330D and 336D Excavators Machine Systems

Desarmado y Armado
330D and 336D Excavators Machine Systems
Número de medio -RENR8648- Fecha de publicación Fecha de actualización

11 -01/01/2010 -27/01/2010

i02154175
Duo-Cone Conventional Seals - Install

SMCS - 7561-012
Installation Procedure
When the Duo-Cone Seals are installed and assembled, you must use the correct
procedures. The Duo-Cone Seal may fail from one or more mistakes that are made
during assembly or during installation of the seal components.
Reference: Special Instruction, SEHS8364, "Assembly and Installation of Conventional

Duo-cone Seals"
Reference: Special Instruction, SEHS8484, "Tool and Specification Chart for

Conventional Duo-Cone Seals"
Table 1
Required Tools
Tool Part Number Part Description Qty
6V-3075 Dial Indicator 1
6V-6167 Contact Point 1

A
3P-1565 Collet Assembly 1
165-8958 Dial Indicator Base 1
B 169-0503 Installation Kit 1
Correct Assembly of Conventional Duo-Cone Seals
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g01092143
Illustration 1
Assembly and Installation Procedure
Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing

the vapors in enclosed areas without adequate ventilation and do not
smoke.
Isopropyl alcohol is flammable. Do not use near open flame, welding

operations, or around heated surfaces exceeding 482°C (900°F).
1. Remove any film, dust or other foreign matter from the following components:
o Rubber toric ring (2)
o Housing ramp (4)
o Seal ring ramp (7)
o Housing retaining lip (3)
o Seal ring retaining lip (8)
o Seal ring housing (5)
Note: Seal rings have very sharp edges. Protective gloves should be worn in
order to prevent injury.
Use the cleaning agents in Tooling (B) or use isopropyl alcohol or other
approved cleaning agents. Use a clean lint free cloth for wiping. All components
should be completely dry before proceeding.
Note: Never permit oil to contact rubber toric ring (2), housing ramp (4) or seal
ring ramp (7) before both seal rings (1) are assembled in the final position.
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Illustration 2
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Illustration 3
2. Put rubber toric ring (2) on seal ring (1). Make sure that the rubber toric ring is
positioned at the bottom of seal ring ramp (7). The rubber toric ring must rest
against retaining lip (8). The rubber toric ring must be straight in the seal ring.
The rubber toric ring must not be twisted.
Note: Be careful when you are working on the rubber toric ring. Nicks, cuts or
scratches may cause leaks.
3. Refer to Special Instruction, SEHS8484, "Tool and Specification Chart for

Conventional Duo-Cone Seals" in order to select the proper installation tool.
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g00534621
Illustration 4
Use towels or a mat (A) that is made of foam to aid with installing the toric ring (2) .
4. Install rubber toric ring (2) on seal ring (1) with installation tool (9). Lightly
dampen the lower half of rubber toric ring (2) with an appropriate lubricant.
Refer to the "Acceptable Lubricants for Assembly" section that is in this
publication for additional information. Use the following techniques in order to
dampen the rubber toric ring:
o Wipe the seal with a lint free cloth.
o Place towels or a mat that is made of foam at the bottom of a container.
Soak the towels or the mat with the lubricant. Dip the rubber toric seal in
the container.
Note: Periodically inspect the installation tool for damage. If necessary, replace
the installation tool.
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Illustration 5
5. Make sure that the lower half of rubber toric ring (2) is still wet. Use installation
tool (9) in order to position seal ring (1) and rubber toric ring (2) squarely
against seal ring housing (5). Make sure that you use sudden pressure and even
pressure when you press a toric ring that has a small diameter. Press rubber toric
ring (2) under housing retaining lip (3) that is part of seal ring housing (5). Use
the following steps in order to install a rubber toric ring that has a large
diameter:
o Push the rubber toric ring over the seal ring retaining lip on one side.
o Tap the installation tool with a rubber mallet on the opposite side of the
rubber toric ring. Tap until the rubber toric ring is past the seal ring
retaining lip of the housing.
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g01092154
Illustration 6
Tooling (A)
(B) Assembled height
(10) Dial indicator
(11) Collet assembly
(12) Dial indicator base (plastic)
(13) Contact point

6. Use Tooling (A) to check the assembled height (B) at four locations that are 90
degrees from each other. The difference in height must not exceed 1.0 mm (0.04
inch). Refer to Illustration 6.
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Illustration 7
7. Do not adjust the seal ring (1) by pushing on the seal ring or by pulling on the
seal ring. Use installation tool (9) in order to push down on the seal.
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Illustration 8
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Illustration 9
Examples of incorrect assembly

8. Rubber toric ring (2) may twist during installation if the seal is not completely
wet or if there are burrs or fins on housing retaining lip (3) that is part of seal
ring housing (5). Misalignments, twists and bulges of the rubber toric ring will
cause Duo-Cone Seal failures. If correct installation is not obvious, remove the
toric ring from the housing and repeat the installation procedure.
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g00446495
Illustration 10
9. Wipe seal ring face (6) that is part of seal rings (1) by using a lint free cloth. No
particles of any kind are permissible on the sealing surfaces. A small piece of
paper from a paper towel can force apart the seal ring face, which will cause a
leak.
Note: Rubber toric ring (2) must never slip on the ramps of seal ring (1) or the
ramps of seal ring housing (5). In order to prevent slippage, allow adequate time
for evaporation of the lubricant before proceeding with the procedure. Once the
rubber toric ring is correctly positioned, the rubber toric ring must roll only on
the ramps.
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g00534623
Illustration 11
10. Apply a thin film of clean oil on the entire seal ring face of one or both seals.
Use a lint free cloth or brush in order to distribute the oil evenly. Be careful not
to get any oil on the rubber toric rings. Lubricate the seal faces by using the
same oil that was used during assembly. Dye may have been used in the oil that
was used during assembly. Use the same kind of oil without dye in order to
lubricate the seal faces.
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g00446497
Illustration 12
11. Make sure that both seal ring housings (5) are in correct alignment and that the
seal ring housings are concentric. Move the parts slowly and move the parts
carefully toward each other.
Note: Do not force the seal ring and the seal ring housing together in a sudden
manner. The seal component could be scratched or the seal component could be
broken if the components are slammed together.
12. Tighten the bolts after the components are in the correct position.
Acceptable Lubricants for Assembly
Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing

the vapors in enclosed areas without adequate ventilation and do not
smoke.
Isopropyl alcohol is flammable. Do not use near open flame, welding

operations, or around heated surfaces exceeding 482°C (900°F).
Note: Do not use any liquid that leaves an oil film. Do not use any liquid that does not
evaporate quickly. All of the guidelines for safety and all of the guidelines for disposal
must be followed when you use a flammable liquid. The following liquids are
acceptable lubricants for assembly:
 Quaker Solvo Clean 68-0

 Houghto-Grind 60 CT
 Isopropyl alcohol
Some seal kits come with silicone toric rings. As an option to using liquid lubricants to
install silicone toric rings, the rings can be chilled for easier installation. This will allow
the toric ring to contract for easier installation.
If chilling is desired, Seals should be placed in a freezer for 5 minutes prior to

installation. Temperature in the freezer should be between -40°C (-40°F) to -18°C (0°F).
Contraction will be sufficient to allow installation. The seals should be allowed to warm
to room temperature prior to further assembly.
Result of Incorrect Assembly
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g00446498
Illustration 13
The slipping of the rubber toric ring on the housing ramp or on the seal ring ramp may
result in uneven pressure on the seal face. Uneven pressure on the seal face causes
galling, scoring, and leakage.
If the rubber toric ring slips at one location but not all the way around the seal ring, the
toric ring will twist.
The twisted toric ring could be cocked. Seals that are cocked will cause uneven pressure
on the seal face. Seals that are cocked may also cause possible galling, scoring, and
leakage.
The twisted toric ring could oscillate when the ring is rotated. Seals that oscillate may
allow dirt into the seal joint. This is caused by the pumping action that is created by the
toric ring that is oscillating.
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Illustration 14
Illustration 14 shows a toric ring that is assembled incorrectly. The upper housing is
stationary. The lower housing is rotating.
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Illustration 15
Illustration 15 shows the same seal after the lower housing has rotated 180 degrees. In
this position, there will be high pressure at Point (B) and at Point (X). These points of
high pressure may result in galling of the toric rings. There will be low pressure at Point
(A) and at Point (Y) which will result in possible leakage.
Copyright 1993 - 2010 Caterpillar Inc. Wed Feb 3 20:28:20 UTC-0300 2010
Todos los derechos reservados.
Red privada para licenciados del SIS.
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11 -01/01/2010 -27/01/2010

i02373199
Hydraulic System Pressure - Release

SMCS - 5050-553-PX
Procedure for Releasing Pressure

The release of hydraulic pressure in a hydraulic circuit is required before service is
performed to that hydraulic circuit. Release the pressure in the following hydraulic
circuits before any hydraulic lines are disconnected or removed from that hydraulic
circuit.
 Boom hydraulic circuit

 Stick hydraulic circuit
 Bucket hydraulic circuit
 Swing hydraulic circuit
 Travel hydraulic circuit
 Attachment hydraulic circuits (if equipped)
 Pilot hydraulic circuit
 Return hydraulic circuit
Note: Refer to the Disassembly and Assembly Manual for additional information
concerning service of the components of specific hydraulic circuits.
Release Of Hydraulic Pressure From A Single

Hydraulic Circuit
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Perform the following Steps in order to release the hydraulic pressure from a single
hydraulic circuit of the main hydraulic system.
1. Position the machine on level ground.
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g00666865
Illustration 1
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the
bucket is parallel to the ground. Lower the boom until the bucket is flat on the
ground. Refer to Illustration 1.
3. Shut off the engine.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires
service to the FULL STROKE positions. This will release the high pressure only
in that single hydraulic circuit. This will also release any pressure that might be
present in the pilot hydraulic circuit.
Note: If the desired hydraulic circuit that requires service requires the activation
of a switch for operation, activate the necessary switches for the operation of the
hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Turn the engine start switch to the OFF position.
9. Slowly loosen the filler plug on the hydraulic tank and release the pressure from
the hydraulic tank. Leave the filler plug loose for a minimum of 45 seconds.
This will release the pressure that may be present in the return hydraulic circuit.
10. Tighten the filler plug on the hydraulic tank to the specified torque.
11. The pressure in the single hydraulic circuit that requires service is now released
and lines and components can be disconnected or removed from that hydraulic
circuit.
Release Of Hydraulic Pressure From Multiple

Hydraulic Circuits
Make sure all of the attachments have been lowered to the ground, and
NOTICE
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
Perform the following Steps in order to release the hydraulic pressure from multiple
hydraulic circuits of the main hydraulic system.
1. Position the machine on level ground.
Ver imagen
g00666865
Illustration 2
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the
bucket is parallel to the ground. Lower the boom until the bucket is flat on the
ground. Refer to Illustration 2.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires
service to the FULL STROKE positions. This will release the high pressure only
in that hydraulic circuit. This will also release any pressure that might be present
in the pilot hydraulic circuit.
Note: If the hydraulic circuit that requires service requires the activation of a
switch for operation, activate the necessary switches for the operation of the
hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Start the engine.
9. Place the hydraulic activation control lever in the UNLOCKED position. Do not
move any joysticks or pedals from the NEUTRAL position during this step.
Do not activate any switches during this Step.
10. Return the hydraulic activation control lever to the LOCKED position.

