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160DLCExcavator
Repair
TECHNICAL MANUAL160DLC Excavator Repair
TM10091 11JAN08 (ENGLISH)
For complete service information also see:
160DLC Excavator Operation and Tests . . . TM10088160DLC Excavator Operator’s Manual . . . . . OMT226911POWERTECH 4.5L/6.8L POWERTECH E6.8L Diesel Engines—Base Engine . . . . . . . CTM104POWERTECH E 6.8L DieselEngines—Level 16 Electronic Fuel Systemwith Denso HPCR . . . . . . . . . . . . . . . . . . . . . CTM502Alternators and Starter Motors. . . . . . . . . . . CTM77Undercarriage Appraisal Manual . . . . . . . . . SP326Super Caddy Oil Cleanup Procedure . . . . . . CTM310
Worldwide ConstructionAnd Forestry Division
LITHO IN U.S.A
Introduction
DX,TMIFC –19–29SEP98–1/1
Foreword
This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.
Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.
This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.
Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.
Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable essential tools, service equipment and tools,other materials needed to do the job, service parts kits,specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.
Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.
TM10091 (11JAN08) 160DLC Excavator Repair011108
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Introduction
TX,TM,FAX –19–03JUL01–1/1
Technical Information Feedback Form
We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.
SEND TO: John Deere Dubuque WorksP.O. Box 538Attn: Publications Supervisor, Dept. 303Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
Ideas, Comments (Please State Page Number):
OVERALL, how would you rate the quality of this publication? (Check one)
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TM10091 (11JAN08) 160DLC Excavator Repair011108
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Introduction
TM10091 (11JAN08) 160DLC Excavator Repair011108
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Contents00
SECTION 00—General InformationGroup 01—SafetyGroup 0003—Torque Values
SECTION 01—Tracks01Group 0130—Track System
SECTION 02—Axles, Differentials and SuspensionSystems
Group 0250—Axle Shaft, Bearings, and ReductionGears
Group 0260—Hydraulic System
SECTION 04—EngineGroup 0400—Removal and Installation
02
SECTION 05—Engine Auxiliary SystemGroup 0510—Cooling SystemGroup 0520—Intake SystemGroup 0560—External Fuel Supply System
SECTION 07—Dampener Drive (Flex Coupling)Group 0752—Elements
SECTION 17—Frame or Supporting StructureGroup 1740—Frame InstallationGroup 1749—Chassis Weights
04
SECTION 18—Operator’s StationGroup 1800—Removal and InstallationGroup 1810—Operator EnclosureGroup 1821—Seat and Seat BeltGroup 1830—Heating and Air Conditioning
SECTION 33—ExcavatorGroup 3302—BucketsGroup 3340—FramesGroup 3360—Hydraulic System
05
SECTION 43—Swing or Pivoting SystemGroup 4350—Mechanical Drive ElementsGroup 4360—Hydraulic System
SECTION 99—Dealer Fabricated ToolsGroup 9900—Dealer Fabricated Tools
All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.
07
COPYRIGHT 2008DEERE & COMPANY
Moline, IllinoisAll rights reserved
A John Deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2007
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TM10091 (11JAN08) i 160DLC Excavator Repair011108
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Contents
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TM10091 (11JAN08) ii 160DLC Excavator Repair011108
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Contents
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TM10091 (11JAN08) iii 160DLC Excavator Repair011108
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Contents
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TM10091 (11JAN08) iv 160DLC Excavator Repair011108
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Section 00General Information
Contents
Page
Group 01—Safety . . . . . . . . . . . . . . . . . . . . . .00-01-1
Group 0003—Torque ValuesTorque Value
Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Torque Value
Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4Service Recommendations for 37° Flare
and 30° Cone Seat Connectors . . . . . . . . .00-0003-5Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6Service Recommendation
O-Ring Boss Fittings In AluminumHousing—Excavators . . . . . . . . . . . . . . .00-0003-8
Service Recommendations For FlaredConnections—Straight or TaperedThreads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10
Service Recommendations For Flat FaceO-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11
Service RecommendationO-Ring Face Seal Fittings with SAE
Inch Hex Nut and Stud End for HighPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
O-Ring Face Seal Fittings with MetricHex Nut and Stud End for StandardPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-14
O-Ring Face Seal Fittings with MetricHex Nut and Stud End for HighPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-16
Service Recommendations for MetricSeries Four Bolt Flange Fitting . . . . . . . .00-0003-18
Service Recommendations For InchSeries Four Bolt Flange Fittings. . . . . . . .00-0003-19
Service RecommendationInch Series Four Bolt Flange For High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-20
TM10091 (11JAN08) 00-1 160DLC Excavator Repair011108
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Contents
00
TM10091 (11JAN08) 00-2 160DLC Excavator Repair011108
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Group 01Safety
00011
TX03679,00016CC –19–03JAN07–1/1
Recognize Safety Information
T13
3555
–UN
–28A
UG
00T
1335
88–1
9–28
AU
G00
This is the safety alert symbol. When this symbol isnoticed on the machine or in this manual, be alert forthe potential of personal injury.
