Excavator Repair

27C ZTS and 35C ZTS
Excavator
Repair
TECHNICAL MANUAL
27C ZTS and 35C ZTS Excavator Repair
TM2053 03OCT12 (ENGLISH)
For complete service information also see:
27C ZTS and 35C ZTS Excavator Operation

and Tests .............................................................. TM2052
27C ZTS and 35C ZTS Excavator Operator’s
Manual .................................................................. OMT190898
Undercarriage Appraisal Manual ....................... SP326
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
DX,TMIFC -19-29SEP98-1/1
TM2053 (03OCT12) 27C ZTS and 35C ZTS Repair

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Introduction
Technical Information Feedback Form

We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works
18600 South John Deere Road
Attn: Publications, Dept. 324
Dubuque, IA 52004-0538
USA
FAX NUMBER: 1-563-589-5800 (USA)
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TX,TM,FAX -19-03JUL01-1/1

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Introduction

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Contents
Section 00—General Information
Group 0001—Safety
Group 0003—Torque Values
Section 01—Tracks
Group 0130—Track System
Section 02—Axles and Suspension

Systems (Propel)
Group 0250—Axle Shaft, Bearings, and Reduction
Gears
Group 0260—Hydraulic System
Section 04—Engine
Group 0400—Removal and Installation
Section 05—Engine Auxiliary Systems

Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
Group 0515—Speed Controls
Group 0560—External Fuel Supply Systems
Section 17—Frame or Supporting Structure

Group 1740—Frame Installation
Group 1749—Chassis Weights
Section 18—Operator's Station

Group 1810—Operator Enclosure
Group 1821—Seat and Seat Belt
Group 1830—Heating
Section 32—Bulldozers (Blade)

Group 3201—Blades
Section 33—Excavator
Group 3302—Buckets
Group 3340—Frames
Section 43—Swing or Pivoting System

Group 4350—Mechanical Drive Elements
Section 99—Dealer Fabricated Tools

Group 9900—Dealer Fabricated Tools
Original Instructions. All information, illustrations and specifications in this

manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2012
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual
Previous Editions
Copyright © 2003
TM2053 (03OCT12) i 27C ZTS and 35C ZTS Repair

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Contents
TM2053 (03OCT12) ii 27C ZTS and 35C ZTS Repair

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Section 00
General Information
Contents
Page Page
Group 0001—Safety Service Recommendations for

Recognize Safety Information ................... 00-0001-1 37° Flare and 30° Cone Seat
Follow Safety Instructions.......................... 00-0001-1 Connectors ............................................ 00-0003-7
Operate Only If Qualified ........................... 00-0001-1 Service Recommendations For
Wear Protective Equipment....................... 00-0001-2 Flared Connections—Straight or
Avoid Unauthorized Machine Tapered Threads ................................... 00-0003-8
Modifications.......................................... 00-0001-2 Service Recommendations For
Add Cab Guarding for Special Inch Series Four Bolt Flange
Uses ...................................................... 00-0001-2 Fittings ................................................... 00-0003-9
Inspect Machine ........................................ 00-0001-2 Service Recommendations for
Stay Clear of Moving Parts........................ 00-0001-3 Metric Series Four Bolt Flange
Avoid High-Pressure Oils .......................... 00-0001-3 Fitting................................................... 00-0003-10
Beware of Exhaust Fumes ........................ 00-0001-3
Prevent Fires ............................................. 00-0001-4
Prevent Battery Explosions ....................... 00-0001-4
Handle Chemical Products Safely.............. 00-0001-4
Dispose of Waste Properly ........................ 00-0001-5
Prepare for Emergencies........................... 00-0001-5
Use Steps and Handholds
Correctly ................................................ 00-0001-5
Start Only From Operator's Seat ............... 00-0001-5
Use and Maintain Seat Belt ....................... 00-0001-6
Prevent Unintended Machine
Movement.............................................. 00-0001-6
Avoid Work Site Hazards........................... 00-0001-6
Keep Riders Off Machine .......................... 00-0001-7
Avoid Backover Accidents ......................... 00-0001-7
Avoid Machine Tip Over ............................ 00-0001-8
Use Special Care When Lifting
Objects .................................................. 00-0001-8
Add and Operate Attachments
Safely..................................................... 00-0001-8
Park and Prepare for Service
Safely..................................................... 00-0001-9
Service Cooling System Safely ................. 00-0001-9
Remove Paint Before Welding or
Heating ................................................ 00-0001-10
Make Welding Repairs Safely ................. 00-0001-10
Drive Metal Pins Safely ........................... 00-0001-10
Group 0003—Torque Values

Unified Inch Bolt and Screw Torque
Values .................................................... 00-0003-1
Metric Bolt and Screw Torque
Values .................................................... 00-0003-2
Additional Metric Cap Screw
Torque Values ........................................ 00-0003-3
Check Oil Lines and Fittings...................... 00-0003-4
Service Recommendations for
O-Ring Boss Fittings.............................. 00-0003-4
Service Recommendations For
Flat Face O-Ring Seal Fittings .............. 00-0003-6
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Contents

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Group 0001
Safety
Recognize Safety Information
This is the safety alert symbol. When this symbol is
T133555 —UN—28AUG00
noticed on the machine or in this manual, be alert for
the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION —
is used with the safety alert symbol. DANGER identifies
the most serious hazards.
On the machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
T133588 —19—28AUG00
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX03679,00016CC -19-03JAN07-1/1
Follow Safety Instructions

Read the safety messages in this manual and on the
T133556 —UN—24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently.
Be sure all operators of this machine understand every
safety message. Replace operator's manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 -19-03JAN07-1/1
Operate Only If Qualified

Do not operate this machine unless the operator's manual machine functions with the machine in an open area
has been read carefully, and you have been qualified by before starting to work.
supervised training and instruction.
Know and observe all safety rules that may apply to every
Operator should be familiar with the job site and work situation and work site.
surroundings before operating. Try all controls and
TX03679,00016FA -19-03JAN07-1/1
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Safety
Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
Wear close fitting clothing and safety equipment
appropriate to the job.
TS206 —UN—23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
TX03679,00016D0 -19-03JAN07-1/1
Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition of unapproved
products or attachments, may affect machine stability or Always contact an authorized dealer before making
reliability, and may create a hazard for the operator or machine modifications that change the intended use,
others near the machine. weight or balance of the machine, or that alter machine
controls, performance or reliability.
TX03679,00016B7 -19-30OCT00-1/1
Add Cab Guarding for Special Uses FOPS (falling object protective structures) and special
Special work situations or machine attachments may screens or guarding should be installed when falling or
create an environment with falling or flying objects. flying objects may enter or damage the machine. Contact
Working near an overhead bank, doing demolition work, your authorized dealer for information on devices intended
using a hydraulic hammer, or working in a wooded area, to provide protection in special work situations.
for example, may require added guarding to protect the
operator.
TX14740,0001EF3 -19-25JAN07-1/1
Inspect Machine
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and properly
installed. Fix damage and replace worn or broken parts
T6607AQ —UN—18OCT88
immediately. Pay special attention to hydraulic hoses and
electrical wiring.
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Safety
Stay Clear of Moving Parts
T133592 —UN—12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 -19-03JAN07-1/1
Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.
T133509 —UN—17MAR06
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
T133840 —UN—20SEP00
TX03679,00016D3 -19-03NOV08-1/1
Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
T133546 —UN—24AUG00
If you must operate in an enclosed space, provide
adequate ventilation. Use an exhaust pipe extension to
remove the exhaust fumes or open doors and windows to
bring outside air into the area.
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Safety
Prevent Fires
T133552 —UN—14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
T133553 —UN—07SEP00
materials inside a machine compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly. T133554 —UN—07SEP00
TX03679,00016F5 -19-03NOV08-1/1
Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TX03679,000174A -19-03NOV08-1/1
Handle Chemical Products Safely

Exposure to hazardous chemicals can cause serious
T133580 —UN—25AUG00
injury. Under certain conditions, lubricants, coolants,

paints and adhesives used with this machine may be
hazardous.
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 -19-03JAN07-1/1

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Safety
Dispose of Waste Properly

Improper disposal of waste can threaten the environment.
T133567 —UN—25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your authorized
dealer for more information.
TX03679,0001733 -19-03JAN07-1/1
Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
TX03679,000174B -19-03JAN07-1/1
Use Steps and Handholds Correctly

Prevent falls by facing the machine when getting on and
T133468 —UN—30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2 -19-15MAR07-1/1
Start Only From Operator's Seat

T133715 —UN—07SEP00
Avoid unexpected machine movement. Start engine only

while sitting in operator's seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799 -19-22APR10-1/1

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Safety
Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to
T133716 —19—14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not
cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every 3 years, regardless of appearance.
TX03679,00016DD -19-03NOV08-1/1
Prevent Unintended Machine Movement

Be careful not to accidentally actuate control levers when
T133863 —UN—20SEP00
co-workers are present. Pull pilot control shutoff lever to
locked position during work interruptions. Pull pilot control
shutoff lever to locked position and stop engine before
allowing anyone to approach machine.
Always lower work equipment to the ground and pull pilot
control shutoff lever to locked position before standing up
or leaving the operator's seat. Stop engine before exiting.
TX03679,0001746 -19-24JAN07-1/1
Avoid Work Site Hazards

Avoid contact with gas lines, buried cables and water
T153094 —UN—01APR02
lines. Call utility line location services to identify all
underground utilities before you dig.
Prepare work site properly. Avoid operating near
structures or objects that could fall onto the machine. Clear
away debris that could move unexpectedly if run over.
Avoid boom or arm contact with overhead obstacles
or overhead electrical lines. Never move any part of
machine or load closer than 3 m (10 ft) plus twice the line
insulator length to overhead wires.
T153096 —UN—01APR02
Keep bystanders clear at all times. Keep bystanders
away from raised booms, attachments, and unsupported
loads. Avoid swinging or raising booms, attachments, or
loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a
signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to
T153097 —UN—01APR02
support machine. When working close to an excavation,

position travel motors away from the hole.
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc.). At high speeds
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seat belt.
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Safety
Keep Riders Off Machine

Only allow operator on machine.
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.
T120807 —UN—14APR99
Riders may obstruct operator’s view or impair his ability
to operate machine safely.
TX14740,0001E7A -19-19MAR02-1/1
Avoid Backover Accidents

Before moving machine, be sure all persons are clear
of both travel and swing paths. Turn around and look
directly for best visibility. Use mirrors to assist in checking
all around machine. Keep windows and mirrors clean,
adjusted, and in good repair.
T120806 —UN—14APR99
Be certain travel alarm is working properly.
Use a signal person when backing if view is obstructed
or when in close quarters. Keep signal person in view at
all times. Use prearranged hand signals to communicate.
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Safety
Avoid Machine Tip Over

Use seat belt at all times.
T133716 —19—14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface.
Use loading ramps and attach them properly to truck bed.
Avoid trucks with steel beds because tracks slip more
easily on steel.
Be careful on slopes. Use extra care on soft, rocky
T133545 —UN—15SEP00
or frozen ground. Machine may slip sideways in these
conditions. When traveling up or down slopes, keep the
bucket on uphill side and just above ground level.
Be careful with heavy loads. Using oversize buckets or
lifting heavy objects reduces machine stability. Extending
a heavy load or swinging it over side of undercarriage
may cause machine to tip.
Ensure solid footing. Use extra care when operating
T133803 —UN—27SEP00
near banks or excavations that may cave-in and cause
machine to tip or fall.
TX03679,00016DF -19-03JAN07-1/1
Use Special Care When Lifting Objects

Never use this machine to lift people.
T133839 —UN—27SEP00
Never lift a load above another person. Keep bystanders
clear of all areas where a load might fall if it breaks free.
Do not leave the seat when there is a raised load.
Do not exceed lift capacity limits posted on machine and
in this manual. Extending heavy loads too far or swinging
over undercarriage side may cause machine to tip over.
Use proper rigging to attach and stabilize loads. Be sure
slings or chains have adequate capacity and are in good
condition. Use tether lines to guide loads and prearranged
hand signals to communicate with co-workers.
TX03679,00016E1 -19-03JAN07-1/1
Add and Operate Attachments Safely is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Always verify compatibility of attachments by contacting
your authorized dealer. Adding unapproved attachments Carefully read attachment manual and follow all
may affect machine stability or reliability and may create a instructions and warnings. In an area free of bystanders
hazard for others near the machine. and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
Ensure that a qualified person is involved in attachment
installation. Add guards to machine if operator protection
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Safety
Park and Prepare for Service Safely

Warn others of service work. Always park and prepare
your machine for service or repair properly.
• Park machine on a level surface and lower equipment
and attachments to the ground.
T133332 —19—14DEC01
• Place pilot shutoff lever in “lock” position. Stop engine
and remove key.
• Attach a “Do Not Operate” tag in an obvious place in
the operator's station.
Securely support machine or attachment before working
under it.
• Do not support machine with boom, arm, or other
hydraulically actuated attachments.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other
devices that may slip out of place.
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TX03679,00016E9 -19-03JAN07-1/1
Service Cooling System Safely

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
DX,RCAP -19-04JUN90-1/1

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Safety
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes Do all work in an area that is well ventilated to carry toxic
before welding or heating. fumes and dust away.
Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
DX,PAINT -19-24JUL02-1/1
Make Welding Repairs Safely

IMPORTANT: Disable electrical power before
T133547 —UN—31AUG00
welding. Turn off main battery switch
or disconnect positive battery cable.
Separate harness connectors to engine and
vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Make sure there is good ventilation. Wear eye protection
Remove paint properly. Do not inhale paint dust or fumes. and protective equipment when welding.
Use a qualified welding technician for structural repairs.
TX03679,00016D5 -19-25APR08-1/1
Drive Metal Pins Safely
T133738 —UN—14SEP00
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened
parts. Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
TX03679,0001745 -19-03JAN07-1/1

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Group 0003
Torque Values
Unified Inch Bolt and Screw Torque Values
TS1671 —UN—01MAY03
Bolt or Screw SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c
Size Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N·m lb.-ft. N·m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N·m lb.-ft. N·m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N·m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the properly start thread engagement. When possible, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ1 -19-12JAN11-1/1

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Torque Values
Metric Bolt and Screw Torque Values

TS1670 —UN—01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N·m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on U-bolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ2 -19-12JAN11-1/1

100312
PN=20
Torque Values
Additional Metric Cap Screw Torque Values
T6873AA —UN—18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly.
They may slip and cause injury.
Check tightness of cap screws periodically. Torque values

listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
Shear bolts are designed to fail under predetermined
T6873AB —UN—18OCT88
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
Make sure fastener threads are clean and you properly
start thread engagement. This will prevent them from
failing when tightening.
T6873AC —UN—18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
METRIC CAP SCREW TORQUE VALUESa
T-Bolt H-Bolt M-Bolt
Nomi-
nal Dia N·m lb-ft N·m lb-ft N·m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is ±10%.
04T,90,M170 -19-29SEP99-1/1

100312
PN=21
Torque Values
Check Oil Lines and Fittings
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
X9811 —UN—23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.
Check all oil lines, hoses and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
T85401 —UN—24JAN89
Make sure hoses are not twisted or touching machine
parts which are moving.
Tubing with dents may cause the oil to overheat. If you
find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in
torque chart.
When you tighten connections, use two wrenches to

prevent bending or breaking tubing and fittings.
T82,FLMA,AI -19-14MAR90-1/1
Service Recommendations for O-Ring Boss

Fittings
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
T6243AE —UN—18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
Continued on next page 04T,90,K66 -19-29SEP99-1/2

100312
PN=22
Torque Values
Angle Fitting
1. Back-off lock nut (A) and back-up washer (B)
completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
contacts face of boss.
T6520AB —UN—18OCT88
3. Turn fitting head-end counterclockwise to proper index
(maximum of one turn).
NOTE: Do not allow hoses to twist when tightening fittings.
4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N·m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is ± 10%.
04T,90,K66 -19-29SEP99-2/2

100312
PN=23
Torque Values
Service Recommendations For Flat Face 4. Tighten fitting or nut to torque value shown on the
O-Ring Seal Fittings chart. Do not allow hoses to twist when tightening
1. Inspect the fitting sealing surfaces and O-ring. They fittings, use backup wrench on straight hose couplings.
must be free of dirt or defects. IMPORTANT: Tighten fittings to 150% of listed torque
2. Lubricate O-rings and install into grove using value if indexing is necessary or if fitting is
petroleum jelly to hold in place. attached to an actuating device.
3. Index angle fittings and tighten by hand pressing joint Tighten fittings to 50% of listed torque value
together to insure O-ring remains in place. if used in aluminum housing.
FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N·m lb-ft N·m lb-ft
6.35 0.250 9/16-18 16 12 12 9
9.52 0.375 11/16-16 24 18 24 18
12.70 0.500 13/16-16 50 37 46 34
15.88 0.625 1-14 69 51 62 46
19.05 0.750 1 3/16-12 102 75 102 75
22.22 0.875 1 3/16-12 102 75 102 75
25.40 1.000 1 7/16-12 142 105 142 105
31.75 1.250 1 11/16-12 190 140 190 140
38.10 1.500 2-12 217 160 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N·m lb-ft
3/8-24 5/8 9/16 12 9
7/16-20 5/8 5/8 21 15
1/2-20 3/4 11/16 26 19
9/16-18 3/4 3/4 34 25
3/4-16 7/8 15/16 73 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 -20% unless otherwise specified.
OUO6092,00010A4 -19-31MAY11-1/1

100312
PN=24
Torque Values
Service Recommendations for 37° Flare and

30° Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt
or obvious defects.
2. Defects in tube flare cannot be repaired.
T6234AC —UN—18OCT88
Overtightening a defective flared fitting will not stop
leaks.
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or
petroleum jelly.
5. Index angle fittings and tighten by hand.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
6. Tighten fitting or nut to torque value shown on torque Thread Size N·m lb-ft
chart. Do not allow hoses to twist when tightening
3/8 - 24 UNF 8 6
fittings.
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160
NOTE: Torque tolerance is ± 10%.
T82,BHMA,EL -19-29SEP99-1/1

100312
PN=25
Torque Values
Service Recommendations For Flared

Connections—Straight or Tapered Threads
1. Inspect flare and flare seat. They must be free of dirt
or obvious defects.
2. Defects in the tube flare cannot be repaired.
T6873AE —UN—18OCT88
Overtightening a defective flared fitting will not stop
leaks.
3. Align the tube with the fitting before attempting to start
the nut.
4. Lubricate the male threads with hydraulic fluid or
petroleum jelly. Straight Thread
5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on the chart.
Do not allow hoses to twist when tightening fittings.
a
TORQUE CHART
b
Straight Thread Tapered Thread
T6873AD —UN—18OCT88
Thread Size N·m lb-ft N·m lb-ft
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
Tapered Thread
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
a
Torque tolerance is ±10%.
b
With seat face.
NOTE: If female thread is cast iron (control valves,

brake valves motors, etc.), torque must be
reduced approximately 10%.
04T,90,M171 -19-28JAN92-1/1

100312
PN=26
Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
T6890BB —UN—01MAR90
A—Sealing Surface C—Pinched O-Ring
B—Split Flange D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause TORQUE CHART

leaks. Roughness causes seal wear. Out-of-flat N·m lb-ft
causes seal extrusion. If defects cannot be polished Nominal Cap Screw
out, replace component. Flange Size
Size Min Max Min Max
2. Install O-ring (and backup washer if required) into 1/2 5/16-18 UNC 20 31 15 23
groove using petroleum jelly to hold it in place.
3/4 3/8-16 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) halves. 1 3/8-16 UNC 37 54 27 40
Make sure split is centrally located and perpendicular 1-1/4 7/16-14 UNC 47 85 35 63
to port. Hand tighten cap screws to hold parts in place. 1-1/2 1/2-13 UNC 62 131 46 97
Do not pinch O-ring (C).
2 1/2-13 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in center 2-1/2 1/2-13 UNC 107 131 79 97
of flange and install cap screws. Flange must be 3 5/8-11 UNC 158 264 117 195
centrally located on port. Hand tighten cap screws to 3-1/2 5/8-11 UNC 158 264 117 195
hold flange in place. Do not pinch O-ring.
4 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap screws.
Tighten all cap screws as specified in the chart below.
DO NOT use air wrenches. DO NOT tighten one cap
screw fully before tightening the others. DO NOT over
tighten.
04T,90,K174 -19-01AUG94-1/1

100312
PN=27
Torque Values
Service Recommendations for Metric Series Four Bolt Flange Fitting
T6890BB —UN—01MAR90
A—Sealing Surface C—Pinched O-Ring
B—Split Flange D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause

DO NOT use air wrenches. DO NOT tighten one cap
leaks. Roughness causes seal wear. Out-of-flat
screw fully before tightening the others. DO NOT over
causes seal extrusion. If defects cannot be polished
tighten.
out, replace component.
TORQUE CHARTa
2. Install the correct O-ring (and backup washer if Thread b
N·m lb-ft
required) into groove using petroleum jelly to hold it
M6 12 9
in place.
M8 30 22
3. Split flange: Loosely assemble split flange (B) halves. M10 57 42
Make sure split is centrally located and perpendicular M12 95 70
to the port. Hand tighten cap screws to hold parts in
M14 157 116
place. Do not pinch O-ring (C).
M16 217 160
4. Single piece flange (D): Place hydraulic line in center M18 334 246
of flange and install four cap screws. Flange must be M20 421 318
centrally located on port. Hand tighten cap screws to a
Tolerance ± 10%. The torques given are enough for the given size
hold flange in place. Do not pinch O-ring. connection with the recommended working pressure. Increasing
cap screw torque beyond these amounts will result in flange and
5. After components are properly positioned and cap cap screw bending and connection failures.
screws are hand tightened, tighten one cap screw, b
Metric standard thread.
then tighten the diagonally opposite cap screw.
Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
04T,90,K175 -19-29SEP99-1/1

100312
PN=28
Section 01
Tracks
Contents
Page
Group 0130—Track System

Track Roller ...............................................01-0130-1
Track Carrier Roller ...................................01-0130-4
Metal Face Seals
Inspect...................................................01-0130-6
Rubber Track.............................................01-0130-7
Steel Track
Components Inspection ........................01-0130-9
Track Shoe ..............................................01-0130-11
Steel Track ..............................................01-0130-12
Spocket....................................................01-0130-14
Front Idler ................................................01-0130-15
Track Adjuster and Recoil Spring ............01-0130-19
Track Adjuster Cylinder ...........................01-0130-24

100312
PN=1
Contents

100312
PN=2
Group 0130
Track System
Track Roller Repair
Remove and Install Track Roller
1. Swing upperstructure 90° and lower bucket to raise
track off ground. Keep angle between boom and arm
T121510 —UN—28OCT99
90—110° and position round side of bucket on ground.
CAUTION: Prevent possible injury from

unexpected machine movement. Put shop
stands under frame to support machine
while removing track roller.
Track Roller—Specification Boom-to-Arm Angle and Bucket Position
27C ZTS
Excavator—Weight.................................. 2820 kg (6220 lb) approximate
35C ZTS 2. Place shop stands under machine.
OUOE049,0000063 -19-19FEB03-1/5
CAUTION: Prevent possible injury from high

pressure grease. Do not remove grease
fitting (2) from valve (1).
IMPORTANT: If gravel or mud is packed between

sprocket and track, it must be removed
T121512 —UN—28OCT99
before loosening track.
3. Loosen track adjuster valve (1) slowly to release

grease.
4. Remove cap screws (4) and track roller (3).
5. Measure track roller tread diameter. See 27ZTS, Track Adjuster Valve
27C ZTS, 35ZTS, and 35C ZTS Track Roller Tread
Diameter. (SP326 Undercarriage Appraisal Manual.)
6. Repair or replace parts as necessary.
7. Apply threadlock and sealer (high strength) to threads
of cap screws (4).
T121513 —UN—28OCT99
8. Install track roller and tighten cap screws (4).
Track Roller—Specification
Track Roller-to-Frame
Cap Screw—Torque................................................... 245 N·m (180 lb-ft)
9. Perform Adjusting Track Sag. (Operator's Manual.)

Track Adjuster and Track Roller
1— Track Adjuster Valve 3— Track Roller
2— Grease Fitting 4— Cap Screw (2 used)
Continued on next page OUOE049,0000063 -19-19FEB03-2/5

100312
PN=31
Track System
Disassemble and Assemble Track Roller
T121516 —UN—28OCT99
Track Roller
1— Stopper Ring 4— Metal Face Seal (2 used) 6— Roller
2— Plug 5— Bushing (2 used) 7— O-Ring
3— Collar 8— Axle
1. Remove plug (2) and drain oil. 8. Apply a thin film of oil to new bushings (5) and install.
2. Remove stopper ring (1). IMPORTANT: O-rings and seat surfaces for O-rings
3. Remove collar (3) using a bearing puller attachment must be clean, dry, and oil free so O-rings
and adapters from puller set. do not slip when roller is turning.
IMPORTANT: Metal face seals can be reused if 9. Thoroughly clean O-ring and seat surfaces using
they are not worn or damaged. A used seal volatile, non-petroleum base solvent and lint-free
must be kept together as a set because of tissues.
wear patterns on seal ring face.
10. Wipe finger prints and foreign material off seal ring
4. Remove metal face seal (4) from roller and collar. face using clean oil and lint-free tissues.
Keep seal rings together as a matched set with seal 11. Apply a thin film of oil to each seal ring face.
ring faces together to protect surfaces.
12. Install metal face seals (4), collar (3), roller (6) and
5. Inspect metal face seals. See Inspect Metal Face axle assembly (8). Apply equal pressure with fingers
Seals. (Group 0130.) For seals that will be reused, at four equally spaced points on seal face. Seal must
put a piece of cardboard between seal rings to protect “pop” down into place so O-ring is tight against seal
seal face. bore. A volatile, non-petroleum base solvent or talcum
6. Remove axle (8) from roller (6). powder may be used as a lubricant.
NOTE: If bushings (5) are worn or damaged complete 13. Install axle to roller using press.
roller must be replaced. 14. Install stopper ring (1).
7. Inspect track roller bushings (5). Replace track roller
if worn or damaged.

100312
PN=32
Track System
15. Fill roller with 35 mL (1.2 oz) of SAE 30 oil meeting 17. Apply pipe sealant to plug threads. Install and tighten
API Service GL-5 (MIL-L-2105B or MIL-L-2105C). plug.
Track Roller—Specification Track Roller—Specification
Track Roller Plug—Torque............................................................... 9.8 N·m (87 lb-in.)
Oil—Capacity.................................................................... 35 mL (1.2 oz)
16. Clean threads of plug. Apply cure primer.

OUOE049,0000063 -19-19FEB03-4/5
Test Track Roller for Oil Leakage

1. Hold the axle assembly and rotate roller several turns
to seat metal face seals.
2. Remove the plug.
T109691B —UN—02JUN97
3. Install parts (A—F). Plug, barbed adapter and
connector are from a leak detector kit such as the
D05361ST Rubber Stopper/Leak Detector Kit.
4. Holding plug so it is not pushed out, slowly pressurize
oil cavity using air.
Track Roller—Specification
Oil Cavity Air
Test—Pressure..........................110 ± 18 kPa (1.1 ± 0.3 bar) (16 ± 4 psi)
A—Plug, Barbed Adapter and D—Pressure Gauge
5. Close valve and wait for a minimum of 30 seconds. Connector E—Snubber (Needle) Valve
B—JT03001 Tee Fitting 7/16-20 F— Air Pressure Regulator
Check for oil leakage. Check gauge to see if air M 37° x 7/16-20 F 37° SW x
pressure has decreased. 7/16-20 M 37°
C—Hose (2 used)
6. If there is leakage, disassemble roller and replace
parts as necessary.
7. Clean threads of plug. Apply cure primer. Track Roller—Specification
Plug—Torque............................................................... 9.8 N·m (87 lb-in.)
8. Apply pipe sealant to threads. Install plug
.
OUOE049,0000063 -19-19FEB03-5/5

100312
PN=33
Track System
Track Carrier Roller Repair

Measure Track Carrier Roller Wear
NOTE: Track carrier roller can be measured for wear
without being removed. See Carrier Roller
T121510 —UN—28OCT99
Measurement. (SP326 Undercarriage Appraisal
Manual.) See 27ZTS, 27C ZTS, 35ZTS, and
35C ZTS Carrier Roller Tread Diameter for carrier
roller tread diameter wear percentages. (SP326
Undercarriage Appraisal Manual.)
SPECIFICATIONS
Track Carrier Roller Boom-to-Arm Angle and Bucket Position
Tread OD 80 mm (3.15 in.) new
Tread OD 74 mm (2.91 in.) minimum used
Keep angle between boom and arm as shown and
SERVICE EQUIPMENT AND TOOLS position round side of bucket on ground.
JT05519a Special Roller Caliper
a
Tools are available in a kit such as the JT05518A or JT05523 CAUTION: Prevent possible injury from
Undercarriage Inspection Service Tool Kit. unexpected machine movement. Put shop
Measure roller tread outer diameter using a caliper. while removing track roller.
Minimum used is the maximum allowable wear for Track Carrier Roller—Specification
rebuilding wear surface. 27C ZTS
Track Carrier Roller—Specification Excavator—Weight.................................. 2820 kg (6220 lb) approximate
Tread—OD............................................................. 80 mm (3.15 in.) new 35C ZTS
OD ........................................................ 74 mm (2.91 in.) minimum used Excavator—Weight.................................. 3470 kg (7650 lb) approximate
Remove and Install Track Carrier Roller 2. Put shop stands under machine to support machine.
track off ground.
Continued on next page CED,TX08227,2889 -19-19FEB03-1/2

100312
PN=34
Track System
CAUTION: High pressure grease is in track

adjuster cylinder. Do not loosen track adjuster
valve (1) quickly or too much. High pressure
grease may cause serious injury. Never loosen
grease fitting (2) to release grease.
T121512 —UN—28OCT99
before loosening track (6).
3. Loosen track adjuster valve (1) slowly to discharge

grease.
IMPORTANT: Place pads between track frame
(3) and hydraulic jack (4) when jacking to
prevent jack from slipping.
4. Using hydraulic jack (4), jack up track (6) until

clearance between track and track carrier roller (5) is
T121514 —UN—28OCT99
enough to allow removal. Place wooden blocks on
track frame (3) to support track (6).
5. Remove cap screw (7) and track carrier roller (5).
6. Replace parts as necessary.
7. Install track carrier roller (5) and cap screw (7) and
tighten.
Track Carrier Roller—Specification
Track Roller-to-Frame
Cap Screw—Torque....................................................... 88 N·m (65 lb-ft)
8. Remove pads and jack.
T121515 —UN—28OCT99
1— Track Adjuster Valve 5— Track Carrier Roller

2— Grease Fitting 6— Track
3— Track Frame 7— Cap Screw
4— Hydraulic Jack
CED,TX08227,2889 -19-19FEB03-2/2

100312
PN=35
Track System
Inspect Metal Face Seals

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

B—Worn Area (Shaded Area) E—Sealing Area (Dark Line)
C—Seal Ring Face
T85079 —UN—24AUG93
Ring Sealing Area
T47,0130,5939HQ -19-19FEB03-1/3
2. Illustration shows examples of worn seal rings (A).

I—Sealing area (D) is in inner half of seal ring face (C).
II—Sealing area (D) not concentric with ID and OD
of seal ring.
T85080 —UN—05DEC96
A—Seal Ring C—Inner Half of Seal Ring Face
B—Worn area (Shaded Area) D—Sealing Area (Dark Line)
Metal Face Seals
T47,0130,5939HQ -19-19FEB03-2/3
3. Clean reusable seals by removing all foreign material

from seal rings, except seal face (A), using a scraper
or a stiff bristled fiber brush.
4. Wash seal rings and O-rings using a volatile,
non-petroleum base solvent to remove all oil.
T82840 —UN—23FEB89
Thoroughly dry parts using a lint-free tissue.

Apply a thin film of oil to seal ring face. Put face of
seal rings together and hold using tape.
A—Seal Face
No Scraper On Seal Face
T47,0130,5939HQ -19-19FEB03-3/3

100312
PN=36
Track System
Rubber Track Repair

Measure Rubber Track Lugs
NOTE: For additional information on rubber track
lug wear see 27ZTS, 27C ZTS, 35ZTS, and
35C ZTS Lug Height—Rubber Track in SP326
T121575 —19—29OCT99
Undercarriage Appraisal Manual.
Measure lug height (1) where indicated.

Replace rubber track if measurement is less than
specification.
Rubber Track—Specification
Rubber Track
Lug—Height....................................................... 5 mm (0.2 in.) minimum 1— Lug Height
FR91424,0000012 -19-19FEB03-1/4
Remove and Install Rubber Track

track off ground.
position round side of bucket on ground.
T121510 —UN—28OCT99
Boom-to-Arm Angle and Bucket Position
27C ZTS
35C ZTS 2. Put shop stands under machine to support machine.
Continued on next page FR91424,0000012 -19-19FEB03-2/4

100312
PN=37
Track System

T121512 —UN—28OCT99

grease. Allow track to lower completely.
4. Install three steel pipes (6) into gaps between rubber
track (4) and track frame (5).
CAUTION: Adjust engine speed to the slowest

speed. Stand clear of steel pipes while moving
sprocket to prevent injury.
T121514 —UN—28OCT99
5. Rotate sprocket in reverse direction until rubber track
(4) is raised off of front idler (3) by the three steel pipes.
CAUTION: Heavy component; use a hoist.

27C ZTS
Excavator—Weight...................................... 125 kg (280 lb) approximate
35C ZTS
Excavator—Weight........................................................... 138 kg (305 lb)
6. Slide rubber track (4) away from track frame (5) and
T121522 —19—29OCT99
remove.
7. Inspect lugs and area between lugs for cracks that
exceed 3 mm (0.1 in.) in depth, reach steel core or
exceed 30 mm (1.2 in.) in length. Inspect for any signs
of exposed steel core. Inspect roller side of track for
cracks that reach steel core. Inspect for separation of
steel core anywhere on track.
8. Repair or replace as necessary. 1— Track Adjuster Valve 4— Rubber Track
2— Grease Fitting 5— Track Frame
9. Install rubber track (4) on sprocket teeth and hand 3— Front Idler 6— Steel Pipe (3 used)
other end over front idler (3).
10. Rotate sprocket in reverse direction to sufficiently
mesh rubber track onto sprocket.

100312
PN=38
Track System
CAUTION: Adjust engine speed to the slowest

speed. Stand clear of steel pipe while moving
sprocket to prevent injury.
IMPORTANT: Make sure rubber track is securely

engaged on sprocket and front idler.
T121533 —19—29OCT99
11. Install one steel pipe (7) into gap between rubber track
(4) and track frame (5). Rotate sprocket to position
rubber track completely onto front idler.
3— Front Idler 5— Track Frame

4— Rubber Track 7— Steel Pipe
FR91424,0000012 -19-19FEB03-4/4
Steel Track Components Inspection

Measure Track Shoe Grouser Wear
SPECIFICATIONS
Track Shoe
T82859 —UN—08NOV88
Grouser Height 22.0 mm (0.87 in.) new
Grouser Height 16.5 mm (0.65 in.) minimum used
SERVICE EQUIPMENT AND TOOLS

a
JT05521 Depth Gauge (200 mm Ruler)
a
JT05534 Right Angle Attachment
a
D05231ST 300 mm Ruler
a
Tools are available in a kit such as the JT05518A or JT05523
Undercarriage Inspection Service Tool Kit. Track Shoe—Specification
Grouser—Height................................................. 22.0 mm (0.87 in.) new
Minimum used is the maximum allowable wear for Height ................................................ 16.5 mm (0.65 in.) minimum used
rebuilding grouser bars with weld.
Measure grouser height of several track shoes to find an
average using a depth gauge.
Continued on next page TX,01,VV2526 -19-19FEB03-1/4

100312
PN=39
Track System
Measure Track Chain Link Wear

NOTE: Track chain link height can be measured for
wear without being removed. See 27ZTS, 27C
ZTS, 35ZTS, and 35C ZTS Link Height for
more information on link height wear. (SP326
T82864 —UN—08NOV88
SPECIFICATIONS
Track Chain
Link Height 60.0 mm (2.36 in.) new
Link Height 55.0 mm (2.17 in.) minimum used

a
JT05521 Depth Gauge (200 mm Ruler) Minimum used is the maximum allowable wear for
a
JT05534 Right Angle Attachment rebuilding links.
a
D05231ST 300 mm Ruler Track Chain—Specification
a
Tools are available in a kit such as the JT05518A or JT05523 Link—Height........................................................ 60.0 mm (2.36 in.) new
Undercarriage Inspection Service Tool Kit. Height ................................................ 55.0 mm (2.17 in.) minimum used
Measure height of several links to find an average using
a depth gauge.
TX,01,VV2526 -19-19FEB03-2/4
Measure Track Chain Bushing Wear

NOTE: Track chain bushing wear can be measure
without being removed. See 27ZTS, 27C ZTS,
35ZTS, and 35C ZTS Bushing Outer Diameter for
more information on chain bushing wear. (SP326
T82865 —UN—08NOV88
SPECIFICATIONS
Track Chain
Bushing OD 32.2 mm (1.27 in.) new
Bushing OD 29.2 mm (1.15 in.) minimum used

a
D17524C1 100 mm Caliper
a
Track Chain—Specification
Tools are available in a kit such as the JT05518A or JT05523 Bushing—OD...................................................... 32.2 mm (1.27 in.) new
Undercarriage Inspection Service Tool Kit.
OD ..................................................... 29.2 mm (1.15 in.) minimum used
Measure bushing outer diameter at the two worn places
using a caliper.
Minimum used is the maximum allowable wear for turning
pins and bushings.

100312
PN=40
Track System
Measure Track Chain Pitch

NOTE: Track chain pitch can measured without being
removed. See 27ZTS, 27C ZTS, 35ZTS, and
35C ZTS Chain Pitch—101.5 mm (3.99 in.) for
more information on chain pitch wear. (SP326
T6813AL —UN—29JAN98
SPECIFICATIONS
Track Chain
Track Chain Pitch 406.4 mm (16.0 in.) new
Track Chain Pitch 412.0 mm (16.22 in.) maximum
used

a
JT05520 Metric Tape Measure Maximum used is the maximum allowable wear for
a
Tools are available in a kit such as the JT05518A or JT05523 turning pins and bushings.
Undercarriage Inspection Service Tool Kit.
Track Chain—Specification
1. Remove slack by putting a wooden block between Track Chain—Pitch............................................ 406.4 mm (16.0 in.) new
sprocket and chain, then slowly move machine in Pitch.............................................. 412.0 mm (16.22 in.) maximum used
reverse to tighten chain.
2. Measure pitch across several four-link sections as
shown, except section on either side of master pin, to
find average chain wear.
TX,01,VV2526 -19-19FEB03-4/4
Track Shoe Remove and Install

track off ground.
T121510 —UN—28OCT99
Track Shoe—Specification
27C ZTS
Excavator—Weight.................................. 2820 kg (6220 lb) approximate 2. Put blocks or stop stands under machine to support
35C ZTS machine.

100312
PN=41
Track System
NOTE: The track shoe and track chain are a welded

assembly. Removal of track shoe involves removal
of track pins on either side of shoe.
3. Rotate sprocket to position track shoe (6) over front

idler.
T121512 —UN—28OCT99


5. Put wooden blocks in front of front idler and under track
to prevent track from falling when track pin is removed.
6. Remove one track pin (4) and lower track to ground.
7. Remove remaining track pin (3) and remove track
T126403 —UN—14JAN00
shoe (6).
8. Check track pin bushing (5) for wear.
9. Repair or replace as necessary.
10. Place track shoe (6) in position and install track pin (3).
11. Pull ends of track together and install track pin (4).
1— Track Adjuster Valve 4— Track Pin
12. Perform Adjusting Track Sag. (Operator's Manual.) 2— Grease Fitting 5— Track Pin Bushing
3— Track Pin 6— Track Shoe
FR91424,0000026 -19-19FEB03-2/2
Steel Track Remove and Install

track off ground.
T121510 —UN—28OCT99

Steel Track—Specification
27C ZTS
Excavator—Weight.................................. 2820 kg (6220 lb) approximate 2. Put blocks or stop stands under machine to support
35C ZTS machine.

100312
PN=42
Track System
NOTE: The track master pin (3) has drilled center holes
on both sides of pin. It also has a head which is
larger in diameter then the rest of pin.
3. Rotate sprocket to position master pin (3) over front

idler.
T121512 —UN—28OCT99



Steel Track—Specification
Steel Track—Weight.................................... 136 kg (300 lb) approximate
T126555 —UN—14JAN00
5. Put wooden blocks in front of front idler and under
track to prevent track from falling when master pin is
removed.
6. Remove master pin (3).
7. Slowly turn sprocket in reverse direction to remove
track from machine.
8. Repair or replace as necessary. 1— Track Adjuster Valve 3— Track Master Pin
2— Grease Fitting
9. Position track on ground beneath front idler and
sprocket.
10. Install end of track on sprocket teeth and slowly turn 11. Pull ends of track together and install master pin (3).
sprocket in forward direction to pull track across top of
track frame to front idler. 12. Perform Adjusting Track Sag. (Operator's Manual.)
FR91424,0000027 -19-19FEB03-2/2

100312
PN=43
Track System
Remove and Install Sprocket

1. Remove track. To remove rubber track, see Rubber
Track Repair. (Group 0130.) To remove steel track,
see Steel Track Remove and Install. (Group 0130.)
2. Remove cap screws (1) and lock washers (2).
3. Remove sprocket (3).
5. Install sprocket (3), cap screws (1), and lock washers
T126423 —UN—14JAN00
(2). Tighten cap screws.
Sprocket—27C ZTS—Specification
Cap Screw—Torque..................................................... 108 N·m (80 lb-ft)
Sprocket—35C ZTS—Specification
6. Install track. To install rubber track, see Rubber Track

Repair. (Group 0130.) To install steel track, see Steel
Track Remove and Install. (Group 0130.) 1— Cap Screw (9 used) 3— Sprocket
2— Lock Washer (9 used)
TX,01,VV2531 -19-19FEB03-1/1

100312
PN=44
Track System
Front Idler Repair

Front Idler Remove and Install
1. Remove track. To remove rubber track, see Rubber
Track Repair. (Group 0130.) To remove steel track,
T121683 —UN—28OCT99
see Steel Track Remove and Install. (Group 0130.)
CAUTION: Prevent possible crushing

injury from heavy component. Use an
appropriate lifting device.
Specification
Front Idler—27C
ZTS—Weight
(approximate).................................................................................. 23 kg
51 lb.
Front Idler—35C
ZTS—Weight
(approximate).................................................................................. 27 kg
T121684 —UN—28OCT99
60 lb.
CAUTION: The front idler may be under

spring force from track adjuster and can
be pushed out from track frame. Prevent
possible injury from spring force. Make sure
area in front of idler is clear.
2. Remove front idler from track frame. 5. Install front idler into track frame.
3. Repair or replace as necessary. 6. Install track. To install rubber track, see Rubber Track
Repair. (Group 0130.) To install steel track, see Steel
4. Clean and apply grease to sliding surfaces inside Track Remove and Install. (Group 0130.)
track frame.
CAUTION: Prevent possible crushing

injury from heavy component. Use an
appropriate lifting device.
Continued on next page TX,01,VV2533 -19-02OCT12-1/4

100312
PN=45
Track System
Front Idler Disassemble and Assemble
T121616 —UN—28OCT99
Front Idler Components
1— Spring Pin (2 used) 3— O-Ring (2 used) 6— Front Idler 9— Plate
2— Metal Face Seal (2 used) 4— Axle 7— Yoke (2 used)
5— Bushing (2 used) 8— Cap Screw (4 used)

100312
PN=46
Track System
1. Remove front idler (6) from track frame. See Front

Idler Repair. (Group 0130.) NOTE: Remove bushings only if replacement is necessary.
2. Remove cap screws (8) and plate (9). 11. Remove bushing using a two-jaw puller and adapter
from D01047AA 17-1/2 and 30-Ton Puller Set.
3. Remove spring pin (1) from one yoke (7).
12. Apply a thin film of oil on bushings. If removed, install
4. Remove yoke and metal face seal (2). bushings with flange tight against shoulder of front idler.
5. Drain oil from front idler. IMPORTANT: O-rings and O-ring grooves must
6. Turn front idler over and remove remaining spring pin, be clean, dry, and free of oil to prevent
yoke, and metal face seal. O-rings from slipping and being damaged
when front idler is turning.
7. Remove O-rings (3) from axle (4).
13. Apply a thin layer of PT569 NEVER-SEEZ® Anti-Seize
8. Remove axle. Lubricant or equivalent to both ends of axle from
IMPORTANT: Metal face seals can be reused if they O-ring grooves, bore of yokes, and spring pins.
are not worn or damaged. To help prevent 14. Install axle.
premature damage to seals, used seals must
be kept together as a set because of wear 15. Install O-rings on axle.
pattern on seal ring face.
16. Install metal face seal and yoke to one side of front
9. Remove and inspect metal face seals. See Inspect idler. Install spring pin to yoke.
Metal Face Seals. (Group 0250.) 17. Position front idler so side with metal face seal
10. Measure axle and bushings (5) for wear or damage. installed is facing down.
Front Idler—27C ZTS—Specification 18. Fill front idler with SAE 30 oil meeting API Service
Axle—OD (new)......................................................................... 30.0 mm GL-5 (MIL-L-2105E) according to specifications.
1.18 in. Front Idler—Specification
OD (allowable limit) ................................................................. 29.20 mm Front Idler—27C
1.15 in. ZTS—Oil Capacity....................................................................... 30.0 mL
Bushing—ID (new)..................................................................... 30.0 mm 1.0 oz.
1.18 in.
ID (allowable limit) ................................................................... 30.50 mm Specification
1.20 in. Front Idler—35C
Flange Thickness (new) ............................................................... 2.0 mm ZTS—Oil Capacity....................................................................... 45.0 mL
0.08 in. 1.5 oz.
Flange Thickness
19. Install remaining metal face seal and yoke. Install
(allowable limit).......................................................................... 1.50 mm
spring pin to yoke.
0.06 in.
Front Idler—35C ZTS—Specification

20. Install plate and tighten cap screws to specification.
Axle—OD (new)......................................................................... 35.0 mm Front Idler—Specification
1.38 in. Yoke Cap
OD (allowable limit) ................................................................. 34.20 mm Screw—Torque............................................................................175 N·m
1.35 in. 130 lb.-ft.
Bushing—ID (new)..................................................................... 35.0 mm
1.38 in. 21. Install front idler. See Front Idler Repair. (Group 0130.)
ID (allowable limit) ................................................................... 35.50 mm
1.40 in.
Flange Thickness (new) ............................................................... 2.0 mm
0.08 in.
Flange Thickness
(allowable limit).......................................................................... 1.50 mm
0.06 in.
NEVER-SEEZ is a trademark of Emhart Chemical Group.