12. Repeat Steps 4 through 11 for each additional hydraulic circuit that requires
service.
13. After releasing the hydraulic pressure in each of the desired hydraulic circuits,
place the hydraulic activation control lever in the LOCKED position.
14. Turn the engine start switch to the OFF position.
15. Slowly loosen the filler plug on the hydraulic tank and release the pressure.
Leave the filler plug loose for a minimum of 45 seconds. This will release the
pressure that may be present in the return hydraulic circuit.
16. Tighten the filler plug on the hydraulic tank to the specified torque.
17. The pressure in the multiple hydraulic circuits that require service is now
released and lines and components can be disconnected or removed from those
hydraulic circuits.
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11 -01/01/2010 -27/01/2010

i03394040
Bucket Cylinder - Remove and Install

SMCS - 5457-010
Removal Procedure
Table 1
Required Tools
A 3S-6224 Electric Hydraulic Pump Gp 1
9U-5266 Sleeve 1

9U-5340 Sleeve Extension 1
6V-3175 Double Acting Cylinder 1
9U-5346 Nut 1
137-8460 Puller Stud 1
Start By:
A. Release the hydraulic system pressure. Refer to Disassembly and Assembly,

"Hydraulic System Pressure - Release".
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
NOTICE
Do not use threaded rods that have not been hardened as tooling with
hydraulic cylinders. The maximum rated tonnage should be stamped on
one end of the puller studs. Do not use threaded rods that have not been
stamped with the rated tonnage.
Cylinders equipped with lock valves can remain pressurized for very
long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or

disassembling a cylinder can result in personal injury or death.
Ensure all pressure is relieved before removing a lock valve or

disassembling a cylinder.
NOTICE
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes
for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss
and this helps to keep contaminants from entering the system.
Ver imagen
g01215853
Illustration 1
1. Attach a suitable lifting device to the rod end of bucket cylinder (1) . The weight
of bucket cylinder (1) is approximately 306 kg (675 lb). Position suitable
blocking under the bucket linkage.
2. Attach a suitable lifting device to Tooling (A) . The weight of Tooling (A) is
approximately 65 kg (140 lb). Remove the nut and bolt (2) . Use Tooling (A) in
order to remove pin (3) . The combined weight of Tooling (A) and pin (3) is
approximately 90 kg (200 lb). Remove any shims that are present.
Ver imagen
g01215868
Illustration 2
3. Raise the rod end of bucket cylinder (1) until bucket cylinder (1) is horizontal.
Attach a suitable lifting device to the head end of bucket cylinder (1) .
Disconnect hose assemblies (4) . Remove bolt (6) and remove pin assembly (5) .
Remove bucket cylinder (1) .
Disassembly and Assembly Information

Table 2
Required Tools
125-0079 Hydraulic Cylinder Repair Stand 1

B
152-4249 Hydraulic Cylinder Repair Stand (1) 1
C 4C-4032 Bearing Mount Compound 1
D 1P-0520 Driver Gp 1
E 120-9143 Cylinder Wash Tank Gp 1
F 9U-6803 Hydraulic Cylinder Tool Gp 1
G 5P-0960 Grease Cartridge 1
3S-6224 Electric Hydraulic Pump Gp 1
9U-5266 Sleeve 1
9U-5340 Sleeve Extension 1

H
9U-5346 Nut 1

( 1 )
CE Compliant
NOTICE
Note: Tooling (H) is used for the removal of the bearings that are located at the rod end
and the head end of the bucket cylinder.


NOTICE
containing fluids.


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g00822205
Illustration 3
(1) Torque for locknut ... 7600 ± 380 N·m (5605 ± 280 lb ft)
(2) Lubricate the seals slightly with the lubricant that is being sealed.
(3) Torque for twelve bolts ... 367 ± 55 N·m (270 ± 41 lb ft)
(4) Torque for setscrew ... 57 ± 10 N·m (42 ± 7 lb ft)
Apply Tooling (B) to the wiper seal groove prior to assembly.
Torque for fittings 9 ± 5 N·m (80 ± 45 lb in)
Table 3
Required Tools
J 5P-0960 Grease Cartridge 1
K 4C-9485 Pin Driver Cap 1
Ver imagen
g01215868
Illustration 4
1. Attach a suitable lifting device to bucket cylinder (1) . The weight of bucket
cylinder (1) is approximately 306 kg (675 lb). Position bucket cylinder (1) onto
the machine. Make sure that the grease fittings that are located at the head end
and the rod end of bucket cylinder (1) are facing away from the stick.
2. Install a shim on each side of the head end of bucket cylinder (1) . Apply
Tooling (J) to pin assembly (5) .
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g01217055
Illustration 5
3. Use the suitable lifting device in order to position the rod end of bucket cylinder
(1) . Install a shim on both sides of the power link. Install the shims between the
power link and the idler links. Apply Tooling (H) to pin (3) . Use two people
and Tooling (J) in order to install pin (3) . The weight of pin (3) is
approximately 27 kg (60 lb).
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Illustration 6
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Illustration 7
4. Install bolt (2) and the nut that secures pin (3) . Tighten the outside nut until the
outside nut is 0.5 mm (0.019 inch) beyond the end of bolt (2) . Tighten the inside
nut against the outside nut to a torque of 530 ± 70 N·m (391 ± 52 lb ft).
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i02451321
Bucket - Remove
SMCS - 6101-011
Removal Procedure
Table 1
Required Tools
141-1785 Receiving Sleeve 1
A 6V-3175 Double Acting Cylinder 1
9U-6809 Nut 1
9U-5346 Nut 1
B 140-7742 Sleeve 2
C 9U-6811 Puller Stud 1
9U-6809 Nut 1
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Illustration 1
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Illustration 2
1. Position bucket (1) on the ground. Position O-ring seals (2) from the pin joint
onto the flanges of bucket (1) .
Ver imagen
Illustration 3 g01209896
2. Attach a suitable lifting device and Tooling (B) to Tooling (A). Attach Tooling
(A) to pin assembly (4). The weight of Tooling (A) is approximately 137 kg
(300 lb).
3. Remove bolt (3). Use Tooling (A) in order to remove pin assembly (4). The
combined weight of Tooling (A) and pin assembly (4) is approximately 170 kg
(375 lb).
Note: Reposition the suitable lifting device as pin assembly (4) is removed.
4. Remove O-ring seals (2) (not shown).
Ver imagen
g01202427
Illustration 4
5. Position O-ring seals (5) from the pin joint onto the flanges of bucket (1) .
Ver imagen
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Illustration 5
6. Attach a suitable lifting device and Tooling (B) to Tooling (C). Attach Tooling
(C) to pin assembly (7). The weight of Tooling (C) is approximately 137 kg (300
lb).
7. Remove bolt (6). Use Tooling (C) in order to remove pin assembly (7). The
combined weight of Tooling (C) and pin assembly (7) is approximately 170 kg
(375 lb).
Note: Reposition the suitable lifting device as pin assembly (7) is removed.
8. Remove O-ring seals (5) (not shown).
9. Use the machine hydraulics in order to raise the stick from bucket (1) .
Ver imagen
g01202447
Illustration 6
10. Remove bolts (11), plate (10), shims (9), and flange (8) from bucket (1) .
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i02451322
Bucket - Install
SMCS - 6101-012
Table 1
Required Tools
D 9U-6225 Pin Driver Cap 1
E 4C-9485 Pin Driver Cap 1
F 5P-0960 Grease Cartridge 1
Ver imagen
g01203298
Illustration 1
1. Apply Tooling (F) to the outside machined surface of flange (8) and the bore for
flange (8). Install flange (8) to bucket (1) .
Note: Ensure that the alignment pin in flange (8) is positioned between two of
the bolt holes.
Ver imagen
g01203184
Illustration 2
2. Position O-ring seals (5) onto the flanges of bucket (1) .
3. Use the machine hydraulics in order to position the stick into bucket (1) .
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g01223803
Illustration 3
4. Install Tooling (D) to pin assembly (7). Apply Tooling (E) to pin assembly (7) .
5. Attach a suitable lifting device to pin assembly (7) and install pin assembly (7).
The weight of pin assembly (7) is approximately 34 kg (75 lb).
6. Remove Tooling (D) from pin assembly (7) .
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Illustration 4
7. Install bolt (6) .
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Illustration 5
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Illustration 6
8. Align the locating hole in plate (10) with the locating pin in flange (8). Position
shims (9) and plate (10). Install bolts (11) and tighten bolts (11) evenly.
9. Move the bucket to the side until the bucket contacts the stick. Measure the
clearance between the bucket and the stick at flange (8). Record this dimension
as Dimension (X). Remove bolts (11) and plate (10). Add or remove shims (9)
until Dimension (X) is between 0.5 mm (0.02 inch) and 1.0 mm (0.04 inch).
Install flange (8) and bolts (11). Tighten bolts (11) evenly.
Ver imagen
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Illustration 7
10. Position O-ring seals (5) from the flanges of bucket (1) into the pin joint.
Ver imagen
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Illustration 8
11. Install Tooling (E) to pin assembly (4). Apply Tooling (F) to pin assembly (4).
Attach a suitable lifting device to pin assembly (4). Position the bucket linkage
and install pin assembly (4). The weight of pin assembly (4) is approximately 34
kg (75 lb). Remove Tooling (E) from pin assembly (4) .
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g01203363
Illustration 9
12. Install bolt (3) to pin assembly (4) .
Ver imagen
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Illustration 10
13. Position O-ring seals (2) from the flanges of bucket (1) into the pin joint.
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11 -01/01/2010 -27/01/2010

i03474464
Bucket Linkage - Remove

SMCS - 6513-011
Removal Procedure
Table 1
Required Tools
A 141-1785 Receiving Sleeve 1
3S-6224 Electric Hydraulic Pump 1
6V-3175 (2) Hydraulic Cylinder Gp 1

1U-5197 (1) Hydraulic Cylinder Gp 1
9U-6809 (1) Fast Runner Nut Assembly (M36) 1
9U-6811 (1) Puller Stud (M36) 1
9U-5346 (2) Fast Runner Nut Assembly (M30) 1
137-8460 (2) Puller Stud (M30) 1
B 140-7742 Sleeve 1

( 1 )
Used for the pin that connects the bucket to the control linkage and the pin that connects the bucket
control linkage to the bucket cylinder
( 2 )
Used for the pin that connects the bucket control linkage to the stick
NOTICE
1. Start the engine. Park the machine on a hard, level surface. Fully extend the
stick. Position the bucket level on the ground. Shut off the engine.
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Illustration 1
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Illustration 2
2. Slide O-ring seals (3) off the pin joints between the bucket and the power link
and onto the flanges of the bucket.
Note: Make sure that the threaded puller hole in pin assembly (1) is clean prior
to installation of Tooling (A) .
3. Remove bolt (2) . Fasten a suitable lifting device to Tooling (A) . The weight of
Tooling (A) is approximately 136 kg (300 lb). Fasten Tooling (A) to pin
assembly (1) .
Note: Reposition the suitable lifting device during the removal of pin assembly
(1) .
4. Use Tooling (A) to remove pin assembly (1) . The combined weight of Tooling
(A) and pin assembly (1) is approximately 191 kg (420 lb).
5. Remove O-ring seals (3) from the flanges of the bucket.
Ver imagen
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Illustration 3
6. Start the engine. Extend the bucket cylinder. Use a suitable blocking in order to
support the bucket cylinder. Shut off the engine.
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Illustration 4
Ver imagen
7. Attach a suitable lifting device and Tooling (B) to power link (4) . The weight of
power link (4) is approximately 240 kg (529 lb). Raise power link (4) to a
horizontal position.
Note: Some bucket control linkages are equipped with shims between the power
link and the right hand idler link.
8. Remove plate (5) from pin assembly (6) . Install suitable cribbing in order to
support the left hand idler link and the right hand idler link. Use Tooling (A) to
remove pin assembly (6) . The weight of pin assembly (6) is approximately 43
kg (95 lb).
9. Remove power link (4) . If equipped, remove the shim between the right hand
idler link and power link (4) .
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g01213104
Illustration 6
Ver imagen
g01213107
Illustration 7
10. Attach a suitable lifting device to left hand idler link (7) . The weight of left
hand idler link (7) is approximately 50 kg (110 lb). Remove plate (8) .
11. Remove the grease fitting from pin assembly (9) . Use Tooling (A) to partially
remove pin assembly (9) in order to remove left hand idler link (7) . The weight
of pin assembly (9) is approximately 43 kg (95 lb).
12. Attach a suitable lifting device to right hand idler link (10) . The weight of right
hand idler link (10) is approximately 52 kg (115 lb). Use Tooling (A) to remove
pin assembly (9) and right hand idler link (10) .
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11 -01/01/2010 -27/01/2010

i02428373
Bucket Linkage Bearings and Seals - Remove

SMCS - 6513-011-BD ; 6513-011-SA
Removal Procedure
Table 1
Required Tools
A 3S-6224 Electric Hydraulic Pump 1
9U-6832 Fast Runner Nut Assembly 1
4C-9634 Puller Stud 1
5H-9817 Cylinder 1
6V-2097 Receiving Sleeve 1
9U-5337 (1) Bearing Puller Adapter 1

9U-5339 (2) Bearing Puller Adapter 1
( 1 )
This bearing puller adapter is for the bearing in the linkage pin bore of the stick.
( 2 )
The bearing puller adapter that is shown is for the bearings in the linkage assembly.
Start By:
A. Remove the bucket control linkage. Refer to Disassembly and Assembly,

"Bucket Linkage - Remove".
Ver imagen
g00619083
Illustration 1
1. Remove lip seal (1) .
Ver imagen
g00619100
Illustration 2
2. Use Tooling (A) to remove the sleeve bearing from the pin bore.
3. Repeat Steps 1 and 2 in order to remove the lip seal and the sleeve bearing from
the other side of the stick.
Ver imagen
g01213578
Illustration 3
4. Remove lip seals (2) .
Ver imagen
g01213579
Illustration 4
5. Use Tooling (A) in order to remove the sleeve bearing from the pin bore.
6. Repeat Steps 4 and 5 in order to remove the lip seals and the sleeve bearing from
the other side of the linkage assembly.
Ver imagen
g01213583
Illustration 5
7. Remove lip seal (3) from the linkage assembly.
Ver imagen
g01213584
Illustration 6
8. Use Tooling (A) to remove the sleeve bearing from the pin bore.
9. Repeat Steps 7 and 8 in order to remove the lip seal and the sleeve bearing from
the other side of the linkage assembly.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02430950
Bucket Linkage Bearings and Seals - Install

SMCS - 6513-012-BD ; 6513-012-SA
Table 1
Required Tools
B 1P-0520 Bearing and Seal Driver 1
Ver imagen
g01214568
Illustration 1
(X) Bucket control linkage
(Y) Sleeve bearing