Follow the precautions and safe operating practiceshighlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — isused with the safety alert symbol. DANGER identifies themost serious hazards.
On the machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located nearspecific hazards. General precautions are on CAUTIONlabels.
TX03679,00016F9 –19–03JAN07–1/1
Follow Safety Instructions
T13
3556
–UN
–24A
UG
00
Read the safety messages in this manual and on themachine. Follow these warnings and instructions carefully.Review them frequently.
Be sure all operators of this machine understand everysafety message. Replace operator’s manual and safetylabels immediately if missing or damaged.
TX03679,00016FA –19–08JAN08–1/1
Operate Only If Qualified
Do not operate this machine unless the operator’smanual has been read carefully, and you have beenqualified by supervised training and instruction.
Operator should be familiar with the job site andsurroundings before operating. Try all controls and
machine functions with the machine in an open areabefore starting to work.
Know and observe all safety rules that may apply toevery work situation and work site.
TM10091 (11JAN08) 00-01-1 160DLC Excavator Repair011108
PN=9
Safety
0001
2
TX03679,00016D0 –19–03JAN07–1/1
Wear Protective Equipment
TS
206
–UN
–23A
UG
88
Guard against injury from flying pieces of metal or debris;wear goggles or safety glasses.
Wear close fitting clothing and safety equipmentappropriate to the job.
Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable oruncomfortable loud noises.
AM40430,00000A9 –19–17JUL07–1/1
Avoid Unauthorized Machine Modifications
John Deere recommends using only genuine JohnDeere replacement parts to ensure machineperformance. Never substitute genuine John Deereparts with alternate parts not intended for theapplication as these can create hazardous situations orhazardous performance. Non-John Deere Parts, or anydamage or failures resulting from their use are notcovered by any John Deere warranty.
Modifications of this machine, or addition ofunapproved products or attachments, may affect
machine stability or reliability, and may create a hazardfor the operator or others near the machine. Theinstaller of any modification which may affect theelectronic controls of this machine is responsible forestablishing that the modification does not adverselyaffect the machine or its performance.
Always contact an authorized dealer before makingmachine modifications that change the intended use,weight or balance of the machine, or that altermachine controls, performance or reliability.
TM10091 (11JAN08) 00-01-2 160DLC Excavator Repair011108
PN=10
Safety
00013
TX03679,00016CE –19–03JAN07–1/1
Add Cab Guarding for Special Uses
T13
3733
–UN
–15S
EP
00
Special work situations or machine attachments maycreate an environment with falling or flying objects.Working near an overhead bank, doing demolition work,using a hydraulic hammer, or working in a wooded area,for example, may require added guarding to protect theoperator.
FOPS (falling object protective structures) and specialscreens or guarding should be installed when falling orflying objects may enter or damage the machine. Contactyour authorized dealer for information on devices intendedto provide protection in special work situations.
TX03679,0001734 –19–03JAN07–1/1
Inspect Machine
T66
07A
Q–U
N–1
8OC
T88
Inspect machine carefully each day by walking around itbefore starting.
Keep all guards and shields in good condition andproperly installed. Fix damage and replace worn or brokenparts immediately. Pay special attention to hydraulichoses and electrical wiring.
TX03679,00016D2 –19–03JAN07–1/1
Stay Clear of Moving Parts
T13
3592
–UN
–12S
EP
01Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintainingany part of machine with moving parts.
Keep guards and shields in place. Replace any guard orshield that has been removed for access as soon asservice or repair is complete.
TM10091 (11JAN08) 00-01-3 160DLC Excavator Repair011108
PN=11
Safety
0001
4
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X98
11–U
N–2
3AU
G88
Escaping fluid under pressure can penetrate the skincausing serious injury.
Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.
Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.
TX03679,00016D3 –19–01OCT07–1/1
Avoid High-Pressure Oils
T13
3509
–UN
–17M
AR
06T
1338
40–U
N–2
0SE
P00
This machine uses a high-pressure hydraulic system.Escaping oil under pressure can penetrate the skincausing serious injury.