100312
PN=47
Track System
Measure Front Idler Wear

NOTE: For additional information on front idler wear,
see 27ZTS, 27C ZTS, 35ZTS, and 35C ZTS Front
Idler Flange Height and see 27ZTS, 27C ZTS,
35ZTS, and 35C ZTS Front Idler Flange Width.
T121638 —UN—28OCT99
(SP326 Undercarriage Appraisal Manual.)
SPECIFICATIONS
Front Idler
Front Idler Diameter (new) 269 mm
10.59 in.
Front Idler Diameter (allowable 263 mm
limit) 10.35 in.
Guide Width (new) 31 mm
1.22 in. 1— Front Idler Diameter 2— Guide Width
Guide Width (allowable limit) 25 mm
0.98 in.
Front Idler—Specification
SERVICE EQUIPMENT AND TOOLS Front Idler—Diameter
a
Depth Gauge (200 mm Ruler) (new)........................................................................................... 269 mm
a 10.59 in.
Right Angle Attachment
a
Tools are available in a kit such as the JT05518A or JT05523 Diameter (allowable
Undercarriage Inspection Service Tool Kit. limit) ........................................................................... 263 mm (10.35 in.)
10.35 in.
Measure front idler diameter (1) and guide width (2). Guide—Width (new)...................................................................... 31 mm
1.22 in.
Width (allowable limit)................................................................... 25 mm
0.98 in.
TX,01,VV2533 -19-02OCT12-4/4

100312
PN=48
Track System
Track Adjuster and Recoil Spring Repair

Remove and Install Track Adjuster and Recoil Spring
1. Remove front idler. See Front Idler Repair. (Group
0130.)
T121675 —UN—28OCT99
CAUTION: Spring or rod may break if dropped
while handling, transporting or disassembling.
Nicks or weld craters in spring and rod assembly
can cause stress concentration resulting
in a weak spot. Weak spots may result in
immediate or eventual failure creating a risk
of personal injury. Put a heavy protective
covering around spring assembly when handling,
transporting, or disassembling.
2. Slide track adjuster (1) and recoil spring out of track

frame (2).
T121676 —UN—28OCT99
IMPORTANT: When installing track adjuster (1) with
recoil spring into track frame (2), make sure that
flat bottom of plate faces down and top radius
of plate aligns with spring guide (3).
4. Install track adjuster (1) with recoil spring into track

frame (2) and push into place until track adjusting
valve protrudes from hole in plate (4).
5. Install front idler. See Front Idler Repair. (Group 0130.)
1— Track Adjuster 3— Spring Guide
T121677 —UN—28OCT99
2— Track Frame 4— Plate

100312
PN=49
Track System
Disassemble and Assemble Track Adjuster

and Recoil Spring
CAUTION: Spring or rod may break if dropped

while handling, transporting or disassembling.
Nicks or weld craters in spring and rod assembly
can cause stress concentration resulting in a
weak spot. Weak spots may result in immediate
or eventual failure creating a risk of personal
injury. Put a heavy protective covering around
spring assembly when handling, transporting,
or disassembling track adjuster.
A compression tool must be used for
disassembly and assembly because of the
extreme preload on spring.

Track Adjuster and Recoil Spring—Specification
Track Recoil Spring
Disassembly and
T6557DY —UN—25OCT88
Assembly Tool—Weight.............................. 225 kg (496 lb) approximate
1. Place an 18-t (20-ton) jack on bottom of ST4920 Track

Recoil Spring Disassembly and Assembly Tool (A).
Remove nuts (B) and top plate (C). See ST4920 Track
Recoil Spring Disassembly and Assembly Tool for
instruction to make tool. (Group 9900.)
NOTE: It is not necessary to remove the recoil
spring to replace wear ring and U-ring packing A—ST4920 Track Recoil Spring C—Top Plate
Disassembly and Assembly
on piston. To replace O-ring in the cylinder, Tool
remove recoil spring and rod. B—Nut
2. Remove nuts (B). Remove top plate (C).


100312
PN=50
Track System
3. Put track adjuster (A) in disassembly and assembly

tool with cylinder end on spacer (B).
4. Install DFT1087 Track Adjuster Recoil Spring
Disassembly and Assembly Guard Tool (F).
T121701 —UN—28OCT99
Installing Track Adjuster in Disassembly and Assembly Tool

100312
PN=51
Track System
5. Install DFT1087 Track Recoil Spring Disassembly and

Assembly Guard Tool (F). See DFT1087 Track Recoil
Spring Disassembly and Assembly Guard Tool for
instructions to make tool. (Group 9900.)
6. Install plate top (A) and nuts (B) with smallest opening
to allow access to nut (D).
7. Extend jack ram to provide enough travel to release
spring.
8. Tighten nuts (B) so plate is tight against retainer plate.
9. Remove valve (C) and special plug (E).
A—Top Plate D—Nut

B—Nut (8 used) E—Special Plug
C—Valve F— DFT1087 Track Recoil
Spring Disassembly and
Assembly Guard Tool
T7720AG —UN—28APR92

100312
PN=52
Track System
10. Raise upper half of guard tool (F). Tighten T-handles.

11. Operate jack to compress spring just enough so nut
(D) can be removed.
12. Lower jack ram to release spring force.
14. If disassembly of track adjuster cylinder is necessary,
see Disassemble and Assemble Track Adjuster
Cylinder. (Group 0130.)
15. Put track adjuster cylinder in assembly tool with
cylinder end on spacer.
16. Install spacer on rod.
17. Install retainer plate.
18. Install guard tool.
19. Install top plate. Install nuts.
20. Raise upper half of guard tool. Tighten T-handles.
T7720AH —UN—28APR92
21. Operate jack to compress spring.
22. Install nut (D) so hole is aligned with hole in rod. Install
and tighten plug.
Plug—Torque........................................................... 14.5 N·m (128 lb-in.)
23. Install and tighten valve.

A—Top Plate D—Nut
B—Nut (8 used) F— DFT1087 Track Recoil
Spring Disassembly and
Assembly Guard Tool
TX,01,VV2537 -19-19FEB03-5/5

100312
PN=53
Track System
Track Adjuster Cylinder Disassemble and Assemble

2
4
5
1 6
7
3
10
15
11
12
T159834 —UN—01OCT02
14
13
T159834
Track Adjuster Cylinder
1— Socket Head Cap Screw (3 4— Piston Rod 8— Rod 14— Retainer Plate
used) 5— Wear Ring 9— Cylinder 15— Recoil Spring
2— Dust Seal 6— U-Ring Packing 10— O-Ring
3— Flange 7— Retaining Ring 11— Plug
12— Valve
13— Nut
CAUTION: Spring or rod may break if dropped A compression tool must be used for
while handling, transporting or disassembling. disassembly and assembly because of the
Nicks or weld craters in spring and rod assembly extreme preload on spring.
can cause stress concentration resulting in a
weak spot. Weak spots may result in immediate NOTE: It is not necessary to remove the recoil spring
or eventual failure of spring or rod creating a to replace wear ring (5), U-ring packing (6) and
risk of personal injury. Put a heavy protective dust seal (2). To replace O-ring (10), remove
covering around spring assembly when handling, recoil spring (15) and rod (8).
transporting, or disassembling.

100312
PN=54
Track System
1. Remove recoil spring if necessary. See Track Adjuster

and Recoil Spring Repair. (Group 0130.)
TX,01,VV2539 -19-19FEB03-2/3
T121703 —UN—28OCT99
1— Socket Head Cap Screw (3 3— Flange 7— Retaining Ring
used) 4— Piston Rod 8— Rod
2— Dust Seal 5— Wear Ring 9— Cylinder
6— U-Ring Packing 10— O-Ring
2. If necessary, remove rod (8) from cylinder (9) using 6. Tighten cap screws (1).
a press.
3. Repair or replace parts as necessary. Flange-to-Track
Adjuster Cylinder Cap
4. Apply multi-purpose grease to U-ring packing (6), dust
Screw—Torque........................................................... 20 N·m (177 lb-in.)
seal (2), wear ring (5), and O-ring (10). Fill grooves
inside flange (3) with grease.
5. Install U-ring packing (6) with lip towards inside of
cylinder.
TX,01,VV2539 -19-19FEB03-3/3

100312
PN=55
Track System

100312
PN=56
Section 02
Axles and Suspension Systems (Propel)
Contents
Page
Group 0250—Axle Shaft, Bearings, and

Reduction Gears
Propel Gearbox
Remove and Install—27C ZTS and 35C
ZTS............................................................02-0250-1
Disassemble and Assemble—27C ZTS................... 02-
0250-3
0250-8

Propel Motor
0260-1
0260-8
Rotary Manifold
Remove and Install .............................02-0260-15
Disassemble and Assemble................02-0260-17

100312
PN=1
Contents

100312
PN=2
Group 0250
Axle Shaft, Bearings, and Reduction Gears
Propel Gearbox Remove and Install—27C
ZTS and 35C ZTS
1. See Rubber Track Repair for removal procedure. 1
(Group 0130.)
See Steel Track Remove and Install for removal
procedure. (Group 0130.) 2
4
CAUTION: High pressure release of oil from 3
T163383 —UN—17JAN03
pressurized system can cause serious burns
or penetrating injury. The hydraulic oil tank is
pressurized. Cap must be loosened to relieve
the air pressure in hydraulic oil tank.
2. Slowly loosen cap to relieve the air pressure in T163383

hydraulic oil tank.
3. Remove the propel motor cover.
4. Put identification tags on lines to aid assembly. See
Propel Hydraulic System Line Connection. (Group
9025-15.)
Disconnect the lines. Close openings using cap and
plugs.
T163407 —UN—17JAN03
1— Propel Motor Lines 4— 27C ZTS—Cap Screw and
2— Right Propel Motor and Lock Washer (9 used)
Gearbox — 35C ZTS—Cap Screw and
3— Left Propel Motor and Lock Washer (11 used)
Gearbox
Continued on next page OUT3035,000033F -19-02JAN03-1/2

100312
PN=59

Propel Gearbox—27C ZTS and 35C ZTS—Specification
Propel Gearbox and
Motor—Weight................................................ 44 kg (97 lb) approximate
T163399 —UN—17JAN03
5. Connect propel gearbox and motor to a hoist using a
lifting strap or a JT01748 Lifting Bracket. Remove a
sprocket-to-gearbox cap screw to install lifting bracket.
6. Remove cap screws and lock washers (4) to remove
propel gearbox and motor.
NOTE: The propel gearbox and motor are removed as
an assembly because the motor housing is also
35C ZTS—Sprocket-
the second planet carrier for the gearbox.
to-Gearbox Cap
Screw—Torque............................................................. 128 N·m (94 lb-ft)
See Propel Gearbox Disassemble and 12. Connect all lines except the drain lines.
Assemble—27C ZTS. (Group 0250.) IMPORTANT: Propel gearbox and motor will be
See Propel Gearbox Disassemble and damaged if not filled with oil before operating
Assemble—35C ZTS. (Group 0250.) machine. Procedures must be performed
whenever a new gearbox and motor is installed or
See Propel Motor Disassemble and Assemble—27C oil has been drained from the gearbox and motor.
ZTS. (Group 0260.)
13. Fill gearbox with gear oil to level on cover. See Check
See Propel Motor Disassemble and Assemble—35C Propel Gearbox Oil Level. (Operator's Manual.)
ZTS. (Group 0260.)
Fill motor with hydraulic oil through the drain port. Use
8. Install propel gearbox and motor. a funnel with suitable diameter neck to allow air to
9. Apply T43513 Thread Lock and Sealer (High Strength) escape. See Hydraulic Oil for correct oil. (Operator's
to cap screw threads. Tighten cap screws and lock Manual.)
washers. Connect the drain lines to motor.
Propel Gearbox—27C ZTS and 35C ZTS—Specification
14. Do break-in operation to prevent propel motors from
27C ZTS—Frame-
seizing:
to-Gearbox Cap
Screw—Torque............................................................. 108 N·m (80 lb-ft) a. Perform Check Hydraulic Oil Tank Level.
35C ZTS—Frame- (Operator's Manual.)
to-Gearbox Cap
Screw—Torque............................................................. 128 N·m (94 lb-ft) b. Run engine at slow idle.
10. Install the sprocket. c. Operate the propel motors at slow speed for 2
minutes or more.
11. Apply T43513 Thread Lock and Sealer (High Strength)
to cap screw threads. Tighten cap screws and lock 15. Install cover. Tighten cap screws and washers.
washers. Propel Gearbox—27C ZTS and 35C ZTS—Specification
Propel Gearbox—27C ZTS and 35C ZTS—Specification Motor Cover-to-Frame
27C ZTS—Sprocket- Cap Screw—Torque....................................................... 49 N·m (36 lb-ft)
to-Gearbox Cap
OUT3035,000033F -19-02JAN03-2/2

100312
PN=60
Propel Gearbox Disassemble and See Propel Gearbox Operation for a cross-section of
Assemble—27C ZTS Propel Gearbox—27C ZTS. (Group 9020-05.)
Disassemble Propel Gearbox
1. See Propel Gearbox Remove and Install—27C ZTS
and 35C ZTS for gearbox and motor removal. (Group
0250.)
Continued on next page OUT3035,0000340 -19-03JAN03-1/7

100312
PN=61
T163440 —UN—17JAN03

100312
PN=62
1— Plug 12— First Planet Carrier 20— Thrust Washer 29— Ring Gear (Housing)
2— O-Ring 13— Second Planet Sun Gear 21— Snap Ring (4 used) 30— Bearing (2 used)
3— Plug (2 used) 14— Spring Pin (3 used) 22— Thrust Washer (4 used) 31— Snap Ring
4— O-Ring (2 used) 15— Thrust Washer (6 used) 23— Second Planet Gear 32— Metal Face Seal (Seal Ring
5— Snap Ring 16— First Planet Gear (3 used) 24— Needle Roller (92 used) and O-Ring)
6— Cover 17— Needle Roller (48 used) 25— Bushing 33— Propel Motor Housing and
7— O-Ring 18— Pin (3 used) 26— Thrust Washer (4 used) Second Planet Carrier
8— Thrust Ring 19— Snap Ring (3 used) 27— Snap Ring 34— Propel Motor
9— Input Shaft and First Planet 28— Housing and Bearings
Sun Gear
10— First Planet Carrier and
Gears
11— Snap Ring
2. Remove plugs (3) and O-rings (4) to drain oil.

CAUTION: Heavy component; use a hoist. Approximate capacity is 0.5 L (0.5 qt).
Propel Gearbox—27C ZTS—Specification
Propel Gearbox and
3. Remove snap ring (5) to remove cover (6) and O-ring
(7).
Remove thrust ring (8) if replacement is necessary.
OUT3035,0000340 -19-03JAN03-3/7
CAUTION: Planet gears can turn. Keep

fingers away from gears.
4. Remove input shaft (9).

NOTE: First planet carrier and gears are serviced
T6639GK —UN—19OCT88
as a assembly.
5. Remove first planet carrier and gears (10).

Disassembly for inspection and cleaning only. Spring
pins (14) and pins (18) cannot be removed because
they are a press fit in the carrier.
6. Remove snap rings (21) to remove parts (22—26)
for second planet gears. Keep parts for each planet
gear together.
OUT3035,0000340 -19-03JAN03-4/7
7. Push the ring gear (29) down slightly using C-clamps

or a shop press so the snap ring (26) can be removed.
8. Push housing (33) out of ring gear and bearings (31)
using a shop press.
IMPORTANT: Metal face seals can be reused if
they are not worn or damaged. A used seal T163448 —UN—17JAN03
must be kept together as a set because of
9. Remove the metal face seals (32) from ring gear and
housing. Keep seal rings together as a matched set
with a piece of clean cardboard between them to
protect the seal ring face.
10. Remove bearings (30) only if replacement is
See Inspect Metal Face Seals to determine if seals necessary. Bearings are a press fit.
can be reused. (Group 0130.)
11. See Propel Motor Disassemble and Assemble—27C
NOTE: New bearings should be installed if removed. ZTS for motor disassembly. (Group 0260.)

100312
PN=63
Assemble Propel Gearbox See Propel Motor Disassemble and Assemble—27C

1. See Propel Gearbox Operation for a cross-section of ZTS for motor assembly. (Group 0260.)
Propel Gearbox—27C ZTS. (Group 9020-05.)
T163440 —UN—17JAN03

100312
PN=64
1— Plug 12— First Planet Carrier 20— Thrust Washer 29— Ring Gear (Housing)
2— O-Ring 13— Second Planet Sun Gear 21— Snap Ring (4 used) 30— Bearing (2 used)
3— Plug (2 used) 14— Spring Pin (3 used) 22— Thrust Washer (4 used) 31— Snap Ring
4— O-Ring (2 used) 15— Thrust Washer (6 used) 23— Second Planet Gear 32— Metal Face Seal (Seal Ring
5— Snap Ring 16— First Planet Gear (3 used) 24— Needle Roller (92 used) and O-Ring)
6— Cover 17— Needle Roller (48 used) 25— Bushing 33— Propel Motor Housing and
7— O-Ring 18— Pin (3 used) 26— Thrust Washer (4 used) Second Planet Carrier
8— Thrust Ring 19— Snap Ring (3 used) 27— Snap Ring 34— Propel Motor
9— Input Shaft and First Planet 28— Housing and Bearings
Sun Gear
10— First Planet Carrier and
Gears
11— Snap Ring
2. Install the new bearings (30) so the thicker edge of 5. Apply equal pressure with fingers at four equally
outer race is against the snap ring (31). spaced points on seal ring face. Seal must “pop” down
into place so O-ring is tight against seal bore and seal
IMPORTANT: The metal face seal O-rings and their ring is installed squarely.
seat surfaces must be clean, dry, and oil
free so the O-rings do not slip. 6. Wipe finger prints and foreign material off seal ring
face using clean oil and lint-free tissues.
3. Thoroughly clean O-rings, seat surfaces in housing
(33), ring gear (29), and seal rings using volatile, 7. Apply a thin film of clean oil on each seal ring face.
non-petroleum base solvent and lint-free tissues. 8. Install ring gear onto housing. Tap around the top
4. Install O-rings on seal rings. Check that O-ring is not edge of ring gear using a soft-faced hammer to seat
twisted. the bearings on housing.
NOTE: A volatile, non-petroleum base solvent or talcum

powder can be used as a lubricant. Solvent must
not damage the O-ring or leave an oil residue.
OUT3035,0000340 -19-03JAN03-7/7
9. Push the ring gear (29) down slightly using C-clamps

or a shop press so the snap ring (26) can be installed
into groove.
10. Check that ring gear can be turned. If not, disassemble
and assemble again because the bearings or metal
face seals are not installed correctly.
T163448 —UN—17JAN03
11. Install parts (26—21) for second planet gears.
a. Install bushings (25) with the beveled end towards
bottom of pin.
b. Install thrust washer with the larger ID (26) over
bushing and against machined surface.
c. Install remaining parts.
16. Install cover so plug holes are aligned with notches
12. Install first planet carrier and gears (10). Install input in ring gear.
shaft (9).
17. Install the snap ring (5)
13. Install O-ring (7) to groove in ring gear. Apply grease
18. Install plugs and O-ring.
to O-ring.
14. Add approximately 0.5 L (0.5 qt) of gear oil to gearbox. Plug and O-Ring to
See Propel Gearbox Oil for specification. (Operator's Cover—Torque................................................ 46—51 N·m (34—38 lb-ft)
Manual.) Level Check Plug
See Check Propel Gearbox Oil Level after plugs and and O-Ring to
O-rings (3 and 4) are installed. (Operator's Manual.) Cover—Torque...........................................12—13 N·m (107—113 lb-in.)
15. Apply grease to thrust ring (8) to hold it in cover (6).

OUT3035,0000340 -19-03JAN03-8/7

100312
PN=65
Propel Gearbox Disassemble and See Propel Gearbox Operation for a cross-section of
Assemble—35C ZTS Propel Gearbox—35C ZTS. (Group 9020-05.)
Disassemble Propel Gearbox
and 35C ZTS for gearbox and motor removal. (Group
0250.)

100312
PN=66
T156462 —UN—06SEP02

100312
PN=67
1— Propel Gearbox 10— Needle Bearing (4 used) 18— First Planet Gear (3 used) 25— O-Ring
2— Metal Face Seal 11— Bearing Race (4 used) 19— Needle Bearing (3 used) 26— Wire (Retainer)
3— Bearing 12— Thrust Washer (4 used) 20— Bearing Race (3 used) 27— Plug (3 used)
4— Bearing Nut (Retainer) 13— Thrust Washer 21— Not Used 28— O-Ring
5— Plug 14— Cap Screw 22— Input Shaft and First Planet 29— Propel Motor Housing and
6— Ring Gear (Housing) 15— Second Planet Sun Gear Sun Gear Second Planet Carrier
7— Steel Ball (132 used) 16— Snap Ring 23— Thrust Washer
8— Pipe Plug (2 used) 17— First Planet Carrier 24— Cover
9— Second Planet Gear (4 used)
2. Remove plugs (27) and O-rings (28) to drain oil.

CAUTION: Heavy component; use a hoist. Approximate capacity is 0.5 L (0.5 qt).
Propel Gearbox and
3. Remove pipe plug (8) located on the side of ring gear
at cover end.
OUT3035,0000341 -19-06JAN03-3/7
4. Install fittings (30) into holes.

5. Turn cover (24) until the end of wire (26) is visible
through hole. Continue turning the cover, pulling the
wire out through the hole.
6. Remove cover and O-ring (25).
T163455 —UN—16JAN03
7. Remove thrust plate (23).
24— Cover 26— Wire (Retainer)

25— O-Ring 30— Fitting (2 used)

100312
PN=68
CAUTION: Planet gears can turn. Keep

fingers away from gears.
8. Remove input shaft (22).

Remove parts for first planet carrier and gears
T6639GK —UN—19OCT88
(17—20), second planet sun gear (15), and second
planet gears (9—14). Keep parts for each planet gear
together.
9. Remove the sprocket.
10. Remove pipe plug (8) located on the side of ring gear
adjacent to the sprocket mounting flange.
Remove the 132 steel balls (7) through the hole.
See Inspect Metal Face Seals to determine if seals
11. Push the housing (29) and bearing (3) out of ring gear can be reused. (Group 0130.)
using a shop press or three M12 x 1.75 cap screws
installed in the sprocket mounting flange and tighten 13. Remove plugs (5). Remove bearing nut (4) using a
against the housing. To protect the housing, use steel spanner wrench or ST3313 Special Tool.
plates between the end of cap screws and housing.
14. Remove bearing (3) from housing for replacement
IMPORTANT: Metal face seals can be reused if only. Bearing is a press fit.
they are not worn or damaged. A used seal
must be kept together as a set because of NOTE: A new bearing should be installed if removed.
15. See Propel Motor Disassemble and Assemble—35C
12. Remove the metal face seals (2) from ring gear and ZTS for motor disassembly. (Group 0260.)
housing. Keep seal rings together as a matched set
with a piece of clean cardboard between them to
protect the seal ring face.

100312
PN=69
Assemble Propel Gearbox See Propel Motor Disassemble and Assemble—35C

1. See Propel Gearbox Operation for a cross-section of ZTS for motor assembly. (Group 0260.)
Propel Gearbox—35C ZTS. (Group 9020-05.)
T156462 —UN—06SEP02

100312
PN=70
1— Propel Gearbox 10— Needle Bearing (4 used) 18— First Planet Gear (3 used) 25— O-Ring
2— Metal Face Seal 11— Bearing Race (4 used) 19— Needle Bearing (3 used) 26— Wire (Retainer)
3— Bearing 12— Thrust Washer (4 used) 20— Bearing Race (3 used) 27— Plug (3 used)
4— Bearing Nut (Retainer) 13— Thrust Washer 21— Not Used 28— O-Ring
5— Plug 14— Cap Screw 22— Input Shaft and First Planet 29— Propel Motor Housing and
6— Ring Gear (Housing) 15— Second Planet Sun Gear Sun Gear Second Planet Carrier
7— Steel Ball (132 used) 16— Snap Ring 23— Thrust Washer
8— Pipe Plug (2 used) 17— First Planet Carrier 24— Cover
9— Second Planet Gear (4 used)
2. Install bearing (3) so the thicker edge of outer race is 10. Install ring gear onto bearing and housing. Tap around
towards the threaded end of housing (29). the top edge of ring gear using a soft-faced hammer to
3. Tighten bearing nut (4) to specifications using spanner seat the ring gear on bearing.
wrench or ST3313 Special Tool. 11. Install the 132 steel balls (7) through hole and into the
Propel Gearbox—35C ZTS—Specification groove in bearing and ring gear.
Bearing-to-Housing
Bearing Nut—Torque.................................. 196 ±10 N·m (144 ± 7.2 lb-ft)
12. Apply pipe sealant to threads of pipe plug (8). Tighten
plug to specification.
4. Tighten plug (5) to specification. Propel Gearbox—35C ZTS—Specification
Propel Gearbox—35C ZTS—Specification Pipe Plug to Ring Gear
Bearing Nut-to-Housing —Torque...................................................................... 7.9 N·m (70 lb-in.)
Plug—Torque........................................................... 14.7 N·m (132 lb-in.)
13. Install thrust plates (12), races (11), needle bearings
IMPORTANT: The metal face seal O-rings and their (10), and second planet gears (9) onto pins.
seat surfaces must be clean, dry, and oil
free so the O-rings do not slip. 14. Install thrust washer (13).
Apply thread lock and sealer (low strength) to threads
5. Thoroughly clean O-rings, seat surfaces in housing of cap screw (14). Tighten cap screws to specifications.
(29), ring gear (6), and seal rings using volatile,
non-petroleum base solvent and lint-free tissues. Propel Gearbox—35C ZTS—Specification
Thrust Washer-
6. Install O-rings on seal rings. Check that O-ring is not to-Housing Cap
twisted. Screw—Torque............................................................ 6.1 N·m (54 lb-in.)
NOTE: A volatile, non-petroleum base solvent or talcum 15. Install snap ring (16) on second planet sun gear (15).
powder can be used as a lubricant. Solvent must Install sun gear.
not damage the O-ring or leave an oil residue.
16. Install races (20) and needle bearings (19).
7. Apply equal pressure with fingers at four equally 17. Install first planet gears (18) so the flat side is against
spaced points on seal ring face. Seal must “pop” down machined surface of first planet carrier (17).
into place so O-ring is tight against seal bore and seal
ring is installed squarely. 18. Install input shaft (22).
8. Wipe finger prints and foreign material off seal ring 19. Install thrust plate (23).
face using clean oil and lint-free tissues.
20. Install O-ring (25) on cover (24). Apply grease to
9. Apply a thin film of clean oil on each seal ring face. O-ring.
OUT3035,0000341 -19-06JAN03-7/7

100312
PN=71
21. Install cover. Install fittings (30).

22. Bend end of wire (26) to 90° approximately 6 mm
(0.24 in.) from end.
23. Push wire through hole and into groove in cover and
ring gear.
T163455 —UN—16JAN03
24. Turn cover to pull remaining wire into the groove.
25. Apply pipe sealant to threads of pipe plug (8). Tighten
plug.
Pipe Plug to Ring Gear
—Torque...................................................................... 7.9 N·m (70 lb-in.)
26. Remove fittings. 24— Cover 26— Wire (Retainer)

25— O-Ring 30— Fitting (2 used)
27. Add approximately 0.5 L (0.5 qt) of gear oil to gearbox.
See Propel Gearbox Oil for specification. (Operator's
Manual.) Propel Gearbox—35C ZTS—Specification
See Check Propel Gearbox Oil Level after plugs and Plug to Cover—Torque................................................... 34 N·m (25 lb-ft)
O-rings (27 and 28) are installed. (Operator's Manual.)
28. Tighten plugs to specification.
OUT3035,0000341 -19-06JAN03-8/7

100312
PN=72
Group 0260
Hydraulic System
Propel Motor Disassemble and 1. See Propel Gearbox Remove and Install—27C ZTS
Assemble—27C ZTS and 35C ZTS for gearbox and motor removal. (Group
0250.)
Disassemble Propel Motor
See Propel Gearbox Disassemble and
Assemble—27C ZTS for gearbox disassembly.
CAUTION: Heavy component; use a hoist. (Group 0250.)
Propel Motor—27C ZTS—Specification
See Propel Motor and Brake Valve Housing Operation
Propel Gearbox and
for a cross-section of Propel Motor and Brake Valve
Housing—27C ZTS. (Group 9025-05.)

100312
PN=73
Hydraulic System
T163627 —UN—21FEB03

100312
PN=74
Hydraulic System
1— Housing Kit 10— Piston and Shoe (9 used) 19— Spacer 30— Spring Pin
2— Propel Motor Housing and 11— Retainer (Holder) 20— Plate (2 used) 31— Brake Valve Housing
Second Planet Carrier 12— Ball Guide (Holder) 21— Disk 32— Dowel Pin
3— Control Piston 13— Pin (3 used) 22— Backup Ring 33— O-Ring (2 used)
4— Oil Seal 14— Cylinder Block 23— O-Ring 34— Park Brake Spring (8 used)
5— Ball Bearing 15— Retainer (2 used) 24— Park Brake Piston 35— Cap Screw (7 used)
6— Drive Shaft 16— Spring 25— O-Ring
7— Pivot Ball (2 used) 17— Snap Ring 26— Backup Ring
8— Swash Plate 18— Valve Plate 27— O-Ring
9— Rotary Group Kit 28— Brake Valve Housing Kit
29— Ball Bearing
CAUTION: Brake valve housing contains springs 5. Remove ball bearing (29) from brake valve housing
under load. Prevent injury from sudden release only if replacement is necessary. Bearing is press fit.
by loosing cap screws evenly. If removed, install new bearings.
6. Remove park brake piston (24).
2. Loosen cap screws (35) evenly to release force of
park brake springs (34). 7. Hold the housing in a horizontal position and then slid
the rotary group (10—17) out of housing and off the
3. Before removing the brake valve housing (31),
drive shaft.
measure and record the distance between it and motor
housings as a reference for assembly.
CAUTION: Cylinder block contains a springs
IMPORTANT: Valve plate can stick to the brake valve under load. Prevent injury from sudden release
housing. Dropping the valve plate can damage by using a press to compress the spring
the highly machined surfaces. Use care when before removing snap ring.
removing the brake valve housing.
8. Disassemble rotary group for inspection and cleaning
4. Remove brake valve housing being careful not to drop only. Rotary group is serviced as an assembly.
the valve plate (18).
Compress spring (16) using a press before removing
Protect machined surfaces of valve plate from damage. the snap ring (21).
OUT3035,0000343 -19-08JAN03-3/7
9. Check the clearance between piston and shoe.

Piston to
Shoe—Clearance.......................................... 0.4 mm (0.0157 in.) or less
10. Substract piston diameter from cylinder block bore
T164706 —UN—03FEB03
diameter to check for wear.
Piston to Cylinder Block
Bore—Clearance....................................... 0.04 mm (0.00157 in.) or less
T164714 —UN—03FEB03

100312
PN=75
Hydraulic System
T163669 —UN—21FEB03
Brake Valve Housing Exploded View—27C ZTS
31— Brake Valve Housing 42— Guide (2 used) 47— Plug (2 used) 52— O-Ring (2 used)
38— Plug (2 used) 43— O-Ring (2 used) 48— O-Ring (2 used) 53— Shuttle Valve Spool
39— O-Ring (2 used) 44— Spring (2 used) 49— Spring 54— Counterbalance Valve
40— Spring (2 used) 45— Check Valve (2 used) 50— Propel Speed Change Valve Orifice (4 used)
41— Washer (2 used) 46— Counterbalance Valve Spool Spool
51— Plug (2 used)
11. Brake valve housing (31) is serviced as an assembly 12. Apply clean hydraulic oil to all machined surfaces after
except the O-rings (39, 43, 48, and 52) and springs (8 cleaning.
and 9). Disassemble for inspection and cleaning only.

100312
PN=76
Hydraulic System
Assemble Propel Motor See Propel Gearbox Disassemble and

1. See Propel Motor and Brake Valve Housing Operation Assemble—27C ZTS for gearbox assembly.
for a cross-section of Propel Motor and Brake Valve (Group 0250.)
T163669 —UN—21FEB03
Brake Valve Housing Exploded View—27C ZTS
31— Brake Valve Housing 42— Guide (2 used) 47— Plug (2 used) 52— O-Ring (2 used)
38— Plug (2 used) 43— O-Ring (2 used) 48— O-Ring (2 used) 53— Shuttle Valve Spool
39— O-Ring (2 used) 44— Spring (2 used) 49— Spring 54— Counterbalance Valve
40— Spring (2 used) 45— Check Valve (2 used) 50— Propel Speed Change Valve Orifice (4 used)
41— Washer (2 used) 46— Counterbalance Valve Spool Spool
51— Plug (2 used)
2. Apply clean hydraulic oil to all parts before installing. Speed Change
Valve-to-Housing
3. Tighten plugs (38, 47, and 51) to specification. Plug—Torque................................................... 46—51 N·m (34—38 lb-ft)
Propel Motor—27C ZTS—Specification Counterbalance
Shuttle Valve-to-Housing Valve-to-Housing
Plug—Torque........................................11.8—21.5 N·m (104—190 lb-in.) Plug—Torque........................................... 167—196 N·m (123—145 lb-ft)

100312
PN=77
Hydraulic System
T163627 —UN—21FEB03
OUT3035,0000343 -19-08JAN03-7/7

100312
PN=78
Hydraulic System
1— Housing Kit 10— Piston and Shoe (9 used) 19— Spacer 30— Spring Pin
2— Propel Motor Housing and 11— Retainer (Holder) 20— Plate (2 used) 31— Brake Valve Housing
Second Planet Carrier 12— Ball Guide (Holder) 21— Disk 32— Dowel Pin
3— Control Piston 13— Pin (3 used) 22— Backup Ring 33— O-Ring (2 used)
4— Oil Seal 14— Cylinder Block 23— O-Ring 34— Park Brake Spring (8 used)
5— Ball Bearing 15— Retainer (2 used) 24— Park Brake Piston 35— Cap Screw (7 used)
6— Drive Shaft 16— Spring 25— O-Ring
7— Pivot Ball (2 used) 17— Snap Ring 26— Backup Ring
8— Swash Plate 18— Valve Plate 27— O-Ring
9— Rotary Group Kit 28— Brake Valve Housing Kit
29— Ball Bearing
4. Install oil seal (4) so the sealing lip (spring side) is 12. Install O-rings (23 and 25) and backup rings (22 and
towards ball bearing (5). Push to the bottom of bore. 26) into grooves of park brake piston (24) making sure
Apply petroleum jelly to lip of oil seal the backup rings are to outer edges.
5. Apply clean hydraulic oil to components before 13. Push park brake piston into housing against the plate.
installing. 14. Add approximately 0.2 L (0.2 qt) of hydraulic oil to
As needed, apply petroleum jelly to help hold housing.
components in place. 15. Push the new ball bearing (29) to bottom of bore in
6. Install a new ball bearing tight against shoulder on brake valve housing (31).
drive shaft (6). 16. Install valve plate (18), springs (34) and O-rings (27
Install shaft into housing so bearing is to the bottom of and 33) to brake valve housing. Use petroleum jelly to
bore. hold parts in place while installing brake valve housing.
7. Install control piston (3) so large diameter end is to 17. Install brake valve housing (2) being careful that the
the bottom of piston bore. valve plate does not drop off.
8. Install swash plate (8) making sure the pivot balls (7) 18. Measure the distance between the two housings and
are seated in the holes in housing and swash plate. compare to measurement made at disassembly. If
not the same, disassemble and check for correct
9. Assemble the rotary group (10—17). assembly.
10. Hold the propel motor housing (2) in a horizontal 19. Tighten cap screws (35) in steps to pull housing down
position. Carefully install the rotary group aligning the evenly against the springs. Tighten cap screws to
splines in ball guide (12) and cylinder block (14) with specification in a diagonal pattern.
the splines on drive shaft.
NOTE: The valve plate (18) is installed on the Brake Valve
brake valve housing. Housing-to-Housing Cap
Screw—Torque................................................ 51—65 N·m (38—48 lb-ft)
11. Install spacer (19).
Starting with a plate (20), alternately install two plates and 35C ZTS for gearbox and motor installation.
and one disk (21). (Group 0250.)
OUT3035,0000343 -19-08JAN03-8/7

100312
PN=79
Hydraulic System
Propel Motor Disassemble and 1. See Propel Gearbox Remove and Install—27C ZTS
Assemble—35C ZTS and 35C ZTS for gearbox and motor removal. (Group
0250.)
Disassemble Propel Motor
See Propel Gearbox Disassemble and
Assemble—35C ZTS for gearbox disassembly.
CAUTION: Heavy component; use a hoist. (Group 0250.)
See Propel Motor and Brake Valve Housing Operation
Propel Gearbox and
for a cross-section of Propel Motor and Brake Valve
43
44
69
70
71
72
73
74
T163830 —UN—17JAN03
T163830
Propel Motor Flow Control Valve—35C ZTS
43— Plug (2 used) 70— Spring Seat (2 used) 72— Housing
44— O-Ring (2 used) 71— Flow Control Valve Spool 73— Cap Screw (3 used)
69— Spring (2 used) 74— O-Ring (3 used)
2. Check the flow control valve spool (71) moves freely

in housing bore.

100312
PN=80
Hydraulic System
T156461 —UN—06SEP02
Propel Motor And Park Brake Exploded View—35C ZTS

100312
PN=81
Hydraulic System
0— Propel Motor and Brake Valve 17— Park Brake Piston 31C— Spring (2 used) 48— Cap Screw (6 used)
Housing 18— Park Brake Spring (8 used) 31D— Plug (2 used) 49— Dowel Pin (2 used)
1— Plug 19— Control Piston (2 used) 31E— O-Ring (2 used) 53— Plug (2 used)
2— Drive Shaft 20— Spring (2 used) 36— Spring Seat (2 used) 55— Plug (2 used)
3— Ball Bearing 21— O-Ring 37— Spring (2 used) 56— Packing (2 used)
4— Oil Seal 23— O-Ring 38— Plug (2 used) 58— Plug (2 used)
5— Swash Plate 25— Valve Plate 39— O-Ring (2 used) 59— Plug (2 used)
6— Pivot Ball (2 used) 26— Dowel Pin 40— Orifice (4 used) 60— O-Ring (2 used)
7— Cylinder Block 27— Ball Bearing 41— Propel Speed Change Valve 61— Plug
8— Washer 28— O-Ring Spool 63— Cap
9— Spring 29— Packing (4 used) 42— Spring 64— Orifice (2 used)
10— Washer 30— Brake Valve Housing 43— Pipe Plug 65— Seal Kit
11— Snap Ring 31— Counterbalance Valve 44— O-Ring (2 used) 66— Brake Valve Housing Kit
12— Pin (3 used) 31A— Counterbalance Valve 45— Pipe Plug (3 used) 67— Cylinder Block Kit
13— Ball Guide (Holder) Spool 46— Dowel Pin (2 used)
14— Retainer (Plate) 31B— Check Valve (2 used) 47— Orifice (4 used)
15— Piston and Shoe (9 used)
16— Park Brake Disk
the highly machined surfaces. Use care when

CAUTION: Brake valve housing contains springs removing the brake valve housing.
under load. Prevent injury from sudden release
by loosing cap screws evenly. 5. Remove brake valve housing being careful not to drop
the valve plate (14).
3. Loosen cap screws (48) evenly to release force of
park brake springs (18). Protect machined surfaces of valve plate from damage.
4. Before removing the brake valve housing (30), 6. Remove ball bearings (3 and 27) from drive shaft
measure and record the distance between it and motor (2) and brake valve housing only if replacement is
housings as a reference for assembly. necessary. Bearings are press fit. New bearings
should be installed if removed.
IMPORTANT: Valve plate can stick to the brake valve
housing. Dropping the valve plate can damage
OUT3035,0000344 -19-14JAN03-3/8
7. Before removing park brake piston (17), take notice of

its position with respect to motor housing. Piston must
be installed so dowel pin holes and springs align with
dowel pins and holes in brake valve housing.
8. Hold the housing in a horizontal position then slid the
rotary group (7—15) out of housing and off the drive
T163857 —UN—16JAN03
shaft.
CAUTION: Cylinder block contains a springs

under load. Prevent injury from sudden release
by using a press to compress the spring
before removing snap ring.
9. Disassemble rotary group for inspection and cleaning

only. Rotary group is serviced as an assembly. 17— Park Brake Piston 29— Oil Passage
28— O-Ring 68— Park Brake Oil Passage
Compress spring (9) using a press before removing
the snap ring (11).