1. Lower the temperature of the sleeve bearing. Use Tooling (A) to install the
sleeve bearing in the linkage assembly. Install the sleeve bearing until
Dimension (a) is 9.5 ± 0.8 mm (0.37 ± 0.03 inch) below the outside surface of
the linkage assembly.
Ver imagen
g01214570
Illustration 2
2. Use Tooling (A) in order to install lip seal (3). Install lip seal (3) with the sealing
lip toward the outside of the linkage assembly. Install lip seal (3) until lip seal
(3) makes contact with the sleeve bearing.
3. Repeat Steps 1 and 2 for the installation of the remaining lip seal and sleeve
bearing.
Ver imagen
g01214571
Illustration 3
(X) Bucket control linkage
(Y) Sleeve bearing

4. Lower the temperature of the sleeve bearing. Use Tooling (A) in order to install
the sleeve bearing. Install the sleeve bearing until Dimension (b) is 9.5 ± 0.8 mm
(0.37 ± 0.03 inch) below the outside surface of the linkage assembly.
Ver imagen
g01214572
Illustration 4
5. Use Tooling (A) in order to install lip seals (2). Install lip seals (2) with the
sealing lip toward the outside of the linkage assembly. Install lip seals (2) until
lip seals (2) make contact with the sleeve bearing.
bearing.
Ver imagen
g01214576
Illustration 5
(Y) Sleeve bearing
(Z) Stick
7. Lower the temperature of the sleeve bearing. Use Tooling (A) to install the
sleeve bearing in the stick. Install the sleeve bearing until dimension (c) is 9.5 ±
0.8 mm (0.37 ± 0.03 inch) below the outside surface of the stick.
Ver imagen
g01214574
Illustration 6
8. Use Tooling (A) to install lip seal (1). Install lip seal (1) with the sealing lip
toward the outside of the stick. Install lip seal (1) until lip seal (1) makes contact
with the sleeve bearing.
bearing.
End By: Install the bucket control linkage. Refer to Disassembly and Assembly,
"Bucket Linkage - Install".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02425888
Bucket Linkage - Install

SMCS - 6513-012
Table 1
Required Tools
B 140-7742 Sleeve 1
C 276-8831 Pin Driver Cap M30 1
D 276-8833 Pin Driver Cap M36 1
E 5P-0960 Grease Cartridge -

1. Apply Tooling (E) to the bearings and the seals in the stick and the power link.
Ver imagen
g01213330
Illustration 1
2. Attach a suitable lifting device to right hand idler link (10). The weight of right
hand idler link (10) is approximately 52 kg (115 lb). Use the suitable lifting
device to position right hand idler link (10) .
3. Install Tooling (C) to pin assembly (9). Apply Tooling (E) to pin assembly (9).
Use two people to position pin assembly (9). The weight of pin assembly (9) is
approximately 43 kg (95 lb). Use Tooling (C) to install pin assembly (9) .
Ver imagen
g01213104
Illustration 2
4. Attach a suitable lifting device to left hand idler link (7). The weight of left hand
idler link (7) is approximately 50 kg (110 lb). Install left hand idler link (7).
Install plate (8) .
5. Remove Tooling (C) and install the grease fitting onto pin assembly (9) .
Ver imagen
g01213417
Illustration 3
6. Temporarily install O-ring seals (3) onto the flanges of the bucket at the pin bore
for the power link.
Ver imagen
g01213331
Illustration 4
Note: Prior to installing power link (4), make sure that the grease fitting in the
rod end of the bucket cylinder is facing away from the stick.
7. Attach a suitable lifting device and Tooling (B) to power link (4). The weight of
power link (4) is approximately 240 kg (529 lb). Position power link (4) on the
rod end of the bucket cylinder and between the right hand idler link and the left
hand idler link.
Note: If necessary, start the machine in order to extend or retract the bucket
cylinder in order to align the power link and the idler links with the bucket
cylinder.
8. Apply Tooling (E) to pin assembly (6) .
9. Install Tooling (D) on pin assembly (6) .

10. Use a suitable lifting device to position pin assembly (6). The weight of pin
assembly (6) is approximately 43 kg (95 lb). Use Tooling (D) to install pin
assembly (6) .
Ver imagen
g01213439
Illustration 5
11. Install plate (5) .
Note: If necessary, start the machine in order to extend or retract the bucket
cylinder in order to align the power link with the bucket cylinder.
12. Lower power link (4) until the pin bore is aligned with the pin bore of the
bucket.
Ver imagen
g01213334
Illustration 6
13. Apply Tooling (E) to pin assembly (1) .

14. Install Tooling (D) on pin assembly (1). Use a suitable lifting device to position
pin assembly (1). The weight of pin assembly (1) is approximately 54 kg (120
lb). Use Tooling (D) to install pin assembly (1) .
Ver imagen
g01213478
Illustration 7
15. Install bolt (2) on pin assembly (1) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02434220
Drift Reduction Valve (Stick) - Remove

SMCS - 5143-011-JJ
Removal Procedure
Table 1
Required Tools
A FT-2674 Vacuum Cap 1
Start By:

NOTICE
containing fluids.

Make sure all of the work tools have been lowered to the ground, and
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior
of the component should be thoroughly cleaned. This will help to prevent dirt from
entering the internal mechanism.
Note: Put identification marks on all lines, on all hoses, on all harness assemblies, and
on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to
prevent fluid loss and this helps to keep contaminants from entering the system.
Ver imagen
g00690963
Illustration 1
1. Install Tooling (A) onto the hydraulic tank. Attach an air supply hose onto
Tooling (A). Apply 276 to 414 kPa (40 to 60 psi) of air. This procedure will pull
vacuum on the hydraulic system.
Ver imagen
g01216058
Illustration 2
2. Remove bolts (1) and platform (2) .
Ver imagen
g01216060
Illustration 3
3. Disconnect hose assemblies (3), (5), (6), and (7) .
4. Remove bolts (4) and drift reduction valve (8) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02434223
Drift Reduction Valve (Stick) - Disassemble

SMCS - 5143-015-JJ
Disassembly Procedure
Table 1
Required Tools
A 6V-7981 Bolt (M10×1.5×70mm) 2
Start By:
A. Remove the drift reduction valve (stick). Refer to Disassembly and Assembly,
"Drift Reduction Valve (Stick) - Remove".
of the component should be thoroughly cleaned. This will prevent dirt from entering the
internal mechanism.
NOTICE
Keep all parts clean from contaminants.
Contamination of the hydraulic system with foreign material will

reduce the service life of the hydraulic system components.
To prevent contaminants from entering the hydraulic system, always

plug or cap the lines, fittings, or hoses as they are disconnected. Cover
any disassembled components and clean them properly before
assembly.
Clean the hydraulic system properly after any major component

exchange or especially after a component failure, to remove any
contamination.
Ver imagen
g00703710
Illustration 1
1. Remove bolts (1). Remove half flanges (2) and the cover. Remove fittings (3)
from valve body (4) .
Ver imagen
g01025377
Illustration 2
2. Remove O-ring seals (5) from both fittings (3) .
Ver imagen
g00703712
Illustration 3
Ver imagen
g00703713
Illustration 4
Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
3. Remove two bolts (6) at this time. Install Tooling (A), as shown. Remove the
remaining two bolts. Remove Tooling (A). Remove cover (7) from the valve
body.
Ver imagen
g01025540
Illustration 5
4. Remove O-ring seal (8) and backup ring (9) from cover (7) .
Ver imagen
g00703715
Illustration 6
5. Remove spring (11) and spool valve (10) from the valve body.
Ver imagen
g00703716
Illustration 7
6. Remove plug (12) and the O-ring seal from the valve body.
Ver imagen
g01025408
Illustration 8
7. Remove O-ring seal (13) from plug (12) .
Ver imagen
g00703719
Illustration 9
pressure.
Ver imagen
g01025453
Illustration 10
Ver imagen
g00703721
Illustration 11
10. Remove spring (18), guide (17), and spool (16) from the valve body.
Ver imagen
g00703722
Illustration 12
Ver imagen
g01025457
Illustration 13
Ver imagen
g00703724
Illustration 14
13. Remove relief valve (21) from the valve body.
Ver imagen
g00703725
Illustration 15
pressure.
14. Remove O-ring seals (23), (24), (25), (26), and (28). Remove backup rings (22)
and (27) .
Ver imagen
g00703726
Illustration 16
15. Remove pipe plug (29) from the valve body.
Ver imagen
g01028609
Illustration 17
16. Remove O-ring seal (30) and O-ring seal (31) from the valve body. Remove
plug (32) and the O-ring seal from the valve body.
Ver imagen
g01025535
Illustration 18
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02434225
Drift Reduction Valve (Stick) - Assemble

SMCS - 5143-016-JJ
Assembly Procedure
Table 1
Required Tools
A 6V-7981 Bolt (M10×1.5×70mm) 2
B 1U-6396 O-Ring Assembly Compound 1

Note: Cleanliness is an important factor. Before assembly, all parts should be
thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags
should not be used to dry parts. Lint may be deposited on the parts which may cause
later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for
replacement.
Note: Apply a light film of hydraulic oil to all components before assembly.
Ver imagen
g01025535
Illustration 1
1. Install O-ring seal (33) onto plug (32) .
Ver imagen
g01028609
Illustration 2
2. Install O-ring seal (30) and O-ring seal (31) onto the valve body. Install plug
(32) and the O-ring seal into the valve body.
Ver imagen
g00703726
Illustration 3
3. Install plug (29) into the valve body. Tighten plug (29) to a torque of 35 ± 4 N·m
(26 ± 3 lb ft).
Ver imagen
g00703725
Illustration 4
Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure

and wear protective equipment.
4. Install O-ring seals (23), (24), (25), (26), and (28). Install backup rings (22) and
(27) .
Ver imagen
g00703724
Illustration 5
5. Install relief valve (21) into the valve body. Tighten relief valve (21) to a torque
of 95 ± 14 N·m (70 ± 10 lb ft).
Ver imagen
g01025457
Illustration 6
Ver imagen
g00703722
Illustration 7
7. Install plug (19) and the O-ring seal into the valve body. Tighten plug (19) to a
torque of 25 ± 5 N·m (18 ± 4 lb ft).
Ver imagen
g00703721
Illustration 8
8. Install spool (16), guide (17), and spring (18) into the valve body.
Ver imagen
g01025453
Illustration 9
Ver imagen
g00703719
Illustration 10
injury.

torque of 50 ± 7 N·m (37 ± 5 lb ft).
Ver imagen
Ver imagen
g00703716
Illustration 12
torque of 5.0 ± 1.5 N·m (44 ± 13 lb in).
Ver imagen
g00703715
Illustration 13
13. Install spool valve (10) and spring (11) into the valve body.
Ver imagen
g01025540
Illustration 14
14. Install backup ring (9) and O-ring seal (8) onto cover (7) .
Ver imagen
g00703713
Illustration 15
Ver imagen
g00703712
Illustration 16
injury.

15. Use Tooling (A) to install cover (7) into the valve body. Install two bolts (6) .
16. Remove Tooling (A) and install remaining bolts (6) .
Ver imagen
g01025377
Illustration 17
17. Install O-ring seal (5) onto fittings (3) .
Ver imagen
g00703710
Illustration 18
18. Install half flanges (2) and the cover. Install bolts (1). Install two fittings (3) into
valve body (4) .
End By: Install the drift reduction valve (stick). Refer to Disassembly and Assembly,
"Drift Reduction Valve (Stick) - Install".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02434222
Drift Reduction Valve (Stick) - Install

SMCS - 5143-012-JJ
Table 1
Required Tools
A FT-2674 Vacuum Cap 1

replacement.
Ver imagen
g01216060
Illustration 1
1. Install drift reduction valve (8) and bolts (4) .
2. Connect hose assemblies (7), (6), (5), and (3) .
Ver imagen
g01216058
Illustration 2
3. Install platform (2) and bolts (1) .
Ver imagen
g00690963
Illustration 3
4. Remove Tooling (A) from the hydraulic tank.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i03477183
Stick Cylinder - Remove and Install

SMCS - 5458-010
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Removal Procedure
Table 1
Required Tools
9U-5344 Puller Stud 1
9U-5346 Nut 1
A 6V-3175 Hydraulic Cylinder Gp 1
6V-0086 Sleeve 1
NOTICE


NOTICE
containing fluids.