Never search for leaks with your hands. Protect hands.Use a piece of cardboard to find location of escaping oil.Stop engine and relieve pressure before disconnectinglines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctorimmediately. Injected oil must be removed surgicallywithin hours or gangrene may result. Contact aknowledgeable medical source or the Deere & CompanyMedical Department in Moline, Illinois, U.S.A.
TM10091 (11JAN08) 00-01-4 160DLC Excavator Repair011108
PN=12
Safety
00015
TX03679,00016D4 –19–03JAN07–1/1
Beware of Exhaust Fumes
T13
3546
–UN
–24A
UG
00
Prevent asphyxiation. Engine exhaust fumes can causesickness or death.
If you must operate in a building, provide adequateventilation. Use an exhaust pipe extension to remove theexhaust fumes or open doors and windows to bringoutside air into the area.
TX03679,00016F5 –19–08MAR07–1/1
Prevent Fires
T13
3552
–UN
–14S
EP
00T
1335
53–U
N–0
7SE
P00
T13
3554
–UN
–07S
EP
00
Handle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or whennear sparks or flame.
Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines and electrical wiring. Never storeoily rags or flammable materials inside a machinecompartment.
Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.
Keep A Fire Extinguisher Available: Always keep amultipurpose fire extinguisher on or near the machine.Know how to use extinguisher properly.
TX03679,000174A –19–03JAN07–1/1
Prevent Battery Explosions
TS
204
–UN
–23A
UG
88
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 objectacross the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).
TM10091 (11JAN08) 00-01-5 160DLC Excavator Repair011108
PN=13
Safety
0001
6
TX03679,00016D7 –19–08JAN08–1/1
Handle Chemical Products Safely
T13
3580
–UN
–25A
UG
00
Exposure to hazardous chemicals can cause seriousinjury. Under certain conditions, lubricants, coolants,paints and adhesives used with this machine may behazardous.
If uncertain about safe handling or use of these chemicalproducts, contact your authorized John Deere dealer for aMaterial Safety Data Sheet (MSDS) or go to internetwebsite http://www.jdmsds.com. The MSDS describesphysical and health hazards, safe use procedures, andemergency response techniques for chemical substances.Follow MSDS recommendations to handle chemicalproducts safely.
TX03679,0001733 –19–03JAN07–1/1
Dispose of Waste Properly
T13
3567
–UN
–25A
UG
00
Improper disposal of waste can threaten the environment.Fuel, oils, coolants, filters and batteries used with thismachine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or intoany water source.
Air conditioning refrigerants can damage the atmosphere.Government regulations may require using a certifiedservice center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact yourlocal environmental or recycling center or your authorizeddealer for more information.
TX03679,000174B –19–03JAN07–1/1
Prepare for Emergencies
TS
291
–UN
–23A
UG
88
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.
TM10091 (11JAN08) 00-01-6 160DLC Excavator Repair011108
PN=14
Safety
00017
TX03679,00016F2 –19–25JAN07–1/1
Use Steps and Handholds Correctly
T13
3468
–UN
–30A
UG
00
Prevent falls by facing the machine when you get on andoff. Maintain 3-point contact with steps and handrails.Never use machine controls as handholds.
Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount ordismount a moving machine.
TX03679,0001799 –19–03JAN07–1/1
Start Only From Operator’s Seat
T13
3715
–UN
–07S
EP
00Avoid unexpected machine movement. Start engine onlywhile sitting in operator’s seat. Ensure all controls andworking tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the startersolenoid terminals.
TX03679,00016DD –19–10JAN07–1/1
Use and Maintain Seat Belt
T13
3716
–19–
14S
EP
00Use seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.
Examine seat belt frequently. Be sure webbing is not cutor torn. Replace seat belt immediately if any part isdamaged or does not function properly.
The complete seat belt assembly should be replacedevery three years, regardless of appearance.
TM10091 (11JAN08) 00-01-7 160DLC Excavator Repair011108
PN=15
Safety
0001
8
DW90712,00002BF –19–26OCT06–1/1
Prevent Unintended Machine Movement
T21
6779
–UN
–22N
OV
05
Be careful not to accidentally actuate control levers whenco-workers are present. Pull pilot control shutoff lever tolocked position during work interruptions. Pull pilot controlshutoff lever to locked position and stop engine beforeallowing anyone to approach machine.
Always lower work equipment to the ground and pull pilotcontrol shutoff lever to locked position before standing upor leaving the operator’s seat. Stop engine before exiting.