100312
PN=82
Hydraulic System

Piston to
Shoe—Clearance.......................................... 0.4 mm (0.0157 in.) or less
11. Substract piston diameter from cylinder block bore
T164706 —UN—03FEB03
Bore—Clearance....................................... 0.04 mm (0.00157 in.) or less
12. Check that spools (31, 41, and 71) move freely in their
bores.
13. Disassemble counterbalance valve (31) for cleaning
and inspection only. Valve is serviced as an assembly
except for the O-rings (31E) and plugs (31D).
14. Apply clean hydraulic oil to all machined surfaces after
T164714 —UN—03FEB03
cleaning.

100312
PN=83
Hydraulic System
Assemble Propel Motor See Propel Motor and Brake Valve Housing Operation
1. See Propel Gearbox Disassemble and for a cross-section of Propel Motor and Brake Valve
Assemble—35C ZTS for gearbox assembly. Housing—35C ZTS. (Group 9025-05.)
(Group 0250.)
T156461 —UN—06SEP02

100312
PN=84
Hydraulic System
0— Propel Motor and Brake Valve 17— Park Brake Piston 31C— Spring (2 used) 48— Cap Screw (6 used)
Housing 18— Park Brake Spring (8 used) 31D— Plug (2 used) 49— Dowel Pin (2 used)
1— Plug 19— Control Piston (2 used) 31E— O-Ring (2 used) 53— Plug (2 used)
2— Drive Shaft 20— Spring (2 used) 36— Spring Seat (2 used) 55— Plug (2 used)
3— Ball Bearing 21— O-Ring 37— Spring (2 used) 56— Packing (2 used)
4— Oil Seal 23— O-Ring 38— Plug (2 used) 58— Plug (2 used)
5— Swash Plate 25— Valve Plate 39— O-Ring (2 used) 59— Plug (2 used)
6— Pivot Ball (2 used) 26— Dowel Pin 40— Orifice (4 used) 60— O-Ring (2 used)
7— Cylinder Block 27— Ball Bearing 41— Propel Speed Change Valve 61— Plug
8— Washer 28— O-Ring Spool 62— Adapter
9— Spring 29— Packing (4 used) 42— Spring 63— Cap
10— Washer 30— Brake Valve Housing 43— Plug 64— Orifice (2 used)
11— Snap Ring 31— Counterbalance Valve 44— O-Ring (2 used) 65— Seal Kit
12— Pin (3 used) 31A— Counterbalance Valve 45— Pipe Plug (3 used) 66— Brake Valve Housing Kit
13— Ball Guide (Holder) Spool 46— Dowel Pin (2 used) 67— Cylinder Block Kit
14— Retainer (Plate) 31B— Check Valve (2 used) 47— Orifice (4 used)
15— Piston and Shoe (9 used)
16— Park Brake Disk
2. Install new O-rings (21, 23, 39, 44, and 60) and
NOTE: The valve plate (25) is installed on the
packings (29 and 56) as needed.
brake valve housing.
3. Apply clean hydraulic oil to all parts before installing.
12. Install park brake piston (17) to position noted at
4. Tighten plugs (38 and 43) and adapter (62) to disassembly. Dowel pin holes and springs (18) in
specification. brake piston must align with dowel pins and holes in
Propel Motor—35C ZTS—Specification brake valve housing.
Counterbalance
13. Add approximately 0.2 L (0.2 qt) of hydraulic oil to
Valve-to-Housing
housing.
Plug—Torque.............................................................. 240 N·m (177 lb-ft)
Propel Speed Change 14. Push the new ball bearing (27) to bottom of bore in
Valve-to-Housing brake valve housing.
Plug—Torque.................................................................. 54 N·m (40 lb-ft)
Propel Speed Change 15. Install valve plate (25) so notch engages dowel pin
Valve-to-Housing
(26). Use petroleum jelly to help hold valve plate in
Adapter—Torque............................................................ 54 N·m (40 lb-ft)
place while installing brake valve housing.
5. Install oil seal (4) to the bottom of bore with the 16. Install brake valve housing (30) being careful that the
sealing lip (spring side) towards ball bearing (3). Apply valve plate does not drop off.
petroleum jelly to lip of oil seal 17. Check that dowel pin holes and springs in brake piston
6. Install a new ball bearing (3) tight against shoulder on are aligned with dowel pins and holes in brake valve
drive shaft (2). Install shaft into housing so bearing housing.
is to the bottom of bore. 18. Measure the distance between the two housings and
7. Install springs (20) into the control pistons (19) and compare to measurement made at disassembly. If
then into propel motor housing so spring is to the not the same, disassemble and check for correct
bottom of piston bore. assembly.
8. Install swash plate (5) making sure the pivot balls (6) 19. Tighten cap screws (48) in steps to pull housing down
are seated in the holes in housing and swash plate. evenly against the spring force. Tighten cap screws to
specification in a diagonal pattern.
9. Install park brake disk (16).
10. Assemble the rotary group (7—15). Brake Valve Housing-
to-Motor Housing Cap
11. Hold the propel motor housing in a horizontal position. Screw—Torque............................................................... 64 N·m (47 lb-ft)
Carefully install the rotary group aligning the splines
for ball guide (13) and cylinder block (7) with the spline
on drive shaft and park brake disk.

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PN=85
Hydraulic System
43
44
69
70
71
72
73
74
T163830 —UN—17JAN03
T163830
Propel Motor Flow Control Valve—35C ZTS
43— Plug (2 used) 70— Spring Seat (2 used) 72— Housing
44— O-Ring (2 used) 71— Flow Control Valve Spool 73— Cap Screw (3 used)
69— Spring (2 used) 74— O-Ring (3 used)
20. Tighten plugs (43) and cap screws (73) to specification.

Propel Motor—35C ZTS—Specification and 35C ZTS for gearbox and motor installation.
Flow Control Valve to (Group 0250.)
Housing Plug—Torque................................................... 54 N·m (40 lb-ft)
Flow Control Valve
Housing-to-Brake
Valve Housing Cap
Screw—Torque............................................................... 37 N·m (27 lb-ft)
OUT3035,0000344 -19-14JAN03-8/8

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PN=86
Hydraulic System
Rotary Manifold Remove and Install
CAUTION: High pressure release of oil from

1. Slowly loosen cap to relieve the air pressure in

hydraulic oil tank.
2. Pull a vacuum in hydraulic oil tank using a vacuum
pump to minimize the loss of oil.
3. Remove the floor mat.
T164100 —UN—22JAN03
4. Remove the plate in front of seat base that contain
the fast speed travel pedal.
NOTE: The retainer has a slot that fits around a boss on the
rotary manifold housing and is open on the lower end.
5. Remove cap screws and lock washers (21) to remove

retainer (22).
5— To Hydraulic Oil Tank 21— Cap Screw and Lock
6. Attach identification tags to lines to aid assembly. See 9— From Swing Motor Drain Washer (2 used)
Propel Hydraulic System Line Connection. Port 22— Retainer
20— Rotary Manifold
Disconnect lines (5 and 9). Close openings using
caps and plugs.
7. Connect rotary manifold (20) to a hoist using a lifting
CAUTION: Heavy component; use a hoist. strap or JT01748 Lifting Brackets.
Rotary Manifold—Specification 8. Remove the bottom cover from undercarriage.
Rotary Mani-
fold—Weight.................................................... 17 kg (37 lb) approximate

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PN=87
Hydraulic System
CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811 —UN—23AUG88
9. Disconnect the remaining lines (1—4, 6—8, and
(10—19).
1— To Right Propel Valve 11— Port G-to-Right Propel

Forward Port Motor Speed Change Port
2— To Right Propel Valve 12— Port G-to-Left Propel
Reverse Port Motor Speed Change Port
3— To Left Propel Valve 13— Port B-to-Right Propel
Reverse Port Motor Top Port
4— To Left Propel Valve 14— Port A-to-Right Propel
Forward Port Motor Bottom Port
5— To Hydraulic Oil Tank 15— Port T-to-Right Propel
6— To Blade Valve Lower Port Motor Drain Port
7— To Blade Valve Raise Port 16— Port E-to-Blade Cylinder
8— From Propel Speed Change Rod End Port
Solenoid Valve 17— Port F-to-Blade Cylinder
9— From Swing Motor Drain Head End Port
Port 18— Port T-to-Left Propel
10— Port C-to-Left Propel Motor Drain Port
Motor Top Port 19— Port D-to-Left Propel
Motor Bottom Port
T122948 —UN—28OCT99
T122946 —UN—28OCT99

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PN=88
Hydraulic System
10. Remove the cap screws (21). Lower the manifold

turning it as necessary to clear the adapters.
11. See Rotary Manifold Disassemble and Assemble for
disassembly and assembly procedure. (Group 0260.)
12. Install retainer. Tighten cap screws.
T164094 —UN—22JAN03
Rotary Manifold—Specification
Retainer-to-Frame Cap
13. Install rotary manifold so boss on housing is to the

right front corner of upperstructure and engages the
open slot in retainer.
The spindle ports E and F for blade cylinder must be 20— Rotary Manifold 21— Cap Screw (4 used)
towards the blade end of undercarriage.
14. Tighten cap screws.
Rotary Manifold—Specification 16. Install bottom cover.
Flange-to-Frame Cap Rotary Manifold—Specification
Screw—Torque............................................................... 49 N·m (36 lb-ft) Bottom Cover-to-Frame
15. Connect the lines. See Propel Hydraulic System Line Cap Screw—Torque....................................................... 88 N·m (65 lb-ft)
Connection.
OUT3035,0000345 -19-16JAN03-3/3
Rotary Manifold Disassemble and Assemble

1. Take notice of the position of ports in spindle and
flange (12) with respect to the boss on side of housing
(1) to aid assembly.
2. Remove cap screws (4) to remove cover (3).
3. Remove snap ring (6) and thrust washer (7).
1— Housing 8— Seal (7 used)

2— O-Ring 9— O-Ring
3— Cover 10— Backup Ring
4— Cap Screw (4 used) 11— Dust Seal
6— Retaining Ring 12— Spindle and Flange
7— Thrust Washer (Ring)
T163831 —UN—17JAN03
Continued on next page FR91424,0000019 -19-21JAN03-1/2

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PN=89
Hydraulic System
4. Push spindle and flange (12) out of housing using a

puller, forcing screw, and shaft protector from a puller
set (4).
5. Remove and replace parts (9—11) as necessary.
6. Apply petroleum jelly or hydraulic oil to seals (8) before
T122994 —UN—28OCT99
installing into grooves. Check that seals are seated in
the groove.
7. Install O-ring into groove so it is towards the seals and
backup ring is towards the dust seal end of housing.
8. Install dust seal so lip is towards the bottom end of
housing. Apply petroleum jelly to seal lip.
9. Put the spindle (12) on a workbench in a vertical
position.
IMPORTANT: Seals can be damaged by pushing
the housing onto the spindle to rapidly. Push
housing onto the spindle slowly.
10. Install housing (1) on the spindle so the boss on side

of housing is aligned with the spindle ports as noted
at disassemble.
Slowly, push housing down onto the spindle by tapping
on end of housing using a soft-face hammer.
11. Install the thrust washer (7).
12. Install snap ring (6) with the flat side towards the thrust
washer and the chamfered side towards the cover.
Check that snap ring is seated in the groove.
13. Install remaining parts (2, 3, and 4). Tighten cap
screws.
T163841 —UN—16JAN03
Rotary Manifold—Specification
Cover-to-Housing Cap
Screw—Torque.......................................................... 10.8 N·m (95 lb-in.)
1— Housing 8— Seal (7 used)

2— O-Ring 9— O-Ring
3— Cover 10— Backup Ring
4— Cap Screw (4 used) 11— Dust Seal
6— Snap Ring 12— Spindle and Flange
7— Thrust Washer (Ring)
FR91424,0000019 -19-21JAN03-2/2

100312
PN=90
Section 04
Engine
Contents
Page

Engine
Remove and Install ...............................04-0400-1
Exhaust Manifold .......................................04-0400-4
Water Pump...............................................04-0400-5
Cylinder Head............................................04-0400-7
Cylinder Block..........................................04-0400-18
Rocker Arm..............................................04-0400-21
Camshaft .................................................04-0400-23
Flywheel ..................................................04-0400-25
Flywheel Housing ....................................04-0400-26
Oil Pan.....................................................04-0400-27
Crankshaft ...............................................04-0400-28
Piston and Connecting Rod.....................04-0400-33
Oil Pump..................................................04-0400-40
Thermostat ..............................................04-0400-42
Fuel Injection Pump.................................04-0400-43
Fuel Injection Nozzle ...............................04-0400-45
Starter......................................................04-0400-47
Alternator .................................................04-0400-49

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PN=1
Contents

100312
PN=2
Group 0400
Removal and Installation
Engine Remove and Install
1. Disconnect negative battery cable.
2. See Cab Remove and Install for removal procedure.
(Group 1800.)
See Canopy Remove and Install for removal
procedure. (Group 1800.)
3. Remove all outer access panels and covers.
4. See Counterweight Remove and Install for removal
CAUTION: Explosive release of fluids from

pressurized cooling system can cause
serious burns. 6. Remove seat. See Seat Remove and Install. (Group
1821.)
Shut off engine. Remove filler cap when cool
to touch. Slowly loosen filler cap to first stop
to relieve pressure, then remove.
5. Drain coolant. Approximate capacity is 6.0 L (6.3 qt).

OUO1082,0000272 -19-04FEB03-1/7
7. Remove floor mat (2) and left side cover (1).

8. Remove power outlet housing (5). Disconnect wiring
harness from power outlet.
9. Remove right side cover (6). Disconnect wiring
harnesses from heater blower switch (4).
T159501B —UN—20SEP02
1— Left Side Cover 4— Heater Blower Switch
2— Floor Mat 5— Power Outlet Housing
3— Manual Holder Door 6— Right Side Cover
OUO1082,0000272 -19-04FEB03-2/7
10. Remove seat base-to-floor plate cap screws (7). Tip

seat base forward so rear edge clears rear support.
7— Cap Screw (5 used)

T164757B —UN—03FEB03
Continued on next page OUO1082,0000272 -19-04FEB03-3/7

100312
PN=93
11. Remove cap screws (8) to remove speed control lever

from bracket on rear support.
12. Loosen nuts to remove speed control cable from
bulkhead bracket.
T164761B —UN—03FEB03
8— Cap Screw (2 used) 9— Heater Shut-Off Valve
OUO1082,0000272 -19-04FEB03-4/7
13. Remove top radiator mount cap screws (10).

14. Remove cap screws (14) and tank support (11).
15. Remove cap screws (13) and line support (12).
16. Disconnect radiator overflow reservoir hoses.
17. Disconnect air cleaner outlet hose.
18. Disconnect fuel filler support bracket.
10— Cap Screw (3 used) 13— Cap Screw (3 used)

11— Tank Support 14— Cap Screw (4 used)
12— Line Support
T164762 —UN—03FEB03

100312
PN=94
19. Attach rear support (16) to a hoist using M16x2.0 lifting

eyebolts such as JT05551 Metric Lifting Eyebolts and 16
lifting straps.
15
20. Remove cap screws (15) to remove rear support.
21. Disconnect speed control cable from engine.
22. Disconnect fuel inlet and return lines.
23. Remove starter so wiring harness can be
disconnected. See Starter Repair. (Group 0400.)
Attach identification tags to wiring to aid installation.
24. Disconnect wiring harnesses from alternator, fuel
shut-off solenoid, switches, and sensor. See Engine
Harness (W3) Component Location. (Group 9015-10.)
T164763 —UN—03FEB03
25. For machines with a heater, disconnect heater hoses.
26. Disconnect radiator hoses.
27. Remove cap screws securing main hydraulic pump
to engine flywheel cover. T164763
28. Pull hydraulic pump away from engine until drive
coupler is disengaged from flywheel and housing.
15— Cap Screw (8 used) 16— Rear Support
29. Remove fan guard. See Fan, Shroud, and Guard
Repair. (Group 0510.)
IMPORTANT: The recommended method for lifting the
CAUTION: Heavy component; use a hoist. engine is using the JDG23 Lifting Sling. The
lifting force must be at 90° to the lifting points.
Engine—Specification
Engine—Weight............................................................... 152 kg (335 lb)
30. Attach engine to a hoist using the JDG23 Lifting Sling.
OUO1082,0000272 -19-04FEB03-6/7
31. Remove cap screws and washers (17). Carefully

remove engine checking that fan clears the fan shroud
and pump drive shaft clears flywheel housing cover.
33. Install engine using JDG23 Lifting Sling. Tighten cap
screws.
Engine Mount-to-Isolator 17
T164765 —UN—03FEB03
34. Align hydraulic pump splines to engine coupler.

Tighten cap screws.
Hydraulic Pump-to- T164765
Flywheel Housing Cover
Cap Screws—Torque..................................................... 88 N·m (65 lb-ft)
17— Cap Screw and Washer (4
35. Connect engine wire harness. See Engine Harness used)
(W3) Component Location. (Group 9015.)
36. Fill radiator and reservoir with coolant. See Cooling
System Fill and Deaeration. (Operator's Manual.) 37. Bleed fuel system. See Bleed Fuel System. (Group
0560.)
OUO1082,0000272 -19-04FEB03-7/7

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PN=95
Exhaust Manifold Remove and Install

1. Remove cap screws (4), nuts (1), exhaust manifold
(3), and gasket (2).
2. Clean all gasket material from exhaust manifold and
cylinder head mating surfaces.
T126986 —UN—14JAN00
3. Install gasket (2) and exhaust manifold (3). Tighten
cap screws (4) and nuts (1).
Exhaust Manifold—Specification
Exhaust Manifold-to-
Cylinder Head Cap Screw
and Nut—Torque........................................................ 24 N·m (212 lb-in.)
1— Nut (2 used) 4— Cap Screw (4 used)

2— Gasket 5— Stud (2 used)
3— Manifold
OU90U50,0000003 -19-28JAN03-1/1

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PN=96
Water Pump Repair

Remove and Install Water Pump

serious burns.
Shut off engine. Only remove filler cap
when cool enough to touch with bare hands.
Slowly loosen cap to relieve pressure before
removing completely.
1. Drain coolant. Approximate coolant capacity is 6.0 L

(6.3 qt).
2. Remove fan guard (2).
3. Remove fan (4) and spacers (5).
4. Remove thermostat housing (6). See Thermostat
Remove and Install. (Group 0400.).
5. Disconnect hose (8).
6. Loosen nut (9) and cap screws (12). Turn cap screw
(11) counter clockwise and remove fan belt (17).
T126071 —UN—14JAN00
7. Remove pulley (14), bracket (10), and water pump
(15).
8. Remove and discard gasket.
10. Apply TY16135 ULTRA BLUE® RTV Silicone
Form-In-Place Gasket to water pump-to-cover mating
surfaces if cover was removed.
11. Install water pump with new gasket. Tighten cap
screws.
Water Pump—Specification
Water Pump Mounting
Cap Screw—Torque................................................... 24 N·m (212 lb-in.)
12. Install pulley. Tighten cap screws.
T164237B —UN—22JAN03
13. Install alternator bracket (10) and fan belt (17). Tighten
cap screws and nuts.
Lower Alternator-to-Block
Upper Alternator-to-
Bracket Nut—Torque.................................................. 24 N·m (212 lb-in.)
Bracket-to-Block Cap 1— Cap Screw (3 used) 10— Bracket
Screw—Torque........................................................... 24 N·m (212 lb-in.) 2— Fan Guard 11— Cap Screw
3— Cap Screw (4 used) 12— Cap Screw
4— Fan 13— Cap Screw
5— Spacer (3 used) 14— Belt Pulley
14. Fill radiator and reservoir with coolant. See Cooling 6— Thermostat Housing 15— Water Pump
System Fill and Deaeration. (Operator's Manual.) 7— Hose Clamp 16— Cap Screw (6 used)
8— Hose 17— Fan Belt
9— Nut 18— Cap Screw (2 used)
ULTRA BLUE is a trademark of Loctite Corp.

Continued on next page OU90U50,0000005 -19-28JAN03-1/5

100312
PN=97
Disassemble Water Pump

1. Remove set screw (7) and cover (5).
2. Remove parts (1—4).
Inspect Water Pump
T123163 —UN—28OCT99
Ball Bearing—End Play..............0.008—0.010 mm (0.0003—0.0004 in.)
0.2 mm (0.0079 in.) maximum
Fan Center-to-Bearing
Shaft—Press Fit...........................0.026—0.061 mm (0.001—0.0024 in.)
1— Fan Center 5— Cover

2— Bearing with Shaft 6— Housing
3— Seal 7— Set Screw
4— Impeller
OU90U50,0000005 -19-28JAN03-2/5
Assemble Water Pump

1. Install bearing with shaft (1) into housing (3) making
sure alignment holes (2) are in line.
2. Install set screw (4) and tighten.
T123159 —UN—28OCT99
Set Screw—Torque.................................................... 12 N·m (108 lb-in.)
1— Bearing with Shaft 4— Set Screw

2— Alignment Holes 5— Fan Center
3— Housing
OU90U50,0000005 -19-28JAN03-3/5
3. Apply a thin coat of TY16135 ULTRA BLUE® RTV

Silicone Form-In-Place Gasket to seal outer diameter
(1) before installation.
1— Seal Outer Diameter
T123160 —UN—28OCT99

Continued on next page OU90U50,0000005 -19-28JAN03-4/5

100312
PN=98
4. Install impeller on shaft to the specified dimension (1).

Pump Impeller Boss-to-
Shaft—Distance.....................................8.6—8.8 mm (0.339—0.346 in.)
5. Measure clearance between impeller and body. 1
T164235 —UN—24JAN03
Impeller-to-
Body—Clearance...........................0.53—2.17 mm (0.0209—0.0854 in.)
6. Install fan center onto shaft to the specified dimension

(2).
T164235
Fan Center-to-Pump
Cover—Distance.................... 109.65—110.25 mm (4.3169—4.3406 in.)

Form-In-Place Gasket to contact area of pump and
install cover.
8. Apply T43512 Thread Lock and Sealer (Medium
T164236 —UN—24JAN03
Strength) to cover cap screws. Tighten cap screws.
1— Impeller Shaft Dimension 2— Fan Hub-to-Cover

Dimension
T164236 2

OU90U50,0000005 -19-28JAN03-5/5
Cylinder Head Repair

Remove and Install Cylinder Head
1. Remove rocker arm cover (2) and gasket (3).
T126963 —UN—14JAN00
1— Cap Screw (9 used) 3— Gasket
2— Rocker Arm Cover
Continued on next page OUO1020,0001253 -19-31JAN03-1/30

100312
PN=99
2. Remove rocker arm shaft bracket (1).

3. Remove nuts (4) and rocker arm shaft springs (3).
Mark to aid in assembly.
4. Remove plug (7) and washer (8).
5. Remove rocker arm shaft (2).
6. Remove rocker arms (5). Mark to aid in assembly.
7. Remove push rods.
T126964 —UN—14JAN00
1— Rocker Arm Shaft Bracket 6— Cap Screw (8 used)
2— Rocker Arm Shaft 7— Plug
3— Rocker Arm Shaft Spring (3 8— Washer
used) 9— Cylinder Head
4— Nut (6 used)
5— Rocker Arm (6 used)
OUO1020,0001253 -19-31JAN03-2/30
8. Loosen cylinder head cap screws a little at a time in

sequence shown. Remove cylinder head.
9. Remove tappets.
10. Discard cylinder head gasket.
T126007 —UN—14JAN00
11. Clean and inspect parts. Replace as necessary.
12. Install tappets.
OUO1020,0001253 -19-31JAN03-3/30
13. Install cylinder head gasket on cylinder block with the

stamp mark (1) up.
14. Install cylinder head.
1— Stamp Mark
T126001 —UN—14JAN00

100312
PN=100
15. Lubricate cap screws with clean engine oil. Tighten

cap screws in sequence shown. After tightening all
cap screws, tighten each M12 cap screw an additional
60—90° turn.
Cylinder Head—Specification
Cylinder Head-to-Block
T126008 —UN—14JAN00
M12 x 1.5 Cap
Screw—Torque Turn........................................ 83—93 N·m (61—69 lb-ft)
plus turn an additional 60—90°
Cylinder Head-to-Block
M8 x 1.25 Cap
Screw—Torque.......................................... 25—34 N·m (221—301 lb-in.)
16. Install push rods.

OUO1020,0001253 -19-31JAN03-5/30
T126015 —UN—14JAN00
1— Rocker Arm Shaft Spring (3 3— Rocker Arm Shaft 8— Cap Screw (8 used)
used) 4— Rocker Arm (6 used) 11— Rocker Arm Shaft Bracket
2— Nut (6 used) 7— Rocker Arm Adjustment
Screw (6 used)
17. Assemble parts (1—4) and (7) and install onto rocker
arm shaft bracket.

100312
PN=101

Form-In-Place Gasket to bottom of the rocker arm APPLY BEAD OF SEALANT
shaft bracket. Avoid getting sealant in the groove
around the oil galley as shown.
19. Install rocker arm shaft bracket making sure push rods
align with rocker arms and tighten cap screw. AVOID THE APPLICATION
OF SEALANT TO THIS
T164805 —19—05FEB03
Cylinder Head—Specification GROOVE.
Rocker Arm Shaft Bracket
Cap Screw—Torque...................................... 8—12 N·m (71—106 lb-in.)
OIL GALLEY
20. Adjust valve clearance. See Check and Adjust Engine
Valve Lash (Clearance). (Group 9010-25.)
T164805
21. Make sure rocker arms, rocker arm shafts, and valve
springs are thoroughly lubricated with clean engine oil.
22. Install front and rear lifting brackets. Tighten cap
Lifting Bracket Cap
screws.

OUO1020,0001253 -19-31JAN03-7/30
23. Install rocker arm cover (1) and gasket (2) on rocker
arm shaft bracket (3).
1— Rocker Arm Cover 3— Rocker Arm Shaft Bracket

2— Gasket
T126004 —UN—14JAN00
OUO1020,0001253 -19-31JAN03-8/30
24. Tighten rocker arm cover (1) cap screws.

Cylinder Head Rocker
Arm Cover Cap
Screw—Torque............................................................... 4 N·m (35 lb-in.)
T126977 —UN—14JAN00
25. Apply ULTRA BLUE® RTV Silicone Form-In-Place

Gasket to surface of air inlet pipe (2).
26. Install air inlet pipe and tighten cap screws.
Air Inlet Pipe Cap
1— Rocker Arm Cover 2— Air Inlet Pipe


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PN=102
Disassemble Cylinder Head

1. Remove connector (1), glow plugs (2), and injectors
(3).
1— Connector 3— Nozzle Holder (3 used)

2— Glow Plug (3 used)
T164234 —UN—24JAN03
OUO1020,0001253 -19-31JAN03-10/30
2. Remove split collar (1) using valve spring compressor

(2).
1— Split Collar 2— Valve Spring Compressor
T164232 —UN—24JAN03
OUO1020,0001253 -19-31JAN03-11/30
1— Split Collar (12 used) 3— Valve Spring (6 used)

2— Spring Seat (6 used) 4— Valve (6 used)
T121744 —UN—28OCT99

100312
PN=103

Apply T43513 Thread Lock and Sealer (High Strength)
to the threads of studs before installation.
1— Stud (5 used) 5— Plug

2— Valve Seal (6 used) 6— Valve Seat Insert (6 used)
T164233 —UN—24JAN03
3— Valve Guide (6 used) 7— Stud
4— Stud (2 used)
OUO1020,0001253 -19-31JAN03-13/30
Inspect Cylinder Head

1. Use a straight edge and feeler gauge to measure four
sides and two diagonals of cylinder head lower face.
2. Grind cylinder head lower face if measured values are
greater than specification, but less than maximum
T114099 —UN—24MAR98
grinding allowance. If measured values exceed
maximum grinding allowance, cylinder head must be
replaced.
Cylinder Head Lower
Face—Out-of-Flat.................................................. 0.075 mm (0.0029 in.)
Out-of-Flat ............................................. 0.15 mm (0.0059 in.) maximum
Grinding Allowance.................................. 0.3 mm (0.0118 in.) maximum
Cylinder Head—Height................................................... 64.00 (2.519 in.)
Height ..................................................... 63.70 mm (2.507 in.) minimum
H—Cylinder Head Height
Continued on next page T126967 —UN—14JAN00

OUO1020,0001253 -19-31JAN03-14/30

100312
PN=104
Inspect Valve Springs

1. Use a vernier caliper to measure valve spring free
length. Replace valve spring if measured value is less
than specification.
T114116 —UN—24MAR98
Intake and Exhaust Valve
Spring—Free Length............................................... 42.1 mm (1.6575 in.)
Free Length ............................................ 40.0 mm (1.5748 in.) minimum
2. Use a surface plate and square to measure the valve

spring inclination. Replace valve spring if measured
value exceeds specification.
Spring—Inclination.................................................... 1.8 mm (0.0709 in.)
Inclination ................................................ 2.5 mm (0.0984 in.) maximum
OUO1020,0001253 -19-31JAN03-15/30
3. Use a spring tester to measure valve spring tension.

Replace valve spring if measured value is less than
specification.
Spring—Tension...................................................... 167 N (37.5 lb-force)
T114117 —UN—24MAR98
Tension .......................................................147 N (33 lb-force) minimum
OUO1020,0001253 -19-31JAN03-16/30
Inspect Valves
1. Measure valve stem diameter at three points
equidistant along its length. Replace valve and
valve guide as a set if measured value is less than
specification.
T122391 —UN—28OCT99
Inlet Valve Stem—OD............................................... 7.0 mm (0.2756 in.)
6.85 mm (0.2697 in.) minimum
Exhaust Valve
Stem—OD................................................................. 7.0 mm (0.2756 in.)
6.80 mm (0.2677 in.) minimum

100312
PN=105
2. Measure valve thickness.

Intake Valve—Thick-
ness............................................................................. 1.0 mm (0.039 in.)
0.7 mm (0.028 in.) minimum
Exhaust Valve—Thick-
T144153 —UN—08FEB02
ness............................................................................. 0.8 mm (0.032 in.)
0.5 mm (0.020 in.) minimum
Replace valve and valve seat insert as a set if

measured value is less than specification.
OUO1020,0001253 -19-31JAN03-18/30
Inspect Valve Seat

1. Measure valve depression.
a. Install valve in cylinder head.
b. Use depth gauge or straight edge with steel rule
T121998 —UN—28OCT99
to measure valve depression from cylinder head
lower surface.
Intake Valve—Depth.................................................. 0.7 mm (0.0276 in.)
Exhaust Valve—Depth.............................................. 0.9 mm (0.0354 in.)
Valve seat insert and valve must be replaced if
1— Valve 2— Cylinder Head
measurement exceeds specification.
OUO1020,0001253 -19-31JAN03-19/30
2. Measure valve contact width.

a. Inspect valve contact faces for roughness and
unevenness.
b. Lap valve contact surfaces if required.
T114108 —UN—24MAR98
c. Measure valve face contact width.
Intake Valve
Contact—Width......................................................... 2.0 mm (0.0787 in.)
Exhaust Valve
Contact—Width......................................................... 2.0 mm (0.0787 in.)
d. Perform “valve seat insert correction” in next step, if

measurement exceeds specification.

100312
PN=106
3. Valve seat insert correction (if required):

a. Remove carbon from valve seat insert surface.
IMPORTANT: Do Not remove more material than
necessary with valve cutter. Use to minimize
scratches and rough areas only.
T122053 —UN—28OCT99
b. Use a valve cutter (15°, 45°, 75° blades) to minimize
scratches and other rough areas. This will bring
contact width to specification.
c. Apply abrasive compound to valve seat insert
surface.
d. Install valve into valve guide.
e. Lap valve to fit valve seat insert. 1— Contact Width
f. Check that valve contact width is correct.

Cylinder Head—Specification g. Check that valve seat insert surface is in contact
Valve Contact—Width................................................... 2.0 mm (0.08 in.) with entire circumference of valve.
OUO1020,0001253 -19-31JAN03-21/30
4. Valve Seat Replacement:

a. Weld a bead (1) around the entire inside
circumference of valve seat insert (3).
b. Allow the valve seat insert to cool for a few minutes
before removing.
T122002 —UN—28OCT99
c. Carefully remove carbon and other foreign material
from the cylinder head insert bore.
1— Bead 3— Valve Seat Insert

2— Cylinder Head 4— Screwdriver
OUO1020,0001253 -19-31JAN03-22/30
5. Carefully place smooth side of attachment (1) on valve

seat insert (3).
IMPORTANT: Do not apply an excessive amount
of pressure with arbor press. Damage to
valve seat insert will result. T122026 —UN—28OCT99
6. Install valve seat insert using an arbor press.
1— Attachment 3— Valve Seat Insert

2— Arbor Press

100312
PN=107
Assemble Cylinder Head

1. Lubricate oil seals and valve stem sealing areas with
engine oil.
2. Use 5-8840-9007-0 Valve Stem Oil Seal Installer (1) to
install oil seal.
T122389 —UN—28OCT99
3. Place cylinder head on a flat wooden surface.
4. Lubricate valve stems with clean engine oil.
1— Valve Stem Installer
OUO1020,0001253 -19-31JAN03-24/30
5. Install valves to their original lapped valve seats.
T122616 —UN—28OCT99
OUO1020,0001253 -19-31JAN03-25/30
6. Install valve springs with their painted end (1) (the

close pitched end) facing down.
1— Painted End
T122615 —UN—28OCT99

100312
PN=108
7. Use valve spring compressor (2) to push valve spring

into position.
8. Install spring seat split collar.
1— Split Collar 2— Valve Spring Compressor
T164232 —UN—24JAN03
OUO1020,0001253 -19-31JAN03-27/30
9. Set spring seat split collar by tapping lightly around

head of collar with a rubber mallet.
T126009 —UN—14JAN00
OUO1020,0001253 -19-31JAN03-28/30
10. Install glow plug (2) to cylinder head and tighten.

Glow Plug—Torque................................... 15—20 N·m (133—177 lb-in.)
11. Install connector (1) to glow plug and tighten.
T122664 —UN—28OCT99
12. Install exhaust manifold gasket.
13. Install exhaust manifold.
1— Connector 2— Glow Plug

100312
PN=109
14. Tighten exhaust manifold cap screws and nuts.

Exhaust Manifold Cap
T126003 —UN—14JAN00
OUO1020,0001253 -19-31JAN03-30/30
Cylinder Block Repair

Cylinder Block Water Jacket Test
Use hydraulic pressure gauge to check pressure in water
jacket.
T122228 —19—29OCT99
Cylinder Block—Specification
Water Jacket Water
Test—Pressure..................................... 5 kg/cm2 (71.1 psi) for 3 minutes
Inspect Cylinder Bore
NOTE: Grade mark is stamped on the top surface
of the cylinder block.
1. Take measurements at 13 mm below the top at

positions X-X and Y-Y near No. 1 compression ring.
Measurements taken at positions X-X and Y-Y cannot
exceed 0.2 mm (0.0079 in.) otherwise boring and
honing of inner diameter will be required.
T122226 —UN—28OCT99
Cylinder Block Bore
(Grade A)—ID........................ 83.100—83.110 mm (3.2716—3.2720 in.)
Cylinder Block Bore
(Grade B)—ID........................ 83.111—83.120 mm (3.2720—3.2724 in.)
Cylinder Block Bore
(Grade C)—ID........................83.121—83.130 mm (3.2724—3.2728 in.)

100312
PN=110
2. Measure piston outside diameter at about 64 mm from

the top of the piston.
Piston —OD...........................83.045—83.060 mm (3.2695—3.2701 in.)
3. Subtract the piston OD from the cylinder bore ID to
T122055 —UN—28OCT99
calculate the cylinder bore and piston clearance.
Cylinder Bore and
Piston—Clearance.....................0.040—0.085 mm (0.0016—0.0033 in.)
If piston and cylinder bore clearance exceeds the
specification, piston and/or cylinder block must be
replaced.
OUOE046,0000091 -19-14FEB03-2/5
Upper Face Out-of-Flat Inspection

1. Use a straight edge (1) and feeler gauge (2) to
measure the four sides and two diagonals of the
cylinder block upper face.
2. Grind the cylinder block upper face if the measured
T122225 —UN—28OCT99
values are greater than the specification, but less than
the maximum grinding allowance. If the measured
values exceed the maximum grinding allowance, the
cylinder block must be replaced.
Cylinder Block Upper
Face—Out-of-Flat.................................................. 0.075 mm (0.0029 in.)
Out-of-Flat ............................................. 0.15 mm (0.0059 in.) maximum
Grinding Allowance.................................. 0.3 mm (0.0118 in.) maximum
1— Straight Edge 2— Feeler Gauge
T122224 —UN—28OCT99
OUOE046,0000091 -19-14FEB03-3/5
Cylinder Block Height Measurement

Measure cylinder block height (1).
Cylinder Block—Height....................................... 308.0 mm (12.1260 in.)
307.7 mm (12.1142 in.) minimum
T126006 —UN—14JAN00
1— Block Height

100312
PN=111
Piston Outside Diameter Measurement

Measure piston outside diameter at approximately 64 mm
from top of piston.
Piston Standard—OD.............83.045—83.060 mm (3.2695—3.2701 in.)
T122056 —UN—28OCT99
Piston Oversize (0.25
in.)—OD.................................83.295—83.310 mm (3.2793—3.2799 in.)
1— Grade Mark
T122055 —UN—28OCT99
OUOE046,0000091 -19-14FEB03-5/5

100312
PN=112
Rocker Arm Repair
T126015 —UN—14JAN00
1— Rocker Arm Shaft Spring (3 3— Rocker Arm Shaft 8— Cap Screw (8 used)
used) 4— Rocker Arm (6 used) 11— Rocker Arm Shaft Bracket
2— Nut (6 used) 7— Rocker Arm Adjustment
Screw (6 used)
Disassemble and Assemble Rocker Arm 4. Apply clean engine oil to all parts before assembling.
1. Remove rocker arms. See Cylinder Head Repair. 5. Install parts.
(Group 0400.)
6. Install rocker arms.
2. Remove parts (1—4 and 7).
3. Clean and inspect parts for wear or damage.

100312
PN=113
Inspect Rocker Arm

1. Measure rocker arm shaft outside diameter using a
micrometer.
Rocker Arm—Specification
Rocker Arm Shaft—OD.......... 11.935—11.955 mm (0.4699—0.4707 in.)
T114124 —UN—24MAR98
If measured value is outside of specified range,
replace rocker arm shaft.
2. Measure rocker arm bushing inside diameter using a
vernier caliper.
Rocker Arm
Bushing—ID........................... 11.960—11.980 mm (0.4709—0.4717 in.)
If measured value is outside of specified range,
replace rocker arm bushing.
3. Calculate the rocker arm bushing and shaft clearance
T114125 —UN—24MAR98
by subtracting the shaft outside diameter from the
bushing inside diameter.
Rocker Arm Bushing and
Shaft—Clearance.......................0.005—0.045 mm (0.0002—0.0018 in.)
Clearance ................................................ 0.2 mm (0.0079 in.) maximum
If clearance exceeds specification, replace either
rocker arm or rocker arm shaft.
4. Check that rocker arm oil port is free of obstructions.
Clean rocker arm oil port of any obstructions.
OUOE046,0000092 -19-14FEB03-2/2

100312
PN=114
Camshaft Repair
T164855 —UN—05FEB03
Camshaft Exploded View
Continued on next page OUT1738,00000AF -19-29MAY12-1/5

100312
PN=115
1— Sleeve 6— Front Bearing 10— Idler Gear Shaft 13— Cap Screw (2 used)
2— Nut 7— Camshaft 11— Idler Gear
3— Flyweight 8— Wear Ring 12— Thrust Collar
4— Camshaft Gear 9— Rear Bearing
5— Snap Ring
OUT1738,00000AF -19-29MAY12-2/5
Remove and Install Camshaft

1. Remove water pump. See Water Pump Repair.
(Group 0400.)
2. Remove timing gear cover.
TX1108846 —UN—22FEB12
3. Remove sleeve (1), nut (2), flyweight (3), and camshaft
gear (4).
4. Remove snap ring (5) and front bearing (6).
Rotate camshaft (7) to aid in removal.
5. Remove wear ring (8) and rear bearing (9).
Idler Gear Installation
6. Clean and inspect camshaft. Replace as necessary.
7. Install wear ring and rear bearing in cylinder block.
8. Apply engine oil on wear ring and front and rear
bearings.
TX1108849 —UN—22FEB12
9. Install camshaft and snap ring. Check camshaft for
smooth rotation.
10. Install camshaft gear with timing mark to the front.
11. Install flyweight and nut. Tighten nut to specification.
Specification
Nut—Torque.......................................................................... 78—98 N·m
Timing Marks
58—72 lb.-ft.
12. Install sleeve. Check sleeve for smooth rotation. 4— Camshaft Gear 13— Cap Screw (2 used)
10— Idler Gear Shaft 14— Timing Mark (5 used)
13. Install idler gear shaft (10) with oil hole up. 11— Idler Gear 15— Crankshaft Gear
12— Thrust Collar
14. Lubricate idler gear shaft and install idler gear (11),
aligning idler gear timing marks (14) with camshaft
gear and crankshaft gear (15) timing marks.
Specification
15. Install thrust collar (12) and cap screws (13). Tighten Cap Screw—Torque.............................................................. 26—34 N·m
cap screws to specification. 20—25 lb.-ft.
Continued on next page OUT1738,00000AF -19-29MAY12-3/5

100312
PN=116
Inspect Camshaft
1. Measure cam lobe height using a micrometer.
NOTE: Cam lobe height = A — B.
If cam lobe height is less than specification, replace
T114131 —UN—24MAR98
camshaft.
Camshaft—Specification
Cam Center
Journal—Diameter.................................................... 52.0 mm (2.047 in.)
51.92 mm (2.044 in.) minimum
Cam Journal Uneven
Wear—Difference..................................... 0.05 mm (0.002 in.) maximum Cam Lobe Height
Cam Lobe
Intake—Height......................................................... 5.98 mm (0.2354 in.)
5.68 mm (0.2236 in.) minimum
Cam Lobe
Exhaust—Height..................................................... 6.28 mm (0.2472 in.)
5.98 mm (0.2354 in.) minimum
OUT1738,00000AF -19-29MAY12-4/5
2. Place camshaft on a measuring stand.

Measure camshaft runout using a dial indicator.
Record total indicator runout (TIR).
If measured runout exceeds specification, replace
camshaft.
T114132 —UN—24MAR98
Camshaft—Specification
Camshaft—Runout.................................................... 0.02 mm (0.008 in.)
Measure Camshaft Runout

OUT1738,00000AF -19-29MAY12-5/5
Flywheel Repair
Remove and Install Flywheel
1. Remove flywheel-to-crankshaft cap crews.
3 1
2. Inspect and repair flywheel. 5 6
2 4 T164806 —UN—05FEB03
3. Lubricate cap screws at areas (1) with engine oil.
4. Tighten cap screws gradually in sequence shown.
Flywheel—Specification
Flywheel-to-Crankshaft 1
Cap Screw—Torque...................................... 88—108 N·m (65—80 lb-ft) T164806
1— Lubrication Areas
Continued on next page OUOE046,0000094 -19-28JAN03-1/2

100312
PN=117
Disassemble and Assemble Flywheel

1. Remove flywheel.
2. Inspect flywheel for cracking, damage, or excessive
wear.
3. Inspect ring gear for damage or excessive wear.
4. Place flywheel with ring gear on flat wood surface and
strike around edges of ring gear with mallet and brass
bar to remove ring gear.
5. Heat ring gear using a oven or torch. Do Not exceed
200°C (390°F).
6. Install hot ring gear using a mallet and brass bar.
T144417 —UN—08FEB02
1— Ring Gear 2— Flywheel
OUOE046,0000094 -19-28JAN03-2/2
Flywheel Housing Remove and Install

1. Remove flywheel. See Flywheel Repair. (Group 0400.)
2
2. Remove flywheel housing-to-cylinder block cap
screws and nuts. 1 3
3. Clean mating surfaces of flywheel housing and
T164830 —UN—05FEB03
cylinder block.
4
Gasket to shaded areas (1—5) of cylinder block.
5. Install flywheel housing on cylinder block. Tighten cap 5
screws and nuts. T164830
Flywheel Housing Repair—Specification

Flywheel Housing- 1— Gasket Application Area 4— Gasket Application Area
to-Cylinder Block 2— Gasket Application Area 5— Gasket Application Area
Cap Screws and 3— Gasket Application Area
Nuts—Torque.................................................. 41—55 N·m (30—40 lb-ft)

OUO1020,0001251 -19-29JAN03-1/1

100312
PN=118
Oil Pan Remove and Install

1. Remove oil drain plug (5) and O-ring (4) to drain
engine oil. Approximate capacity is 6.4 L (6.8 qt).
2. Remove oil pan (3).
3. Remove all gasket material from oil pan and cylinder
block.
4. Install O-ring and drain plug.
5. Install new gasket and oil pan.
IMPORTANT: Do Not over tighten cap screws and
nuts. Over tightening will cause gasket to leak.
6. Evenly tighten cap screws and nuts.

