and Install Fuel Tank 6. Install float (fuel level sender) (11) and tighten cap
screws (12).
1. Drain fuel from fuel tank. Approximate capacity is
360 L (95 gal). Fuel Tank—Specification
Float (Fuel Level Sender) and
Gasket-to-Fuel Tank Cap
2. Disconnect wiring connector (26). Screw—Torque ....................................................... 4.5 N•m (40 lb-in.)
CAUTION: Heavy component; use a hoist. 7. Install fuel tank (3) and tighten cap screws (22).
Fuel Tank—Specification Fuel Tank—Specification

Fuel Tank—Weight ................................... 91 kg (200 lb) approximate Frame-to-Fuel Tank Cap
without fuel Screw—Torque ..................................................... 205 N•m (152 lb-ft)
3. Remove cap screws (22) and remove fuel tank. 8. Fill fuel tank with proper fuel. See Diesel Fuel.
9. Bleed Fuel System. (CTM 170.)
thread of cap screws (12).
05
0560
2
TX,05,GG2307 –19–19NOV01–2/2

010904
PN=122
Primary Fuel Filter (Water Separator) Repair
Remove and Install Primary Fuel Filter (Water

Separator)
1. Loosen drain valve to drain fuel into a container.

Dispose of fuel properly.
2. Loosen clamps (2) and disconnect hoses (3—4).
3. Remove cap screws (1) and remove primary fuel filter

(5).
4. Replace parts as necessary. Disassemble and

assemble primary fuel filter as required. See Final Fuel
Filter Assembly - Tier 2. (CTM170.)
5. Install primary fuel filter and tighten cap screws.
6. Bleed Fuel System. (Operator’s Manual.)
–UN–02AUG01
05
1—Cap Screw, Lock Washer and Washer (2 used)
0560
2—Clamp (2 used)
3
3—Primary Filter-to-Fuel Tank
T142498B
4—Primary Filter-to-Final Fuel Filter
5—Primary Fuel Filter (Water Separator)
200CLC Shown
TX,05,GG2315 –19–19NOV01–1/1

010904
PN=123
Final Fuel Filter Repair
Remove and Install Final Fuel Filter
1. Loosen drain valve to drain fuel into a container.

Dispose of fuel properly.
2. Disconnect electrical connectors (1 and 7).
3. Disconnect lines (4, 5 and 8).
–UN–02AUG01
4. Remove cap screws (2) and remove final fuel filter (6).
5. Replace parts as necessary. Disassemble and
T142510B
assemble final fuel filter as required. See Final Fuel
Filter Assembly - Tier 2. (CTM170.)
6. Install final fuel filter (6) and tighten cap screws (2). 1—Transfer Pump Electrical Connector
7. Connect electrical connectors (1 and 7). 3—Transfer Pump
4—Final Fuel Filter-to-Injector Pump Line
05 8. Connect lines (4, 5 and 8). 5—Injector Return Port-to-Final Fuel Filter Line
0560 6—Final Fuel Filter
4 7—Fuel Pressure Sensor Electrical Connector
9. Bleed Fuel System. (Operator’s Manual.) 8—From Primary Fuel Filter Line
9—Clamp
TX,05,GG2314 –19–19NOV01–1/1

010904
PN=124
Section 07
Dampener Drive (Flex Coupling)
Contents
Page
Group 0752—Elements
Dampener Drive (Flex Coupling) . . . . . . . . . .07-0752-1
07

010904
PN=1
Contents
07

010904
PN=2
Group 0752
Elements
Dampener Drive (Flex Coupling) Repair
Remove and Install Dampener Drive (Flex Coupling)
1. Remove hydraulic pump. See Hydraulic Pump and

Drive Gearbox Repair. (Group 3360.)
NOTE: Flex coupling may come off with pump or stay on

flywheel.
2. Remove parts (A—H).
4. Install parts (A—H). Apply thread lock and sealer

(medium strength) to set screws (B) and to cap screws
(D and G).
NOTE: Spring pin (F) is for alignment of insert (E) to

flywheel.
–UN–20NOV96
5. Tighten set screws (B).
Dampener Drive (Flex Coupling)—Specification
T105285
Coupling-to-Pump Shaft Set
Screw—Torque .............................................................. 108 N•m (80 lb-ft)
6. Tighten cap screws (D and G). A—Coupling

07
0752
B—Set Screw (2 used)
Dampener Drive (Flex Coupling)—Specification 1
C—Flex Coupling
Insert-to-Flywheel and Coupling D—Cap Screw (4 used)
Cap Screw—Torque .................................................... 215 N•m (160 lb-ft) E—Insert (4 used)
F—Spring Pin (4 used)
7. Install hydraulic pump. See Hydraulic Pump and Drive G—Cap Screw (4 used)
H—Insert (4 used)
Gearbox Repair. (Group 3360.)
TX,07,DH5336 –19–19NOV01–1/1

010904
PN=127
Elements
07
0752
2

010904
PN=128
Section 17
Frame or Supporting Structure
Contents
Page
Group 1740—Frame Installation

Welding On Machine . . . . . . . . . . . . . . . . . . .17-1740-1
Welding Repair of Major Structure. . . . . . . . .17-1740-2
Group 1749—Chassis Weights

Counterweight . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1
17

010904
PN=1
Contents
17

010904
PN=2
Group 1740
Frame Installation
Welding On Machine
IMPORTANT: Electrical current traveling from the

welder through the machine electrical
system may damage the machine
electrical system, including battery,
EPC controller. Disconnect battery
ground cable and EPC electrical
connectors before welding on the
machine.
Before welding on the machine, follow the steps listed

below to protect the machine electrical system.
TX,16,UU3948 –19–16OCT00–1/2
1. Disconnect the battery ground and positive cables.
NOTE: Console cover located behind seat in cab, must

be removed to gain access to engine and pump
controller connectors.
–UN–20JUL01
2. Remove rear console cover.
3. Disconnect electrical connectors (1) from engine and
T143053B
pump controller.
17
NOTE: See cab harness (W1) component location 1740
diagram for connector information. 1
1—EPC connector (4 used).
TX,16,UU3948 –19–16OCT00–2/2

010904
PN=131
Frame Installation
Welding Repair of Major Structure
• AWS-ER-70S-3 wire electrode with gas metal arc

CAUTION: Avoid potentially toxic fumes and
welding (GMAW) process.
dust. Hazardous fumes can be generated
• AWS-E70T-1 or E71T-1 wire electrode with flux
when paint is heated by welding, soldering,
core arc welding (FCAW) process.
or using a torch. Do all work outside or in a
well ventilated area. Dispose of paint and Welding Repair of Major Structure—Specification
solvent properly. Weld Metal—Tensile Strength ....................... 482.6 mPa (70,000 psi)
Yield Strength ................................................ 413.7 mPa (60,000 psi)
If you sand or grind paint, avoid breathing Elongation ..................................................................................... 22%
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. IMPORTANT: Area to be repaired must be
Allow fumes to disperse at least 15 minutes preheated to allow better weld
before welding or heating. penetration.
1. Remove paint before welding or heating. 3. To repair weld metal failure, remove failed weld
metal using arc or grinding equipment. Thoroughly
IMPORTANT: Disconnect battery ground strap or clean area to be welded. Preheat structural
turn battery disconnect switch to assemblies to a minimum of 38°C (100°F). Preheat
"OFF". Also disconnect the wiring ground engaging tools (cutting edges, skid shoes,
harness connectors to the engine and teeth shanks) to 177°C (350°F).
and pump controller.
To repair base metal failure remove enough
Have only a qualified welder do this material to allow weld to penetrate to the bottom of
job. Connect welder ground clamp crack. Preheat structural assemblies to a minimum
close to each weld area so electrical of 38°C (100°F). Preheat ground engaging tools
current does not pass through any (cutting edges, skid shoes, and teeth shanks) to
bearings. Remove or protect all parts 177°C (350°F).
that can be damaged by heat or weld
17 Welding Repair of Major Structure—Specification
1740 splatter.
Structural Assemblies—Preheat
2 Temperature ................................................................... 38°C (100°F)
2. Use one of the following weld processes: Ground Engaging Tools—
Preheat Temperature.................................................... 177°C (350°F)
• AWS-E-7018 covered electrode with shielded
metal arc welding (SMAW) process.
TX,17,GG2439 –19–19SEP98–1/1

010904
PN=132
Group 1749
Chassis Weights
Counterweight Repair
Remove and Install Counterweight
1. Park machine on level ground.
–UN–20JUL01
2. Remove two plastic caps from top of counterweight (1).
T143043
The lifting capacity of a lifting eyebolt
decreases as the lift angle increases from
vertical. A spreader bar should be used to
obtain, as close as possible, a vertical lift from
eyebolts.
Counterweight—Specification
Counterweight (200CLC)—Weight ............ 4250 kg (9370 lb) approximate
–UN–03SEP02
Counterweight (230CLC)—Weight ......... 5400 kg (11,900 lb) approximate
Counterweight (270CLC)—Weight ......... 6100 kg (13,450 lb) approximate
NOTE: For 270CLC, use JT05558 Metric Lifting Eyebolt

with spreader bar.
T143044
3. Connect the counterweight to a hoist (2) using a
spreader bar (3).
4. Remove cap screws and washers (4).
5. Remove counterweight.
–UN–20JUL01
17
7. Install cap screws and washers (4) and tighten. 1749
1
T143045
Counterweight—Specification
Frame-to-Counterweight Cap
Screw (200CLC)—Torque ......................................... 1150 N•m (830 lb-ft)
Frame-to-Counterweight Cap
Screw (230CLC and 270CLC)— 1—Counterweight
Torque ..................................................................... 1910 N•m (1410 lb-ft) 2—Hoist
3—Spreader Bar
4—Cap Screw and Washer (4 used)
OUOE027,000003C –19–19NOV01–1/1

010904
PN=133
Chassis Weights
17
1749
2

010904
PN=134
Section 18
Operator’s Station
Contents
Page

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1
Group 1810—Operator Enclosure

Windowpane
Two Piece Molding . . . . . . . . . . . . . . . . . .18-1810-1
One Piece Molding . . . . . . . . . . . . . . . . . .18-1810-2
Sliding Windows . . . . . . . . . . . . . . . . . . . . . .18-1810-3
Windowpanes . . . . . . . . . . . . . . . . . . . . . . . .18-1810-4
Group 1821—Seat and Seat Belt

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-1
Group 1830—Heating and Air Conditioning

Refrigerant Cautions and Proper
Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Flush and Purge Air Conditioner System. . . .18-1830-3
R134a Refrigerant Oil Information . . . . . . . . .18-1830-6
R134a Refrigerant Recovery/Recycling
and Charging Station Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7
Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-8
Evacuate R134a System . . . . . . . . . . . . . . . .18-1830-9
Charge R134a System . . . . . . . . . . . . . . . .18-1830-10
Compressor. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11
Receiver-Dryer . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Air Conditioner and Heater . . . . . . . . . . . . .18-1830-14
Condenser . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-16
18

010904
PN=1
Contents
18

010904
PN=2
Group 1800
Cab Repair
Remove and Install Cab
NOTE: Seat removal is optional.
1. Disconnect battery ground (-) cable at battery.
2. Remove monitor controller. See Remove and Install

Monitor Controller and Display (A5). (Group 9015-20.)
3. Disconnect electrical connectors.
4. Remove fresh air intake cowl.
5. Disconnect windshield washer hose.
Continued on next page SMCLEAN,000000B –19–19NOV01–1/4
18
1800
1

010904
PN=137
3
2
1
2
3 3
2 2
4
5
18
1800
2
6
–UN–20JUL01
T143008
T143008
1—Cap Screw (2 used) 3—Cap Screw (7 used) 5—Washer (4 used) 6—Rubber Mount (4 used)
2—Washer (9 used) 4—Lock Nut (4 used)
Continued on next page SMCLEAN,000000B –19–19NOV01–2/4

010904
PN=138
6. Remove lock nuts (4) securing cab to rubber 7. Remove cap screws (1 and 3).
mounts at all four corners. Discard lock nuts.
SMCLEAN,000000B –19–19NOV01–3/4
Cab—Specification
Cab—Weight ................................................. 290 kg (640 lb) approximate
8. Use lifting straps and connect cab to hoist.
–UN–15JAN97
NOTE: Move cab forward slightly to clear propel pedals
during removal.
T106453
9. Remove cab.
NOTE: Check that all lines and cables are out of the way
before installing cab.
11. Install cab.
12. Install cap screws (1 and 3).
Cab—Specification
Cab-to-Platform Cap Screw—
Torque ............................................................................. 50 N•m (37 lb-ft)
13. Install washers (5) and new lock nuts (4).
Cab—Specification
Cab Mount Lock Nut—Torque .................................... 205 N•m (152 lb-ft)
14. Connect electrical connectors. See Monitor Harness

(W3) Component Location and See Cab Harness 18
(W1) Component Location Diagram. (Group 9015-05.) 1800
3
15. Install monitor controller. See Remove and Install

Monitor Controller and Display (A5). (Group 9015-20.)
SMCLEAN,000000B –19–19NOV01–4/4

010904
PN=139
18
1800
4

010904
PN=140
Group 1810
Operator Enclosure
Windowpane and Two Piece Molding Repair
Remove and Install Windowpane and Two Piece

Molding
1. Use insert tool to remove locking strip (A) from
–UN–19OCT88
molding.
A—Locking Strip
T5903AI
TX,1800,VV2501 –19–21SEP98–1/4
IMPORTANT: Extreme care is required prevent

windowpane damage.
2. Carefully push windowpane out from molding.
3. Inspect molding for damage; replace if necessary.
–UN–19OCT88
T5903AJ
TX,1800,VV2501 –19–21SEP98–2/4
4. Apply instant gel adhesive in molding (B) frame

channel. Install molding.
5. Install windowpane using insertion tool (A) and soap

lubricant.
–UN–19OCT88
A—Window Pane
B—Windowpane Insertion Tool
18
T5903AK
1810
1
TX,1800,VV2501 –19–21SEP98–3/4
6. Use weather strip installation tool (B) to install locking

strip (A).
A—Locking Strip
B—Weather Strip Installation Tool
–UN–19OCT88
T5903AL
TX,1800,VV2501 –19–21SEP98–4/4

010904
PN=141
Operator Enclosure
Windowpane and One Piece Molding Repair
Remove and Install Windowpane and One Piece

Molding
1. Lift inside of molding over cab frame and carefully
–UN–19OCT88
push windowpane and molding out.
2. Remove molding from windowpane; replace if

necessary.
T6439XE
TX,18,VV2502C –19–10JAN97–1/2
3. Install molding on windowpane. Position drain notches

(A) at bottom and towards outside of windowpane.
4. Install windowpane and molding. Lift inside of molding

over cab frame.
–UN–19OCT88
A—Drain Notches
T6439XD
TX,18,VV2502C –19–10JAN97–2/2
18
1810
2

010904
PN=142
Operator Enclosure
Sliding Windows Repair
Remove and Install Sliding Windows
1. Remove molding (3) from inside of window.
2. Use putty knife to cut adhesive (4) between cab flange

and window frame (1).
IMPORTANT: Work carefully to avoid damaging frame

and windowpane. Two technicians are
required during window removal; one to
push window out of cab, and one to
prevent window from falling.
3. Carefully remove window frame from cab.
4. Lift frame slightly at top-center to remove and install

windowpanes.
–UN–30APR01
5. Apply instant gel adhesive to cab flange.
6. Install windows and frame with spacers (2) at the

bottom.
T140968
7. Using water as a lubricant, push window frame tight
against cab flange.
1—Window Frame
8. Install molding (3) around window and cab flange. 2—Bottom Spacer (4 used)
3—Molding
4—Adhesive
OUOE047,0000044 –19–11APR01–1/1
18
1810
3

010904
PN=143
Operator Enclosure
Windowpanes Repair
Remove and Install Windowpanes 2. Scrape any broken glass off existing adhesive. DO
NOT remove adhesive from window frame or cab.
The adhesive used to secure windowpanes is a
urethane adhesive used on automobile windshields. IMPORTANT: Adhesive will not stick to bare metal.
Urethane adhesive manufactured by Loctite
Corporation or equivalent is recommended. DO NOT 3. If existing adhesive is removed and paint is
use any other type of adhesive. It is recommended scraped, paint window frame. Paint must be fully
that an auto glass dealer install windowpanes. cured before installing windowpane.
IMPORTANT: Windowpanes must include an 4. Trim existing adhesive to form a smooth surface.
ultra-violet barrier around edge so
adhesive will not deteriorate. IMPORTANT: Follow manufacturer’s instructions
Windowpanes ordered through John for using adhesive.
Deere Parts have this ultra-violet
barrier. If windowpane is purchased 5. Apply 6 mm (1/4 in.) bead of adhesive over existing
through glass dealer, the dealer adhesive.
must incorporate an ultra-violet
barrier on the glass. DO NOT paint 6. Position windowpane in cab frame. Use hand
border of glass. pressure to force windowpane down until edges are
even with metal frame.
If auto glass dealer does not install windowpanes,
proceed as follows: 7. Secure windowpane with duct tape until adhesive
cures. Allow adhesive to cure for 24 hours before
1. Remove windowpane frame from cab. operating machine.
T52,1810,C19 –19–05JUN98–1/1
18
1810
4

010904
PN=144
Group 1821
Seat and Seat Belt
Seat Belt Repair
18
1821
1
–UN–05AUG96
TP48113
Continued on next page TX,18,GG2447 –19–14JAN97–1/2

010904
PN=145
Seat and Seat Belt
0—Seat Belt 4—Belt 6—Spacer (Sleeve) (2 used) 11—Cap Screw (2 used)

1—Bracket 5—Spacer (Sleeve) 8—Cap Screw 12—Spring Washer (4 used)
3—Belt
TX,18,GG2447 –19–14JAN97–2/2
18
1821
2

010904
PN=146
Group 1830
Heating and Air Conditioning
Refrigerant Cautions and Proper Handling
R134a is used in the air conditioning

CAUTION: DO NOT allow liquid refrigerant to
system. Because it does not contain
contact eyes or skin. Liquid refrigerant will
chlorine, R134a is not detrimental to
freeze eyes or skin on contact. Wear
the ozone in the atmosphere.
goggles, gloves and protective clothing.
However, it is illegal to discharge
any refrigerant into the atmosphere.
If liquid refrigerant contacts eyes or skin, DO
It must be recovered using the
NOT rub the area. Splash large amounts of
appropriate recovery stations.
COOL water on affected area. Go to a
physician or hospital immediately for
Use correct refrigerant recovery,
treatment.
recycling and charging stations.
Never mix refrigerants, hoses,
DO NOT allow refrigerant to contact open
fittings, components or refrigerant
flames or very hot surfaces such as electric
oils.
welding arc, electric heating element and
lighted smoking materials.
Use only John Deere approved
R134a refrigerant products. Mixing of
DO NOT heat refrigerant over 52°C (125°F) in
products not compatible will cause
a closed container. Heated refrigerant will
system damage and contaminate
develop high pressure which can burst the
recovery, recycling and charging
container.
station equipment. Care must be
taken to identify and use equipment,
Keep refrigerant containers away from heat
refrigerant oil and refrigerant
sources. Store refrigerant in a cool place.
designed only for R134a refrigerant
systems. Refrigerant should be
DO NOT handle damp refrigerant container
tested for type and purity before
with your bare hands. Skin may freeze to
recovery, recycling or charging of
container. Wear gloves.
system. JT02167A refrigerant test
instrument should be used before
If skin freezes to container, pour COOL
any testing or repair to system is
water over container to free the skin. Go to a
preformed.
physician or hospital immediately for
treatment.
IMPORTANT: To meet government standards

relating to the use of refrigerants,
18
1830
1
Continued on next page TX,9031,DY5073 –19–19NOV01–1/2

010904
PN=147
Prism Pro Refrigerant Identification

Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A
To safely identify type and check purity of refrigerant

prior to recovery, recycling and recharging of A/C
systems.
TX,9031,DY5073 –19–19NOV01–2/2
18
1830
2

010904
PN=148
Flush and Purge Air Conditioner System
b. Connect flusher outlet hose to inlet end of

CAUTION: Liquid refrigerant will freeze eyes
compressor discharge line using JT02102
or skin on contact. Wear goggles, gloves
Adapter.
and protective clothing.
c. Pour flushing solvent into suction port and
See Refrigerant Cautions and Proper
discharge port. Plug both ports in compressor
Handling. (See procedure in this group.)
manifold, using JT02099 and JT03194 Caps.
NOTE: Flushing can be performed on machine. Flush and Purge Air Conditioner System—Specification
Flushing Solvent in Suction
1. Recover R134a Refrigerant. (See procedure in this Port—Volume............................................................. 240 mL (8 fl oz)
group.) Flushing Solvent in Discharge
Port—Volume............................................................. 120 mL (4 fl oz)
Add flushing solvent to system with JT02075
Flusher and JT02098 Flusher Fitting Kit.
2. Remove and discard receiver/dryer. d. Turn compressor end for end and roll it side to
side.
3. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 Adapter. e. Remove both plugs from manifold ports and
drain solvent from compressor.
4. Fill flusher tank with solvent and fasten all
connections. Dispose of solvent properly. f. Connect battery power to compressor clutch coil.
Rotate pulley at least five revolutions to move
Flush and Purge Air Conditioner System—Specification solvent out of cylinders.
Flusher Tank—Capacity ..................................................... 4 L (1 gal)
g. Invert compressor. Roll end for end and side to
NOTE: Air pressure must be at least at specification side. Drain thoroughly.
for flushing and purging.
h. Repeat previous two steps at least three times.
Flush and Purge Air Conditioner System—Specification
Air Pressure—Pressure ............................. 620 kPa (90 psi) (6.2 bar)
8. Divide system into two circuits:
minimum for flushing and
purging
• Condenser circuit, including inlet and outlet
5. Connect a supply line of moisture-free compressed hoses.
air or dry nitrogen to flusher air valve. • Evaporator circuit, including inlet and outlet
hoses. 18
6. Open air valve to force flushing solvent into 1830
condenser circuit. Flusher tank is empty when hose 9. Condenser: 3
pulsing stops. Additional flushing cycles are

required if system is heavily contaminated with IMPORTANT: DO NOT attempt to flush through
burned oil or metal particles. compressor or receiver/dryer.
Flushing through expansion valve is
7. Clean compressor as follows: acceptable if refrigerant oil has a
normal odor and appearance.
a. Remove compressor and measure oil drained
from both manifold ports. a. Flush/Purge Condenser:
Continued on next page TX,18,DU2461 –19–19NOV01–1/3

010904
PN=149
b. Remove and discard receiver/dryer. If system is contaminated with burned refrigerant

oil or debris, remove and bench flush evaporator.
c. Connect flusher outlet hose to inlet end of See following steps to flush evaporator through
compressor discharge line using JT02102 expansion valve, if oil appears normal.
Adapter.
11. Flush evaporator:
d. Fill flusher tank with solvent and fasten all
connections. a. Remove evaporator and expansion valve. See
Air Conditioner and Heater Repair. (See
Flush and Purge Air Conditioner System—Specification procedure in this group.)
b. Force flushing solvent through evaporator inlet
with compressed air.
NOTE: Air pressure must be at least to specification c. Purge system until dry.
for flushing and purging.
d. Install evaporator and then go to step 13.
Air Pressure—Pressure ............................. 620 kPa (90 psi) (6.2 bar)
minimum for flushing and 12. Flush evaporator through expansion valve:
purging.
a. Connect flusher outlet hose to connection of
e. Connect a supply line of moisture-free receiver/dryer outlet hose using JT03188
compressed air or dry nitrogen to flusher air adapter.
valve.
b. Fill flusher tank and fasten all connections.
f. Open air valve to force flushing solvent into
condenser circuit. Flusher tank is empty when Flush and Purge Air Conditioner System—Specification
hose pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with
burned oil or metal particles.
g. Attach a return hose and aerator nozzle to end NOTE: Air pressure must be at least to specification
of receiver/dryer inlet hose using JT03197 for flushing and purging.
Adapter. Put nozzle in container to collect
flushing solvent. Air Pressure—Pressure ............................. 620 kPa (90 psi) (6.2 bar)
minimum for flushing and
NOTE: Purging the condenser circuit takes 10—12 purging.
minutes to thoroughly remove solvent.
18
1830 c. Connect a supply line of moisture-free
4 h. Disconnect hose from aeration nozzle to check compressed air or dry nitrogen to flusher air
circuit for solvent. Hold hose close to a piece of valve.
cardboard; continue purging until cardboard is
dry. d. Attach a hose and aerator nozzle to
compressor inlet line using JT02101 adapter.
10. See flush evaporator, if evaporator requires Put nozzle in a container to collect solvent.
flushing.
Continued on next page TX,18,DU2461 –19–19NOV01–2/3

010904
PN=150
NOTE: Purging evaporator circuit takes 12—15 bracket. See Receiver-Dryer Repair. (See
minutes to thoroughly remove solvent. procedure in this group.)
13. Disconnect hose from aeration nozzle to check 15. Add required oil. See R134a Refrigerant Oil
circuit for solvent. Hold hose close to a piece of Information. (See procedure in this group.)
cardboard and continue purging until cardboard is
dry. 16. Install compressor and connect refrigerant lines to
manifold.
14. Install a new receiver/dryer compatible with R134a
refrigerant. Fasten connections and mounting 17. Connect clutch coil wire and install drive belt.
TX,18,DU2461 –19–19NOV01–3/3
18
1830
5

010904
PN=151
R134a Refrigerant Oil Information
Refrigerant Oil Capacity—Specification

CAUTION: All new compressors are charged Oil—Volume ............................................................ 210 mL (7.1 fl oz)
with a mixture of nitrogen, R134a refrigerant R134a—Weight.............................................. 850 ± 50g (1.9 ± 0.1 lb)
and TY22025 (R134a) refrigerant oil. Wear
safety goggles and discharge the If any section of hose is removed and flushed or
compressor slowly to avoid possible injury. replaced, measure length of hose and use formula 3
mL per 30 cm (0.1 fl oz per ft ) to determine correct
IMPORTANT: Do not add any more oil than amount of oil to be added.
required or maximum cooling will be
reduced. Drain compressor oil into graduated container while
rotating compressor shaft and record amount.
DO NOT leave system or R134a
compressor oil containers open. If oil drained from a compressor removed from
Refrigerant oil easily absorbs operation is very black or amount of oil is less than 6
moisture. DO NOT spill R134a mL (0.2 fl oz), perform the following and discard oil
compressor oil on acrylic or ABS properly:
plastic. This oil will deteriorate these
materials rapidly. Identify R134a oil ❒ Determine if R134a leakage was detected, remove
containers and measures to component and repair or replace component.
eliminate accidental mixing of ❒ Remove and discard receiver/dryer.
different oils. ❒ Flush complete system with TY16134 Air
Conditioning Flushing Solvent.
A new compressor from parts depot contains new oil.
The oil level visible through the suction port normally is If component is serviceable, pour flushing solvent in
below the drive shaft. ports and internally wash out old oil and discard oil
properly.
Normal operating oil level of a compressor removed
from operation cannot be seen through suction port of Install a new receiver-dryer. See Receiver-Dryer
compressor. Repair. (See procedure in this group.)
Compressors can be divided into three categories Install required amount of TY22025 Refrigerant Oil in
when determining correct oil charge for system. compressor.
• New compressor from parts depot Connect all components, evacuate and charge system.
• Used compressor removed from operation See Evacuate R134a System and Charge R134a
• Compressor internally washed with flushing solvent System. (See procedures in this group.)
18
1830 Determining the amount of system oil charge prior to
6
installation of compressor on a machine.
When complete system, lines, and components are

flushed add correct amount of oil as described.
TX,9031,QQ2365 –19–19NOV01–1/1

010904
PN=152
R134a Refrigerant Recovery/Recycling and

Charging Station Installation Procedure
CAUTION: Liquid refrigerant will freeze eyes or

skin on contact. Wear goggles, gloves and
protective clothing.
See Refrigerant Cautions and Proper Handling.

(See procedure in this group.)
IMPORTANT: Use only John Deere approved R134a

refrigerant products. Mixing of products
not compatible will cause system
damage and contaminate recovery,
recycling and charging station
equipment.
CAUTION: Do not remove high pressure relief

valve (D). Air conditioning station will discharge
–UN–06DEC93
rapidly causing possible injury.
IMPORTANT: Use only John Deere approved

refrigerant recovery/recycling and
T8118AG
charging stations. DO NOT mix
refrigerant, hoses, fittings, components
or refrigerant oils.
A—High Pressure Hose Charge Port Cap
1. Follow procedures. See Refrigerant Cautions and B—Red Hose
Proper Handling. (See procedure in this group.) C—Blue Hose
D—High Pressure Relief Valve
E—Refrigerant Recovery/Recycling and Charging
2. Close both high-side and low-side valves on refrigerant Station
recovery/recycling and charging station (E).
3. Remove cap from low-side charge port.
4. Connect blue hose (C) from refrigerant

recovery/recycling and charging station (E) to low-side 18
test port. 1830
7
5. Remove cap (A) from charge port on high pressure
hose and connect red hose (B).
6. Follow the manufacturers’ instructions when using

refrigerant recovery/recycling and charging station.
TX,9031,DU1693 –19–19NOV01–1/1

010904
PN=153
Recover R134a Refrigerant
CAUTION: Liquid refrigerant will freeze eyes or

skin on contact. Wear goggles, gloves and
protective clothing.
See Refrigerant Cautions and Proper Handling.

CAUTION: Do not remove high pressure relief

valve. Air conditioning system will discharge
rapidly causing possible injury.
IMPORTANT: Use correct refrigerant

recovery/recycling and charging
stations. DO NOT mix refrigerant,
hoses, fittings, components or
refrigerant oils.
1. Run air conditioning system for three minutes to help in

recovery process. Turn air conditioning system off
before proceeding with recovery steps.
2. With engine OFF identify refrigerant type using

JT02167A Refrigerant Identification Instrument.
3. Connect refrigerant recovery system. See R134a

Refrigerant Recovery/Recycling and Charging Station
Installation Procedure. (See procedure in this group.)
4. Follow manufacturers’ instructions when using

refrigerant recovery/recycling and charging station.
18
1830
8
TX,9031,DU1694 –19–19NOV01–1/1

010904
PN=154
Evacuate R134a System
4. Evacuate system until low-side gauge registers 98

kPa (980 mbar) (29 in. Hg) vacuum.
and protective clothing. Air Conditioning System—Specification
Evacuate System—Vacuum ............... 98 kPa (980 mbar) (29 in. Hg)
Handling. (See procedure in this group.) If above specification vacuum cannot be obtained in 15
minutes, test the system for leaks. See Refrigerant
Do not remove high pressure relief valve. Air Leak Test. (Group 9031-25.)
conditioning system will discharge rapidly
causing possible injury. 5. When vacuum reaches above specification, close
low-side and high-side valves. Turn vacuum pump
1. Connect refrigerant recovery system. See R134a off.
Refrigerant Recovery/Recycling and Charging
Station Installation Procedure. (See procedure in 6. If vacuum decreases more than specification in 5
this group.) minutes, there is a leak in system.
2. Open low-side and high-side valves on refrigerant Air Conditioning System—Specification

recovery/recycling and charging station. Evacuate System—Vacuum .................. 3.4 kPa (34 mbar) (1 in. Hg)
3. Follow manufacturers’ instructions and evacuate 7. Repair leak.

system.
8. Evacuate system for 30 minutes after 98 kPa (980
NOTE: Vacuum specifications listed are for sea level mbar) (29 in. Hg) vacuum is reached.
conditions. Subtract 3.4 kPa (34 mbar) (1 in.
Hg) from 98 kPa (980 mbar) (29 in. Hg) for 9. Close low-side and high-side valves. Stop
each 300 m (1000 ft) elevation above sea evacuation.
level.
10. Charge system. See Charge R134a System. (See
Air Conditioning System—Specification procedure in this group.)
Evacuate System—Vacuum ................ Subtract 3.4 kPa (34 mbar) (1
in. Hg) from 98 kPa (980 mbar)
(29 in. Hg) for each 300 m
(1000 ft) elevation above sea
level
18
1830
9
TX,1830,DT474 –19–19NOV01–1/1

010904
PN=155
Charge R134a System
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)
and protective clothing.
from 98 kPa (980 mbar) (29 in. Hg) for each
300 m (1000 ft) elevation above sea level.
Handling. (See procedure in this group.) Air Conditioning System—Specification
Evacuate System—Vacuum ................ Subtract 3.4 kPa (34 mbar) (1
IMPORTANT: Use only John Deere approved in. Hg) from 98 kPa (980 mbar)
refrigerant recovery/recycling and (29 in. Hg) for each 300 m
charging stations. DO NOT mix (1000 ft) elevation above sea
level
refrigerant, hoses, fittings,
components or refrigerant oils.
4. Follow manufacturer’s instructions and charge
system.
1. Identify refrigerant type using JT02167A Refrigerant
Identification Instrument.
5. Add refrigerant to system .
2. Connect R134a Refrigerant Recovery/Recycling Air Conditioning System—Specification
and Charging Station. See R134a Refrigerant Air Conditioning System
Recovery/Recycling and Charging Station Refrigerant—Refrigerant
Installation Procedure. (See procedure in this Quantity...................................................................... 0.85 kg (1.87 lb)
group.)
6. Check air conditioning for proper function. See
3. Evacuate system. See Evacuate R134a System. Diagnose Air Conditioning System Malfunctions.
(See procedure in this group.) (Group 9031-25.)
NOTE: Before beginning to charge air conditioning

system, the following conditions must exist:
18
1830
10
TX,18,DU2481 –19–19NOV01–1/1

010904
PN=156
Compressor Repair
Remove and Install Compressor
1. Recover refrigerant from the system. See Recover

R134a Refrigerant. (See procedure in this group.)
2. Disconnect electrical connector (6) and power lead (5).
3. Remove belt.
–UN–20JUL01
4. Remove cap screw, lock washer and washer (2).
Disconnect high and low pressure lines (1).
T143114B
5. Remove cap screws, lock washers and washers (3)
and remove compressor (4).
6. Repair or replace parts as necessary. 1—Hi and Low Pressure Lines

2—Cap Screw, Lock Washer and Washer
7. Install compressor (4) and tighten cap screw (3). 3—Cap Screw, Lock Washers and Washers (4
used)
Compressor—Specification 4—Compressor
Pressure Line Cap Screw— 5—Power Lead
Torque ........................................................................... 28 N•m (247 lb-in) 6—Electrical Connector
8. Install high and low pressure lines (1).
9. Inspect and adjust compressor belt tension. See

Inspect Fan Belt. (Operator’s Manual.)
10. Evacuate and charge the system. See Evacuate

R134a System and Charge R134a System. (See
procedures in this group.)
18
1830
11
OUOE003,00000E5 –19–16JUL01–1/1

010904
PN=157
Receiver-Dryer Repair
Remove and Install Receiver-Dryer

2. Disconnect electrical connector (5).
3. Remove cap screw, lock washer, washer (2) and

high-pressure input line (3).
4. Remove cap screw, lock washer, washer (4) and

high-pressure output line (6).
5. Loosen cap screws (7) and remove receiver-dryer (1)

from bracket (8).
–UN–20JUL01
7. Install receiver-dryer (1).
8. Tighten high-pressure output line cap screw (4) and

high-pressure input line cap screw (2).
T143115B
Receiver-Dryer—Specification
High-Pressure Output and Input
Line Cap Screw—Torque .................................................. 5 N•m (44 lb-in) 1—Receiver-Dryer
2—Cap Screw, Lock Washer and Washer
9. Evacuate and charge the system. See Evacuate 3—High Pressure Input Line
R134a System and Charge R134a System. (See 4—Cap Screw, Lock Washer and Washer
5—Electrical Connector
6—High Pressure Output Line
8—Bracket
18
1830
12
OUOE003,00000E6 –19–25JUL01–1/1

010904
PN=158
18
1830
13

010904
PN=159
Air Conditioner and Heater Repair
4
3
8
1
2 11
27 10
18 15
1830 20
14
21
22 19 12
23
24
18
17
13
25
–UN–27AUG01
16
26
15
T145044
T145044 14
Continued on next page OUOE003,00000E7 –19–25APR01–1/2

010904
PN=160
1—Duct 8—Air Conditioner 14—Hose 21—Cap Screw (2 used)

2—Air Conditioner Low 9—Cap Screw (6 used) 15—Hose Clamp (4 used) 22—Filter
Pressure Hose 10—Air Conditioner High 16—Nipple 23—Clip
3—Cap Screw (4 used) Pressure Hose 17—Gasket 24—Clip
4—Air Conditioning Controller 11—Cap Screw 18—Hose 25—Cap Screw (2 used)
5—Duct 12—Bushing 19—Hose 26—Duct
6—Duct 13—Hose 20—Duct 27—Cap Screw (2 used)
Remove and Install Air Conditioner and Heater 3. Remove air conditioner (8).
1. Drain coolant from radiator. Approximate capacity is 4. Replace parts as necessary.