TM10091 (11JAN08) 00-01-8 160DLC Excavator Repair011108
PN=16
Safety
00019
TX03679,0001748 –19–13DEC07–1/1
Avoid Work Site Hazards
T13
4986
–UN
–31O
CT
00T
1336
50–U
N–2
7SE
P00
T13
3549
–UN
–24A
UG
00
Avoid contact with gas lines, buried cables and waterlines. Call utility line location services to identify allunderground utilities before you dig.
Prepare work site properly. Avoid operating nearstructures or objects that could fall onto the machine.Clear away debris that could move unexpectedly if runover.
Avoid boom or arm contact with overhead obstaclesor overhead electrical lines. Never move any part ofmachine or load closer than 3 m (10 ft) plus twice the lineinsulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or asignal person to keep vehicles and pedestrians away. Usea signal person if moving machine in congested areas orwhere visibility is restricted. Always keep signal person inview. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient tosupport machine. When working close to an excavation,position travel motors away from the hole.
Reduce machine speed when operating with tool on ornear ground when obstacles may be hidden (e.g., duringsnow 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.
TX03679,0001726 –19–03JAN07–1/1
Keep Riders Off Machine
T72
73A
H–U
N–0
8JU
N90
Only allow operator on machine.
Riders are subject to injury. They may fall from machine,be caught between machine parts, or be struck by foreignobjects.
Riders may obstruct operator’s view or impair his ability tooperate machine safely.
TM10091 (11JAN08) 00-01-9 160DLC Excavator Repair011108
PN=17
Safety
000110
TX03679,00016F3 –19–03JAN07–1/1
Avoid Backover Accidents
T13
3548
–UN
–24A
UG
00
Before moving machine, be sure all persons are clearof both travel and swing paths. Turn around and lookdirectly for best visibility. Use mirrors to assist in checkingall around machine. Keep windows and mirrors clean,adjusted, and in good repair.
Be certain travel alarm is working properly.
Use a signal person when backing if view isobstructed or when in close quarters. Keep signalperson in view at all times. Use prearranged hand signalsto communicate.
TX03679,00016DF –19–03JAN07–1/1
Avoid Machine Tip Over
T13
3716
–19–
14S
EP
00T
1335
45–U
N–1
5SE
P00
T13
3803
–UN
–27S
EP
00
Use seat belt at all times.
Do not jump if the machine tips. You will be unlikely tojump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Besure truck is wide enough and on a firm level surface. Useloading ramps and attach them properly to truck bed.Avoid trucks with steel beds because tracks slip moreeasily on steel.
Be careful on slopes. Use extra care on soft, rocky orfrozen ground. Machine may slip sideways in theseconditions. When traveling up or down slopes, keep thebucket on uphill side and just above ground level.
Be careful with heavy loads. Using oversize buckets orlifting heavy objects reduces machine stability. Extendinga heavy load or swinging it over side of undercarriagemay cause machine to tip.
Ensure solid footing. Use extra care when operatingnear banks or excavations that may cave-in and causemachine to tip or fall.
TM10091 (11JAN08) 00-01-10 160DLC Excavator Repair011108
PN=18
Safety
000111
TX03679,00016E1 –19–24SEP07–1/1
Use Special Care When Lifting Objects
T13
3839
–UN
–27S
EP
00
Never use this machine to lift people.
Never lift a load above another person. Keep bystandersclear 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 andin this manual. Extending heavy loads too far or swingingover undercarriage side may cause machine to tip over.
Use proper rigging to attach and stabilize loads. Be sureslings or chains have adequate capacity and are in goodcondition. Use tether lines to guide loads and prearrangedhand signals to communicate with coworkers.
TX03679,00016F0 –19–12FEB07–1/1
Add and Operate Attachments Safely
Always verify compatibility of attachments by contactingyour authorized dealer. Adding unapproved attachmentsmay affect machine stability or reliability and may create ahazard for others near the machine.
Ensure that a qualified person is involved in attachmentinstallation. Add guards to machine if operator protectionis required or recommended. Verify that all connectionsare secure and attachment responds properly to controls.
Carefully read attachment manual and follow allinstructions and warnings. In an area free of bystandersand obstructions, carefully operate attachment to learn itscharacteristics and range of motion.
TM10091 (11JAN08) 00-01-11 160DLC Excavator Repair011108
PN=19
Safety
000112
TX03679,00016E9 –19–03JAN07–1/1
Park and Prepare for Service Safely
T13
3332
–19–
14D
EC
01T
S22
9–U
N–2
3AU
G88
Warn others of service work. Always park and prepareyour machine for service or repair properly.
• Park machine on a level surface and lower equipmentand attachments to the ground.
• Place pilot shutoff lever in “lock” position. Stop engineand remove key.