Oil Pan—Specification
Oil Pan Cap Screws and
Nuts—Torque.......................................... 8—12 N·m (70.8—106.2 lb-in.)
7. Fill engine crankcase to proper level with appropriate

oil. See Diesel Engine Oil. (Operator's Manual.)
T164866 —UN—05FEB03
1— Gasket 4— O-Ring
2— Cap Screw (18 used) 5— Drain Plug
3— Oil Pan 6— Nut (2 used)
OUO1020,0001252 -19-31JAN03-1/1

100312
PN=119
Crankshaft Repair
T126016 —UN—14JAN00
1— Cap Screw (8 used) 4— Crankshaft 7— Crankshaft Bearing (Upper

2— Bearing Cap (4 used) 5— Cylinder Block Half) (4 used)
3— Crankshaft Bearing (Lower 6— Thrust Bearing (2 used)
Half) (4 used)
Continued on next page OUOE046,0000096 -19-20MAR12-1/7

100312
PN=120
Remove and Install Crankshaft 15. Apply engine oil to crankshaft journals and crankshaft
1. Remove cylinder head. See Cylinder Head Repair. bearing surfaces and install crankshaft.
(Group 0400.) 16. Apply engine oil to thrust bearing oil grooves.
2. Remove oil pan. See Oil Pan Remove and Install. NOTE: Thrust bearing oil groove must face
(Group 0400.) toward crankshaft.
3. Remove timing gear cover.
17. Install thrust bearing by hand to both sides of No. 1
4. Remove flywheel. See Flywheel Repair. (Group 0400.) journal.
5. Remove pistons and connecting rods. See Piston and 18. Install lower half of crankshaft bearings.
Connecting Rod Repair. (Group 0400.)
IMPORTANT: Bearing cap arrow must be pointing
6. Before removing crankshaft thrust bearings, measure to the front of engine.
end play at No.1 crankshaft journal.
The numbers stamped on the caps coincide with
Crankshaft—Specification the numbers on the cylinder for installation.
No. 1 Crankshaft
Journal—End Play..........................0.06—0.26 mm (0.0024—0.0102 in.) 19. Install bearing caps.
End Play .................................................. 0.3 mm (0.0118 in.) maximum
20. Lubricate bearing cap screws in clean engine oil and
If measured value exceeds specification, replace install.
thrust bearings.
21. Tighten cap screws gradually in order shown until
7. Remove lower half of crankshaft journal bearings (3). specified torque is reached.
8. Keep bearings and bearing caps in order. Bearing cap Crankshaft—Specification
position and location must be maintained. Bearing Cap
9. Remove crankshaft (4), upper half of crankshaft
bearings (7), and thrust bearings (6). 22. Rotate crankshaft by hand. Crankshaft must rotate
smoothly.
10. Inspect and repair as necessary
23. Install pistons and connecting rods. See Piston and
11. Wipe away any foreign material from surface contact Connecting Rod Repair. (Group 0400.)
area between cylinder block and upper crankshaft
bearing. 24. Install flywheel. See Flywheel Repair. (Group 0400.)
NOTE: All upper crankshaft bearings have an 25. Install timing gear cover.
oil hole and grooves.
26. Install oil pan. See Oil Pan Remove and Install.
12. Install upper bearings to their original location, if they (Group 0400.)
are being reused. 27. Install cylinder head. See Cylinder Head Repair.
13. Clean crankshaft in solvent. (Group 0400.)
14. Remove all sludge or restrictions from oil passages.

100312
PN=121
F
5 1 4 8
T164894 —UN—04FEB03
6 2 3 7
T164894
Bearing Cap Tightening Sequence
OUOE046,0000096 -19-20MAR12-3/7
Inspect Crankshaft
1. Inspect crankshaft journal surfaces and crank pin
surfaces for excessive wear and damage.
2. Inspect oil seal fitting surfaces of crankshaft front and
rear ends for excessive wear and damage.
T164973 —UN—07FEB03
3. Repair or replace crankshaft if any excessive wear
or damage is discovered.
4. Inspect crankshaft oil ports for obstructions. Use a
regulated air source to clean oil ports if necessary.
5. Measure crankshaft journal outside diameter at points
shown using a micrometer.
Crankshaft—Specification
Crankshaft Crankshaft—Specification
Journal—OD............................................................ 60.0 mm (2.3622 in.) Crankshaft Pin—OD................................................ 49.0 mm (1.9291 in.)
59.86 mm (2.3567 in.) minimum 48.87 mm (1.9240 in.) minimum
6. Measure crankshaft pin outside diameter using the NOTE: If uneven wear is found, replace crankshaft.
same procedure.

100312
PN=122
7. Install main bearing caps with bearings to cylinder

block and tighten to specified torque.
Crankshaft Bearing
Cap—Torque.................................................................. 94 N·m (69 lb-ft)
NOTE: The arrow mark on the bearing cap must be
T164974 —UN—07FEB03
pointing to the front of the engine when installed.
The numbers stamped on the caps coincide with
the numbers on the cylinder for installation.
8. Use an inside micrometer to measure main bearing

diameter at points shown.
Main Bearing—ID....................................................... 60 mm (2.3622 in.) 11. Set a dial indicator at center of crankshaft journal.
9. Use crankshaft journal outside and journal bearing 12. Rotate crankshaft in normal direction of engine
inside diameters to determine bearing clearance. rotation, reading dial indicator as crankshaft is turning.
If bearing clearance exceeds specification, crankshaft If radial runout exceeds specification, replace
and/or bearing must be replaced. crankshaft.
Crankshaft—Specification Crankshaft—Specification
Journal-to-Main Crankshaft—Radial
Bearing—Clearance................... 0.029—0.072 mm (0.0011—0.0028 in.) Runout..................................................................... 0.025 mm (0.001 in.)
0.12 mm (0.0047 in.) maximum 0.05 mm (0.002 in.) maximum
10. Mount ends of crankshaft on a set of V-blocks.
OUOE046,0000096 -19-20MAR12-5/7
Measuring Crankshaft with PLASTIGAGE®

1. Clean cylinder block journal bearing seating areas,
bearing caps, and inside and outside surfaces of
bearings.
2. Install new journal bearings in cylinder block.
T114162 —UN—24MAR98
3. Carefully place crankshaft on bearings.
4. Rotate crankshaft approximately 30° to seat bearings.
5. Place PLASTIGAGE® over one crankshaft journal
across full width of bearing.
6. Install bearing cap with bearing.
NOTE: Do not allow crankshaft to turn during bearing 8. Remove bearing cap.
cap installation and tightening.

Bearing Cap-to-
Cylinder Block Cap
PLASTIGAGE is a trademark of DANA Corp.

100312
PN=123
9. Compare width of PLASTIGAGE® attached to

crankshaft journal or bearing against scale printed on
PLASTIGAGE® container.
If measured value exceeds specification, perform
following additional steps:
T114163 —UN—24MAR98
a. Measure crankshaft journal outside diameter using
a micrometer.
b. Measure bearing inside diameter using an inside
micrometer.
c. Replace crankshaft and/or bearing if measured
values exceed specification.
Crankshaft 16. Compare width of PLASTIGAGE® attached to
Journal—OD............................................................ 60.0 mm (2.3622 in.) crankshaft or bearing against scale printed on
59.86 mm (2.3567 in.) minimum PLASTIGAGE® container.
Main Bearing—ID....................................................... 60 mm (2.3622 in.) If measured value exceeds specification, perform
10. Clean crankshaft, connecting rod, bearing cap, and following additional steps.
bearings. a. Measure crankshaft pin outside diameter using a
11. Install bearing to connecting rod. micrometer.
12. Hold connecting rod so bearing is against crankshaft b. Measure bearing inside diameter using an inside
pin. micrometer.
13. Attach PLASTIGAGE® to crankshaft pin. c. Replace crankshaft and/or bearing if measured
values exceed specification.
NOTE: Do not allow connecting rod to move when
installing and tightening the bearing cap.
Crankshaft Pin—OD................................................ 49.0 mm (1.9291 in.)
48.87 mm (1.9240 in.) minimum
14. Install connecting rod bearing cap. Tighten cap screws
Connecting Rod
to specified torque.
Bearing—ID............................................................. 49.0 mm (1.9291 in.)
Connecting Rod—Specification
Bearing Cap-to- 17. Visually inspect crankshaft gear for wear or damage.
Connecting Rod Cap Replace as necessary.
15. Remove bearing cap.

OUOE046,0000096 -19-20MAR12-7/7

100312
PN=124
Piston and Connecting Rod Repair

Remove and Install Piston and Connecting Rod
1. Remove cylinder head. See Cylinder Head Repair.
(Group 0400.)
T122325 —UN—28OCT99
2. Remove oil pan. See Oil Pan Remove and Install.
(Group 0400.)
3. Use a scraper to remove any carbon deposits from
upper portion of cylinder wall.
4. Remove nuts on connecting rod bearing caps.
5. Remove bearing caps and lower half of rod bearings.
Keep bearings in order to aid installation into their 1— 1st Compression Ring 3— Oil Ring
original position. 2— 2nd Compression Ring
6. Move piston to top of cylinder and push on connecting

rod with hammer handle to remove piston from
cylinder block.
7. Remove top half of rod bearing. Keep bearings in
order to aid installation into their original position.
8. Clean pistons in solvent.
9. Remove any foreign material in cylinder bores and on
pistons and connecting rods.
10. Install upper half of rod bearing in connecting rod.
11. Apply engine oil to cylinder wall, upper bearing surface
and crank pin of crankshaft.
12. Position piston ring gaps as shown making sure the
ring gaps are away from the thrust side.
13. Lubricate piston, piston rings, and connecting rod
bearings with clean engine oil.
OUOE046,0000097 -19-04FEB03-1/14
14. Position piston front mark (2) toward front of engine.

15. Use piston ring compressor (1) to compress piston
rings.
16. Use a hammer handle to push piston in until it makes
contact with crank pin. At same time, rotate crankshaft
T122323 —UN—28OCT99
until crank pin reaches its highest point.
1— Piston Ring Compressor 2— Front Mark

100312
PN=125
17. Align bearing cap cylinder number marks with

connecting rod cylinder marks (1).
NOTE: The marks must be towards the injection
pump side.
T122322 —UN—28OCT99
18. Apply engine oil to lower half of connecting rod bearing
and install bearing in rod cap.
19. Install connecting rod cap nuts and tighten.
Piston and Connecting Rod—Specification
Connecting Rod Cap
Nut—Torque.................................................... 74—83 N·m (54—61 lb-ft)
1— Cylinder Number Mark
OUOE046,0000097 -19-04FEB03-3/14
Disassemble Piston and Connecting Rod

1. Remove connecting rod bearings (6). Keep bearing
sets in order to aid installation into their original
position.
1— Piston Pin 5— Bushing

2— Piston 6— Connecting Rod Bearing
3— Piston Ring (3 used) 7— Nut (2 used)
4— Snap Ring (2 used) 8— Connecting Rod
T122220 —UN—28OCT99

100312
PN=126
IMPORTANT: Only use piston ring pliers to remove

rings. Use of any other tool may result in
reduced piston ring tension.
2. Use piston ring pliers (1) to remove piston rings.
T121966 —UN—28OCT99
OUOE046,0000097 -19-04FEB03-5/14
3. Use snap ring pliers (1) to remove snap rings.
T121964 —UN—28OCT99
OUOE046,0000097 -19-04FEB03-6/14
IMPORTANT: Keep piston, piston pin, and connecting

rod together for each cylinder. Removed parts
must stay together if reused.
4. Tap piston pin (1) out with a mallet and brass bar.
T121963 —UN—28OCT99

100312
PN=127
Inspect Piston and Connecting Rod

1. Inspect piston ring gap.
a. Insert piston ring horizontally (in the position it would
be in if it were installed in piston) into cylinder bore.
T144461 —UN—08FEB02
b. Push ring into cylinder bore until it reaches point
where bore is the smallest. Do not allow ring to
slant, it must remain perfectly horizontal
c. Use feeler gauge to measure piston ring gap.
1st Compression
Ring—Gap........................................0.2—0.35 mm (0.0079—0.0138 in.)
2.0 mm (0.0787 in.) maximum 1— Feeler Gauge 2— Straight Edge
2nd Compression
Ring—Gap..........................................0.2—0.4 mm (0.0079—0.0157 in.)
2.0 mm (0.0787 in.) maximum Oil Ring
Oil Ring—Gap....................................0.2—0.4 mm (0.0079—0.0157 in.) Expansion—Force......................... 24.5—39.2 N (5.508—8.813 lb-force)
1.0 mm (0.0394 in.) maximum 17.652 N (3.969 lb-force) minimum
If measured value exceeds specification, piston ring If measured value is less than specification, piston
must be replaced. ring must be replaced.
2. Inspect piston ring and ring groove clearance. 4. Use a micrometer to measure piston pin outside
a. Visually inspect piston ring grooves. If groove is diameter at several points.
damaged or distorted, piston must be replaced. Piston and Connecting Rod—Specification
Piston Pin—OD.......................................................... 25 mm (0.9843 in.)
NOTE: When measuring clearance for 1st ring, press
24.97 mm (0.9831 in.) minimum
piston ring with straight edge (2) as shown.
If measured value is less than specification, piston pin
b. Measure clearance between piston ring and ring must be replaced.
groove at several points around piston using feeler
gauge (1). 5. Use an inside micrometer to measure pin hole
diameter in piston. Subtract piston pin diameter
measured in previous step from pin hole diameter.
1st Compression
The difference is the clearance value.
Ring—Clearance..........................0.07—0.105 mm (0.0028—0.0041 in.)
0.3 mm (0.012 in.) maximum Piston and Connecting Rod—Specification
2nd Compression Pin Hole-to-Piston
Ring—Clearance............................0.05—0.085 mm (0.002—0.0033 in.) Pin—Clearance..........................0.007—0.017 mm (0.0003—0.0007 in.)
If clearance value exceeds specification and piston
Oil Ring—Clearance.......................0.03—0.07 mm (0.0012—0.0028 in.)
pin diameter is within specification, the piston must
0.15 mm (0.0059 in.) maximum
be replaced.
If measured value exceeds specification, piston ring
must be replaced. 6. Use a micrometer to measure clearance between
piston pin and connecting rod small end bushing.
3. Use expansion force gauge to measure piston ring
expansion force.
Pin-to-Connecting
Piston and Connecting Rod—Specification Rod Small End
1st Compression Ring Bushing—Clearance..................0.008—0.020 mm (0.0003—0.0008 in.)
Expansion—Force......................... 11.2—15.9 N (2.518—3.574 lb-force) 0.05 mm (0.0020 in.) maximum
5.884 N (1.323 lb-force) minimum
2nd Compression Ring If clearance value exceeds the specification, piston pin
Expansion—Force........................... 9.7—14.0 N (2.181—3.147 lb-force) and/or connecting rod assembly must be replaced.
5.884 N (1.323 lb-force) minimum

100312
PN=128
7. Use a connecting rod alignment tool to measure Piston and Connecting Rod—Specification
distortion and parallelism between connecting rod big Connecting Rod
end hole and small end hole. Alignment—Torsion...............................0.08 mm (0.003 in.) per 100 mm
(3.94 in.) length of connecting rod
0.2 mm (0.0079 in.) maximum per 100 mm
Parallelism ........................................0.05 mm (0.002 in.) per of 100 mm
0.15 mm (0.0059 in.) maximum per of 100
mm (3.94 in.) length of connecting rod
OUOE046,0000097 -19-04FEB03-9/14
8. Inspect crankshaft and connecting rod bearing

clearance.
a. Clean crankshaft, connecting rod, bearing cap and
bearings.
b. Install bearings and bearing cap on connecting rod.
c. Put connecting rod in vise and tighten rod bearing
cap nuts.
Connecting Rod Bearing
Cap Nut—Torque............................................. 74—83 N·m (54—61 lb-ft)
d. Use inside micrometer to measure connecting

rod bearing inside diameter. Use micrometer to
T144457 —UN—08FEB02
measure corresponding crankshaft pin diameter.
Calculate crankshaft pin and connecting rod bearing
clearance.
Connecting Rod
Bearing—ID............................................................. 49.0 mm (1.9291 in.)
Crankshaft Pin—OD................................................ 49.0 mm (1.9291 in.)
48.87 mm (1.9240 in.) minimum
Connecting Rod 1— Crankshaft Measurements 2— Connecting Rod
Measurements
Bearing-to-Crank
Pin—Clearance..........................0.035—0.073 mm (0.0014—0.0029 in.)
0.12 mm (0.0047 in.) maximum
9. Check cylinder bore clearance. See Cylinder Block
If clearance between connecting rod bearing and Repair. (Group 0400.)
crank pin exceeds specification, bearing and/or
crankshaft must be replaced.

100312
PN=129
Assemble Piston and Connecting Rod

1. Heat pistons to specification using a piston heater.
Piston—Specification
Piston Heat—Tempera-
ture............................................................... 100°C (212°F) approximate
1— Piston Pin 5— Bushing

2— Piston 6— Connecting Rod Bearing
3— Piston Ring (3 used) 7— Nut (2 used)
4— Snap Ring (2 used) 8— Connecting Rod
T122220 —UN—28OCT99
T114219 —UN—07APR98
Piston Heater
OUOE046,0000097 -19-04FEB03-11/14
2. Install connecting rod to piston following marks as

shown.
3. Install piston pin into piston and connecting rod
bushing.
T122229 —UN—28OCT99
1— Front Mark 3— Grade Mark

2— Grade Mark

100312
PN=130
4. Install piston pin snap ring.

5. Make sure piston moves smoothly on piston pin.
T114222 —UN—07APR98
OUOE046,0000097 -19-04FEB03-13/14
6. Use a piston ring installer to install three piston rings.

7. Install piston rings in the following order:
1. Oil Ring
2. 2nd Compression Ring
3. 1st Compression Ring
T114224 —19—13APR98
NOTE: The marked side of the two compression
rings must be facing up.
The undercut side of the second compression
will be facing down.
The oil ring may face either direction.
8. Lubricate piston ring surfaces with clean engine oil.

9. Make sure piston rings rotate smoothly in piston ring
grooves.
OUOE046,0000097 -19-04FEB03-14/14

100312
PN=131
Oil Pump Repair 3. Remove cap screw to remove crankshaft pulley.

Remove and Install Oil Pump 4. Remove engine speed control cable. See Engine
1. Remove oil pan. See Oil Pan Remove and Install. Speed Control Cable Remove and Install. (Group
(Group 0400.) 0515.)
2. Remove fan belt. See Fan Belt Repair. (Group 0510.) 5. Remove timing gear cover.
T126017 —UN—14JAN00
1— Cap Screw 3— Oil Pump 5— Oil Strainer
2— Cap Screw (4 used) 4— Oil Pickup Tube
6. Remove oil strainer (5) and oil pickup tube (4).

11. Install timing gear cover.
7. Remove oil pump (3).
12. Install engine speed control cable.
13. Install crankshaft pulley and cap screw.
9. Install oil pump (3) and tighten cap screw (2). Oil Pump—Specification
Oil Pump—Specification Crankshaft Pulley-
Oil Pump Cap to-Crankshaft Cap
Screw—Torque........................................................... 28 N·m (252 lb-in.) Screw—Torque........................................................... 186 N·m (137 lb-ft)
10. Install oil pickup tube (4) and oil strainer (5). Tighten 14. Install fan belt. See Fan Belt Repair. (Group 0510.)
cap screw (1).
15. Install oil pan. See Oil Pan Remove and Install.
Oil Pump—Specification (Group 0400.)
Oil Strainer Cap

100312
PN=132
Disassemble and Assemble Oil Pump

Inspect Oil Pump
1. Inspect parts for excessive wear and damage.
Replace as necessary.
T122807 —UN—28OCT99
2. Measure clearance between the outer rotor and inner
rotor and pump cover.
Oil Pump—Specification
Outer Rotor and
Inner Rotor-to-Pump
Cover—Clearance......................0.040—0.085 mm (0.0016—0.0033 in.)
0.15 mm (0.0059 in.) maximum
3. Measure clearance between the periphery of the outer 1— Gerotor Assembly 6— Cap Screw
rotor and pump body. 2— Pin (2 used) 7— Relief Valve
3— Cap Screw (4 used) 8— Spring
Oil Pump—Specification 4— Housing 9— Plug
Outer Rotor-to-Pump 5— Cap Screw (2 used) 10— Gasket
Body—Clearance.........................0.10—0.185 mm (0.0039—0.0073 in.)
4. Measure clearance between inner rotor and outer Oil Pump—Specification

rotor. If clearance exceeds specifications, replace Inner-to-Outer
inner or outer rotor. Rotor—Clearance.................................................... 0.17 mm (0.0067 in.)
OUOE046,0000098 -19-04FEB03-2/2

100312
PN=133
Thermostat Remove and Install

serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
1. Drain coolant from radiator until level is below

thermostat housing.
2. Loosen clamp (1) and disconnect upper radiator hose
(2).
3. Disconnect electrical connector (4) and wires from
temperature gauge (6).
4. Remove thermostat housing (3).
5. Remove thermostat (8).
6. Replace thermostat as necessary.
7. Replace thermostat housing gasket.
8. Install thermostat housing and caps screws.
Thermostat—Specification
Housing Cap
9. Connect electrical connector and temperature gauge

wires.
10. Connect upper radiator hose and tighten clamp.
11. Fill radiator and reservoir with coolant. See Cooling
T126152 —UN—14JAN00
System Fill and Deaeration. (Operator's Manual.)
1— Clamp 5— Temperature Sending Unit

2— Hose 6— Temperature Gauge
3— Thermostat Housing 7— Cap Screw (2 used)
4— Electrical Connector 8— Thermostat
OUOE054,000003B -19-04FEB03-1/1

100312
PN=134
Fuel Injection Pump Remove and Install
CAUTION: Escaping diesel fuel under pressure

can have sufficient force to penetrate the skin,
causing serious injury. Before disconnecting
lines, be sure to relieve pressure. Before applying
X9811 —UN—23AUG88
pressure to the system, be sure ALL connections
are tight and lines, pipes and hoses are not
damaged. Keep hands and body away from
pinholes and nozzles which eject fluid under
pressure. Use a piece of cardboard or wood,
rather than hands, to search for suspected leaks.
If ANY fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type of injury or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere & Company
T165025B —UN—07FEB03
IMPORTANT: Do Not disassemble the fuel injection

pump further than necessary to install
available repair parts. Do Not disassemble
fuel injection pump for cleaning.
Be sure that all identification numbers are
legible so that pump is set to the correct
specification for its intended application. 1— Supply Line 3— Return Hose
2— Injection Line 4— Supply Hose
1. Remove fuel injection line (2).
2. Disconnect hoses (3 and 4) at injection pump.
3. Remove fuel supply line (1).
OUO1020,0001257 -19-14FEB03-1/4
4. Align hole of fuel cut-off lever (2) with hole of governor

cover (3). Install pin (1) into hole.
1— Pin 3— Cover
2— Lever
T122388 —UN—28OCT99

100312
PN=135
5. Remove side cover from engine block to view control

link.
6. Check to see if pin groove of control link (1) is at
center of injection pump (2).
T122387 —UN—28OCT99
1— Control Link 3— Pin
2— Injection Pump Center
Position
OUO1020,0001257 -19-14FEB03-3/4
7. Identify each pump to position in cylinder block to aid

in assembly.
Remove fuel injection pump (3) and shim (4). Discard
old shim; replace with new shim of same thickness.
NOTE: For injection pump repair and testing, have an
authorized ADS diesel injection repair station
perform the work. Unauthorized repairs made to
the fuel injection pump will void warranty.
T165039 —UN—07FEB03
8. Repair or replace injection pump as necessary.
9. Install new shim (4) with same thickness as removed.
10. Install fuel injection pump making sure that rack pin
is in groove of control link before tightening injection
pump cap screws and nuts.
Fuel Injection Pump—Specification
Pump Cap Screw and 1— Cap Screw (2 used) 3— Fuel Injection Pump
2— Nut (2 used) 4— Shim
Nut—Torque............................................... 19—28 N·m (168—248 lb-in)
11. Remove pin from fuel cut-off lever. Make sure lever
moves smoothly. 14. Connect hoses.
12. Apply TY16135 ULTRA BLUE® RTV Silicone 15. Install fuel injection line and tighten nut.
Form-In-Place Gasket to mating surfaces of side cover
and install on engine block. Fuel Injection Pump—Specification
Line Nut—Torque...................................... 15—25 N·m (133—221 lb-in.)
Fuel Injection Pump—Specification
Side Cover Cap Screw NOTE: Any time the fuel system has been opened up for
and Nut—Torque........................................... 8—12 N·m (71—106 lb-in.) service (lines disconnected or filters removed), it
will be necessary to bleed air from the system.
13. Install fuel supply line, washers, cap screw and tighten.
Fuel Injection Pump—Specification 16. Bleed fuel system. See Bleed Fuel System. (Group
Fuel Supply Line Cap 0560.)
OUO1020,0001257 -19-14FEB03-4/4

100312
PN=136
Fuel Injection Nozzle Repair

Remove and Install Fuel Injection Nozzle
CAUTION: Escaping diesel fuel under pressure

can have sufficient force to penetrate the skin,
X9811 —UN—23AUG88
causing serious injury. Before disconnecting
lines, be sure to relieve pressure. Before applying
pressure to the system, be sure ALL connections
are tight and lines, pipes and hoses are not
damaged. Keep hands and body away from
pinholes and nozzles which eject fluid under
pressure. Use a piece of cardboard or wood,
rather than hands, to search for suspected leaks.
If ANY fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type of injury or
gangrene may result. Doctors unfamiliar with
T165025C —UN—07FEB03
this type of injury may call the Deere & Company
IMPORTANT: Before removal, thoroughly remove

all dirt from the cylinder head around fuel
injection nozzles. Clean with compressed air to
prevent dirt from entering the cylinders. Plug
the bore in the cylinder head after each nozzle
has been removed. Cap fuel line openings 1— Fuel Leak-Off Line 4— Fuel Injection Line (3 used)
2— Fuel Return Hose 5— Nozzle Holder Bracket (3
as soon as they are disconnected. 3— Fuel Injection Nozzle (3 used)
used)
Do not bend the fuel delivery lines, as this may
affect their durability. When loosening the fuel
pressure lines, hold male union of nozzle line
stationary with a backup wrench. Fuel Injection Nozzle—Specification
Nozzle Holder Bracket
1. Remove fuel injection line (4) using a backup wrench Cap Screw—Torque........................................ 31—41 N·m (23—30 lb-ft)
on nozzle and pump connections.
8. Install washers and leak-off line. Tighten cap screw.
2. Disconnect fuel return hose (2) from leak-off line (1).
Fuel Injection Nozzle—Specification
3. Remove fuel leak-off line and washers. Line must be Leak-Off Line Cap
removed as an assembly. Screw—Torque............................................ 10—14 N·m (89—124 lb-in.)
4. Remove nozzle holder bracket (5) 9. Install fuel injection line using a backup wrench on
nozzle and injection pump connections.
5. Remove fuel injection nozzle (3). Cover opening to
avoid contamination. Fuel Injection Nozzle—Specification
Line Nut—Torque...................................... 15—25 N·m (133—221 lb-in.)
NOTE: Any time the fuel system has been opened up for
IMPORTANT: Before installing injection nozzles, make service (lines disconnected or filters removed), it
sure nozzles are clean and free from oil or grease. will be necessary to bleed air from the system.
Nozzle bore in cylinder head must be clean.
10. Bleed fuel system. See Bleed Fuel System. (Group
Clean bore using a nozzle bore cleaning tool.
0560.)
7. Install injection nozzle (3). Tighten nozzle holder
bracket (5) cap screw.

100312
PN=137
Disassemble and Assemble Fuel Injection Nozzle

1. Disassemble parts (1—8).
2. Clean and inspect parts for wear or damage.
3. Assemble parts (1—8).
4. Check fuel injection nozzle pressure. See Check Fuel
Injection Nozzle. (Group 9010-25.)
1— Nozzle Holder 5— Valve Seat

2— Injection Nozzle 6— Bolt
3— Pin 7— Shim
4— Spacer 8— Spring
T165057 —UN—07FEB03
OUO1020,0001256 -19-14FEB03-2/2

100312
PN=138
Starter Repair
Remove and Install Starter
IMPORTANT: Always disconnect the negative
battery cables before removing starter or
a short circuit could result.
1. Disconnect negative battery cables.

2. Remove seat. See Seat Remove and Install. (Group
1821.)
3. Tilt seat base forward.
4. Disconnect wiring leads (1).
5. Remove nut (4) and battery cable.
6. Remove cap screw (3).
7. Remove nut (2) and starter.
T125137 —UN—18NOV99
9. Install starter. Tighten cap screw (3).
Starter—Specification
Starter-to-Flywheel
Housing Cap
Screw—Torque.............................................. 85—103 N·m (63—76 lb-ft)
10. Connect wiring leads.

11. Connect negative battery cables.
1— Wiring Leads 3— Cap Screw
2— Nut 4— Nut
Continued on next page CED,OUOE002,1304 -19-12NOV96-1/3

100312
PN=139
Disassemble and Assemble Starter

Repair or replace starter as necessary.
T125138 —UN—14JAN00
Continued on next page CED,OUOE002,1304 -19-12NOV96-2/3

100312
PN=140
1— Bushing 8— O-Ring 13— Boot 22— Roller

2— Armature 9— End Cover 14— Nut 23— Pinion Retainer
3— Bushing 10— Cap Screw and Lock Washer 15— Nut 24— Clutch
4— O-Ring 11— Cap Screw 16— Housing 25— Cap Screw (2 used)
5— Housing (Yoke) 12— Drain Pipe 17— Gear
6— Spring 18— Spring
7— Brush Holder 19— Gear
20— Ball
21— Housing
The housing (yoke) (5), spring (6), ball (20), housing (21),
and rollers (22) are not available for service. Replace the
starter.
CED,OUOE002,1304 -19-12NOV96-3/3
Alternator Repair
Remove and Install Alternator
IMPORTANT: Always disconnect negative battery
cables before removing alternator or a
short circuit could result.
T165076 —UN—07FEB03
1. Disconnect negative battery cables.
2. Remove seat. See Seat Remove and Install. (Group
1821.)
3. Tilt seat base forward.
4. Disconnect wiring lead and electrical connector.
5. Loosen cap screws and nuts (1, 2, and 4). 1— Cap Screw 3— Fan Belt Adjusting Screw
2— Cap Screw 4— Cap Screw
6. Turn fan belt adjusting screw (3) to loosen fan belt.
7. Remove alternator.
Alternator-to-Bracket
8. Repair or replace alternator as necessary. Nut—Torque.............................................. 19—28 N·m (168—248 lb-in.)
Alternator-to-Engine
9. Install alternator. Tighten cap screws and nuts (1, 2, Block Cap Screw and
and 4) finger tight. Nut—Torque.................................................... 34—46 N·m (25—34 lb-ft)
10. Install fan belt. Tighten belt using fan belt adjusting 12. Connect wiring lead and electrical connector.
screw (3).
11. Tighten cap screws and nuts (1, 2, and 4).
Alternator—Specification
Fan Belt Adjusting
Bracket-to-Water
Pump Housing Cap
Continued on next page FR91424,000001B -19-06FEB03-1/3

100312
PN=141
Disassemble and Assemble Alternator

Repair or replace parts as necessary.
Continued on next page FR91424,000001B -19-06FEB03-2/3

100312
PN=142
T123532 —UN—29OCT99
1— Nut 10— Rotor 18— Brush 24— Cover

2— Pulley 11— Bearing 19— Cap Screw (2 used) 25— Nut (2 used)
3— Collar 12— Cover 20— Cap Screw 26— Bushing
4— Drive End Frame 13— Cap Screw (3 used) 21— Voltage Regulator 27— Nut
5— Stator 14— Cover 22— Rectifier 28— Cap Screw (5 used)
6— Stud 15— Cap Screw 23— Cap Screw (2 used)
7— Bearing 16— Brush Holder
8— Retainer 17— Spring
The rotor (10), cover (14), brush (18), voltage regulator

(21), rectifier (22), and cap screws (15 and 28) are not
available for service. Replace the alternator.
FR91424,000001B -19-06FEB03-3/3

100312
PN=143

100312
PN=144
Section 05
Engine Auxiliary Systems
Contents
Page
Group 0505—Cold Weather Starting Aids

Engine Glow Plugs
Group 0510—Cooling System

Fan Belt
Repair....................................................05-0510-1
Fan, Shroud, and Guard
Repair....................................................05-0510-2
Radiator and Oil Cooler
Group 0515—Speed Controls

Engine Speed Control Cable
Fuel Shut-Off Solenoid
Fuel Shut-Off Solenoid Linkage
Group 0560—External Fuel Supply Systems

Fuel Tank
Water Separator
Repair....................................................05-0560-2
Final Fuel Filter
Repair....................................................05-0560-2
Fuel System
Bleed .....................................................05-0560-2

100312
PN=1
Contents

100312
PN=2
Group 0505
Cold Weather Starting Aids
Glow Plug Remove and Install
IMPORTANT: Make sure ignition switch is in OFF
position. To prevent damage to connector
strip (1), remove entirely even if replacing
only one glow plug.
T164821B —UN—03FEB03
1. Remove nuts (3) and electrical lead from connector
strip (1).
2. Remove connector strip (1).
3. Remove glow plugs (2).
4. Remove parts as necessary.
5. Install glow plugs. 1— Connector Strip 3— Nut (3 used)
Glow Plug—Specification 2— Glow Plug (3 used)
Glow Plug-to-Cylinder
Block—Torque........................................... 15—20 N·m (133—177 lb-in.)
6. Position connector strip on all glow plugs. 8. Install nuts.
7. Install electrical lead on connector strip.

OUO1082,0000273 -19-05FEB03-1/1

100312
PN=147
Cold Weather Starting Aids

100312
PN=148
Group 0510
Cooling System
Fan Belt Repair
CAUTION: Shut off engine. Let front of engine

cool enough to touch with bare hands.
OUO1082,0000275 -19-05FEB03-1/3
NOTE: Alternator access panel is located behind

operator's seat.
1. Remove alternator access panel (1). 1
2. Loosen adjusting screw lock (3) and cap screw (7).
T164849 —UN—05FEB03
3. Move alternator (6) toward engine using adjusting
screw (5).
4. Remove cap screws (8) and fan guard (9).
5. Remove fan belt (2).
6. Replace parts as necessary. T164849
7. Install fan belt (2).
1— Access Panel 6— Alternator

2— Fan Belt 7— Cap Screw
3— Adjusting Screw Lock 8— Cap Screw (3 used)
4— Alternator Bracket 9— Fan Guard
5— Adjusting Screw
T164850 —UN—05FEB03
T164852B —UN—05FEB03

100312
PN=149
Cooling System
8. Check belt tension with belt tension gauge at midway

between fan pulley (10) and alternator pulley (11).
Adjust belt tension as necessary with adjusting screw
(5).
Fan Belt—Specification
Belt—Deflection....................................................................7.5—8.5 mm
T164853 —UN—05FEB03
(0.30—0.33 in.) at 98 N (22 lb force)
9. Move alternator until tension is correct and tighten

adjusting screw lock (3) and cap screw (7).
Fan Belt—Specification
Alternator-to-Adjusting
Screw Nut—Torque.................................................... 24 N·m (212 lb-in.)
Alternator-to-Block Cap 10— Fan Pulley 12— Crank Pulley
11— Alternator Pulley
10. Install fan guard and cap screws.

11. Install alternator access panel.
OUO1082,0000275 -19-05FEB03-3/3
Fan, Shroud, and Guard Repair

Remove and Install Fan, Shroud, and Guard

serious burns.
To remove fan, shroud, and guard it is necessary to

remove radiator and oil cooler. See Radiator and Oil
Cooler Remove and Install. (Group 0510.)
OUO1082,0000279 -19-06FEB03-1/1

100312
PN=150
Cooling System
Radiator and Oil Cooler Remove and Install

serious burns.
1. Remove right side access cover.

2. Drain coolant from radiator. Approximate capacity is
6.0 L (6.3 qt).
3. Disconnect hoses (3 and 7). Remove cap screws (2),
overflow tank (8), and bracket (1).
4. Remove cap screws (4 and 5). Remove bracket (6).
T164856B —UN—04FEB03
CAUTION: The hydraulic oil tank is pressurized.
High pressure release of oil from pressurized
system can cause serious burns or penetrating
injury. Release pressure from tank by loosening
cap. It is not necessary to remove cap.
5. Loosen cap (9) to release air pressure in hydraulic

oil tank.
1— Bracket 6— Bracket
6. Pull a vacuum in hydraulic oil tank using a vacuum 2— Cap Screw (2 used) 7— Overflow-to-Atmosphere
pump or drain hydraulic oil tank. Approximate oil 3— Overflow-to-Radiator Hose Hose
4— Cap Screw (2 used) 8— Overflow Tank
capacity is 30 L (8 gal). 5— Cap Screw (2 used) 9— Cap
OUO1082,0000274 -19-05FEB03-1/9
7. Disconnect all oil cooler line mounting straps.

8. Loosen clamps (2) and disconnect hoses (1).
9. Remove cap screws (3).
10. Remove cap screws (4) and oil cooler (5).
11. Inspect oil cooler for damage or leakage. Repair or
replace oil cooler as needed.
1— Hose (2 used) 4— Cap Screw (2 used)

2— Clamp (4 used) 5— Oil Cooler
T126944 —UN—14JAN00

100312
PN=151
Cooling System
T126355 —UN—14JAN00
1— Cap Screw (3 used) 3— Upper Bushing (2 used) 5— Hose Clamp (2 used) 7— Lower Drain Hose
2— Bracket 4— Radiator 6— Petcock
12. Remove cap screws (1), bracket (2), and upper 13. Disconnect lower drain hose (7).
bushings (3).

100312
PN=152
Cooling System
14. Loosen hose clamps (1) to remove upper and lower

radiator hoses (2 and 3).
15. Remove cap screws (4) and fan guard (5).
16. Remove radiator. Carefully move oil cooler lines away
from radiator when removing radiator.
T126354 —UN—14JAN00
1— Clamp (4 used) 4— Cap Screw (3 used)
2— Upper Radiator Hose 5— Fan Guard
3— Lower Radiator Hose
OUO1082,0000274 -19-05FEB03-4/9
1— Cap Screw (4 used) 2— Shroud 4— Bushing (2 used) T126356 —UN—14JAN00

3— Radiator
17. Remove cap screws (1) to remove shroud (2) from 20. Install shroud (2), cap screws (1), and bushings (4).
radiator (3).
21. Install radiator (3).
18. Remove lower bushings (4).

100312
PN=153
Cooling System
22. Position fan guard (5) and install cap screws (4).
23. Install upper and lower radiator hoses (2 and 3) and
tighten clamps (1).
1— Clamp (4 used) 4— Cap Screw (3 used)

2— Upper Radiator Hose 5— Fan Guard
T126354 —UN—14JAN00
3— Lower Radiator Hose

100312
PN=154
Cooling System
T126355 —UN—14JAN00
1— Cap Screw (3 used) 3— Upper Bushing (2 used) 5— Hose Clamp (2 used) 7— Lower Drain Hose
2— Bracket 4— Radiator 6— Petcock
24. Connect lower drain hose (7). 25. Install upper bushings (3), bracket (2), and cap screws
(1).

100312
PN=155
Cooling System
26. Position oil cooler (5) in place and install cap screws
(3 and 4).
27. Connect all oil cooler line mounting straps.
28. Connect hoses (1) and tighten clamps (2).
1— Hose (2 used) 4— Cap Screw (2 used)

2— Clamp (4 used) 5— Oil Cooler
T126944 —UN—14JAN00
OUO1082,0000274 -19-05FEB03-8/9
29. Install bracket (1), overflow tank (8), and cap screws
(2).
30. Connect hoses (3 and 7).
31. Install bracket (6) and cap screws (4 and 5).
T126352 —UN—14JAN00
32. Check oil level in hydraulic oil tank. Add oil as
necessary. See Hydraulic Oil. (Operator's Manual.)
IMPORTANT: Hydraulic pump will be damaged if not
filled with oil before starting. Procedure must be
performed to fill pump housing whenever oil has
been drained from the pump or hydraulic oil tank.
33. Perform Hydraulic Pump Start-Up Procedure. (Group

3360.) 1— Bracket 5— Cap Screw (2 used)
2— Cap Screw (2 used) 6— Bracket
34. Fill radiator with coolant. See Cooling System Fill and 3— Overflow-to-Radiator Hose 7— Overflow-to-Atmosphere
4— Cap Screw (2 used) Hose
Deaeration. (Operator's Manual.) 8— Overflow Tank
OUO1082,0000274 -19-05FEB03-9/9

100312
PN=156
Group 0515
Speed Controls
Engine Speed Control Cable Remove and Install
T121715 —UN—28OCT99
1— Nut and Washer (2 used) 4— Ball Joint 9— Engine Bracket 14— Nut
2— Engine Speed Control Cable 5— Control Lever 10— Cable Bracket 15— Nut and Washer (2 used)
3— Nut 6— Lock Washer 11— Washer
7— Nut 12— Split Pin
8— Cab Bracket 13— Governor Lever
Continued on next page OUO1082,000027D -19-13FEB03-1/2

100312
PN=157
Speed Controls
NOTE: Before removing control cable (2), measure or

count threads exposed at either end of control
cable to aid in installation.
1. Remove nut (7) and washer (6). Remove engine

speed control cable (2) from control lever (5).
2. Remove split pin (12) and washer (11) to remove
engine speed control cable (2) from governor lever
(13).
3. Loosen nuts and washers (1 and 15). Remove engine
T121729 —UN—28OCT99
speed control cable from brackets (8 and 9).
4. Remove ball joint (4) and nuts (3 and 14). Remove
cable bracket (10) from engine speed control cable (2).
NOTE: Ball joint (4) and cable bracket (10) are
used to adjust cable length to allow full travel
from slow idle stop (17) to fast idle stop (16)
13— Governor Lever 17— Slow Idle Stop
of the governor lever (13). 16— Fast Idle Stop
6. Install ball joint (4), nut (3), cable bracket (10), and nut
(14) on engine speed control cable (2). Set at points
measured before removing. 10. Install engine speed control cable (2) into engine
bracket (9) by positioning nuts and washers (15) on
7. Install ball joint (4) to control lever (5) using nut (7) both sides of bracket.
and washer (6).
11. Move control lever (5) and check that governor lever
8. Install cable bracket (10) to governor lever (13) using (13) touches slow idle stop (17) when moved forward
washer (11) and split pin (12). and fast idle stop (16) when moved rearward.
9. Install engine speed control cable (2) into cab bracket 12. If governor lever (13) fails to touch either stop, turn
(8) by positioning nuts and washers (1) on both sides nuts (15) to adjust engine speed control cable (2).
of bracket.
OUO1082,000027D -19-13FEB03-2/2

100312
PN=158
Speed Controls
Fuel Shut-Off Solenoid Remove and Install

1. Disconnect electrical connectors (1).
2. Remove fuel shut-off solenoid (2).
T159550B —UN—20SEP02
IMPORTANT: Do not allow ULTRA BLUE® RTV
Silicone Form-In-Place Gasket to contact
screw threads (4).