23.0 L (6.1 gal).
5. Install air conditioner.
NOTE: Evaporator and heater core are integral parts
of the air conditioner. If evaporator or heater 6. Evacuate and charge the system. See Evacuate
core need replacement, replace entire air R134a System and Charge R134a System. (See
conditioner unit. procedures in this group.)

OUOE003,00000E7 –19–25APR01–2/2
18
1830
15

010904
PN=161
Condenser Repair
Remove and Install Condenser

2. Remove cap screws (1). Secure receiver-dryer (2) and

bracket so it will not interfere with condenser removal.
3. Remove cap screw, lock washer, and washer (5) and
–UN–20JUL01
disconnect high pressure gas input line (4)
4. Remove cap screw, lock washer, and washer (7) and
T143116B
disconnect high pressure liquid output line (6).
5. Remove cap screws, lock washers, washers (8) and

condenser (3). 1—Cap Screw (2 used)
2—Receiver-Dryer
6. Repair or replace condenser as necessary. 3—Condenser
4—High Pressure Gas Input Line
7. Install condenser (3). 5—Cap Screw, Lock Washer, Washer
6—High Pressure Liquid Output Line
7—Cap Screw, Lock Washer, Washer
8. Tighten high pressure liquid output line (6) cap screw 8—Cap Screw (4 used)
(7). Lock Washer (4 used)
Washer (4 used)
Condenser—Specification
Output Line Cap Screw—Torque ................................. 14 N•m (124 lb-in.)
9. Tighten high pressure gas input line (4) cap screw (5).
Condenser—Specification
Input Line Cap Screw—Torque .................................... 23 N•m (204 lb-in.)
10. Evacuate and charge the system. See Evacuate

R134a System and Charge R134a System. (See
18
1830
16
OUOE003,00000E8 –19–19NOV01–1/1

010904
PN=162
Section 33
Excavator
Contents
Page Page
Group 3302—Buckets Arm Cylinder Disassemble and Assemble—

Bucket 200CLC, 270CLC . . . . . . . . . . . . . . . . . 33-3360-104
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1 Arm Cylinder Disassemble and
Adjust Pivot End Play . . . . . . . . . . . . . . . .33-3302-3 Assemble—230CLC. . . . . . . . . . . . . . . . 33-3360-118
Pin-Up Data . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4 Bucket Cylinder Remove and Install . . . . . 33-3360-124
Bucket Cylinder Disassemble and
Group 3340—Frames Assemble—200CLC, 270CLC . . . . . . . . 33-3360-130
Bucket Links . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-1 Bucket Cylinder Disassemble and
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-3 Assemble—230CLC. . . . . . . . . . . . . . . . 33-3360-144
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-6 Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-152
Inspect Boom, Arm, and Bucket Pins,
Bushings and Bosses . . . . . . . . . . . . . . .33-3340-11
Bushings and Seals . . . . . . . . . . . . . . . . . .33-3340-14

Hydraulic Oil Tank Pressure Release
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-1
Hydraulic Oil Cleanup Procedure Using
Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-2
Hydraulic Pump and Drive Gearbox
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3
Pilot Pump Drive Shaft and Gear . . . . . . . .33-3360-21
Hydraulic Pump Regulator. . . . . . . . . . . . . .33-3360-22
Pilot Pump . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-27
Pilot Pressure Regulating Valve and Filter
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-30
Pilot Shut-Off Valve. . . . . . . . . . . . . . . . . . .33-3360-31
Power Boost, Propel Speed, Swing
Priority, and Arm Regenerative Solenoid
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-35
Pilot Controller . . . . . . . . . . . . . . . . . . . . . .33-3360-37
Propel Pilot Controller . . . . . . . . . . . . . . . . .33-3360-40
Pilot Signal Manifold . . . . . . . . . . . . . . . . . .33-3360-43 33
Control Valve . . . . . . . . . . . . . . . . . . . . . . .33-3360-49
Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . .33-3360-66
Restriction Valve Repair . . . . . . . . . . . . . . .33-3360-69
Oil Cooler Bypass Valve . . . . . . . . . . . . . . .33-3360-71
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-74
Remove and Install Boom Cylinder . . . . . . .33-3360-75
Boom Cylinder Disassemble and Assemble—
200CLC, 270CLC . . . . . . . . . . . . . . . . . .33-3360-80
Boom Cylinder Disassemble and Assemble—
230CLC . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-94
Arm Cylinder Remove and Install . . . . . . . 33-3360-100

010904
PN=1
Contents
33

010904
PN=2
Group 3302
Buckets
Bucket Repair
3
3
5
4 7
3
2
1
8
–UN–24JUL01
1
4
2
3
T142450
T142450
1—Bushing (4 used) 3—O-Ring (4 used) 5—Pin (2 used) 7—Pin

2—Dust Seal (2 used) 4—Ring (2 used) 6—Pin 8—Bucket
Remove and Install Bucket 4. Repair or replace as necessary.
5. Align pin bores in bucket with pin bores in arm link

to prevent damage to dust seals (2) when pins are
Bucket—Specification installed.
Bucket (200CLC)—Weight ................... 670 kg (1480 lb) approximate
Bucket (230CLC and 6. Adjust bucket pivot end play. See Adjust Bucket
270CLC)—Weight ................................. 953 kg (2100 lb) approximate Pivot End Play. (See procedure in this group.)
1. Position bucket (8) on level surface. 7. Adjust bucket to arm joint. See Adjusting Bucket to
Arm Joint. (Operator’s Manual.)
2. Remove parts (5, 6 and 7).
33
3302
3. Remove bucket. 1

010904
PN=165
Buckets
7
6 6
8
5
9
10
11
12
2
3
13
4
3
2
33
3302
2 1
–UN–24JUL01
T142451
T142451

010904
PN=166
Buckets
1—Side Cutter (2 used) 4—Cap Screw (12 used) 7—Cap Screw (6 used) 10—Boss (2 used)
2—Nut (12 used) 5—Boss (2 used) 8—Washer (6 used) 11—Stopper (2 used)
3—Washer (12 used) 6—Shims (as required) 9—Plate (2 used) 12—Boss (2 used)
TX,33,GG2401 –19–19NOV01–3/3
Adjust Bucket Pivot End Play
1. Slide O-ring up on boss of bucket.
2. Measure clearance (D) between bushing (B) and arm.
–UN–10NOV88
Adjust clearance as close to specification.
Bucket—Specification
Bucket Pivot Bushing-to-Arm—
Clearance ............................................... As close to but not less than 0.5
T95775
mm (0.020 in.)
NOTE: Alternate buckets may have different adjustment

procedures.
3. Remove plate (F).
4. Remove shims (E) as needed to allow bushing to

move in to adjust clearance and take up excessive
–UN–06DEC88
play.
5. Install plate. Tighten cap screws.
T6879DU
Bucket—Specification
Bucket Pivot Shim-to-Plate Cap
6. Slide O-ring back into position.
A—Bucket
B—Bushing
C—Pin
–UN–10NOV88
D—Clearance
E—Shim (As Required)
F—Plate
T95788
33
3302
3
TX,33,GG2403 –19–19NOV01–1/1

010904
PN=167
Buckets
Bucket Pin-Up Data
33
3302
4
–19–19NOV01
T142485
TX,33,GG2405 –19–19NOV01–1/1

010904
PN=168
Group 3340
Frames
Bucket Links Repair
8
7
9
6
10
12
11 3
4
2
5
1
4
3
2
–UN–24JUL01
5
T142977
T142977
1—Nut (4 used) 4—Dust Seal (2 used) 7—Cylinder Pin 10—Right Side Link
2—Cap Screw (2 used) 5—Bushing (2 used) 8—Wooden Block 11—Left Side Link
3—Thrust Plate (2 used) 6—Thrust Plate (4 used) 9—Center Link 12—Pin
Remove and Install Bucket Links arm to hold cylinder up when cylinder pin (7) is
removed.
NOTE: Removal of bucket is not necessary for
removal of just bucket links. 2. Remove parts (1—5).
1. Connect hoist to center link (9) using lifting strap. As cylinder pin (7) is removed, lower links (10 and
Put wooden block (8) between bucket cylinder and 11) to ground.
33
3340
1

010904
PN=169
Frames
3. Inspect bushings (2 and 4) and dust seals (1). See 1 1

Inspect Boom, Arm, and Bucket Pins, Bushings and
Bosses. (See procedure in this group.)

4
5. Before installing pins, align pin bores to prevent
4
damage to dust seal when pins are installed.
3
6. Apply multi-purpose grease to all lubrication fittings. 1
1—Dust Seal (6 used) 1

2—Bushing (2 used) 3
3—Lubrication Fitting (2 used) 3
–UN–19NOV01
4—Bushing (4 used) 2
5—Shim (As Required)
6—Bushing (2 used)
1
7—Spacer
T142978
2
200CLC and 230CLC
2 1
5
1
7
6
2 1
3
1 5
–UN–19NOV01
1
1 6
T147422
5 3
270CLC
33
3340
2
TX,33,GG2406 –19–19NOV01–2/2

010904
PN=170
Frames
Arm Repair
Remove and Install Arm
1. Remove bucket. See Bucket Repair. (Group 3302.)
2. Retract arm cylinder.
3. Put floor stand under end of boom so load is on boom,

not on arm cylinder.
Extend arm cylinder just enough to put end of arm on

ground.

5. Loosen bucket cylinder hydraulic lines to release any

residual pressure.
Remove bucket cylinder and linkage only if necessary

to repair arm. See Bucket Cylinder Remove and Install.
(Group 3360.)
7. Remove bucket links and bucket cylinder. See Bucket

Links Repair. (See procedure in this group.) See
Bucket Cylinder Remove and Install. (Group 3360.)
33
3340
3

010904
PN=171
Frames
Arm—Specification
Standard Arm (200CLC)—Weight ............... 593 kg (1310 lb) approximate
Bucket Cylinder (200CLC)—
Arm—Specification
Long Arm (230CLC)—Weight ..................... 878 kg (1936 lb) approximate
Standard Arm (230CLC)—Weight ............... 685 kg (1510 lb) approximate
Short Arm (230CLC)—Weight ....................... 182 kg (400 lb) approximate
Arm—Specification
Arm (270CLC)—Weight.................................................. 1500 kg (3306 lb)
8. Attach hoist to arm.
–UN–31OCT88
T6626JC
Arm With Bucket Cylinder
33
3340
4

010904
PN=172
Frames
9. Put wooden block between arm cylinder and boom to 4

hold cylinder up when cylinder pin (6) is removed. 5
4
10. Remove parts (1-13).
11. Remove arm and lower to floor.
12. Inspect bushings and dust seals. See Inspect Boom, 6

3
Arm, and Bucket Pins, Bushings and Bosses. (See
1
13. Repair or replace parts as necessary. See Bushings 2
and Seals Repair. (See procedure in this group.)
14. Install thrust plates (4 and 12) equally on each side of

arm to get minimal amount of clearance between
boom and arm.
15. Connect lines. See Main Hydraulic System

–UN–27SEP01
16. Apply multi-purpose grease to all lubrication fittings.
1—Nut (2 used)
T142652
2—Stopper
3—Cap Screw
4—Thrust Plate (2 used)
5—Thrust Plate
13 12
6—Cylinder Pin
7—Cap Screw 12
8—Washer
9—Plate
10—Block
11—Pin 11
–UN–24JUL01
13—Thrust Plate
10
7
T142653
9
8
TX,33,GG2407 –19–19NOV01–3/3
33
3340
5

010904
PN=173
Frames
Boom Repair
Remove and Install Boom
1. Remove bucket and arm. See Bucket Repair and Arm

Repair. (See procedures in this group, and group
3302.)
2. Lower boom to ground.

TX,33,GG2408 –19–19NOV01–1/7
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.
–UN–23AUG88
4. Loosen hydraulic lines at frame end of boom to release
any residual pressure.
X9811
6. Disconnect wiring harness.
7. Disconnect lubrication lines at rod end of cylinders.
8. Remove arm cylinder only if necessary to repair boom.

See Arm Cylinder Remove and Install. (Group 3360.)
33
3340
6

010904
PN=174
Frames
Boom—Specification
Boom Cylinder (200CLC)—
–UN–30DEC96
T105828
9. Attach hoist to boom cylinder (F) using lifting strap.
F—Boom Cylinder (2 used)
TX,33,GG2408 –19–19NOV01–3/7
10. Remove parts (1—3 and 5).
11. Push boom cylinder-to-boom pin (4) into boom.
12. Lower boom cylinder (6) on floor stand.Repeat

procedure for second boom cylinder.
1—Nut (4 used)
2—Retainer (2 used)
4—Boom Cylinder Rod End-to-Boom Pin
–UN–24JUL01
6—Boom Cylinder (2 used)
T142979
33
3340
7

010904
PN=175
Frames
CAUTION: Heavy components; use a hoist.
Boom (200CLC)—Weight .......................... 1230 kg (2712 lb) approximate
Arm Cylinder (200CLC)—Weight .................. 259 kg (571 lb) approximate
13. Attach hoist to boom. Use protective covering to

prevent damage to pin if chain is used.
Arm end of boom is heavy end with arm cylinder

installed. Frame end is heavy end when arm cylinder
is removed.
–UN–31OCT88
T6626JW
33
3340
8

010904
PN=176
Frames
14. Remove parts (1—3 and 6).
15. Insert bar between plate of boom-to-frame pin (4) and

bracket (6). Pull plate out.
16. Remove boom-to-frame pin. Remove washers (5).
17. Remove boom.
18. Inspect bushings and dust seals. See Inspect Boom,

Arm, and Bucket Pins, Bushings and Bosses. (See
–UN–24JUL01
19. Repair or replace parts as necessary. See Bushings

and Seals Repair. (See procedure in this group.)
T143018
20. Install washers (5) equally on each side of boom to
get minimal amount of clearance between boom and 1—Cap Screw
frame. 2—Spacer
3—Block
21. Install boom. Tighten boom-to-frame cap screws. 4—Boom-to-Frame Pin
5—Washer (As Required)
6—Washer
Boom-to-Frame Cap Screw— 7—Bracket
Torque ......................................................................... 400 N•m (295 lb-ft)
22. Connect rod end of boom cylinders.
Install thrust plates (5) equally on each side to get

minimum amount of clearance between boom and
cylinder rod end.
23. Tighten nuts (1) against each other allowing cap

screw (3) to be free to turn in hole.
Boom Cylinder Rod End-to-Boom
Pin Retainer Nut—Torque ........................ 550 N•m (405 lb-ft) (tighten nut
against nut)

25. Connect wiring harness. See System Functional

Schematic, Component Location, and Wiring Diagram 33
Master Legend. (Group 9015-10). 3340
9
26. Connect lubrication lines at rod end of cylinders.

010904
PN=177
Frames
27. Apply multi-purpose grease to all pivot joints. See

Track Adjuster, Working Tool Pivot, Swing Bearing,
and Swing Bearing Gear Grease. (Operator’s
Manual.)
TX,33,GG2408 –19–19NOV01–7/7
33
3340
10

010904
PN=178
Frames
Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses
–UN–11JUN92
T7779AC
A—Boom Cylinder Head D—Boom-to-Arm Joint G—Bucket Cylinder Head I—Side Links-to-Arm Joint
End-to-Frame Joint E—Arm Cylinder Head End-to-Arm Joint J—Center Link-to-Bucket Joint
B—Boom Cylinder Rod End-to-Boom Joint H—Bucket Cylinder Rod K—Bucket-to-Arm Joint
End-to-Boom Joint F—Arm Cylinder Rod End-to-Side and Center
C—Boom-to-Frame Joint End-to-Arm Joint Links Joint
Boom (200CLC)—Specification Boom-to-Arm Joint Bushing

Boom Cylinder Head (200CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal
End-to-Frame Joint Pin ID ......................................................... 91.5 mm (3.60 in.) limit of use
(200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal
OD........................................................ 79.0 mm (3.11 in.) limit of use Arm (200CLC)—Specification
Boom Cylinder Head Arm Cylinder Head
End-to-Frame Joint Bushing End-to-Boom Joint Pin
(200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal (200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal
ID ......................................................... 81.5 mm (3.21 in.) limit of use OD........................................................ 79.0 mm (3.11 in.) limit of use
Boom Cylinder Head Arm Cylinder Head
End-to-Frame Joint Boss End-to-Boom Joint Bushing
(200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal (200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal
ID ......................................................... 81.5 mm (3.21 in.) limit of use ID ......................................................... 81.5 mm (3.21 in.) limit of use
Boom Cylinder Rod Arm Cylinder Head
End-to-Boom Joint Pin End-to-Boom Joint Boss
(200CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal (200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal
OD........................................................ 89.0 mm (3.50 in.) limit of use ID ......................................................... 81.5 mm (3.21 in.) limit of use
Boom Cylinder Rod Arm Cylinder Rod End-to-Arm
End-to-Boom Joint Bushing Joint Pin (200CLC)—OD .......................... 80.0 mm (3.15 in.) nominal
(200CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use
ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm
Boom Cylinder Rod Joint Bushing (200CLC)—ID .................... 80.0 mm (3.15 in.) nominal
End-to-Boom Joint Boss ID ......................................................... 81.5 mm (3.21 in.) limit of use
(200CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal Arm Cylinder Rod End-to-Arm
ID ......................................................... 91.5 mm (3.60 in.) limit of use Joint Boss (200CLC)—ID ......................... 80.0 mm (3.15 in.) nominal
Boom-to-Frame Joint Pin ID ......................................................... 81.5 mm (3.21 in.) limit of use
OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket (200CLC)—Specification 33
Boom-to-Frame Joint Bushing
Bucket Cylinder Head 3340
(200CLC)—ID ........................................... 90.0 mm (3.45 in.) nominal End-to-Arm Joint Pin 11
ID ......................................................... 91.5 mm (3.60 in.) limit of use (200CLC)—OD ......................................... 71.0 mm (2.80 in.) nominal
Boom-to-Arm Joint Pin
OD........................................................ 70.0 mm (2.76 in.) limit of use
Continued on next page CED,TX08227,3206 –19–19NOV01–1/4

010904
PN=179
Frames
Bucket Cylinder Head Boom Cylinder Rod

End-to-Arm Joint Bushing End-to-Boom Joint Bushing
Bucket Cylinder Head Boom Cylinder Rod
End-to-Arm Joint Boss End-to-Boom Joint Boss
Bucket Cylinder Rod Boom-to-Frame Joint Pin
End-to-Side and Center Links (230CLC)—OD ....................................... 100.0 mm (3.94 in.) nominal
Joint Pin (200CLC)—OD .......................... 80.0 mm (3.15 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use
OD........................................................ 79.0 mm (3.11 in.) limit of use Boom-to-Frame Joint Bushing
Bucket Cylinder Rod (230CLC)—ID ......................................... 100.0 mm (3.94 in.) nominal
End-to-Side and Center Links ID ......................................................... 101.5 mm (4.0 in.) limit of use
Joint Bushings (200CLC)—ID .................. 80.0 mm (3.15 in.) nominal Boom-to-Arm Joint Pin
ID ......................................................... 81.5 mm (3.21 in.) limit of use (230CLC)—OD ....................................... 100.0 mm (3.94 in.) nominal
Side Links-to-Arm Joint Pin OD........................................................ 99.0 mm (3.90 in.) limit of use
(200CLC)—OD ......................................... 71.0 mm (2.80 in.) nominal Boom-to-Arm Joint Bushing
OD........................................................ 70.0 mm (2.76 in.) limit of use (230CLC)—ID ......................................... 100.0 mm (3.94 in.) nominal
Side Links-to-Arm Joint ID ......................................................... 101.5 mm (4.0 in.) limit of use
Bushing (200CLC)—ID ............................. 71.0 mm (2.80 in.) nominal
ID ......................................................... 72.5 mm (2.85 in.) limit of use Arm (230CLC)—Specification
Center Link-to-Bucket Joint Pin Arm Cylinder Head
(200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal End-to-Boom Joint Pin
OD........................................................ 79.0 mm (3.11 in.) limit of use (230CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal
Center Link-to-Bucket Joint OD........................................................ 89.0 mm (3.50 in.) limit of use
Bushing (200CLC)—ID ............................. 80.0 mm (3.15 in.) nominal Arm Cylinder Head
ID ......................................................... 81.5 mm (3.21 in.) limit of use End-to-Boom Joint Bushing
Bucket-to-Arm Joint Pin (230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal
(200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use
OD........................................................ 79.0 mm (3.11 in.) limit of use Arm Cylinder Head
Bucket-to-Arm Joint Bushing End-to-Boom Joint Boss
Arm Cylinder Rod End-to-Arm
Boom (230CLC)—Specification Joint Pin (230CLC)—OD .......................... 90.0 mm (3.54 in.) nominal
Boom Cylinder Head OD........................................................ 89.0 mm (3.50 in.) limit of use
End-to-Frame Joint Pin Arm Cylinder Rod End-to-Arm
(230CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal Joint Bushing (230CLC)—ID .................... 90.0 mm (3.54 in.) nominal
Boom Cylinder Head Arm Cylinder Rod End-to-Arm
End-to-Frame Joint Bushing Joint Boss (230CLC)—ID ......................... 90.0 mm (3.54 in.) nominal
(230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use
ID ......................................................... 91.5 mm (3.60 in.) limit of use
Boom Cylinder Head Bucket (230CLC)—Specification
End-to-Frame Joint Boss Bucket Cylinder Head
(230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal End-to-Arm Joint Pin
ID ......................................................... 91.5 mm (3.60 in.) limit of use (230CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal
Boom Cylinder Rod OD........................................................ 79.0 mm (3.11 in.) limit of use
End-to-Boom Joint Pin Bucket Cylinder Head
(230CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal End-to-Arm Joint Bushing
OD........................................................ 89.0 mm (3.50 in.) limit of use (230CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal
33
3340 ID ......................................................... 81.5 mm (3.21 in.) limit of use
12

010904
PN=180
Frames
Bucket Cylinder Head Boom-to-Frame Joint

End-to-Arm Joint Boss Bushing—ID ............................................ 100.0 mm (3.94 in.) nominal
(230CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use
ID ......................................................... 81.5 mm (3.21 in.) limit of use Boom-to-Arm Joint Pin—OD .................. 100.0 mm (3.94 in.) nominal
Bucket Cylinder Rod OD........................................................ 99.0 mm (3.90 in.) limit of use
End-to-Side and Center Links Boom-to-Arm Joint Bushing—ID ............ 100.0 mm (3.94 in.) nominal
Joint Pin (230CLC)—OD .......................... 90.0 mm (3.54 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use
Bucket Cylinder Rod Arm (270CLC)—Specification
End-to-Side and Center Links Arm Cylinder Head
Joint Bushings—ID ................................... 90.0 mm (3.54 in.) nominal End-to-Boom Joint Pin—OD..................... 90.0 mm (3.54 in.) nominal
ID ......................................................... 91.5 mm (3.60 in.) limit of use OD........................................................ 89.0 mm (3.50 in.) limit of use
Side Links-to-Arm Joint Pin— Arm Cylinder Head
OD............................................................. 80.0 mm (3.15 in.) nominal End-to-Boom Joint Bushing—ID............... 90.0 mm (3.54 in.) nominal
Side Links-to-Arm Joint Arm Cylinder Head
Bushing—ID .............................................. 80.0 mm (3.15 in.) nominal End-to-Boom Joint Boss—ID.................... 90.0 mm (3.54 in.) nominal
Center Link-to-Bucket Joint Arm Cylinder Rod End-to-Arm
Pin—OD .................................................... 90.0 mm (3.54 in.) nominal Joint Pin—OD ........................................... 90.0 mm (3.54 in.) nominal
OD........................................................ 89.0 mm (3.50 in.) limit of use OD........................................................ 99.0 mm (3.90 in.) limit of use
Center Link-to-Bucket Joint Arm Cylinder Rod End-to-Arm
Bushing—ID .............................................. 90.0 mm (3.54 in.) nominal Joint Bushing—ID ..................................... 90.0 mm (3.54 in.) nominal
Bucket-to-Arm Joint Pin—OD ................... 90.0 mm (3.54 in.) nominal Arm Cylinder Rod End-to-Arm
OD........................................................ 89.0 mm (3.50 in.) limit of use Joint Boss—ID .......................................... 90.0 mm (3.54 in.) nominal
Bucket-to-Arm Joint Bushing— ID ......................................................... 91.5 mm (3.60 in.) limit of use
ID .............................................................. 90.0 mm (3.54 in.) nominal
ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket (270CLC)—Specification
Bucket Cylinder Head
Boom (270CLC)—Specification End-to-Arm Joint Pin—OD ....................... 80.0 mm (3.15 in.) nominal
Boom Cylinder Head OD........................................................ 79.0 mm (3.11 in.) limit of use
End-to-Frame Joint Pin—OD.................. 100.0 mm (3.94 in.) nominal Bucket Cylinder Head
OD........................................................ 99.0 mm (3.90 in.) limit of use End-to-Arm Joint Bushing—ID ................. 80.0 mm (3.15 in.) nominal
Boom Cylinder Head ID ......................................................... 81.5 mm (3.21 in.) limit of use
End-to-Frame Joint Bushing— Bucket Cylinder Head
ID ............................................................ 100.0 mm (3.94 in.) nominal End-to-Arm Joint Boss—ID ...................... 80.0 mm (3.15 in.) nominal
Boom Cylinder Head Bucket Cylinder Rod
End-to-Frame Joint Boss—ID................. 100.0 mm (3.94 in.) nominal End-to-Side and Center Links
ID ......................................................... 101.5 mm (4.0 in.) limit of use Joint Pin—OD ........................................... 90.0 mm (3.54 in.) nominal
Boom Cylinder Rod OD........................................................ 89.0 mm (3.50 in.) limit of use
End-to-Boom Joint Pin—OD................... 100.0 mm (3.94 in.) nominal Bucket Cylinder Rod
OD........................................................ 99.0 mm (3.90 in.) limit of use End-to-Side and Center Links
Boom Cylinder Rod Joint Bushings—ID ................................... 90.0 mm (3.54 in.) nominal
End-to-Boom Joint Bushing—ID............. 100.0 mm (3.94 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use
ID ......................................................... 101.5 mm (4.0 in.) limit of use Side Links-to-Arm Joint Pin—
Boom Cylinder Rod OD............................................................. 80.0 mm (3.15 in.) nominal
End-to-Boom Joint Boss—ID.................. 100.0 mm (3.94 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use
ID ......................................................... 101.5 mm (4.0 in.) limit of use Side Links-to-Arm Joint
Boom-to-Frame Joint Pin—OD............... 100.0 mm (3.94 in.) nominal Bushing—ID .............................................. 80.0 mm (3.15 in.) nominal
OD........................................................ 99.0 mm (3.90 in.) limit of use ID ......................................................... 81.5 mm (3.21 in.) limit of use 33
3340
13

010904
PN=181
Frames
Center Link-to-Bucket Joint Bucket-to-Arm Joint Pin—OD ................... 90.0 mm (3.54 in.) nominal
Pin—OD .................................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use
OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket-to-Arm Joint Bushing—
Center Link-to-Bucket Joint ID .............................................................. 90.0 mm (3.54 in.) nominal
Bushing—ID .............................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use
ID ......................................................... 91.5 mm (3.60 in.) limit of use
CED,TX08227,3206 –19–19NOV01–4/4
Bushings and Seals Repair
Remove and Install Bushings and Seals
IMPORTANT: Only install bushings using press as

shown. Bushings will be damaged if
installed with driver.
NOTE: Bushing can also be removed by welding three to

five weld beads on the inside of bushing. Bushing
will shrink enough to permit removal using a
hammer.
1. Remove bushings (C) and dust seals using bushing,

bearing, and seal driver set.
2. Install bushings with lubrication hole aligned with

lubrication passage in pivot.
3. Install bushing to a depth equal to thickness of dust

seal (H).
–UN–01NOV88
4. Install dust seals with lip toward outside of component.
A—Hydraulic Ram T95237

B1—Pipe—Minimum ID to Clear Bushing OD
B2—Pipe—Maximum OD
B3—Pipe—Length of Bushing
C—Bushing
33 D—Disks
3340 E—Bushing Stop (Disk)
14 F—Pilot (Disk)
G—Ram Stop (Disk)
H—Thickness of Dust Seal
–UN–31OCT88
T6641CW
CED,OUOE023,2178 –19–19NOV01–1/1

010904
PN=182
Group 3360
Hydraulic System
Hydraulic Oil Tank Pressure Release
Procedure
CAUTION: High pressure release of oil from

pressurized system can cause serious burns or
penetrating injury. Relieve pressure by SLOWLY
loosening cap (1).
1. Insert 4 mm hex wrench (4) into hole (5) and turn

counterclockwise to release locking pin.
2. Slowly turn cap (1) counterclockwise a few degrees to

relieve pressure.
–UN–06NOV00
3. Remove cap.
1—Cap
T135189
2—Aligning Marks
3—Case Assembly
4—4 mm Hex Key Wrench
5—Hole
OUOE054,000000F –19–07OCT02–1/1
33
3360
1

010904
PN=183
Hydraulic System
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
SPECIFICATIONS four times.

Hydraulic Oil Tank (200CLC)
Hydraulic Oil Tank Capacity 130 L (34 gal) approximate Hydraulic Oil Tank (200CLC)—Specification
Hydraulic Oil Tank—Capacity.................. 130 L (34 gal) approximate
Hydraulic Oil Tank Filtering 11 minutes approximate Filtering Time ................................................. 11 minutes approximate
Time
Hydraulic System Capacity 200 L (52.4 gal) approximate Hydraulic Oil Tank (230CLC and 270CLC)—Specification
Hydraulic Oil Tank—Capacity.................. 148 L (39 gal) approximate
Hydraulic System Filtering Time 17 minutes approximate
Filtering Time ................................................. 13 minutes approximate
Hydraulic Oil Tank (230CLC and 270CLC)
Hydraulic Oil Tank Capacity 148 L (39 gal) approximate NOTE: Filtering time for hydraulic tank is 0.089 minute
Hydraulic Oil Tank Filtering 13 minutes approximate x number of liters (0.33 minutes x number of
Time gallons).
Hydraulic System Capacity 250 L (66 gal) approximate
Hydraulic System Filtering Time 22 minutes approximate 4. Leave filter caddy operating for the next step.
SERVICE EQUIPMENT AND TOOLS 5. Start the engine and run it at fast idle.
Portable Filter Caddy
IMPORTANT: For the most effective results,
3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2
used) cleaning procedure must start with
the smallest capacity circuit then
Quick Disconnect Fittings
proceed to the next larger capacity
Suction Wand circuit.
Discharge Wand
6. Starting with the smallest capacity circuit, operate
1. Install new return filter elements. each function through a complete cycle.
NOTE: For a failure that creates a lot of debris, Repeat procedure until the total system capacity
remove access cover from hydraulic tank. has circulated through filter caddy seven times.
Drain hydraulic tank. Connect filter caddy Each function must go through a minimum of three
suction line to drain port. Add a minimum of 19 complete cycles for a thorough cleaning of oil.
L (5 gal) of oil to reservoir. Operate filter caddy
and wash out the hydraulic tank. Hydraulic Oil Tank (200CLC)—Specification
Hydraulic System—Capacity ................ 200 L (52.4 gal) approximate
IMPORTANT: The minimum ID for a connector is
13 mm (1/2 in.) to prevent cavitation Hydraulic Oil Tank (230CLC and 270CLC)—Specification
of filter caddy pump. Hydraulic System—Capacity ................... 250 L (66 gal) approximate
2. Put filter caddy suction and discharge wands into
hydraulic tank filler hole so ends are as far apart as NOTE: Filtering time for complete hydraulic system is
possible to obtain a thorough cleaning of oil. 0.158 minute x number of liters (0.6 minute x
number of gallons). Filtering time for machines
33 3. Start the filter caddy. Check to be sure oil is flowing with auxiliary hydraulic functions must be
3360 through the filters. increased because system capacity is larger.
2
Operate filter caddy until all the oil in hydraulic tank 7. Stop the engine. Remove the filter caddy.
has been circulated through the filter a minimum of
8. Install new return filter elements.
Continued on next page OUOE027,000001D –19–19NOV01–1/2

010904
PN=184
Hydraulic System
9. Check Hydraulic Oil. (Operator’s Manual.)
OUOE027,000001D –19–19NOV01–2/2
Hydraulic Pump and Drive Gearbox Repair
Remove and Install Hydraulic Pump and Drive

Gearbox

1. Do Hydraulic Oil Tank Vent Procedure. (See procedure

in this group.)
2. Drain hydraulic oil tank. Approximate capacity is 130 L

(34 gal) for 200CLC and 148 L (39 gal) for 230CLC
and 270CLC.
3. Drain pump drive gearbox. Approximate oil capacity is

1.0 L (1.1 qt).
4. Remove hood, hood support and covers.
5. Remove muffler and muffler bracket.
Hydraulic Pump and Drive Gearbox—Specification

Hydraulic Pump and Drive
Gearbox—Weight .......................................... 168 kg (370 lb) approximate
8. Install lifting eyebolts to pump. Connect a hoist to

eyebolts using lifting straps.
33
3360
3

010904
PN=185
Hydraulic System
9. Remove cap screws (1) and remove pump.
IMPORTANT: Align dampener drive on drive gearbox

with mating part on engine flywheel.