• Attach a “Do Not Operate” tag in an obvious place inthe operator’s station.
Securely support machine or attachment before workingunder it.
• Do not support machine with boom, arm, or otherhydraulically actuated attachments.
• Do not support machine with cinder blocks or woodenpieces that may crumble or crush.
• Do not support machine with a single jack or otherdevices that may slip out of place.
Understand service procedures before beginning repairs.Keep service area clean and dry. Use two peoplewhenever the engine must be running for service work.
DX,RCAP –19–04JUN90–1/1
Service Cooling System SafelyT
S28
1–U
N–2
3AU
G88
Explosive release of fluids from pressurized coolingsystem can cause serious burns.
Shut off engine. Only remove filler cap when cool enoughto touch with bare hands. Slowly loosen cap to first stopto relieve pressure before removing completely.
TM10091 (11JAN08) 00-01-12 160DLC Excavator Repair011108
PN=20
Safety
000113
DX,PAINT –19–24JUL02–1/1
Remove Paint Before Welding or Heating
TS
220
–UN
–23A
UG
88
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from areato 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 withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.
Do not use a chlorinated solvent in areas where weldingwill take place.
Do all work in an area that is well ventilated to carry toxicfumes and dust away.
Dispose of paint and solvent properly.
TM10091 (11JAN08) 00-01-13 160DLC Excavator Repair011108
PN=21
Safety
000114
TX03679,00016D5 –19–12SEP07–1/1
Make Welding Repairs Safely
T13
3547
–UN
–31A
UG
00
IMPORTANT: Disable electrical power before welding.Turn off main battery switch ordisconnect positive battery cable.Separate harness connectors to engineand vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines.Flammable spray may result and cause severe burns ifpressurized lines fail as a result of heating. Do not let heatgo beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.Use a qualified welding technician for structural repairs.Make sure there is good ventilation. Wear eye protectionand protective equipment when welding.
TX03679,0001745 –19–17JUL07–1/1
Drive Metal Pins Safely
T13
3738
–UN
–14S
EP
00Always wear protective goggles or safety glasses andother protective equipment before striking hardened parts.Hammering hardened metal parts such as pins andbucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer andobject to prevent chipping.
TM10091 (11JAN08) 00-01-14 160DLC Excavator Repair011108
PN=22
Group 0003Torque Values
0000031
OUT3035,TORQUE2 –19–22MAR06–1/1
Metric Bolt and Cap Screw Torque Values
TO
RQ
2–U
N–0
7SE
P99
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Thread Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.b "Dry" means plain or zinc plated without any lubrication.
Fasteners should be replaced with the same or higher property class.CAUTION: Use only metric tools on metric hardware. If higher property class fasteners are used, these should only beOther tools may not fit properly. Tool may slip and tightened to the strength of the original.cause injury.
Make sure fastener threads are clean and that you properly startthread engagement. This will prevent them from failing when
DO NOT use these values if a different torque value or tightening tightening.procedure is given for a specific application. Torque values listed arefor general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut,Shear bolts are designed to fail under predetermined loads. Always not to the bolt head. Tighten toothed or serrated-type lock nuts to thereplace shear bolts with identical property class. full torque value.
TM10091 (11JAN08) 00-0003-1 160DLC Excavator Repair011108
PN=23
Torque Values
000003
2
04T,90,M170 –19–29SEP99–1/2
Additional Metric Cap Screw Torque Values
T68
73A
A–U
N–1
8OC
T88
T68
73A
B–U
N–1
8OC
T88
T68
73A
C–U
N–1
8OC
T88
CAUTION: Use only metric tools on metrichardware. Other tools may not fit properly. Theymay slip and cause injury.
Check tightness of cap screws periodically. Torque valueslisted are for general use only. Do not use these values ifa different torque value or tightening procedure is listedfor a specific application.
Shear bolts are designed to fail under predeterminedloads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or highergrade. If higher grade fasteners are used, these shouldonly be tightened to the strength of the original.
Make sure fastener threads are clean and you properlystart thread engagement. This will prevent them fromfailing when tightening.
Tighten cap screws having lock nuts to approximately 50percent of amount shown in chart.
Continued on next page
TM10091 (11JAN08) 00-0003-2 160DLC Excavator Repair011108
PN=24
Torque Values
0000033
04T,90,M170 –19–29SEP99–2/2
METRIC CAP SCREW TORQUE VALUESa
T-Bolt H-Bolt M-Bolt
NominalDia 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 687aTorque tolerance is ±10%.