1. Start the engine and fully retract the bucket cylinder and the stick cylinder.
Lower the boom until the bucket is lowered onto the ground. Shut off the
engine.
2. Relieve hydraulic system pressure. Refer to Disassembly and Assembly,

Ver imagen
g01224101
Illustration 1
3. Attach a suitable lifting device to both ends of stick cylinder (1) . The weight of
stick cylinder (1) is approximately 525 kg (1157 lb).
4. Install Tooling (A) . Remove bolt (3) .
5. Use Tooling (A) and a suitable lifting device to remove pin assembly (2) . The
weight of Tooling (A) and pin assembly (2) is approximately 50 kg (110 lb).
Ver imagen
g01224103
Illustration 2
6. Install Tooling (A) . Remove bolt (5) .
7. Use Tooling (A) and a suitable lifting device to remove pin assembly (6) . The
weight of Tooling (A) and pin assembly (6) is approximately 50 kg (110 lb).
8. Remove stick cylinder (1) .
Disassembly and Assembly Information

Table 2
Required Tools
B 4C-4032 Bearing Mount Compound 1
1P-1837 Bearing Puller Adapter 1
1A-1935 Full Nut 1

C
6V-3160 Hydraulic Cylinder Gp 1
6V-2098 Press Sleeve 1
NOTICE
Note: Tooling (C) is for the removal and installation of the bearings that are located at
the rod end and the head end of the stick cylinder.


Ver imagen
g01316998
Illustration 3
(1) Torque for the nut ... 15500 ± 800 N·m (11400 ± 600 lb ft)
(1) Lubricate the threads of the cylinder rod with clean hydraulic oil.
(2) Lubricate the inside diameter and the outside diameter with clean grease.
(3) Lubricate the sealing lip slightly with the lubricant that is being sealed.
Table 3
Required Tools
D 4C-9485 Pin Driver Cap 1
E 5P-0960 Grease Cartridge 1
Ver imagen
g01316227
Illustration 4
1. Attach a suitable lifting device to both ends of stick cylinder (1) . The weight of
stick cylinder (1) is approximately 525 kg (1157 lb). Position stick cylinder (1)
onto the machine.
2. Apply Tooling (E) to pin assembly (2) . Use Tooling (D) to install pin assembly
(2) . Install bolt (3) .
Ver imagen
g01316302
Illustration 5
3. Apply Tooling (E) to pin assembly (6) . Use Tooling (D) to install pin assembly
(6) . Install bolt (5) .
4. Connect hose assemblies (4) .
5. Fill the hydraulic oil tank. Refer to Operation and Maintenance Manual,
"Hydraulic Oil Level - Check".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02459118
Stick - Remove
SMCS - 6502-011
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Removal Procedure
Table 1
Required Tools
9U-5344 Puller Stud 1
9U-5346 Nut 1
A 6V-3175 Hydraulic Cylinder Gp 1
9U-5266 Sleeve 1
B 1U-5197 Hydraulic Cylinder Gp 1

9U-6809 Nut 1
Start By:
A. Remove the bucket. Refer to Disassembly and Assembly, "Bucket - Remove".
NOTICE
containing fluids.

1. Start the machine. Fully retract the bucket cylinder. Secure the linkage to the
stick.
Ver imagen
g00686746
Illustration 1
2. Fully extend the stick cylinder. Lower the stick to the floor. Block the end of the
stick that connects to the boom. Stop the engine.
Ver imagen
g00686722
Illustration 2
3. Place a suitable block under stick cylinder (1) .
Ver imagen
g01223940
Illustration 3
4. Install Tooling (A). Remove retaining bolt (2) from pin assembly (3) .
Note: Shims are located between the stick cylinder and the stick at the pin bore.
5. Remove pin assembly (3) and the spacer from the stick. The weight of pin
assembly (3) and Tooling (A) is approximately 50 kg (110 lb).
6. Start the machine. Fully retract the stick cylinder. Stop the engine.
7. Remove the shims that are located between the stick cylinder and the stick at the
pin bore.
Ver imagen
g00690283
Illustration 4
8. Position suitable blocks between the stick and the boom, as shown.
9. Release hydraulic system pressure. Refer to Disassembly and Assembly,

Ver imagen
g01227196
Illustration 5
10. Disconnect hose assemblies (4). Remove retaining bolt (6) from pin assembly
(5). Attach a suitable lifting device to Tooling (B). The weight of Tooling (B) is
approximately 136 kg (300 lb). Use Tooling (B) and the suitable lifting device in
order to remove pin assembly (5). The combined weight of pin assembly (5) and
Tooling (B) is approximately 200 kg (440 lb).
Note: Shims are located between the boom and stick (7) at the pin bore.
11. Start the machine. Raise the boom away from stick (7) .
Note: The suitable blocks that are located between stick (7) and the boom will
fall when the boom is raised.
12. Swing the machine so that the boom may be lowered to the floor. Lower the
boom to the floor. Stop the engine.
13. Remove the shims that are located between stick (7) and the boom at the pin
bore.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02440032
Stick Bearings and Seals - Remove

SMCS - 6502-011-BD ; 6502-011-SA
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Removal Procedure
Table 1
Required Tools
9U-5339 Bearing Puller Adapter (2) 1
9U-5338 Bearing Puller Adapter (2) 1
A 9U-6832 Nut 1
3S-6224 Electric Hydraulic Pump (115 Volt) (1) 1
9U-5266 Receiving Sleeve 1

( 2 )
Used for removing the bearing that is located on the boom side of the stick
( 2 )
Used for removing the bearing that is located on the bucket side of the stick
( 1 )
8S-8033 Electric Hydraulic Pump (230 Volt) is available.
Start By:
A. Remove the stick. Refer to Disassembly and Assembly, "Stick - Remove".
Note: For the removal of the sleeve bearings from the stick at the pin joint for the
bucket control linkage, refer to Disassembly and Assembly, "Bucket Linkage Bearings
and Seals - Remove".
Ver imagen
g00592359
Illustration 1
1. Remove lip type seal (1) from the bore for the boom to stick pin.
Ver imagen
g00592391
Illustration 2
2. Use Tooling (A) to remove the sleeve bearing.
3. Repeat Steps 1 and 2 in order to remove the lip type seal and the sleeve bearing
from the opposite side of the stick.
Ver imagen
g00604131
Illustration 3
4. Remove lip type seal (2) from the bore for the stick to bucket pin.
Ver imagen
g00687381
Illustration 4
5. Use Tooling (B) to remove the sleeve bearing.
6. Repeat Steps 4 and 5 in order to remove the lip type seal and the sleeve bearing
from the opposite side of the stick.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02440061
Stick Bearings and Seals - Install

SMCS - 6502-012-BD ; 6502-012-SA
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Table 1
Required Tools
C 5P-0960 Molybdenum Grease 1
D 1P-0520 Driver Gp 1
Note: Make sure that the bearing bores for the sleeve bearings are free of paint and
grease prior to the installation of the sleeve bearings.
1. Lower the temperature of the new sleeve bearing for the heel end of the stick.
2. Insert the new sleeve bearing into the stick at the connection of the stick and the
heel.
Ver imagen
g01032811
Illustration 1
(A) Angle for the Thrust Groove (60 ± 5 Degrees)
Note: The sleeve bearing must be assembled so that the open end of the thrust
groove is directed toward the center cavity.
3. Insert the sleeve bearing so that the thrust groove is 60 ± 5 degrees off set from
the perpendicular of the bottom of the stick.
Ver imagen
g01032927
Illustration 2
(D) 9.50 ± 0.8 mm (0.374 ± 0.032 inch)

4. Use Tooling (A) to drive the new sleeve bearing into the bearing bore in the
stick. Drive the new sleeve bearing into the bearing bore to the depth of
Dimension (D) .
Ver imagen
g01032914
Illustration 3
Typical example
5. Use Tooling (A) to install lip seal (1) in the outside of the sleeve bearing. Install
lip seal (1) so that the lip faces outward. Drive the seal until the seal makes
contact with the sleeve bearing. Apply Tooling (D) to the sealing lip of lip seal
(1) and to the sleeve bearings.
6. Repeat Step 1 through Step 5 for installation of the sleeve bearing and of the lip
seal on the other side of the stick.
7. Lower the temperature of the new sleeve bearing for the boom end of the stick.
8. Insert the new sleeve bearing into the stick at the connection of the stick and of
the boom.
Ver imagen
g00592848
Illustration 4
(E) 9.5 ± 0.8 mm (0.37 ± 0.03 inch)

9. Use Tooling (A) to drive the new sleeve bearing into the bearing bore in the
stick. Drive the new sleeve bearing into the bearing bore to the depth of
Dimension (E) .
Ver imagen
g01219099
Illustration 5
10. Use Tooling (A) to install lip seal (3) in the outside of the sleeve bearing. Install
lip seal (3) so that the lip faces outward. Drive the lip seal until the lip seal
makes contact with the sleeve bearing. Apply Tooling (C) to the sealing lip of
lip seal (3) and to the sleeve bearing.
11. Repeat Step 7 through Step 10 for installation of the sleeve bearing and of the lip
seal on the other side of the stick.
End By: Install the stick. Refer to Disassembly and Assembly, "Stick - Install".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02451324
Stick - Install
SMCS - 6502-012
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Table 1
Required Tools
C 5P-0960 Grease Cartridge 1
D 9U-6225 Pin Driver Cap 1
E 4C-9485 Pin Driver Cap 1
Note: Make sure that the pin bores in the stick and in the boom are thoroughly clean
and free of dirt and debris prior to the installation of the stick on the boom.
1. Put a thin coat of Tooling (C) on the sleeve bearings and on the lips of lip seals.
2. Start the machine. Raise the boom. Swing the boom over the stick. Align the pin
bores for the boom to stick pin.
Ver imagen
g01224011
Illustration 1
Ver imagen
g01213266
Illustration 2
(B) Boom. (S) Stick.

3. Install a shim (8) on each side of the boom between the boom and the stick at the
pin bore. Shim (8) is identified by the tab on the shim. Install Tooling (D) into
pin assembly (5). Attach a suitable lifting device to pin assembly (5). The weight
of pin assembly (5) is approximately 64 kg (140 lb).
4. Force the stick to one side of the boom. Measure the total clearance between the
stick and the boom. Install the required shims.
5. Use Tooling (D) and a suitable hammer in order to install pin assembly (5) .
6. Measure the total clearance between the stick and the boom at the pin bore. The
total clearance is Dimension (X) plus Dimension (Y). The total clearance must
not be more than 0.8 mm (0.03 inch). If the total clearance is less than 0.8 mm
(0.03 inch), the addition of shims will not be necessary. If the total clearance is
more than 0.8 mm (0.03 inch), the addition of shims will be required.
7. If shims are required, remove pin assembly (5). Install the required amount of
shims (9) and (10) between the stick and the boom on the side opposite retaining
bolt (6). Locate shims (9) and (10) between the boom and shim (8). Install pin
assembly (5) .
8. Install the washer and retaining bolt (6) .
9. Release the hydraulic system pressure. Refer to Disassembly and Assembly,

"Hydraulic System Pressure - Release" in this manual.
10. Install new O-ring seals in the ends of all hose assemblies (4). Connect all hose
assemblies (4) in the hose's original location.
Ver imagen
g01224014
Illustration 3
11. Fasten a suitable lifting device to the rod end of stick cylinder (1). Extend stick
cylinder (1) until the pin bore lines up with the pin bores in the stick. Install a
shim on each side of the stick cylinder at the pin bore.
12. Install the spacer. Use Tooling (E) in order to install pin assembly (3). Install the
washer and retaining bolt (2) .
End By: Install the bucket. Refer to Disassembly and Assembly, "Bucket - Install" in
this manual.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02441152
Load Control Valve (Boom Cylinder) - Remove

SMCS - 5811-011-BCD
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Removal Procedure
Start By:

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on
all tube assemblies for installation purposes. Plug all hose assemblies and all tube
assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from
entering the system.
NOTICE
containing fluids.

NOTICE


assembly.

contamination.
At operating temperature, the hydraulic oil is hot and under pressure.
Hot oils can cause burns.
To prevent possible personal injury, release the pressure in the

implement hydraulic circuit (boom, stick, bucket, and swing), travel
circuits, and the hydraulic oil tank at the filler cap before any hydraulic
lines or components are disconnected or removed.
Remove the filler cap only when the engine is stopped and the filler cap
is cool enough to touch.


Ver imagen
g01219716
Illustration 1
1. Loosen nut (2). Turn seat (1) counterclockwise in order to release the hydraulic
pressure in the boom cylinder.
Ver imagen
g01219715
Illustration 2
2. Disconnect hose assemblies (3). Disconnect tube assemblies (4) and (5).
Remove bolts (6) .
Ver imagen
g01219742
Illustration 3
3. Remove bolts (8). Use two people to remove the load control valve (7). The
weight of load control valve (7) is approximately 32 kg (70 lb).
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02440921
Load Control Valve (Boom Cylinder) - Disassemble
SMCS - 5811-015-BCD
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Start By:
A. Remove the boom lowering control valve. Refer to Disassembly and Assembly,
"Boom Lowering Control Valve - Remove".
NOTICE


assembly.

contamination.
Ver imagen
g01219462
Illustration 1
1. Remove bolts (1) .
2. Remove pilot valve (2) from relief valve (3) .
3. Remove O-ring seals (4) .
Ver imagen
g01219487
Illustration 2
pressure.
4. Remove plugs (5) and O-ring seals (6) from pilot valve (4) .
6. Remove cover (9) .