Gasket to solenoid-to-block mating surface (3).
5. Install fuel shut-off solenoid (2) and tighten.
Fuel Shut-Off Solenoid—Specification
Fuel Shut-Off
Solenoid—Torque....................................................... 20 N·m (177 lb-in.)
6. Connect electrical connectors (1).
T121740 —UN—28OCT99
1— Electrical Connector (2 4— Screw Threads
used) 5— Fuel Injection Pump
2— Fuel Shut-Off Solenoid
3— Solenoid-to-Block Mating
Surface

OUO1082,000027E -19-13FEB03-1/1

100312
PN=159
Speed Controls
Fuel Shut-Off Solenoid Linkage Remove and Install
T121764 —UN—28OCT99
Continued on next page OUO1082,000027F -19-13FEB03-1/3

100312
PN=160
Speed Controls
1— C-Clip 15— Cap 24— Control Link 34— Nut

2— Washer 16— Floating Lever 25— Link Plate 35— Return Spring
3— Spring 17— Snap Pin (2 used) 26— Guide Piece 36— Main Spring Lever
4— C-Clip 18— Fuel Cut Shaft 27— Shifter 37— Shaft
5— Governor Cover 19— Return Spring 28— C-Clip 38— Lever Bushing (2 used)
6— O-Ring 20— Start Spring Bracket 29— Floating Shaft 39— Sleeve
7— Nut 21— Guide Lever 30— Shifter Shaft 40— Flyweight
8— Fuel Cut Lever 22— Set Spring 31— Main Spring 41— Cam Gear
9— Washer 23— Start Spring 32— Tensioner Lever 42— Timing Gear Cover
10— Set Screw 33— Adjuster
11— Washer
12— Nut
13— Washer
14— Cap Nut
Continued on next page OUO1082,000027F -19-13FEB03-2/3

100312
PN=161
Speed Controls
T159887 —UN—24OCT02
Governor
1— Control Link 7— Governor Shaft 13— Adjuster 20— Main Spring
2— Link Plate 8— Set Spring 14— Full Load Stopper 21— Main Spring Lever
3— Start Spring 9— Governor Cover 15— Shifter
4— Idle Speed Screw 10— Guide Lever 16— Flyweight
5— Idle (Sub) Spring 11— Timing Gear Case 17— Sleeve
6— Fuel Cut Cover 12— Tensioner Lever 18— Camshaft
19— Floating Lever
OUO1082,000027F -19-13FEB03-3/3

100312
PN=162
Group 0560
External Fuel Supply Systems
Fuel Tank Remove and Install
1. Remove battery. See Battery Remove and Install
(Group 9015-20.)
2. Remove left-side covers.
T165040B —UN—06FEB03
4. Drain fuel using valve (5). Approximate capacity is
40 L (11 gal).
5. Disconnect fuel level sender harness (1).
NOTE: Residual fuel may drain from tank when
removing hoses. Place drain on track prior to
disconnecting fuel hoses to tank.
6. Disconnect vent hose (3). 1— Harness 5— Drain Valve

2— Tank Strap 6— Pick-Up Hoses
7. Disconnect pick-up hoses (6). 3— Vent Hose 7— Cap Screw
4— Fill Tube Pad
8. Remove fill tube pad (4) and remove fill tube.
9. Remove cap screw (7).
OUO1082,0000276 -19-05FEB03-1/2
10. Remove cap screws (11) to remove plate (10).

11. Remove cap screws (12) to remove front cover (8).
12. Loosen cap screws (9).
NOTE: It is only necessary to lift floor plate enough
for fuel tank bottom sump to clear recess in
upper structure. Tank strap (2) must also be
held up when removing tank.
13. Attach a hoist to left-side of floor plate and raise floor

plate.
14. Remove fuel tank.
T165042 —UN—06FEB03
16. Position fuel tank and tank strap.
17. Install floor plate.
18. Install front plate.
19. Connect hoses and harness.
8— Front Cover 11— Cap Screw (2 used)
20. Install sill plate. 9— Cap Screw (6 used) 12— Cap Screw (4 used)
10— Plate
21. Install cab or canopy.
22. Install battery.
23. Fill fuel tank.
OUO1082,0000276 -19-05FEB03-2/2

100312
PN=163
External Fuel Supply Systems
Water Separator Repair

1. Remove side covers to gain access to water separator
(4).
2. Disconnect hoses (1 and 3).
T125483 —UN—14JAN00
3. Remove cap screw (2) to remove water separator.
5. Place water separator in position. Install cap screw.
6. Connect hoses.
0560.)
1— Hose 3— Hose
8. Install side covers. 2— Cap Screw 4— Water Separator
OUO1082,0000278 -19-06FEB03-1/1
Final Fuel Filter Repair

1. Remove side covers to gain access to fuel filter.
2. Disconnect hoses (1 and 3).
3. Remove cap screw (2) to remove final fuel filter (4).
T125480 —UN—14JAN00
5. Place final fuel filter in position. Install cap screw.
6. Connect hoses.
0560.)
8. Install side covers. 1— Hose 3— Hose
2— Cap Screw 4— Final Fuel Filter
OUO1082,0000277 -19-06FEB03-1/1
Bleed Fuel System 2. Loosen plug in the final fuel filter head to bleed air.
IMPORTANT: Air in the fuel system will cause the Tighten plug when fuel flows from the hole.
engine to start hard and/or run rough. Be
3. Turn key switch to ON and hold for 10—15 seconds to
sure to bleed air from system after replacing
engage automatic bleeding.
fuel filter or draining fuel tank.
4. Start engine and check for fuel leakage.
Bleeding Procedure (Automatic Bleeding Device)
1. Confirm that fuel level is more than one half of tank
capacity. If lower, automatic bleeding cannot be
accomplished. Add fuel.
CED,OUOE003,30019 -19-14FEB03-1/1

100312
PN=164
Section 17
Frame or Supporting Structure
Contents
Page
Group 1740—Frame Installation

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

Counterweight

100312
PN=1
Contents

100312
PN=2
Group 1740
Frame Installation
Welding on Machine causing damage. The welder ground clamp
must be connected as close to each weld
IMPORTANT: Electrical current traveling from area as possible so electrical current does
the welder through the machine electrical not pass through any bearings.
system can damage the machine electrical
system, including the battery, and any Disconnect the battery ground cable.
electronic control units. Before welding on
the machine, disconnect the battery ground Disconnect wiring harness connectors to any electronic
cable and wiring harness connectors to control units.
any electronic control units.
Connect the welder ground clamp as close to the weld
Electrical current traveling from the welder area as possible.
through a bearing can arc inside the bearing
CED,OUOE023,149 -19-24JAN03-1/1
Welding Repair of Major Structure
CAUTION: Avoid potentially toxic fumes and dust.

• AWS-E70T-1 or E71T-1 wire electrode with flux core
arc welding (FCAW) process.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. Welding Repair of Major Structure—Specification
Do all work outside or in a well ventilated area. Weld Metal—Tensile
Dispose of paint and solvent properly. Strength...............................................................482.6 mPa (70,000 psi)
Yield Strength .....................................................413.7 mPa (60,000 psi)
If you sand or grind paint, avoid breathing the Elongation......................................................................................... 22%
dust. Wear an approved respirator. If you use
solvent or paint stripper, remove stripper with IMPORTANT: Area to be repaired must be preheated
soap and water before welding. Remove solvent to allow better weld penetration.
or paint stripper containers and other flammable
material from area. Allow fumes to disperse at 3. To repair weld metal failure, remove failed weld metal
least 15 minutes before welding or heating. using arc or grinding equipment. Thoroughly clean
area to be welded. Preheat structural assemblies to a
1. Remove paint before welding or heating. minimum of 38°C (100°F). Preheat ground engaging
tools (cutting edges, skid shoes, and teeth shanks) to
IMPORTANT: Disconnect battery ground strap or 177°C (350°F).
turn battery disconnect switch to “OFF”. Also
disconnect the wiring harness connectors to To repair base metal failure remove enough material to
the engine and pump controller. allow weld to penetrate to the bottom of crack. Preheat
structural assemblies to a minimum of 38°C (100°F).
Have only a qualified welder do this job. Connect Preheat ground engaging tools (cutting edges, skid
welder ground clamp close to each weld area shoes, and teeth shanks) to 177°C (350°F).
so electrical current does not pass through any
bearings. Remove or protect all parts that can Welding Repair of Major Structure—Specification
be damaged by heat or weld splatter. Structural
Assembly—Preheat
2. Use one of the following weld processes: Temperature........................................................................ 38°C (100°F)
Ground Engaging
• AWS-E-7018 covered electrode with shielded metal Tool—Preheat
arc welding (SMAW) process. Temperature...................................................................... 177°C (350°F)
• AWS-ER-70S-3 wire electrode with gas metal arc
welding (GMAW) process.
TX,17,SB603 -19-24JAN03-1/1

100312
PN=167
Frame Installation

100312
PN=168
Group 1749
Chassis Weights
Counterweight Remove and Install
1. Park machine on a level surface.
2. Open hood (2) and access cover (3).
3. Remove cover (1).
T159459B —UN—17SEP02
1— Cover 3— Access Cover
2— Hood
Hood And Covers
Continued on next page CED,OUOE003,21050 -19-24JAN03-1/2

100312
PN=169
Chassis Weights

The lifting capacity of a lifting eyebolt decreases
as the lift angle increases from vertical. A
spreader bar should be used to obtain, as close
as possible, a vertical lift from lifting eyebolts.
T159474B —UN—17SEP02
Counterweight—Specification
Counterweight—27C
ZTS—Weight............................................... 300 kg (660 lb) approximate
Counterweight—35C
ZTS—Weight............................................. 570 kg (1257 lb) approximate
4. Remove plastic plugs. Connect counterweight (9) to Counterweight Lifting Configuration

hoist using a spreader bar and M16x2.0 lifting eyebolts
(10) such as JT05551 Metric Lifting Eyebolts.
5. Remove cap screws (11) and washers (12). Remove
counterweight.
7. Install counterweight.
Counterweight—Specification
Counterweight-to-Frame
Cap Screw—Torque................................................... 540 N·m (400 lb-ft)
9. Install plugs.
9— Counterweight 11— Cap Screw (2 used)

10— JT05551 Metric Lifting 12— Washer (2 used)
Eyebolts (2 used)
T125352 —UN—14JAN00
CED,OUOE003,21050 -19-24JAN03-2/2

100312
PN=170
Section 18
Operator's Station
Contents
Page

Cab
Canopy
Platform
Group 1810—Operator Enclosure

Windowpane and Molding .........................18-1810-1
Bonded Windowpane ................................18-1810-1
Sliding Window ..........................................18-1810-2
Windowpane
Dimensions ...........................................18-1810-3
Group 1821—Seat and Seat Belt

Seat
Seat Base
Seat Belt
Group 1830—Heating
Heater and Blower

100312
PN=1
Contents

100312
PN=2
Group 1800
Cab Remove and Install
Cab—Specification
Cab—Weight............................................... 120 kg (265 lb) approximate
T159954B —UN—10OCT02
1. Remove plugs from rear lift points (1) and install lifting
eyes in front and rear lifting points (1 and 2).
2. Attach hoist to cab lifting points using lifting straps.
3. Disconnect battery negative (-) cable.
4. Disconnect cab harness to floor harness connector (3). Cab Lifting Points
5. Remove front and rear cab mount cap screws (4 and 5).
6. Slowly lift cab from platform. Cab must be moved
forward while being raised to allow front of cab to clear
front of propel pedals.
T159955B —UN—10OCT02
1— Rear Lift Points 4— Cab-to-Platform Cap Screw
2— Front Lift Points (2 used)
3— Cab Harness to Floor 5— Rear Cab Mount Cap
Harness Connector Screws
Cab Harness to Floor Harness Connector
T159956B —UN—10OCT02
Cab-to-Platform Cap Screws
T159957B —UN—10OCT02
Rear Cab Mount Cap Screws
Continued on next page CED,OUOE003,21054 -19-26SEP02-1/2

100312
PN=173
4 6
7
4
6 8
6 7 9
10
7 8
8 9
10
9
10
9
7
9 11
T159958 —UN—01OCT02
7
11
9
7
T159958 11
Cab Mounting Hardware
4— Cab-to-Platform Cap Screw (2 6— Washer (4 used) 9— Isolator (8 used)
used) 7— Stop (8 used) 10— Isolator (4 used)
5— Rear Cab Mount Screw (2 8— Spacer (4 used) 11— Spacer (4 used)
used)
NOTE: When installing cab, check that all lines and wiring Rear Cab Mount Cap
harness have not been pinched when cab is lowered. Screw—Torque........................................................... 205 N·m (151 lb-ft)
8. Position cab mounting hardware and lower cab into

position. 10. Connect cab harness to floor harness connector.
9. Tighten cap screws (4 and 5). 11. Connect battery negative (-) cable.
Cab—Specification
Cab-to-Platform Cap
Screw—Torque........................................................... 205 N·m (151 lb-ft)
CED,OUOE003,21054 -19-26SEP02-2/2

100312
PN=174
Canopy Remove and Install

Canopy—Specification
Canopy—Weight........................................... 72 kg (160 lb) approximate
1. Attach lifting straps (1) to canopy lifting points (2).

2. Remove cap screws (6), lock washers (5), and
handrail (7).
4. Remove canopy (8).
6. Lower canopy into position.
7. Install cap screws (3) and lock washers (4) and tighten.
Canopy Mount Cap
Screw—Torque........................................................... 205 N·m (151 lb-ft)
T125351 —UN—19JAN00
8. Install handrail (7), lock washers (5), and cap screws
(6). Tighten cap screws.
Handrail-to-Canopy
and Platform Cap
1— Safety Strap (2 used) 5— Lock Washer (3 used)
2— Canopy Lifting Points (4 6— Cap Screw (3 used)
used) 7— Handrail
3— Cap Screw (4 used) 8— Canopy
4— Lock Washer (4 used)
CED,OUOE003,21055 -19-26SEP02-1/1

100312
PN=175
Platform Remove and Install

1. Loosen cap to release air pressure in hydraulic oil tank.

pressurized cooling system can cause For hoses without a shut-off valve, close hoses using
serious burns. a clamp. See Drain Cooling System for procedure.
(Operator's Manual.) Approximate coolant capacity
Shut off engine. Only remove filler cap when is 6 L (6.3 qt).
loosen cap to first stop to relieve pressure 4. Disconnect the heater hoses from heater core tubes
before removing completely. behind the right rear corner of seat. Close openings
using caps and plugs.
3. For a machine with a heater, close the shut-off valve 5. Remove floor mat.
for heater hoses at rear of engine or drain the coolant.
OUT3035,0000348 -19-11FEB03-1/4
6. Remove lower left covers (2 and 3) and front cover (4).

7. Remove upper right cover over the hydraulic oil tank. 1 1
8. Remove the angle bracket that fastens the floor plate

to the right side bracket.
9. Remove the floor plate-to-support cap screws (1 and
5). Two cap screws used to fasten the seat base to the 5
support are located behind the seat. Do not remove
the seat base-to-floor plate cap screws.
5
1— Cap Screw (4 used) 4— Front Cover
2— Left Cover 5— Cap Screw (6 used)
3— Left Cover (Step) 4
1
T165326 —UN—17FEB03
3
T165326
1 2
Continued on next page OUT3035,0000348 -19-11FEB03-2/4

100312
PN=176
10. Remove the plate in front of seat base. Disconnect

wiring lead connectors (10) from the propel speed
switch.
11. Disconnect quick coupler for pilot lines (7) at the
manifold (6). Identify lines to aid assembly. Close
T165317B —UN—19FEB03
openings using caps and plugs
12. Disconnect floor harness connectors (9) for harnesses
to heater blower motor and switches. Cut tie band (8)
that fastens harnesses to floor plate.
6— Manifold 9— Floor Harness Connector

7— Pilot Line (3 used) (4 used)
8— Tie Band 10— Propel Speed Switch
Wiring Lead Connector (2
used)
OUT3035,0000348 -19-11FEB03-3/4
13. Disconnect quick coupler for pilot lines (12) at pilot

line bulkhead (11). Identify lines to aid assembly.
See Control Valve Operation for control valve pilot
pressure line identification. Close openings using
caps and plugs.
14. Cut tie bands that fasten the fuel level sender wiring
harness to the edge of floor plate.
15. Disconnect wiring harness connectors from the propel
pressure sensors in the propel pilot controller.
Turn the propel pressure sensors down so they do not
catch on brackets when removing the floor plate.
T165320B —UN—19FEB03
Platform—Specification
Floor Plate, Seat Base,
Heater, Pilot Controllers,
and Seat—Weight......................................... 95 kg (210 lb) approximate
16. Fasten floor plate to a hoist using lifting straps and

11— Pilot Line Bulkhead 12— Pilot Lines (18 used)
lifting brackets such as JT01748 Lifting Bracket.
17. Carefully lift floor plate and seat checking to be sure all
lines and wiring harnesses are disconnect and propel
21. Install the covers.
pressure sensors do not catch on a support bracket.
22. Install the cab or canopy.
23. Fill radiator with coolant. See Cooling System Fill and
19. Install floor plate and seat being careful not to catch
Deaeration (Operator's Manual.)
propel pressure sensor on a support bracket.
Install the angle bracket and all cap screws.
20. Connect the pilot lines, heater hoses, and wiring
harnesses.
OUT3035,0000348 -19-11FEB03-4/4

100312
PN=177

100312
PN=178
Group 1810
Operator Enclosure
Windowpane and Molding Repair
Remove and Install Windowpane and One
Piece Molding
1. Lift inside of molding over cab frame and carefully
push windowpane and molding out.
T6439XE —UN—19OCT88
2. Remove molding from windowpane; replace if
necessary.
TX,1800,VV2501 -19-19FEB03-1/2
3. Install molding on windowpane. Position drain notches

(A) at bottom and towards outside of windowpane.
4. Install windowpane and molding. Lift inside of molding
over cab frame.
T6439XD —UN—19OCT88
A—Drain Notches
TX,1800,VV2501 -19-19FEB03-2/2
Bonded Windowpane Repair

Remove and Install Bonded Windowpanes
IMPORTANT: Adhesive will not stick to bare metal.
Adhesive used to secure windowpanes is urethane
adhesive used on automobile windshields. Urethane 3. If existing adhesive is removed and paint is scraped,
adhesive, manufactured by Loctite Corporation or paint window frame. Paint must be fully cured before
equivalent, is recommended. DO NOT use any other type installing windowpane.
of adhesive. It is recommended that auto glass dealer
4. Trim existing adhesive to form smooth surface.
install windowpanes.
IMPORTANT: Follow manufacturer’s instructions
IMPORTANT: Windowpanes must include an
for using adhesive.
ultra-violet barrier around edge so adhesive will
not deteriorate. Windowpanes ordered through
5. Apply 6 mm (1/4 in.) bead of adhesive over existing
John Deere Parts have this ultra-violet barrier. If
adhesive.
windowpane is purchased through glass dealer,
the dealer must incorporate an ultra-violet barrier 6. Position windowpane in cab frame. Use hand pressure
on the glass. DO NOT paint border of glass. to force windowpane down until edges are even with
metal frame.
If auto glass dealer does not install windowpanes, proceed
as follows: 7. Secure windowpane with duct tape until adhesive
cures. Allow adhesive to cure for 24 hours before
1. Remove windowpane frame from cab. operating machine.
2. Scrape any broken glass off existing adhesive. DO
NOT remove adhesive from window frame or cab.
T52,1810,C19 -19-19FEB03-1/1

100312
PN=179
Operator Enclosure
Sliding Window Repair

Remove and Install Sliding Windows
1. Remove molding (3) from inside of window.
2. Use putty knife to cut adhesive (4) between cab flange
and window frame (1).
IMPORTANT: Work carefully to avoid damaging frame
and windowpane. Two technicians are required
during window removal; one to push window out
of cab, and one to prevent window from falling.
3. Carefully remove window frame from cab.

4. Lift frame slightly at top-center to remove and install
windowpanes.
5. Apply instant gel adhesive to cab flange.
6. Install windows and frame with spacers (2) at bottom.
7. Using water as lubricant, push window frame tight
T140968 —UN—30APR01
against cab flange.
8. Install molding (3) around window and cab flange.
1— Window Frame 3— Molding

2— Bottom Spacer (4 used) 4— Adhesive
TX,18,VV2503 -19-19FEB03-1/1

100312
PN=180
Operator Enclosure
Windowpane Dimensions
T125216 —UN—14JAN00
Continued on next page CED,OUOE023,63 -19-22OCT99-1/4

100312
PN=181
Operator Enclosure
T125217 —UN—14JAN00

100312
PN=182
Operator Enclosure
T125219 —UN—14JAN00

100312
PN=183
Operator Enclosure
T125218 —UN—14JAN00
CED,OUOE023,63 -19-22OCT99-4/4

100312
PN=184
Group 1821
Seat and Seat Belt
Seat Remove and Install
1. Remove cap screws (1) from seat base.
2. Remove seat.
4. Install seat.
1— Cap Screw (4 Used)
T164245 —UN—28JAN03
OUO1082,000026F -19-31JAN03-1/1
Seat Base Remove and Install

2. Remove floor mat.
3. Remove manual holder door (3), and left side cover (4).
4. Remove and disconnect power outlet housing (1).
5. Remove right side cover (5) and disconnect heater
blower motor switch if equipped.
6. Remove left and right console lower covers (2).
T164511B —UN—28JAN03
1— Power Outlet Housing 4— Left Side Cover
2— Left and Right Console 5— Right Side Cover
Lower Covers
3— Manual Holder Door

100312
PN=185
Seat and Seat Belt
7. Turn off heater control valve (6) and disconnect heater

hoses (8) if equipped.
8. Disconnect wire harnesses (7) from right control
console. See Floor Harness (W2) Component
Location and Propel Alarm Harness (W11) and Propel
T164515B —UN—28JAN03
Alarm Cancel Switch Harness (W12) Component
Location. (Group 9015-10.)
6— Heater Control Valve 8— Heater Hose (2 used)

7— Wire Harness
OUO1082,0000270 -19-31JAN03-2/3
9. Remove cap screws (10) and remove seat.

10. Disconnect heater blower motor connector (13).
11. Remove fuse panel mounting screws (9).
12. Remove electrical box (14) and disconnect electrical
T164516B —UN—28JAN03
component harness.
13. Remove mounting cap screws (11) from left and right
control consoles and lay consoles off to side.
14. Remove seat base mounting cap screws (12).
15. Remove wiring harness from seat base.
16. Remove seat base from platform.
9— Screw (2 used) 12— Cap Screw (5 used)
17. Replace parts as necessary. 10— Cap Screw (4 used) 13— Connector
11— Cap Screw (10 used) 14— Electrical Box
18. Position wiring harness in seat base and install seat
base.
19. Connect electrical harnesses.
22. Connect battery negative (-) cable.
20. Install seat and consoles.
21. Install covers.
OUO1082,0000270 -19-31JAN03-3/3

100312
PN=186
Seat and Seat Belt
Seat Belt Remove and Install
T164247
T164247 —UN—28JAN03
1— Cap Screw and Washer 2— Seat Belt Latch
1. Remove cap screws and washers (1) and remove

seat belt (2). Continued on next page OUO1082,0000271 -19-31JAN03-1/2

100312
PN=187
Seat and Seat Belt
2. Replace as needed.
OUO1082,0000271 -19-31JAN03-2/2

100312
PN=188
Group 1830
Heating
Heater and Blower Motor Remove and Install
1. Remove floor mat (2), manual holder door (3), and left
side cover (1).
T159501B —UN—20SEP02
3. Remove power outlet bracket (5) and disconnect
harness from power outlet.
4. Remove right side cover (6) and disconnect heater
blower switch (4).

2— Floor Mat 5— Power Outlet Bracket
FR91424,000001C -19-12SEP02-1/9
5. Remove cap screws (8) and remove heater duct (7).

6. Close heater shut-off valve (9).
7— Heater Duct 9— Heater Shut-Off Valve

8— Cap Screws
T159614B —UN—20SEP02
FR91424,000001C -19-12SEP02-2/9
7. Remove floor access panel (10) and disconnect

harness from propel speed change switch (11).
8. Disconnect blower motor connector (13).
9. Remove electrical component cover (12) and
disconnect or remove electrical components and set
T159615B —UN—20SEP02
aside.
10— Floor Access Panel 12— Electrical Component

11— Propel Speed Change Cover
Switch 13— Blower Motor Connector
Continued on next page FR91424,000001C -19-12SEP02-3/9

100312
PN=189
Heating
10. Remove cap screws (14) from engine compartment.

11. Remove heater and blower motor.
14— Cap Screws (4 Used)
T159620B —UN—20SEP02
FR91424,000001C -19-12SEP02-4/9

serious burns.
T159626B —UN—20SEP02
NOTE: Heater core and heater hoses contain coolant.

Properly dispose of coolant.
12. Drain coolant from system or install clamp (15) to

heater hoses. See Drain Cooling System. (Operator's
Manual.)
16. Connect heater hoses.
13. Disconnect heater hoses.
17. Install heater and blower motor.
14. Drain coolant from heater core and hoses.
FR91424,000001C -19-12SEP02-5/9
18. Install cap screws (14).
14— Cap Screws (4 Used) T159620B —UN—20SEP02
Continued on next page FR91424,000001C -19-12SEP02-6/9

100312
PN=190
Heating
19. Connect or install electrical components to electrical

component cover and install cover (12).
20. Connect blower motor connector (13).
21. Connect harness to propel speed change switch (11)
and install floor access panel (10).
T159615B —UN—20SEP02
10— Floor Access Panel 12— Electrical Component
11— Propel Speed Change Cover
Switch 13— Blower Motor Connector
FR91424,000001C -19-12SEP02-7/9
22. Open heater shut-off valve (9).

23. Install heater duct (7) using cap screws (8).
7— Heater Duct 9— Heater Shut-Off Valve

8— Cap Screws
T159614B —UN—20SEP02
FR91424,000001C -19-12SEP02-8/9
24. Connect heater blower switch (4) and install right side
cover (6).
25. Connect harness to power outlet and install power
outlet bracket (5).
26. Install left side cover (1), manual holder door (3), and
T159501B —UN—20SEP02
floor mat (2).
27. Connect battery negative (-) cable.
28. Check engine coolant level. See Check Recovery
Tank Coolant Level. (Operator's Manual.)

2— Floor Mat 5— Power Outlet Bracket
FR91424,000001C -19-12SEP02-9/9

100312
PN=191
Heating

100312
PN=192
Section 32
Bulldozers (Blade)
Contents
Page
Group 3201—Blades
Blade
Repair....................................................32-3201-1

Blade Cylinder
Blade Pilot Controller
Repair....................................................32-3260-2

100312
PN=1
Contents

100312
PN=2
Group 3201
Blades
Blade Repair
Remove and Install Blade
1. Lower all equipment to ground.
2. Stop the engine.

Specification
Blade—Weight................................................................. 205 kg (450 lb)
T119390 —UN—20JAN99
3. Attach blade (3) to a hoist (1) by the lifting holes (2)
using chains or lifting straps.
1— Hoist 3— Blade
2— Lifting Holes (2 used)
Continued on next page OUO1082,000027C -19-07FEB03-1/3

100312
PN=195
Blades
T125450 —UN—14JAN00
1— Blade 3— Bushing (3 used) 5— Cylinder

2— Cap Screw (3 used) 4— Pin (3 used)
4. Put support stands under the arms of blade (1) and 7. Replace parts as necessary.
cylinder (5).
8. Apply grease to all pins.
5. Remove cap screws (2), bushings (3), and pins (4).
9. Install blade.
6. Remove blade (3).
Continued on next page OUO1082,000027C -19-07FEB03-2/3

100312
PN=196
Blades
Disassemble and Assemble Blade
T125452 —UN—14JAN00
1— Blade 3— Bushing (2 used)
2— Dust Seal (4 used)
Repair or replace parts as needed. See Welding Repair of Major Structure before welding
See Welding on Machine. (Group 1740.) on the blade. (Group 1740.)
OUO1082,000027C -19-07FEB03-3/3

100312
PN=197
Blades

100312
PN=198
Group 3260
Hydraulic System
Blade Cylinder Remove and Install pressurized. Cap must be loosened to relieve
1. Lower blade to ground.
pressurized system can cause serious burns 3. Remove blade cylinder guard.
3
2
1
T165360 —UN—14FEB03
T165360
1— Cap Screw (2 used) 3— Pin (2 used) 5— Line (2 used)

2— Bushing (2 used) 4— Blade Cylinder
4. Disconnect hydraulic lines (5). Close openings using 7. Remove blade cylinder (4).
caps and plugs.
8. Repair or replace blade cylinder as necessary. See
CAUTION: Heavy component; use a hoist. Blade and Boom Swing Cylinder Disassemble and
Assemble. (Group 3360.)
Blade Cylinder—Specification
Blade Cylinder—27C Apply grease to all pins.
ZTS—Weight................................................... 19 kg (42 lb) approximate
Blade Cylinder—35C
9. Install blade cylinder.
ZTS—Weight................................................... 24 kg (53 lb) approximate 10. Install blade cylinder guard.
5. Attach blade cylinder (4) to a hoist using lifting straps. 11. Check oil level. See Check Hydraulic Oil Tank Level.
Add oil as necessary. See Hydraulic Oil. (Operator’s
6. Remove cap screws (1) to remove bushings (2), and Manual.)
pins (3).
OUO1082,000027A -19-07FEB03-1/1

100312
PN=199
Hydraulic System
Blade Pilot Controller Repair

Remove and Install Blade Pilot Controller
1. Lower blade to ground.


3. Remove cap screws (32) to remove cover (31).
Disconnect wiring leads to 12V Power Outlet.
T163591 —UN—23JAN03
30— Control Lever 32— Cap Screw (4 used)
31— Cover
Blade Pilot Controller Control Lever
OUO1082,000027B -19-07FEB03-1/4
4. Remove cap screws (38) to remove lever (30). 38 30

5. Identify hoses (35) for assembly. See Blade Hydraulic
System Component Location. (Group 9025-15.)
Disconnect hoses. 37 39
6. Remove cap screws (39) to remove blade pilot
controller (40).
35 40
8. Install controller. Connect the lines.
9. Install lever. 41
10. Install cover.
T163592 —UN—24JAN03
30— Lever 39— Cap Screw (2 used)
35— Hose (4 used) 40— Blade Pilot Controller
37— Bracket 41— Cap Screw (2 used)
T163592
Continued on next page OUO1082,000027B -19-07FEB03-2/4

100312
PN=200
Hydraulic System
Disassemble and Assemble Blade Pilot Controller
1
12
2 12
3
13
4 13
14
5
15 14
16
15
16
6
7 5 17
17
18
6 19 18
20
8
9
9
10 21
10
11
11
T160028 —UN—07OCT02
T160028
1— Boot 7— Shaft 13— Spring Seat (2 used) 18— Outer Spring (2 used)
2— Set Screw 8— Cover 14— Inner Spring (2 used) 19— Plug
3— Cam 9— Packing (2 used) 15— Shim (2 used) 20— O-Ring
4— Steel Ball (2 used) 10— Plug (2 used) 16— Washer (2 used) 21— Housing
5— Cap Screw (2 used) 11— O-Ring (2 used) 17— Spool (2 used)
6— Bushing (2 used) 12— Push Rod (2 used)
Continued on next page OUO1082,000027B -19-07FEB03-3/4

100312
PN=201
Hydraulic System
IMPORTANT: If damage to cam (3), cover (8), push Compress the spring just enough to install spring seats
rods (12), spools (17), or housing (21) is noticed, (13) onto spools through the larger diameter hole.
the pilot controller must be replaced.
8. Install the outer spring (18).
1. Take notice of part location with respect to its mating
part for assembly. 9. Carefully install spool assemblies into the same ports
from which they were removed.
2. Remove set screw (2). Thread lock and sealer
(medium strength) is used on the threads of set screws. 10. Install O-rings (11) on plugs (10).
Remove shaft (7) to remove cam (3) from cover (8). 11. Apply grease to packings (9). Install packing in plugs
Steel balls (4) cannot be removed. with lip towards O-ring end of plug.
3. Loosen the cap screws (5) to relieve the slight spring 12. Apply hydraulic oil to push rods (12) before pushing
force. Remove cover (8) from housing (21). rod through the packing in plugs (10). Install plug and
push rod into housing.
4. Remove packings (9), plugs (10), O-rings (11), and
push rods (12). 13. Install cover (8). Tighten cap screws (5).
Blade Pilot Controller—Specification
IMPORTANT: The spool assemblies are adjusted for
equal pressure using shims. The shims and
Screw—Torque........................................................ 23.5 N·m (208 lb-in.)
washers must be kept with it respective spool.
14. Install cams (3). Install the shafts (7) through cover and
The spools must be installed into the same
cam so hole in shaft aligns with tapped hole in cam.
port from which it was removed.
15. Apply thread lock and sealer (medium strength) to
5. Remove spool assemblies (13—17) and outer springs threads of set screw (2). Tighten set screw.
(18). Keep parts for each spool together.
Blade Pilot Controller—Specification
6. Clean and repair or replace parts as necessary. Cam-to-Shaft Set
Screw—Torque............................................................ 5.0 N·m (44 lb-in.)
7. Install washer (16), shim (15), and inner spring (14)
onto their original spool (17).
OUO1082,000027B -19-07FEB03-4/4

100312
PN=202
Section 33
Excavator
Contents
Page Page
Group 3302—Buckets Hydraulic Cylinder Bleed

Tooth Shank Procedure ............................................ 33-3360-58
Group 3340—Frames
Bucket Links
Arm
Boom
Boom Swing
Arm, Boom, and Boom Swing Pins and Bushings
Inspect.................................................33-3340-14
Bushings and Seals

Hydraulic Pump
Disassemble..........................................33-3360-2
Assemble ..............................................33-3360-7
Start-Up Procedure .............................33-3360-12
Dampener Drive (Flex Coupling)
Solenoid Valve Manifold
Repair..................................................33-3360-13
Pilot Controller
Repair..................................................33-3360-15
Propel Pilot Controller
Repair..................................................33-3360-20
Auxiliary Pilot Controller
Repair..................................................33-3360-25
Boom Swing Pilot Controller
Repair..................................................33-3360-28
Control Valve
Pilot Controller Pattern Conversion Valve
Repair..................................................33-3360-40
One Way/Two Way Valve
Hydraulic Oil Tank
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Blade and Boom Swing Cylinder

100312
PN=1
Contents

100312
PN=2
Group 3302
Buckets
Tooth Shank Remove and Install
IMPORTANT: Electrical current traveling from the
welder through the machine's electrical system
can damage the electrical system, including the
battery, and any electronic control units. Before
welding on the machine, the battery ground
T92509 —UN—31OCT88
cable and wiring harness connectors to any
electronic control units must be disconnected
to protect the machine's electrical system.
1. Disconnect the battery ground strap and the wiring

harness connectors to any electronic control units.
2. Being careful not to cut into cutting edge, remove weld
using a cutting torch or air arc equipment to remove
shank. See Welding on Machine. (Group 1740.)
3. Grind all surfaces smooth.
T92510 —UN—31OCT88

100312
PN=205
Buckets
IMPORTANT: Good welds are important. Have only a T5985AQ —UN—31OCT89

Install center shanks so they are tight against bevel
qualified welder do the welding. Before welding, edge and spaced equally across width of bucket.
clean all dirt and paint from weld area. Connect
the welder ground clamp as close to each weld 6. Tack weld at the top rear center to hold it in position.
area as possible so electrical current does not
pass through any bearings or bushings. Use E7018 electrodes for welding or Lincoln Electric
Co. gasless flux core process electrode type NS3M.
4. Before welding shank, remove the tooth tip so rubber 3/32 or 1/8 in. rod may be used.
pin lock is not damaged by the heat.
5. Install shank into corner so it is tight against the bevel
edge and side of bucket.

100312
PN=206
Buckets
7. Preheat shank and cutting edge to 204—316°C

(400—600°F). Check temperature using a temperature
stick to be sure correct temperature is obtained.
Tooth Shank—Specification
Tooth Shank—Preheat
Temperature................................................... 204—316°C (400—600°F)
T82798 —UN—31OCT88
IMPORTANT: All weld beads must be continuous
starting at rear center, around the corner and
along the side for a good strong weld joint. DO
NOT start or stop welding at a corner.
8. Weld shank to cutting edge using 12.7 mm (0.5 in.)

fillet weld (1).
Starting at the rear center of shank, weld a continuous
bead across end, around the corner, and along the
side stopping 25 ± 6 mm (0.98 ± 0.24 in.) from edge
of cutting edge.
Tooth Shank—Specification
T82799 —UN—31OCT88
Tooth Shank-to-Cutting
Edge Fillet Weld—Size.................................................. 12.7 mm (0.5 in.)
Distance...................................................................... 25 ± 6 mm (0.98 ±
0.24 in.) from edge of cutting edge
Alternating from side to side, make as many passes

as necessary to get the specified bead size.
9. Allow the weld area to cool slowly at room temperature.
1— Fillet Weld
OUT3035,0000346 -19-22JAN03-3/3

100312
PN=207
Buckets

100312
PN=208
Group 3340
Frames
Bucket Link Remove and Install
9
3
8
6
3
9
11
7 4
5 10
4
5 5
4
5
4
1
2
4
5
T159968 —UN—04OCT02
5
4
T159968
Bucket Links
1— Retainer (2 used) 4— Plate (Washer) (6 used) 7— Pin (2 used) 10— Links-to-Arm Pin
2— Left Side Link 5— Plate (Washer) (6 used) 8— Cylinder Pin 11— Right Side Link
3— O-Ring (2 used) 6— Center Link 9— Lubrication Fitting (2 used)
NOTE: Removal of bucket is not necessary for the to hold cylinder up when links-to-bucket cylinder pin
removal of just the bucket links. Remove the bucket (8) is removed.
if the arm is also being removed. See Installing
Bucket With Quick Coupler. (Operator's Manual.) 2. Remove retainers (1) and pins (7).
As links-to-bucket cylinder pin (8) is removed, lower
1. Connect center link (6) to a hoist using a lifting strap. left (2) and right (11) side links to ground.
Put a wood block between bucket cylinder and arm

100312
PN=209
Frames
3. Inspect bushings (4 and 7) and dust seals (5 and 6).

See Inspect Arm, Boom, Bucket, and Boom Swing
Pins and Bushings. (Group 3340.)
Replace parts as necessary.
4. Install plates (washers) (2) equally on each side of
joint to get a minimal amount of clearance in the joints.
There must be some clearance in the joints.
5. Before installing pins, align pin bores so as not to
damage dust seal when pins are installed.
T119728 —UN—29JAN99
6. Install pins and retainers.
7. Apply multi-purpose grease to pivot joints.
1— O-Ring (2 used) 5— Dust Seal (2 used)

2— Plate (Washer) (4 used) 6— Dust Seal (4 used)
3— Center Link 7— Bushing (2 used)
4— Bushing (2 used)
CED,OUOE003,1536 -19-01OCT02-2/2

100312
PN=210
Frames
Arm Remove and Install

21
11
21
22
12
22
16 5
31
30
31
30 30
31
30 31
6 6 31 30
17 7
35 36
22
30
31
35
22 31
30 36
30
31 39 37
40
27
21 26
14 10
9
5 25
24
16 21
13
15 29
2
T159754 —UN—30SEP02
17
17 11
16 13
12
T159754

100312
PN=211
Frames
1— Bushing 11— Pin 22— O-Ring (4 used) 36— O-Ring (2 used)

2— Cap Screw 12— Pin 24— Cap Screw 37— Hydraulic Hose (2 used)
3— Washer 13— Bucket-to-Arm Pin 25— Bushing 39— Plug (8 used)
4— Arm-to-Boom Pin 14— Bucket-to-Center Link Pin 26— Cap Screw 40— Plug (2 used)
5— Link 16— Pin (4 used) 27— Bushing
6— Stop (2 used) 17— Retainer (4 used) 29— Shim (3 used)
7— Link 21— Lubrication Fitting (4 used) 30— Shim (8 used)
9— Arm-to-Arm Cylinder Pin 31— Shim (8 used)
10— Arm-to-Bucket Cylinder Pin 35— Adapter (2 used)
1. Remove bucket. See Installing Bucket With Quick or penetrating injury. The hydraulic oil tank is
Coupler. (Operator's Manual.) pressurized. Cap must be loosened to relieve
2. Retract arm cylinder.
3. Place a floor stand under boom so load is on boom, 5. Slowly loosen cap to relieve the air pressure in
not on arm cylinder. hydraulic oil tank.
4. Stop engine.

CED,OUOE003,21128 -19-17JAN00-2/4

X9811 —UN—23AUG88
6. Loosen bucket cylinder hydraulic lines to release any
residual pressure. Disconnect lines.

Arm—Specification
Arm—27C
ZTS—Weight................................................. 95 kg (210 lb) approximate
Arm—35C 7. Attach arm to hoist.
ZTS—Weight................................................118 kg (260 lb) approximate
8. Place a wood block between arm cylinder and boom
to keep cylinder off lines.
NOTE: Remove bucket cylinder and linkage only

if necessary to repair arm.

100312
PN=212
Frames
T124955 —UN—03NOV99
1— Cap Screw 3— Boom-to-Arm Pin 5— Bushing
2— Bushing 4— Cap Screw 6— Boom-to-Boom Cylinder Pin
9. Remove parts (1—6). Remove arm.

13. Remove wood block.
14. Remove hoist.
11. Install arm.
15. If removed, install bucket cylinder.
Install shims equally on each side of joint to get a
16. Connect bucket cylinder hydraulic lines.
minimal amount of clearance in the joints. There must
be some clearance in the joints. 17. If removed, install bucket links.
Arm—Specification 18. Install bucket. See Installing Bucket With Quick
Arm and Cylinder Coupler. (Operator's Manual.)
Joints—Clearance........................................... 0.5 mm (0.020 in.) or less
19. Check oil level and add oil if necessary. See Hydraulic
12. Install parts (1—6). Apply T43513 Thread Lock and Oil. (Operator's Manual.)
Sealer (High Strength) to threads of cap screws.
Tighten cap screws (1 and 4). 20. Apply multi-purpose grease to all joints.
Arm—Specification 21. Perform Hydraulic Cylinder Bleed Procedure. (Group
Cylinder-to-Arm Pin 3360.)
M12 Cap Screw—27C
ZTS—Torque.................................................................. 88 N·m (65 lb-ft)
Cylinder-to Arm Pin
M14 Cap Screw—35C
ZTS—Torque.............................................................. 137 N·m (101 lb-ft)
CED,OUOE003,21128 -19-17JAN00-4/4

100312
PN=213
Frames
Boom Remove and Install
5 1
9
10
15
11
13
12
6
7 4
8 3
4 17 14
16
16
17
T159763 —UN—01OCT02
T159763
Boom
1— Boom-to-Arm Cylinder Pin 5— Shim (6 used) 10— Cap Screw 15— Plug (5 used)
2— Arm-to-Boom Pin 6— Boom-to-Boom Cylinder Pin 11— Bushing 16— Bushing (2 used)
3— Shim (2 used) 7— Bushing 12— Cap Screw 17— Seal (2 used)
4— Shim (2 used) 8— Cap Screw 13— Lock Washer
9— Bushing 14— Lubrication Fitting

CAUTION: High pressure release of oil from hydraulic oil tank.
or penetrating injury. The hydraulic oil tank is 2. Remove bucket. See Installing Bucket With Quick
pressurized. Cap must be loosened to relieve Coupler. (Operator's Manual.)
3. Remove arm. See Arm Remove and Install. (Group
3340.)