Pump Drive Gearbox-to-Flywheel
Housing Cap Screw—Torque.......................................... 49 N•m (36 lb-ft)
12. Connect electrical connectors. See System Functional

Schematic, Component Location, and Wiring Diagram
–UN–20JUL01
Master Legend. (Group 9015.)
T142503
14. Install split flange and tighten cap screws.

Split Flange 8 mm Cap Screw—
Torque ............................................................................. 50 N•m (37 lb-ft)
Split Flange 10 mm Cap Screw—
Torque ............................................................................. 90 N•m (67 lb-ft)
15. Apply pipe sealant to pump drive gearbox drain plug

threads.
IMPORTANT: Hydraulic pump and drive gearbox will

be damaged if not filled with oil before
starting engine. Start-up procedure
must be performed whenever a new
pump or gearbox is installed or oil has
been drained from the pump, gearbox
or hydraulic oil tank.
16. Fill pump housing and pump drive gearbox with oil.
See Hydraulic Pump and Drive Gearbox Start-Up
Procedure. (See procedure in this group.)
17. Check pump regulator adjustments. (Group 9025-25.)

33
3360 For minimum flow:
4

010904
PN=186
Hydraulic System
• See Hydraulic Pump Regulator Test and

Adjustment—Minimum Flow—200CLC. (Group
9025-25.)
9025-25.)
9025-25.)
For maximum flow:

Adjustment—Maximum Flow—200CLC. (Group
9025-25.)
9025-25.)
9025-25.)
Disassemble and Assemble Hydraulic Pump and Drive

Gearbox
33
3360
5

010904
PN=187
Hydraulic System
10
7 8 9 11
22 23
21
19 20 24
12
18
17
6 16
15
13
13
5
14
23
4
22
3 20
2 21
25
18
1
26
17
32 16
15
33
27
32 28
31 29
30
27
28
37
36
35
56 34
40 45
38 46
47
39
55 35 41
54
57
33 43
3360 44 42 48
6
49
–UN–20JUL01
50
51
53 52
T142373
T142373 58 51

010904
PN=188
Hydraulic System
1—Pump Housing 15—Bearing Nut (2 used) 28—Plug (2 used) 43—Drain Plug

2—Lock Washer (6 used) 16—Roller Bearing (2 used) 29—O-Ring 44—O-Ring
3—Cap Screw (6 used) 17—Ring (2 used) 30—Special Fitting 45—Cap Screw (2 used)
4—Spring Pin (4 used) 18—Roller Bearing (2 used) 31—Spring Pin (2 used) 46—Lock Washer (2 used)
5—O-Ring (10 used) 19—Pump 1 (Front) Drive 32—Oil Seal (2 used) 47—Washer (2 used)
6—O-Ring (2 used) Shaft 33—Snap Ring (2 used) 48—Pilot Pump
7—Cap Screw (4 used) 20—Pin (2 used) 34—Fill Plug 49—Snap Ring
8—Right Regulator Pump 1 21—Center Shaft (2 used) 35—Snap Ring (2 used) 50—Snap Ring
(Front) 22—Spring (2 used) 36—Pump 1 (Front) Driven 51—Ball Bearing
9—Cap Screw (2 used) 23—Piston (14 used) Gear 52—Pilot Pump Drive Gear
10—Cap Screw (2 used) 24—Cylinder Block (Rotor) 37—Gasket 53—Pilot Pump Drive Shaft
11—Cap Screw (2 used) (2 used) 38—Cap Screw (2 used) 54—Snap Ring
12—Left Regulator Pump 2 25—Pump 2 (Rear) Drive Shaft 39—Pump 2 (Rear) Drive Gear 55—Oil Seal
(Rear) 26—Spacer Ring (Pump 2 40—Dipstick 56—Pump Drive Gearbox
13—O-Ring (4 used) [Rear] Drive Shaft only) 41—Dipstick Tube 57—Set Screw (2 used)
14—O-Ring (6 used) 27—O-Ring (2 used) 42—Gasket 58—Dampener Drive Coupling
33
3360
7

010904
PN=189
Hydraulic System
72
71 73
70
74
71
68
67
75
62
63
60
64
63 69
60
62
61 60
62 76
66 63
78
65
60 77
59
60 63
62
61 79
82 66
80
60 60
59
81
82
–UN–20JUL01
T142375
T142375
33
3360 59—Dowel Pin 65—Pump 2 (Rear) Valve Plate 71—O-Ring (4 used) 77—Servo Piston (2 used)
8 60—Snap Ring (12 used) 66—Dowel Pin (4 used) 72—Cap Screw (8 used) 78—Pin (2 used)
61—Dowel Pin (2 used) 67—Backup Ring 73—Cover (2 used) 79—O-Ring (2 used)
62—Lever (4 used) 68—O-Ring 74—O-Ring (2 used) 80—Stop (2 used)
63—Dowel Pin (4 used) 69—Spring Pin (2 used) 75—Cap Screw (12 used) 81—Cap Screw (8 used)
64—Pump 1 (Front) Valve 70—Cylinder Head (Cover) 76—Set Screw (2 used) 82—Feedback Link (2 used)
Plate

010904
PN=190
Hydraulic System
2. Remove pilot pump (48).

Hydraulic Pump and Drive Gearbox—Specification 3. Remove cap screws (3) and lock washers (2) to
Hydraulic Pump and Drive remove pump housing (1) from pump drive gearbox
Gearbox—Weight ................................... 168 kg (370 lb) approximate (56).
1. Loosen set screws (57) and remove dampener

drive coupling (58).
33
3360
9

010904
PN=191
Hydraulic System
4. To aid in reassembly, make timing marks on drive

shafts (A and C), and mark (B) on drive (E) and driven
(F) gears. The gears are not interchangeable.
Measure amount of backlash between gears.
–UN–11DEC96
Pump Drive and Driven Gear—
Backlash ........................................................ 0.68 mm (0.027 in.) nominal
1.50 mm (0.059 in.) limit of use
T105624
Remove snap rings (D) and remove gears (E and F).
5. Remove pump regulators (8 and 12). For repair. See A—Pump 1 (Front) Drive Shaft-to-Driven Gear
Hydraulic Pump Regulator Repair. (See procedure in Timing Mark
this group.) B—Driven Gear-to-Drive Gear Timing Mark
C—Pump 2 (Rear) Drive Shaft-to-Drive Gear
Timing Mark
CAUTION: Heavy component; use a hoist. D—Snap Ring (2 used
E—Drive Gear
Hydraulic Pump and Drive Gearbox—Specification F—Driven Gear
Cylinder Head—Weight ..................................... 30 kg (66 lb) approximate
IMPORTANT: The valve plates (64 and 65) are

connected to the feedback linkage and
must remain on the cylinder blocks (24).
The valve plates and end of cylinder
blocks are made with highly machined
surfaces and can be damaged.
6. Remove cap screws (75) and carefully remove cylinder

head (70).
7. Remove servo pistons (77) only if replacement is

necessary.
Heat set screw (76) to loosen thread lock and sealer

(medium strength) used. Remove set screw using a 6
mm hex key wrench. Remove pin (78).
33
3360
10

010904
PN=192
Hydraulic System
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)

(65) valve plates are not
interchangeable. Take notice of the
location and position of ports in plate.
The inlet port in valve plate is located
towards the center and top of pump
housing.
8. Remove pump 1 (front) (64) and pump 2 (rear) (65)

valve plates. Protect machined surfaces of plates from
damage.
9. Remove special fittings (30) before removing pump 1

(front) (19) and pump 2 (rear) (25) drive shafts.
10. Remove spacer ring (26) for pump 2 (rear) drive shaft
(25) from bore.
11. Remove bearing nut (15) using JDG769 Spanner

Wrench.
12. Remove roller bearings (16 and 18) from pump 1

(front) (19) and pump 2 (rear) (25) drive shafts using
a knife edge puller and a press.
OUOE027,0000017 –19–19NOV01–9/21
13. Measure diameter of oil seal contact surfaces (A, B,

and D) on pump 1 (front) (E) and pump 2 (rear) (C)
drive shafts.

Pump 2 (Rear) Drive Shaft Oil
Seal Contact Surface (A)—OD .......................... 45 mm (1.77 in.) nominal
–UN–09JAN97

Pump 2 (Rear) Drive Shaft Oil 33
Seal Contact Surface (B)—OD .......................... 55 mm (2.17 in.) nominal 3360
54.8 mm (2.16 in.) limit of use 11
T105725
Pump 1 (Front) Drive Shaft Oil

Seal Contact Surface—OD ................................ 55 mm (2.17 in.) nominal
A—Oil Seal Contact Surface

B—Oil Seal Contact Surface
C—Pump 2 (Rear) Drive Shaft
D—Oil Seal Contact Surface
E—Pump 1 (Front) Drive Shaft

010904
PN=193
Hydraulic System
14. Measure play (H) between piston connecting rod (F)

and socket in front and rear drive shafts (G).

Piston-to-Drive Shaft Socket—
Play ............................................................ 0.058 mm (0.0023 in.) nominal
F—Piston Connecting Rod

G—Rear Drive Shaft
–UN–09JAN97
H—Play
T105726
OUOE027,0000017 –19–19NOV01–11/21
15. Measure ID of cylinder block piston bore. Measure

OD of piston. Subtract the OD from the ID for
clearance.

Cylinder Block Bore-to-Piston—
–UN–18OCT88
Clearance .................................................. 0.043 mm (0.0017 in.) nominal
T6557EM
–UN–18OCT88
33
T6557EN
3360
12

010904
PN=194
Hydraulic System
16. Clamp the connecting rod end of a piston in a vise

with soft-jaw faces. Measure play between connecting
rod and piston.

Piston-to-Connecting Rod—Play ............... 0.150 mm (0.0059 in.) nominal
–UN–18OCT88
T6557EK
OUOE027,0000017 –19–19NOV01–13/21
17. Measure OD (C) of small and large end of servo

piston (D). Measure ID (B) of small and large end of
bore in cylinder head (A). Subtract the OD from the
ID for clearances.

Servo Piston-to-Cylinder Head
Bore—Clearance ....................................... 0.079 mm (0.0033 in.) nominal
A—Cylinder Head
B—ID
C—OD
D—Servo Piston
–UN–19DEC96
T105727
33
3360
13

010904
PN=195
Hydraulic System
18. Measure OD (C) of servo piston pin (B). Measure ID

(D) of bore in valve plate (A). Subtract the OD from
the ID for the clearance.

Servo Piston Pin-to-Valve Plate
Bore—Clearance ....................................... 0.051 mm (0.0020 in.) nominal
–UN–09JAN97
A—Valve Plate
B—Piston Pin
T105729
C—OD
D—ID
33
3360
14

010904
PN=196
Hydraulic System

Use a thermometer. Do not allow a flame or
19. Heat roller bearings (6 and 8).
–UN–12DEC96
Roller Bearing Heat—
Temperature ......................................................... 50—80°C (122—176°F)
T105658
20. Apply oil to bearing. Push roller bearing (6) on drive
shaft so inner race is tight against shoulder.
21. Install spacer ring (7) and roller bearing (8).
22. Apply oil to threads of bearing nut (9).
23. Tighten bearing nut using JDG769 Spanner Wrench.

Pump Drive Shaft Bearing Nut—
Rolling Drag Torque .................................. 2.16 ± 0.49 N•m (19 ± 4 lb-in.)
–UN–12DEC96
3—Pump 2 (Rear) Drive Shaft
4—Pump 1 (Front) Drive Shaft
6—Roller Bearing
7—Spacer Ring
8—Roller Bearing
T105660
9—Bearing Nut
OUOE027,0000017 –19–19NOV01–16/21
24. Install spacer ring (10) into housing bore for pump 2 33
(rear) drive shaft. 3360
15
10—Spacer Ring
–UN–11DEC96
T105628

010904
PN=197
Hydraulic System
25. To help installation of drive shafts (3 and 4), heat

pump housing using a heat gun such as the JT07010
Two Temperature Heat Gun.

Pump Housing Heat—
–UN–11DEC96
Temperature ......................................................... 50—80°C (122—176°F)
26. Apply a film of oil to outer race of bearings. Install the

drive shafts.
T105626
27. Install and tighten special fittings (15).
Hydraulic Pump and Drive Gearbox—Specification 3—Drive Shaft

Special Plug-to-Pump Housing 4—Drive Shaft
Special Fitting—Torque ................................................ 34 N•m (300 lb-in.) 15—Special Fitting (2 used)
28. Apply multi-purpose grease to lips of oil seals. Install

oil seals with lip (spring side) toward inside of
housing. Install snap rings.
33
3360
16

010904
PN=198
Hydraulic System
29. For original parts, install drive (E) and driven (F)
gears on shafts so timing marks (A, B, and C) are
aligned.
For new parts, install the JDG1054 Aligning Bar on

the socket (I and J) end of drive shafts.
–UN–11DEC96
Install aligning bar so end marked “Long Shaft Side”
is to pump 2 (rear) drive shaft (H). Turn shafts so
socket alignment dowels (L and M) engage a socket
T105624
in drive shafts. The socket for pump 1 (front) drive
shaft is slightly below the centerline of socket for
pump 2 (rear) drive shaft when shafts are timed
correctly.
Install cap screws (N) to hold bar in position.
30. From the splined end of shafts, turn shafts to the left
to remove any play between socket alignment dowels
–UN–04OCT94
and sockets.
31. Install gear on pump 2 (rear) drive shaft. Install the

snap ring.
T8323AQ
Install gear on pump 1 (front) drive shaft. As
necessary, turn shaft slightly or turn gear to another
A—Pump 1 (Front) Drive Shaft-to-Driven Gear
position so teeth on gears engage. Install snap ring.
Timing Mark
B—Driven Gear-to-Drive Gear Timing Mark
32. Apply oil to center shaft (21), pistons (23) and C—Pump 2 (Rear) Drive Shaft-to-Drive Gear
cylinder blocks (24). Use petroleum jelly to hold pin Timing Mark
(20) in hole in center shaft. D—Snap Ring (2 used)
E—Drive Gear
F—Driven Gear
33. Install cylinder block so pin engages slot in cylinder G—JDG1054 Aligning Bar (Pump Timing Tool)
block. H—Pump 2 (Rear) Drive Shaft
I—Socket
34. Apply thread lock and sealer (medium strength) to J—Socket
K—Pump 1 (Front) Drive Shaft
threads of dowel pins (63). Tighten dowel pins into
L—Socket Alignment Dowel
pump 1 (front) (64) and pump 2 (rear) (65) valve M—Socket Alignment Dowel
plates. N—M8-1.25 Cap Screw (2 used)

Dowel Pin-to-Pump 1 (Front) and
Pump 2 (Rear) Valve Plate—
Torque ........................................................................... 9.8 N•m (86 lb-in.)
33
3360
17

010904
PN=199
Hydraulic System
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)

(65) valve plates are not
interchangeable. The inlet port in valve
plate is located toward the center and
top of pump housing.
35. Apply oil to valve plates.
Install valve plates so inlet port is toward the center

and top of pump housing.
Connect levers (62) for feedback linkage to valve

plates.
36. Install servo pistons (77) and pins (78).
Apply thread lock and sealer (medium strength) to

threads of set screw (76).
Tighten set screw (76) using a 6 mm hex key wrench.

Servo Piston-to-Pin Set Screw—
Torque .......................................................................... 34 N•m (300 lb-in.)
Tighten cap screws (72) for stop (80) and cover (73).

Stop and Cover-to-Cylinder Head
Cap Screw—Torque .................................................. 19.5 N•m (180 lb-in.)
37. Install cylinder head (70) checking to be sure that

pins engage middle hole in valves plates.
Tighten cap screws (75).

Cylinder Head-to-Pump Housing
Cap Screw—Torque ...................................................... 108 N•m (80 lb-ft)
38. Remove air bleed plugs from pump regulators (8 and

12).
Install regulators making sure groove in remote

control sleeve and load sleeve engage dowel pin (61)
33
3360 in feedback link (82). Check through hole that groove
18 in sleeves engage dowel pin.

010904
PN=200
Hydraulic System
Tighten cap screws.

Regulator-to-Pump Housing Cap
39. Tighten pump pressure sensors.

Pump Pressure Sensor-to-Pump
Housing—Torque............................................................. 98 N•m (72 lb-ft)

Pump Housing-to-Gearbox
Housing Cap Screw—Torque...................................... 147 N•m (109 lb-ft)
41. Apply rigid form-in-place gasket to mounting surface

for pilot pump (48).
Tighten cap screws (45).

Pilot Pump-to-Gearbox Cap
42. Apply multi-purpose grease to lips of oil seal (55).

Install oil seal with lip (spring side) toward inside of
housing.

threads of set screws (57) in dampener drive coupling
(58).
Tighten set screws. For assembly of dampener drive.

See Dampener Drive (Flex Coupling) Repair. (Group
0752.)

Dampener Drive Hub-to-Pump 2
(Rear) Drive Shaft Set Screw—
Torque ........................................................................... 108 N•m (80 lb-ft)
44. Fill pump and pump drive gearbox with oil. See
Hydraulic Pump and Drive Gearbox Start-Up
33
3360
19
OUOE027,0000017 –19–19NOV01–21/21

010904
PN=201
Hydraulic System
Hydraulic Pump and Drive Gearbox Start-Up

Procedure
IMPORTANT: Hydraulic pump and drive gearbox will

be damaged if not filled with oil before
starting engine. Procedure must be
performed whenever a new pump or
gearbox is installed or oil has been
drained from the pump, gearbox or
hydraulic oil tank.
Procedure is to ensure the pumps and

gearbox are filled with oil and air is bled
from suction side of pumps to prevent
cavitation.
1. Remove air bleed plugs (C) from the top of pump

regulators to allow housing to fill with oil from the
hydraulic oil tank and to let air escape.
–UN–15JUL96
2. When pump housing is full of oil, install plugs.
3. As necessary, add oil to hydraulic oil tank until it is

between marks on sight glass. See Hydraulic Oil.
T101875
(Operator’s Manual). Tighten tank cap. Tighten vent
plug.
4. Start engine and run at slow idle. Slowly raise boom to C—Air Bleed Plug (2 used)
full height and then lower to pressurize hydraulic oil
tank.
5. Purge air from the hydraulic system by slowly

operating each function through three cycles. Air in
pilot circuits are purged automatically.
TX,25,GG2226 –19–19NOV01–1/2
33 6. Fill pump drive gearbox with oil through filler pipe (B)
3360 so level is above “H” mark on dipstick (A). See Swing
20
Gearbox, Propel Gearbox and Pump Gearbox Oils.
A—Dipstick
–UN–15JUL96
B—Filler Pipe
T101493
TX,25,GG2226 –19–19NOV01–2/2

010904
PN=202
Hydraulic System
Pilot Pump Drive Shaft and Gear Repair
Disassemble and Assemble Pilot Pump Drive Shaft

and Gear
1. Remove snap rings (6 and 7).
–UN–12DEC96
2. Remove pilot pump drive shaft (4) and upper ball
bearing (5) using a blind-hole puller or an internal
puller. Ball bearings are a press fit on drive shaft and
T105640
in housing.
3. Remove pilot pump drive gear (3) through opening for

hydraulic pump.
1—Pump Drive Gearbox Case

3—Pilot Pump Drive Gear
4—Pilot Pump Drive Shaft
5—Ball Bearing (2 used)
–UN–12DEC96
6—Snap Ring
7—Snap Ring
T105657
–UN–20JUL01
T142290
OUOE027,0000018 –19–19NOV01–1/1
33
3360
21

010904
PN=203
Hydraulic System
Hydraulic Pump Regulator Repair
Remove and Install Hydraulic Pump Regulator
NOTE: Pump 1 (front) and pump 2 (rear) regulators are

similar in design. Removal of pump 2 (rear)
regulator is shown.


in this group.)

and Refill Capacities, 230CLC Drain and Refill
Capacities, or 270CLC Drain and Refill Capacities.
33
3360
22

010904
PN=204
Hydraulic System
5. Remove cap screws (1) and regulator (2).
7. Install regulators making sure groove in remote control

sleeve and load sleeve engage dowel pin in feedback
link. Check through hole that groove in sleeves engage
dowel pin.
Pump Regulator—Specification
Pump 1 (Front) and Pump 2
(Rear) Regulator-to-Pump
–UN–20JUL01
Housing Cap Screw—Torque.......................................... 49 N•m (36 lb-ft)

T142278B
Master Legend. (Group 9015-10.)
10. Connect lines. See Pilot Signal Manifold-to-Control

Valve Component Location. (Group 9025-15.) 1—Cap Screw (8 used)
2—Hydraulic Pump Regulator (2 used)
IMPORTANT: Hydraulic pump will be damaged if not
filled with oil before starting engine.
Procedure must be performed whenever
a new pump installed or oil has been
drained from the pump or hydraulic oil
tank.
11. Fill pump housing with oil. See Hydraulic Pump and
Drive Gearbox Start-Up Procedure. (See procedure in
this group.)
33
3360
23

010904
PN=205
Hydraulic System
–UN–20JUL01
T142272B
Pump 2 (Rear) Regulator Shown
1—Cap Screw (4 used) 8—O-Ring (3 used) 15—Spring (2 used) 22—Piston

2—Nut 9—Load Adjusting Screw 16—Remote Control Spool 23—Load Piston
3—Nut (2 used) (Stop) 17—Remote Control Sleeve 24—Cylinder
4—Minimum Flow Adjusting 10—Regulator Body 18—O-Ring 25—Load Sleeve
Screw 11—Cap Screw (4 used) 19—Backup Ring 26—Load Spool
5—Cover 12—End Plate 20—O-Ring 27—Inner Spring
6—Nut (2 used) 13—Flow Adjusting Cartridge 21—Cylinder
7—Load Adjusting Cartridge 14—Maximum Flow Adjusting
Screw (Stop)
Disassemble and Assemble Hydraulic Pump 1. Remove the end plate (12) and cover (5) with the
Regulator adjusting screws and cartridges installed.
NOTE: Pump 1 (front) and pump 2 (rear) regulators 2. Repair or replace parts as necessary.
are similar. Pump 2 (rear) regulator is shown,
3. Tighten cap screws (1 and 11).
IMPORTANT: Removal of adjusting screws (4, 9
33 and 14) and cartridges (7 and 13) Pump Regulator—Specification
3360 from end plate (12) and cover (5) will Pump 1 (Front) and Pump 2
24 (Rear) End Plate and
required the adjustment of pump Cover-to-Housing Cap Screw—
regulators. Only remove parts from Torque................................................................. 19.8 N•m (180 lb-in.)
end plate and cover if replacement is
necessary.

010904
PN=206
Hydraulic System
–UN–09JAN97
T105706
2—Load Sleeve 13—Load Adjusting Screw 24—Maximum Flow Adjusting 34—Nut
3—Load Spool (Stop) Screw (Stop) 35—End Plate
5—Cylinder 15—Spring 27—Remote Control Sleeve 36—Cover
6—Load Piston 16—Nut (2 used) 28—Remote Control Spool 37—Cap Screw (8 used)
12—Load Adjusting Cartridge 17—Nut (2 used) 29—Minimum Flow Adjusting 47—Outer Spring
(Stop) 20—Piston Screw 48—Inner Spring
—Flow Adjusting Cartridge 21—Cylinder
(Stop)
4. Tighten cap screws. For minimum flow:
5. Tighten air bleed plug. • See Hydraulic Pump Regulator Test and
Adjustments—Minimum Flow—200CLC. (Group
Pump Regulator—Specification 9025-25.)
Pump 1 (Front) and Pump 2 • See Hydraulic Pump Regulator Test and
(Rear) Air Bleed
Plug-to-Housing—Torque ......................................... 78 N•m (58 lb-ft) Adjustments—Minimum Flow—230CLC. (Group
9025-25.)
IMPORTANT: Hydraulic pump will be damaged if • See Hydraulic Pump Regulator Test and
not filled with oil before starting Adjustment—Minimum Flow—270CLC. (Group
engine. Procedure must be 9025-25.)
performed whenever a new pump
installed or oil has been drained For maximum flow:
from the pump or hydraulic oil tank.
33
6. Fill pump housing with oil. See Hydraulic Pump and Adjustments—Maximum Flow—200CLC. (Group
3360
Drive Gearbox Start-Up Procedure. (See procedure 9025-25.) 25
in this group.) • See Hydraulic Pump Regulator Test and
Adjustments—Maximum Flow—230CLC. (Group
7. Check pump regulator adjustments. (Group 9025-25.)
9025-25.)

010904
PN=207
Hydraulic System

9025-25.)
OUOE027,000001A –19–19NOV01–5/5
33
3360
26

010904
PN=208
Hydraulic System
Pilot Pump Repair
Remove and Install Pilot Pump


in this group.)
2. Drain pump drive gearbox. Approximate oil capacity is

1.0 L (1.1 qt).
–UN–20JUL01
T142279B
4. Disconnect lines. 1—Adapter

5. Remove adapter (1). 3—Pilot Pump
6. Remove cap screws (2) and pilot pump (3).
8. Apply Rigid Form-In-Place Gasket to mounting surface

for pilot pump.
9. Tighten cap screw (2).
Pilot Pump—Specification
Pump-to-Drive Gearbox Cap
10. Install adapter (1) and O-ring.

12. Fill pump drive gearbox so level is above “H” mark on

dipstick. See Change Pump Drive Gearbox Oil. 33
(Operator’s Manual.) 3360
27
Continued on next page OUOE027,000001B –19–19NOV01–1/4

010904
PN=209
Hydraulic System
33
–UN–13MAY96
3360
28
TP47901
0—Pilot Pump 5—Snap Ring 10—Key (2 used) 16—Cap Screw and Washer
2—Flange 6—Seal (2 used) 12—O-Ring (2 used) (4 used)
3—Oil Seal 9—Backup Retainer (2 used) 15—Washer (4 used)
Continued on next page OUOE027,000001B –19–19NOV01–2/4

010904
PN=210
Hydraulic System
Disassemble and Assemble Pilot Pump
OUOE027,000001B –19–19NOV01–3/4
IMPORTANT: Be careful not to lose keys (B).
1. Check bushings (D). If inside diameter and surface

toward gear are rough or worn, replace pump.
2. Check gears (A and C) and housing. If gear teeth,
–UN–13MAY92
shaft, and inside of housing is rough or worn, replace
pump.
IMPORTANT: Apply clean hydraulic oil to all parts.
T7685IX
Pump failure can result if pump is
assembled dry.
3. Apply clean hydraulic oil to all parts. A—Drive Gear

B—Keys (2 used)
C—Driven Gear
4. Apply multi-purpose grease to lip of oil seal. Install oil D—Bushing
seal with lip (spring side) towards inside of housing.
Pilot Pump—Specification
Cover-to-Flange Cap Screw—
Torque ............................................................................. 41 N•m (31 lb-ft)
6. Check pilot pressure setting. See Pilot Pressure

Regulating Valve Test and Adjustment. (Group
9025-25.)
OUOE027,000001B –19–19NOV01–4/4
33
3360
29

010904
PN=211
Hydraulic System
Pilot Pressure Regulating Valve and Filter

Repair
Remove and Install Pilot Pressure Regulating Valve

and Filter


in this group.)
OUOE027,000001F –19–19NOV01–1/3
3. Remove cap screws (1) and remove pilot pressure

regulating valve (2) and pilot filter (3).
5. Install cap screws (1).
Pilot Pressure Regulating Valve and Filter—Specification

Filter Head-to-Support Cap
6. Replace pilot filter (3) element.
–UN–20JUL01
Pilot Filter Element
Housing-to-Filter Head—Torque .................................. 25 N•m (220 lb-in.)
7. Connect lines. See Main Hydraulic System Component

T143074B
8. Check pilot pressure setting. See Pilot Pressure

Regulating Valve Test and Adjustment. (Group
9025-25.) 2—Pilot Pressure Regulating Valve
33
3360 3—Pilot Filter
30
Continued on next page OUOE027,000001F –19–19NOV01–2/3

010904
PN=212
Hydraulic System
Disassemble and Assemble Pilot Pressure Regulating

Valve and Filter
1
1. Remove plug (6) with O-ring (5).
2
2. Remove parts (2—4). 3
4
5
3. Inspect, clean and replace parts as necessary.
6
4. Check that poppet (2) slides smoothly in pilot pressure
regulating valve housing (1).
–UN–20JUL01
5. Tighten plug (6).
T143094
Plug-to-Housing—Torque ................................................ 49 N•m (36 lb-ft)
1—Pilot Pressure Regulating Valve Housing

2—Poppet
3—Shim (As required)
4—Spring
5—O-Ring
6—Plug
OUOE027,000001F –19–19NOV01–3/3
Pilot Shut-Off Valve Repair
Remove and Install Pilot Shut-Off Valve
1. Turn upperstructure 90° to tracks.


in this group.)
33
3360
4. Disconnect spring.
31
Continued on next page OUOE027,000001C –19–19NOV01–1/4

010904
PN=213
Hydraulic System
5. Remove cap screws (1) and remove valve with lever

attached.
1
7. Install valve. Tighten cap screws.
Pilot Shut-Off Valve—Specification

Valve Housing-to-Cab Platform
Cap Screw—Torque ........................................................ 49 N•m (36 lb-ft)
8. Connect spring.
9. Connect lines. See Pilot Controllers-to-Pilot Signal

Manifold Component Location—Excavator Pattern.
–UN–20JUL01
(Group 9025-15.)
T142504
33
3360
32

010904
PN=214
Hydraulic System
–UN–17JUL01
T143031
33
1—Washer 5—Lever Stop Cap Screw 8—Backup Ring 11—Bracket 3360
2—Backup Ring 6—Retaining Ring 9—O-Ring 12—Pin 33
3—O-Ring 7—Washer 10—Spool 13—Cap Screw (3 used)
4—Body
Disassemble and Assemble Pilot Shut-Off Valve
1. Remove spring pin and remove lever from valve.