7. Remove O-ring seal (7) .
8. Remove guide (10), shims (11), spring (12), and guide (13) .
9. Remove spring (14) and guide (15) .
Ver imagen
g01219520
Illustration 3
pressure.
10. Remove nut (16), plug (17), O-ring seal (18), seat (19), and ball (21) from relief
valve (3) .
11. Remove bolts (29) and cover (30) .
12. Remove guide (26), spring (27), and valve (28) .
13. Remove guide (31), ring (32), O-ring seal (33), spring (34), and valve (35) .
14. Remove plugs (20) and O-ring seals (22) .
15. Remove plug (24) and O-ring seal (23) .
16. Remove valve (25) .
17. Remove O-ring seal (36) .
Ver imagen
g01219592
Illustration 4
18. Remove O-ring seals (38), (39), (40), (41), and (43) from valve (25). Remove
backup ring (37) and (42) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02440914
Load Control Valve (Boom Cylinder) - Assemble

SMCS - 5811-016-BCD
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Assembly Procedure
NOTICE


assembly.

contamination.
Ver imagen
1. Install backup ring (37) and (42). Install O-ring seals (38), (39), (40), (41), and
(43) from valve (25) .
Ver imagen
g01219520
Illustration 2
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to

release the spring force.
2. Install O-ring seal (36) .
3. Install valve (25) .
4. Install plug (24) and O-ring seal (23) .
5. Install plugs (20) and O-ring seals (22) .
6. Install valve (35), spring (34), O-ring seal (33), ring (32) and guide (31) .
7. Install valve (28), spring (27), and guide (26) .
8. Position cover (30) and install bolts (29) .
9. Install ball (21), seat (19), O-ring seal (18), plug (17), and nut (16) into relief
valve (3) .
Ver imagen
g01219487
Illustration 3


10. Install guide (15) and spring (14) .
11. Install guide (13), spring (12), shims (11), and guide (10) .
12. Install O-ring seal (7) .
14. Install O-ring seals (6) and plugs (5) into pilot valve (2) .
Ver imagen
g01219462
Illustration 4
15. Install O-ring seals (4) onto relief valve (3) .
16. Position pilot valve (2) onto relief valve (3) .
17. Install bolts (1) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02441150
Load Control Valve (Boom Cylinder) - Install

SMCS - 5811-012-BCD
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Ver imagen
g01219742
Illustration 1
1. Use two people to position the load control valve (7). The weight of load control
valve (7) is approximately 32 kg (70 lb). Install bolts (8) .
Ver imagen
g01219715
Illustration 2
2. Install bolts (6). Connect tube assemblies (4) and (5). Connect hose assemblies
(3) .
Ver imagen
g01219716
Illustration 3
3. Tighten seat (1). Tighten nut (2) to a torque of 2.25 ± .25 N·m (20 ± 2 lb in).
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02958683
Boom Cylinder - Remove and Install

SMCS - 5456-010
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Removal Procedure
Table 1
Required Tools
A 9U-6225 Pin Driver Cap 1
9U-6751 Sleeve 1
8C-4032 Nut 1

B
127-4904 Hydraulic Cylinder Repair Stand Gp 1
- M36 x 4.0 x 440 mm Threaded Rod 1


NOTICE
containing fluids.

1. Fully extend the bucket cylinder. Fully extend the stick cylinder. Lower the
boom until the stick assembly is in contact with the ground.
2. Release the pressure in the hydraulic system. Refer to Disassembly and

Assembly, "Hydraulic System Pressure - Release".
Ver imagen
g01225112
Illustration 1
3. Remove bolts (1) and clamps (2) .
Ver imagen
g01225115
Illustration 2
4. Remove bolts (3) and support assemblies (4) .
Ver imagen
g01225114
Illustration 3
5. Remove bolts (5) and reposition tube assembly (6) out of the way.
Ver imagen
g01225117
Illustration 4
6. Remove bolts (7) and reposition valve assembly (8) out of the way.
Ver imagen
g01225136
Illustration 5
7. Attach a suitable lifting device to boom cylinder (9) . The weight of boom
cylinder (11) is approximately 380 kg (838 lb).
Ver imagen
g01225137
Illustration 6
8. Disconnect grease hose assembly (10) .
9. Remove bolts (11) and plate (12) . Remove spacer (13) (not shown).
Ver imagen
g01225161
Illustration 7
10. Attach Tooling (A) to pin (14) . Use a suitable driver in order to reposition pin
(14) .
Note: Note the location and the quantity of shims for installation purposes.
Ver imagen
g01227786
Illustration 8
11. Lower boom cylinder (9) onto suitable cribbing and attach a suitable lifting
device to boom cylinder (9) , as shown. The weight of boom cylinder (9) is
approximately 380 kg (838 lb).
Ver imagen
g01225175
Illustration 9
12. Disconnect hose assemblies (15) and reposition hose assemblies (15) out of the
way.
13. Remove bolt (16) and the spacer.
14. Use Tooling (B) and a suitable lifting device in order to remove pin assembly
(17) .
Note: Note the location and the quantity of shims for installation purposes.
Ver imagen
g01227786
Illustration 10
15. Use the suitable lifting device to remove boom cylinder (9) .
Disassembly and Assembly

Table 2
Required Tools
C 127-4904 Hydraulic Cylinder Repair Stand Gp 1
D 7M-7456 Bearing Mount Compound 1
E 1P-0808 Multipurpose Grease 1
F 195-4609 Seal Pick 1
9S-5564 Pin Puller Sleeve As 1

G
9U-6832 Nut 1
9U-5338 Bearing Puller Adapter 1
9S-5564 Pin Puller Sleeve As 1

H
9U-6832 Nut 1
9U-5339 Bearing Puller Adapter 1


Ver imagen
g01218033
Illustration 11
Note: Tooling (G) is used for the removal and installation of bearing (8) . Tooling (H) is
used for the removal and installation of bearing (2) .
(3) Torque for the nut ... 11000 ± 550 N·m (8120 ± 410 lb ft)
(1) Torque for the bolts ... 367 ± 55 N·m (270 ± 40 lb ft)
Tighten the setscrew that retains nut (3) to a torque of 57 ± 11 N·m (42 ± 8 lb ft).
The slit of ring (5) must be in the direction of the piston.
Apply Tooling (E) to seals (4) prior to assembly.
Lubricate seals (6) with the lubricant that is being sealed.
Apply Tooling (D) to the wiper seal (7) prior to assembly.
Table 3
Required Tools
Ver imagen
g01227786
Illustration 12
1. Attach a suitable lifting device to boom cylinder (9) , as shown. The weight of
boom cylinder (9) is approximately 380 kg (838 lb). Position boom cylinder (9)
onto the machine.
Ver imagen
g01225175
Illustration 13
2. Use Tooling (A) in order to install pin assembly (17) .
3. Install bolt (16) and the spacer.
Ver imagen
g01225136
Illustration 14
5. Use the suitable lifting device in order to position boom cylinder (9) onto
suitable cribbing. Reposition the suitable lifting device near the rod end of boom
cylinder (9) . The weight of boom cylinder (9) is approximately 380 kg (838 lb).
Use the suitable lifting device to raise the rod end of boom cylinder (9) into
position.
Ver imagen
g01225161
Illustration 15
Typical Example
6. Install the correct number of shims and use Tooling (A) and a suitable hammer
in order to install pin (14) through the rod eye of the boom cylinder.
Ver imagen
g01225137
Illustration 16
7. Install spacer (13) (not shown), plate (12) and bolts (11) .
8. Connect grease hose assembly (10) .
Ver imagen
g01225117
Illustration 17
9. Position valve assembly (8) and install bolts (7) .
Ver imagen
g01225114
Illustration 18
10. Position tube assembly (6) and install bolts (5) .
Ver imagen
g01225115
Illustration 19
11. Install support assemblies (4) and bolts (3) .
Ver imagen
g01225112
Illustration 20
12. Install clamps (2) and bolts (1) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02460145
Boom - Remove
SMCS - 6501-011
Removal Procedure
Table 1
Required Tools
B 1U-9202 Lever Puller Hoist 1
9U-6809 Nut 1
Start By:

B. Remove the stick. Refer to Disassembly and Assembly, "Stick - Remove".
Ver imagen
g01225073
Illustration 1
1. Disconnect grease hose assembly (1) from boom cylinder (3). Remove bolts (2),
plate (4), and the spacer.
Ver imagen
g01225067
Illustration 2
2. Attach a suitable lifting device to boom cylinder (3). The weight of boom
cylinder (3) is approximately 380 kg (838 lb). Install Tooling (A) into pin (5).
Use a hammer to drive pin (5) out of boom cylinder (3). Lower boom cylinder
(3) .
Note: Remove any shims that may be present. Mark the shims for installation
purposes.
3. Repeat Steps 1 through 2 for the other boom cylinder.
Ver imagen
g01212891
Illustration 3
4. Remove bolts (6). Remove cover (7) .
Ver imagen
g01212899
Illustration 4
5. Remove bolts (8). Remove step (9) .
Ver imagen
g01212931
Illustration 5
Ver imagen
g01212925
Illustration 6
6. Open cover (10) of the storage box. Remove bolts (13). Remove bolts (12) and
remove handhold (11) .
Ver imagen
g01227852
Illustration 7
7. Position plate (4) and bolts (2) onto each side of pin (5). Attach a suitable lifting
device to each side of pin (5) .
Ver imagen
g01217554
Illustration 8
Ver imagen
g01212951
Illustration 9
8. Attach a suitable lifting device to pin assembly (15). The weight of pin assembly
(15) is approximately 61 kg (135 lb). Install pin assembly (15) and install bolt
(16) .
9. Attach Tooling (B) and a suitable lifting device to boom (14) and pin assembly
(15). The combined weight of boom (14) and the stick cylinder is between 2835
kg (6250 lb) and 2914 kg (6425 lb). Apply slight lifting tension to boom (14) .
Ver imagen
g01225070
Illustration 10
10. Disconnect hose assemblies (17) .
Ver imagen
g01225071
Illustration 11
11. Disconnect harness assembly (19). Disconnect hose assemblies (18), (20), (21),
and (22) .
Ver imagen
g01225068
Illustration 12
Ver imagen
g01226791
Illustration 13
12. Remove bolt (24). Attach a suitable lifting device to Tooling (C). The weight of
Tooling (C) is approximately 136 kg (300 lb). Attach Tooling (C) to pin
assembly (23). Use Tooling (C) in order to remove pin assembly (23). The
(540 lb).
13. Remove the boom. Remove any shims that may be present.
Note: Note the locations of any shims for assembly purposes.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i03397221
Boom Bearings and Seals - Remove and Install

SMCS - 6501-010-BD ; 6501-010-SA
Removal Procedure
Table 1
Required Tools
9U-6832 Nut 1
5P-8712 Bushing 1

A
316-1489 Hydraulic Cylinder Gp 1
5P-8625 Spacer 1
284-2368 Bearing Puller Adapter 1
Start By:
A. Remove the boom. Refer to Disassembly and Assembly, "Boom - Remove".
NOTICE
Ver imagen
g00479266
Illustration 1
Ver imagen
g00479267
Illustration 2
2. Use Tooling (A) to remove the sleeve bearing.
3. Repeat Steps 1 through 2 in order to remove the lip seal and the sleeve bearing
from the other side of the boom.
Table 2
Required Tools
B 1P-0520 Bearing and Seal Driver 1
C 5P-0960 Molybdenum Grease -

1. Make sure that the bores for the sleeve bearings are free of paint and grease prior
to the installation of the sleeve bearings. Coat the sleeve bearings and the
bearing bores with Tooling (C) prior to the installation of the sleeve bearings in
the bores. Sleeve bearings must be installed with the identification numbers
toward the outside of the boom.
Note: Make sure that the bearings are installed in the bore so that the
identification numbers of the bearings are facing outward.
Ver imagen
g00599079
Illustration 3
(X) Boom
(Y) Bearing
2. Lower the temperature of the sleeve bearings to -40 °C (-40 °F). Use Tooling
(B) to install the sleeve bearing in the pin bore at the foot of the boom. Install
the sleeve bearing until Dimension (a) is 9.5 ± 0.8 mm (0.37 ± 0.03 inch) below
the outside surface of the boom.
Ver imagen
g00479266
Illustration 4
3. Use Tooling (B) to install lip seal (1) in the pin bore at the foot of the boom.
Install the seal with the sealing lip toward the outside of the boom. Install the lip
seal until the lip seal makes contact with the sleeve bearing.
4. Repeat Steps 2 through 3 in order to install the sleeve bearing and the lip seal on
the other side of the boom.
5. Put a thin coat of Tooling (C) on the sleeve bearings. Put a thin coat of Tooling
(C) on the lips of lip seals (1) .
End By: Install the boom. Refer to Disassembly and Assembly, "Boom - Install".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02460146
Boom - Install
SMCS - 6501-012
Table 1
Required Tools
B 1U-9202 Lever Puller Hoist 1
9U-6809 Nut 1
D 5P-0960 Grease Cartridge 1
Note: Make sure that the pin bores in the boom and the pin bores in the upper frame are
clean and free of dirt and debris prior to installing the boom in the upper frame.
1. Apply Tooling (D) to the bores in the upper frame and in the bore of the boom.
Ver imagen
g01227852
Illustration 1
Ver imagen
g01217554
Illustration 2
Ver imagen
g01212951
Illustration 3
2. Position plate (4) and install bolts (2) onto each side of pin (5).
3. Attach a suitable lifting device to pin assembly (15). The weight of pin assembly
(15) is approximately 61 kg (135 lb). Install pin assembly (15) and install bolt
(16) .
4. Attach Tooling (B) and a suitable lifting device to boom (14). The combined
weight of boom (14) and the stick cylinder is between 2835 kg (6250 lb) and
2914 kg (6425 lb). Position boom (14) onto the machine.
Ver imagen
g01217774
Illustration 4
5. Apply Tooling (D) to pin assembly (23). Attach a suitable lifting device to pin
assembly (23). The weight of pin assembly (23) is approximately 109 kg (240
lb). Use Tooling (A) and the suitable lifting device in order to install pin
assembly (23) .
Ver imagen
g01213028
Illustration 5
6. Measure the total clearance between the boom and the upper frame at the bore
for the boom foot pin assembly. The total clearance of Dimension (a) plus
Dimension (b) must not be more than 1.0 mm (0.04 inch). If the total clearance
is less than 1.0 mm (0.04 inch), the addition of shims between the boom and the
upper frame will not be required. If the total clearance is more than 1.0 mm
(0.04 inch), add the correct thickness of shims in order to obtain the required
clearance.
7. Use the following table to determine the correct shims (25).