100312
PN=214
Frames
Boom Cylinder—35C
4. Lower boom so the end is on a support stand.
CAUTION: Heavy component; use a hoist. 5. Attach a hoist to boom cylinder.

Boom—Specification
Boom Cylinder—27C
CED,OUOE003,21129 -19-24SEP02-2/6
6. Remove cap screw (6), bushing (7), pin (5), and shims
(3 and 4). Lower end of boom cylinder to a support
stand. Remove cover (1) if cylinder is being removed
for repaired.
7. Remove arm cylinder only if necessary to repair boom.
T124958 —UN—29OCT99
1— Cover 5— Boom-to-Boom Cylinder
2— Cap Screw and Washer Pin
3— Shim (2 used) 6— Cap Screw
4— Shim (2 used) 7— Bushing
CED,OUOE003,21129 -19-24SEP02-3/6

under pressure, stop engine, and relieve the
pressure in the system before disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure.
X9811 —UN—23AUG88
8. Remove cover.
9. Attach identification tags to lines to aid assembly. See
Main Hydraulic System Line Connection.
Disconnect lines (1—8). Close openings using caps
and plugs.

Boom—27C
Boom—35C
10. Attach boom to a hoist.
1— Arm Cylinder Rod End Line 5— Boom Cylinder Head End

T127390 —UN—19JAN00
2— Bucket Cylinder Rod End Line

Line 6— Boom Cylinder Rod End
3— Bucket Cylinder Head End Line
Line 7— Auxiliary Left Port Line
4— Arm Cylinder Head End 8— Auxiliary Right Port Line
Line

100312
PN=215
Frames
11. Remove cap screw and nuts (2). Remove the pin (1)
and shims (3).
12. Remove boom.
T124957 —UN—28OCT99
14. Install boom. Install parts (1—3).
Install shims (3) equally on each side of joint to get a
minimal amount of clearance in the joint. There must
be some clearance in the joint.
Boom, Arm, and Cylinder
15. Apply T43513 Thread Lock and Sealer (High Strength) 1— Boom-to-Frame Pin 3— Shim (2 used)
2— Cap Screw and Nuts
to threads of nuts.
Tighten the nuts against each other, not the boss.
There must be clearance between nuts and boss. Cap Nut-to-Boss
screw must be free to turn in hole. —Clearance.....................................................3—5 mm (0.12—0.20 in.)
Boom-to-Frame Pin
Cap Screw and
Nuts—Torque................................................................. 88 N·m (65 lb-ft)
tighten nut against nut, not the boss
CED,OUOE003,21129 -19-24SEP02-5/6
16. Raise boom cylinder.

Install shims (3 and 4) equally on each side of joint to
get a minimal amount of clearance in the joint. There
must be some clearance in the joint.
Install pin (5).
T124958 —UN—29OCT99
to threads of cap screw (6).
Install bushing (7) and cap screw. Tighten cap screw.
Boom-to-Cylinder Pin
Retainer M12 Cap
Screw—Torque............................................................... 88 N·m (65 lb-ft) 1— Cover 5— Boom Cylinder-to-Boom
Cover-to-Boom Cylinder 2— Cap Screw and Washer Pin
Cap Screw—Torque....................................................... 49 N·m (36 lb-ft) 3— Shim (2 used) 6— Cap Screw
18. Install arm cylinder.
19. Connect hydraulic lines.
20. Install cover. Oil. (Operator's Manual.)
21. Install arm. See Arm Remove and Install. (Group 24. Apply multi-purpose grease to all joints.
3340.)
25. Perform Hydraulic Cylinder Bleed Procedure. (Group
22. Install bucket. See Installing Bucket With Quick 3360.)
Coupler. (Operator's Manual.)
CED,OUOE003,21129 -19-24SEP02-6/6

100312
PN=216
Frames
Boom Swing Remove and Install

T124958 —UN—29OCT99

hydraulic oil tank.

Boom Swing—Specification
Boom Cylinder—27C 1— Cover 5— Boom Cylinder-to-Boom
ZTS—Weight................................................... 29 kg (62 lb) approximate 2— Cap Screw and Washer Pin
Boom Cylinder—35C 3— Shim (2 used) 6— Cap Screw
2. Attach a hoist to boom cylinder

4. Remove cap screw (6), bushing (7), pin (5), and shims
3. Remove cap screw and washer (2). Remove cover (1). (3 and 4). Remove cover (1) only if cylinder is being
removed for repaired.
CED,OUOE003,21130 -19-24JAN03-1/6

X9811 —UN—23AUG88
5. Loosen boom cylinder hydraulic lines (1 and 2) to
release any residual pressure. Disconnect hydraulic
lines (1 and 2).
6. Remove nuts (5 and 6), cap screw (3), pin (4), and
shims (7). Remove boom cylinder.
7. Remove boom. See Boom Remove and Install.
(Group 3340.)
1— Head End Line 5— Nut

2— Rod End Line 6— Nut
3— Cap Screw 7— Shim (2 used)
4— Frame-to-Boom Cylinder
Pin
T127389 —UN—19JAN00

100312
PN=217
Frames
8. Disconnect hydraulic lines (1 and 2).

9. Remove cover (4).
10. Remove manifold (3).
1— Hydraulic Line “A6” 3— Manifold

2— Hydraulic Line “A” 4— Cover
T124961 —UN—28OCT99

100312
PN=218
Frames
T155504 —UN—12JUN02

100312
PN=219
Frames
3— Frame 19— Cap Screw (2 used) 30— Nut (2 used) 40— 0.9 mm Shim (2 used)
4— Thrust Washer 20— Pin 32— Pin 41— 0.8 mm Shim (2 used)
6— Cover 21— Cap Screw 33— Cap Screw 42— 1.0 mm Shim (2 used)
7— Cover 22— Nut (2 used) 34— Nut (2 used) 46— Plug (4 used)
8— Cap Screw, Lock Washer, and 24— Pin 37— 0.5 mm Shim (2 used) 47— Plug (3 used)
Washer (2 used) 25— Cap Screw 38— 0.8 mm Shim (2 used)
9— Half Clamp (2 used) 26— Nut (2 used) 39— 1.0 mm Shim (2 used)
16— Pin 28— Pin
29— Cap Screw
11. Remove nuts (34), cap screw, (33), and pin (32) to
disconnect boom swing cylinder.
Bottom Pin-to-Frame
Cap Screw and
CAUTION: Heavy component; use a hoist. Nuts—Torque................................................................. 88 N·m (65 lb-ft)
12. Attach a hoist to boom swing frame (3) using a lifting Nut-to-Boss—Clear-
strap. ance..................................................................3—5 mm (0.12—0.20 in.)
13. Remove parts (6—9, 16, 19, 20, 21, and 22) to remove 18. Connect boom swing cylinder to boom swing frame.
frame and thrust washer (4).
Apply T43513 Thread Lock and Sealer (High Strength)
14. Repair or replace parts as necessary. to threads of nuts (34).
15. Install boom swing frame (3). Tighten the nuts against each other, not the boss.
16. Install cover (6). Tighten cap screws (19). There must be clearance between nuts and boss. Cap
screw must be free to turn in hole.
Top Pin Cover-to-Frame Boom Swing—Specification
Cap Screw—Torque....................................................... 88 N·m (65 lb-ft) Boom Swing Cylinder
Pin-to-Frame Cap Screw
17. Apply T43513 Thread Lock and Sealer (High Strength) and Nuts—Torque.......................................................... 50 N·m (37 lb-ft)
to threads of nuts (22). tighten nut against nut, not the boss
Nut-to-Boss—Clear-
Tighten the nuts (22) against each other, not the boss. ance..................................................................3—5 mm (0.12—0.20 in.)
There must be clearance between nuts and boss. Cap
screw must be free to turn in hole.

100312
PN=220
Frames
19. Install manifold (3).

20. Connect hydraulic lines (1 and 2).
21. Install cover (4).
22. Install boom and boom cylinder. See Boom Remove
and Install. (Group 3340.)
Install shims (37—39 and 40—42) equally on each
side of joint to get a minimal amount of clearance in
the joint. There must be some clearance in the joint.
T124961 —UN—28OCT99
Boom and Cylinder

to threads of nuts (26 and 30).
Tighten the nuts against each other, not the boss.
There must be clearance between nuts and boss. Cap
screw must be free to turn in hole. 1— Hydraulic Line “A6” 3— Manifold
Boom Swing—Specification 2— Hydraulic Line “A” 4— Cover
Boom and Cylinder-
to-Frame Pin M10
Cap Screw and 24. Connect remaining hydraulic lines.
tighten nut against nut, not the boss 25. Check oil level and add oil if necessary. See Hydraulic
Boom-to-Frame Pin Oil. (Operator's Manual.)
M12 Cap Screw and
26. Apply multi-purpose grease to all joints.
Nut-to-Boss
—Clearance.....................................................3—5 mm (0.12—0.20 in.)
CED,OUOE003,21130 -19-24JAN03-6/6

100312
PN=221
Frames
Inspect Arm, Boom, Bucket, and Boom Swing Pins and Bushings
T124959 —UN—04NOV99
A—Boom Cylinder Head E—Arm Cylinder Rod End-to-Arm I— Bucket Cylinder Rod M—Boom Swing Cylinder Rod
End-to-Frame Joint Joint End-to-Boom Joint End-to-Boom Swing Joint
B—Boom-to-Frame Joint F— Boom-to-Arm Joint J— Center Link-to-Bucket Joint N—Frame-to-Boom Swing
C—Boom Cylinder Rod G—Bucket Cylinder Head K—Bucket-to-Arm Joint Cylinder Head End Joint
End-to-Boom Joint End-to-Arm Joint L— Boom Swing-to-Frame Joint
D—Arm Cylinder Head H—Side Links-to-Arm Joint
End-to-Boom Joint
NOTE: Specifications listed are for both the 27C ZTS Boom-to-Frame Joint
and 35C ZTS unless otherwise noted. Bushing—ID.................................................. 45.0 mm (1.77 in.) nominal
ID ..............................................................46.5 mm (1.83 in.) limit of use
Boom—Specification Boom-to-Arm Joint
Boom Cylinder Head Pin—OD........................................................ 45.0 mm (1.77 in.) nominal
End-to-Frame Joint OD ............................................................44.0 mm (1.73 in.) limit of use
Pin—OD........................................................ 40.0 mm (1.58 in.) nominal Boom-to-Arm Joint
OD ............................................................39.0 mm (1.54 in.) limit of use Bushing—ID.................................................. 45.0 mm (1.77 in.) nominal
Boom Cylinder Head ID ..............................................................46.5 mm (1.83 in.) limit of use
End-to-Frame Joint
Bushing—ID.................................................. 40.0 mm (1.58 in.) nominal Boom Swing—Specification
Boom Swing-to-Frame
Boom Cylinder Rod Pin—27C ZTS—OD...................................... 71.0 mm (2.80 in.) nominal
End-to-Boom Joint OD ............................................................70.0 mm (2.76 in.) limit of use
Pin—OD........................................................ 40.0 mm (1.58 in.) nominal Boom Swing-to-Frame
OD ............................................................39.0 mm (1.54 in.) limit of use Bushing—27C ZTS—ID................................ 71.0 mm (2.80 in.) nominal
Boom Cylinder Rod
End-to-Boom Joint Boom Swing-to-Frame
Bushing—ID.................................................. 40.0 mm (1.58 in.) nominal Pin—35C ZTS—OD...................................... 80.0 mm (3.15 in.) nominal
ID ..............................................................41.5 mm (1.63 in.) limit of use OD ............................................................79.0 mm (3.11 in.) limit of use
Boom-to-Frame Joint Boom Swing-to-Frame
Bushing—35C ZTS—ID................................ 80.0 mm (3.15 in.) nominal
Pin—OD........................................................ 45.0 mm (1.77 in.) nominal
OD ............................................................44.0 mm (1.73 in.) limit of use ID ..............................................................81.5 mm (3.21 in.) limit of use

100312
PN=222
Frames
Boom Swing Arm Cylinder Rod

Cylinder-to-Boom Swing End-to-Arm Joint
Pin—27C ZTS—OD...................................... 40.0 mm (1.58 in.) nominal Bushing—35C ZTS—ID................................ 45.0 mm (1.77 in.) nominal
Boom Swing
Bucket—Specification
Cylinder-to-Boom Swing
Bucket Cylinder Head
End-to-Arm Joint
Pin—27C ZTS—OD...................................... 35.0 mm (1.38 in.) nominal
Boom Swing
OD ............................................................34.0 mm (1.34 in.) limit of use
End-to-Arm Joint
Boom Swing
End-to-Arm Joint
Frame-to-Boom Swing
Cylinder Pin—27C
ZTS—OD....................................................... 40.0 mm (1.58 in.) nominal
End-to-Arm Joint
Frame-to-Boom Swing
Cylinder Bushing—27C
Bucket Cylinder Rod
ZTS—ID........................................................ 40.0 mm (1.58 in.) nominal
End-to-Side and Center
Links Joint Pin—27C
Frame-to-Boom Swing
Cylinder Pin—35C
Bucket Cylinder Rod
End-to-Side and Center
Frame-to-Boom Swing
Links Joint Bushing—27C
Cylinder Bushing—35C
Bucket Cylinder Rod
Arm—Specification End-to-Side and Center
Arm Cylinder Head Links Joint Pin—35C
End-to-Boom Joint ZTS—OD....................................................... 40.0 mm (1.58 in.) nominal
Pin—27C ZTS—OD...................................... 40.0 mm (1.58 in.) nominal OD ............................................................39.0 mm (1.54 in.) limit of use
OD ............................................................39.0 mm (1.54 in.) limit of use Bucket Cylinder Rod
Arm Cylinder Head End-to-Side and Center
End-to-Boom Joint Links Joint Bushing—35C
Bushing—27C ZTS—ID................................ 40.0 mm (1.58 in.) nominal ZTS—ID........................................................ 40.0 mm (1.58 in.) nominal
ID ..............................................................41.5 mm (1.63 in.) limit of use ID ..............................................................41.5 mm (1.63 in.) limit of use
Arm Cylinder Head Side Links-to-Arm Joint
End-to-Boom Joint Pin—27C ZTS—OD...................................... 35.0 mm (1.38 in.) nominal
Pin—35C ZTS—OD...................................... 45.0 mm (1.77 in.) nominal OD ............................................................34.0 mm (1.34 in.) limit of use
OD ............................................................44.0 mm (1.73 in.) limit of use Side Links-to-Arm Joint
Arm Cylinder Head Bushing—27C ZTS—ID................................ 35.0 mm (1.38 in.) nominal
End-to-Boom Joint ID ..............................................................36.5 mm (1.44 in.) limit of use
Bushing—35C ZTS—ID................................ 45.0 mm (1.77 in.) nominal Side Links-to-Arm Joint
ID ..............................................................46.5 mm (1.83 in.) limit of use Pin—35C ZTS—OD...................................... 40.0 mm (1.58 in.) nominal
Arm Cylinder Rod OD ............................................................39.0 mm (1.54 in.) limit of use
End-to-Arm Joint Side Links-to-Arm Joint
Pin—27C ZTS—OD...................................... 40.0 mm (1.58 in.) nominal Bushing—35C ZTS—ID................................ 40.0 mm (1.58 in.) nominal
Arm Cylinder Rod Center Link-to-Bucket
End-to-Arm Joint Joint Pin—27C
Bushing—27C ZTS—ID................................ 40.0 mm (1.58 in.) nominal ZTS—OD....................................................... 35.0 mm (1.38 in.) nominal
ID ..............................................................41.5 mm (1.63 in.) limit of use OD ............................................................34.0 mm (1.34 in.) limit of use
Arm Cylinder Rod Center Link-to-Bucket
End-to-Arm Joint Joint Bushing—27C
Pin—35C ZTS—OD...................................... 45.0 mm (1.77 in.) nominal ZTS—ID........................................................ 35.0 mm (1.38 in.) nominal

100312
PN=223
Frames
Center Link-to-Bucket Bucket-to-Arm Joint

Joint Pin—35C Bushing—27C ZTS—ID................................ 35.0 mm (1.38 in.) nominal
ZTS—OD....................................................... 40.0 mm (1.58 in.) nominal ID ..............................................................36.5 mm (1.44 in.) limit of use
OD ............................................................39.0 mm (1.54 in.) limit of use Bucket-to-Arm Joint
Center Link-to-Bucket Pin—35C ZTS—OD...................................... 40.0 mm (1.58 in.) nominal
Joint Bushing—35C OD ............................................................39.0 mm (1.54 in.) limit of use
ZTS—ID........................................................ 40.0 mm (1.58 in.) nominal Bucket-to-Arm Joint
ID ..............................................................41.5 mm (1.63 in.) limit of use Bushing—35C ZTS—ID................................ 40.0 mm (1.58 in.) nominal
Bucket-to-Arm Joint ID ..............................................................41.5 mm (1.63 in.) limit of use
CED,OUOE023,8 -19-30SEP02-3/3
Bushing and Seal Remove and Install

NOTE: Bushing can also be removed by welding three to
five weld beads on the inside of bushing. Bushing will
shrink enough to permit removal using a hammer.
1. Remove bushings (C) and dust seals using bushing,

bearing, and seal driver set.
2. Install bushings with lubrication hole aligned with
lubrication passage in pivot.
3. Install bushing to a depth equal to thickness of dust
seal (H).
4. Install dust seals with lip toward outside of component.
A—Hydraulic Ram D—Disks

B1—Pipe—Minimum ID to E—Bushing Stop (Disk)
Clear Bushing OD F— Pilot (Disk)
B2—Pipe—Maximum OD G—Ram Stop (Disk)
B3—Pipe—Length of Bushing H—Thickness of Dust Seal
C—Bushing
T95237 —UN—01NOV88
T6641CW —UN—31OCT88
CED,OUOE023,2178 -19-27JAN03-1/1

100312
PN=224
Group 3360
Hydraulic System
Hydraulic Pump Remove and Install

X9811 —UN—23AUG88

hydraulic oil tank.
2. Drain hydraulic oil tank. Approximate capacity is 30.0
L (7.9 gal).
3. Remove left side covers to access hydraulic pump.

4. Disconnect hoses (1—4). Close openings using caps

and plugs.
5. Loosen clamp (8). Disconnect hose (9).
T162980B —UN—17DEC02
Hydraulic Pump—Specification
Hydraulic
Pump—Weight................................................ 21 kg (46 lb) approximate
6. Attach shop hoist to hydraulic pump. Remove cap

screws (6) and lock washers (5). Remove hydraulic
pump (7). Hydraulic Pump
7. See Hydraulic Pump Disassemble to procedure.
(Group 3360.) 1— Pilot Pump-to-Pilot Filter 6— Cap Screw (2 used)
Inlet Port Hose 7— Hydraulic Pump
See Hydraulic Pump Assemble for procedure. (Group 2— Hydraulic Pump 8— Clamp
3360.) 3-to-Control Valve Hose 9— Hose
3— Hydraulic Pump
8. Install hydraulic pump (7), lock washers (5) and cap 2-to-Control Valve Hose
screws (6). Tighten cap screws. 4— Hydraulic Pump
1-to-Control Valve Hose
Hydraulic Pump—Specification 5— Lock Washer (2 used)
Hydraulic Pump-to-
Flywheel Housing Cover
Cap Screw—Torque....................................................... 90 N·m (67 lb-ft) Procedure must be performed whenever the
pump is installed or oil has been drained from
9. Connect hose (9). Tighten clamp (8). the pump or hydraulic oil tank.
10. Connect hoses (1—4).
11. Perform Hydraulic Pump Start-Up Procedure. (Group
IMPORTANT: Hydraulic pump will be damaged 3360.)
if not filled with oil before starting engine.
FR91424,000001F -19-28JAN03-1/1

100312
PN=225
Hydraulic System
Hydraulic Pump Disassemble
T125690 —UN—14JAN00
1— Snap Ring 15— Hose Fitting 27— Spring Pin 40— O-Ring
2— Seal 16— Pin (Stop, Long) 28— Bearing 41— O-Ring
3— Shaft 17— Ceramic Ball (2 used) 29— Spring Seat 42— O-Ring
4— Bearing 18— Piston (10 used) 30— Spring 43— Bushing
5— Snap Ring 19— Retainer 31— Spring Seat 44— Coupling
6— O-Ring (2 used) 20— Bushing 32— Pin 45— Hydraulic Pump 3
7— Plug (2 used) 21— Pin (3 used) 33— O-Ring (2 used) 46— Washer (2 used)
8— Pin 22— Cylinder Block 34— Pump Housing 47— Cap Screw (2 used)
9— Pump Housing 23— Washer (2 used) 35— Sealing Washer 48— Cap Screw (4 used)
10— Gasket 24— Spring 36— Adjusting Screw 49— O-Ring
11— Disk Spring (4 used) 25— Snap Ring 37— Nut
12— Pin (Stop, Short) 26— Valve Plate 38— Lock Washer (5 used)
13— Rod 39— Cap Screw (5 used)
14— Swash Plate

100312
PN=226
Hydraulic System
1. Remove cap screws (48), hose fitting (15), and O-ring

(49).
15— Hose Fitting 49— O-Ring

T125691 —UN—14JAN00
CED,OUOE003,21266 -19-28JAN03-2/13
NOTE: Ring (43) and coupling (44) may come off with
hydraulic pump 3 (45) or remain on hydraulic pump.
2. Remove cap screws (47), washers (46) to remove

hydraulic pump 3 (45).
T125692 —UN—14JAN00
3. Remove bushing (43) and coupling (44).
4. Remove O-rings (40—42).
NOTE: Adjusting screw controls the maximum pump flow
rate. Removal will require a test and adjustment to
get the correct setting for maximum pump flow rate.
5. Remove nut (37), sealing washer (35), and adjusting

screw (36) for inspection or replacement only.
Measure length of adjusting screw from pump housing
to end of screw to aid assembly.
T125693 —UN—14JAN00
35— Sealing Washer 42— O-Ring
36— Adjusting Screw 43— Bushing
37— Nut 44— Coupling
38— Lock Washer (5 used) 45— Hydraulic Pump 3
39— Cap Screw (5 used) 46— Washer (2 used)
40— O-Ring 47— Cap Screw (2 used)
41— O-Ring
CED,OUOE003,21266 -19-28JAN03-3/13
IMPORTANT: When separating pump housing, use

care not to drop the valve plate.
7. Separate pump housing (9 and 34).

8. Remove gasket (10) and valve plate (26).
T125694 —UN—14JAN00
9— Pump Housing 26— Valve Plate

10— Gasket 34— Pump Housing

100312
PN=227
Hydraulic System
9. Remove spring pin (27), spring seat (31) and O-ring

(33).
10. Remove bearing (28) for replacement only. Bearing
is press fit.
T125695 —UN—14JAN00
27— Spring Pin 31— Spring Seat
28— Bearing 33— O-Ring (2 used)
CED,OUOE003,21266 -19-28JAN03-5/13
11. Remove spring (30), spring seat (29) and O-ring (33).
29— Spring Seat 33— O-Ring (2 used)

30— Spring
T125696 —UN—14JAN00
CED,OUOE003,21266 -19-28JAN03-6/13
IMPORTANT: When removing rotary group,

use care not to damage cylinder block
and piston assembly.
The original pistons must be installed into
the same bores of original cylinder block
T125697 —UN—14JAN00
because of wear patterns.
12. Mark pistons (18) with respect to cylinder block (22)

bores for assembly. Remove parts (18—22).
18— Piston (10 used) 21— Pin (3 used)

19— Retainer 22— Cylinder Block
20— Bushing

100312
PN=228
Hydraulic System
CAUTION: Spring is under load. Spring must be

compressed before removing snap ring.
13. Remove snap ring (25), washers (23), and spring (24)
for inspection or replacement only. Apply force to
outer washer using a press. Remove snap ring.
T125698 —UN—14JAN00
23— Washer (2 used) 25— Snap Ring
24— Spring
CED,OUOE003,21266 -19-28JAN03-8/13

Piston to
Shoe—Clearance........................................ 0.2 mm (0.00787 in.) or less
Substract piston diameter from cylinder block bore
T164706 —UN—03FEB03
Bore—Clearance..................................... 0.050 mm (0.00197 in.) or less
T164714 —UN—03FEB03
CED,OUOE003,21266 -19-28JAN03-9/13
15. Remove swash plate (14) and ceramic balls (17).

NOTE: Pin (16) has two cavities and is longer than pin
(12). Note location of pins to aid in assembly.
16. Remove parts (11—13 and 16).

T125699 —UN—14JAN00
17. Remove plugs (7) and O-rings (6).
6— O-Ring (2 used) 13— Rod

7— Plug (2 used) 14— Swash Plate
11— Disk Spring (4 used) 16— Pin (Stop, Long)
12— Pin (Stop, Short) 17— Ceramic Ball (2 used)

100312
PN=229
Hydraulic System
18. Remove snap ring (5).
5— Snap Ring
T125700 —UN—14JAN00
CED,OUOE003,21266 -19-28JAN03-11/13
19. Remove shaft (3) using a press.
3— Shaft
T125701 —UN—14JAN00
CED,OUOE003,21266 -19-28JAN03-12/13
20. Remove snap ring (1). Remove seal (2).

21. Remove bearing (4) for replacement only. Bearing is
press fit in pump housing.
22. Remove pins (8 and 32) for replacement only.
T125702 —UN—14JAN00
23. See Hydraulic Pump Assemble.
1— Snap Ring 8— Pin

2— Seal 32— Pin
4— Bearing T125703 —UN—14JAN00
CED,OUOE003,21266 -19-28JAN03-13/13

100312
PN=230
Hydraulic System
Hydraulic Pump Assemble
T125704 —UN—14JAN00

100312
PN=231
Hydraulic System
1— Snap Ring 15— Hose Fitting 27— Spring Pin 40— O-Ring
2— Seal 16— Pin (Stop, Long) 28— Bearing 41— O-Ring
3— Shaft 17— Ceramic Ball (2 used) 29— Spring Seat 42— O-Ring
4— Bearing 18— Piston (10 used) 30— Spring 43— Bushing
5— Snap Ring 19— Retainer 31— Spring Seat 44— Coupling
6— O-Ring (2 used) 20— Bushing 32— Pin 45— Hydraulic Pump 3
7— Plug (2 used) 21— Pin (3 used) 33— O-Ring (2 used) 46— Washer (2 used)
8— Pin 22— Cylinder Block 34— Pump Housing 47— Cap Screw (2 used)
9— Pump Housing 23— Washer (2 used) 35— Sealing Washer 48— Cap Screw (4 used)
10— Gasket 24— Spring 36— Adjusting Screw 49— O-Ring
11— Disk Spring (4 used) 25— Snap Ring 37— Nut
12— Pin (Stop, Short) 26— Valve Plate 38— Lock Washer (5 used)
13— Rod 39— Cap Screw (5 used)
14— Swash Plate
CED,OUOE003,21267 -19-28JAN03-2/12
1. Install pins (8 and 32).

2. Install bearing (4) using a press.
3. Install seal (2).
4. Install snap ring (1).
T125702 —UN—14JAN00
1— Snap Ring 8— Pin
2— Seal 32— Pin
4— Bearing
T125703 —UN—14JAN00
CED,OUOE003,21267 -19-28JAN03-3/12
5. Install shaft (3) using a press.
3— Shaft
T125701 —UN—14JAN00

100312
PN=232
Hydraulic System
6. Install snap ring (5).
5— Snap Ring
T125700 —UN—14JAN00
CED,OUOE003,21267 -19-28JAN03-5/12
7. Install O-rings (6) and plugs (7).

8. Install disk springs (11) so convex side is against head
of pins (12 and 16).
9. Install pins (12 and 16) into their original bores.
T125699 —UN—14JAN00
10. Install rod (13) so the larger diameter end is towards
the swash plate (14).
11. Install ceramic balls (17) and swash plate (14).
6— O-Ring (2 used) 13— Rod

7— Plug (2 used) 14— Swash Plate
11— Disk Spring (4 used) 16— Pin (Stop, Long)
12— Pin (Stop, Short) 17— Ceramic Ball (2 used)
CED,OUOE003,21267 -19-28JAN03-6/12
12. Install washers (23) and spring (24).

13. Apply force to outer washer (23) to compress spring.
Install snap ring (25).
23— Washer (2 used) 25— Snap Ring

24— Spring
T125698 —UN—14JAN00

100312
PN=233
Hydraulic System
14. Install pins (21), bushing (20), retainer (19), and

pistons (18) into cylinder block (22) so marks on
pistons and cylinder block are aligned.
15. Install cylinder block (22).
T125697 —UN—14JAN00
18— Piston (10 used) 21— Pin (3 used)
19— Retainer 22— Cylinder Block
20— Bushing
CED,OUOE003,21267 -19-28JAN03-8/12
16. Install O-ring (33), spring seat (29) and spring (30).
29— Spring Seat 33— O-Ring (2 used)

30— Spring
T125696 —UN—14JAN00
CED,OUOE003,21267 -19-28JAN03-9/12
17. Install bearing (28) using a press.

18. Install O-ring (33), spring seat (31), and spring pin (27).
27— Spring Pin 31— Spring Seat

28— Bearing 33— O-Ring
T125695 —UN—14JAN00

100312
PN=234
Hydraulic System
IMPORTANT: Valve plate has highly machined

surfaces and can be damaged. Do not
drop valve plate.
19. Apply petroleum jelly to valve plate (26) to help hold it

in place on pump housing (34).
T125694 —UN—14JAN00
20. Install gasket (10).
21. Join pump housing (9 and 34). Pull the housings
together against the spring using M10 x 65 mm cap
screw.
9— Pump Housing 26— Valve Plate

10— Gasket 34— Pump Housing
CED,OUOE003,21267 -19-28JAN03-11/12
22. Install lock washers (38) and cap screws (39). Tighten
cap screws.
Housing-to-Housing Cap
T125693 —UN—14JAN00
23. Install adjusting screw (36), sealing washer (35) and
nut 37) so screw is to the measurement taken at
disassembly. See Hydraulic Pump 1 and 2 Regulator
Test and Adjustment—Engine Pulldown to check
maximum pump flow rate after pump is installed.
(Group 9025-25.)
24. Install O-rings (40—42).
25. Install bushing (43) and coupling (44).
26. Install hydraulic pump 3 (45), washers (46), and cap
screws (47). Tighten cap screws.
T125692 —UN—14JAN00
Hydraulic Pump
3-to-Pump Housing Cap
27. Install O-ring, hose fitting and cap screws.
35— Sealing Washer 42— O-Ring

36— Adjusting Screw 43— Bushing
37— Nut 44— Coupling
38— Lock Washer (5 used) 45— Hydraulic Pump 3
39— Cap Screw (5 used) 46— Washer (2 used)
40— O-Ring 47— Cap Screw (2 used)
41— O-Ring
CED,OUOE003,21267 -19-28JAN03-12/12

100312
PN=235
Hydraulic System
Hydraulic Pump Start-Up Procedure

IMPORTANT: Hydraulic pump will be damaged if not
filled with oil before starting engine. Procedure
must be performed whenever a new hydraulic
pump is installed or oil has been drained from
the pump or hydraulic oil tank.
Procedure is to ensure pump is filled with
oil and air is bled from suction side of
pump to prevent cavitation.
1. Add oil until it is between marks on hydraulic oil tank

sight glass. Approximate capacity is 30.0 L (7.9 gal).
See Hydraulic Oil. (Operator's Manual.)
T162991B —UN—17DEC02
2. Remove air bleed plug (1) from the top of pump
housing. Fill pump housing with hydraulic oil.
3. Install plug after pump housing is full of oil.
4. Check oil level in hydraulic oil tank. Add oil as
necessary. Tighten hydraulic oil tank cap.
5. Start engine and run at slow idle. Slowly raise boom Hydraulic Pump Air Bleed Plug
to full height and then lower to pressurize hydraulic
oil tank. 1— Air Bleed Plug
6. Purge air from the hydraulic system by starting engine

and run at slow idle. Slowly loosen air bleed plug (1)
allowing air to escape. Tighten plug when hydraulic
oil appears.
CED,OUOE003,21080 -19-07FEB03-1/1
Dampener Drive (Flex Coupling) Remove

10
and Install
1. See Hydraulic Pump Remove and Install for removal
19
CAUTION: Heavy component; use a hoist. 18
Dampener Drive (Flex Coupling)—Specification 17 19
Engine—Weight.......................................... 152 kg (335 lb) approximate
13 18
2. Support engine (10) using a service jack and wooden
22 17
block under the flywheel housing.
13
3. Remove rear engine mounts (12, 13, 16—19, 21,
and 22). 12 12
T164797 —UN—04FEB03
21
13 13
10— Engine 18— Washer (2 used)
12— Cap Screw (6 used) 19— Cap Screw (2 used) 16
13— Isolator (4 used) 21— Bracket 16
16— Holder (2 used) 22— Bracket
17— Washer (2 used)
T164797
Continued on next page JP51892,0000012 -19-29JAN03-1/2

100312
PN=236
Hydraulic System
4. Remove cap screws (1), nuts (2), and lock washers

(3) to remove cover (4). 6 7
4
5. Remove parts (5—9). 5
3
6. Replace parts as necessary. 2
8
7. Install parts. Apply thread lock and sealer (medium
strength) to cap screws (9).
9
Dampener Drive (Flex Coupling)—Specification
Flex Coupling-
T163552 —UN—23JAN03
to-Flywheel Cap
9. Install cover (4), lock washers (3), nuts (2), and cap 1
screws (1).
Dampener Drive (Flex Coupling)—Specification T163552
Cover-to-Flywheel
Housing Cap
Screw—Torque............................................................... 49 N·m (36 lb-ft) 1— Cap Screw (6 used) 6— Flex Coupling
2— Nut (2 used) 7— Plug
10. Install rear engine mounts. Tighten cap screws (12 3— Lock Washer (2 used) 8— Pin
and 19). 4— Cover 9— Cap Screw (3 used)
5— Seal
Dampener Drive (Flex Coupling)—Specification
Bracket-to-Flywheel
Housing M10 Cap
11. Install hydraulic pump. See Hydraulic Pump Remove
Engine Mount-to-
Frame M12 Cap
JP51892,0000012 -19-29JAN03-2/2
Solenoid Valve Manifold Repair

Remove and Install Solenoid Valve Manifold


hydraulic oil tank.
2. See Main Hydraulic System Line Connection to identify
hoses for assembly. (Group 9025-15.) Disconnect
T164486B —UN—23JAN03
lines (5) and wiring harness connectors (4).
1— Pilot Shut-Off Solenoid 4— Wiring Harness Connector

Valve (2 used)
2— Pilot Pressure Regulating 5— Line (5 used)
Valve 6— Propel Speed Change
3— Solenoid Valve Manifold Solenoid Valve

100312
PN=237
Hydraulic System
3. Remove cap screws (15) and bracket (14).

4. Remove plug (11). Remove cap screws (12) to
remove manifold.
5. Remove and replace parts as necessary.
Install solenoid valve manifold. Tighten cap screws.
6. Install bracket, cap screws, and plug.
7. Connect lines and connectors.
11— Plug 14— Bracket

12— Cap Screw (2 used) 15— Cap Screw (4 used)
T164489B —UN—30JAN03
Solenoid Valve Manifold Cap Screws

100312
PN=238
Hydraulic System
Disassemble and Assemble Solenoid Valve Manifold

Remove and replace parts as necessary.
Solenoid Valve Manifold—Specification
Pilot Pressure Regulating
Valve-to-Manifold
Guide—Torque................................................ 74—88 N·m (55—65 lb-ft)
Solenoid Valve Manifold—Specification
Solenoid-to-Manifold
Tube—Torque.................................................. 47—74 N·m (35—55 lb-ft)
Solenoid-to-Tube
Nut—Torque................................................................. 4.9 N·m (3.6 lb-ft)
1— Guide 8— Solenoid
2— O-Ring 9— Tube
3— Washer 10— O-Ring
4— Spring 11— Spool
5— Washer 12— Spring
6— Spool 13— Manifold
7— Nut
T164374 —UN—27JAN03
JP51892,0000026 -19-29JAN03-3/3
Pilot Controller Repair

Remove and Install Pilot Controller

1. Loosen cap to relieve air pressure from hydraulic oil

tank.
2. Remove screws (3) to Remove cover (4).
T163028B —UN—19DEC02
1— Lever 3— Screw (3 used)

2— Boot 4— Cover
Left Pilot Controller
Continued on next page TX,33,GG2415 -19-29JAN03-1/5

100312
PN=239
Hydraulic System
NOTE: Left pilot controller lever is equipped

with horn switch.
3. Remove tie band (5). Disconnect horn switch

connector (6).
T163030B —UN—19DEC02
4. Remove screws (7) and plates (8).
5— Tie Band (Left Pilot 7— Screw (4 used)

Controller Only) 8— Plate (2 used)
6— Horn Switch Connector
(Left Pilot Controller Only)
Left Pilot Controller Shown
T163032B —UN—19DEC02

100312
PN=240
Hydraulic System
5. Remove tie band (9). Loosen nut (10). Remove lever

(1) and boot (2). Remove left pilot controller lever with
horn switch wires attached.
6. Disconnect lines from pilot controller. Attach
identification tags to lines to aid assembly. See
T163034B —UN—19DEC02
Pilot Controller to Pattern Conversion Valve Line
Connection. (Group 9025-15.)
Close openings using caps and plugs.
7. Remove cap screws (12 and 13). Remove pilot
controller.
9. Install pilot controller. Tighten cap screws (12 and 13).
Pilot Controller—Specification 9— Tie Band 12— Cap Screw with Spring
10— Nut Pin (Left Pilot Controller)
Console-to-Pilot
11— Horn Switch Wires (Left 13— Cap Screw (3 used Left
Controller Cap Pilot Controller) Pilot Controller)
Screw—Torque............................................................... 20 N·m (15 lb-ft) — Cap Screw (4 used Right
Pilot Controller)
10. Connect lines to pilot controller. See Pilot Controller
to Pattern Conversion Valve Line Connection. (Group
9025-15.)
13. Install plates (8) and screws (7)
11. Install lever (1) and boot (2). Tighten nut (10).
14. Connect horn switch connector (6). Install tie band (5).
Pilot Controller—Specification
Control Lever-to-Pilot 15. Install cover (4). Tighten screws (3).
Controller Nut—Torque............................................... 140 N·m (100 lb-ft)
16. After pilot controller is installed, check operation of all
12. Route horn switch wires as shown (11). Install tie functions to be sure they operate as expected.
band (9).

100312
PN=241
Hydraulic System
Disassemble and Assemble Pilot Controller
13
12
14
11
15
11
10
8
9
7
16
21
21
5
20
6 20
19
3
4
18
2
1 T143186 —UN—17JUL01
17
T143186
1— Spacer (4 used) 6— Return Spring B (2 used) 12— Cam 19— O-Ring

2— Shim (As required) 7— Snap Ring (4 used) 13— Coupling 20— Dowel Pin (2 used)
3— Balance Spring A (2 used) 8— Pusher A (2 used) 14— U-Joint 21— O-Ring (2 used)
4— Balance Spring B (2 used) 9— Pusher B (2 used) 15— Oil Seal (4 used)
5— Return Spring A (2 used) 10— Block 16— Spring Guide (4 used)
11— Cap Screw (2 used) 17— Spool (4 used)
18— Housing
IMPORTANT: The housing (18) and spools (17) are same port from which it was removed. The port
replaced as an assembly because the spools numbers are stamped on the housing.
are select fitted to bores in housing.
Note port location and quantity of shims
Some parts from ports 1 and 3 are different than (2) when removing. Same number of shims
parts from ports 2 and 4. Parts for each port must be used when installing.
must be kept together and installed into the Continued on next page TX,33,GG2415 -19-29JAN03-4/5

100312
PN=242
Hydraulic System
1. Remove parts from housing. Remember to keep parts Pilot Controller—Specification

removed from each port together. Identify each group Block-to-Housing Cap
of parts by port numbers stamped on housing. Screw—Torque......................................................... 19.6 N·m (14.5 lb-ft)
Remove U-joint (14) only for replacement. Thread lock 7. Apply multi-purpose grease to the end of each pushers
and sealer (medium strength) is used on the threaded (8 and 9) and to the joint of U-joint (14).
end of U-joint in block.
8. Install cam (12) on U-joint (14). Adjust clearance
2. Repair or replace parts as necessary. between pushers (8 and 9) and cam.
3. Install parts. Install spring guides (16) with protrusion Pilot Controller—Specification
facing up. Cam-to-Pusher—Clear-
ance................................................................0—0.20 mm (0—0.008 in.)
4. Apply multi-purpose grease to oil seals.
5. Install pushers (8 and 9). Pushers with grooves go Hold cam (12) and tighten coupling (1).
into ports 1 and 3. Pushers without grooves go into Pilot Controller—Specification
ports 2 and 4. Coupling-to-Cam and
U-Joint—Torque.......................................................... 88.2 N·m (65 lb-ft)
6. Tighten cap screw (11).
TX,33,GG2415 -19-29JAN03-5/5

100312
PN=243
Hydraulic System
Propel Pilot Controller Repair

Remove and Install Propel Pilot Controller


2. Disconnect connectors (1).
3. Remove left and right propel pressure sensors (2).
T124711 —UN—29OCT99
4. Disconnect lines (3—8). Attach identification tags to
lines to aid assembly. See Propel Hydraulic System
Line Connection.
Install plugs and caps.
5. Remove cap screws (11) to remove levers and pedals
(10).
6. Remove cap screws (12) to remove propel pilot
controller (9).
8. Tighten cap screws (12).
T124712 —UN—29OCT99
Propel Pilot Controller—Specification
Controller-to-Cab
Platform Cap
9. Tighten cap screws (11).

Propel Pilot Controller—Specification
Lever and Pedal-to-Cam 1— Connector (2 used) 7— Propel Pilot Controller 1
Cap Screw—Torque....................................................... 30 N·m (22 lb-ft) 2— Propel Pressure Switch (2 Port-to-Propel Left Control
used) Valve Left-Side Port
10. After propel pilot controller is installed, check that all 3— Propel Pilot Connector 8— Propel Pilot Controller 2
functions operate correctly. P Port-to-Pilot Shut-Off Port-to-Propel Left Control
Solenoid Valve A Port Valve Right-Side Port
4— Propel Pilot Controller T 9— Propel Pilot Controller
Port-to-Tank 10— Lever and Pedal (2 used)
5— Propel Pilot Controller 11— Cap Screw (4 used)
3 Port-to-Propel Right 12— Cap Screw (4 used)
Control Valve Left-Side Port
6— Propel Pilot Controller
4 Port-to-Propel Right
Control Valve Right-Side
Port

100312
PN=244
Hydraulic System
Propel Pilot Controller Disassemble and Assemble
T124709 —UN—29OCT99

100312
PN=245
Hydraulic System
1— Set Screw (2 used) 10— Bushing 22— Spring Seat (4 used) 31— Push Rod (4 used)
2— Shaft (2 used) 11— Ball 23— Spring (4 used) 32— Steel Ball (4 used)
3— Cam (2 used) 12— Seat 24— Spring (4 used) 33— Boot (2 used)
4— Grease Cup (4 used) 13— Seat 25— Piston (4 used) 34— Bushing (4 used)
5— Damper Housing 14— Housing 26— O-Ring (4 used) 35— Plug (6 used)
6— Ball (12 used) 15— Spool (4 used) 27— Cover (2 used) 36— O-Ring (2 used)
7— O-Ring (4 used) 16— O-Ring (3 used) 28— Cap Screw (4 used)
8— Inner Spring (4 used) 17— Plug (3 used) 29— Plug (4 used)
9— Outer Spring (4 used) 18— Washer (4 used) 30— Packing (4 used)
19— Shim (4 used)
20— O-Ring (2 used)
21— Plug (2 used)
1. Remove boots (33). 10. Remove O-rings (7 and 36).