010904
PN=215
Hydraulic System
NOTE: Make alignment marks on body (4) and 7. Position bracket (11) on spool (10).
bracket (11) to aid in reassembly.
8. Apply thread lock and seal (medium strength) to
2. Remove parts (6—9) and remove spool (10) from threads of cap screws (13) and tighten.
body (4).
Pilot Shut-Off Valve —Specification
Bracket-to-Spool Cap Screw—
3. Remove parts (1—3) from body.
Torque..................................................................... 3.9 N•m (2.9 lb-ft)
4. Remove cap screws (13) and bracket (11) from

9. Install parts (1—3) into body (4).
spool (10).
10. Apply hydraulic oil to spool (10) and install into
NOTE: Remove pin (12) and cap screw (5) only if
body (4).
necessary.
11. Install parts (7—9) in body (4) and retaining ring
5. Inspect and replace parts as necessary.
(6) to spool (10).
6. If cap screw (5) has been removed, apply thread
12. Align marks on bracket (11) with body (4).
lock and sealer (medium strength) to threads and
tighten.
13. Install lever and spring pin to valve.
Pilot Shut-Off Valve—Specification
Lever Stop Cap Screw—Torque ........................ 29.4 N•m (21.5 lb-ft)
OUOE027,000001C –19–19NOV01–4/4
33
3360
34

010904
PN=216
Hydraulic System
Power Boost, Propel Speed, Swing Priority,

and Arm Regenerative Solenoid Valve Repair
Remove and Install Power Boost, Propel Speed,

Swing Priority, and Arm Regenerative Solenoid Valve

–UN–20JUL01
in this group.)
2. Disconnect electrical connector.
T143099B
3. Remove cap screws (1) and remove solenoid valve coil
(2). Be careful not to lose spring and O-ring.
2—Solenoid Valve Coil (4 used)
4. Keep parts for each individual solenoid valve together.
5. Install solenoid valve coil (2) with O-ring (8) and spring
(7).
Solenoid Valve—Specification
Solenoid Valve Coil-to-Manifold
Cap Screws—Torque ..................................................... 3 N•m (24 lb-in.)
7. Connect electrical connectors.
8. Check pressure setting of solenoid valves. See Power

Boost, Propel Speed, Swing Priority, and Arm
Regenerative Solenoid Valve Test and Adjustment.
(Group 9025-25.)
Continued on next page OUOE027,000001E –19–19NOV01–1/2
33
3360
35

010904
PN=217
Hydraulic System
–UN–20JUL01
T143123
1—Cap Screw (2 used) 5—Adjusting Screw 10—Spool 15—O-Ring
2—Proportional Solenoid 6—Spring 11—Washer 16—Sleeve
Valve Coil 7—Spring 12—Spring 17—Plate
3—O-Ring 8—O-Ring 13—O-Ring 18—Washer
4—Lock Nut 9—Diaphragm 14—O-Ring
Disassemble and Assemble Proportional Solenoid 3. Apply clean oil to sleeve (16), O-rings (13, 14 and
Valve 15) and spool (10).
1. Remove parts (7—18). After installing spool, push spool against spring to
check that spool slides smoothly in sleeve.
NOTE: Only remove the lock nut (4) and adjusting
screw (5) if replacement of O-ring (3) is 4. Install sleeve (16) so ports align with ports in
necessary. If disassembled, pressure setting of manifold.
proportional solenoid valve will need to be
adjusted. See Power Boost, Propel Speed, 5. Install washer (11) and spring (12) on spool and
Swing Priority, and Arm Regenerative Solenoid install spool.
33 Valve Test and Adjustment. (Group 9025-25.)
3360
6. Install spring (7), O-ring (8) and diaphragm (9).
36
OUOE027,000001E –19–19NOV01–2/2

010904
PN=218
Hydraulic System
Pilot Controller Repair
Remove and Install Pilot Controller


in this group.)
2. Remove covers.
3. Disconnect wiring harness and remove lever.
4. Remove cap screws and remove pilot controller from

console.
7. Connect lines. See Main Hydraulic System Component

NOTE: Position cap screw with spring pin, in lower right

hole of controller.
8. Install pilot controller and tighten cap screws.
Pilot Controller—Specification
Pilot Controller-to-Console Cap
Screw—Torque ............................................................... 10 N•m (7.2 lb-ft)
9. After pilot controller is installed, check operation of all

functions to be sure they operate as shown on decal
mounted on console.
33
3360
37

010904
PN=219
Hydraulic System
13
12
14
11
15
11
10
8
9
7
16
21
21
5
20
6 20
19
3
4
18
2
–UN–17JUL01
1
17
T143186
T143186
33
3360 1—Spacer (4 used) 7—Retaining Ring (4 used) 12—Cam 17—Spool (4 used)
38 2—Shim (As required) 8—Pusher A (2 used) 13—Coupling 18—Housing
3—Balance Spring A (2 used) 9—Pusher B (2 used) 14—U-Joint 19—O-Ring
4—Balance Spring B (2 used) 10—Block 15—Oil Seal (4 used) 20—Dowel Pin (2 used)
5—Return Spring A (2 used) 11—Cap Screw (2 used) 16—Spring Guide (4 used) 21—O-Ring (2 used)
6—Return Spring B (2 used)

010904
PN=220
Hydraulic System
Disassemble and Assemble Pilot Controller 3. Install parts.
IMPORTANT: The housing (18) and spools (17) are 4. Apply multi-purpose grease to oil seals.
replaced as an assembly because
the spools are select fitted to bores 5. Install pushers (8 and 9). Pushers with grooves go
in housing. into ports 1 and 3. Pushers without grooves go into
ports 2 and 4.
Some parts from ports 1 and 3 are
different than parts from ports 2 and 6. Tighten cap screw (11).
4. Parts for each port must be kept
together and installed into the same Pilot Controller—Specification
port from which it was removed. The Block-to-Housing Cap Screw—
Torque................................................................. 19.6 N•m (14.5 lb-ft)
port numbers are stamped on the
housing.
7. Apply multi-purpose grease to the end of each
pushers (8 and 9) and to the joint of U-joint (14).
Remove U-joint (14) only if
necessary.
8. Install cam (12) on U-joint (14). Adjust clearance
between pushers (8 and 9) and cam.
Note port location and quantity of
shims (2) when removing. Same Pilot Controller—Specification
number of shims must be used when Cam-to-Pusher—Clearance...................... 0—0.20 mm (0—0.008 in.)
installing.
Hold cam (12) and tighten coupling (1).
1. Remove parts from housing. Remember to keep
parts removed from each port together. Identify Pilot Controller—Specification
each group of parts by port numbers stamped on Coupling-to-Cam and U-Joint—
housing. Torque.................................................................... 88.2 N•m (65 lb-ft)
NOTE: Install spring guides (16) with protrusion facing

up.
OUOE027,0000020 –19–19NOV01–3/3
33
3360
39

010904
PN=221
Hydraulic System
Propel Pilot Controller Repair
Remove and Install Propel Pilot Controller


in this group.)
–UN–20JUL01
3. Remove cap screws (3) and remove pedals and levers.
T143206B
4. Remove cap screws (2) and remove propel pilot
controller (1).
1—Propel Pilot Controller
5. Repair or replace parts as necessary. 2—Cap Screw (2 used)
Propel Pilot Controller—Specification

Controller-to-Cab Platform Cap

Propel Pedal-to-Lever Cap

9. After propel pilot controller is installed, check the

operation of all functions to be sure they operate
correctly.
33
3360
40

010904
PN=222
Hydraulic System
35 2
34
33
32
3
31 4
6 5
7
30
8
29
27 28 9
11
10 12
13
23
26 14
22
25
24 20 21
15
19
18 16
17 –UN–17JUL01
T143207
T143207
33
1—Cap Screw (2 used) 10—Holder 19—Spacer (4 used) 28—Cap Screw (4 used) 3360
2—Cover 11—Oil Seal (4 used) 20—Shim (As required) 29—Lock Washer (4 used) 41
3—Pin (2 used) 12—O-Ring (4 used) 21—Balance Spring (4 used) 30—Adjusting Bolt (4 used)
4—O-Ring (2 used) 13—Bushing (4 used) 22—Spring Guide (4 used) 31—Bushing (4 used)
5—O-Ring (2 used) 14—Casing 23—Pusher (4 used) 32—Cam (2 used)
6—Dampener (2 used) 15—O-Ring 24—Spring Pin (2 used) 33—Lock Nut (4 used)
7—Rubber Seat (2 used) 16—Plug 25—Spring Pin (2 used) 34—Spring Pin (2 used)
8—Cap Screw (2 used) 17—Spool (4 used) 26—Bracket (2 used) 35—Spring Pin (2 used)
9—Lock Washer (2 used) 18—Spring (4 used) 27—Spring Pin (2 used)

010904
PN=223
Hydraulic System
Disassemble and Assemble Propel Pilot Controller 6. Lock pins (34 and 35) in position by displacing the
bore above spring pin using a punch and hammer.
IMPORTANT: The casing (14) and spools (17) are
replaced as an assembly because 7. Install holder (10) to casing (14) with cap screws
the spools are select fitted to bores (8), lock washers (9) and tighten.
in housing.
Parts for each port must be kept Holder-to-Casing Cap Screw—
Torque....................................................................... 49 N•m (36 lb-ft)
together and installed into the same
port from which it was removed. The
8. Adjust clearance between cams (32) and pushers
port numbers are stamped on the
(23) .
housing.
Note port location and quantity of Cams-to-Pusher—Clearance .................... 0—0.20 mm (0—0.008 in.)
shims (20) when removing. Same
number of shims must be used when 9. Tighten lock nut (33).
installing.
1. Remove parts from casing. Remember to keep Cam Adjusting Bolt Lock Nut—
parts removed from each port together. Identify Torque..................................................................... 9.8 N•m (7.2 lb-ft)
each group of parts by port numbers stamped on
casing. 10. Apply multi-purpose grease to O-rings (4 and 5)
and install on pin (3).
NOTE: Spring pins (24 and 25) are stepped and can
only be removed from one direction. 11. Position rubber seat (7) and dampener (6) on pin
(3) with lever facing upward.
Remove spring pin (27) and bushings (31) only
if necessary. 12. Install cap screws (28), lock washers (29) and
tighten.
Dampener-to-Holder Cap
3. Install spools (17), springs (18), spacers (19), shims Screw—Torque .......................................................... 7 N•m (5.1 lb-ft)
(20) and balance springs (21) into casing (14).
IMPORTANT: Note direction of insertion for spring
Use number of shims (20) removed. pins (24 and 25).
Install spring guides (22) with stepped end facing Spring pins must be positioned with
down. slits 90° apart.
4. Apply multi-purpose grease to the end of each Align brackets with marks made
pushers (23) and to oil seals (11). during disassembly.
IMPORTANT: Note direction of insertion for spring 13. Install brackets (26) and spring pins (24 and 25).
33 pins (34 and 35).
3360
14. Lock pins (24 and 25) in position by displacing the
42
5. Assemble cam (32) in holder (10) with spring pins bore above spring pin using a punch and hammer.
(34 and 35), and pin (3). Install spring pins with slits
90° apart.

010904
PN=224
Hydraulic System
15. Install cover (2) and cap screws (1) and tighten.

Cover-to-Holder Cap Screw—
Torque........................................................................ 5 N•m (3.6 lb-ft)
16. Apply multi-purpose grease to spring pin (27).
OUOE027,0000021 –19–19NOV01–4/4
Pilot Signal Manifold Repair
Remove and Install Pilot Signal Manifold


in this group.)

33
3360
43

010904
PN=225
Hydraulic System
5. Remove cap screws (3).
7. Position manifold (1) on bracket (2) and tighten cap

screws (3).
Pilot Signal Manifold—Specification

Pilot Signal Manifold-to-Bracket
Cap Screw—Torque ........................................................ 50 N•m (37 lb-ft)
–UN–20JUL01
Master Legend . (Group 9015.)
T143184C
9. Install hose and tube adapters and tighten.

Hose and Tube Adapter-to-Pilot 1—Pilot Signal Manifold
Signal Manifold—Torque .............................................. 39 N•m (347 lb-in.) 2—Bracket
10. Connect lines. See Pilot Controllers-to-Pilot Signal
Manifold Component Location—Excavator Pattern.
(Group 9025-15.)
33
3360
44

010904
PN=226
Hydraulic System
33
3360
45

010904
PN=227
Hydraulic System
14 21 14
15
22 10
16
17 23 9
13 19 12 8
20 24
11
6 7
5
18
19 4
16 20
17
3
2
C
B
25
26
19
27
A 16
15
20 14
17
33
28
3360
46 29
19
–UN–17JUL01
17
16
15
T143485
T143485

010904
PN=228
Hydraulic System
1—Cap Screw (10 used) 9—Gasket 16—O-Ring (7 used) 23—Valve

2—Body 10—Body 17—Spring (4 used) 24—O-Ring
3—Gasket 11—Name Plate 18—Spring 25—Spring
4—Body 12—Screw (4 used) 19—Spring Seat (7 used) 26—Spool
5—Gasket 13—Plate 20—Spool (6 used) 27—Spring
6—Body 14—Cap Screw (11 used) 21—Plate 28—Spring
7—Gasket 15—Plug (7 used) 22—O-Ring 29—Plate
8—Body
Disassemble and Assemble Pilot Signal Manifold
33
3360
47

010904
PN=229
Hydraulic System
30 32
31
32
31
30
A
B
31
30
33
3360
48
–UN–17JUL01
C D
T143486
T143486
30—Filter (17 used) 31—Shuttle Valve (21 used) 32—Spring (4 used)

010904
PN=230
Hydraulic System
Install hose and tube adapters and tighten.

Hose and Tube Adapter-to-Pilot
Signal Manifold—Torque ....................................... 39 N•m (347 lb-in.)
OUOE027,0000027 –19–19NOV01–6/6
Control Valve Repair
Remove and Install Control Valve


in this group.)
2. Drain hydraulic oil tank. See 200CLC Drain and Refill

Capacities, 230CLC Drain and Refill Capacities or
270CLC Drain and Refill Capacities. (Operator’s
Manual.)
TX,33,UU4002 –19–19NOV01–1/18
3. Disconnect hydraulic tubes.
4. Disconnect electrical connectors (6).
5. Remove cap screws (2) and washers (3). Place pilot

signal manifold (4) with bracket (5) to side.
6. Attach hoist to control valve using lifting strap. 33

3360
49
1—Control Valve
–UN–24JUL01

3—Washer (3 used)
4—Pilot Signal Manifold
5—Bracket
6—Electrical Connector (4 used)
T143184B
Continued on next page TX,33,UU4002 –19–19NOV01–2/18

010904
PN=231
Hydraulic System
Control Valve—Specification
Control Valve—Weight .................................. 183 kg (400 lb) approximate
7. Remove cap screws (1) and washers (2). Remove

control valve.

2
Mounting Bracket-to-Control
Valve Cap Screw—Torque .......................................... 210 N•m (152 lb-ft)
10. Install pilot signal manifold with bracket. Tighten cap 3

screws.
1
Pilot Signal Manifold
–UN–02AUG01
Bracket-to-Control Valve Cap
2 4
11. Connect hydraulic tubes. See Main Hydraulic System
T143187
Component Location. (Group 9025-15.) T143187 1
12. Connect electrical connectors. See Cab Harness (W1)

Component Location Diagram. (Group 9015-10.) 1—Cap Screw (4 used)
2—Washer (4 used)
3—Front Mounting Bracket
13. Check Hydraulic Oil. (Operator’s Manual.) 4—Rear Mounting Bracket
14. Do Hydraulic Pump and Drive Gearbox Start-Up

33
3360
50

010904
PN=232
Hydraulic System
28
29 31
27 36
26 30
32
37
24
38 33
23 39
34
22
19
35
H
18 I D C
21 25
G E
20 F
J 40
16
H 44
15 42 45
A
G 46
17 47
F 48
B
13
A 49
12 50 41
E
7
14 43 51
11 52
6 66
53
10 54
5 8 67 55
1 9
4 56
D 61 57
–UN–19NOV01
B 62 C 58
3 68 59
63 60
2
69 64
T143188
T143188 J 65
Control Valve—5-Spool 33
3360
Disassemble and Assemble Control Valve 5-Spool 51

010904
PN=233
Hydraulic System
114
111 112 113
110
106 107
105
109
104
108
115
98 103
102
101
100
99
93
97
96
85 95
94
84
83 90
88 116
82 92
81 91
89
76 80 87 104
86 106
105
79
84 85 122
78
121
77 83 90 120
75 88
74 82 119
92 118 117
73
81 91
72 89
71 70 80 87
123 86
–UN–19NOV01
79 78
77
T143190
T143190
33 5-Spool—Side Components
3360
52

010904
PN=234
Hydraulic System
1—Auxiliary Function Flow 35—Swing Spool 67—O-Ring 97—Poppet

Combiner Valve 36—Special Cap Screw (5 68—O-Ring 98—Auxiliary Flow Combiner
2—Cap Screw (2 used) used) 69—Arm In Circuit Relief and Valve Check Valve
3—Cap 37—Spring Seat (5 used) Anti-Cavitation Valve 99—Cap Screw (2 used)
4—O-Ring 38—Spring (5 used) 70—Lift Check (Boom II Power 100—Flange
5—Spring Seat 39—Spring Seat (5 used) Passage) 101—O-Ring
6—Spring 40—Spool 71—Cap Screw (4 used) 102—Spring
7—Spool 41—Arm Reduced Leakage 72—Flange 103—Poppet
8—Bottom Pilot Cap (5 used) Valve 73—O-Ring 104—Cap Screw (8 used)
9—Cap Screw (10 used) 42—Cap Screw (4 used) 74—Spring 105—Cover (2 used)
10—Plug 43—O-Ring 75—Poppet 106—O-Ring (2 used)
11—O-Ring 44—Plug 76—Auxiliary Flow Rate Valve 107—Lift Check (Arm I Power
12—Plug 45—O-Ring 77—Plug (2 used) Passage)
13—O-Ring 46—Piston 78—O-Ring (2 used) 108—Plug
14—O-Ring (5 used) 47—Spring 79—Cap Screw (8 used) 109—O-Ring
15—Plug 48—Body 80—Housing (2 used) 110—Arm I Power
16—O-Ring 49—O-Ring 81—Spool (2 used) Passage-to-Housing Lift
17—Housing 50—O-Ring 82—Spring (2 used) Check Cap Screw (4
18—O-Ring 51—Sleeve 83—Spring Seat (2 used) used)
19—System Relief and Power 52—Backup Ring 84—O-Ring (2 used) 111—Flange
Boost Valve 53—O-Ring 85—Plug (2 used) 112—O-Ring
20—O-Ring 54—O-Ring 86—O-Ring (2 used) 113—Spring
21—Plug 55—Backup Ring 87—Sleeve (2 used) 114—Poppet
22—O-Ring 56—Spool 88—Spring (2 used) 115—Housing
23—Plug 57—Poppet 89—Plug (2 used) 116—O-Ring (6 used)
24—Cap Screw (6 used) 58—Washer 90—Spring (2 used) 117—Lift Check (Swing Neutral
25—O-Ring (5 used) 59—Spring 91—Poppet (2 used) Passage)
26—Top Pilot Cap 60—Lift Check and Orifice 92—Poppet (2 used) 118—Cap Screw (4 used)
27—O-Ring (Left Propel Power 93—Lift Check (Left Propel 119—Flange
28—Plug Passage) Neutral Passage) 120—O-Ring
29—Plug 61—Plug 94—Left Propel Neutral 121—Spring
30—O-Ring 62—Backup Ring Passage-to-Housing Lift 122—Poppet
31—Left Travel Spool 63—O-Ring Check Plug 123—Arm Priority Flow Rate
32—Auxiliary Spool 64—Spring 95—O-Ring Valve
33—Boom II Spool 65—Poppet 96—Spring
34—Arm I Spool 66—Arm Out Circuit Relief and
Anti-Cavitation Valve
1. Remove cap screws (24) and top pilot cap (26). NOTE: Hold the spool in a vise by the spool end
between wooden blocks.
2. Remove cap screws (9) and bottom pilot caps (8).
The procedures for disassembly and assembly
3. Spool —5 Spool (31—35): of spool (31—35) are the same.
IMPORTANT: The spool (31—35) are select fitted b. Remove parts (36—39)
to bores in housing and are a
different design for each function. c. Inspect control valve spools for wear and
Spools must be installed into the damage.
same bores from which they were
removed for proper operation of d. Replace parts as necessary. 33
machine. 3360
e. Assemble parts (36—40). Tighten special cap 53
a. Remove spool (31—35). screws (36).

010904
PN=235
Hydraulic System
Control Valve—Specification d. Install plug (44) loosely.

Special Cap Screw-to-Control
valve Spool—Torque ................................................ 15 N•m (11 lb-ft)
e. Tighten cap screws (42).
Arm Reduced Leakage Valve
NOTE: Apply hydraulic oil to spools before installation. Body-to-Housing Cap Screw—
Torque....................................................................... 62 N•m (46 lb-ft)
f. Install spool (31—35) into housing (17) while
rotating them slowly.
g. After installing spool (31—35) into housing (17), f. Tighten plug (44).
push them by hand to confirm smoothness.
Plug-to-Arm Reduced Leakage
h. Repeat procedure for remaining spool Valve—Torque ........................................................ 108 N•m (80 lb-ft)
4. Auxiliary Function Flow Combiner Valve (1):
a. Inspect parts (2—7) for wear and damage. 7. Auxiliary Flow Combiner Valve Check Valve
(98):
b. Replace parts as necessary.
a. Remove parts (99—103).
c. Tighten cap screws (2).
b. Install flange (100) and tighten cap screws (99).
Auxiliary Function Flow
Combiner Valve-to-Housing
Auxiliary Flow Combiner Valve
Cap Screw—Torque ................................................... 11 N•m (7 lb-ft)
Check Valve-to-Housing Cap
Screw—Torque ......................................................... 61 N•m (46 lb-ft)
5. Lift Check And Orifice (Left Propel Power

Passage) (60): 8. Lift Check (Left Propel Neutral Passage) (93):
a. Inspect parts (61—65) for wear and damage. a. Remove plug (94).
b. Replace parts as necessary. b. Remove parts (95—97).
6. Arm Reduced Leakage Valve (41): c. Replace parts as necessary
a. Remove cap screws (42) and body (48). d. Install plug (94) and tighten.
b. Replace parts as necessary. Control Valve—Specification

Left Propel Neutral
33 c. Apply petroleum jelly to washer (62) and spring Passage-to-Housing Lift Check
3360 (63) to hold in place. Plug—Torque ............................................................ 76 N•m (56 lb-ft)
54
IMPORTANT: Install spool (56) with the hole side
towards poppet (57) for proper
operation of valve. 9. Lift Check (Arm I Power Passage) (107):

010904
PN=236
Hydraulic System
a. Remove cap screws (110) and flange (111). 11. Auxiliary Flow Rate Valve (76) And Arm Priority
Flow Rate Valve (123):
a. Remove cap screws (79) and housing (80).
c. Install flange (111) and tighten cap screws (110).
Arm I Power c. Install housing (80) and tighten cap screws
Passage-to-Housing Lift Check
Cap Screw—Torque ................................................. 61 N•m (46 lb-ft) (79).
Flow Rate Valve
Housing-to-Housing Cap
10. Lift Check (Boom II Power Passage) (70) and Screw—Torque ......................................................... 61 N•m (46 lb-ft)
Lift Check (Swing Neutral Passage) (117):
a. Remove cap screws (71 and 118) and flanges

(72 and 119). d. Tighten plug (85).
b. Replace parts as needed. Control Valve—Specification

Flow Rate Valve Housing
Plug—Torque ............................................................ 98 N•m (72 lb-ft)
c. Install flanges (72 and 119) and tighten cap
screws (71 and 118).
Power Passage-to-Housing
33
3360
55

010904
PN=237
Hydraulic System
12. System Relief and Power Boost Valve (19) 1
NOTE: Disassemble valve for cleaning and inspection 2

only. Valve is serviced as an assembly. 3
a. Tighten nuts (4 and 9). 4
System Relief Valve—Specification 5

System Relief Valve 27 mm Nut
(4)—Torque ..................................................................... 64 N•m (47 lb-ft) 6
System Relief Valve 32 mm Nut
7
(9)—Torque ..................................................................... 83 N•m (61 lb-ft)
8
9
b. Tighten valve cartridge (10).
10
System Relief Valve—Specification 11
System Relief Valve
Cartridge-to-Housing—Torque ........................................ 83 N•m (61 lb-ft) 12
13
14
–UN–02AUG01
15
c. Check and adjust pressure setting for system relief 16
valve and power boost. See System Relief and
17
T143388
Power Boost Valve Test and Adjustment. (Group T143388
9025-25.)
13. Replace parts as necessary. 1—First Adjusting Plug

2—O-Ring
14. Install top pilot cap (26) and tighten cap screws (24). 3—Piston
4—Nut
5—Second Adjusting Plug
6—O-Ring
Top Pilot Cap-to-Housing Cap
7—Pilot Poppet Spring
8—Pilot Poppet
9—Nut
15. Install bottom pilot caps (8) and tighten cap screws 10—Cartridge
(9). 11—O-Ring
12—Pilot Poppet Seat
Control Valve—Specification 13—Backup Ring
Bottom Pilot Caps-to-Housing 14—O-Ring
Cap Screw—Torque ....................................................... 42 N•m (32 lb-ft) 15—Main Poppet Spring
16—Main Poppet
17—Main Poppet Seat
33
3360
56

010904
PN=238
Hydraulic System
27
26
34 35
28
29
38 36
25
30 39
40 37
24 51 41
45 44
31
42
23 H 32 46 47
G 43
F 48
E 50
D 33
49
H 52
20 C
22 53
64
56 54 63
65
21 G 57 55 66
19 59
9 58 67
8 60 68
B F
7 B
70 61
6 13 18
17 E
1 5 62 69 71
72
14 81
16 73
4 82
11 15 74
75
3 12 83 80
76
–UN–19NOV01
B 77
10 84
2 78
85 C 79
T143189
86
T143189
87 D
Control Valve—4-Spool 33
3360
Disassemble and Assemble Control Valve 4-Spool 57

010904
PN=239
Hydraulic System
97 118
116
98 113 114
112
99 117
111 115
100 107
102 110
89 101 108 119
120
96
95 100 121
94 103
92 104
91
105
93 106
128 127
90 126
125
122 127
126 124
125 123
124
123
136
135
134
133
132
131
130 129
137
138
–UN–19NOV01
139
88 T143191
T143191
33 4-Spool—Side Components
3360
58

010904
PN=240
Hydraulic System
1—Propel Flow Combiner 33—O-Ring 69—O-Ring 105—Plug

Valve 34—Right Travel Spool 70—O-Ring 106—O-Ring
2—Cap Screw (2 used) 35—Bucket Spool 71—Sleeve 107—Lift Check and Orifice
3—Cap 36—Boom I Spool 72—Backup Ring (Arm II Power Passage)
4—O-Ring 37—Arm II Spool 73—O-Ring 108—Poppet
5—Cap Screw 38—Plug 74—O-Ring 109—Spring
6—Spring Seat 39—Backup Ring 75—Backup Ring 110—O-Ring
7—Spring 40—O-Ring 76—Spool 111—O-Ring (3 used)
8—Spring Seat 41—Sleeve 77—Poppet 112—O-Ring
9—Spool 42—Spring 78—Washer 113—Housing
10—Cap Screw (8 used) 43—Poppet 79—Spring 114—O-Ring
11—O-Ring 44—Special Cap Screw (4 80—Arm Regenerative Valve 115—Screw
12—Plug used) 81—Spring 116—O-Ring
13—Bottom Pilot Cap (4 used) 45—Spring Seat (3 used) 82—Spacer 117—Nut
14—Arm Regenerative Valve 46—Plug 83—O-Ring 118—Nut
Check Valve 47—Spring Seat (4 used) 84—Backup Ring 119—Cap Screw (4 used)
15—Plug 48—Backup Ring 85—Spool 120—O-Ring
16—O-Ring 49—O-Ring 86—Boom Up Circuit Relief 121—Plug
17—Spring 50—Spring Seat and Anti-Cavitation Valve 122—Lift Check (Boom I
18—Poppet 51—Spool 87—Bucket Load Circuit Relief Power Passage)
19—O-Ring (4 used) 52—Spring and Anti-Cavitation Valve 123—Poppet
20—Housing 53—Spring 88—Housing 124—Spring
21—O-Ring 54—Spring Seat 89—Bucket Flow Rate Valve 125—O-Ring
22—Plug 55—Spring Seat 90—Poppet 126—Flange
23—O-Ring 56—Poppet (2 used) 91—Poppet 127—Cap Screw (4 used)
24—Bucket Dump Circuit 57—Spring (2 used) 92—Spring 128—Lift Check (Arm II Neutral
Relief and Anti-Cavitation 58—O-Ring (2 used) 93—Plug Passage)
Valve 59—Backup Ring (2 used) 94—Spring 129—By-Pass Shut-Off Valve
25—O-Ring (4 used) 60—Plug (2 used) 95—Sleeve 130—Spool
26—Top Pilot Cap 61—Boom Reduced Leakage 96—O-Ring 131—Spring
27—Plug Valve 97—Plug 132—O-Ring
28—O-Ring 62—O-Ring 98—O-Ring 133—Flange
29—Pressure Sensor (Arm 63—Cap Screw (4 used) 99—Spring Seat 134—Cap Screw (2 used)
Roll-In) 64—Plug 100—Spring 135—O-Ring
30—Cap Screw (6 used) 65—O-Ring 101—Spool 136—Plug
31—O-Ring 66—Piston 102—Housing 137—Cap Screw (4 used)
32—Boom Down Circuit Relief 67—Spring 103—Cap Screw (4 used) 138—Flange
and Anti-Cavitation Valve 68—Body 104—O-Ring 139—O-Ring
1. Remove cap screws (30) and top pilot cap (26). Spools must be installed into the
same bores from which they were
2. Remove cap screws (10) and caps (13) from removed for proper operation of
housing (20). machine.
3. Spool —4 Spool (34—37): a. Remove spool (34—37).
NOTE: When disassembling spool (35, and 36), heat NOTE: Hold the spool in a vise by the spool end,
plugs (38, 46, and 60) to 200—300 °C (392— using wooden blocks.
482 °F) to melt the thread lock and sealer.
b. Remove special cap screw (44) and spools. 33
IMPORTANT: The spool (34—37) are select fitted 3360
to bores in housing and are a c. Heat plugs (38, 46, and 60) with heat gun to 59
different design for each function. melt threadlock and sealer and remove plugs.

010904
PN=241
Hydraulic System
d. Inspect control valve spools for wear and c. Inspect valve spools for wear and damage.
damage.
d. Replace parts as necessary.
e. Replace parts as necessary.
e. Assemble parts (6—8) and tighten cap screw
f. For right travel spool (34) and arm II spool (37), (5).
install spool and tighten special cap screw (44).
Control Valve—Specification Cap Screw-to-Flow Combiner
Special Cap Screw-to-Control Valve Spool—Torque.................................................. 11 N•m (7 lb-ft)
Valve Spool—Torque................................................ 15 N•m (11 lb-ft)
f. Install spool (9), cap (3) and tighten cap screws

g. For bucket and boom I spool (35 and 36): (2).
Apply threadlock and sealer (high strength) on Control Valve—Specification

plugs (38, 46, and 60). Cap-to-Housing Cap Screw—
Torque......................................................................... 10 N•m (7 lb-ft)
h. Install plugs (38, 46, and 60) onto spool (35 and
36) and tighten.
5. Arm Regenerative Valve Check Valve (14):
Plugs-to-Control Valve Spool—
Torque....................................................................... 15 N•m (11 lb-ft) a. Replace parts as necessary.
b. Install parts (16—18) and tighten plug (15).
i. Install special cap screw (44) into spool and Control Valve—Specification
Arm Regenerative
tighten.
Valve-to-Housing Plug—Torque ............................... 76 N•m (56 lb-ft)
Special Cap Screw-to-Control
Valve Spool—Torque................................................ 15 N•m (11 lb-ft)
6. Arm Regenerative Valve (80):
NOTE: Do not disassemble spool (85) unless

NOTE: Apply hydraulic oil to spools before installation. necessary.
j. Install spool (34—37) into housing (20) while a. Inspect valve spool for wear and damage.
rotating them slowly.
IMPORTANT: After installing spool (34—37) into
housing (20), push them by hand to 7. Boom Reduced Leakage Valve (61):
confirm smoothness.
33
3360 a. Replace parts as necessary.
60 4. Propel Function Flow Combiner Valve (1):
b. Install spool (76), with hole side towards poppet
a. Remove cap screws (2) and spool (9). (77).
b. Remove parts (5—8).

010904
PN=242
Hydraulic System
Apply petroleum jelly to washer (78) and spring NOTE: Do not remove nuts (117 and 118) and screw
(79) to hold them in place. (115) from housing (113) unless necessary.
c. Loosely install plug (64). b. Replace parts as necessary.
d. Install and tighten cap screws (63). c. Tighten screw (115).
Control Valve—Specification d. Tighten 13 mm nut (117) and 4 mm nut (118).

Boom Reduced Leakage Valve
Body-to-Housing Cap Screw— Control Valve—Specification
Torque....................................................................... 62 N•m (46 lb-ft) Lift Check and Orifice (Arm II
Power Passage) 4 mm Nut—
Torque........................................................................... 7 N•m (5 lb-ft)
e. Tighten plug (64). Control Valve—Specification

Lift Check and Orifice (Arm II
Control Valve—Specification Power Passage) 13 mm Nut—
Torque....................................................................... 13 N•m (10 lb-ft)
Boom Reduced Leakage
Valve-to-Body Plug—Torque .................................. 108 N•m (80 lb-ft)
e. Install housing (113) and tighten cap screws

8. Bucket Flow Rate Valve (89): (119).
a. Remove cap screws (103) and housing (102). Control Valve—Specification

Lift Check and Orifice (Arm II
Power Passage)
b. Replace parts as necessary. Housing-to-Housing Cap
c. Install housing (102) and tighten cap screws
(103).
Control Valve—Specification 10. By-Pass Shut-Off Valve (129):

Bucket Flow Rate Valve
Housing-to-Housing Cap
Screw—Torque ......................................................... 61 N•m (46 lb-ft) a. Remove cap screws (134) and flange (133).
d. Tighten plug (97). c. Install flange (133) and tighten cap screws
(134).
Flow Rate Valve Housing Control Valve—Specification
Plug—Torque ............................................................ 98 N•m (72 lb-ft) By-Pass Shut-Off
Valve-to-Housing Cap Screw—
Torque....................................................................... 61 N•m (46 lb-ft)
33
9. Lift Check and Orifice (Arm II Power Passage) 3360
(107): 61
a. Remove cap screws (119) and housing (113).