Table 2
Table for Shims (25)
Shim Thickness (mm)
166-1487 2.0 (2)
113-2127 0.5
093-0084 1.0
093-0116 2.0
( 2 )
This shim is required to be used. This shim must be next to the boom.
Ver imagen
g01226791
Illustration 6
8. If shims (25) need to be installed, attach a suitable lifting device to Tooling (C).
The weight of Tooling (C) is approximately 136 kg (300 lb). Attach Tooling (C)
to pin assembly (23). Use Tooling (C) in order to remove pin assembly (23). The
(540 lb).
9. Install the correct amount of shims. Repeat Step 6.
Ver imagen
g01225068
Illustration 7
10. Remove Tooling (C) and the suitable lifting device. Install bolt (24) that retains
pin assembly (23) .
Ver imagen
g01225071
Illustration 8
11. Connect harness assembly (19). Connect hose assemblies (18), (20), (21), and
(22). Tighten hose assemblies (18) and (20) to a torque of 76 ± 4 N·m (56 ± 3 lb
ft).
Ver imagen
g01225070
Illustration 9
Ver imagen
g01212931
Illustration 10
Ver imagen
g01212925
Illustration 11
13. Position handhold (11) and bolts (12). Install bolts (13). Close cover (10) of the
storage box.
Ver imagen
g01212899
Illustration 12
14. Install step (9). Install bolts (8) .
Ver imagen
g01212891
Illustration 13
15. Install cover (7). Install bolts (6) .
Ver imagen
g01225067
Illustration 14
16. Use Tooling (A) in order to drive pin (5) so that the pin is flush with the boom.
Remove Tooling (A) and install Tooling (A) onto the other side of pin (5) .
Attach a suitable lifting device to boom cylinder (3). The weight of boom
cylinder (3) is approximately 380 kg (838 lb).
Raise boom cylinder (3) into position. Install any shims that were present. Install
Tooling (A) into pin (5). Use a hammer to drive pin (5) into boom cylinder (3).
Remove Tooling (A). Repeat for the other boom cylinder (3) .
Ver imagen
g01225073
Illustration 15
17. Install the plate (4) and the spacer. Install bolts (2). Connect grease hose
assembly (1) .
End By: Install the stick. Refer to Disassembly and Assembly, "Stick - Install".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02607411
Upper Frame and Undercarriage Frame - Separate

SMCS - 4150-076; 7051-076
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Separation Procedure
Table 1
Required Tools
8S-7650 Cylinder As 2
4C-6486 Stand 2
A 8S-7615 Pin 4
8S-7631 Tube 2
8S-7625 Collar 2
8S-8048 Saddle 2
B - Bar Stock3 1/2 inch by 31 inch 1
C 228-4533 Boom Cylinder Link Gp 1
D FT-2765 Support Beam As 1
8S-7650 Cylinder As 2
4C-6486 Stand 2

E
8S-7615 Pin 4
8S-7631 Tube 2
8S-7625 Collar 2
1U-6221 Torque Wrench Gp 1
F 132-8143 Wrench Link 1
132-8223 Hydraulic Pump and Motor Gp 1
G 189-0863 Shackle As 2
H 1U-7505 Jack 1
J - Guide Bolt M24 - 3 by 8 inch 4

Start By:
A. Remove the bucket. Refer to Disassembly and Assembly, "Bucket - Remove".
NOTICE
containing fluids.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes
for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss
and this helps to keep contaminants from entering the system.
1. Start the engine. Park the machine on a hard, level surface.
Without the sun gear in place, the brakes are ineffective. Personal injury
or death could result. Provide other means to hold or stop the machine.
2. Remove the sun gear from both final drives. Refer to the Operation and
Maintenance Manual, "Final Drive Ring Gear Removal".
3. Start the engine. Rotate the upper structure until the upper structure is at 90
degrees to the undercarriage frame . Raise the boom and fully extend the stick
cylinder. Stop the engine.
4. Remove the right side boom cylinder. Refer to Disassembly and Assembly,
"Boom Cylinder - Remove".
Ver imagen
g01217403
Illustration 1
5. Adjust the length of Tooling (C) and install Tooling (C) in place of the right
hand boom cylinder. Be sure to use six bolts, six washers, and six nuts in order
to hold Tooling (C) together. The weight of Tooling (C) is approximately 408 kg
(900 lb). Install plate (1) and pin assembly (2) .
Note: Do not lower the boom after Tooling (C) has been installed in the place of
the right hand boom cylinder.
Ver imagen
g01217408
Illustration 2
6. Install Tooling (B) into stick (3) . Position Tooling (B) and stick (3) onto
Tooling (A) .
Ver imagen
g01200687
Illustration 3
7. Attach a suitable lifting device to Tooling (D) and position Tooling (D) onto
Tooling (E) . The weight of Tooling (D) is approximately 249 kg (550 lb).
Ver imagen
g01217455
Illustration 4
8. Position Tooling (D) and Tooling (E) under the main frame of the machine.
At operating temperature, the hydraulic oil is hot and under pressure.

Hot oils can cause burns.
To prevent possible personal injury, release the pressure in the work

tool hydraulic circuit (boom, stick, bucket, and swing), travel circuits,
and the hydraulic oil tank at the filler cap before any hydraulic lines or
components are disconnected or removed.
Remove the filler cap only when the engine is stopped and the filler cap
is cool enough to touch.
9. Release the hydraulic system pressure. Refer to Disassembly and Assembly,
Ver imagen
g01217511
Illustration 5
10. Position Tooling (H) under guards (4) . Remove bolts (5) . The weight of each
guard (4) is approximately 23 kg (50 lb).
Note: The guards can be heavier due to debris on top of the guards.
Ver imagen
g01207683
Illustration 6
11. Drain the oil from the hydraulic oil tank into a suitable container for storage or
disposal. Refer to Operation and Maintenance Manual, "Hydraulic System Oil -
Change".
12. Disconnect hose assemblies (6) and (7) . Disconnect fitting (8) from swivel (9) .
Ver imagen
g01217473
Illustration 7
13. Disconnect tube assembly (10) . Use Tooling (F) and remove bolts (11) that
secure the upper structure to the undercarriage frame.
14. Install Tooling (J) in the upper structure. Install the four guide bolts with 90
degree angles between the guide bolts. Install Tooling (J) through the swing gear
and bearing into the upper structure.
Ver imagen
g01217520
Illustration 8
Ver imagen
g01217455
Illustration 9
Note: It is important to keep the upper structure level when the upper structure
is being removed from the undercarriage frame.
Note: The weight of the upper structure and the undercarriage frame will vary
depending on the attachments. The weights that are listed below are only
approximations.
15. Carefully, raise the upper structure from the undercarriage frame with Tooling
(A) and Tooling (E) in 6.4 mm (0.25 inch) increments. The weight of the upper
structure is approximately 18598 kg (41000 lb).
Ver imagen
g01200420
Illustration 10
16. Attach Tooling (G) to the undercarriage frame and attach suitable chains to
Tooling (G) . Use Tooling (G) and the suitable chains in order to position the
undercarriage frame away from the upper structure.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02619720
Upper Frame and Undercarriage Frame - Connect

SMCS - 4150-077; 7051-077
Connection Procedure
Table 1
Required Tools
1U-6221 Hydraulic Torque Wrench 1
132-8143 36 mm Hex Link 1

A
Hydraulic Pump and Motor (115 V 50/60 Hz Single
132-8223 1
Phase) (1)
4C-6486 Stand 1
8S-7615 Pin 2
B 8S-7625 Collar 1
8S-7641 Tube 1
8S-7650 Cylinder 1
8S-8048 Saddle 1
C 4C-6486 Stand 2
8S-7615 Pin 4
8S-7625 Collar 2

8S-7641 Tube 2
8S-7650 Cylinder 2
D 228-4533 Link Assembly 1
E - M24 Guide Bolt 4
F 4C-5593 Anti-Seize Compound
G 1U-8846 Sealant
H 9S-3263 Thread Lock Compound

( 1 )
132-8231 Hydraulic Pump and Motor (230 V 50/60 Hz Single Phase) is available.
( 2 )
8S-8033 Electric Hydraulic Pump (230 Volt) is available.
NOTICE
containing fluids.

1. Make sure that the mating surfaces of the upper structure and of the
undercarriage frame are thoroughly clean and free of dirt and debris prior to the
installation.
Ver imagen
g01024046
Illustration 1
2. Make sure that Tooling (E) in the upper structure is positioned correctly and that
the guide bolts are not bent.
Note: Two locating dowels are used to align the upper structure with the
undercarriage frame. Make sure that these dowels are in position in the
undercarriage frame prior to installation.
3. Apply Tooling (F) in the bores of the swing gear and the bearing that are for the
locating dowels in the upper structure.
4. Apply Tooling (G) on the mating surfaces of the upper structure and the
undercarriage frame.
5. Remove the suitable blocks under the main frame and from the subframe of the
upper structure.
6. Use a lift truck to position the undercarriage frame under the upper structure.
Ver imagen
g00722451
Illustration 2
Note: There is minimal clearance between pinion shaft (12) and swing gear and
bearing (13) . Careful alignment of upper structure (11) and the undercarriage
frame is required. Make sure that Tooling (E) in the upper structure does not
bend during the installation. Bending of the guide bolts indicates that the correct
alignment has not been achieved. Keep the upper structure level during the
installation.
7. Lower upper structure (11) slowly onto the undercarriage frame with Tooling
(B) and (C) in 6.4 mm (0.25 inch) increments. As the upper structure is being
lowered, align Tooling (E) in the upper structure with the correct bolt holes in
the undercarriage frame.
8. Apply Tooling (F) on the threads of some of the bolts that secure the upper
structure to the undercarriage frame. Install only the bolts that are easy to access
at this time. Tighten the bolts evenly. Remove Tooling (E) from the upper
structure.
Ver imagen
g01207683
Illustration 3
9. Connect hose assemblies (7) and (8) . Connect fitting (9) to swivel (9) . Tighten
fitting (9) to a torque of 76 ± 4 N·m (56 ± 3 lb ft).
Ver imagen
g00715422
Illustration 4
10. Install cover assemblies (5) and (6) under the undercarriage frame.
Ver imagen
g00519531
Illustration 5
12. Remove Tooling (D) from the machine.
NOTICE
When the main hydraulic pump has been serviced or the hydraulic oil
has been replaced, the air in the hydraulic system must be purged. Do
not start the engine until the main hydraulic pump has been filled with
oil.
Operating the hydraulic pump without proper lubrication will damage

the pump and other hydraulic components.
13. Fill the hydraulic oil tank. Refer to Operation and Maintenance Manual,
"Hydraulic System Oil - Change".
Ver imagen
g00722448
Illustration 6
14. Install right hand boom cylinder (3) . Refer to Disassembly and Assembly,
"Boom Cylinder - Install".
Ver imagen
g00519669
Illustration 7
15. Remove Tooling (C) that is under the rear of the machine.
Ver imagen
g00365081
Illustration 8
16. Remove Tooling (B) that is under the stick.
Ver imagen
g00722444
Illustration 9
17. Apply Tooling (F) on the threads of remaining bolts (1) that secure the upper
structure to the undercarriage frame. Install the remainder of bolts (1) and
tighten the bolts. The machine can be rotated to the left or to the right in order to
make access to bolts (1) easier. Use Tooling (A) to tighten all bolts (1) to a
torque of 900 ± 100 N·m (660 ± 75 lb ft).
18. Connect tube assemblies (2) to the fitting on the frame of the upper structure.
19. Drain the oil from each final drive into a suitable container for storage or
disposal. Refer to Operation and Maintenance Manual, "Final Drive Oil -
Change".
Without the sun gear in place, the brakes are ineffective. Personal injury
or death could result. Provide other means to hold or stop the machine.
20. Install the final drive ring gear. Refer to the Disassembly and Assembly, "Final
Drive - Assemble" for the procedure to install the sun gear in the final drive.
21. Fill each final drive with oil to the correct level. Refer to Operation and
Maintenance Manual, "Final Drive Oil - Change".
End By: Install the bucket. Refer to Disassembly and Assembly, "Bucket - Install" in
this manual.
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02486537
Window Wiper Motor - Remove and Install - Upper