2. Take notice of part location with respect to its mating IMPORTANT: The spool assemblies are adjusted for
part for assembly. equal pressure using shims. The shims and
3. Remove set screws (1). Thread lock and sealer washers must be kept with it respective spool.
(medium strength) is used on the threads of set screws. The spools must be installed into the same
4. Remove shafts (2) to remove cams (2). Steel balls port from which it was removed. The port
(32) cannot be removed. numbers are stamped on the housing.
5. Remove cap screws (28), covers (27), and damper 11. Remove spool (15), inner spring (8), washer (18), and
casing (5). shim (19) assemblies and outer springs (9). Keep
parts for each spool together.
6. Remove push rods (31), grease cups (4), and
packings (30). 12. Remove plugs (17) and O-rings (16).
7. Remove plugs (29) and O-rings (26). 13. Remove plugs (35).
8. Remove pistons (25) and springs (24). 14. Remove parts (10—13, 20, and 21).
9. Remove spring seats (23) and steel balls (6). 15. Repair or replace parts as necessary.

100312
PN=246
Hydraulic System
T124708 —UN—29OCT99
1— Set Screw (2 used) 10— Bushing 22— Spring Seat (4 used) 31— Push Rod (4 used)
2— Shaft (2 used) 11— Ball 23— Spring (4 used) 32— Ball (4 used)
3— Cam (2 used) 12— Seat 24— Spring (4 used) 33— Boot (2 used)
4— Grease Cup (4 used) 13— Seat 25— Piston (4 used) 34— Bushing (4 used)
5— Damper Housing 14— Housing 26— O-Ring (4 used) 35— Plug (6 used)
6— Ball (12 used) 15— Spool (4 used) 27— Cover (2 used) 36— O-Ring (2 used)
7— O-Ring (4 used) 16— O-Ring (3 used) 28— Cap Screw (4 used)
8— Inner Spring (4 used) 17— Plug (3 used) 29— Plug (4 used)
9— Outer Spring (4 used) 18— Washer (4 used) 30— Packing (4 used)
19— Shim (4 used)
20— O-Ring (2 used)
21— Plug (2 used)
16. Install parts (10—13, 20, and 21). 18. Install plugs (17) and O-rings (16).
17. Install plugs (35).

100312
PN=247
Hydraulic System
IMPORTANT: The spool assemblies are adjusted for 28. Apply hydraulic oil to push rods (31). before pushing
equal pressure using shims. The shims and rods through the packing in plugs.
29. Install plugs and push rods into damper housing.
port from which it was removed. The port 30. Install damper housing (5) and covers (27).
numbers are stamped on the housing. 31. Tighten cap screws (28).
19. Install washer (18), shim (19), and inner spring (8) Propel Pilot Controller—Specification
onto spool (15). Make sure washers and shims are Covers and Damper
installed on their original spool. Housing-to-Housing Cap
20. Compress the spring just enough to install spring
seats (22) onto spools through the larger diameter hole. 32. Install the grease cups (4) on the push rods. Fill cups
with grease.
21. Install outer springs (9).
22. Carefully install spool (15) assemblies into the same cam so hole in shaft aligns with tapped hole in cam.
ports from which they were removed.
23. Install O-rings (7 and 36). threads of set screws (1). Tighten set screws.
24. Install balls (6) and spring seats (23). Propel Pilot Controller—Specification
Cam-to-Shaft Set
25. Install springs (24) and pistons (25). Screw—Torque............................................................... 5 N·m (44 lb-in.)
26. Install O-rings (26) on plugs (29). 35. Install boots (33).
27. Apply grease to packings (30). Install packings in plug
so lip is towards the flange end of plug.
CED,OUOE003,21210 -19-29JAN03-5/5

100312
PN=248
Hydraulic System
Auxiliary Pilot Controller Repair

Remove and Install Auxiliary Pilot Controller


2. Remove front cover for access to lines (36).
3. Disconnect lines. Identify lines for assembly.
T163606 —UN—23JAN03
4. Remove cap screws (30) and pedal (33).
5. Remove cap screws (38) to remove auxiliary pilot
controller (34).
7. Install controller. Tighten cap screws.
Auxiliary Pilot Controller—Specification
Housing-to-Plate Cap
30— Cap Screw (2 used) 35— Plate
31— Cap Screw (2 used) 36— Line (4 used)
32— Cover 37— Cap Screw (2 used)
8. Connect lines. 33— Pedal 38— Cap Screw (2 used)
34— Auxiliary Pilot Controller
9. Install pedal. Tighten cap screws.
Pedal-to-Cam Cap

100312
PN=249
Hydraulic System
Disassemble and Assemble Auxiliary Pilot Controller
1
12
2 12
3
13
4 13
14
5
15 14
16
15
16
6
7 5 17
17
18
6 19 18
20
8
9
9
10 21
10
11
11
T160028 —UN—07OCT02
T160028

100312
PN=250
Hydraulic System
Remove shaft (7) to remove cam (3) from cover (8).. 11. Apply grease to packings (9). Install packing in plugs
FR91424,0000017 -19-30JAN03-3/3

100312
PN=251
Hydraulic System
Boom Swing Pilot Controller Repair

Remove and Install Boom Swing Pilot Controller


2. Remove front cover for access to lines (36).
3. Disconnect lines. Identify lines for assembly.
T163606 —UN—23JAN03
4. Remove cap screws (30) and pedal (33).
5. Remove cap screws (38) to remove auxiliary pilot
controller (34).
7. Install controller. Tighten cap screw.
Boom Swing Pilot Controller—Specification
Housing-to-Plate Cap
30— Cap Screw (2 used) 35— Plate
31— Cap Screw (2 used) 36— Line (4 used)
32— Cover 37— Cap Screw (2 used)
8. Connect lines. 33— Pedal 38— Cap Screw (2 used)
34— Boom Swing Pilot
9. Install pedal. Tighten cap screws. Controller
Pedal-to-Cam Cap
Continued on next page JP51892,0000014 -19-03FEB03-1/3

100312
PN=252
Hydraulic System
Disassemble and Assemble Boom Swing

Pilot Controller
1
12
2 12
3
13
4 13
14
5
15 14
16
15
16
6
7 5 17
17
18
6 19 18
20
8
9
9
10 21
10
11
11
T160028 —UN—07OCT02
T160028

100312
PN=253
Hydraulic System
Remove shaft (7) to remove cam (3) from cover (8). 11. Apply grease to packings (9). Install packing in plugs
JP51892,0000014 -19-03FEB03-3/3

100312
PN=254
Hydraulic System
Control Valve Remove and Install

X9811 —UN—23AUG88

2. Pull a vacuum in hydraulic oil tank using a vacuum
pump or drain hydraulic oil tank. Approximate oil
capacity is 28.0 L (7.4 gal).
4. Perform Platform Remove and Install. (Group 1800.)

5. Identify lines for assembly. Disconnect lines. See

Control Valve Operation. (Group 9025-05.) Install
T164767B —UN—29JAN03
caps and plugs.

Control Valve—Specification
Control Valve—Weight.................................... 35 kg (77 lb) approximate
6. Remove cap screws (10) to remove the control valve

Control Valve
and plate. The pilot controller pattern conversion valve
and the one way/two way valve can be left attached
to the plate. 10— Cap Screws (4 used) 11— Cap Screws (4 used)
7. Remove cap screws (11) and lift control valve off the
plate.
8. Repair or replace parts as necessary. See Control Mounting Plate-to-
Valve Disassemble and Assemble. (Group 3360.) Main Frame Cap
9. Install control valve.
12. Connect lines.
10. Install cap screws (11).
Control Valve—Specification 13. Check oil level in the hydraulic oil tank. See Check
Mounting Plate-to- Hydraulic Oil Tank Level. (Operator's Manual.) Add oil
Control Valve Housing as necessary. See Hydraulic Oil. (Operator's Manual.)
Cap Screw—Torque....................................................... 50 N·m (37 lb-ft) 14. Perform Hydraulic Pump Start-Up Procedure. (Group
11. Install the control valve and plate. Tighten cap screws 3360.)
(10).
JP51892,0000027 -19-29JAN03-1/1

100312
PN=255
Hydraulic System
Control Valve Disassemble and Assemble
T163354 —UN—23JAN03
Control Valve—Rear Sections

100312
PN=256
Hydraulic System
1— Bucket Control Valve 29— Not Used 58— Spring 87— Guide
2— Cover 30— Boom Control Valve 59— Plug 88— Spring
3— Cap Screw (2 used) 31— Cover 60— O-Ring 89— Guide
4— Guide 32— Cap Screw (2 used) 61— Spool 90— Cap Screw (2 used)
5— Spring 33— Guide 62— Sleeve 91— Cover
6— Guide 34— Spring 63— Backup Ring 92— O-Ring
7— O-Ring 35— Guide 64— O-Ring 93— Housing
8— Spool 36— O-Ring 65— O-Ring 94— Not Used
9— Circuit Relief Valve 37— Spool 66— Backup Ring 95— Inlet Section
10— Plug 38— Circuit Relief Valve 67— Poppet 96— Plug
11— O-Ring 39— Circuit Relief Valve 68— Valve Seat 97— Filter
12— Spring 40— Plug 69— Spring 98— Cover
13— Poppet 41— Plug 70— Cap Screw (5 used) 99— Cap Screw (2 used)
14— Plug 42— O-Ring 71— Housing 100— O-Ring
15— O-Ring 43— Spring 72— O-Ring 101— Spool
16— Spring 44— Poppet 73— Not Used 102— System Relief Valve
17— Poppet 45— Poppet 74— Not Used 103— O-Ring
18— Circuit Relief Valve 46— Spring 75— Left Propel Control Valve 104— Plug
19— O-Ring 47— O-Ring 76— Cover 105— System Relief Valve
20— Guide 48— Backup Ring 77— Cap Screw (2 used) 106— O-Ring
21— Spring 49— Spacer 78— Guide 107— Cap Screw (2 used)
22— Guide 50— O-Ring 79— Spring 108— Cover
23— Cap Screw (2 used) 51— O-Ring 80— Guide 109— Plug
24— Cover 52— Guide 81— O-Ring 110— O-Ring
25— Stud (4 used) 53— Spring 82— Spool 111— Housing
26— Nut (4 used) 54— Guide 83— Spring
27— Housing 55— Housing 84— Poppet
28— Not Used 56— Plug 85— Plug
57— Piston 86— O-Ring

100312
PN=257
Hydraulic System
T163355 —UN—24JAN03
Control Valve—Middle Sections

100312
PN=258
Hydraulic System
115— Right Propel Control Valve 138— Guide 163— Housing 189— Cap Screw (2 used)
116— Cover 139— Spring 164— Not Used 190— Cover
117— Cap Screw (2 used) 140— O-Ring 165— Auxiliary Control Valve 191— Housing
118— Guide 141— Guide 166— Cover 192— Not Used
119— Spring 142— Spool 167— Cap Screw (2 used) 193— Not Used
120— Guide 143— Circuit Relief Valve 168— Guide 194— Not Used
121— O-Ring 144— O-Ring 169— Spring 195— Auxiliary Flow Combiner
122— Spool 145— O-Ring 170— O-Ring Section
123— O-Ring 146— O-Ring 171— Guide 196— Cover
124— Plug 147— Plug 172— Spool 197— Cap Screw (2 used)
125— O-Ring 148— O-Ring 173— Plug 198— Guide
126— Guide 149— Spring 174— O-Ring 199— Spring
127— Spring 150— Poppet 175— Plug 200— O-Ring
128— Guide 151— Circuit Relief Valve 176— O-Ring 201— Guide
129— Cap Screw (2 used) 152— O-Ring 177— Spring 202— Spool
130— Cover 153— Guide 178— Poppet 203— Plug
131— Poppet 154— Spring 179— Plug 204— Plug
132— Spring 155— Guide 180— O-Ring 205— O-Ring
133— Housing 156— Cap Screw (2 used) 181— Spring 206— Cap Screw (2 used)
134— Not Used 157— Cover 182— Plug 207— Cover
135— Arm Control Valve 158— Plug 183— Plug 208— Housing
136— Cover 159— Poppet 184— Plug
137— Cap Screw (2 used) 160— Spring 185— O-Ring
161— O-Ring 186— Guide
162— Plug 187— Spring
188— Guide

100312
PN=259
Hydraulic System
T163356 —UN—23JAN03
Control Valve—Front Sections

100312
PN=260
Hydraulic System
215— Boom Swing Control Valve 239— Not Used 263— Not Used 287— Not Used
216— Cover 240— Swing Control Valve 264— Not Used 288— Not Used
217— Cap Screw (2 used) 241— Cover 265— Blade Control Valve 289— Not Used
218— Guide 242— Cap Screw (2 used) 266— Cover 290— Flow Combiner Valve
219— Spring 243— Guide 267— Cap Screw (2 used) 291— Cover
220— Guide 244— Spring 268— Guide 292— Cap Screw (2 used)
221— O-Ring 245— Guide 269— Spring 293— Guide
222— Spool 246— O-Ring 270— Guide 294— Spring
223— Poppet 247— Spool 271— O-Ring 295— Guide
224— Spring 248— Plug 272— Spool 296— O-Ring
225— Plug 249— O-Ring 273— Plug 297— Spool
226— O-Ring 250— Spring 274— O-Ring 298— System Relief Valve
227— Spring 251— Poppet 275— Spring 299— Nut (4 used)
228— Poppet 252— O-Ring 276— Poppet 300— Plug
229— O-Ring 253— Guide 277— O-Ring 301— O-Ring
230— Guide 254— Spring 278— Guide 302— Cap Screw (2 used)
231— Spring 255— Guide 279— Spring 303— Plug
232— Guide 256— Cap Screw (2 used) 280— Guide 304— Cover
233— Cap Screw (2 used) 257— Cover 281— Cap Screw (2 used) 305— O-Ring
234— Cover 258— O-Ring 282— Cover 306— Housing
235— O-Ring 259— Housing 283— O-Ring
236— Housing 260— Not Used 284— Housing
237— Not Used 261— Not Used 285— Not Used
238— Not Used 262— Not Used 286— Not Used
NOTE: Complete control valve must be removed from 3. Remove circuit relief valves (9, 18, 38, 39, 143 and
machine to remove individual valve sections. 151).
1. See Control Valve Remove and Install for removal 4. Remove nuts (26) and studs (25) to disassemble the
procedure. (Group 3360.) control valve into sections.
2. Remove system relief valves (102, 105 and 298).

100312
PN=261
Hydraulic System
147 148
149
150
155 157 152 141 137

139 136
140 138
T163430 —UN—24JAN03
154 156 153
142
159 135
T163430
Arm Control Valve Section Shown

100312
PN=262
Hydraulic System
IMPORTANT: Because spools are fitted to a bore and

the design is different for each section, spools 135
must be installed into the same bores from
which they were removed for proper operation. 146
Spools are disassembled for inspection and
cleaning only. Each spool and housing is
serviced as an assembly. 145
5. Spool Disassemble And Assemble: 159
a. Remove parts (136—142, 150, and 152—157). 310
T163449 —UN—24JAN03
160
b. Replace parts as necessary.
161
c. Install parts.
d. Tighten cap screws (137 and 156).
Control Valve—Specification T163449 162
Arm Regenerative Valve
Screw—Torque................................................ 7—10 N·m (61—87 lb-in.)
6. Arm Regenerative Valve, Check Valve, and Orifice 135— Arm Control Valve 152— O-Ring
Disassemble And Assemble: Housing 153— Guide
136— Cover 154— Spring
a. Remove parts (145—150 159—162, and 310). 137— Cap Screw (2 used) 155— Guide
138— Guide 156— Cap Screw (2 used)
b. Replace parts as necessary. 139— Spring 157— Cover
140— O-Ring 159— Arm Regenerative Valve
c. Install orifice. 141— Guide Poppet
142— Spool 160— Spring
147— Plug 161— O-Ring
Arm Regenerative 148— O-Ring 162— Plug
Valve Orifice to 149— Spring 310— Orifice
Housing—Torque............................................................ 2 N·m (17 lb-in.) 150— Lift Check Poppet
d. Apply grease to O-rings.

e. Install parts. Control Valve—Specification
Plug to Boom Reduce
Leakage Valve
Arm Regenerative
Housing—Torque......................................................... 29.4 N·m (22 lb-ft)
Valve Plug to
Housing—Torque......................................................... 29.4 N·m (22 lb-ft) f. Tighten plug (56) into plug (59).
Control Valve—Specification Control Valve—Specification
Lift Check Plug to Piston and Spring Plug to
Housing—Torque......................................................... 29.4 N·m (22 lb-ft) Boom Reduce Leakage
Valve Plug—Torque..................................................... 29.4 N·m (22 lb-ft)
7. Boom Reduce Leakage Valve Disassemble And
Assemble: 8. Tighten system relief valves (102, 105 and 298).
a. Remove cap screws (70) to remove housing (55) Control Valve—Specification
from boom control valve (30). System Relief Valve to
Valve Housing—Torque................................... 59—69 N·m (43—51 lb-ft)
b. Remove parts (45—69).
9. Tighten circuit relief valves (9, 18, 38, 39, 143 and 151).
c. Replace parts as necessary.
d. Tighten cap screws (70). Circuit Relief Valve to
Valve Housing—Torque................................... 59—69 N·m (43—51 lb-ft)
Boom Reduce Leakage 10. Tighten nuts (26) and studs (25).
Valve Housing-to-Boom
Control Valve Housing Control Valve—Specification
Cap Screw—Torque........................................ 7—10 N·m (61—87 lb-in.) Housing-to-Housing Stud
and Nut—Torque....................................... 26.5—28.4 N·m (20—21 lb-ft)
e. Tighten plug (59).
JP51892,0000010 -19-04FEB03-8/8

100312
PN=263
Hydraulic System
11. See Control Valve Remove and Install for installation.

(Group 3360.)
JP51892,0000010 -19-04FEB03-9/8

Repair
Remove and Install Pilot Controller Pattern
Conversion Valve

1. Loosen cap to relieve the air pressure in hydraulic

oil tank.
T159921B —UN—27SEP02
2. Disconnect hydraulic lines. Identify lines for assembly.
See Control Valve Operation and See Pilot Controller
to Pattern Conversion Valve Line Connection.
3. Remove cap screws (2 and 3) to remove pilot
controller pattern conversion valve (1).
5. Install cap screws (2 and 3).
1— Pilot Controller Pattern 3— Cap Screw (4 used)
6. Connect hydraulic lines. Conversion Valve
Oil. (Operator's Manual.)
Continued on next page TX19495,0000002 -19-27SEP02-1/3

100312
PN=264
Hydraulic System
Disassemble and Assemble Pilot Controller

Pattern Conversion Valve
T155889 —UN—17JUN02
Continued on next page TX19495,0000002 -19-27SEP02-2/3

100312
PN=265
Hydraulic System
0— Pilot Controller Pattern 5— Cover 12— Packing 18— Ring

Conversion Valve 6— Plug 13— Backup Ring 19— Rivet
1— Housing 7— Handle 14— Bolt 20— Housing
2— Spindle 8— Spring 15— Spring Pin 21— Seal Kit
4— Cover 9— Detent Ball 17— Identification Plate
10— Packing
11— O-Ring
Remove plug (6), spring (8), and detent ball (9) before
removing spindle (2) from housing (1).
TX19495,0000002 -19-27SEP02-3/3
One Way/Two Way Valve Remove and Install

X9811 —UN—23AUG88

2. Pull a vacuum in hydraulic tank using a vacuum pump
or drain hydraulic oil tank. Approximate capacity is
30.0 L (7.9 gal).

under pressure, stop engine, and relieve the
3. Disconnect hydraulic lines (1—3).

4. Remove cap screws, lock washers, washers, and nuts
(4).
5. Remove one way/two way valve.
7. Install one way/two way valve.
1— Hydraulic Oil Tank B 3— One Way/Two Way A

Hose-to-One Way/Two Way Hose Left Port-to-Auxiliary
Valve Right Port Line Manifold Top Rear Port Line
2— One Way/Two Way by 4— Cap Screw, Lock Washer,
T126484 —UN—14JAN00
Hose Top Port-to-Auxiliary Washer, and Nut (2 used)

Control Valve Top Left Port
Line
CED,OUOE003,21068 -19-23DEC02-1/1

100312
PN=266
Hydraulic System
Hydraulic Oil Tank Remove and Install

T159961B —UN—10OCT02

NOTE: Filter replacement does not require draining
and removing the hydraulic oil tank.
2. See Replace Hydraulic Oil Tank Filter for filter

replacement. (Operator's Manual.)
1— Line 3— Line
3. Disconnect lines (1—4) at front side of tank. 2— Line 4— Line
Continued on next page CED,OUOE003,21214 -19-03FEB03-1/3

100312
PN=267
Hydraulic System
T155507 —UN—11JUN02

100312
PN=268
Hydraulic System
0— Hydraulic Oil Tank 10— Drain Plug 22— Filler Cap 38— Bracket
1— Strainer (Suction Screen) 11— Strainer, Rod, and Nuts 24— Manifold 39— Cap Screw, Lock Washer,
2— Cap Screw (4 used) 12— O-Ring 25— Cap Screw, Lock Washer, and Washer (2 used)
3— Washer (4 used) 13— Cover and Washer (4 used) 41— Shim (2 used)
4— Rod 14— Cap Screw and Lock Washer 26— O-Ring 42— Cap Screw, Lock Washer,
5— Nut (3 used) (6 used) 28— Adapter and O-Ring and Washer (2 used)
6— Clip 16— Filter Element 29— Elbow and O-Ring
7— Hose 17— Bypass Valve 30— Fitting and O-Ring
8— Level Gauge 18— Spring 34— Cover
8A—Cap Screw (2 used) 19— O-Ring 35— Packing
9— Washer (4 used) 20— Cover 37— Cap Screw (2 used)
21— Cap Screw and Lock Washer
(4 used)
4. Remove plug (10) to drain hydraulic oil tank. 10. Install hydraulic oil tank.
Approximate oil capacity is 30.0 L (7.9 gal).
11. Add hydraulic oil to tank until it is between marks on
5. See Change Hydraulic Tank Oil, Clean Suction Screen sight glass. See Check Hydraulic Oil Tank Level for
for removal and installation of strainer, rod, and nuts procedure. (Operator's Manual.) See Hydraulic Oil for
(11). (Operator's Manual.) correct oil to use. (Operator's Manual.)
6. Disconnect lines at manifold (24) and the suction tube. IMPORTANT: Hydraulic pump will be damaged if not
Identify lines for assembly filled with oil before starting. Procedure must be
7. Remove cap screws (39 and 42) to remove bracket performed to fill pump housing whenever oil has
(38) and shim (41). been drained from the pump or hydraulic oil tank.
8. Remove cap screws (2) and washers (3) to remove 12. Perform Hydraulic Pump Start-Up Procedure. (Group
hydraulic oil tank (0). 3360.)
CED,OUOE003,21214 -19-03FEB03-3/3

100312
PN=269
Hydraulic System
Boom Cylinder Disassemble and Assemble
T159624 —UN—01OCT02
1— Rod 10— Connector Ring 18— Cushion 27— Dust Seal (4 used)
2— Wiper Seal 11— Snap Ring 19— Wear Ring 28— Bushing
3— Rod Guide 12— Retainer 20— Piston 29— Grease Fitting
4— O-Ring 13— Backup Ring 21— Steel Ball 30— Bushing
5— Backup Ring 14— O-Ring 22— Set Screw 31— Grease Fitting
6— O-Ring 15— Cushion Ring 23— O-Ring
7— Bushing 16— Spacer 24— Cap Seal
8— Backup Ring—35C ZTS Only 17— Snap Ring 25— Wear Ring
9— U-Cup Seal 26— Cylinder Barrel
Boom Cylinder—35C
CAUTION: Heavy component, use a hoist. ZTS—Weight................................................... 35 kg (77 lb) approximate
Boom Cylinder—Specification
Boom Cylinder—27C 1. Fasten head end of cylinder to cylinder service stand.

100312
PN=270
Hydraulic System
27
17
16
15
14
13
27
12
28
1
11
10
9
8
29
7
6
5
4
3
2
27
25 30
24
23 26
22
21
20 27
19
18
31
T159623 —UN—04FEB03
T159623

100312
PN=271
Hydraulic System
1— Rod 10— Connector Ring 18— Cushion 27— Dust Seal (4 used)
2— Wiper Seal 11— Snap Ring 19— Wear Ring 28— Bushing
3— Rod Guide 12— Retainer 20— Piston 29— Grease Fitting
4— O-Ring 13— Backup Ring 21— Steel Ball 30— Bushing
5— Backup Ring 14— O-Ring 22— Set Screw 31— Grease Fitting
6— O-Ring 15— Cushion Ring 23— O-Ring
7— Bushing 16— Spacer 24— Cap Seal
8— Backup Ring—35C ZTS Only 17— Snap Ring 25— Wear Ring
9— U-Cup Seal 26— Cylinder Barrel
2. Bend the crimp from notch in rod guide (3) being 17. Install retainer (12), connector (10), and snap ring (11).
careful not to damage the end of cylinder barrel (26).
18. Install O-ring (23) and cap seal (24). Check that O-ring
IMPORTANT: Carefully remove components so is not twisted.
as not to damage piston rod or sliding
surfaces during disassembly. 19. Install wear rings (25 and 19) so the splits are offset.
3. Pull rod (1) out approximately 200 mm (8 in.). Loosen 20. Install rod guide (3) onto rod (1).
rod guide (3) using JDG28 Spanner Wrench. 21. Install cushion (18) tapered end first. Install piston
4. Attach rod to a hoist using a lifting strap. (20). Tighten piston.
5. Pull rod and piston (20) from cylinder barrel (26).
Piston-to-Rod—27C
6. Remove the staking from piston and set screw (22). ZTS—Torque.............................................................. 686 N·m (506 lb-ft)
Remove set screw and steel ball (21). Piston-to-Rod—35C
7. Remove piston (22), and cushion (18).
22. Install steel ball (21) and set screw (22). Tighten set
8. Remove rod guide. screw. Stake the set screw head in two places to
IMPORTANT: Take care not to damage other prevent loosening.
parts when removing seals. Boom Cylinder—Specification
Piston-to-Rod
Do not reuse wear rings (19 and 25), cap Set Screw—27C
seal (24) and O-ring (23). ZTS—Torque............................................................... 6.9 N·m (65 lb-in.)
Piston-to-Rod
9. Repair or replace parts as necessary. Set Screw—35C
10. Clean and dry parts to be reuse. Apply a light film of ZTS—Torque........................................................... 16.7 N·m (148 lb-in.)
clean hydraulic oil to all sealing parts and machined 23. Install rod and piston. Make sure wear rings do not
surfaces. come off while installing rod and piston.
11. Install bushing (7) so it is even with the end of rod 24. Tighten rod guide.
guide. Bushing is a press fit.
12. Install backup ring—35C ZTS (8). Install U-cup seal Rod Guide-to-Cylinder
(9) so flat side is towards the rod end. Barrel—27C
13. Install wiper seal (2) so lip is towards the outside of
Rod Guide-to-Cylinder
rod guide.
Barrel—35C
14. Install O-ring (6), backup ring (5), and O-ring (4). ZTS—Torque.............................................................. 333 N·m (246 lb-ft)
15. Install cushion ring (15). Install spacer (16) so notches 25. Crimp the edge of cylinder barrel into the notch in rod
are towards the cushion ring. Install snap ring (17). guide using a punch and hammer.
16. Install O-ring (14) and backup ring (13).
CED,OUOE003,21219 -19-13JAN00-3/3

100312
PN=272
Hydraulic System
Arm Cylinder Disassemble and Assemble
T159627 —UN—10OCT02
1— Rod 8— U-Cup Seal 15— Cushion 22— Wear Ring
2— Wiper Seal 9— Bushing 16— Wear Ring 23— Cushion
3— Rod Guide 10— Backup Ring 17— Piston 24— Washer
4— O-Ring 11— O-Ring 18— Steel Ball 25— Cap Screw
5— Backup Ring 12— Cushion Ring 19— Set Screw 26— Cylinder Barrel
6— O-ring 13— Spacer 20— Cap Seal
7— Backup Ring—35C ZTS Only 14— Snap Ring 21— O-Ring
Arm Cylinder—35C
CAUTION: Heavy component, use a hoist. ZTS—Weight................................................... 33 kg (73 lb) approximate
Arm Cylinder—Specification
Arm Cylinder—27C 1. Fasten head end of cylinder to cylinder service stand.

100312
PN=273
Hydraulic System
T159625 —UN—01OCT02

100312
PN=274
Hydraulic System
1— Rod 8— U-Cup Seal 15— Cushion 22— Wear Ring

2— Wiper Seal 9— Bushing 16— Wear Ring 23— Cushion
3— Rod Guide 10— Backup Ring 17— Piston 24— Washer
4— O-Ring 11— O-Ring 18— Steel Ball 25— Cap Screw
5— Backup Ring 12— Cushion Ring 19— Set Screw 26— Cylinder Barrel
6— O-ring 13— Spacer 20— Cap Seal
7— Backup Ring—35C ZTS Only 14— Snap Ring 21— O-Ring
2. Bend the crimp from notch in rod guide (3) being

careful not to damage the end of cylinder barrel (26). 19. Install wear rings (22 and 16) so the splits are offset.
IMPORTANT: Carefully remove components so 20. Install rod guide (3) onto rod (1).
as not to damage piston rod or sliding 21. Install cushion (15) tapered end first. Install piston
surfaces during disassembly. (17). Tighten piston.
3. Pull rod (1) out approximately 200 mm (8 in.). Loosen Arm Cylinder—Specification
rod guide (3) using JDG28 Spanner Wrench. Piston-to-Rod—27C
4. Attach rod to a hoist using a lifting strap. Piston-to-Rod—35C
5. Pull rod and piston from cylinder barrel (26).
6. Heat cap screw (25) for 10 to 15 seconds to loosen screw. Stake the set screw head in two places to
the thread lock and sealer (high strength). prevent loosening.
Remove cap screw to remove washer (24) and Arm Cylinder—Specification
cushion (23). Piston-to-Rod
Set Screw—27C
7. Remove the staking from piston and set screw (19).
ZTS—Torque............................................................... 6.9 N·m (65 lb-in.)
Remove set screw and steel ball (18).
Piston-to-Rod
8. Remove piston (17), and cushion (15). Set Screw—35C
9. Remove rod guide.
23. Install cushion (23) so tapered end is towards
IMPORTANT: Take care not to damage other threaded of rod. Apply T43513 Thread Lock and
parts when removing seals. Sealer (High Strength) to cap screw (25). Install
Do not reuse wear rings (16 and 22), cap washer (24) and cap screw.
seal (20), or O-ring (21). Arm Cylinder—Specification
Cushion-to-Rod
10. Repair or replace parts as necessary. Cap Screw—27C
ZTS—Torque............................................................... 6.9 N·m (65 lb-in.)
11. Clean and dry parts to be reuse. Apply a light film of
Cushion-to-Rod
clean hydraulic oil to all sealing parts and machined
Cap Screw—35C
surfaces.
12. Install bushing (9) to bottom of bore. Bushing is a
24. Install rod and piston. Make sure wear rings do not
press fit.
come off while installing rod and piston.
13. Install backup ring—35C ZTS (7). Install U-cup seal
25. Tighten rod guide (3).
(8) so flat side is towards the rod end.
Specification
14. Install wiper ring (2) so lip is towards the outside of Rod Guide-to-Arm
rod guide. Cylinder Barrel—27C
15. Install O-ring (6), backup ring (5), and O-ring (4). ZTS—Torque.............................................................. 300 N·m (221 lb-ft)
Rod Guide-to-Arm
16. Install O-ring (11) and backup ring (10). Cylinder Barrel—35C
17. Install cushion ring (12). Install spacer (13) so notches
are towards the cushion ring. Install snap ring (14). 26. Crimp the edge of cylinder barrel into the notch in rod
guide using a punch and hammer.
18. Install O-ring (21) and cap ring (20). Check that O-ring
is not twisted.
CED,OUOE003,21220 -19-13JAN00-3/3

100312
PN=275
Hydraulic System
Bucket Cylinder Disassemble and Assemble
T159629 —UN—01OCT02
1— Rod 8— U-Cup Seal 14— Cap Seal 20— Grease Fitting
2— Wiper Seal 9— Bushing 15— O-Ring 21— Grease Fitting
3— Rod Guide 10— Wear Ring 16— Wear Ring 22— Bushing
4— O-Ring 11— Piston 17— Cylinder Barrel
5— Backup Ring 12— Steel Ball 18— Dust Seal
6— O-Ring 13— Set Screw 19— Bushing
7— Backup Ring—35C ZTS Only
Bucket Cylinder—35C
CAUTION: Heavy component; use a hoist. ZTS—Weight................................................... 20 kg (44 lb) approximate
Bucket Cylinder—Specification
Bucket Cylinder—27C 1. Fasten head end of cylinder to cylinder service stand.

100312
PN=276
Hydraulic System
18
19
16
15
14
13
12
11
20
18 10
9
8
7
6
5
4
18
3
2
21
22
18
17
T159628 —UN—01OCT02
T159628

100312
PN=277
Hydraulic System
1— Rod 8— U-Cup Seal 14— Cap Seal 20— Grease Fitting

2— Wiper Seal 9— Bushing 15— O-Ring 21— Grease Fitting
3— Rod Guide 10— Wear Ring 16— Wear Ring 22— Bushing
4— O-Ring 11— Piston 17— Cylinder Barrel
5— Backup Ring 12— Steel Ball 18— Dust Seal
6— O-Ring 13— Set Screw 19— Bushing
7— Backup Ring—35C ZTS Only
2. Bend the crimp from notch in rod guide (3) being 15. Install O-ring (15) and cap seal (14). Check that O-ring
careful not to damage the end of cylinder barrel (17). is not twisted.
IMPORTANT: Carefully remove components so 16. Install wear rings (16 and 10) so the splits are offset.
as not to damage piston rod or sliding
surfaces during disassembly. 17. Install rod guide (3) onto rod (1).
3. Pull rod (1) out approximately 200 mm (8 in.). Loosen 18. Install piston (11). Tighten piston.
rod guide (3) using JDG28 Spanner Wrench. Bucket Cylinder—Specification
Piston-to-Rod—27C
4. Attach rod to a hoist using a lifting strap.
5. Pull rod from cylinder barrel (17). Piston-to-Rod—35C
Remove set screw and steel ball (12). 19. Install steel ball (12) and set screw (13). Tighten set
screw. Stake the set screw head in two places to
7. Remove piston (11). prevent loosening.
8. Remove rod guide (3). Bucket Cylinder—Specification
Piston-to-Rod
IMPORTANT: Take care not to damage other Set Screw—27C
parts when removing seals. ZTS—Torque............................................................... 6.9 N·m (65 lb-in.)
Do not reuse wear rings (10 and 16), cap Piston-to-Rod
seal (14), or O-ring (15). Set Screw—35C
ZTS—Torque................................................................. 6.9 N·m (65 lb-ft)
9. Repair or replace parts as necessary. 20. Install rod and piston. Make sure wear rings do not
10. Clean and dry parts to be reuse. Apply a light film of come off while installing rod and piston.
clean hydraulic oil to all sealing parts and machined 21. Tighten rod guide.
surfaces.
Bucket Cylinder—Specification
11. Install bushing (9) so it is even with the top end of Rod Guide-to-Cylinder
bore. Bushing is a press fit. Barrel—27C
12. Install backup ring—35C ZTS (7). Install U-cup seal
Rod Guide-to-Cylinder
(8) so flat side is towards the rod end.
Barrel—35C
13. Install wiper seal (2) so lip is towards the outside of ZTS—Torque.............................................................. 294 N·m (217 lb-ft)
rod guide.
22. Crimp the edge of cylinder barrel into the notch in rod
14. Install O-ring (6), backup ring (5), and O-ring (4). guide using a punch and hammer.
CED,OUOE003,21221 -19-04FEB03-3/3

100312
PN=278
Hydraulic System
Blade and Boom Swing Cylinder Disassemble

and Assemble
T126379 —UN—14JAN00
Cylinder Cross Section
1— Rod 7— Bushing 12— Piston 18— Cylinder Barrel
2— Wiper Seal 8— U-Ring 13— Steel Ball 19— Seal (4 used)
3— Rod Guide 9— Backup Ring 14— Set Screw 20— Bushing (2 used)
4— O-Ring 10— Retaining Ring 15— Cap Seal
5— Backup Ring 11— Wear Ring 16— O-Ring
6— O-Ring 17— Wear Ring
Boom Swing
CAUTION: Heavy component; use a hoist. Cylinder—35C
Blade and Boom Swing Cylinder—Specification ZTS—Weight........................................................................ 32 kg (71 lb)
Blade Cylinder—27C
ZTS—Weight........................................................................ 19 kg (42 lb) NOTE: Disassembly procedure is the same for both
Blade Cylinder—35C blade and boom swing cylinders.
ZTS—Weight........................................................................ 24 kg (53 lb)
Boom Swing 1. Fasten head end of cylinder to cylinder service stand.
Cylinder—27C
ZTS—Weight........................................................................ 26 kg (57 lb)

100312
PN=279
Hydraulic System
19
10
9
19
20 8
7
6
1
5
4
3
2
17
16
15
14
13
12
11
19 18
20
19
T159565 —UN—01OCT02
T159565
Blade Cylinder Exploded View—35C ZTS

100312
PN=280
Hydraulic System
1— Rod 7— Bushing 12— Piston 18— Cylinder Barrel

2— Wiper Seal 8— U-Ring 13— Steel Ball 19— Seal (4 used)
3— Rod Guide 9— Backup Ring 14— Set Screw 20— Bushing (2 used)
4— O-Ring 10— Retaining Ring 15— Cap Seal
5— Backup Ring 11— Wear Ring 16— O-Ring
6— O-Ring 17— Wear Ring
2. Bend the crimp from notch in rod guide (3) being Blade and Boom Swing Cylinder—Specification
careful not to damage the end of cylinder barrel (18). Blade Cylinder
IMPORTANT: Carefully remove components so Piston-to-Rod—27C
as not to damage piston rod or sliding ZTS—Torque.............................................................. 961 N·m (710 lb-ft)
surfaces during disassembly. Blade Cylinder
Piston-to-Rod—35C
3. Pull rod (1) out approximately 200 mm (8 in.). Loosen ZTS—Torque......................................................... 1373 N·m (1,015 lb-ft)
rod guide (3) using a JDG28 Spanner Wrench or Boom Swing Cylinder
equivalent. Piston-to-Rod—27C
4. Attach rod to a hoist using a lifting strap. Boom Swing Cylinder
Piston-to-Rod—35C
5. Pull rod from cylinder barrel (18).
Remove set screw and steel ball (13).
screw. Stake set screw head in two places to prevent
7. Remove piston (12). loosening.
8. Remove rod guide (3). Blade Cylinder and Boom Swing—Specification
Blade Cylinder
IMPORTANT: Take care not to damage other Piston-to-Rod
parts when removing seals. Set Screw—27C
ZTS—Torque.................................................................. 7 N·m (62 lb-in.)
Do not reuse wear rings (11 and 17), cap Blade Cylinder
seal (15), and O-ring (16). Piston-to-Rod
Set Screw—35C
9. Repair or replace parts as necessary. ZTS—Torque.................................................................. 32 N·m (25 lb-ft)
10. Clean and dry parts to be reuse. Apply a light film of Boom Swing Cylinder
clean hydraulic oil to all sealing parts and machined Piston-to-Rod Set
surfaces. Screw—27C ZTS and
35C ZTS—Torque.......................................................... 7 N·m (62 lb-in.)
NOTE: Assembly procedure is the same for both
blade and boom swing cylinders. 20. Install rod and piston. Make sure wear rings do not
come off while installing rod and piston.
11. Install bushing (7) so it is even with top end of bore. 21. Tighten rod guide (3).
Bushing is a press fit.
Blade and Boom Swing Cylinder—Specification
12. Install O-ring (6), backup ring (5), and O-ring (4). Rod Guide-to-Blade
Cylinder Barrel—27C
13. Install U-cup seal (8) so flat side is towards the rod
end. Install backup ring (9) and snap ring (10).
Rod Guide-to-Blade
14. Install wiper seal (2) so lip is towards the outside of Cylinder Barrel—35C
rod guide. ZTS—Torque.............................................................. 363 N·m (270 lb-ft)
Rod Guide-to-Boom
15. Install O-ring (16). Check that O-ring is not twisted. Swing Cylinder
Install cap seal (15) using JDG840-3 Installer and Barrel—27C
JGD840-6 Pusher. ZTS—Torque.............................................................. 324 N·m (240 lb-ft)
16. Install wear rings (17 and 11) so the splits are offset. Rod Guide-to-Boom
Swing Cylinder
17. Install rod guide (3) onto rod. Barrel—35C
18. Install piston (12). Tighten piston.
22. Crimp the edge of cylinder barrel into the notch in rod
guide using a punch and hammer.
CED,OUOE003,21071 -19-04FEB03-3/3

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Hydraulic System
Hydraulic Cylinder Bleed Procedure on hydraulic system, or when machine has

been in storage for a period of time.
IMPORTANT: Trapped air suddenly compressed in a
cylinder is heated and ignites the oil used for 1. Run engine at slow idle.
assembly causing cap seal and ring damage.
Start with cylinder rod retracted and the rod 2. Slowly operate function to move cylinder to the most
end filled with clean oil. Connect the cylinder horizontal position possible.
head end and line. Operate function to slowly
extend rod. Procedure will eliminate most of the 3. Slowly extend and retract cylinder several times to
air and reduce the possibility of damage. approximately 100 mm (4 in.) from end of stroke.
Bleed air at initial startup, whenever major 4. Operate cylinder several times to full stroke.
repairs or maintenance (oil change) is done
TX,33,GG2374 -19-07FEB03-1/1

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Section 43
Swing or Pivoting System
Contents
Page
Group 4350—Mechanical Drive Elements

Swing Gearbox
4350-2
4350-6
Upperstructure
Swing Bearing
Repair..................................................43-4350-11

Swing Motor and Park Brake
Disassemble..........................................43-4360-2
Start-Up Procedure
Swing Motor ..........................................43-4360-5

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Contents

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Group 4350
Mechanical Drive Elements
Swing Gearbox Remove and Install
1. See Canopy Remove and Install for removal
procedure. (Group 1800). See Cab Remove and
Install for removal procedure. (Group 1800.)
2. See Platform Remove and Install for removal
X9811 —UN—23AUG88

3. Disconnect hydraulic lines (1—5). Install caps and

plugs.