010904
PN=243
Hydraulic System
12. Install top pilot cap (26) and tighten cap screws 13. Install bottom pilot caps (13) and tighten cap
(30). screws (10).
Control Valve—Specification Control Valve—Specification

Top Pilot Cap-to-Housing Cap Bottom Pilot Cap-to-Housing
Screw—Torque ......................................................... 42 N•m (32 lb-ft) Cap Screw—Torque ................................................ 42 N•m (32 lb-ft)
33
3360
62

010904
PN=244
Hydraulic System
23
10 9 25
8 24
7
13 6
21
18 17 19
22
20
16
15
14 3
4 26
4
4
10 4
9 3
8
7
11 12
10
9
8
7
5 12
3
–UN–02AUG01
4
1
T143217
T143217 3 2
Disassemble and Assemble 5-Spool and 4-Spool 33

3360
1— Housing—5-Spool 9—Flange (3 used) 14—Poppet 22—Plug 63
2—Cap Screw (6 used) 10—Cap Screw (6 used) 15—Spring 23—System Relief Valve
3—Plug (6 used) 11—System Relief Valve 16—O-Ring Isolation Check Valve—
4—O-Ring (6 used) Isolation Check Valve— 17—Flange 4-Spool
5—Propel Flow Combiner 5-Spool 18—Cap Screw (2 used) 24—O-Ring (15 used)
Valve Check Valve 12—Poppet 19—Poppet 25—O-Ring (16 used)
6—Poppet (2 used) 13—Right Propel and Bucket 20—Spring 26—Housing—4-Spool
7—Spring (3 used) Combined Function Check 21—O-Ring
8—O-Ring (3 used) Valve and Orifice

010904
PN=245
Hydraulic System
Disassemble and Assemble Control Valve 5-Spool 3. Propel Flow Combiner Valve Check Valve (5)
and 4-Spool Sections and System Relief Valve Isolation Check Valve
(11):
1. Right Propel And Bucket Combined Function
Check Valve And Orifice (13): a. Remove cap screws (10) and flange (9).
a. Remove cap screws (18) and flange (17). b. Replace parts as necessary.
b. Remove parts (19—22). c. Install flange (9) and tighten cap screws (10).
c. Replace parts as necessary. Control Valve—Specification

Propel Flow Combiner Valve
Check Valve Cap
d. Install and tighten plug (22). Screw-to-5-Spool Housing—
Torque....................................................................... 61 N•m (46 lb-ft)
Control Valve—Specification System Relief Valve Isolation
Right Propel and Bucket Check Valve Cap
Combined Function Check Screw-to-5-Spool Housing—
Valve and Orifice-to-4-Spool Torque....................................................................... 61 N•m (46 lb-ft)
Housing Plug—Torque ............................................. 76 N•m (56 lb-ft)
e. Install flange (17) and tighten cap screws (18). CAUTION: Heavy component; use a hoist.
Control Valve—Specification Control Valve—Specification

Right Propel and Bucket 5-Spool Housing—Weight ........................ 75 kg (165 lb) approximate
Combined Function Check
Valve and Orifice Control Valve—Specification
Flange-to-4-Spool Housing Cap 4-Spool Housing—Weight ........................ 74 kg (163 lb) approximate
d. Remove cap screws (2). Separate 5-spool
housing (1) from 4-spool housing (26).
2. System Relief Valve Isolation Check Valve— e. Remove plugs (3) and O-rings (4)
4-Spool (23):
a. Remove cap screws (10) and flange (9).
5. Combine 5-spool housing (1) and 4-spool housing
b. Replace parts as necessary. (26) and tighten cap screws (2).
c. Install flange (9) and tighten cap screws (10). Control Valve—Specification
5-Spool-to-4-Spool Cap
Control Valve—Specification Screw—Torque .................................. 167—177 N•m (123—130 lb-ft)
System Relief Valve and
Isolation Check
Valve-to-4-Spool Housing Cap
33
3360
64

010904
PN=246
Hydraulic System
–UN–04MAY93
T7996AE
A—Nut F—O-Ring K—Piston and Main Poppet O—Pilot Poppet Spring
B—Plug G—Backup Ring Spring P—O-Ring
C—O-Ring (2 used) H—Anti-Cavitation Sleeve L—Cartridge Q—Adjusting Screw
D—Backup Ring I—Piston M—Pilot Poppet
E—O-Ring J—Main Poppet N—Anti-Cavitation Sleeve
Spring
6. Circuit Relief and Anti-Cavitation Valve 5-Spool b. Check and adjust pressure setting. See Circuit
and 4-Spool Relief Valve Test and Adjustment. (Group
9025-25.)
NOTE: Disassemble valves for cleaning and
inspection only. Valves are serviced as
assemblies.
a. Tighten valve into housing.
Circuit Relief and Anti-Cavitation Valve—Specification

Circuit Relief and 33
Anti-Cavitation Valve-to-Control 3360
Valve Housing—Torque............................................ 83 N•m (61 lb-ft) 65
TX,33,UU4002 –19–19NOV01–18/18

010904
PN=247
Hydraulic System
Hydraulic Oil Tank Repair
Remove and Install Hydraulic Oil Tank


in this group.)

Capacities, 230CLC Drain and Refill Capacities, or
Manual.)
4. Disconnect electrical connector on bottom of tank.
33
3360
66

010904
PN=248
Hydraulic System
5. Remove cap screws (1), lock washers (2) and washers

(3).
Hydraulic Oil Tank—Specification

Hydraulic Oil Tank—Weight .......................... 150 kg (330 lb) approximate
6. Remove hydraulic oil tank using a hoist and lifting

straps. 4
8. Install hydraulic oil tank (4).
–UN–20JUL01
3
2
T143359
Oil Tank-to-Frame Cap Screw— 1
Torque ......................................................................... 205 N•m (152 lb-ft)
10. Connect lines. See Main Hydraulic System 1—Cap Screw (4 used)
Component Location. (Group 9025-15.) 2—Lock Washer (4 used)
3—Washer (4 used)
4—Hydraulic Oil Tank
T-Bolt Type Clamp—Torque ......................................... 4.4 N•m (40 lb-in.)
Worm Gear Type Clamp—Torque ............... 5.9—6.9 N•m (52—61 lb-in.)
11. Connect electrical connector on bottom of tank.
12. Fill hydraulic oil tank. See 200CLC Drain and Refill
Capacities, 230CLC Drain and Refill Capacities ,
270CLC Drain and Refill Capacities, and Hydraulic
Oil. (Operator’s Manual.)
IMPORTANT: Hydraulic pump will be damaged if not

filled with oil before starting. Procedure
must be performed to fill pump housing
whenever oil has been drained from the
pump or hydraulic oil tank.
13. Do Hydraulic Pump and Drive Gearbox Start-Up

33
3360
67

010904
PN=249
Hydraulic System
6 7
5
8
18
4 9
10
11 19
12
13 20
14
21
15
2 16
17
3 22
1 23
38
24
37 36
26 26 25
35
34
33
3360
68
–UN–20JUL01
33
32
27
T143368
31 30
T143368 29 28

010904
PN=250
Hydraulic System
1—Suction Strainer 11—Cap Screw (6 used) 21—O-Ring 30—Plug

2—Nut (3 used) 12—Cover 22—Filter Element 31—Cap Screw (4 used)
3—Rod 13—O-Ring 23—Hydraulic Oil Tank 32—Lock Washer (4 used)
4—Cap Screw (4 used) 14—Bracket 24—Level Gauge 33—Washer (4 used)
5—Cover 15—Washer 25—Cap Screw (2 used) 34—Plug
6—Cap 16—Lock Washer 26—Seal (4 used) 35—Elbow
7—Nut 17—Cap Screw 27—Gasket 36—Adapter (3 used)
8—Element 18—Cap Screw (6 used) 28—Sensor 37—Elbow
9—Body 19—Cover 29—Plug 38—Tee
10—O-Ring 20—Spring
Disassemble and Assemble Hydraulic Oil Tank Tighten nuts (2).
1. Tighten cap screws (11 and 18). Hydraulic Oil Tank—Specification

Suction Strainer Rod Nuts—
Torque.................................................................... 17 N•m (153 lb-in.)
Covers-to-Hydraulic Oil Tank
Cap Screws—Torque ............................................... 49 N•m (36 lb-ft)
2. Adjust the length of rod (3) on suction strainer (1).

Suction Strainer Rod—Length ................................ 683 mm (26.9 in.)
OUOE027,0000022 –19–19NOV01–4/4
Restriction Valve Repair
Remove and Install Restriction Valve


in this group.)
2. Pull vacuum in hydraulic oil tank using vacuum pump

or drain hydraulic oil tank. See 200CLC Drain and
Refill Capacities, 230CLC Drain and Refill Capacities,
or 270CLC Drain and Refill Capacities. (See Operator’s 33
3360
Manual.)
69

010904
PN=251
Hydraulic System
2
5
–UN–02AUG01
T143376
T143376
33 200CLC Machine Shown

3360
70 1—Coupling 3—Restriction Valve 4—Hydraulic Oil Tank 5—Oil Cooler
2—Snap Ring
3. Repair or replace restriction valve (3) and snap ring

(2).

010904
PN=252
Hydraulic System
4. Tighten nuts on coupling (1). IMPORTANT: Hydraulic pump will be damaged if

not filled with oil before starting.
Restriction Valve—Specification Procedure must be performed to fill
Oil Cooler-to-Hydraulic Oil Tank pump housing whenever oil has
Return Line Coupling Nut—
Torque......................................................... 10.3—12.4 N•m (91—110 been drained from the pump or
lb-in.) hydraulic oil tank.
5. Fill and check Hydraulic Oil level. See 200CLC 6. Do Hydraulic Pump and Drive Gearbox Start-Up
Drain and Refill Capacities, 230CLC Drain and Procedure. (See procedure in this group.)
Refill Capacities, or 270CLC Drain and Refill
Capacities. (See Operator’s Manual.)
OUOE027,0000023 –19–24OCT01–3/3
Oil Cooler Bypass Valve Repair
Remove and Install Oil Cooler Bypass Valve


in this group.)

or 270CLC Drain and Refill Capacities. (Operator’s
Manual.)
33
3360
71

010904
PN=253
Hydraulic System
5
1
4
3
2
–UN–02AUG01
T143377
T143377
33 200CLC Machine Shown

3360
72 1—Control Valve 3—O-Ring 5—Coupling 6—Hydraulic Oil Tank
2—Oil Cooler Bypass Valve 4—Cap Screw (2 used)
3. Repair or replace oil cooler bypass valve (2).

010904
PN=254
Hydraulic System
4. Tighten nuts on coupling (5). Refill Capacities, or 270CLC Drain and Refill
Capacities. (Operator’s Manual.)
Oil Cooler Bypass Valve—Specification
Control Valve-to-Hydraulic Oil IMPORTANT: Hydraulic pump will be damaged if
Tank Return Line Coupling
Nut—Torque ............................................... 10.3—12.4 N•m (91—110 not filled with oil before starting.
lb-in.) Procedure must be performed to fill
pump housing whenever oil has
5. Tighten cap screw (4). been drained from the pump or
hydraulic oil tank.
Oil Cooler Bypass Valve—Specification
Split Coupling-to-Control Valve 7. Do Hydraulic Pump and Drive Gearbox Start-Up
6. Fill and check Hydraulic Oil level. See 200CLC

Drain and Refill Capacities, 230CLC Drain and
OUOE027,0000024 –19–19NOV01–3/3
33
3360
73

010904
PN=255
Hydraulic System
Oil Cooler Repair
Remove and Install Oil Cooler
1. Remove radiator. See Radiator Repair. (Group 0510.)


in this group.)
–UN–02AUG01
T142696
1—Cap Screw (8 used).
5. Remove cap screws (1 and 2). 2—Cap Screw (4 used).
Oil Cooler—Specification
Oil Cooler—Weight ............................................ 32 kg (70 lb) approximate
6. Remove oil cooler.
8. Install radiator. See Radiator Repair. (Group 0510.)
9. Install oil cooler.

12. Fill and check Hydraulic Oil level. See 200CLC Drain
33 and Refill Capacities, 230CLC Drain and Refill
3360 Capacities, or 270CLC Drain and Refill Capacities.
74 (Operator’s Manual.)
OU90U48,0000028 –19–19NOV01–1/1

010904
PN=256
Hydraulic System
Remove and Install Boom Cylinder
NOTE: Procedure is the same for both boom cylinders.
1. Park machine on firm, level surface.
–UN–10JAN97
2. Retract arm and bucket cylinders and lower bucket to
ground.
T106031
3. Perform Hydraulic Oil Tank Pressure Release

Procedure. (Group 3360.)
4. Loosen boom cylinder hydraulic lines at frame end of

boom to release any residual pressure.
6. Disconnect lubrication line at rod end of cylinder.
FR91424,0000002 –19–04NOV03–1/6
Specification
Boom Cylinder—200CLC—
Weight......................................................................... 171 kg approximate
377 lb approximate
480 lb approximate
–UN–30DEC96
540 lb approximate
7. Attach hoist to boom cylinder (F) using lifting strap.

T105828
F—Boom Cylinder 33
3360
75
Continued on next page FR91424,0000002 –19–04NOV03–2/6

010904
PN=257
Hydraulic System
8. Remove parts (1—3, and 5).
9. Push pin (4) into boom.
Lower boom cylinder (6) on floor stand.
1—Nut (2 used)
2—Retainer
3—Cap Screw
4—Boom Cylinder-to-Boom Pin
5—Shim (2 used)
–UN–24JUL01
6—Boom Cylinder
T142979
33
3360
76

010904
PN=258
Hydraulic System
10. Disconnect hydraulic lines (7) from head end of boom 8 8

cylinder (6). 6
9
11. Mark location of shims (8) to aid in assembly.
12. Remove parts (8—11) and remove boom cylinder (6).
–UN–02AUG01
7 7 10 11
14. Install shims equally on each side of cylinder head
T143048
end to get the minimum amount of clearance in joint. 11
15. Align pin bores so Shims are not damaged as pin

6—Boom Cylinder
(10) is installed. 7—Rod End-to-Boom Section Bottom Port Line
—Head End-to-Boom Section Top Port Line
16. Connect boom cylinder head end to frame. 8—Shim (as required)
10—Boom Cylinder-to-Frame Pin (2 used)
11—Nut (4 used)
screws (9) to be free to turn in hole.
Specification
Boom Cylinder-to-Frame Pin
Retainer Nut—200CLC—Torque........... 271 N•m (tighten nut against nut)
200 lb-ft (tighten nut against nut)
Specification
Boom Cylinder-to-Frame Pin
Retainer Nut—230CLC,
270CLC—Torque................................... 549 N•m (tighten nut against nut)

Tighten boom cylinder hoses.
Specification
Boom Cylinder Hose—200CLC—
Torque .......................................................................................... 175 N•m
130 lb-ft
Specification
Boom Cylinder Hose—230CLC,
270CLC—Torque.......................................................................... 206 N•m
152 lb-ft
33
3360
77

010904
PN=259
Hydraulic System
IMPORTANT: Trapped air suddenly compressed in a

cylinder is heated and ignites the oil
used for assembly causing cap seal and
ring damage. Start with cylinder rod
retraced and the rod end filled with
clean oil. Connect the cylinder head end
and lines. Operate function to slowly
extend rod. Procedure will eliminate
most of the air and reduce the
possibility of damage.
19. Start engine.
20. Slowly extend boom cylinder (6) to align pin bores so

shims (5) are not damaged as pin (4) is installed.
21. Install Shims to get the minimum amount of clearance

between boom and boom cylinder rod end.
22. Connect boom cylinder rod end to boom.

Specification
Boom Cylinder-to-Boom Pin
Specification
Boom Cylinder-to-Boom Pin
24. Connect lubrication line.
Specification
Boom Cylinder Pivot Lubrication
Line—Torque ............................................................................... 29.5 N•m
21.5 lb-ft
25. Lubricate all pivot joints. See Track Adjuster, Working

Tool Pivot, Swing Bearing, And Swing Bearing Gear
Grease. (Operator’s Manual.)
33
3360 26. Bleed air from cylinder. See Hydraulic Cylinder Bleed
78 Procedure. (Group 3360.)

010904
PN=260
Hydraulic System
27. Check hydraulic oil level . See Check Hydraulic Oil

Level. (Operator’s Manual.)
FR91424,0000002 –19–04NOV03–6/6
33
3360
79

010904
PN=261
Hydraulic System
Boom Cylinder Disassemble and Assemble—200CLC, 270CLC
33
3360
80
–UN–09MAY03
T190994
Boom Cylinder—200CLC, 270CLC—Right Cylinder Shown


010904
PN=262
Hydraulic System
1—Cylinder Barrel and 11—Back-Up Ring 21—Nut 32—O-Ring

Bushings 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (4 used)
2—Rod and Bushings 13—Cushion 23—Steel Ball 34—Band
3—Rod Guide 14—Cushion Seal 25—Seal (2 used) 35—Clamp
4—Wear Ring 15—Piston 26—Retainer Ring 36—Cap Screw (2 used)
5—Snap Ring 16—Cap Seal and O-Ring 27—Seal (2 used) 37—Lock Washer (2 used)
6—Buffer Ring Seal 17—Back-Up Ring (2 used) 28—Hydraulic Line 38—Half Clamp (2 used)
7—U-Cup Seal 18—Buffer Seal (2 used) 29—Hydraulic Line 39—Cap Screw
8—Back-Up Ring 19—Wear Ring (2 used) 30—O-Ring 40—Lock Washer
9—Wiper Seal 20—Shim 31—Cap Screw (4 used) 41—Lubrication Fitting
10—O-Ring
NOTE: Disassemble and assemble procedures are the 1. Fasten head end of cylinder to JT30043 cylinder
same for both right and left boom cylinders. service stand.
Specification
Boom Cylinder—Weight ...................................... 171 kg approximate
377 lb approximate
FR91424,0000003 –19–05NOV03–2/20
2. Remove line (B).
3. Pull rod out so piston is against rod guide.
4. Connect rod to a hoist using a lifting strap.
–UN–27OCT88
5. Remove cap screws (A).
6. Remove rod, rod guide and piston from barrel.
T6557HI
A—Cap Screw
B—Line
33
3360
81

010904
PN=263
Hydraulic System
7. Install rod eye in sliding housing (B) and install housing

in the JT30043 cylinder service stand.
B—Sliding Housing
–UN–27OCT88
T6557HK
FR91424,0000003 –19–05NOV03–4/20
8. Remove the staked material from set screw (A) hole

using a small air grinder or a drill and bit.
9. Remove set screw (A) and steel ball (B).
A—Set Screw
–UN–27OCT88
B—Steel Ball
T6585XI
33
3360
82

010904
PN=264
Hydraulic System
IMPORTANT: To avoid damaging the tapped hole for

set screw, the cap screw in the
JT30043-30 Hex Piston Nut Wrench
must be tightened against a side of the
nut without the tapped hole.
To avoid gouging side of nut, install a

piece of steel flat stock between nut
and cap screw.
10. Install JT30043-30 Hex Piston Nut Wrench so cap

screw is tightened against side of nut (B) without
tapped hole.
11. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece

of steel flat stock between nut and cap screw. Tighten
cap screw.
12. Loosen nut (B).
–UN–22MAY92
Specification
Boom Cylinder Piston-to-Rod
Nut—Torque ............................................................................... 4780 N•m
3,525 lb-ft
T7768AG
B—Nut
33
3360
83

010904
PN=265
Hydraulic System
13. Remove parts (A—D and G).
NOTE: Note direction of flat face (E) on cushion and

notches (F) in cushion seal and cushion for
assembly.
–UN–27OCT88
14. Remove parts from rod guide and piston.
NOTE: Inspect the piston, inside the rod guide and barrel
for wear, scratches and nicks that may cut or
T6585XK
damage a seal or wear ring.
A—Nut
B—Shim
C—Piston
D—Cushion
E—Flat Face
F—Notch
G—Cushion Seal
–UN–16JUL94
T8286BL
33
3360
84

010904
PN=266
Hydraulic System
15. Remove and inspect dust seals (A) and bushings (B)
for wear or damage. See Boom, Arm, and Bucket
Pins, Bushings and Bosses Inspection. Repair or
replace parts as necessary. (Group 3340.)
Boom Cylinder—200CLC—Specification
–UN–27OCT88
Boom Cylinder Head End
Bushing—ID.................................................................... 80.0 mm nominal
3.15 in. nominal
ID ............................................................................... 81.5 mm limit of use
3.21 in. limit of use
T6557HR
Boom Cylinder Rod End
3.54 in. nominal
ID ............................................................................... 91.5 mm limit of use
Bushing—ID.................................................................. 100.0 mm nominal
3.94 in. nominal
–UN–27OCT88
ID ............................................................................. 101.5 mm limit of use
Bushing—ID.................................................................. 100.0 mm nominal
3.94 in. nominal
T6585XG
ID ............................................................................. 101.5 mm limit of use
16. Check for rod curvature on V-blocks using dial

A—Dust Seal
indicator. B—Bushing
Specification
Boom Rod—Curvature .................................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft
17. Inspect rod surface for scratches or wear.
Boom Cylinder—Specification
Boom Rod Allowable Scratch—
Depth ........................................................ 0.1 mm (enough to detect by a
fingernail)
0.004 in. (enough to detect by a
fingernail)
Boom Rod—200CLC—OD ......................................... 84.973—85.00 mm
3.349— 3.35 in.
Boom Rod—270CLC—OD ......................................... 94.910—95.00 mm
3.736— 3.74 in.
18. Repair or replace parts as necessary. 33

3360
85

010904
PN=267
Hydraulic System
33
3360
86
–UN–09MAY03
T190994
Boom Cylinder—200CLC, 270CLC—Right Cylinder Shown
19.

010904
PN=268
Hydraulic System
–UN–16JAN97
T106211
Boom Cylinder—200CLC, 270CLC

Bushings 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (4 used)
3—Rod Guide 14—Cushion Seal 25—Seal (2 used) 35—Clamp
4—Wear Ring 15—Piston 26—Retainer Ring 36—Cap Screw (2 used)
6—Buffer Ring Seal 17—Back-Up Ring (2 used) 28—Hydraulic Line 38—Half Clamp (2 used)
7—U-Cup Seal 18—Buffer Seal (2 used) 29—Hydraulic Line 39—Cap Screw
8—Back-Up Ring 19—Wear Ring (2 used) 30—O-Ring 40—Lock Washer
9—Wiper Seal 20—Shim 31—Cap Screw (4 used) 41—Lubrication Fitting
10—O-Ring
Install boom cylinder barrel and rod bushings to a NOTE: Use a cylinder repair kit when assembling a
depth equal to the thickness of seals (25 and 27). cylinder.
NOTE: The left and right boom cylinders are the same 20. Install seals (25 and 27) tight against bushing with
except for the head (28) and rod (29) end seal lip outward.
lines, and clamps (34 and 35).
33
3360
87

010904
PN=269
Hydraulic System
21. Push wear ring (C) to bottom of bore using a driver

disk and a press.
22. Install the snap ring (B).
23. Install back-up ring (A) and O-ring (D).
A—Back-Up Ring
B—Snap Ring
C—Wear Ring
D—O-Ring
–UN–27OCT88
T6585XN
33
3360
88

010904
PN=270
Hydraulic System
24. Install buffer ring seal (I) with notched side towards
wear ring (B).
25. Install black buffer ring (D) with notched side (C)
towards the wear ring.
26. Install green buffer ring (E).
27. Install U-cup seal (F) with lip towards wear ring (B)
using the bending method (K).
28. Install back-up ring (G).
29. Install wiper seal (H) with lip towards outside of

cylinder.
30. Install rod guide (J) on the rod.

A—Snap Ring
B—Wear Ring
C—Notched Side
–UN–01APR93
D—Black Buffer Ring
E—Green Buffer Ring
F—U-Cup Seal
G—Back-Up Ring
H—Wiper Seal
T7963AK
I—Buffer Ring Seal
J—Rod Guide
K—Bending Method Seal Installation
33
3360
89
–UN–22OCT91
T7623AF

010904
PN=271
Hydraulic System
31. Install O-ring (C) into the middle groove of piston.
32. Install the buffer seals (D). The buffer seal in groove
above helps support the thin section of installer. The
buffer seal below keeps the cap seal from going into
that groove if pushed too far.
33. Apply clean oil to installer.
34. Push the cap seal (B) down the installer and into the
middle groove over the O-ring (C) using the correct
size pusher (A).
A—JDG901-3 Pusher
—JDG917 Installer—200CLC
—JDG842-1 Installer—270CLC
B—Cap Seal
C—O-Ring
D—Wear Ring
–UN–18MAR93
T7964AQ
FR91424,0000003 –19–05NOV03–13/20
35. Check the cap seal, seal must fit tight against O-ring
and not turn. If seal can be turned, it has been
stretched too much and can be damaged during
assembly into cylinder barrel.
36. For a cap seal that has been stretched too much,
shrink it to its original size using a ring compressor or
a plastic tie band and hose clamp.
When using a ring compressor, put a piece of shim

stock between cap seal and compressor at the joint
so it does not damage seal.
When using a plastic tie band and hose clamp, grind

33 a taper on one end of tie band. Install tie band with
3360 the taper against cap seal. Before tightening the hose
90 clamp, check to be sure tie band is under hose clamp
all around piston.
–UN–27OCT88
T6396AC

010904
PN=272
Hydraulic System
37. Install a back-up ring (C) on each side of cap seal.
38. Install the buffer seals (B) and wear rings (A).
Turn the seals and rings so the slits are 180° from
each other
–UN–27OCT88
A—Wear Ring (2 used)
B—Buffer Seal (2 used)
C—Back-Up Ring (2 used)
T6557HV
FR91424,0000003 –19–05NOV03–15/20
39. Install cushion seal (G) so notches (F) are towards

the piston and threaded section of rod.
40. Install cushion (D) so wide end of flat face (E) is

towards the rod guide and narrow end is towards the
piston.
–UN–16JUL94
D—Cushion
E—Flat Face
F—Notch
T8286BL
G—Cushion Seal
Boom Cylinder Rod
FR91424,0000003 –19–05NOV03–16/20
41. Install piston (C) so flat side is against the cushion

(D)
42. Install shim (B).
43. Install nut (A).

–UN–27OCT88
A—Nut 33
B—Shim 3360
C—Piston 91
T6585XK
D—Cushion

010904
PN=273
Hydraulic System


and cap screw.
44. Tighten nut using the JT30043-30 Hex Piston Nut

Wrench. Install wrench so cap screw is tighten
against a side of nut (B) without the tapped hole.
Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece

cap screw.
Specification
Boom Cylinder Piston-to-Rod
Nut—Torque ............................................................................... 4780 N•m
–UN–22MAY92
3525 lb-ft
B—Nut
T7768AH
FR91424,0000003 –19–05NOV03–18/20
45. Install steel ball (B).
46. Tighten set screw (A).
Specification
Boom Cylinder Nut-to-Rod Set
Screw—Torque .............................................................................. 57 N•m
–UN–27OCT88
42 lb-ft
33
3360
47. Stake set screw in two places 90° from previous
92
stake marks.
T6585XI
A—Set Screw
B—Steel Ball

010904
PN=274
Hydraulic System
48. Apply clean oil to piston and seals. Attach a hoist to

rod using a lifting strap. Carefully install piston, rod
and rod guide into barrel.
49. Tighten cap screws (A).
–UN–27OCT88
Specification
Boom Cylinder Rod
Guide-to-Barrel Cap Screw—
Torque ......................................................................................... 267 N•m
197 lb-ft
T6557HI
50. Install the lines (B).
A—Cap Screw
B—Lines
FR91424,0000003 –19–05NOV03–20/20
33
3360
93

010904
PN=275
Hydraulic System
Boom Cylinder Disassemble and Assemble—230CLC
5 11
3
9
10
13
14
7
15
23
20
21
18
22
21
4 20
29
28
44 34
30
42 32
25
37
31 36
33 33
3360
94 30 1 40
–UN–26NOV03
26
28
29
T196495
T196495
Boom Cylinder—230CLC—Right Cylinder Shown

010904
PN=276
Hydraulic System
1—Bushings (2 used) 11—Snap Ring 23—Packing 33—Clamp

2—Rod and Bushings 13—Bushing 25—Cap Screw (6 used) 34—Cap Screw (2 used)
3—Seal 14—Snap Ring 26—Hydraulic Line 36—Clamp
4—Rod Guide 15—Cushion Ring 28—Cap Screw (4 used) 37—Cap Screw
5—Cap Screw (12 used) 18—Piston 29—Cap Screw (4 used) 40—Lubrication Fitting
7—O-Ring 20—Piston Ring (2 used) 30—O-Ring (2 used) 42—Washer (6 used)
9—Seal 21—Wear Ring (2 used) 31—Hydraulic Line 44—Hydraulic Cylinder Barrel
10—Ring 22—Seal Ring 32—Clamp
NOTE: Disassemble and assemble procedures are the 1. Fasten head end of cylinder to JT30043 cylinder
same for both right and left boom cylinders. service stand.
Specification
Boom Cylinder—Weight ...................................... 217 kg approximate
480 lb approximate
FR91424,0000006 –19–11NOV03–2/8
2. Remove line (B).
–UN–27OCT88
T6557HI
A—Cap Screw
B—Line
33
3360
95

010904
PN=277
Hydraulic System

8. Remove cap screws (25) and washers (42) from piston

(18).
–UN–27OCT88
9. Remove piston (18), cushion ring (15), rod guide (4)
from rod (2).
10. Remove piston rings (20), wear rings (21), seal ring
T6557HK
(22), and O-ring (23) from piston (18).
for wear, scratches and nicks that may cut or B—Sliding Housing
11. Remove snap ring (11), seal (3), seal (9), ring (10),
snap ring (14), and bushing (13) from rod guide (4).
12. Remove and inspect rod (2) and hydraulic cylinder

barrel bushings (1) for wear or damage. See Boom,
Arm, and Bucket Pins, Bushings and Bosses
Inspection. Repair or replace parts as necessary.
(Group 3340.)
3.54 in. nominal
ID ............................................................................... 91.5 mm limit of use
3.54 in. nominal
ID ............................................................................... 91.5 mm limit of use
33
3360
96

010904
PN=278
Hydraulic System

indicator.
Specification
Boom Rod—Curvature .................................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft
–UN–27OCT88
Boom Cylinder—Specification
Boom Rod Allowable Scratch—
T6585XG
fingernail)
fingernail)
Boom Rod—230CLC—OD ........................................... 89.910—90.0 mm
3.536— 3.540 in.
33
3360
97

010904
PN=279
Hydraulic System
5 11
3
9
10
13
14
7
15
23
20
21
18
22
21
4 20
29
28
44 34
30
42 32
25
37
31 36
33
30 1 40
33
3360
98
–UN–26NOV03
26
28
29
T196495
T196495
Boom Cylinder—230CLC—Right Cylinder Shown
16.

010904
PN=280
Hydraulic System
–UN–10DEC03
T196497
Boom Cylinder—230CLC
1—Bushings (2 used) 11—Snap Ring 23—Packing 33—Clamp

2—Rod and Bushings 13—Bushing 25—Cap Screw (6 used) 34—Cap Screw (2 used)
3—Seal 14—Snap Ring 26—Hydraulic Line 36—Clamp
4—Rod Guide 15—Cushion Ring 28—Cap Screw (4 used) 37—Cap Screw
5—Cap Screw (12 used) 18—Piston 29—Cap Screw (4 used) 40—Lubrication Fitting
7—O-Ring 20—Piston Ring (2 used) 30—O-Ring (2 used) 42—Washer (6 used)
9—Seal 21—Wear Ring (2 used) 31—Hydraulic Line 44—Hydraulic Cylinder Barrel
Install boom cylinder head end and rod end bushings. Ensure that ring and seals are
installed so that slotted side is
NOTE: The left and right boom cylinders are the same facing toward cylinder head end
except for the hydraulic lines (26 and 31), and (pressure side).
clamps (32 and 33).
19. Install ring (10), seal (9), seal (3), and snap ring
NOTE: Use a cylinder repair kit when assembling a (11).
cylinder.
33
20. Install O-ring (7). 3360
17. Install bushing (13) to bottom of bore in rod guide 99
(4) using a driver disk and a press. 21. Install packing (23), seal ring (22), wear rings (21),
and piston rings (20) on piston (18).
18. Install the snap ring (14).
22. Install rod guide assembly on rod (2).
IMPORTANT: Ring (10), seal (9), and seal (3) must
be installed in the correct direction.