TM10091 (11JAN08) 00-0003-3 160DLC Excavator Repair011108
PN=25
Torque Values
000003
4
OUT3035,TORQUE1 –19–14JAN04–1/1
Unified Inch Bolt and Cap Screw Torque Values
TO
RQ
1A–U
N–2
7SE
P99
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Thread Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,and for all other types of bolts and screws of any length.b "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.c "Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to theFasteners should be replaced with the same or higher grade. If full torque value.higher grade fasteners are used, these should only be tightened tothe strength of the original.
TM10091 (11JAN08) 00-0003-4 160DLC Excavator Repair011108
PN=26
Torque Values
0000035
T82,BHMA,EL –19–29SEP99–1/1
Service Recommendations for 37° Flare and30° Cone Seat Connectors
T62
34A
C–U
N–1
8OC
T88
1. Inspect flare and flare seat. They must be free of dirtor obvious defects.
2. Defects in tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or petroleumjelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torquechart. Do not allow hoses to twist when tighteningfittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N•m lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160
NOTE: Torque tolerance is ± 10%.
TM10091 (11JAN08) 00-0003-5 160DLC Excavator Repair011108
PN=27
Torque Values
000003
6
04T,90,K66 –19–29SEP99–1/2
Service Recommendations for O-Ring BossFittings
T62
43A
E–U
N–1
8OC
T88
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring overtape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
Continued on next page
TM10091 (11JAN08) 00-0003-6 160DLC Excavator Repair011108
PN=28
Torque Values
0000037
04T,90,K66 –19–29SEP99–2/2
T65
20A
B–U
N–1
8OC
T88
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 washercontacts face of boss.
3. Turn fitting head-end counterclockwise to proper index(maximum of one turn).
NOTE: Do not allow hoses to twist when tighteningfittings.
4. Hold fitting head-end with a wrench and tighten locknutand 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%.
TM10091 (11JAN08) 00-0003-7 160DLC Excavator Repair011108
PN=29
Torque Values
000003
8
OUT3035,0000353 –19–14JAN04–1/2
O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators
T19
6315
–UN
–17N
OV
03
O-Ring Boss Straight and Adjustable Fittings
1—Straight Fitting 3—Stud End 5—Hex Nut 6—Backup Washer2—O-Ring 4—Adjustable Fitting
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUDEND NUT WITH METRIC THREAD IN ALUMINUM HOUSINGTORQUE VALUES—Tolerance is ± 10% unless otherwise
specified
Thread Size Hex Nut Sizemm mm N•m (lb-ft)
M12 x 1.5 17 39 (29)
M14 x 1.5 19 39 (29)
M16 x 1.5 22 55 (41)
M22 x 1.5 27 75 (55)
M27 x 2 32 110 (81)
M30 x 2 36 141 (104)
M33 x 2 41 165 (122)
M38 x 2 46 165 (122)
M42 x 2 50 275 (203)
Continued on next page
TM10091 (11JAN08) 00-0003-8 160DLC Excavator Repair011108
PN=30
Torque Values
0000039
OUT3035,0000353 –19–14JAN04–2/2
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUDEND NUT WITH INCH THREAD IN ALUMINUM HOUSINGTORQUE VALUES—Tolerance is ± 10% unless otherwise
specified
Thread Sizein. N•m (lb-ft)
1/8 —
1/4 28 (20)
3/8 39 (29)
1/2 75 (55)
3/4 126 (93)
1 165 (122)
1-1/8 —
1-1/4 259 (191)
1-3/8 —
1-1/2 330 (243)
1-3/4 —
2 —
O-RING BOSS PLUG STUD END WITH INCH THREAD INALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10%
unless otherwise specified
Thread Sizein. N•m (lb-ft)
1/8 7.8 (5.80)
1/4 11.8 (8.70)
3/8 23 (17)
1/2 39 (29)
3/4 55 (41)
1 86 (64)
1-1/4 126 (93)
1-1/2 157 (116)
2 204 (150)
1. Inspect fitting and O-ring boss sealing surfaces andthe O-ring. They must be free of dirt, scratches,nicks, or burrs. O-ring must be free of dirt, cuts,cracks, swelling or flatten condition.
2. Back the stud end hex nut (5) off as far as possible.Push backup washer (6) towards the nut to fullyexpose the turn down section of stud end. Washermust fit turned down section and not be too loose
3. Wrap electrical tape over threads to protect O-ring.Slide O-ring over the tape into turned down section.Remove tape. Apply hydraulic oil to the threads ofstud end, turned down section, and O-ring.
4. Turn fitting into the boss by hand until face of nut orbackup washer squeezes O-ring into the seat andcontacts face of boss. Loosen an adjustable fittingno more than one turn for alignment.