SMCS - 7305-010-MQ
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - JBT1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Removal Procedure
Note: The wiper motor must be in the OFF position.
Ver imagen
g01207837
Illustration 1
1. Remove cover (1) . Remove bolt (2) and cup (3) .
Ver imagen
2. Remove screw (4) and bolt (5) . Reposition cover (6) to the side.
Ver imagen
g01207842
Illustration 3
3. Remove bolts (7) and cover assembly (8) .
Ver imagen
g01207848
Illustration 4
4. Remove rod (9) . Reposition floor mat (10) to the side.
Ver imagen
g01207860
Illustration 5
Ver imagen
g01207861
Illustration 6
6. Remove linkage (15) . Remove nuts (13) and bolts (14) . Disconnect harness
assembly (17) . Remove windshield wiper motor (16) .
Note: The wiper motor must be in the OFF position.
Ver imagen
g01207861
Illustration 7
1. Position windshield wiper motor (16) . Connect harness assembly (17) . Install
nuts (13) and bolts (14) . Install linkage (15) so that the ball joint for rod (9) (not
shown) is straight above the nut.
Ver imagen
g01207860
Illustration 8
Ver imagen
g01207848
Illustration 9
3. Install rod (9) . Position floor mat (10) .
Ver imagen
g01207842
Illustration 10
4. Position cover assembly (8) and install bolts (7) .
Ver imagen
g01207838
Illustration 11
5. Position cover (6) to the side. Install screw (4) and bolt (5) .
Ver imagen
g01207837
Illustration 12
6. Install cup (3) and bolt (2) . Install cover (1) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02416675
Window Wiper Motor - Remove and Install - Lower

SMCS - 7305-010-MQ
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Removal Procedure
Ver imagen
g01207890
Illustration 1
1. Remove bolts (1) and sheet assembly (2) .
Ver imagen
g01207891
Illustration 2
2. Open the cover and remove nut (3). Remove wiper arm assembly (4) .
Ver imagen
g01207892
Illustration 3
3. Disconnect harness assembly (5). Remove bolts (6) and bracket assembly (7) .
Ver imagen
g01207893
Illustration 4
4. Remove bolts (8) and wiper motor (9) from bracket assembly (7) .
Ver imagen
g01207893
Illustration 5
1. Position wiper motor (9) onto bracket assembly (7) and install bolts (8) .
Ver imagen
g01207892
Illustration 6
2. Position bracket assembly (7) and install bolts (6). Tighten bolts (6) to a torque
of 55 ± 10 N·m (41 ± 7 lb ft). Connect harness assembly (5) .
Ver imagen
g01207891
Illustration 7
3. Position wiper arm assembly (4) and install nut (3). Close the cover.
Ver imagen
g01207890
Illustration 8
4. Position sheet assembly (2) and install bolts (1) .
Desarmado y Armado
11 -01/01/2010 -27/01/2010

i02431463
Cab - Remove
SMCS - 7301-011
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Removal Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 4

Start By:
A. Remove the storage box and covers. Refer to Disassembly and Assembly,
"Storage Box and Covers (Cab) - Remove and Install".
Ver imagen
g01208263
Illustration 1
1. Remove guard (2) and floor mat (1) .
Ver imagen
g01208264
Illustration 2
2. Remove cover (3) and duct (4) .
Ver imagen
g01208273
Illustration 3
Ver imagen
g01208274
Illustration 4
Ver imagen
g01208275
Illustration 5
5. Disconnect harness assembly (8). Remove duct (7) .
Ver imagen
g01208276
Illustration 6
6. Disconnect harness assemblies (9) and (10) .
Ver imagen
g01208281
Illustration 7
7. Disconnect harness assemblies (11), (12), (13), (14), and (16). Remove duct (15)
.
Ver imagen
g01208282
Illustration 8
8. Disconnect hoses (17) .
Ver imagen
g01208286
Illustration 9
Ver imagen
g01208289
Illustration 10
9. Attach Tooling (A) and a suitable lifting device to cab (18). The weight of cab
(18) is approximately 408 kg (900 lb). Remove ten bolts (20) and two bolts (19).
Remove cab (18) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02431464
Cab - Install
SMCS - 7301-012
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Table 1
Required Tools
B 154-9731 Thread Lock Compound -
Ver imagen
g01208286
Illustration 1
Ver imagen
g01208289
Illustration 2
1. Attach Tooling (A) and a suitable lifting device to cab (18). The weight of cab
(18) is approximately 408 kg (900 lb). Position cab (18) on the machine.
2. Apply Tooling (B) to bolts (20). Install ten bolts (20) and two bolts (19). Tighten
bolts (20) to a torque of 115 ± 10 N·m (85 ± 7 lb ft).
Ver imagen
g01208282
Illustration 3
3. Connect hoses (17) .
Ver imagen
g01208281
Illustration 4
4. Install duct (15). Connect harness assemblies (11), (12), (13), (14), and (16) .
Ver imagen
g01208276
Illustration 5
5. Connect harness assemblies (9) and (10) .
Ver imagen
g01208275
Illustration 6
6. Install duct (7). Connect harness assembly (8) .
Ver imagen
g01208274
Illustration 7
Ver imagen
g01208273
Illustration 8
8. Install cover (5) .
Ver imagen
g01208264
Illustration 9
9. Install duct (4) and cover (3) .
Ver imagen
g01208263
Illustration 10
10. Install floor mat (1) and guard (2) .
End By: Install the storage box and covers. Refer to Disassembly and Assembly,
"Storage Box and Covers (Cab) - Remove and Install".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02440646
Counterweight - Remove and Install

SMCS - 7056-011; 7056-012
Removal Procedure
Table 1
Required Tools
A 189-0863 Shackle As 2
Ver imagen
g01210446
Illustration 1
Ver imagen
g01223797
Illustration 2
1. Attach Tooling (A) and a suitable lifting device to counterweight (1). The
weight of counterweight (1) is approximately 6804 kg (15000 lb).
2. Remove bolts (2) and remove counterweight (1) .
Table 2
Required Tools
A 189-0863 Shackle As 2
B 4C-5592 Anti-Seize Compound 1
Ver imagen
g01210446
Illustration 3
Ver imagen
g01223797
Illustration 4
1. Attach Tooling (A) and a suitable lifting device to counterweight (1). The
weight of counterweight (1) is approximately 6804 kg (15000 lb). Install
counterweight (1) .
2. Apply Tooling (B) to bolts (2). Install bolts (2) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02552449
Fuel Tank - Remove

SMCS - 1273-011
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Removal Procedure
Table 1
Required Tools
B 138-7575 Link Bracket 2
NOTICE
containing fluids.

1. Swing the upper frame in order to gain access to the fuel tank.
2. Drain the fuel into a suitable container for storage or disposal. Refer to
Operation and Maintenance Manual, "Fuel Tank Water and Sediment Drain".
Ver imagen
g01213760
Illustration 1

Ver imagen
g01213765
Illustration 2
4. Open the right rear access door. Remove bolts (2) and (4). Remove step (3) .
Ver imagen
g01213768
Illustration 3
Ver imagen
g01213795
Illustration 4
6. Disconnect harness assembly (7). Disconnect hose assembly (8) .
Ver imagen
g01213844
Illustration 5
7. Remove sheet (9) from the underside of the machine.
Ver imagen
g01213832
Illustration 6
8. Close valve (12). Disconnect hoses (10) and (11). Remove clips (13) .
Ver imagen
g01213856
Illustration 7
Ver imagen
g01213861
Illustration 8
9. Attach Tooling (A), Tooling (B), and a suitable lifting device to fuel tank (15).
The weight of fuel tank (15) is approximately 136 kg (300 lb).
10. Remove mirror assembly (14). Remove bolts (16) and remove fuel tank (15) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02552453
Fuel Tank - Install

SMCS - 1273-012
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Table 1
Required Tools
B 138-7575 Link Bracket 2
C 154-9731 Thread Lock Compound 1
Ver imagen
g01213856
Illustration 1
Ver imagen
g01213861
Illustration 2
1. Attach Tooling (A), Tooling (B), and a suitable lifting device to fuel tank (15).
The weight of fuel tank (15) is approximately 136 kg (300 lb).
2. Install fuel tank (15). Apply Tooling (C) to bolts (16). Install bolts (16). Install
mirror assembly (14) .
Ver imagen
g01213832
Illustration 3
3. Connect hoses (10) and (11). Tighten the clamps for hoses (10) and (11) to a
torque of 3 ± .4 N·m (27 ± 4 lb in). Install clips (13). Open valve (12) .
Ver imagen
g01213844
Illustration 4
4. Install sheet (9) to the underside of the machine.
Ver imagen
g01213795
Illustration 5
5. Connect harness assembly (7). Connect hose assembly (8) .
Ver imagen
g01213768
Illustration 6
6. Install cover (6). Install bolts (5).
Ver imagen
g01213765
Illustration 7
7. Install step (3). Install bolts (2) and (4). Close the right rear access door.
Ver imagen
g01213760
Illustration 8
8. Install cover (1) .
9. Fill the fuel tank. Prime the fuel system. Refer to Operation and Maintenance
Manual, "Fuel System - Prime".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02441401
Check Valve (Cooler Bypass) - Remove

SMCS - 5071-011
Removal Procedure
Start By:
A. Release hydraulic system pressure. Refer to Disassembly and Assembly,

NOTICE
containing fluids.

1. Drain the oil from the hydraulic tank into a suitable container for storage or
disposal. Refer to Operation and Maintenance Manual, "Hydraulic System Oil -
Change".
Ver imagen
g01219964
Illustration 1
2. Remove bolts (1) and bottom plate (2) .
Ver imagen
Ver imagen
g01219971
Illustration 3
Ver imagen
g01219972
Illustration 4
5. Disconnect hose (6) .
Ver imagen
g01219974
Illustration 5
Ver imagen
g01219975
Illustration 6
6. Disconnect clip (7) .
7. Remove bolts (8) and bracket (9) .
Ver imagen
g01219980
Illustration 7
Ver imagen
g01219978
Illustration 8
Ver imagen
g01219982
Illustration 9
10. Remove bolt (12) .
11. Remove bolt (13), panel (14), and panel (15) .
Ver imagen
g01219983
Illustration 10
12. Remove bolts (16) and walkway (17) .
Ver imagen
g01219985
Illustration 11
13. Disconnect hose assemblies (18) .
Ver imagen
g01219986
Illustration 12
Ver imagen
g01219987
Illustration 13
14. Remove bolts (20). Position tube assembly (19) out of the way. Remove bolts
(21). Position tube assembly (22) out of the way.
Ver imagen
g01220007
Illustration 14
15. Remove bolts (23) from tube assembly (24) .
Ver imagen
g01220010
Illustration 15
16. Remove bolts (25). Remove oil cooler bypass valve (26) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i03709868
Check Valve (Cooler Bypass) - Disassemble

SMCS - 5071-015
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Table 1
Required Tools
Tool Part Number Part Description QTY
A FT-3154 Modified Socket 1
Start By:
A. Remove the check valve. Refer to Disassembly and Assembly, "Check Valve
(Cooler Bypass) - Remove".
Ver imagen
g02000618
Illustration 1
1. Remove nut (1), valve stop (2), spring (3), valve (4) and retaining ring (5) from
cooler bypass (8). Use tooling (A) in order to remove ring (6) from cooler
bypass (8). Remove bolt (7) from cooler bypass (8) .
Ver imagen
g02000960
Illustration 2
2. Remove nut (9), valve stop (10), spring (11) and valve (12) from cooler bypass
(8). Use tooling (A) in order to remove ring (13) from cooler bypass (8).
Remove bolt (14) from cooler bypass (8) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i03709867
Check Valve (Cooler Bypass) - Assemble

SMCS - 5071-016
Número de pieza -
S/N - MPL1-UP
Número de pieza -
S/N - WET1-UP
Número de pieza -
S/N - MEY1-UP
Número de pieza -
S/N - EAH1-UP
Número de pieza -
S/N - W3K1-UP
Número de pieza -
S/N - JLP1-UP
Número de pieza -
S/N - RAS1-UP
Número de pieza -
S/N - KKT1-UP
Número de pieza -
S/N - PRF1-UP
Número de pieza -
S/N - D3P1-UP
Número de pieza -
S/N - T2Y1-UP
Número de pieza -
S/N - THJ1-UP
Número de pieza -
S/N - JWR1-UP
Número de pieza -
S/N - EDX1-UP
Número de pieza -
S/N - NBD1-UP
Número de pieza -
S/N - KDJ1-UP
Número de pieza -
S/N - HAS1-UP
Número de pieza -
S/N - LMG1-UP
Número de pieza -
S/N - ERN1-UP
Número de pieza -
S/N - MYP1-UP
Número de pieza -
S/N - M4T1-UP
Número de pieza -
S/N - J2F1-UP
Número de pieza -
S/N - MWP1-UP
Número de pieza -
S/N - DTS1-UP
Número de pieza -
S/N - GGE1-UP
Número de pieza -
S/N - B6H1-UP
Número de pieza -
S/N - FFK1-UP
Número de pieza -
S/N - LRM1-UP
Número de pieza -
S/N - JBT1-UP
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description QTY
A FT-3154 Modified Socket 1
B 9S-3263 Thread Lock Compound -
Ver imagen
g02000960
Illustration 1
1. Install bolt (14). Apply Tooling (B) to ring (13). Use Tooling (A) in order to
install ring (13). Install valve (12), spring (11), valve stop (10) and nut (9).
Tighten nut (9) to a torque of 9 ± 1 N·m (80 ± 8.9 lb in) in order to compress the
spring to the proper tension.
Ver imagen
g02000618
Illustration 2
2. Install bolt (7). Apply Tooling (B) to ring (6). Use tooling (A) in order to install
ring (6). Install retaining ring (5), valve (4), spring (3), and valve stop (2) in
cooler bypass (8). Install nut (1) to a torque of 9 ± 1 N·m (80 ± 8.9 lb in) in
order to compress the spring to the proper tension.
End By: Install the check valve. Refer to Disassembly and Assembly, "Check Valve
(Cooler Bypass) - Remove".
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11 -01/01/2010 -27/01/2010

i02441414
Check Valve (Cooler Bypass) - Install

SMCS - 5071-012
replacement.
Ver imagen
g01220010
Illustration 1
1. Install oil cooler bypass valve (26) and bolts (25) .