010904
PN=281
Hydraulic System
IMPORTANT: Cushion ring (15) must be installed 25. Apply clean oil to piston and seals. Attach a hoist
in the correct direction. Ensure that to rod using a lifting strap. Carefully install piston,
cushion ring is installed so that rod and rod guide into barrel.
slotted end is facing toward piston
(18). 26. Install and tighten cap screws (5).
23. Install cushion ring (15) on rod (2). Specification

Boom Cylinder Rod
Guide-to-Hydraulic Cylinder
24. Secure rod assembly on bench and install piston Barrel Cap Screw—Torque .................................................. 395 N•m
(18) assembly to rod (2). Install cap screws (25) 290 lb-ft
and washers (42).
27. Install hydraulic lines (26 and 31).
Specification
Piston-to-Rod Cap Screw—
Torque.................................................................................... 395 N•m
290 lb-ft
FR91424,0000006 –19–11NOV03–8/8
Arm Cylinder Remove and Install
FR91424,0000004 –19–11NOV03–1/6
2. Retract arm and bucket cylinders and lower bucket to

ground.

–UN–10JAN97
T106031
4. Loosen arm cylinder hydraulic lines at frame end of
boom to release any residual pressure.
33
3360
,100

010904
PN=282
Hydraulic System
6. Insert wood block (3 ) between arm cylinder (1) and

boom (2).
–UN–02AUG01
Specification
Arm Cylinder—200CLC—Weight ............................... 259 kg approximate
570 lb approximate
630 lb approximate
T143063
680 lb approximate
7. Attach arm cylinder to hoist using lifting straps. 1—Arm Cylinder

2—Boom
3—Wood Block
FR91424,0000004 –19–11NOV03–3/6
8. Remove parts (1 and 2).
NOTE: Note location of shims (3) to aid in assembly.
9. Push pin (4) out and remove shims.
10. Disconnect lubrication line.
1—Nut (2 used)
2—Cap Screw
3—Shim (as required)
–UN–02AUG01
4—Arm Cylinder-to-Arm Pin
T143064
33
3360
,101

010904
PN=283
Hydraulic System
NOTE: Note location of shims (3) to aid in assembly.
12. Push pin (4) out and remove shims.
–UN–02AUG01
13. Remove arm cylinder
14. Repair or replace parts as necessary. See Arm

Cylinder Disassemble and Assemble—200CLC,
T143065
270CLCor see Arm Cylinder Disassemble and
Assemble—230CLC. (Group 3360.)
1—Nut (2 used)
15. Install shims equally on each side of cylinder to get 2—Cap Screw
minimum amount of clearance in joint. There must be 3—Shim (as required)
some clearance in the joint. 4—Arm Cylinder-to-Boom Pin
16. Align pin bores so shims are not damaged as pin (4)
is installed.
Specification
Arm Cylinder Pivot Lubrication
Line—Torque ............................................................................... 29.5 N•m
21.5 lb-ft
18. Connect arm cylinder head end to boom.

Specification
Arm Cylinder-to-Boom Pin
Arm Cylinder-to-Boom Pin
33
3360
,102

010904
PN=284
Hydraulic System

20. Slowly extend arm cylinder to align pin bores so

shims are not damaged as pin is installed.
21. Connect arm cylinder rod end to arm.

Specification
Arm Cylinder-to-Arm Pin Retainer
Nut—200CLC—Torque ......................... 550 N•m (tighten nut against nut)
Arm Cylinder-to-Arm Pin Retainer
Nut—230CLC, 270CLC—Torque .......... 750 N•m (tighten nut against nut)
Specification
Arm Cylinder Pivot Lubrication
Line—Torque ............................................................................... 29.5 N•m
21.5 lb-ft
24. Connect lines.

Tool Pivot, Swing Bearing, And Swing Bearing Gear
26. Bleed air from cylinder. See Hydraulic Cylinder Bleed

27. Check hydraulic oil level. See Check Hydraulic Oil

33
3360
,103
FR91424,0000004 –19–11NOV03–6/6

010904
PN=285
Hydraulic System
Arm Cylinder Disassemble and Assemble—200CLC, 270CLC
33
3360
,104
–UN–09MAY03
T190996
Arm Cylinder

010904
PN=286
Hydraulic System

Bushing 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (8 used)
3—Rod Guide 14—Cushion Seal 24—Cushion 35—Band
4—Wear Ring 15—Piston 25—Cushion Seal 36—Cap Screw (2 used)
5—Snap Ring 16—Cap Seal and O-Ring 26—Retainer Ring 37—Lock Washer (2 used)
6—Buffer Ring Seal 17—Back-Up Ring (2 used) 27—Ring 38—Clamp
7—U-Cup Seal 18—Buffer Seal (2 used) 29—Seal 39—Cap Screw
8—Back-Up Ring 19—Wear Ring (2 used) 30—Shoulder Fitting 40—Lock Washer
9—Wiper Seal 20—Shim 31—Hydraulic Line 41—Lubrication Fitting
10—O-Ring
Arm Cylinder—270CLC—
CAUTION: Heavy components; use a hoist. Weight .................................................................. 307 kg approximate
680 kg approximate
Specification
Arm Cylinder—200CLC—
1. Fasten head end of cylinder to JT30043 cylinder
Weight .................................................................. 259 kg approximate
571 lb approximate service stand.
FR91424,0000005 –19–11NOV03–2/22
2. Remove line (B).
–UN–27OCT88
T6557HI
A—Cap Screw
B—Line
FR91424,0000005 –19–11NOV03–3/22
7. Install rod eye in sliding housing (B) and install housing 33

in the JT30043 cylinder service stand. 3360
,105
B—Sliding Housing
–UN–27OCT88
T6557HK

010904
PN=287
Hydraulic System

A—Set Screw
–UN–27OCT88
B—Steel Ball
T6585XI
FR91424,0000005 –19–11NOV03–5/22


and cap screw.

tapped hole.

cap screw.
12. Loosen nut (B).
–UN–22MAY92
Specification
Arm Cylinder Piston-to-Rod Nut—
200CLC, 270CLC—Torque ..................................................... 10 200 N•m
7,520 lb-ft
T7768AG
B—Nut
33
3360
,106

010904
PN=288
Hydraulic System
13. Remove parts (A—D and G).
NOTE: Note direction of flat face (E) on cushion and

notches (F) in cushion seal and cushion for
assembly.
–UN–27OCT88
A—Nut
B—Shim
C—Piston
D—Cushion
T6585XK
E—Flat Face
F—Notch
G—Cushion Seal
–UN–16JUL94
T8286BL
FR91424,0000005 –19–11NOV03–7/22
14. Remove ring (A).
Push cushion (C) against shoulder.
Remove retainer ring (B) and remove cushion.
–UN–10JUN92
NOTE: Note direction of flat face on cushion and notches
in cushion seal for assembly.
Remove cushion seal (D).
15. Remove parts from rod guide and piston. T7778AU

Arm Cylinder Rod End Cushion
NOTE: Inspect the piston, inside the rod guide and barrel A—Ring
for wear, scratches and nicks that may cut or B—Retainer Ring 33
damage a seal or wear ring. C—Cushion 3360
D—Cushion Seal ,107

010904
PN=289
Hydraulic System
16. Remove and inspect dust seals (A) and bushing (B)
for wear or damage. Replace parts as necessary. See
Boom, Arm, and Bucket Pins, Bushings and Bosses
Inspection. (Group 3340.)
Arm Cylinder—200CLC—Specification
–UN–27OCT88
Arm Cylinder Head End and Rod
End Bushing—ID ............................................................ 80.0 mm nominal
3.15 in. nominal
ID ............................................................................... 81.5 mm limit of use
T6557HR
Arm Cylinder Head End and Rod
End Bushing—ID ............................................................ 90.0 mm nominal
3.54 in. nominal
ID ............................................................................... 91.5 mm limit of use

indicator.
–UN–27OCT88
Specification
Arm Rod—Curvature ....................................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft
T6585XG
A—Dust Seal
Arm Rod Allowable Scratch—
B—Bushing
fingernail)
fingernail)
Arm Rod—OD .............................................................. 94.973—95.0 mm
3.739—3.740 in.
fingernail)
fingernail)
Arm Rod—OD ................................................................. 99.91—100 mm
3.936—3.940 in.
33
3360
,108

010904
PN=290
Hydraulic System
33
3360
,109
–UN–09MAY03
T190996
Arm Cylinder
20.

010904
PN=291
Hydraulic System
–UN–16JAN97
T106126
Arm Cylinder

Bushing 12—Cap Screw (12 used) 22—Set Screw 33—Cap Screw (8 used)
3—Rod Guide 14—Cushion Seal 24—Cushion 35—Band
4—Wear Ring 15—Piston 25—Cushion Seal 36—Cap Screw (2 used)
5—Snap Ring 16—Cap Seal and O-Ring 26—Retainer Ring 37—Lock Washer (2 used)
6—Buffer Ring Seal 17—Back-Up Ring (2 used) 27—Ring 38—Clamp
7—U-Cup Seal 18—Buffer Seal (2 used) 29—Seal (4 used) 39—Cap Screw
8—Back-Up Ring 19—Wear Ring (2 used) 30—Shoulder Fitting 40—Lock Washer
9—Wiper Seal 20—Shim 31—Hydraulic Line 41—Lubrication Fitting
10—O-Ring
Install arm cylinder barrel and rod bushings to a depth 21. Install seals (29) tight against bushing with seal lip
equal to the thickness of seals (29). outward.
NOTE: Use a cylinder repair kit when assembling a

cylinder.
33
3360
,110

010904
PN=292
Hydraulic System

disk and a press.
A—Back-Up Ring
B—Snap Ring
C—Wear Ring
D—O-Ring
–UN–27OCT88
T6585XN
33
3360
,111

010904
PN=293
Hydraulic System
wear ring (B).
Install black buffer ring (D) with notched side (C)

Install green buffer ring (E).
Install back-up ring (G).

cylinder.

A—Snap Ring
B—Wear Ring
C—Notched Side
–UN–01APR93
F—U-Cup Seal
G—Back-Up Ring
H—Wiper Seal
T7963AK
J—Rod Guide
33
3360
,112
–UN–22OCT91
T7623AF

010904
PN=294
Hydraulic System
size pusher (A).
A —JDG901-3 Pusher
B—Cap Seal
C—O-Ring
D—Wear Ring
–UN–18MAR93
T7964AQ
FR91424,0000005 –19–11NOV03–14/22


a taper on one end of tie band. Install tie band with 33
the taper against cap seal. Before tightening the hose 3360
clamp, check to be sure tie band is under hose clamp ,113
all around piston.
–UN–27OCT88
T6396AC

010904
PN=295
Hydraulic System
35. Install a back-up ring (C) on each side of cap seal

and O-ring.
–UN–27OCT88
each other

T6557HV
FR91424,0000005 –19–11NOV03–16/22
37. Install cushion seals (A and C) so notches (B) are

towards the piston and threaded section of rod.
A—Cushion Seal
B—Notch
C—Cushion Seal
–UN–10JUN92
T7778AV
Arm Cylinder Rod
33
3360
,114

010904
PN=296
Hydraulic System
38. Install cushion (C) so wide end of flat face is towards

the end of rod and narrow end is towards the piston.
39. Install retainer ring in groove.
40. Pull cushion out against retainer ring.
–UN–10JUN92
41. Install ring (A).
T7778AU
A—Ring
B—Retainer Ring
C—Cushion
D—Cushion Seal Arm Cylinder Rod Cushion
FR91424,0000005 –19–11NOV03–18/22

(D)
–UN–27OCT88
A—Nut
B—Shim
C—Piston
T6585XK
D—Cushion
33
3360
,115

010904
PN=297
Hydraulic System


and cap screw.


cap screw.
Specification
Arm Cylinder Piston-to-Rod Nut—
Torque ..................................................................................... 10 200 N•m
–UN–22MAY92
7,520 lb-ft
B—Nut
T7768AH
FR91424,0000005 –19–11NOV03–20/22
Specification
Arm Cylinder Nut-to-Rod Set
Screw—Torque .............................................................................. 57 N•m
–UN–27OCT88
42 lb-ft
33
3360
,116
stake marks.
T6585XI
A—Set Screw
B—Steel Ball

010904
PN=298
Hydraulic System

–UN–27OCT88
Specification
Arm Cylinder Rod Guide-to-Barrel
Cap Screw—Torque .................................................................... 365 N•m
270 lb-ft
T6557HI
51. Install the lines (B).
A—Cap Screw
B—Lines
FR91424,0000005 –19–11NOV03–22/22
33
3360
,117

010904
PN=299
Hydraulic System
Arm Cylinder Disassemble and Assemble—230CLC
46
11 5
7
9
10
13
14
30 32
29 35
31 40 4
40 6
27 39
39 48
49
53
15
52
21 36
51
22
21
52
54
25
33
3360
,118 1
34
37
–UN–26NOV03
1
34 56
37
T196496
T196496
Arm Cylinder—230CLC

010904
PN=300
Hydraulic System
1—Bushing (2 used) 13—Bushing 31—Cap Screw (2 used) 46—Lubrication Fitting

2—Rod and Bushings 14—Snap Ring 32—O-Ring 48—Stop
4—Rod Guide 15—Cushion Ring 34—Clamp (2 used) 49—Ball
5—Cap Screw (14 used) 21—Piston Ring (2 used) 35—Clamp 51—Piston
6—O-Ring 22—Seal Ring 36—Clamp 52—Ring (2 used)
7—Seal 25—Cap Screw (6 used) 37—Cap Screw (4 used) 53—Plunger
9—Seal 27—Spring 39—Clamp (2 used) 54—Washer (6 used)
10—Scraper Ring 29—Hydraulic Line 40—Cap Screw (4 used) 56—Hydraulic Cylinder Barrel
11—Snap Ring 30—Cap Screw (2 used)

service stand.
Specification
Arm Cylinder—Weight ......................................... 285 kg approximate
630 lb approximate
FR91424,0000010 –19–21NOV03–2/8
2. Remove line (B).
–UN–27OCT88
IMPORTANT: To avoid damaging sliding surfaces, be

sure to pull out rod, rod guide, and
T6557HI
piston straight out of cylinder barrel.

A—Cap Screw
B—Hydraulic Line
33
3360
,119

010904
PN=301
Hydraulic System


(51).
–UN–27OCT88
from rod (2).
10. Remove spring (37), stop (48), ball (49), and plunger
T6557HK
(53) from piston (51).
11. Remove piston rings (21), wear rings (52), and seal
ring (22) from piston (51). B—Sliding Housing

(Group 3340.)
Arm Cylinder Head End
3.54 in. nominal
ID ............................................................................... 91.5 mm limit of use
Arm Cylinder Rod End Bushing—
ID .................................................................................... 90.0 mm nominal
3.54 in. nominal
ID ............................................................................... 91.5 mm limit of use
33
3360
,120

010904
PN=302
Hydraulic System

indicator.
Specification
Arm Rod—Curvature ....................................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft
–UN–27OCT88
Arm Cylinder—Specification
T6585XG
fingernail)
fingernail)
Arm Rod—230CLC—OD.......................................... 104.910—105.0 mm
4.126— 4.130 in.
33
3360
,121

010904
PN=303
Hydraulic System
46
11 5
7
9
10
13
14
30 32
29 35
31 40 4
40 6
27 39
39 48
49
53
15
52
21 36
51
22
21
52
54
25
33 1
34
3360
,122
37
–UN–26NOV03
1
34 56
37
T196496
T196496
17.

010904
PN=304
Hydraulic System
–UN–09DEC03
T196498
1—Bushing (2 used) 13—Bushing 31—Cap Screw (2 used) 46—Lubrication Fitting

2—Rod and Bushings 14—Snap Ring 32—O-Ring 48—Stop
4—Rod Guide 15—Cushion Ring 34—Clamp (2 used) 49—Ball
5—Cap Screw (14 used) 21—Piston Ring (2 used) 35—Clamp 51—Piston
6—O-Ring 22—Seal Ring 36—Clamp 52—Wear Ring (2 used)
7—Seal 25—Cap Screw (6 used) 37—Cap Screw (4 used) 53—Plunger
9—Seal 27—Spring 39—Clamp (2 used) 54—Washer (6 used)
10—Scraper Ring 29—Hydraulic Line 40—Cap Screw (4 used) 56—Hydraulic Cylinder Barrel
11—Snap Ring 30—Cap Screw (2 used)
Install arm cylinder head end and rod end bushings. facing toward cylinder head end
(pressure side).
cylinder. 20. Install ring (10), seal (9), seal (7), and snap ring
(11).
18. Install bushing (13) to bottom of bore in rod guide
(4) using a driver disk and a press. 21. Install O-ring (6).
33
3360
19. Install the snap ring (14). 22. Install seal ring (22), piston rings (21), and wear ,123
rings (52) on piston (51).
IMPORTANT: Ring (10), seal (9), and seal (7) must
be installed in the correct direction. 23. Install plunger (53), ball (49), stop (48), and spring
Ensure that ring and seals are (27).
installed so that slotted side is

010904
PN=305
Hydraulic System
24. Install rod guide assembly on rod (2). 27. Apply clean oil to piston and seals. Attach a hoist
to rod using a lifting strap. Carefully install piston,
IMPORTANT: Cushion ring (15) must be installed rod and rod guide into barrel.
in the correct direction. Ensure that
cushion ring is installed so that 28. Install and tighten cap screws (5).
(51). Specification
Arm Cylinder Rod
25. Install cushion ring (15) on rod (2). Barrel Cap Screw—Torque .................................................. 395 N•m
290 lb-ft
26. Secure rod assembly on bench and install piston
(51) assembly to rod (2). Install cap screws (25) 29. Install hydraulic line (29).
and washers (54).
Specification
Torque.................................................................................... 539 N•m
400 lb-ft
FR91424,0000010 –19–21NOV03–8/8
Bucket Cylinder Remove and Install
2. Retract arm cylinder and bucket cylinder (B) and lower

bucket to ground. Position end of arm (C) on wood
–UN–10JAN97
block (D).

High pressure release of oil can cause serious T106031

33
3360
,124 B—Bucket Cylinder
C—End of Arm
D—Wood Block
–UN–09JAN97
T106135

010904
PN=306
Hydraulic System
5. Connect center link to hoist using lifting strap.
6. Put wood block (5) between bucket cylinder and arm to

hold cylinder up when pin (1) is removed.
–UN–02AUG01
NOTE: Mark location of shims (3) to aid in assembly.
T143075
8. Push pin (1) out and remove shims (3).
1—Side and Center Links-to-Bucket Cylinder Pin

2—Cap Screw
3—Shim (as required)
4—Bucket Cylinder Rod End-to-Bucket Section Top
Port Line
5—Wood Block
6—Nut (2 used)
7—Side Link
33
3360
,125

010904
PN=307
Hydraulic System
CAUTION: Heavy component; use a hoist. 4
Bucket Cylinder—Specification
Bucket Cylinder—200CLC—
Weight......................................................................... 145 kg approximate 5
320 lb approximate
6
400 lb approximate 3
2
480 lb approximate
–UN–02AUG01
1
9. Disconnect bucket cylinder rod end hose (1).
10. Connect bucket cylinder (2) to hoist using lifting strap.
T143076
1—Bucket Cylinder Rod End Hose
NOTE: Mark location of shims (4) to aid in assembly. 2—Bucket Cylinder
3—Nut (2 used)
12. Push pin (6) out and remove shims (4). 4—Shim (as required)
5—Cap Screw
13. Remove bucket cylinder. 6—Bucket Cylinder-to-Arm Pin
14. Repair or replace parts as necessary. See Bucket

Cylinder Disassemble and Assemble—200CLC,
270CLC or see Bucket Cylinder Disassemble and
Assemble—230CLC. (Group 3360.)
15. Install shims equally on each side of bucket cylinder

head end to get minimum amount of clearance in
joint.
16. Align pin bores so shims are not damaged as pin is

installed.
17. Connect bucket cylinder head end to arm.

Bucket Cylinder-to-Arm Pin
33 200 lb-ft (tighten nut against nut)
3360 Bucket Cylinder-to-Arm Pin
,126 Retainer Nut—230CLC,

010904
PN=308
Hydraulic System

Tighten bucket cylinder hoses.
Bucket Cylinder Hose—
200CLC—Torque.......................................................................... 175 N•m
130 lb-ft
Bucket Cylinder Hose—230CLC,
270CLC—Torque.......................................................................... 205 N•m
152 lb-ft

20. Start engine.
21. Slowly extend bucket cylinder to align pin bores so

shims are not damaged as pin is installed.
22. Install shims equally on each side of cylinder rod end

and side links to get minimum amount of clearance in
joint.
23. Connect bucket cylinder head end to arm.
24. Tighten nuts against each other allowing cap screw to

be free to turn in hole.
Bucket Cylinder-to-Pin Retainer
Nut—Torque .......................................... 550 N•m (tighten nut against nut)

Tool Pivot, Swing Bearing, and Swing Bearing Gear
Grease. (Operator’s Manual.) 33
3360
,127
26. Bleed air from cylinder. See Hydraulic Cylinder Bleed

010904
PN=309
Hydraulic System

FR91424,0000011 –19–21NOV03–5/5
33
3360
,128

010904
PN=310
Hydraulic System
33
3360
,129

010904
PN=311
Hydraulic System
Bucket Cylinder Disassemble and Assemble—200CLC, 270CLC
33
3360
,130
–UN–09MAY03
T190997
Bucket Cylinder

010904
PN=312
Hydraulic System
1—Cylinder Barrel and 10—O-Ring 20—Nut 29—O-Ring (2 used)

Bushings 11—Back-Up Ring 21—Set Screw 30—Cap Screw (8 used)
2—Rod and Bushings 12—Cap Screw (12 used) 22—Steel Ball 31—Band
3—Rod Guide 13—Cushion 23—Lubrication Fitting (2 32—Band
4—Wear Ring 14—Piston used) 33—Cap Screw (2 used)
6—Buffer Ring Seal 16—Back-Up Ring (2 used) 26—Seal (2 used) 35—Clamp
7—U-Cup Seal 17—Buffer Seal (2 used) 27—Elbow Fitting 36—Cap Screw
8—Back-Up Ring 18—Wear Ring (2 used) 28—Hydraulic Line 37—Lock Washer
9—Wiper Seal 19—Shim
CAUTION: Heavy components; use a hoist. Weight .................................................................. 216 kg approximate
480 lb approximate
Specification
Weight .................................................................. 145 kg approximate
320 lb approximate service stand.
FR91424,0000012 –19–21NOV03–2/20
2. Remove line (B).
–UN–27OCT88
T6557HI
A—Cap Screw
B—Line
FR91424,0000012 –19–21NOV03–3/20
7. Install rod eye in sliding housing (B) and install housing 33

in the JT30043 cylinder service stand. 3360
,131
B—Sliding Housing
–UN–27OCT88
T6557HK

010904
PN=313
Hydraulic System

A—Set Screw
–UN–27OCT88
B—Steel Ball
T6585XI
FR91424,0000012 –19–21NOV03–5/20


and cap screw.

tapped hole.

cap screw.
12. Loosen nut (B).
–UN–22MAY92
Specification
Bucket Cylinder Piston-to-Rod
Nut—Torque .............................................................................. 6570 N•m
4,850 lb-ft
T7768AG
B—Nut
33
3360
,132

010904
PN=314
Hydraulic System
13. Remove parts (A—D).
14. Remove parts from rod guide and piston.
–UN–27OCT88
A—Nut
B—Shim
T6585XK
C—Piston
D—Cushion
E—Flat Face
F—Notch
G—Cushion Seal
–UN–16JUL94
T8286BL
33
3360
,133

010904
PN=315
Hydraulic System
15. Remove and inspect dust seals (A) and bushing (B)
for wear or damage. Replace parts as necessary. See
Boom, Arm, and Bucket Pins, Bushings and Bosses
Inspection. (Group 3340.)
Bucket Cylinder—200CLC—Specification
–UN–27OCT88
Bucket Cylinder Head End
2.80 in. nominal
ID ............................................................................... 72.5 mm limit of use
T6557HR
Bucket Cylinder Rod End
3.15 in. nominal
ID ............................................................................... 81.5 mm limit of use
3.15 in. nominal
–UN–27OCT88
ID ............................................................................... 81.5 mm limit of use
3.54 in. nominal
T6585XG
ID ............................................................................... 91.5 mm limit of use

A—Dust Seal
indicator. B—Bushing
Specification
Bucket Rod—Curvature................................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft
Bucket Rod Allowable Scratch—
fingernail)
fingernail)
Bucket Rod—200CLC—OD .......................................... 79.81—80.00 mm
3.143—3.150 in.
Bucket Rod—270CLC—OD .......................................... 89.81—90.00 mm
3.533—3.540 in.
33 18. Repair or replace parts as necessary.

3360
,134

010904
PN=316
Hydraulic System
33
3360
,135
–UN–09MAY03
T190996
Bucket Cylinder
19.

010904
PN=317
Hydraulic System
–UN–17JAN97
T106212
Bucket Cylinder
1—Cylinder Barrel and 10—O-Ring 20—Nut 29—O-Ring (2 used)

Bushings 11—Back-Up Ring 21—Set Screw 30—Cap Screw (8 used)
2—Rod and Bushings 12—Cap Screw (12 used) 22—Steel Ball 31—Band
3—Rod Guide 13—Cushion 23—Lubrication Fitting (2 32—Band
4—Wear Ring 14—Piston used) 33—Cap Screw (2 used)
6—Buffer Ring Seal 16—Back-Up Ring (2 used) 26—Seal (2 used) 35—Clamp
7—U-Cup Seal 17—Buffer Seal (2 used) 27—Elbow Fitting 36—Cap Screw
8—Back-Up Ring 18—Wear Ring (2 used) 28—Hydraulic Line 37—Lock Washer
9—Wiper Seal 19—Shim
Install cylinder barrel and rod bushing to a depth equal 20. Install seals (24 and 26) tight against bushing with
to the thickness of seals (24 and 26). seal lip outward.

cylinder.
33
3360
,136

010904
PN=318
Hydraulic System

disk and a press.
A—Back-Up Ring
B—Snap Ring
C—Wear Ring
D—O-Ring
–UN–27OCT88
T6585XN
33
3360
,137

010904
PN=319
Hydraulic System
wear ring (B).
25. Install black buffer ring (D) with notched side (C)
26. Install green buffer ring (E).
28. Install back-up ring (G).

cylinder.

A—Snap Ring
B—Wear Ring
C—Notched Side
–UN–01APR93
F—U-Cup Seal
G—Back-Up Ring
H—Wiper Seal
T7963AK
J—Rod Guide
33
3360
,138
–UN–22OCT91
T7623AF

010904
PN=320
Hydraulic System
size pusher (A).
A—JDG840-6 Pusher
B—Cap Seal
C—O-Ring
D—Wear Ring
–UN–18MAR93
T7964AQ
FR91424,0000012 –19–21NOV03–13/20


a taper on one end of tie band. Install tie band with 33
the taper against cap seal. Before tightening the hose 3360
clamp, check to be sure tie band is under hose clamp ,139
all around piston.
–UN–27OCT88
T6396AC

010904
PN=321
Hydraulic System
37. Install a back-up ring (C) on each side of cap seal.
each other
–UN–27OCT88
T6557HV
FR91424,0000012 –19–21NOV03–15/20
NOTE: For bucket cylinder, no cushion seal is used under

the cushion.
39. Install cushion (D) so wide end of flat face (E) is

towards the rod guide and narrow end is towards the
piston.
–UN–16JUL94
D—Cushion
E—Flat Face
F—Notch (not on bucket cylinder)
T8286BL
G—Cushion Seal (not on bucket cylinder)
Boom Cylinder Rod Shown
FR91424,0000012 –19–21NOV03–16/20

(D)

–UN–27OCT88
33 A—Nut
3360 B—Shim
,140 C—Piston
T6585XK
D—Cushion

010904
PN=322
Hydraulic System


and cap screw.


cap screw.
Specification
Bucket Cylinder Piston-to-Rod
Nut—Torque .............................................................................. 6570 N•m
–UN–22MAY92
4,850 lb-ft
B—Nut
T7768AH
FR91424,0000012 –19–21NOV03–18/20
Specification
Bucket Cylinder Nut-to-Rod Set
Screw—Torque .............................................................................. 57 N•m
–UN–27OCT88
42 lb-ft
33
3360
,141
stake marks.
T6585XI
A—Set Screw
B—Steel Ball

010904
PN=323
Hydraulic System

–UN–27OCT88
Specification
Bucket Cylinder Rod
Guide-to-Barrel Cap Screw—
Torque .......................................................................................... 267 N•m
197 lb-ft
T6557HI
A—Cap Screw
B—Lines
FR91424,0000012 –19–21NOV03–20/20
33
3360
,142

010904
PN=324
Hydraulic System
33
3360
,143

010904
PN=325
Hydraulic System
Bucket Cylinder Disassemble and Assemble—230CLC
42
11
7
9 5
10
13
14
19 44
24
15
22 4
19
20
18
21
28 20
46
26
41
31
27
1
25
33
3360
,144 1
35 32
34
–UN–26NOV03
30
T196499
T196499
Bucket Cylinder—230CLC

010904
PN=326
Hydraulic System
1—Bushings (2 used) 11—Snap Ring 22—Packing 32—Cap Screw (2 used)

2—Rod and Bushings 13—Bushing 24—Cap Screw (6 used) 34—Clamp
4—Rod Guide 14—Snap Ring 25—Hydraulic Line 35—Cap Screw (2 used)
5—Cap Screw (12 used) 15—Cushion Ring 26—Cap Screw (2 used) 41—Lubrication Fitting
6—O-Ring 18—Piston 27—Cap Screw (2 used) 42—Lubrication Fitting
7—Seal 19—Piston Ring (2 used) 28—O-Ring 44—Washer (6 used)
9—Seal 20—Wear Ring (2 used) 30—Clamp 46—Hydraulic Cylinder Barrel

service stand.
Specification
Bucket Cylinder—Weight ..................................... 182 kg approximate
400 lb approximate
FR91424,0000013 –19–21NOV03–2/9
2. Remove line (B).
–UN–27OCT88
IMPORTANT: To avoid damaging sliding surfaces, be

sure to pull out rod, rod guide, and
T6557HI
piston straight out of cylinder barrel.

A—Cap Screw
B—Line
33
3360
,145

010904
PN=327
Hydraulic System


(18).
–UN–27OCT88
from rod (2).
10. Remove piston rings (19), wear rings (20), seal ring
T6557HK
(21), and packing (22) from piston (18).
for wear, scratches and nicks that may cut or B—Sliding Housing

(Group 3340.)
3.15 in. nominal
ID ............................................................................... 81.5 mm limit of use
3.54 in. nominal
ID ............................................................................... 91.5 mm limit of use
33
3360
,146

010904
PN=328
Hydraulic System

indicator.
Specification
Bucket Rod—Curvature................................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft
–UN–27OCT88
Bucket Rod Allowable Scratch—
T6585XG
fingernail)
fingernail)
Bucket Rod—230CLC—OD ......................................... 89.910—90.0 mm
3.536— 3.540 in.
33
3360
,147

010904
PN=329
Hydraulic System
42
11
7
9 5
10
13
14
19 44
24
15
22 4
19
20
18
21
28 20
46
26
41
31
27
1
25
33
1
3360
,148 32
35
34
–UN–26NOV03
30
T196499
T196499

010904
PN=330
Hydraulic System
NOTE: Use a cylinder repair kit when assembling a 16.

cylinder.
33
3360
,149

010904
PN=331
Hydraulic System
–UN–10DEC03
T196860
1—Bushings (2 used) 11—Snap Ring 22—Packing 32—Cap Screw (2 used)

2—Rod and Bushings 13—Bushing 24—Cap Screw (6 used) 34—Clamp
4—Rod Guide 14—Snap Ring 25—Hydraulic Line 35—Cap Screw (2 used)
5—Cap Screw (12 used) 15—Cushion Ring 26—Cap Screw (2 used) 41—Lubrication Fitting
6—O-Ring 18—Piston 27—Cap Screw (2 used) 42—Lubrication Fitting
7—Seal 19—Piston Ring (2 used) 28—O-Ring 44—Washer (6 used)
9—Seal 20—Wear Ring (2 used) 30—Clamp 46—Hydraulic Cylinder Barrel
Install bucket cylinder head end and rod end bushings. installed so that slotted side is
facing toward cylinder head end
NOTE: Use a cylinder repair kit when assembling a (pressure side).
cylinder.
19. Install ring (10), seal (9), seal (7), and snap ring
17. Install bushing (13) to bottom of bore in rod guide (11).
(4) using a driver disk and a press.
20. Install O-ring (6).
33
3360
18. Install the snap ring (14).
,150 21. Install packing (22), seal ring (21), wear rings (20),
IMPORTANT: Ring (10), seal (9), and seal (7) must and piston rings (19) on piston (18).
be installed in the correct direction.
Ensure that ring and seals are 22. Install rod guide assembly on rod (2).

010904
PN=332
Hydraulic System
IMPORTANT: Cushion ring (15) must be installed 25. Apply clean oil to piston and seals. Attach a hoist
in the correct direction. Ensure that to rod using a lifting strap. Carefully install piston,
cushion ring is installed so that rod and rod guide into barrel.
(18). 26. Install and tighten cap screws (5).
23. Install cushion ring (15) on rod (2). Specification

Bucket Cylinder Rod
24. Secure rod assembly on bench and install piston Barrel Cap Screw—Torque .................................................. 395 N•m
(18) assembly to rod (2). Install cap screws (25) 290 lb-ft
and washers (42).
27. Install hydraulic line (25).
Specification
Torque.................................................................................... 395 N•m
290 lb-ft
FR91424,0000013 –19–21NOV03–9/9
33
3360
,151

010904
PN=333
Hydraulic System
Hydraulic Cylinder Bleed Procedure

NOTE: Bleed air at initial start-up, whenever major repairs

or maintenance (oil change) is done on hydraulic
system, or when machine has been in storage for
a period of time.
1. Run engine at slow idle.
2. Slowly operate function to move cylinder to the most

horizontal position possible.
3. Slowly extend and retract cylinder several times to

approximately 100 mm (4 in.) from end of stroke.
4. Operate cylinder several times to full stroke.