5. Tighten straight fitting or hex nut to the torque valuegiven. Hold body of adjustable fitting using asecond wrench when tightening hex nut.
TM10091 (11JAN08) 00-0003-9 160DLC Excavator Repair011108
PN=31
Torque Values
000003
10
04T,90,M171 –19–28JAN92–1/1
Service Recommendations For FlaredConnections—Straight or Tapered Threads
T68
73A
E–U
N–1
8OC
T88
Straight Thread
T68
73A
D–U
N–1
8OC
T88
Tapered Thread
1. Inspect flare and flare seat. They must be free of dirtor obvious defects.
2. Defects in the tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.
3. Align the tube with the fitting before attempting to startthe nut.
4. Lubricate the male threads with hydraulic fluid orpetroleum jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tighteningfittings.
TORQUE CHART a
Straight Thread b Tapered Thread
ThreadSize 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
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434aTorque tolerance is ±10%.bWith seat face.
NOTE: If female thread is cast iron (control valves, brakevalves motors, etc.), torque must be reducedapproximately 10%.
TM10091 (11JAN08) 00-0003-10 160DLC Excavator Repair011108
PN=32
Torque Values
00000311
04T,90,K67 –19–02MAR00–1/1
Service Recommendations For Flat Face O-Ring Seal Fittings
1. Inspect the fitting sealing surfaces and O-ring. Theymust be free of dirt or defects.
2. Lubricate O-rings and install into grove usingpetroleum jelly to hold in place.
3. Index angle fittings and tighten by hand pressingjoint together to insure O-ring remains in place.
4. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tightening
fittings, use backup wrench on straight hosecouplings.
IMPORTANT: Tighten fittings to 150% of listedtorque value if indexing is necessaryor if fitting is attached to anactuating devise.
Tighten fittings to 50% of listedtorque value if used in aluminumhousing.
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.
TM10091 (11JAN08) 00-0003-11 160DLC Excavator Repair011108
PN=33
Torque Values
000003
12
OUT3035,0000420 –19–14JAN04–1/2
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High PressureService Recommendations
E
A BDC
EFH
G
F
H70
406
–UN
–12D
EC
01
A—90° Swivel Elbow and Tube C—Stud Straight and Tube Nut E—Stud End G—Swivel NutNut D—Bulkhead Union and Nut F—Tube Nut H—Hex Nut
B—90° Adjustable Stud Elbow
O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size TorqueOD
mm Dash Size mm (in.) in. in. N•m (lb-ft) in. N•m (lb-ft)
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 11/16 24 (18) 13/16 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 13/16 37 (27) 1 42 (31)
12 -8 12.70 (0.500) 13/16-16 15/16 75 (55) 1-1/8 93 (69)
16 -10 15.88 (0.625) 1-14 1-1/8 103 (76) 1-5/16 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 1-3/8 152 (112) 1-1/2 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 — 152 (112) — 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 1-5/8 214 (158) 1-3/4 247 (182)
32 -20 31.75 (1.250) 1-11/16-12 1-7/8 286 (211) 2 328 (242)
38 -24 38.10 (1.500) 2-12 2-1/4 326 (240) 2-3/8 374 (276)
Continued on next page
TM10091 (11JAN08) 00-0003-12 160DLC Excavator Repair011108
PN=34
Torque Values
00000313
OUT3035,0000420 –19–14JAN04–2/2
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Thread Size Straight Hex Sizea Adjustable Nut Hex Size Steel or Gray Iron Torque
in. in. in. N•m (lb-ft)
3/8-24 5/8 9/16 18 (13)
7/16-20 5/8 5/8 24 (18)
1/2-20 3/4 11/16 30 (22)
9/16-18 3/4 3/4 37 (27)
3/4-16 7/8 15/16 75 (55)
7/8-14 1-1/16 1-1/16 103 (76)
1-1/16-12 1-1/4 1-3/8 177 (131)
1-3/16-12 1-3/8 1-1/2 231 (170)
1-5/16-12 1-1/2 1-5/8 270 (199)
1-5/8-12 1-3/4 1-7/8 286 (211)
1-7/8-12 2-1/8 2-1/8 326 (240)a Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
1. Inspect fitting and connector sealing surfaces andthe O-rings. They must be free of dirt, scratches,nicks, and burrs. O-ring must be free of dirt, cuts,cracks, swelling or flatten condition.