Swing Gearbox—Specification
Swing Motor
and Gearbox
T164491B —UN—29JAN03
Assembly—Weight.......................................... 33 kg (73 lb) approximate
NOTE: When removing the swing gearbox, the swing

motor and gearbox are usually removed as a
unit. The swing motor can be removed from the
swing gearbox if so desired. See Swing Motor
and Park Brake Remove and Install.
4. Remove cap screws (6). Attach swing motor and

1— B2 Swing Control Valve 4— Swing Motor Park
gearbox to a hoist using JT01748 Lifting Brackets and Right Work Port-to-Swing Brake Changeover Valve
a lifting strap. Motor Right Front Port B Port-to-Pilot Shut-Off Valve
Line Left End Port Line
5. Remove the swing motor and gearbox. 2— M Main Control Valve 5— A2 Swing Control Valve Left
Center Cap-to-Swing Motor Work Port-to-Swing Motor
6. Make repairs as necessary. Top Front Port Line Port A Line
3— Swing Motor Front Bottom 6— Cap Screw (6 used)
7. Install the swing motor and gearbox. Tighten cap Port-to-Rotary Manifold
screws (6) to specification. Top Front Port Line
Swing Gearbox—Specification
Swing Gearbox
Housing-to-Frame Cap 10. See Canopy Remove and Install for installation
Screw—Torque........................................................... 137 N·m (101 lb-ft) procedure. (Group 1800). See Cab Remove and
Install for installation procedure. (Group 1800.)
11. Perform Swing Motor Start-Up Procedure. (Group
9. Install platform. See Platform Remove and Install.
4360.)
(Group 1800.)
CED,OUOE003,21136 -19-21JAN03-1/1

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Swing Gearbox Disassemble and

Assemble—27C ZTS
T126562 —UN—14JAN00

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1— Shaft 8— Cap Screw (2 used) 21— Inner Race (3 used) 24— Thrust Plate
2— Collar 9— Plate 22— Needle Bearing (3 used) 25— Drive Gear
3— Plate 10— Collar 23— Planetary Gear (3 used) 26— O-Ring
4— Bearing 19— Carrier
5— Housing 20— Thrust Washer (3 used)
6— Oil Seal
7— Bearing
1. Remove cap screws (8). Remove swing motor. 5. Using a press, remove inner race of bearing (4), plate
2. Remove parts (19—25) from housing (5). (3), and collar (2) from shaft (1).
3. Remove collar (10) and plate (9) from housing (5). 6. Remove oil seal (6) from housing (5).
4. Remove shaft (1) from housing (5) using a press. 7. Remove outer race of bearing (7) from housing (5).

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T164291 —UN—28JAN03

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1— Shaft 8— Cap Screw (2 used) 21— Inner Race (3 used) 24— Thrust Plate
2— Collar 9— Plate 22— Needle Bearing (3 used) 25— Drive Gear
3— Plate 10— Collar 23— Planetary Gear (3 used) 26— O-Ring
4— Bearing 19— Carrier 27— Swing Motor
5— Housing 20— Thrust Washer (3 used)
6— Oil Seal
7— Bearing
IMPORTANT: Oil seal (6) must be installed so lip 8. Install thrust washer (20), inner race (21), needle
is toward planetary gear end of gearbox, bearing (22), planetary gear (23), and thrust plate (24)
otherwise, seal will leak. on carrier (19).
1. Install oil seal (6) into housing (5) so lip is toward 9. Install drive gear (25).
planetary gear end of gearbox. 10. Install O-ring (26) on swing motor.
2. Install outer race of bearing (7) into housing (5) using 11. Install swing motor onto housing (5). Tighten cap
a press. screws (8) to specification.
3. Install collar (2), plate (3), and inner race of bearing (4) Swing Gearbox—27C ZTS—Specification
onto shaft (1) using a press. Swing Motor-to-Gearbox
4. Pack inner race of bearing (4) with grease.
5. Install shaft assembly (1) into housing (5).
12. See Swing Gearbox Remove and Install for installation
6. Install inner race of bearing (7) into housing (5) using procedure. (Group 4350.)
a press.
7. Install collar (9) and plate (10) onto housing (5).
IMPORTANT: Thrust washers (20) and thrust
plate (24) must be installed so beveled
side is toward motor.
FR91424,0000024 -19-21JAN03-4/4

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Swing Gearbox Disassemble and Assemble—35C ZTS
T126517 —UN—14JAN00

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1— Shaft 12— Thrust Washer (4 used) 18— Second Planet Sun Gear 23— First Planet Gear (4 used)
2— Collar 13— Inner Race (4 used) 19— First Planet Carrier 24— Thrust Plate
3— Plate 14— Needle Bearing (4 used) 20— Thrust Washer (4 used) 25— First Planet Sun Gear
4— Bearing 15— Second Planet Gear (4 used) 21— Inner Race (4 used) 26— O-Ring
5— Housing 16— Thrust Plate 22— Needle Bearing (4 used)
6— Oil Seal 17— Cap Screw (4 used)
7— Bearing
9— Plate
10— Collar
11— Second Planet Carrier
1. Remove cap screws (8). Remove swing gearbox from 7. Remove thrust plate (16), second planet gear (15),
swing motor. needle bearing (14), inner race (13), and thrust washer
2. Remove first planet sun gear (25). (12) in this order.
3. Remove thrust plate (24), first planetary gear (23), 8. Remove collar (10) and plate (9) from housing (5).
needle bearing (22), inner race (21), thrust washer 9. Remove shaft (1) from housing (5) using a press.
(20), and first planet carrier (19) from housing (5).
10. Remove inner race of bearing (4) using a press.
4. Remove second planet sun gear (18) from housing (5). Remove plate (3) and collar (2) from shaft (1)
5. Remove second planet carrier (11) from housing (5). 11. Remove oil seal (6) from housing (5).
6. Remove cap screws (17). 12. Remove outer race of bearing (7) from housing (5).

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T126516 —UN—14JAN00

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1— Shaft 12— Thrust Washer (4 used) 18— Second Planet Sun Gear 24— Thrust Plate
2— Collar 13— Inner Race (4 used) 19— First Planet Carrier 25— First Planet Sun Gear
3— Plate 14— Needle Bearing (4 used) 20— Thrust Washer (4 used) 26— O-Ring
4— Bearing 15— Second Planet Gear (4 used) 21— Inner Race (4 used) 27— Swing Motor
5— Housing 16— Thrust Plate 22— Needle Bearing (4 used)
6— Oil Seal 17— Cap Screw (4 used) 23— First Planet Gear (4 used)
7— Bearing
9— Plate
10— Collar
11— Second Planet Carrier
1. Install oil seal (6) into housing (5). Swing Gearbox—35C ZTS—Specification
2. Install outer race of bearing (7) into housing (5) using Second Planet
a press. Carrier-to-Thrust Plate
Cap Screw—Torque....................................................... 4 N·m (35 lb-in.)
3. Install collar (2), plate (3), and inner race of bearing (4)
onto shaft (1) using a press. 10. Install second planet carrier assembly into housing (5).
4. Pack inner race of bearing (4) with grease. 11. Install second planet sun gear (18).
5. Install shaft assembly (1) into housing (5). 12. Assemble thrust washer (20), inner race (21), needle
bearing (22), first planet gear (23), and thrust plate
6. Install inner race of bearing (7) into housing (5) using (24) on first planet carrier (19) in this order.
a press.
13. Install first planet carrier (19) into housing (5).
7. Install thrust washer (12), inner race (13), needle
bearing (14), second planet gear (15), and thrust plate 14. Install O-ring (26) on swing motor. Install swing motor
(16) on second planet carrier (11). into housing with cap screws and tighten.
Swing Gearbox—35C ZTS—Specification
8. Apply T43513 Thread Lock And Sealer (High Strength)
Swing Motor-to-Gearbox
to cap screws (17) threads.
9. Tighten cap screws (17) to specification.
15. See Swing Gearbox Remove and Install for installation
FR91424,0000025 -19-21JAN03-4/4

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Upperstructure Remove and Install

1. Clean the machine thoroughly.
2. Remove boom, arm, and bucket as an assembly. See
Boom Remove and Install. (Group 3340.)
procedure. (Group 1800.) See Cab Remove and
4. See Counterweight Remove and Install for removal
5. See Rotary Manifold Remove and Install for removal
T164521 —UN—29JAN03
Upperstructure—Specification
Upperstructure Without
Boom, Arm, Bucket,
Cab or Canopy, and
Counterweight—Weight.......................... 1588 kg (3500 lb) approximate
6. Attach upperstructure to a hoist using lifting straps or

chains, a spreader bar, and M16x2.0 lifting eyebolts 1— Boom Pivot Support 3— Frame
(2) such as JT05551 Metric Lifting Eyebolts. Install 2— JT05551 Metric Lifting
Eyebolt (2 used)
eyebolts in the cab mount holes in rear support (3).
Attach lifting strap or chains to boom pivot support (1)
at front of machine.
7. Adjust length of lifting straps or chains as needed to
balance the upperstructure. Remove all slack from
lifting straps or chains.

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8. Make alignment marks on swing bearing (A) and

upperstructure to aid in assembly.
9. Remove swing bearing-to-upperstructure cap screws
and washers (B).
10. Lift upperstructure slowly from undercarriage.
T6626JK —UN—06DEC88
11. Move upperstructure away from undercarriage and set
upperstructure down on a clean flat level surface.
12. Make repairs as necessary.
13. See Swing Bearing Remove and Install for procedure
to remove swing bearing (A). (Group 4350.)
14. Clean mating surfaces of swing bearing and
upperstructure. A—Swing Bearing B—Cap Screw and Washer (24
used)
15. Slowly lower upperstructure onto undercarriage while
making sure the marks previously made are aligned.
16. Install swing bearing-to-upperstructure cap screws 18. See Canopy Remove and Install for installation
and washers (B). Tighten to specifications. procedure. (Group 1800.) See Cab Remove and
Install for installation procedure. (Group 1800.)
Swing Bearing—Specification
Swing Bearing-to- 19. See Counterweight Remove and Install for installation
Upperstructure Cap procedure. (Group 1749.)
20. See Boom Remove and Install for installation
17. See Rotary Manifold Remove and Install for installation procedure. (Group 3340.)
CED,OUOE003,21139 -19-21JAN03-2/2
Swing Bearing Remove and Install

1. Remove upperstructure. See Upperstructure Remove
T164480 —UN—28JAN03
Swing Bearing—27C
Swing Bearing—35C
2. Make alignment marks (3) on swing bearing inner race

(1) and undercarriage (2).
1— Swing Bearing Inner Race 3— Alignment Marks
2— Undercarriage Frame

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PN=295
3. Remove cap screws (1) from swing bearing inner race

(2).
1— Cap Screws (20 used) 2— Swing Bearing Inner Race
T164481 —UN—28JAN03
CED,OUOE003,21141 -19-21JAN03-2/4
4. Attach swing bearing to a hoist using lifting brackets

(1) such as JT01748 Lifting Brackets. Remove swing
bearing.
6. Clean mating surfaces of swing bearing,
upperstructure, and undercarriage.
7. Apply T43514 Rigid Form-In-Place Gasket to mating
surfaces on swing bearing.
T164482 —UN—28JAN03

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PN=296
IMPORTANT: The inner and outer bearing races are

marked with the letter “S” to indicate the “soft
zone”. The area marked with this letter must be
installed on the left side of machine so the use
of that part of swing bearing is minimized.
8. Install swing bearing on undercarriage so the area

on both inner and outer races marked with an “S” is
to the left side of machine at approximately the 282°
position as shown.
9. Install swing bearing-to-undercarriage cap screws.
T164483 —UN—28JAN03
Tighten to specification.
Swing Bearing-to-
Undercarriage Cap
10. Apply multi-purpose EP grease to swing bearing

teeth and pinion shaft. See Track Adjuster, Working
Tool Pivot, Swing Bearing, and Swing Bearing Gear 1— Outer Race “S” Location 3— Front of Machine
2— Inner Race “S” Location
Grease. (Operator's Manual.)
11. Install upperstructure. See Upperstructure Remove
CED,OUOE003,21141 -19-21JAN03-4/4

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Group 4360
Hydraulic System
Swing Motor and Park Brake Remove and
Install
procedure. (Group 1800.) See Cab Remove and
X9811 —UN—23AUG88
2. Remove platform. See Platform Remove and Install.
(Group 1800.)

3. Disconnect hydraulic lines (1—5).

4. Remove cap screws (6) to remove the swing motor.
5. Make repairs as necessary.
6. Install the swing motor. Tighten cap screws to
specification.
T164491C —UN—29JAN03
Swing Motor and Park Brake—Specification
Swing Motor-to-Swing
Gearbox Cap

8. Install platform. See Platform Remove and Install.
(Group 1800.)
1— B2 Swing Control Valve 4— Swing Motor Park
9. See Canopy Remove and Install for installation Right Work Port-to-Swing Brake Changeover Valve
Motor Right Front Port B Port-to-Pilot Shut-Off Valve
procedure. (Group 1800.) See Cab Remove and Line Left End Port Line
Install for installation procedure. (Group 1800.) 2— M Main Control Valve 5— A2 Swing Control Valve Left
Center Cap-to-Swing Motor Work Port-to-Swing Motor
10. Perform Hydraulic Pump Start-Up Procedure. (Group Top Front Port Line Port A Line
3360.) 3— Swing Motor Front Bottom 6— Cap Screw (2 used)
Port-to-Rotary Manifold
11. Do swing motor start-up procedure. See Perform Top Front Port Line
Swing Motor Start-Up Procedure. (Group 4360.)
CED,OUOE003,21146 -19-24JAN03-1/1

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Hydraulic System
Swing Motor and Park Brake Disassemble

and Assemble
T126553 —UN—14JAN00
Continued on next page TX19495,0000001 -19-24JAN03-1/5

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Hydraulic System
1— Relief Valve (2 used) 9— Holder 19— Retaining Ring 28— Pin

2— Anti-Cavitation Valve (2 used) 10— Cap Screw (2 used) 20— Disk Plate 29— Bearing
3— Housing 11— O-Ring 21— O-Ring 30— Pin
4— Bearing 12— Plug 22— O-Ring 31— Cover
5— Shaft 13— Orifice 23— Brake Piston 32— Cap Screw (5 used)
6— Swash Plate 14— Pin (3 used) 24— Spring Seat (2 used) 33— O-Ring (2 used)
7— Piston (9 used) 15— Cylinder Block 25— Disk Spring 34— Plug (2 used)
8— Retainer 16— Collar 26— O-Ring 35— O-Ring (2 used)
17— Spring 27— Valve Plate
18— Washer
1. Evenly loosen five cap screws (32). 7. Remove pistons (7), retainer (8), holder (9), and pins
IMPORTANT: Care must be taken when removing (14) from cylinder block (15).
cover (31). Valve plate (27) may fall,
causing damage to plate. CAUTION: Washer (18) and spring (17) may fly
out if retaining ring (19) is removed without
2. Remove cap screws, cover (31), valve plate (27), and safely compressing spring (17). Always use
O-ring (26). a press to compress spring (17), otherwise,
serious injury may result.
3. Remove bearing (29) and O-rings (35) from cover (31).
4. Remove disk spring (25) and spring seats (24) from 8. Remove retaining ring (19), washer (18), spring (17),
housing (3). and collar (16) from cylinder block (15) using a press.
5. Remove brake piston (23) and O-rings (21 and 22) 9. Remove shaft (5) from housing (3) by striking end of
from housing (3). shaft with a plastic hammer.
IMPORTANT: Be careful so as not to damage 10. Remove bearing (4) from shaft (5) using a press.
the sliding surface of swashplate (6) while
IMPORTANT: Apply clean hydraulic oil to all moving
removing it from housing (3).
parts during the assembly process.
6. Remove cylinder block (15), piston assembly,
swashplate (6), and disk plate (20) from housing (3).
TX19495,0000001 -19-24JAN03-2/5
12. Install bearing (4) onto shaft (5) so snap ring is toward
shaft splines as shown in illustration.
4— Bearing 5— Shaft
T126564 —UN—14JAN00

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Hydraulic System
T126552 —UN—14JAN00
1— Relief Valve (2 used) 9— Holder 19— Snap Ring 28— Pin
2— Anti-Cavitation Valve (2 used) 10— Cap Screw (2 used) 20— Disk Plate 29— Bearing
3— Housing 11— O-Ring 21— O-Ring 30— Pin
4— Bearing 12— Plug 22— O-Ring 31— Cover
5— Shaft 13— Orifice 23— Brake Piston 32— Cap Screw (5 used)
6— Swash Plate 14— Pin (3 used) 24— Spring Seat (2 used) 33— O-Ring (2 used)
7— Piston (9 used) 15— Cylinder Block 25— Disk Spring 34— Plug (2 used)
8— Retainer 16— Collar 26— O-Ring 35— O-Ring (2 used)
17— Spring 27— Valve Plate
18— Washer
IMPORTANT: Forcing bearing (4) beyond where 17. Install holder (9) on pin (14).
snap ring contacts the housing wall will
cause snap ring to deform. 18. Install pistons (7) and retainer (8) assembly into
cylinder block (15).
13. Install shaft and bearing into housing (3) until snap
ring on bearing (4) just contacts the housing wall. 19. Install swashplate (6) into housing (3) so beveled side
is toward housing and the polished side will contact
14. Install collar (16), spring (17), and washer (18) into the cylinder block pistons.
cylinder block (15). Beveled side of collar must be
toward cylinder block. 20. Install cylinder block (15) and piston assembly into
housing (3).
15. Compress spring (17) to install snap ring (19).
21. Install O-rings (21 and 22) onto brake piston (23), then
16. Apply petroleum jelly to pin (14) and install pin (14) install them into housing (3).
into cylinder block (15).

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Hydraulic System
22. Install spring seats (24) and disk spring (25) into
housing (3) as shown in illustration.
23. Install O-ring (26) into housing (3).
24. Install bearing (29) into cover (31).
T126565 —UN—14JAN00
25. Apply petroleum jelly to mating surfaces of valve plate
(27) and cover (31) to hold valve plate in position to
prevent it from falling.
Install O-rings (35) and valve plate (27) onto cover (31).
26. Install cover (31) onto housing (3) using cap screws
(32).
27. Evenly tighten cap screws (32) to specification.
24— Spring Seat (2 used) 25— Disk Spring
Swing Motor—Specification
28. See Swing Motor and Park Brake Remove and Install
for installation procedure.
TX19495,0000001 -19-24JAN03-5/5
Swing Motor Start-Up Procedure

IMPORTANT: Swing motor will be damaged if not
filled with oil before operating swing function.
This procedure must be performed whenever
a new swing motor is installed or oil has
been drained from the motor.
T126424 —UN—14JAN00
This procedure is to ensure the swing motor is filled with
oil before operating the swing function.
1. Disconnect swing motor drain line (1).
2. Fill motor with hydraulic oil through drain port until oil
reaches the level of drain port. Air must be allowed
to escape from the swing motor while filling. See
Hydraulic Oil. (Operator's Manual.) 1— Drain Line
3. Connect drain line.

CED,OUOE003,21217 -19-24JAN03-1/1

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Hydraulic System

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

ST4920 Track Recoil Spring
Tool ........................................................ 99-9900-1
DFT1087 Track Recoil Spring
Guard Tool ............................................. 99-9900-5

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Contents

100312
PN=2
Group 9900
ST4920 Track Recoil Spring Disassembly
and Assembly Tool
NOTE: See DFT1087 Track Recoil Spring Disassembly
and Assembly Guard Tool that is recommended to
be used with track recoil spring disassembly
and assembly tool.
Dimensions given are metric.
Tool is the same as used on other machines except the

holder (C). For each track adjuster use the holder with the
correct size hole for the nut on that track adjuster.
Track Recoil Spring Disassembly and Assembly Tool
(compression tool) is used with hydraulic jack to compress
recoil spring in track adjuster repair.
Material required:
• 1020 HR Steel for Holder (C), Supporting Plate (E),
Base Plate (F), and Base (G).
• “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A),
T6585UY —UN—24MAR98
and Cap Screws (H).
• “F” Grade (SAE Grade 8) for Studs (B).
Print Numbers:
• A-ST4050 Nut
• B-ST4045 Bolt
• C-ST4035 Holder (Plate)
• -ST4036 Holder (Plate)
• -ST4037 Holder (Plate) A—Nut (12 used) F— Base Plate
• D-ST4047 Eyebolt B—Stud (4 used) G—Base (4 used)
• E-ST4040 Supporting Base C—Holder H—Cap Screw (8 used)
• F-ST4042 Base Plate D—Eyebolt (2 used) I— Lock Washer (8 used)
• G-ST4041 Base E—Supporting Plate
• H-ST4046 Cap Screw
• I-ST4049 Lock Washer
Continued on next page TX,9900,AA3574 -19-20FEB92-1/4

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T7029CI —UN—06JUL89

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T7029CH —UN—06JUL89

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T7029CG —UN—06JUL89
TX,9900,AA3574 -19-20FEB92-4/4

100312
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DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
T7162AF —UN—17OCT89
A—3/16 in. 1020 CR Steel Plate C—1/2 in. Nut (2 used) E—1/2 x 3 in. Steel Round Stock
B—9/16 in. Hole (2 places) D—1/2 x 2 in. Cap Screw (2 used) (2 used)
Track Disassembly and Assembly Guard Tool is used with

ST4920 Track Recoil Spring Disassembly and Assembly • 3/16 in. 1020 CR Steel Plate (A)
Tool. • 1/2 in. Nut (C) (2 used)
• 1/2 x 2 in. Cap Screw (D) (2 used)
Material required: • 1/2 x 3 in. Steel Round Stock (E) (2 used)
TX,9900,BA499 -19-26AUG05-1/1

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Index
Page Page
A Brake—27C ZTS
Park, propel motor disassemble .................... 02-0260-1
Adjuster Brake—35C ZTS
Track, disassemble and assemble............... 01-0130-24 Park, propel motor disassemble .................... 02-0260-8
Track, remove and install............................. 01-0130-19 Bucket
Adjuster and recoil spring Links, remove and install ............................... 33-3340-1
Track, disassemble and assemble............... 01-0130-20 Bucket cylinder
Alternator Bleed procedure........................................... 33-3360-58
Disassemble and assemble ......................... 04-0400-50 Disassemble and assemble ......................... 33-3360-52
Remove and install ...................................... 04-0400-49 Bushing
Repair .......................................................... 04-0400-49 Measure wear, track chain ........................... 01-0130-10
Arm Bushings and pins, arm and boom
Remove and install ........................................ 33-3340-3 Inspect ......................................................... 33-3340-14
Arm cylinder Bushings and seals
Bleed procedure........................................... 33-3360-58 Remove and install ...................................... 33-3340-16
Disassemble and assemble ......................... 33-3360-49
Arm pins and bushings C
Inspect ......................................................... 33-3340-14
Attachments Cab
Adding safely ................................................. 00-0001-8 Remove and install ........................................ 18-1800-1
Operating safely............................................. 00-0001-8 Cab guarding ..................................................... 00-0001-2
Auxiliary pilot controller Camshaft
Repair .......................................................... 33-3360-25 Inspect ......................................................... 04-0400-25
Remove and install ...................................... 04-0400-24
B Repair .......................................................... 04-0400-23
Canopy
Battery explosions Remove and install ........................................ 18-1800-3
Prevent........................................................... 00-0001-4 Carrier roller
Blade Track, measure wear ..................................... 01-0130-4
Disassemble and assemble ........................... 32-3201-3 Track, remove and install............................... 01-0130-4
Remove and install ........................................ 32-3201-1 Track, repair................................................... 01-0130-4
Repair ............................................................ 32-3201-1 Chemical products
Blade cylinder Handling......................................................... 00-0001-4
Bleed procedure........................................... 33-3360-58 Connecting rod and piston
Disassemble and assemble ......................... 33-3360-55 Remove and install ...................................... 04-0400-33
Remove and install ........................................ 32-3260-1 Control valve
Blade pilot controller Disassemble and assemble ......................... 33-3360-32
Repair ............................................................ 32-3260-2 Remove and install ...................................... 33-3360-31
Bleed fuel system .............................................. 05-0560-2 Controller
Bolt and screw torque values Auxiliary pilot, repair..................................... 33-3360-25
Metric ............................................................. 00-0003-2 Blade pilot, repair ........................................... 32-3260-2
Unified inch .................................................... 00-0003-1 Boom Swing pilot, repair .............................. 33-3360-28
Bonded windowpane Pilot, disassemble and assemble................. 33-3360-18
Remove and install ........................................ 18-1810-1 Pilot, remove and install............................... 33-3360-15
Boom Pilot, repair................................................... 33-3360-15
Remove and install ........................................ 33-3340-6 Propel pilot, repair........................................ 33-3360-20
Swing, remove and install .............................. 33-3340-9 Counterbalance valve—27C ZTS
Boom cylinder Propel motor disassemble ............................. 02-0260-1
Bleed procedure........................................... 33-3360-58 Counterbalance valve—35C ZTS
Disassemble and assemble ......................... 33-3360-46 Propel motor disassemble ............................. 02-0260-8
Boom pins and bushings Counterweight
Inspect ......................................................... 33-3340-14 Remove and install ........................................ 17-1749-1
Boom swing cylinder Crankshaft
Bleed procedure........................................... 33-3360-58 Inspect ......................................................... 04-0400-30
Disassemble and assemble ......................... 33-3360-55 Remove and install ...................................... 04-0400-29
Boom Swing pilot controller Repair .......................................................... 04-0400-28
Repair .......................................................... 33-3360-28 Cylinder
Arm, disassemble and assemble ................. 33-3360-49
Continued on next page
TM2053 (03OCT12) Index-1 27C ZTS and 35C ZTS Repair

100312
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Index
Page Page
Blade, disassemble and assemble .............. 33-3360-55 Fan, shroud, and guard
Bleed procedure, hydraulic .......................... 33-3360-58 Repair ............................................................ 05-0510-2
Boom swing, disassemble and Filter
assemble.................................................... 33-3360-55 Final fuel, repair ............................................. 05-0560-2
Boom, disassemble and assemble .............. 33-3360-46 Final fuel filter
Bucket, disassemble and assemble............. 33-3360-52 Repair ............................................................ 05-0560-2
Install bushings and seals............................ 33-3340-16 Fire prevention................................................... 00-0001-4
Track adjuster, disassemble and Flywheel
assemble.................................................... 01-0130-24 Disassemble and assemble ......................... 04-0400-26
Cylinder block Remove and install ...................................... 04-0400-25
Cylinder bore inspection .............................. 04-0400-18 Repair .......................................................... 04-0400-25
Height measurement.................................... 04-0400-19 Flywheel housing
Piston outside diameter measure- Remove and install ...................................... 04-0400-26
ment ........................................................... 04-0400-20 Front idler
Repair .......................................................... 04-0400-18 Disassemble and assemble ......................... 01-0130-16
Upper face out-of-flat inspection .................. 04-0400-19 Remove and install ...................................... 01-0130-15
Water jacket test .......................................... 04-0400-18 Fuel
Cylinder head .................................................... 04-0400-7 Final filter, repair ............................................ 05-0560-2
Assemble ..................................................... 04-0400-16 Fuel injection nozzle
Disassemble ................................................ 04-0400-11 Disassemble and assemble ......................... 04-0400-46
Inspect ......................................................... 04-0400-12 Remove and install ...................................... 04-0400-45
Remove and Install ........................................ 04-0400-7 Repair .......................................................... 04-0400-45
Valve seat, inspect ....................................... 04-0400-14 Fuel injection pump
Valve springs, inspect .................................. 04-0400-13 Remove and install ...................................... 04-0400-43
Valves, inspect ............................................. 04-0400-13 Fuel shut-off solenoid
Remove and install ........................................ 05-0515-3
D Fuel shut-off solenoid linkage
Dampener drive (flex coupling) Fuel system
Remove and install ...................................... 33-3360-12 Bleed.............................................................. 05-0560-2
Dealer fabricated tools Fuel tank
DFT1087 track recoil spring guard................. 99-9900-5 Remove and install ........................................ 05-0560-1
ST4920 track recoil spring assembly ............. 99-9900-1
Drive sprocket G
Driving metal pins ............................................ 00-0001-10 Gearbox
Swing, disassemble and assemble—27C
E ZTS .............................................................. 43-4350-2
Swing, disassemble and assemble—35C
Electrical ZTS .............................................................. 43-4350-6
Precautions before welding............................ 17-1740-1 Swing, remove and install .............................. 43-4350-1
Emergency preparation ..................................... 00-0001-5 Gearbox—27C ZTS
Engine Propel, disassemble and assemble ............... 02-0250-3
Remove and install ........................................ 04-0400-1 Propel, remove and install ............................. 02-0250-1
Engine glow plugs Gearbox—35C ZTS
Remove and install ........................................ 05-0505-1 Propel, disassemble and assemble ............... 02-0250-8
Engine speed control cable Propel, remove and install ............................. 02-0250-1
Remove and install ........................................ 05-0515-1 Grouser
Exhaust fumes................................................... 00-0001-3 Track shoe, measure wear ............................ 01-0130-9
Exhaust manifold Guard
Remove and install ........................................ 04-0400-4 Fan, repair...................................................... 05-0510-2
Explosion
Battery............................................................ 00-0001-4 H
F Handhold Use.................................................... 00-0001-5

Hardware torque values
Fan Belt Metric ............................................................. 00-0003-2
Repair ............................................................ 05-0510-1 Unified inch .................................................... 00-0003-1

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Index
Page Page
Heater and blower motor Swing, remove and install .............................. 43-4360-1
Remove and install ........................................ 18-1830-1 Swing, start-up procedure.............................. 43-4360-5
High-pressure oils Motor—27C ZTS
Avoid .............................................................. 00-0001-3 Propel, counterbalance valve
Hydraulic disassemble ................................................. 02-0260-1
Fittings, 30° cone seat ........................... 00-0003-7 Propel, disassemble and assemble ............... 02-0260-1
Fittings, 37° flare .................................... 00-0003-7 Propel, park brake disassemble..................... 02-0260-1
Hydraulic cylinder Propel, propel speed change valve
Bleed procedure........................................... 33-3360-58 disassemble ................................................. 02-0260-1
Hydraulic fitting Propel, shuttle valve disassemble.................. 02-0260-1
Flared connections......................................... 00-0003-8 Motor—35C ZTS
Hydraulic oil tank Propel, counterbalance valve
Remove and install ...................................... 33-3360-43 disassemble ................................................. 02-0260-8
Hydraulic pump Propel, disassemble and assemble ............... 02-0260-8
Assemble ....................................................... 33-3360-7 Propel, park brake disassemble..................... 02-0260-8
Disassemble .................................................. 33-3360-2 Propel, propel speed change valve
Remove and install ........................................ 33-3360-1 disassemble ................................................. 02-0260-8
Start-up procedure ....................................... 33-3360-12 Moving parts
Safety............................................................. 00-0001-3
I Servicing ........................................................ 00-0001-3
Idler N
Front, remove and install ............................. 01-0130-15
Idler, front Nozzle
Disassemble and assemble ......................... 01-0130-16 Fuel injection, repair..................................... 04-0400-45
Inspect machine ................................................ 00-0001-2
O
L
O-ring boss fittings............................................. 00-0003-4
Leakage test, oil Oil Cooler
Track roller ..................................................... 01-0130-3 Remove and Install ........................................ 05-0510-3
Lifting objects Oil lines and fittings
Special care ................................................... 00-0001-8 Checking ........................................................ 00-0003-4
Link Oil pan
Measure wear, track chain ........................... 01-0130-10 Remove and install ...................................... 04-0400-27
Links Oil pump
Bucket, remove and install............................. 33-3340-1 Disassemble and assemble ......................... 04-0400-41
M Repair .......................................................... 04-0400-40
One way/two way valve
Machine inspection............................................ 00-0001-2 Remove and install ...................................... 33-3360-42
Machine movement Operation qualification....................................... 00-0001-1
Unintended..................................................... 00-0001-6
Machine tip over P
Avoiding ......................................................... 00-0001-8
Manifold Park brake
Exhaust, remove and install........................... 04-0400-4 Swing motor, disassemble and
Rotary, disassemble and assemble ............. 02-0260-17 assemble...................................................... 43-4360-2
Rotary, remove and install ........................... 02-0260-15 Swing motor, remove and install .................... 43-4360-1
Metal face seals Park brake—27C ZTS
Inspect ........................................................... 01-0130-6 Propel motor disassemble ............................. 02-0260-1
Metal pins ........................................................ 00-0001-10 Park brake—35C ZTS
Metric bolt and screw torque values .................. 00-0003-2 Propel motor disassemble ............................. 02-0260-8
Molding Pilot control shutoff lever ................................... 00-0001-6
Windowpane and one piece, remove and Pilot controller
install ............................................................ 18-1810-1 Auxiliary, repair ............................................ 33-3360-25
Motor Boom Swing, repair...................................... 33-3360-28
Swing, disassemble and assemble................ 43-4360-2 Disassemble and assemble ......................... 33-3360-18

100312
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Index
Page Page
Propel, repair ............................................... 33-3360-20

Remove and install ...................................... 33-3360-15 R
Repair .......................................................... 33-3360-15
Pilot controller pattern conversion valve Radiator
Repair .......................................................... 33-3360-40 Remove and Install ........................................ 05-0510-3
Pilot pressure regulating valve Recoil spring and track adjuster
Repair .......................................................... 33-3360-13 Disassemble and assemble ......................... 01-0130-20
Pilot shut-off solenoid valve Remove and install ...................................... 01-0130-19
Repair .......................................................... 33-3360-13 Remove and install
Pins and Bushings, arm and boom Heater and blower motor ............................... 18-1830-1
Inspect ......................................................... 33-3340-14 Seat................................................................ 18-1821-1
Piston and connecting rod Seat base....................................................... 18-1821-1
Assemble ..................................................... 04-0400-38 Seat belt......................................................... 18-1821-3
Disassemble ................................................ 04-0400-34 Riding machine.................................................. 00-0001-7
Inspect ......................................................... 04-0400-36 Rocker arm
Remove and install ...................................... 04-0400-33 Disassemble and assemble ......................... 04-0400-21
Repair .......................................................... 04-0400-33 Inspect ......................................................... 04-0400-22
Pitch Roller
Track chain, measure wear.......................... 01-0130-11 Track carrier, measure wear .......................... 01-0130-4
Platform Track carrier, remove and install.................... 01-0130-4
Remove and install ........................................ 18-1800-4 Track carrier, repair........................................ 01-0130-4
Propel gearbox—27C ZTS Track, repair................................................... 01-0130-1
Disassemble and assemble ........................... 02-0250-3 Roller, track
Propel gearbox—27C ZTS Disassemble and assemble ........................... 01-0130-2
Remove and install ........................................ 02-0250-1 Oil leakage test .............................................. 01-0130-3
Propel gearbox—35C ZTS Remove and install ........................................ 01-0130-1
Disassemble and assemble ........................... 02-0250-8 Rotary manifold
Propel gearbox—35C ZTS Disassemble and assemble ......................... 02-0260-17
Remove and install ........................................ 02-0250-1 Remove and install ...................................... 02-0260-15
Propel motor—27C ZTS Rubber track
Counterbalance valve, disassemble .............. 02-0260-1 Remove and install ........................................ 01-0130-7
Disassemble and assemble ........................... 02-0260-1 Repair ............................................................ 01-0130-7
Park brake disassemble................................. 02-0260-1 Rubber track lugs
Propel speed change valve, Measure ......................................................... 01-0130-7
disassemble ................................................. 02-0260-1
Shuttle valve, disassemble ............................ 02-0260-1 S
Propel motor—35C ZTS
Counterbalance valve, disassemble .............. 02-0260-8 Safety
Disassemble and assemble ........................... 02-0260-8 Operator's seat .............................................. 00-0001-5
Park brake disassemble................................. 02-0260-8 Safety equipment............................................... 00-0001-2
Propel speed change valve, Safety information
disassemble ................................................. 02-0260-8 Recognizing ................................................... 00-0001-1
Propel pilot controller Safety instructions ............................................. 00-0001-1
Repair .......................................................... 33-3360-20 Safety symbols .................................................. 00-0001-1
Propel speed change solenoid valve Seal
Repair .......................................................... 33-3360-13 Metal face, inspect ......................................... 01-0130-6
Propel speed change valve—27C ZTS Seat
Propel motor disassemble ............................. 02-0260-1 Remove and install ........................................ 18-1821-1
Propel speed change valve—35C ZTS Seat base
Propel motor disassemble ............................. 02-0260-8 Remove and install ........................................ 18-1821-1
Protective equipment......................................... 00-0001-2 Seat belt
Pump Remove and install ........................................ 18-1821-3
Fuel injection, remove and install................. 04-0400-43 Use and maintenance .................................... 00-0001-6
Hydraulic, assemble....................................... 33-3360-7 Servicing machine safely................................... 00-0001-9
Hydraulic, disassemble .................................. 33-3360-2 Shoe
Hydraulic, Remove and install ....................... 33-3360-1 Track, remove and install............................. 01-0130-11
Hydraulic, start-up procedure....................... 33-3360-12 Shroud
Water, repari .................................................. 04-0400-5 Fan, repair...................................................... 05-0510-2

100312
PN=4
Index
Page Page
Shuttle valve—27C ZTS 37° flare hydraulic fittings....................... 00-0003-7

Propel motor disassemble ............................. 02-0260-1 Flared connections......................................... 00-0003-8
Sliding window Flat face O-ring seal fitting ............................. 00-0003-6
Remove and install ........................................ 18-1810-2 Inch SAE four bolt flange fitting...................... 00-0003-9
Solenoid valve manifold Metric cap screw ............................................ 00-0003-3
Repair .......................................................... 33-3360-13 Metric four bolt flange fitting......................... 00-0003-10
Spring O-Ring boss fitting ......................................... 00-0003-4
Track recoil, remove and install ................... 01-0130-19 Track
Spring and adjuster Rubber, remove and install ............................ 01-0130-7
Track recoil, disassemble and Rubber, repair ................................................ 01-0130-7
assemble.................................................... 01-0130-20 Shoe, remove and install ............................. 01-0130-11
Sprocket Steel , remove and install............................. 01-0130-12
Remove and install ...................................... 01-0130-14 Steel, component inspection.......................... 01-0130-9
Start-up procedure Track adjuster and recoil spring
Hydraulic pump ............................................ 33-3360-12 Disassemble and assemble ......................... 01-0130-20
Swing motor ................................................... 43-4360-5 Remove and install ...................................... 01-0130-19
Starter Track adjuster cylinder
Disassemble and assemble ......................... 04-0400-48 Disassemble and assemble ......................... 01-0130-24
Remove and install ...................................... 04-0400-47 Track carrier roller
Repair .......................................................... 04-0400-47 Measure wear ................................................ 01-0130-4
Steel track Remove and install ........................................ 01-0130-4
Components inspection ................................. 01-0130-9 Repair ............................................................ 01-0130-4
Remove and install ...................................... 01-0130-12 Track chain
Steps Use .......................................................... 00-0001-5 Bushing, measure wear ............................... 01-0130-10
Structure Link, measure wear...................................... 01-0130-10
Welding repair of major.................................. 17-1740-1 Pitch, measure wear .................................... 01-0130-11
Swing bearing Track shoe grouser, measure wear ............... 01-0130-9
Remove and install ...................................... 43-4350-11 Track lugs
Swing gearbox Rubber, measure ........................................... 01-0130-7
Disassemble and assemble—27C Track roller
ZTS .............................................................. 43-4350-2 Disassemble and assemble ........................... 01-0130-2
Disassemble and assemble—35C Remove and install ........................................ 01-0130-1
ZTS .............................................................. 43-4350-6 Repair ............................................................ 01-0130-1
Remove and install ........................................ 43-4350-1 Test for oil leakage ......................................... 01-0130-3
Swing motor Track shoe
Start-up procedure ......................................... 43-4360-5 Remove and install ...................................... 01-0130-11
Swing motor and park brake Track shoe grouser
Disassemble and assemble ........................... 43-4360-2 Measure wear ................................................ 01-0130-9
U
T
Unified inch bolt and screw torque
Tank values .............................................................. 00-0003-1
Fuel, remove and install................................. 05-0560-1 Upperstructure
Hydraulic oil, remove and install .................. 33-3360-43 Remove and install ...................................... 43-4350-10
Thermostat
Remove and install ...................................... 04-0400-42 V
Tip over
Avoiding ......................................................... 00-0001-8 Valve
Tools, dealer fabricated Control, disassemble and assemble ............ 33-3360-32
DFT1087 track recoil spring guard................. 99-9900-5 Control, remove and install .......................... 33-3360-31
ST4920 track recoil spring assembly ............. 99-9900-1 Counterbalance, propel motor
Tooth shank disassemble—27C ZTS ............................... 02-0260-1
Remove and install ........................................ 33-3302-1 Counterbalance, propel motor
Torque charts disassemble—35C ZTS ............................... 02-0260-8
Metric ............................................................. 00-0003-2 One way/two way, remove and install.......... 33-3360-42
Unified inch .................................................... 00-0003-1 Pilot controller pattern conversion,
Torque value repair .......................................................... 33-3360-40
30° cone seat hydraulic fittings .............. 00-0003-7 Pilot pressure regulating, repair ................... 33-3360-13

100312
PN=5
Index
Page Page
Pilot shut-off solenoid , repair ...................... 33-3360-13 Inspect ........................................................... 04-0400-6

Propel speed change solenoid, repair ......... 33-3360-13 Repair ............................................................ 04-0400-5
Propel speed change, propel motor Water separator
disassemble—27C ZTS ............................... 02-0260-1 Repair ............................................................ 05-0560-2
Propel speed change, propel motor Welding on machine .......................................... 17-1740-1
disassemble—35C ZTS ............................... 02-0260-8 Welding repair of major structure ...................... 17-1740-1
Shuttle, propel motor disassemble—27C Welding repairs................................................ 00-0001-10
ZTS .............................................................. 02-0260-1 Window
Sliding, remove and install ............................. 18-1810-2
W Windowpane
Bonded, remove and install ........................... 18-1810-1
Waste disposal .................................................. 00-0001-5 Dimensions .................................................... 18-1810-3
Water pump One piece molding, remove and
Assemble ....................................................... 04-0400-6 install ............................................................ 18-1810-1
Disassemble .................................................. 04-0400-6

100312
PN=6
Index

100312
PN=7
Index

100312
PN=8

Excavator Repair

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27C ZTS and 35C ZTS

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27C ZTS and 35C ZTS Excavator Operation

TM2053 (03OCT12) 27C ZTS and 35C ZTS Repair

Technical Information Feedback Form

FAX NUMBER: 1-563-589-5800 (USA)

TM2053 (03OCT12) 27C ZTS and 35C ZTS Repair

TM2053 (03OCT12) 27C ZTS and 35C ZTS Repair

Section 02—Axles and Suspension

Section 05—Engine Auxiliary Systems

Section 17—Frame or Supporting Structure

Section 18—Operator's Station

Section 32—Bulldozers (Blade)

Section 43—Swing or Pivoting System

Section 99—Dealer Fabricated Tools

Original Instructions. All information, illustrations and specifications in this

TM2053 (03OCT12) i 27C ZTS and 35C ZTS Repair

TM2053 (03OCT12) ii 27C ZTS and 35C ZTS Repair

Group 0001—Safety Service Recommendations for

Group 0003—Torque Values

TM2053 (03OCT12) 00-1 27C ZTS and 35C ZTS Repair

TM2053 (03OCT12) 00-2 27C ZTS and 35C ZTS Repair

Follow Safety Instructions

Operate Only If Qualified

TM2053 (03OCT12) 00-0001-1 27C ZTS and 35C ZTS Repair

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

TM2053 (03OCT12) 00-0001-2 27C ZTS and 35C ZTS Repair

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

TM2053 (03OCT12) 00-0001-3 27C ZTS and 35C ZTS Repair

Prevent Battery Explosions

Handle Chemical Products Safely

injury. Under certain conditions, lubricants, coolants,

TM2053 (03OCT12) 00-0001-4 27C ZTS and 35C ZTS Repair

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Avoid unexpected machine movement. Start engine only

TM2053 (03OCT12) 00-0001-5 27C ZTS and 35C ZTS Repair

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

support machine. When working close to an excavation,

TM2053 (03OCT12) 00-0001-6 27C ZTS and 35C ZTS Repair

Keep Riders Off Machine

Avoid Backover Accidents

TM2053 (03OCT12) 00-0001-7 27C ZTS and 35C ZTS Repair

Avoid Machine Tip Over

Use Special Care When Lifting Objects

TM2053 (03OCT12) 00-0001-8 27C ZTS and 35C ZTS Repair

Park and Prepare for Service Safely

Service Cooling System Safely

TM2053 (03OCT12) 00-0001-9 27C ZTS and 35C ZTS Repair

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Avoid welding or heating near pressurized fluid lines.

Drive Metal Pins Safely

TM2053 (03OCT12) 00-0001-10 27C ZTS and 35C ZTS Repair

TM2053 (03OCT12) 00-0003-1 27C ZTS and 35C ZTS Repair

Metric Bolt and Screw Torque Values