TX,33,GG2374B –19–26NOV03–1/1
33
3360
,152

010904
PN=334
Section 43
Swing or Pivoting System
Contents
Page
Group 4350—Mechanical Drive Elements

Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . .43-4350-1
Upperstructure . . . . . . . . . . . . . . . . . . . . . .43-4350-12
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . .43-4350-19

Swing Motor and Park Brake. . . . . . . . . . . . .43-4360-1
Crossover Relief Valve and Make-Up
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-11
Swing Motor
Brake Release Valve—270CLC . . . . . . . . .43-4360-13
43

010904
PN=1
Contents
43

010904
PN=2
Group 4350
Mechanical Drive Elements
Swing Gearbox Repair
Remove and Install Swing Gearbox


or 270CLC Drain and Refill Capacities. (Operator’s
Manual.)
Continued on next page AGALLARDO,0000039 –19–19NOV01–1/14
43
4350
1

010904
PN=337
NOTE: Swing motor may be removed by itself or with

swing gearbox. To remove swing motor. See
Swing Motor and Park Brake Repair. (Group
4360.)
Mark swing gearbox housing to machine

upperstructure to aid in installation.
–UN–02AUG01
4. Install JT01748 Lifting Brackets and connect to hoist.
Swing Gearbox—Specification
Swing Motor, Brake, and
T143498B
Gearbox—200CLC—Weight ......................... 230 kg (507 lb) approximate
Swing Motor, Brake, and
Swing Motor, Brake, and 200CLC Machine Shown
1—Cap Screw and Washer (12 used)
5. Remove cap screws and washers (1).
6. Remove swing gearbox.
8. Apply rigid-form-in place gasket to mating surfaces of

swing gearbox housing and upperstructure.
9. Install swing gearbox.
Swing Gearbox-to-Upperstructure
Cap Screw—Torque .................................................... 500 N•m (370 lb-ft)
11. Connect electrical connector.

13. If hydraulic oil tank was drained, fill hydraulic oil tank.
See 200CLC Drain and Refill Capacities, 230CLC
Drain and Refill Capacities, or 270CLC Drain and
Refill Capacities. (Operator’s Manual.)
43
4350
2

010904
PN=338
14. Do Swing Gearbox Start-Up Procedure. (See

procedure in this group.) See Swing Motor Start-Up
Procedure . (Group 4360.)
43
4350
3

010904
PN=339
22
23
24 2
4
3 5 6
31
25
7
21 8
20
9 11
19
26 10 12
18 13
27
17
28
16
29
15
14
–UN–14MAY01
30
43
4350
T142044
T142044
4

010904
PN=340
1—Swing Motor 9—Pin (3 used) 17—Cap Screw (2 used) 25—Housing

2—First Planet Sun Gear 10—Spring Pin (3 used) 18—Second Planet Carrier 26—Oil Seal
3—Thrust Plate 11—Thrust Plate (6 used) 19—Thrust Plate 27—Roller Bearing
4—Pin (3 used) 12—Bearing (3 used) 20—Second Planet Sun Gear 28—Sleeve
5—Spring Pin (3 used) 13—Planetary Gear (3 used) 21—First Planet Carrier 29—O-Ring
6—Needle Bearing (3 used) 14—Roller Bearing 22—Cap Screw (8 used) 30—Shaft
7—Planetary Gear (3 used) 15—Bearing Nut 23—Cap Screw (12 used) 31—Drain Valve
8—Thrust Plate (3 used) 16—Lock Plate 24—Ring Gear
Disassemble and Assemble Swing Gearbox— 5. Remove second planet carrier (18).
200CLC and 230CLC
NOTE: Second planet sun gear may be removed
1. Make alignment marks between swing motor (1), separately or with carrier.
ring gears (24), and between ring gear (24) and
housing (25) to aid in assembly. 6. Disassemble first planet carrier (21) assembly.
7. Tap spring pin (5) into pin (4).

Swing Gearbox—Specification NOTE: Procedure for the disassembly of first and

Swing Motor—200CLC and second planetary carriers is the same.
230CLC—Weight ...................................... 46 kg (100 lb) approximate
8. Remove pin (4), planetary gear (7), needle bearing
2. Remove cap screws (22) and swing motor (1) from (6), and thrust plate (8) from first planet carrier (21).
swing gearbox.
9. Inspect needle bearing for wear.
3. Remove first planet carrier (21) from ring gear (24).
10. Remove thrust plate (3) from carrier.
NOTE: First planet sun gear may be removed
separately or along with carrier. IMPORTANT: Damaging the surface of pin (4) can
cause bearing failure, use care when
handling pin.
Swing Gearbox—Specification 11. Using wood blocks, clamp pin (4) in vise. Tap
Ring Gear—200CLC and spring pin (5) out.
230CLC—Weight ...................................... 23 kg (50 lb) approximate
12. Remove cap screws (17) and lock plate (16).
4. Remove cap screws (23) and ring gear (24).
AGALLARDO,0000039 –19–19NOV01–5/14
13. Remove bearing nut (15) from shaft (30) using

DFT1220 Swing Gearbox Nut Spanner Wrench.
(Group 9900.)
15—Bearing Nut
–UN–14MAY01
43
4350
5
T142064

010904
PN=341
NOTE: Bearing and sleeve are pressed onto shaft.
14. Using press, push upper end of shaft (1) and remove
from housing (2). Inner race of roller bearing (27) and
sleeve (28) are removed with shaft (30).
–UN–19NOV01
15. Remove oil seal (26).
16. Remove outer race from housing by inserting bar

through oil passage in housing, and tap it out.
T146941
1—Shaft
2—Housing
AGALLARDO,0000039 –19–19NOV01–7/14
17. Inspect shaft (1), roller bearing (2), and sleeve (3).
18. If disassembly is necessary, use press to push upper

end of shaft to remove roller bearing and sleeve.
1
–UN–19NOV01
20. Apply rigid form-in-place gasket to OD of oil seal (26). 2
21. Install oil seal so lip (spring side) is toward bottom of
T146899
bore. Push seal to bottom of bore. 3
22. Apply thin layer of multi-purpose grease to O-ring (29)

1—Shaft
and lip of oil seal.
2—Roller Bearing
3—Sleeve
23. Apply hydraulic oil to all internal parts.
24. Apply film of grease on threaded surface of bearing

nut (15). Install bearing nut on shaft (30) with stepped
side of bearing nut towards roller bearing (14).
25. Tighten bearing nut so splines of lock plate (16) and

shaft (30) are aligned. Use DFT1220 Swing Gearbox
Nut Spanner Wrench. (Group 9900.)
Bearing Nut—200CLC and
230CLC—Torque......................................................... 490 N•m (360 lb-ft)
43
4350
6

010904
PN=342
26. Install spring pins (5 and 10) with slit towards end of
pin.
27. Install thrust plate (19) with oil grooves towards

second planet sun gear (20).
–UN–22JUN01
28. Install second planet carrier (18) so notch is aligned
with lock plate (16).
29. Install second planet sun gear (20) into second planet
T142429
carrier (18) assembly with small diameter part of
second planet sun gear towards up.
1—Slit
30. Install first planet sun gear (2) into first planet carrier
(21) assembly with stepped side of sun gear towards
down.
31. Apply rigid form-in-place gasket to ring gear (24),

housing (25) and swing motor (1) mating surfaces.

cap screws (22 and 23). Tighten Cap Screws.
Ring Gear-to-Housing Cap
Screw—200CLC and 230CLC—
Torque ......................................................................... 206 N•m (152 lb-ft)
Swing Motor-to-Ring Gear Cap
Screw—Torque .................................................................. 88 N•m (65 lb-ft
43
4350
7

010904
PN=343
13
14
12
11 15
16
19 17
18
10
21
20
22
7 23
9 25 24
26 21
6
8
27
29
30
5 28
31
3 4
32
2 29
33
–UN–19NOV01
1
43 34
4350
T146719
8 T146719

010904
PN=344
1—Shaft 10—Housing 19—First Planet Carrier 27—Second Planet Carrier

2—Sleeve 11—Ball Bearing 20—Second Planet Sun Gear 28—O-Ring
3—Cap Screw (10 used) 12—Snap Ring 21—Thrust Plate (6 used) 29—Thrust Plate (6 used)
4—O-Ring 13—Swing Motor 22—Needle Bearing (3 used) 30—Bushing (3 used)
5—Oil Seal 14—Cap Screw (12 used) 23—Planetary Gear (3 used) 31—Planetary Gear (3 used)
6—Cover 15—First Planet Sun Gear 24—Thrust Plate 32—Cap Screw (12 used)
7—Ball Bearing 16—Thrust Plate 25—Pin (3 used) 33—Ring Gear
8—Drain Plug 17—Pin (3 used) 26—Spring Pin (3 used) 34—O-Ring
9—Pipe 18—Spring Pin (3 used)
Disassemble and Assemble Swing Gearbox— 5. Remove second planet carrier (27).
270CLC
NOTE: Second planet sun gear may be removed
1. Make alignment marks between swing motor (13), separately or with carrier.
ring gears (33), and between ring gear (33) and
housing (10) to aid in assembly. 6. Disassemble first planet carrier (19) assembly .
7. Tap spring pin (18) into pin (17).

Swing Gearbox—Specification NOTE: Procedure for the disassembly of first and

Swing Motor—270CLC— second planetary carriers is the same.
Weight ....................................................... 66 kg (150 lb) approximate
8. Remove pin (17), planetary gear (23), needle
2. Remove cap screws (14) and swing motor (13) bearing (22), and thrust plate (21) from first planet
from swing gearbox. carrier (19).
3. Remove first planet carrier assembly (19) from ring 9. Inspect needle bearing for wear.
gear (33).
10. Remove thrust plate (16) from carrier.
NOTE: First planet sun gear may be removed
separately or along with carrier. IMPORTANT: Damaging the surface of pin (17) can
cause bearing failure, use care when
handling pin.
Swing Gearbox—Specification 11. Using wood blocks, clamp pin (17) in vise. Tap
Ring Gear—270CLC—Weight .................... 36 kg (80 lb) approximate spring pin (18) out.
4. Remove cap screws (32) and ring gear (33). 12. Remove snap ring (12).

43
4350
9

010904
PN=345
NOTE: Bearing and sleeve are pressed onto shaft.
13. Using press, push upper end of shaft (1) and remove
from housing (2). Ball bearing (7) and sleeve (2) are
removed with shaft (1).
–UN–19NOV01
14. Secure cover (6) in vise and remove oil seal (5).
1—Shaft
2—Housing
T146941
AGALLARDO,0000039 –19–19NOV01–12/14
15. Inspect sleeve (1), ball bearing (2), and shaft (3) for
wear. Repair or replace parts as necessary.
16. Use press to push at upper end of shaft and remove

ball bearing and sleeve. 3
2
–UN–19NOV01
17. Apply rigid form-in-place gasket to OD of oil seal (5).
18. Install oil seal so lip (spring side) is toward bottom of

bore. Push seal to bottom of bore. 1
T146889
19. Apply thin layer of multi-purpose grease to O-ring (4)
and lip of oil seal.
1—Sleeve
2—Ball Bearing
20. Apply hydraulic oil to all internal parts. 3—Shaft
43
4350
10

010904
PN=346
21. Install spring pins (18 and 26) with slit towards end of
pin.
22. Install thrust plate (24) with oil grooves towards

second planet sun gear (20).
–UN–22JUN01
23. Install second planet sun gear (20) into second planet
carrier (27) assembly with small diameter part of
second planet sun gear towards up.
T142429
24. Install first planet sun gear (15) into first planet carrier
(19) assembly with stepped side of sun gear towards
down.
1—Slit
25. Apply rigid form-in-place gasket to ring gear (33),

housing (10) and swing motor (13) mating surfaces.

cap screws (14 and 32). Tighten cap screws.
Ring Gear-to-Housing Cap
Screw—270CLC—Torque ........................................... 400 N•m (300 lb-ft)
AGALLARDO,0000039 –19–19NOV01–14/14
Swing Gearbox Start-Up Procedure
IMPORTANT: Swing gearbox will be damaged if not

filled with oil before operating swing
function. Procedure must be performed
whenever a new swing gearbox is
installed or oil has been drained from
the gearbox.
1. Check that drain line plug is installed.
2. Remove fill cap and add oil. See Swing Gearbox,

Propel Gearbox and Pump Gearbox Oils. (Operator’s
43
Manual.)
4350
11
3. Install fill cap. Check oil level on dipstick.
TX,25,GG2228 –19–19NOV01–1/1

010904
PN=347
Upperstructure Repair
Remove Upperstructure
NOTE: Procedure requires two technicians. The cement

floor must be a minimum of 102 mm (4 in.) thick.
Area must be large enough so the upperstructure
can be turned 180° with the angle between boom
and arm at 90—100° and the tracks laid out flat
on the floor.
1. Clean machine thoroughly.
TX,43,SB524 –19–19NOV01–1/10
CAUTION: Keep the angle between boom and

arm at 90—100° to prevent machine from sliding
backwards.
2. Park machine with boom to left side (cab side toward

sprocket) of undercarriage.
3. Disconnect tracks and lay out flat on floor to sprocket

end of undercarriage. See Track Chain Repair. (Group
0130.)
–UN–24FEB92
NOTE: To make removal of main frame-to-swing bearing
cap screws easier after machine is raised into
position, loosen the cap screws one turn at this
T7712AG
time.
4. Turn upperstructure and raise right side of machine,

using boom down function.

43
4350
12

010904
PN=348
5. Put hardwood blocks (B), approximately 254 mm (10

in.) between lower track rollers (A) and track chain (C).
6. Turn upperstructure back to left side so it is 90° to

track.
–UN–07MAY92
A—Track Rollers
B—Hardwood Blocks
C—Track Chain
T7720AM
TX,43,SB524 –19–19NOV01–3/10
Upperstructure—Specification
200CLC Machine—Without
Tracks—Weight ....................................................... 17 330 kg (38,200 lb)
approximate
approximate
approximate
7. Put two DFT1089 Barrel Support under counterweight

(D). (Group 9900.)
To provide enough clearance, use bridge planks (E)

and hardwood blocks (F) to raise height of supports
and planks to 1.4 m (55 in.). Height is approximate
clearance needed to clear bottom of rotary manifold.
Do not put blocks under cap screw heads. Keep height
below maximum.
–UN–07MAY92
Floor-to-Bottom of Main Frame—
Height .................................................................... 1.4 m (55 in.) minimum
T7720AS
Height ................................................................. 1.45 m (57 in.) maximum
D—Counterweight
E—Bridge Plank (As Required)
F—Hardwood Block (As Required)
G—DFT1089 Barrel Support (4 used)

43
4350
13

010904
PN=349
–UN–07MAY92
T7720AO
A—DFT1089 Barrel Support (4 B—3.7 m (12 ft) Length of W8 C—Hardwood Block (Use as
used) x 28 lb Wide Flange Beam Required)
(2 used)
8. Slowly raise left side, using boom down function, Install hardwood blocks (C) as needed to make up
until machine is level. for any unevenness.
9. Place DFT1089 Barrel Support and 3.7 m (12 ft) 10. Lower machine so main frame and corner of cab
length of W8 x 28 lb Wide Flange Beam (B) under are on beam.
main frame at right boom cylinder and right corner
of cab. (Group 9900.) Check that bottom of main frame is 1.4 m (55 in.)
off floor and level. Keep height to maximum of
For maximum support, barrel supports must be 1.45 m (57 in.).
positioned so beam is under main frame and corner
of cab as far as possible.

43
4350
14

010904
PN=350
11. Install 13 mm (1/2 in.) chain around boom cylinder

head end boss on frame and rod end boss on boom.
Tighten chain just enough to remove slack using
chain binder.
12. Disconnect negative battery cables.

13. Do Hydraulic Oil Tank Vent Procedure. (See

14. Disconnect lines and fittings from rotary manifold.
–UN–05OCT89
T7149AJ
TX,43,SB524 –19–19NOV01–6/10
Undercarriage—200CLC—Weight ......... 5134 kg (11,319 lb) approximate
–UN–20DEC96
15. Raise undercarriage into position using two 18-t
(20-ton) service jacks.
T105961
16. Remove cap screws (B) from swing bearing (A).
17. Slowly lower undercarriage onto track chain.

A—Swing Bearing
18. Lift sprocket end of undercarriage so sprocket clears B—Cap Screw (31 used)
track chain.
19. Pull undercarriage out from under upperstructure.

43
4350
15

010904
PN=351
Install Upperstructure
1. Push undercarriage under upperstructure.
–UN–20DEC96
T105961
2. Install DFT1144 Guide Pin to help align holes in swing
bearing (A) with holes in main frame. (Group 9900.)
A—Swing Bearing
3. Raise undercarriage into position using two 18-t B—Cap Screw (31 used)
(20-ton) service jacks. It may be necessary to turn
swing bearing inner race to align teeth on swing motor
pinion shaft.
4. Install cap screws (B) and tighten.
Swing Bearing-to-Upperstructure
Cap Screw—200CLC—Torque ................................... 510 N•m (375 lb-ft)
Swing Bearing-to-Upperstructure
Cap Screw—230CLC and
If all cap screws are not accessible, tighten them after

machine has been lowered and supports have been
removed.
5. Connect fittings and lines to rotary manifold. See

Propel System Component Location. (Group 9025-15.)
6. Install stop on rotary manifold.
Rotary Manifold Stop Cap
8. Connect negative battery cable.
43
4350
16

010904
PN=352
9. Put hardwood blocks (B) between lower track rollers

(A) and track chain (C) on counterweight side.
A—Track Rollers
B—Wooden Blocks
C—Track Chain
–UN–07MAY92
T7720AM
43
4350
17

010904
PN=353
–UN–07MAY92
T7720AO
A—DFT1089 Barrel Support (4 B—3.7 m (12 ft) Length of W8 C—Hardwood Block (use as
used) x 28 lb Wide Flange Beam required)
(2 used)
10. Raise machine just enough to remove hardwood 15. Tighten any remaining swing bearing-to-main
blocks (C), wide flange beam (B), and barrel frame cap screws.
supports (A).
11. Lower machine so lower track rollers and front Swing
Bearing-to-Upperstructure Cap
idler are on track chain. Screw—200CLC—Torque .................................... 510 N•m (375 lb-ft)
Swing
12. Remove bridge planks and barrel supports from Bearing-to-Upperstructure Cap
other side. Screw—230CLC and
270CLC—Torque .................................................. 640 N•m (470 lb-ft)
13. Turn upperstructure to other side and raise
machine just enough to remove hardwood blocks 16. Install track chains. See Track Chain Repair. (See
between roller and track chain. Group 0130.)
14. Lower machine so lower track rollers and front 17. Check and Adjust Track Sag. (Operator’s Manual.)
idler are on track chain.
43
4350
18
TX,43,SB524 –19–19NOV01–10/10

010904
PN=354
Swing Bearing Repair
Remove and Install Swing Bearing
1. Remove upperstructure. See Upperstructure Repair.

Swing Bearing—Specification
Swing Bearing—200CLC—Weight ................ 220 kg (485 lb) approximate
Swing Bearing—230CLC and
270CLC—Weight ........................................... 331 kg (730 lb) approximate
2. Connect swing bearing to hoist using lifting brackets

(C) such as JT01748 Lifting Brackets.
3. Remove cap screws and lock washers (D) and remove

swing bearing.
4. Check and replace swing bearing upper and lower
–UN–07MAY92
seals if necessary. SeeSwing Bearing Repair. (See
5. Replace steel balls and ball supports as necessary.
T7764AB
C—JT01748 Lifting Brackets
7. Clean mating surfaces of swing bearing, D—Cap Screw and Lock Washer
upperstructure, and undercarriage.
43
4350
19

010904
PN=355
IMPORTANT: The tooth marked with the letter “G” or

“S” or equivalent is the starting and
stopping point for the hardening
process. The tooth and the bearing
loading plug must be installed on the
right side of the machine so the use of
–UN–11APR90
that part of the swing bearing is
minimized.
8. Install swing bearing on undercarriage so tooth (A)
T5925AA
marked “G” or “S” or equivalent and bearing loading
plug (B) is to right side of machine.
9. Install cap screws and lock washers and tighten. A—Tooth

B—Loading Plug
Swing Bearing—Specification
Undercarriage-to-Swing Bearing
Cap Screw—200CLC—Torque ................................... 490 N•m (360 lb-ft)
Undercarriage-to-Swing Bearing
Cap Screw—230CLC and
10. Apply multi-purpose grease to swing bearing teeth

and pinion shaft. See Track Adjuster, Working Tool
Pivot, Swing Bearing, and Swing Bearing Gear
11. Install upperstructure. See Upperstructure Repair.

43
4350
20

010904
PN=356
–UN–07NOV88
T6626JP
A—Lubrication Fitting (2 used) —Spacer—270CLC (90 used) —Steel Ball—270CLC (90 F—Inner Race
B—Outer Race D—Steel Ball—200CLC & used) G—Upper Seal
C—Spacer—200CLC & 230CLC 230CLC (121 used) E—Lower Seal
(121 used)
Disassemble and Assemble Swing Bearing
1. Check swing bearing upper seal (G) and lower seal

(E). If damaged, replace. See Swing Bearing
Repair. (See procedures in this group.)
43
4350
21

010904
PN=357
2. Grind tack weld (A) off top of taper pin (B).
3. Drive taper pin out from bottom side of bearing.
4. Remove loading plug (C) using an M8-1.25 cap screw.
A—Tack Weld
B—Taper Pin
C—Loading Plug
–UN–07MAY92
T6876FI
TX,43,SB526 –19–19NOV01–4/8
5. Remove steel balls (A) and spacers (B).
6. Turn inner race to remove remaining steel balls and

spacers.
7. Lift outer race off inner race.
–UN–07MAY92
9. Install spacers (B) and steel balls (A).
Turn inner race as needed to install spacers and steel

balls.
T6876FK
A—Spacer—200CLC & 230CLC (121 used)
—Spacer—270CLC (90 used)
B—Steel Ball—200CLC & 230CLC (121 used)
—Steel Ball—270CLC (90 used) –UN–07MAY92
43
T7763AB
4350
22

010904
PN=358
10. Install loading plug (C).
11. Install taper pin (B) even with top of swing bearing.
12. Tack weld pin (A) to swing bearing.
13. Add multi-purpose grease to swing bearing through

lubrication fittings. See Track Adjuster, Working Tool
Pivot, Swing Bearing, and Swing Bearing Gear
–UN–07MAY92
A—Tack Weld
B—Taper Pin
C—Loading Plug
T6876FI
43
4350
23

010904
PN=359
Install Swing Bearing Upper Seal

2. Remove old seal (A).
–UN–11APR90
3. Scrape old adhesive from seal groove.
Thoroughly clean seal groove and new seal using cure
T5925AM
primer.
4. Apply instant gel adhesive sparingly to seal groove.

A—Seal
5. Install seal with lip against inner bearing race.
Start about 76 mm (3 in.) from end of seal using blunt

instrument to force seal into groove. Push seal in
direction of portion already installed to avoid stretching
seal.
6. Before bringing ends of seal together, cut off excess

length.
7. Apply instant gel adhesive to both ends of seal. Push

ends into seal groove making sure they come together.
IMPORTANT: To avoid pulling seal out of groove,

adhesive must cure for at least 24
hours before using swing function.
8. Install upperstructure. See Upperstructure Repair. (See

Install Swing Bearing Lower Seal


43
4350
24

010904
PN=360
NOTE: Part of swing bearing shown cut away to show

lower seal in groove.
2. Remove old seal (A).
3. Scrape old adhesive from seal groove (B).
–UN–17MAY89
Thoroughly clean seal groove and new seal using cure
primer.
T5936BA
4. Apply instant gel adhesive sparingly to seal groove.
5. Install seal with seal lip against outer race.

A—Seal
Start about 76 mm (3 in.) from end of seal using blunt B—Seal Groove
instrument to force seal into groove. Push seal in
direction of portion already installed to avoid stretching
seal.
6. Before bringing ends of seal together, cut off excess

length.
7. Apply adhesive to both ends of seal. Push ends into

seal groove making sure they come together.
IMPORTANT: To avoid pulling seal out of groove,

adhesive must cure for at least 24
hours before using swing function.
8. Install upperstructure. See Upperstructure Repair. (See

TX,43,SB526 –19–19NOV01–8/8
43
4350
25

010904
PN=361
43
4350
26

010904
PN=362
Group 4360
Hydraulic System
Swing Motor and Park Brake Repair
Remove and Install Swing Motor and Park Brake
–UN–20JUL01
T143358B
Capacities, 230CLC Drain and Refill Capacities, 200CLC Machine Shown
or270CLC Drain and Refill Capacities. (Operator’s
Manual.)
CAUTION: Heavy Component; use a hoist.
Swing Motor and Park Brake—Specification

Swing Motor and Park Brake
(200CLC and 230CLC
Machine)—Weight ........................................... 47 kg (104 lb) approximate
(270CLC Machine)—Weight............................ 66 kg (150 lb) approximate
5. Remove cap screws (1) and remove swing motor and

park brake.
7. Install swing motor and brake.

9. Connect electrical connector (2).

43
4360
1
Continued on next page TX,4360,DV1356 –19–19NOV01–1/10

010904
PN=363
Hydraulic System
11. Fill hydraulic oil tank. See 200CLC Drain and Refill
Capacities, 230CLC Drain and Refill Capacities, or
Manual.)
12. Do Swing Motor Start-Up Procedure. (See procedure

in this group).
43
4360
2

010904
PN=364
Hydraulic System
43
4360
3

010904
PN=365
Hydraulic System
10
10
8
7
6
11
5
4
3 12
1 15 16 14
2 13
17 19
18
18
21 17
16
15
28
29 22
33 30 20
23
31
24
32 25
26
27
–UN–22JUN01
43
4360
T142065
T142065
4

010904
PN=366
Hydraulic System
1—Housing 10—Plate (4 used) 19—Valve Housing 26—O-Ring

2—Oil Seal 11—Friction Plate (3 used) 20—Crossover Relief Valve (2 27—O-Ring
3—Bearing 12—Cap Screw (4 used) used) 28—O-Ring
4—Shaft 13—O-Ring (2 used) 21—O-Ring 29—Piston
5—Trust Plate 14—Plug (2 used) 22—Bearing 30—Spring
6—Piston (9 used) 15—Plug (2 used) 23—Valve Plate 31—Ball
7—Plate 16—O-Ring (2 used) 24—Spring (24 used) 32—Plug (2 used)
8—Retainer 17—Spring (2 used) 25—Brake Piston 33—Snap Ring
9—Cylinder Block 18—Poppet (2 used)
Disassemble Swing Motor and Park Brake— dropped. Hold valve plate during
200CLC and 230CLC disassembly.
1. Drain oil. Approximate capacity is 1.5 L (1.6 qt). 3. Remove valve plate (23) and springs (24).
4. Remove brake piston (25).

Swing Motor and Park Brake—Specification 5. Remove parts (6—9) from shaft (4).
(200CLC and 230CLC)— 6. Remove snap ring (33) and shaft (4).
Weight .................................................... 46.4 kg (100 lb) approximate
7. Push out oil seal (2) and remove outer race of
CAUTION: Swing motor valve housing and bearing (3).
cover is under spring pressure. Remove cap
screws evenly to release spring force. 8. Remove inner race of bearing from shaft.
2. Mark alignment of swing motor housing and valve NOTE: Filter and orifice are mounted inside of piston
housing assembly. Loosen cap screws (12). (29). Unless clogged or deformed, do not
disassemble. Do so only when absolutely
IMPORTANT: Valve plate has a polished surface. needed. If internal parts need to be replaced,
Valve plate may remain on valve replace piston as an assembly.
housing or stay with cylinder block.
Valve plate may be damaged if 9. Replace parts as necessary.
43
4360
5

010904
PN=367
Hydraulic System
15
11
14
17
6 16 18
12
19
13
4
7 23
8
9
10
20
3
2 21
1 22
5
24
25
26
27 38
34
28
29
30
31 36
39
32
40 37
33
35
41
42
44
45
46
47
48
–UN–19NOV01
49
43
43
4360
T146945
6 T146945

010904
PN=368
Hydraulic System
1—Bearing 13—O-Ring (2 used) 26—Spacer 38—Cap Screw (3 used)

2—Snap Ring 14—Plate 27—Spring 39—Brake Release Valve
3—Dowel Pin (2 used) 15—Cap Screw (4 used) 28—Washer 40—Housing
4—O-Ring 16—O-Ring (2 used) 29—Cylinder Block 41—Shaft
5—Crossover Relief Valve (2 17—Plug (2 used) 30—Pin (12 used) 42—Snap Ring
used) 18—Valve Plate 31—Washer 43—Spacer (2 used)
6—Valve Housing 19—Spring (22 used) 32—Ball Bushing 44—Bearing
7—Poppet (2 used) 20—Brake Piston 33—Retainer 45—Snap Ring
8—Spring (2 used) 21—O-Ring 34—Piston (9 used) 46—O-Ring
9—O-Ring (2 used) 22—O-Ring 35—Thrust Plate 47—Oil Seal
10—Drain Plug (2 used) 23—Friction Plate (3 used) 36—Plug 48—Cover
11—Cap Screw (4 used) 24—Plate (4 used) 37—O-Ring 49—Snap Ring
12—O-Ring (2 used) 25—Snap Ring
Disassemble Swing Motor and Park Brake— dropped. Hold valve plate during
270CLC disassembly.
2. Remove valve plate (18) and springs (19).

Swing Motor and Park Brake—Specification 3. Remove brake piston (20).

(270CLC Machine)—Weight ..................... 66 kg (150 lb) approximate 4. Remove parts (29—34) from shaft (41).
5. Remove snap ring (49) from housing (40) to

CAUTION: Swing motor valve housing and
remove cover (48) and O-ring (46).
cover is under spring pressure. Remove cap
screws evenly to release spring force.
6. Install cover (48) in vise and remove oil seal (47).
1. Mark alignment of swing motor housing and valve
7. Tap shaft (41) assembly lightly and remove from
housing assembly. Loosen cap screws (11).
housing (40). Bearing (44), snap rings (42 and 45),
and spacers (43) are removed with shaft.
IMPORTANT: Valve plate has a polished surface.
Valve plate may remain on valve
housing or stay with cylinder block.
Valve plate may be damaged if
43
4360
7

010904
PN=369
Hydraulic System
Inspect Swing Motor and Park Brake
1. Measure clearance between outer diameter of piston

and inner bore of cylinder.

Piston-to-Cylinder—Clearance ........................ 0.027 mm (0.0011 in.) new
0.052 mm (0.0020 in.) maximum
used
–UN–22JUN01
T142067
TX,4360,DV1356 –19–19NOV01–7/10
2. Measure clearance between piston and slipper at

caulked position.

Piston-to-Slipper—Clearance .................................... 0.0 mm (0.0 in.) new
0.3 mm (0.0118 in.) maximum
used
–UN–22JUN01
43
4360
8
T142069

010904
PN=370
Hydraulic System
3. Measure thickness of slipper.

Slipper—Thickness .................................................. 5.5 mm (0.22 in.) new
5.3 mm (0.21 in.) minimum
4. Measure thickness of friction plate.

Friction Plate—Thickness ........................................ 2.0 mm (0.08 in.) new
1.8 mm (0.07 in.) minimum
–UN–22JUN01
Assemble Swing Motor and Park Brake—200CLC and
230CLC
1. Align spline teeth of friction plates (11) with cylinder
T142072
block (9) and outer tabs of plates (10) with housing (1).
Slipper Thickness
2. Apply petroleum jelly to valve plate (23).
3. Install thrust plate (5) with chamfered edge towards

housing (1).
4. Align mating marks on valve housing (19) and housing

(1) and tighten cap screws (12).

Valve Housing Cap Screw
–UN–22JUN01
5. Install poppet (18) and spring (17). Tighten plug (15)
with O-ring (16) attached.

Poppet Plug (200CLC and
T142073
230CLC)—Torque ....................................................... 330 N•m (245 lb-ft)
Friction Plate Thickness

6. Install crossover relief valves (20) into valve housing
(19).

Crossover Relief Valve—Torque ................................. 175 N•m (130 lb-ft)
Assemble Swing Motor and Park Brake—270CLC
1. Align spline teeth of friction plates (23) with cylinder

block and outer tabs of plates (24) with housing (40).
2. Apply petroleum jelly to valve plate (18).
43
4360
9

010904
PN=371
Hydraulic System
3. Install thrust plate (35) with chamfered edge towards

housing (40).
4. Align mating marks on valve housing (6) and housing

(40) and tighten cap screws (11).

270CLC Valve Housing Cap
5. Install poppet (7) and spring (8). Tighten plug (10) with
O-ring (9) attached.

270CLC Poppet Plug—Torque ................................... 400 N•m (300 lb-ft)
6. Install crossover relief valves (5) into valve housing (6).

TX,4360,DV1356 –19–19NOV01–10/10
43
4360
10

010904
PN=372
Hydraulic System
Crossover Relief Valve and Make-Up Valve Repair
1
3
–UN–30APR01
T139645
T139645
1—Make-Up Valve 2—Make-Up Valve 3—Crossover Relief Valve 4—Crossover Relief Valve
TX,4360,DV2980 –19–19NOV01–1/4
Remove and Install Crossover Relief Valve
1. Tighten crossover relief valve (1).
Crossover Relief and Make-Up Valves—Specification

–UN–19NOV01
2. Check crossover relief valve pressure setting. See

Swing Motor Crossover Relief Valve Test and
Adjustment—200CLC and 230CLC or Swing Motor
T147132B
Crossover Relief Valve Test and Adjustment—270CLC.