Ver imagen
g01220007
Illustration 2
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Illustration 3
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g01219986
Illustration 4
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g01219985
Illustration 5
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g01219983
Illustration 6
6. Install walkway (17) and bolts (16) .
Ver imagen
g01219982
Illustration 7
7. Install panel (15), panel (14), bolt (13), and bolt (12) .
Ver imagen
g01219978
Illustration 8
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g01219980
Illustration 9
Ver imagen
g01219975
Illustration 10
Ver imagen
g01219974
Illustration 11
10. Install bracket (9) and bolts (8) .
11. Connect clip (7) .
Ver imagen
g01219972
Illustration 12
12. Connect hose (6) .
Ver imagen
g01219971
Illustration 13
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g01219969
Illustration 14
14. Install cover (4) and bolts (3) .
Ver imagen
g01219964
Illustration 15
15. Install bottom plate (2) and bolts (1) .
16. Fill the hydraulic tank with oil. Refer to Operation and Maintenance Manual,
"Hydraulic System Oil - Change".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02424410
Piston Pump (Hydraulic Fan) - Remove

SMCS - 1387-011-QP ; 5070-011-HFN
Removal Procedure
Note: Put identification marks on all lines, on all hoses, on all harness assemblies, and
on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to
prevent fluid loss and this helps to keep contaminants from entering the system.
NOTICE
containing fluids.

1. Drain the hydraulic fluid into a suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, "Refill Capacities".
Ver imagen
g01206719
Illustration 1
2. Open door (1) .
Ver imagen
g01211399
Illustration 2
3. Disconnect hose assembly (2) .
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g01211400
Illustration 3
4. Disconnect hose assemblies (3) and (4) .
5. Disconnect harness assembly (5) .
6. Remove bolts (6) and piston motor (7) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02732014
Piston Pump (Hydraulic Fan) - Disassemble

SMCS - 1387-015-QP ; 5070-015-HFN
Table 1
Required Tools
A 1P-0510 Driver Gp 1

B 1P-1857 Retaining Ring Pliers 1
C 9S-9152 Bearing Puller Gp 1
Start By:
A. Remove the piston pump. Refer to Disassembly and Assembly, "Piston Pump
(Hydraulic Fan) - Remove".
Ver imagen
g01212895
Illustration 1
1. Remove bolts (1) and controller (2) .
Ver imagen
g01212896
Illustration 2
2. Remove O-ring seals (3) .
Ver imagen
g01212897
Illustration 3
3. Remove nut (5) and coil (4) .
Ver imagen
g01212898
Illustration 4


4. Remove housing (21) , O-ring seal (20) , shim (19) , spring (18) , spring (17) ,
poppet (16) , and spool (15) from housing (2) .
5. Cartridge (14) , O-ring seal (13) , backup ring (11) , O-ring seal (12) , spool (10)
, retainer (9) , spring (8) , and retainer (7) .
6. Remove screw (6) from housing (2) .
Ver imagen
g01212900
Illustration 5


7. Remove bolts (22) and head (23) .
Ver imagen
g01212901
Illustration 6
8. Remove O-ring seals (24) , port plate (25) , and bearing cup (26) .
Ver imagen
g01212902
Illustration 7
9. Remove spring (27) , piston (29) , and O-ring seal (28) .
Ver imagen
g01212903
Illustration 8
10. Remove piston (30) .
Ver imagen
g01212904
Illustration 9
11. Remove bearing cone (31) .
Ver imagen
g01212905
Illustration 10
12. Remove shim (33) and rotating group (32) .
Ver imagen
g01212906
Illustration 11
13. Remove pistons (34) , retainer (35) , and bearing (36) .
Ver imagen
g01212907
Illustration 12
14. Remove pins (37) from barrel (38) .
Ver imagen
g01212908
Illustration 13


15. Use Tooling (A) , Tooling (B) , and a suitable press in order to remove retaining
ring (39) from barrel (38) .
Ver imagen
g01373818
Illustration 14
16. Remove shim (42) , spring (41) , and shim (40) from barrel (38) .
Ver imagen
g01212910
Illustration 15
17. Remove swashplate (43) .
Ver imagen
g01212911
Illustration 16
18. Remove shaft (45) , bearing cone (46) , and bearings (44) .
Ver imagen
g01212912
Illustration 17
19. Use Tooling (C) in order to remove bearing cone (46) from shaft (45) .
Ver imagen
g01212913
Illustration 18
20. Use Tooling (B) in order to remove retaining ring (47) .
Ver imagen
g01212915
Illustration 19
22. Remove bearing cup (49) .
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02732015
Piston Pump (Hydraulic Fan) - Assemble

SMCS - 1387-016-QP ; 5070-016-HFN
Assembly Procedure
Table 1
Required Tools
B 1P-1857 Retaining Ring Pliers 1
D 8T-5096 Dial Indicator Gp 1
Ver imagen
g01212915
Illustration 1
1. Lower the temperature of bearing cup (49) . Install bearing cup (49) .
Ver imagen
g01212913
Illustration 2
2. Install lip seal (48) .
3. Use Tooling (B) in order to install retaining ring (47) .
Ver imagen
g01213404
Illustration 3
4. Raise the temperature of bearing cone (46) .
5. Install bearing cone (46) onto shaft (45) .
Ver imagen
g01213405
Illustration 4
6. Install bearing cone (46) , shaft (45) , and bearing cone (31) .
Ver imagen
g01213407
Illustration 5
7. Lower the temperature of bearing cone (26) . Install bearing cone (26) .
Ver imagen
g01212900
Illustration 6
8. Position head (23) onto the housing.
Ver imagen
g01213409
Illustration 7
10. Use Tooling (D) in order to determine the end play of shaft (45) .
Ver imagen
g01212900
Illustration 8
11. Remove bolts (22) and head (23) .
Ver imagen
g01213405
Illustration 9
12. Remove bearing cone (31) .
Ver imagen
g01213433
Illustration 10
13. Install bearings (44) .
Ver imagen
g01212910
Illustration 11
14. Install swashplate (43) .
Ver imagen
g01373818
Illustration 12
15. Install shim (40) , spring (41) , and shim (42) to barrel (38) .
Ver imagen
g01212908
Illustration 13
injury.

16. Use Tooling (A) , Tooling (B) , and a suitable press in order to install retaining
ring (39) into barrel (38) .
Ver imagen
g01212907
Illustration 14
17. Install pins (37) into barrel (38) .
Ver imagen
g01212906
Illustration 15
18. Install bearing (36) , retainer (35) , and pistons (34) .
Ver imagen
g01212905
Illustration 16
19. Install rotating group (32) and shim (33) .
Note: Shim thickness was determined on Step 9.
Ver imagen
g01212904
Illustration 17
20. Install bearing cone (31) .
Ver imagen
g01212903
Illustration 18
21. Install piston (30) .
Ver imagen
g01212902
Illustration 19
22. Install spring (27) , piston (29) , and O-ring seal (28) .
Ver imagen
g01213436
Illustration 20
23. Install O-ring seals (24) and port plate (25) .
Ver imagen
g01212900
Illustration 21
injury.

24. Install head (23) and bolts (22) .
Ver imagen
g01212898
Illustration 22
injury.

25. Install spool (15) , poppet (16) , spring (17) , spring (18) , shim (19) , O-ring seal
(20) , and housing (21) into housing (2) .
26. Install retainer (7) , spring (8) , retainer (9) , spool (10) , O-ring seal (12) ,
backup ring (11) , O-ring seal (13) , and cartridge (14) .
27. Install screw (6) into housing (2) .
Ver imagen
g01212897
Illustration 23
28. Install coil (4) and nut (5) .
Ver imagen
g01212896
Illustration 24
29. Install O-ring seals (3) .
Ver imagen
g01212895
Illustration 25
30. Install controller (2) and bolts (1) .
End By: Install the piston pump. Refer to Disassembly and Assembly, "Piston Pump
(Hydraulic Fan) - Install".
Desarmado y Armado

11 -01/01/2010 -27/01/2010

i02424411
Piston Pump (Hydraulic Fan) - Install

SMCS - 1387-012-QP ; 5070-012-HFN
replacement.
Ver imagen
g01211400
Illustration 1
1. Position piston pump (7) and install bolts (6) .
2. Connect harness assembly (5) .
3. Connect hose assemblies (3) and (4) .
Ver imagen
g01211399
Illustration 2
4. Connect hose assembly (2) .
Ver imagen
g01206719
Illustration 3
5. Close door (1) .
6. Fill the hydraulic system with oil. Refer to Operation and Maintenance Manual,
"Refill Capacities".

330D and 336D Excavators Machine Systems

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Desarmado y Armado

330D and 336D Excavators Machine Systems

Número de medio -RENR8648- Fecha de publicación Fecha de actualización

Duo-Cone Conventional Seals - Install

Reference: Special Instruction, SEHS8364, "Assembly and Installation of Conventional

Reference: Special Instruction, SEHS8484, "Tool and Specification Chart for

Tool Part Number Part Description Qty

6V-3075 Dial Indicator 1

6V-6167 Contact Point 1

165-8958 Dial Indicator Base 1

B 169-0503 Installation Kit 1

Correct Assembly of Conventional Duo-Cone Seals

Assembly and Installation Procedure

Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing

Isopropyl alcohol is flammable. Do not use near open flame, welding

3. Refer to Special Instruction, SEHS8484, "Tool and Specification Chart for

(B) Assembled height

(10) Dial indicator

(11) Collet assembly

(12) Dial indicator base (plastic)

(13) Contact point

Examples of incorrect assembly

Acceptable Lubricants for Assembly

Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing

Isopropyl alcohol is flammable. Do not use near open flame, welding

 Quaker Solvo Clean 68-0

If chilling is desired, Seals should be placed in a freezer for 5 minutes prior to

Result of Incorrect Assembly

Número de medio -RENR8648- Fecha de publicación Fecha de actualización

Hydraulic System Pressure - Release

Procedure for Releasing Pressure

 Boom hydraulic circuit

Release Of Hydraulic Pressure From A Single

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

3. Shut off the engine.

5. Place the hydraulic activation control lever in the UNLOCKED position.

7. Place the hydraulic activation control lever in the LOCKED position.

8. Turn the engine start switch to the OFF position.

Release Of Hydraulic Pressure From Multiple

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

1. Position the machine on level ground.

3. Shut off the engine.

5. Place the hydraulic activation control lever in the UNLOCKED position.

7. Place the hydraulic activation control lever in the LOCKED position.

8. Start the engine.

11. Shut off the engine.

14. Turn the engine start switch to the OFF position.

Número de medio -RENR8648- Fecha de publicación Fecha de actualización

Bucket Cylinder - Remove and Install

Tool Part Number Part Description Qty

A 3S-6224 Electric Hydraulic Pump Gp 1

9U-5266 Sleeve 1

6V-3175 Double Acting Cylinder 1

9U-5346 Nut 1

137-8460 Puller Stud 1

A. Release the hydraulic system pressure. Refer to Disassembly and Assembly,

Failure to relieve pressure before removing a lock valve or

Ensure all pressure is relieved before removing a lock valve or

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Dispose of all fluids according to local regulations and mandates.

Disassembly and Assembly Information

Tool Part Number Part Description Qty