(Group 9025-25.)
270CLC Machine Shown
43
1—Crossover Relief Valve (2 used)
4360
11

010904
PN=373
Hydraulic System
Disassemble and Assemble Crossover Relief Valve
Tighten plug (4).

Crossover Relief Valve Plug—
Torque ........................................................................... 118 N•m (88 lb-ft)
1—Shim
2—Piston
3—Sleeve
–UN–22JUN01
4—Plug
5—O-Ring
6—O-Ring
7—O-Ring
T142068
TX,4360,DV2980 –19–19NOV01–3/4
Remove and Install Make-Up Valve
Tighten make-up valve (1).

200CLC and 230CLC Make-Up
–UN–19NOV01
Valve—Torque ............................................................. 332 N•m (245 lb-ft)
270CLC Make-Up Valve—Torque............................... 400 N•m (300 lb-ft)
1—Make-Up Valve (2 used)
T147132C
270CLC Machine Shown
TX,4360,DV2980 –19–19NOV01–4/4
43
4360
12

010904
PN=374
Hydraulic System
Swing Motor Start-Up Procedure
IMPORTANT: Swing motor will be damaged if not

filled with oil before operating swing
function. Start-up procedure must be
performed whenever a new swing motor
–UN–20JUL01
is installed or oil has been drained from
the motor.
T143358D
Procedure is to ensure swing motor is filled with oil.
1. Disconnect swing motor hydraulic line (1). 200CLC Machine Shown
2. Fill motor with Hydraulic Oil through port until oil 1—Hydraulic Line
reaches level of port. (Operator’s Manual.)
NOTE: Air must be allowed to escape from the swing

motor while filling.
3. Connect hydraulic line (1).
OUOE027,000003D –19–19NOV01–1/1
Brake Release Valve Repair—270CLC
Remove and Install Brake Release Valve
2. Disconnect hydraulic line (3).
3. Remove cap screws (2) and remove brake release

valve (4).
4. Repair or replace parts as necessary. –UN–19NOV01
T147133B

3—Hydraulic Line
4—Brake Release Valve

43
4360
13

010904
PN=375
Hydraulic System
Disassemble and Assemble Brake Release Valve

2 3 4
1 5
1—O-Ring
2—O-Ring
6
3—Poppet
4—Spring 12
5—O-Ring
6—Spring 11
7—Spool
8—Housing
9—Bushing 10
10—Filter
–UN–19NOV01
11—Spacer 9 7
12—Orifice
T147146
8
OUOE054,0000021 –19–19NOV01–2/2
43
4360
14

010904
PN=376
Section 99
Dealer Fabricated Tools 99
Contents
Page
Group 9900—Dealer Fabricated Tools

DF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-1
ST4920 Track Recoil Spring
Disassembly and Assembly Tool . . . . . . . .99-9900-3
DFT1087 Track Recoil Spring
Disassembly and Assembly Guard Tool. . .99-9900-7
DFT1110 Spacer. . . . . . . . . . . . . . . . . . . . . .99-9900-8
DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .99-9900-9
DF1036A Propel Gearbox Nut Wrench . . . .99-9900-10
DF1038 Torque Adapter . . . . . . . . . . . . . . .99-9900-11
DFT1109 Holding Bar . . . . . . . . . . . . . . . . .99-9900-12
Rotary Manifold Lifting Tool. . . . . . . . . . . . .99-9900-13
DFT1089 Barrel Support . . . . . . . . . . . . . . .99-9900-14
DFT1144 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-15
DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-16
DFT1220 Swing Gearbox Nut Spanner
Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-18

010904
PN=1
Contents
99

010904
PN=2
Group 9900
Dealer Fabricated Tools
DF1063 Lift Bracket
Tool is the same as used on other machines. Only the lift 99

9900
bracket of the tool is used for this machine with adapter 1
DFT1130.
Lift Bracket is used to remove and install propel motor.
Material required:
• 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16
–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)
T8318AC
Continued on next page CED,OUTX818,81 –19–11MAY00–1/2

010904
PN=379
99
9900
2
–19–25APR90
T7247BW
CED,OUTX818,81 –19–11MAY00–2/2

010904
PN=380
ST4920 Track Recoil Spring Disassembly and

Assembly Tool
99
9900
NOTE: It is recommended that DFT1087 Track Recoil 3
Spring Disassembly and Assembly Guard Tool be
used with track recoil spring disassembly and
assembly tool.
Dimensions given are metric.
Tool is the same as used on other machines except the

holder (C). For each track adjuster use the holder with the
correct size hole for the nut on that track adjuster.
Track Recoil Spring Disassembly and Assembly Tool

(compression tool) is used with hydraulic jack to compress
recoil spring in track adjuster repair.
Material required:
–UN–24MAR98
• 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).
T6585UY
• “F” Grade (SAE Grade 8) for Studs (B).
Print Numbers:
A—Nut (12 used)
• A-ST4050 Nut B—Stud (4 used)
C—Holder
• B-ST4045 Bolt
D—Eyebolt (2 used)
• C-ST4035 Holder (Plate) E—Supporting Plate
• C-ST4036 Holder (Plate) F—Base Plate
• C-ST4037 Holder (Plate) G—Base (4 used)
• D-ST4047 Eyebolt H—Cap Screw (4 used)
I—Lock Washer (8 used)
• E-ST4040 Supporting Base
• F-ST4042 Base Plate
• G-ST4041 Base
• H-ST4046 Cap Screw
• I-ST4049 Lock Washer
Continued on next page TX,99,SB548 –19–08JAN97–1/4

010904
PN=381
99
9900
4
–UN–06JUL89
T7029CI

010904
PN=382
99
9900
5
–UN–06JUL89
T7029CH

010904
PN=383
99
9900
6
–UN–06JUL89
T7029CG
TX,99,SB548 –19–08JAN97–4/4

010904
PN=384
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

99
9900
7
–UN–17OCT89
T7162AF
A—3/16 in. 1020 CR Steel Plate C—1/2 in. Nut (2 used) D—1/2 x 2 in. Cap Screw (2 E—1/2 x 3 in. Steel Round
B—9/16 in. Hole (2 places) used) Stock (2 used)
Track Disassembly and Assembly Guard Tool is used • 3/16 in. 1020 CR Steel Plate (A)
with ST4920 Track Recoil Spring Disassembly and • 9/16 in. Hole (2 places) (B)
Assembly Tool. • 1/2 in. Nut (2 used) (C)
• 1/2 x 2 in. Cap Screw (D) (2 used)
Material required: • 1/2 x 3 in. Steel Round Stock (E) (2 used)
TX,99,SB542 –19–08JAN97–1/1

010904
PN=385
DFT1110 Spacer
99
9900
8
–UN–23FEB92
T7708AC
Spacer is used with ST4920 Track Recoil Spring Material Required:
Disassembly and Assembly Tool. Spacer is installed
on the bottom plate so force is applied to spring flange • 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy
on cylinder and not to the piston. Wall Steel Pipe
Cut the ends of spacer so they are parallel to each

other.
TX,99,SB549 –19–08JAN97–1/1

010904
PN=386
DFT1130 Adapter
99
9900
9
–UN–20SEP94
T8319BN
A—Adapter Plate B—Tube C—Stop Plate
Adapter is used with DF1063 Lift Bracket to remove • 1.3 mm (1/2 in.) 1020 Steel Plate (A)
and install propel motor. • 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)
Material required: • .6 mm (1/4 in.) 1020 Steel Plate (C)
CED,OUTX818,84 –19–11MAY00–1/1

010904
PN=387
DF1036A Propel Gearbox Nut Wrench

99
9900
10
–UN–28FEB92
T7681FZ
Propel Gearbox Nut Wrench is used to remove and • 16 mm (5/8 in.) Flat Bar Stock
install the hub-to-housing nut in the propel gearbox. • M24 (1 in.) Nut
• M10-1.5 x 60 mm Cap Screw (2 used)
Material required: • M10-1.5 Nut (2 used)
TX,99,SB544 –19–19NOV01–1/1

010904
PN=388
DF1038 Torque Adapter

99
9900
11
–UN–25OCT95
T6557CH
Torque Adapter is used to check rolling drag torque on • 17 mm (0.125 in.) hex head driver
rotor drive shaft.
Material required:
CED,OUTX818,83 –19–11MAY00–1/1

010904
PN=389
DFT1109 Holding Bar

99
9900
12
–UN–27FEB92
T7690AA
Holding Bar is used with the DF1036A Propel Gearbox Material required:
Nut Wrench as a guide when loosening the
hub-to-housing nut in the propel gearbox. • 16 mm (5/8 in.) Flat Bar Stock
TX,99,SB550 –19–23MAY00–1/1

010904
PN=390
Rotary Manifold Lifting Tool
Tool is used to remove and install rotary manifold. 99

9900
13
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
A—Threads
–UN–24OCT88
T6641DO
TX,99,SB546 –19–08JAN97–1/1

010904
PN=391
DFT1089 Barrel Support

99 Barrel supports are used to support the upperstructure
9900
14
when removing the undercarriage.
CAUTION: Cutting tops off barrels that
–UN–09JAN97
contained flammable or explosive material can
cause serious injury or death.
Material required:
T7149AC
• Clean metal 55 gallon barrels of equal height with lids
removed. (Must be 34.5—35.5 in. height x 24 in. wide.) A—2 x 4 in. Slotted Hole, Recessed
• 1/2 x 4 x 24 in. 1020 CR Plate B—1/2 x 4 x 24 in. 1020 CR Plate
• 1/2 x 4 x 12 in. 1020 CR Plate C—1/2 x 4 x 12 in. 1020 CR Plate
• One empty 3 lb coffee can or equivalent D—1/4 in. Fillet Weld
• Highway Cement (9 bag mix). Mix extra dry to aid E—One Empty 3 lb Coffee Can or Equivalent
curing time.
Insert hook assembly into barrel before cement is set.

Hold assembly in position, using a steel plate or wire, until
cement begins to cure.
Level off cement with top of barrels.
Cement must cure for a minimum of ten days.
The approximate weight of each barrel support is 545 kg

(1200 lb). The approximate support capacity of each
barrel support is 385 560 kg (850,000 lb).
TX,99,SB551 –19–08JAN97–1/1

010904
PN=392
DFT1144 Guide Pin
Guide pin is used to align cap screw holes in swing 99

9900
bearing and upperstructure. 15
Remove threads for a distance (B) and then grind a taper
–UN–24OCT88
on same end.
Materials required:
T6641EK
• M20-2.5 x 230 mm (9 in.) Threaded Rod
A—230 mm (9 in.)
B—100 mm (4 in.)
TX,99,SB552 –19–08JAN97–1/1

010904
PN=393
DFT1119 Pump Support

99
9900
16
–UN–23APR93
T7955AA
Pump support is used with a hand hoist to support a • 88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.) Square
pump(s) when an engine is removed. Steel Tubing
• 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) Square
Two end stands are needed. Steel Tubing
• 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) Square
Drill the holes through the square steel tubing so they Steel Tubing
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
Material required: Grade 5) Cap Screw (2 used)
• M10 or 3/8 in. D Grade (SAE Grade 5) Nut (2 used)
• C3 x 5 Steel Channel
TX,99,SB553 –19–08JAN97–1/1

010904
PN=394
99
9900
17

010904
PN=395
DFT1220 Swing Gearbox Nut Spanner Wrench

99
9900
18
–UN–17JUL01
T143704
Continued on next page OUOE047,000000E –19–19NOV01–1/2

010904
PN=396
1—Weld (4 Places)
Material required: • 159.4 x 38.1 x 6.35 mm (6.65 x 1.5 x .25 in.) 99

9900
19
• 159.4 x 82.5 mm (6.275 x 3.25 in.) Steel Tubing
OUOE047,000000E –19–19NOV01–2/2

010904
PN=397
99
9900
20

010904
PN=398
Index
Page Page
A Belt, seat
Remove and install . . . . . . . . . . . . . . . . .18-1821-1
Adjuster, track Bleed procedure
Disassemble and assemble . . . . . . . . .01-0130-21 Hydraulic cylinder . . . . . . . . . . . . . . . . 33-3360-152
Remove and install . . . . . . . . . . . . . . . .01-0130-19 Boom
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-2 Remove and install . . . . . . . . . . . . . . . . .33-3340-6
Air conditioner Boom cylinder Indx
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 1
Compressor, remove and install . . . . . .18-1830-11
Condenser, remove and install . . . . . . .18-1830-16 Inspect pins and bushings. . . . . . . . . . .33-3340-11
Receiver-dryer, remove and install . . . .18-1830-12 Remove and install . . . . . . . . . . . . . . . .33-3360-75
Remove and install . . . . . . . . . . . . . . . .18-1830-15 Boom cylinder—200CLC, 270CLC
Air conditioner and heater Disassemble and assemble . . . . . . . . .33-3360-80
Remove and install . . . . . . . . . . . . . . . .18-1830-15 Boom cylinder—230CLC
Air conditioner system Disassemble and assemble . . . . . . . . .33-3360-94
Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3 Boom pins and bushings
Air conditioning Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Charge R134a system . . . . . . . . . . . . .18-1830-10 Boom, arm, and bucket bushings and bosses
Evacuate R134a system . . . . . . . . . . . . .18-1830-9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Recover R134a refrigerant . . . . . . . . . . .18-1830-8 Boom, arm, and bucket pins
Refrigerant handling and cautions. . . . . .18-1830-1 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
R134a refrigerant oil information . . . . . . .18-1830-6 Bucket
R134a station installation . . . . . . . . . . . .18-1830-7 Adjust pivot end play. . . . . . . . . . . . . . . .33-3302-3
Air intake system Pin-up data . . . . . . . . . . . . . . . . . . . . . . .33-3302-4
Leakage test . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Remove and install . . . . . . . . . . . . . . . . .33-3302-1
Air test Bucket cylinder
Rotary manifold. . . . . . . . . . . . . . . . . . .02-0260-25 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152
Arm Inspect pins and bushings. . . . . . . . . . .33-3340-11
Remove and install . . . . . . . . . . . . . . . . .33-3340-3 Remove and install . . . . . . . . . . . . . . . 33-3360-124
Arm cylinder Bucket cylinder—200CLC, 270CLC
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Disassemble and assemble . . . . . . . . 33-3360-130
Inspect pins and bushings. . . . . . . . . . .33-3340-11 Bucket cylinder—230CLC
Remove and install . . . . . . . . . . . . . . . 33-3360-100 Dissassemble and assemble. . . . . . . . 33-3360-144
Arm cylinder—200CLC, 270CLC Bucket links
Disassemble and assemble . . . . . . . . 33-3360-104 Remove and install . . . . . . . . . . . . . . . . .33-3340-1
Arm cylinder—230CLC Bucket pins
Disassemble and assemble . . . . . . . . 33-3360-118 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Arm pins and bushings Bushings and seals
Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3340-14
Arm regenerative solenoid valve
Remove and install . . . . . . . . . . . . . . . .33-3360-35
C
Cab
B Remove and install . . . . . . . . . . . . . . . . .18-1800-1
Carrier roller, track
Bearing, swing Disassemble and assemble . . . . . . . . . .01-0130-6
Disassemble and assemble . . . . . . . . .43-4350-21 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1
Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . . .01-0130-5
Remove and install . . . . . . . . . . . . . . . .43-4350-19 Chain sprocket, track
Upper seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . .01-0130-14
Belt, fan Chain, track
Remove and install . . . . . . . . . . . . . . . . .05-0510-2 Disassemble and assemble . . . . . . . . .01-0130-12
TM1931 (09JAN04) Index-1 200CLC, 230CLC & 270CLC Excavator Repair

010904
PN=1
Index
Page Page
Disassemble and assemble to replace broken Controller, propel pilot

part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13 Disassemble and assemble . . . . . . . . .33-3360-42
Remove and install . . . . . . . . . . . . . . . .01-0130-10 Remove and install . . . . . . . . . . . . . . . .33-3360-40
Charge R134a system . . . . . . . . . . . . . . .18-1830-10 Cooler, oil
Cleaner, air Remove and install . . . . . . . . . . . . . . . .33-3360-74
Remove and install . . . . . . . . . . . . . . . . .05-0520-2 Counterbalance valve, propel motor
Indx Cleanup procedure, hydraulic oil Disassemble and assemble—200CLC and
2 Using portable filter caddy. . . . . . . . . . . .33-3360-2 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17
Compressor Disassemble and assemble—
Remove and install . . . . . . . . . . . . . . . .18-1830-11 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18
Condenser, air conditioner Counterweight
Remove and install . . . . . . . . . . . . . . . .18-1830-16 Remove and install . . . . . . . . . . . . . . . . .17-1749-1
Control valve Coupling, flex (dampener drive)
Arm priority flow rate valve . . . . . . . . . .33-3360-51 Remove and install . . . . . . . . . . . . . . . . .07-0752-1
Arm reduced leakage valve. . . . . . . . . .33-3360-51 Crossover relief valve
Arm regenerative valve . . . . . . . . . . . . .33-3360-57 Disassemble and assemble . . . . . . . . .43-4360-12
Arm regenerative valve check valve . . .33-3360-57 Remove and install . . . . . . . . . . . . . . . .43-4360-11
Auxiliary flow combiner valve check Crossover relief valve, propel motor
valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Disassemble and assemble—200CLC and
Auxiliary flow rate valve . . . . . . . . . . . .33-3360-51 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17
Auxiliary function flow combiner Disassemble and assemble—
valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18
Boom reduced leakage valve . . . . . . . .33-3360-57 Cylinder
Bucket flow rate valve . . . . . . . . . . . . . .33-3360-57 Arm, remove and install . . . . . . . . . . . 33-3360-100
Bypass shut-off valve . . . . . . . . . . . . . .33-3360-57 Arm—200CLC, 270CLC, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-104
Circuit relief and anti-cavitation
Arm—230CLC, disassemble and
valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64
assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-118
Lift check and orifice (arm II power
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152
passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-57
Boom, remove and install . . . . . . . . . . .33-3360-75
Lift check and orifice (left propel power
Boom—200CLC, 270CLC, disassemble and
passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51
assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-80
Lift check (arm I power passage) . . . . .33-3360-51
Boom—230CLC, disassemble and
Lift check (boom II power passage) . . .33-3360-51
assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-94
Lift check (left propel neutral
Bucket, remove and install . . . . . . . . . 33-3360-124
passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51
Bucket—200CLC, 270CLC, disassemble and
Lift check (swing neutral passage) . . . .33-3360-51 asemble. . . . . . . . . . . . . . . . . . . . . . 33-3360-130
Propel flow combiner valve check Bucket—230CLC, disassemble and
valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-144
Propel function flow combiner valve . . .33-3360-57 Bushings and seals, remove and
Remove and install . . . . . . . . . . . . . . . .33-3360-49 install. . . . . . . . . . . . . . . . . . . . . . . . .33-3340-14
Right propel and bucket combined function
check valve and orifice . . . . . . . . . . .33-3360-64
Spool assemblies (4-spool) . . . . . . . . . .33-3360-57
Spool assemblies (5 spool) . . . . . . . . . .33-3360-51 D
System relief and power boost valve. . .33-3360-51
System relief valve isolation check Dampener drive
valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 Remove and install . . . . . . . . . . . . . . . . .07-0752-1
4-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-57 Dealer fabricated tools
5-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 DFT1087 track recoil spring disassembly and
Controller, pilot assembly guard tool . . . . . . . . . . . . . .99-9900-7
Disassemble and assemble . . . . . . . . .33-3360-39 DFT1089 barrel support . . . . . . . . . . . .99-9900-14
Remove and install . . . . . . . . . . . . . . . .33-3360-37 DFT1109 holding bar . . . . . . . . . . . . . .99-9900-12

010904
PN=2
Index
Page Page
DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-8 Flush air conditioner system . . . . . . . . . . . .18-1830-3

DFT1114 guide pin . . . . . . . . . . . . . . . .99-9900-15 Front idler
DFT1119 pump support . . . . . . . . . . . .99-9900-16 Disassemble and assemble . . . . . . . . .01-0130-17
DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1
DFT1220 swing gearbox nut spanner Remove and install . . . . . . . . . . . . . . . .01-0130-16
wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-18 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19
DF1036A propel gearbox nut Fuel filter, final Indx
3
wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10 Remove and install . . . . . . . . . . . . . . . . .05-0560-4
DF1038 torque adapter . . . . . . . . . . . . .99-9900-11 Fuel filter, primary
DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1 Remove and install . . . . . . . . . . . . . . . . .05-0560-3
Rotary manifold lifting tool. . . . . . . . . . .99-9900-13 Fuel injection pump
ST4920 track recoil spring disassembly and Remove and install . . . . . . . . . . . . . . . . .04-0400-4
assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3 Fuel tank
Drive gearbox and hydraulic pump Remove and install . . . . . . . . . . . . . . . . .05-0560-2
Disassemble and assemble . . . . . . . . . .33-3360-5
Drive, dampener (flex coupling)
G
Gearbox
Pump drive, pilot pump drive shaft . . . .33-3360-21
E Gearbox, drive and hydraulic pump
End play, bucket pivot Remove and install . . . . . . . . . . . . . . . . .33-3360-3
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-3 Gearbox, propel
Engine Disassemble and assemble—200CLC and
Remove and install . . . . . . . . . . . . . . . . .04-0400-1 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0250-5
Engine air cleaner Disassemble and assemble—
Remove and install . . . . . . . . . . . . . . . . .05-0520-2 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0250-11
Evacuate R134a system. . . . . . . . . . . . . . .18-1830-9 Remove and install . . . . . . . . . . . . . . . . .02-0250-1
Gearbox, swing
Disassemble and assemble—200CLC and
230CLC . . . . . . . . . . . . . . . . . . . . . . . .43-4350-5
F
Disassemble and assemble—270CLC . .43-4350-9
Fan
Fan belt
Remove and install . . . . . . . . . . . . . . . . .05-0510-2 H
Fan guard
Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Heater
Fan shroud Remove and install . . . . . . . . . . . . . . . .18-1830-15
Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Hydraulic
Filter, final fuel Fittings, 30° cone seat . . . . . . . . . . . . . .00-0003-9
Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Fittings, 37° flare. . . . . . . . . . . . . . . . . . .00-0003-9
Filter, pilot Hydraulic cylinder
Disassemble and assemble . . . . . . . . .33-3360-31 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152
Remove and install . . . . . . . . . . . . . . . .33-3360-30 Hydraulic fitting
Filter, primary fuel Flared connections . . . . . . . . . . . . . . . .00-0003-10
Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Hydraulic oil
Final fuel filter Cleanup procedure using portable filter
Remove and install . . . . . . . . . . . . . . . . .05-0560-4 caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-2
Flex coupling Hydraulic oil tank
Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Disassemble and assemble . . . . . . . . .33-3360-69

010904
PN=3
Index
Page Page
Pressure release procedure . . . . . . . . . .33-3360-1 Disassemble and assemble—270CLC . .02-0260-7

Remove and install . . . . . . . . . . . . . . . .33-3360-66 Remove and install—200CLC and
Hydraulic pump 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1
Start-up procedure . . . . . . . . . . . . . . . .33-3360-20 Remove and install—270CLC . . . . . . . . .02-0260-1
Hydraulic pump and drive gearbox
Indx Remove and install . . . . . . . . . . . . . . . . .33-3360-3
4
O
Hydraulic pump regulator
Disassemble and assemble . . . . . . . . .33-3360-24
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6
Oil
Carrier roller, specification. . . . . . . . . . . .01-0130-1
Front idler, specification . . . . . . . . . . . . .01-0130-1
I Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-5
Track roller, specification . . . . . . . . . . . .01-0130-1
Idler, front Oil cooler
Disassemble and assemble . . . . . . . . .01-0130-17 Remove and install . . . . . . . . . . . . . . . .33-3360-74
Remove and install . . . . . . . . . . . . . . . .01-0130-16 Oil cooler bypass valve
Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19 Remove and install . . . . . . . . . . . . . . . .33-3360-71
Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-1 Oil information
Injection pump R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6
Remove and install . . . . . . . . . . . . . . . . .04-0400-4 Oil leakage test
Front idler . . . . . . . . . . . . . . . . . . . . . . .01-0130-19
Track roller . . . . . . . . . . . . . . . . . . . . . . .01-0130-4
Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-5
L Oil tank, hydraulic
Leakage test Remove and install . . . . . . . . . . . . . . . .33-3360-66
Air intake system . . . . . . . . . . . . . . . . . .05-0520-1
Links, bucket
P
Pilot controller
M Disassemble and assemble . . . . . . . . .33-3360-39
Manifold, pilot signal Pilot controller, propel
Disassemble and assemble . . . . . . . . .33-3360-47 Disassemble and assemble . . . . . . . . .33-3360-42
Remove and install . . . . . . . . . . . . . . . .33-3360-43 Remove and install . . . . . . . . . . . . . . . .33-3360-40
Manifold, rotary Pilot filter
Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25 Disassemble and assemble . . . . . . . . .33-3360-31
Remove and install . . . . . . . . . . . . . . . .02-0260-22 Pilot filter and pilot pressure regulating valve
Metal face seals Disassemble and assemble . . . . . . . . .33-3360-31
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Remove and install . . . . . . . . . . . . . . . .33-3360-30
Metric torque values . . . . . . . . . . . . . . . . . .00-0003-2 Pilot pressure regulating valve and filter
Motor cover, propel Disassemble and assemble . . . . . . . . .33-3360-31
Disassemble and assemble—200CLC and Remove and install . . . . . . . . . . . . . . . .33-3360-30
230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Pilot pump
Disassemble and assemble— Disassemble and assemble . . . . . . . . .33-3360-29
270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Drive shaft and gear, disassemble . . . .33-3360-21
Motor, propel Remove and install . . . . . . . . . . . . . . . .33-3360-27
Disassemble and assemble—200CLC and Pilot shut-off valve
230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-4 Disassemble and assemble . . . . . . . . .33-3360-33

010904
PN=4
Index
Page Page
Remove and install . . . . . . . . . . . . . . . .33-3360-31 Pump, pilot

Pilot signal manifold Disassemble and assemble . . . . . . . . .33-3360-29
Remove and install . . . . . . . . . . . . . . . .33-3360-43 Purge air conditioner system . . . . . . . . . . .18-1830-3
Pin-up data
Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4
Portable filter caddy Indx
R 5
Hydraulic oil cleanup procedure . . . . . . .33-3360-2
Power boost solenoid valve
Radiator
Pressure release procedure
Receiver-dryer
Hydraulic oil tank . . . . . . . . . . . . . . . . . .33-3360-1
Primary fuel filter
Recoil spring, track
Propel gearbox
Recover R134a refrigerant . . . . . . . . . . . . .18-1830-8
230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0250-5
Refrigerant
Disassemble and assemble—
Cautions and proper handling . . . . . . . . .18-1830-1
270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0250-11
Recover R134a, air conditioning . . . . . . .18-1830-8
Refrigerant oil information
Propel motor
R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6
Refrigerant recovery/recycling and charging
230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-4
Charging station installation
procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7
270CLC . . . . . . . . . . . . . . 02-0260-7, 02-0260-18
Regulator, hydraulic pump
Remove and install—200CLC and
230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1
Remove and install—270CLC . . . . . . . . .02-0260-1
Relief valve, crossover, propel motor
Start-up procedure . . . . . . . . . . . . . . . .02-0260-22
Propel motor cover
230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17
230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17
270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18
Restriction valve
270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18
Propel motor, counterbalance valve
Roller, track
230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17
Oil leakage test . . . . . . . . . . . . . . . . . . . .01-0130-4
270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18
Rotary manifold
Propel pilot controller
Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25
Propel speed solenoid valve
R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8
R134a refrigerant recovery and charging station
Pump
Installation procedure . . . . . . . . . . . . . . .18-1830-7
Fuel injection, remove and install . . . . . .04-0400-4
R134a system charge. . . . . . . . . . . . . . . .18-1830-10
Pump regulator, hydraulic
R134a system evacuate . . . . . . . . . . . . . . .18-1830-9
Pump, hydraulic and drive gearbox
Disassemble and assemble . . . . . . . . . .33-3360-5 S
Start-up procedure . . . . . . . . . . . . . . . .33-3360-20 Safety signs . . . . . . . . . . . . . . . . . . . . . . .00-0001-13

010904
PN=5
Index
Page Page
Seals, metal face Swing motor make-up valve

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Remove and install . . . . . . . . . . . . . . . .43-4360-12
Seat belt
Shoe, track
T
Indx Shut-off valve, pilot
6
Tank pressure release procedure . . . . . . . .33-3360-1
Tank, fuel
Signal manifold, pilot
Tank, hydraulic oil
Sliding window
Torque value
Flared connections . . . . . . . . . . . . . . . .00-0003-10
Specification
Flat face O-ring seal fitting . . . . . . . . . . .00-0003-8
Carrier roller oil . . . . . . . . . . . . . . . . . . . .01-0130-1
Inch SAE four bolt flange fitting. . . . . . .00-0003-11
Front idler oil. . . . . . . . . . . . . . . . . . . . . .01-0130-1
Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3
Track roller oil . . . . . . . . . . . . . . . . . . . . .01-0130-1
Metric four bolt flange fitting . . . . . . . . .00-0003-12
Spring, track recoil
O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6
30° cone seat hydraulic fittings . . . . . . . .00-0003-9
37° flare hydraulic fittings . . . . . . . . . . . .00-0003-9
Sprocket
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1
Start-up procedure
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-20
Track adjuster
Propel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22
Swing gearbox . . . . . . . . . . . . . . . . . . .43-4350-11
Swing motor . . . . . . . . . . . . . . . . . . . . .43-4360-13
Track adjuster cylinder
Starter
Track carrier roller
Swing bearing
Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24
Track chain
Upper seal, install . . . . . . . . . . . . . . . . .43-4350-24
Disassemble and assemble to replace broken
Swing gearbox
part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13
230CLC . . . . . . . . . . . . . . . . . . . . . . . .43-4350-5
Track chain sprocket
Disassemble and assemble—270CLC . .43-4350-9
Track roller
Swing motor
Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1
Swing motor and park brake
Test for oil leakage . . . . . . . . . . . . . . . . .01-0130-4
Assemble—200CLC and 230CLC . . . . . .43-4360-9
Track shoe
Assemble—270CLC . . . . . . . . . . . . . . . .43-4360-9
Disassemble—200CLC and 230CLC . . .43-4360-5
Disassemble—270CLC . . . . . . . . . . . . . .43-4360-7
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-8
Remove and install . . . . . . . . . . . . . . . . .43-4360-1 U
Swing motor brake release valve
Disassemble and assemble . . . . . . . . .43-4360-14 Upperstructure
Remove and Install . . . . . . . . . . . . . . . .43-4360-13 Install . . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-16

010904
PN=6
Index
Page
Remove . . . . . . . . . . . . . . . . . . . . . . . .43-4350-12
Valve Indx
Disassemble and assemble— 7
270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18
Valve, brake release, swing motor
Valve, control
Valve, counterbalance, propel motor
270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18
Valve, crossover relief
Valve, make-up, swing motor
Valve, oil cooler bypass
Valve, pilot pressure regulating
Valve, pilot shut-off
Valve, restriction
Water separator, primary fuel filter

Welding on machine . . . . . . . . . . . . . . . . . .17-1740-1
Window, sliding
Windowpane and one piece molding
Windowpane and two piece molding
Windowpanes

010904
PN=7
Index
Indx
8

010904
PN=8

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For complete service information also see:

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

Technical Information Feedback Form

We need your help to continually improve our technical

SEND TO: John Deere Dubuque Works

FAX NUMBER: 563-589-5800

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

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

SECTION 02—Axles and Suspension Systems

SECTION 07—Dampener Drive (Flex Coupling) 05

SECTION 17—Frame or Supporting Structure

SECTION 18—Operator’s Station

SECTION 43—Swing or Pivoting System

SECTION 99—Dealer Fabricated Tools 33

All information, illustrations and specifications in this manual are based on

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

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

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

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

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

Group 0003—Torque Values

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

TM1931 (09JAN04) 00-2 200CLC, 230CLC & 270CLC Excavator Repair

This is the safety alert symbol. When you see this

Follow the precautions and safe operating practices

A signal word — DANGER, WARNING, or CAUTION — is

Follow Safety Instructions

Read the safety messages in this manual and on the

Be sure all operators of this machine understand every

Operate Only If Qualified

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

Guard against injury from flying pieces of metal or debris;

Wear close fitting clothing and safety equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding For Special Uses

Special work situations or machine attachments may

FOPS (falling object protective structures) and special

TM1931 (09JAN04) 00-0001-2 200CLC, 230CLC & 270CLC Excavator Repair

Inspect machine carefully each day by walking around it

Keep all guards and shields in good condition and

Stay Clear Of Moving Parts

Stop engine before examining, adjusting or maintaining

Avoid High-Pressure Fluids

This machine uses a high-pressure hydraulic system.

Never search for leaks with your hands. Protect hands.

If hydraulic fluid penetrates your skin, see a doctor

Contact a knowledgeable medical source or the Deere &

TM1931 (09JAN04) 00-0001-3 200CLC, 230CLC & 270CLC Excavator Repair

Prevent asphyxiation. Engine exhaust fumes can cause

Keep A Fire Extinguisher Available: Always keep a

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

Never check battery charge by placing a metal object

Do not charge a frozen battery; it may explode. Warm