2. Back the stud end hex nut off as far as possible.Push backup washer towards the nut to fullyexpose the turn down section. Washer must fitturned down section and not be too loose
3. Lubricate O-rings using a thin film of clean hydraulicoil or as needed, petroleum jelly to hold O-ring inplace.
Install O-ring into groove making sure it is seated atthe bottom. Excess petroleum jelly will preventseating of O-ring and cause it to pop out.
To protect an O-ring from threads, wrap electricaltape over the threads. Slide O-ring over the tapeinto the turned down section. Remove the tape.
4. Turn fitting into the boss by hand until face of nut orwasher squeezes the O-ring into the seat andcontacts face of boss. Loosen adjustable fittings nomore than one turn for alignment.
Hold connections together while tightening nut toensure O-ring remains in place.
5. Tighten fitting or nut to torque value shown. Use asecond wrench to hold the fitting in position or tokeep hose from twisting while tightening nut.
TM10091 (11JAN08) 00-0003-13 160DLC Excavator Repair011108
PN=35
Torque Values
000003
14
OUT3035,0000366 –19–14JAN04–1/2
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard PressureService Recommendations
1 2 3 4
6
7
10
11
8
98 11
10
6
10
5
811
T196337 T19
6337
–UN
–18N
OV
03
1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove3—Stud Straight 6—Tube Nut 9—Hex Nut
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa(275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size TorqueOD
mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 16 (12) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 24 (18) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 50 (37) 30 93 (69)
16 -10 15.88 (0.625 1-14 30 69 (51) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 102 (75) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 102 (75) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 142 (105) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 50 190 (140) 50 328 (242)
38 -24 38.10 (1.500) 2-12 60 217 (160) 60 374 (276)
50 -32 50.80 (2.000) — — — — —
Continued on next page
TM10091 (11JAN08) 00-0003-14 160DLC Excavator Repair011108
PN=36
Torque Values
00000315
OUT3035,0000366 –19–14JAN04–2/2
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Steel or Gray Iron Torque Aluminum or BrassSize Torque
mm. mm mm N•m (lb-ft) N•m (lb-ft)
M8 x 1 12 12 8 (6) 5 (4)
M10 x 1 14 14 15 (11) 10 (7)
M12 x 1.5 17 17 25 (18) 17 (12)
M14 x 1.5 19 19 40 (30) 27 (20)
M16 x 1.5 22 22 45 (33) 30 (22)
M18 x 1.5 24 24 50 (37) 33 (25)
M22 x 1.5 27 27 69 (51) 46 (34)
M27 x 2 32 32 100 (74) 67 (49)
M30 x 2 36 36 130 (96) 87 (64)
M33 x 2 41 41 160 (118) 107 (79)
M38 x 2 46 46 176 (130) 117 (87)
M42 x 2 50 50 210 (155) 140 (103)
M48 x 2 55 55 260 (192) 173 (128)
M60 x 2 65 65 315 (232) 210 (155)a Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.b Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
1. Inspect fitting and connector sealing surfaces andthe O-rings. They must be free of dirt, scratches,nicks, and burrs. O-ring must be free of dirt, cuts,cracks, swelling or flatten condition.
2. Back the stud end hex nut off as far as possible.Push backup washer towards the nut to fullyexpose the turn down section. Washer must fitturned down section and not be too loose
3. Lubricate O-rings using a thin film of clean hydraulicoil or as needed, petroleum jelly to hold O-ring inplace.
Install O-ring into groove making sure it is seated atthe bottom. Excess petroleum jelly will preventseating of O-ring and cause it to pop out.
To protect an O-ring from threads, wrap electricaltape over the threads. Slide O-ring over the tapeinto the turned down section. Remove the tape.
4. Turn fitting into the boss by hand until face of nut orwasher squeezes the O-ring into the seat andcontacts face of boss. Loosen adjustable fittings nomore than one turn for alignment.
Hold connections together while tightening nut toensure O-ring remains in place.
5. Tighten fitting or nut to torque value shown. Use asecond wrench to hold the fitting in position or tokeep hose from twisting while tightening nut.
TM10091 (11JAN08) 00-0003-15 160DLC Excavator Repair011108
PN=37
Torque Values
000003
16
OUT3035,0000421 –19–14JAN04–1/2
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure ServiceRecommendations
1 2 3 4
6
7
10
11
8
98 11
10
6
10
5
811
T196337 T19
6337
–UN
–18N
OV
03
1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove3—Stud Straight 6—Tube Nut 9—Hex Nut
O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size TorqueOD
mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 24 (18) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 37 (27) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 75 (55) 30 93 (69)
16 -10 15.88 (0.625) 1-14 30 103 (76) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 152 (112) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 152 (112) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 214 (158) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 — 286 (211) 50 328 (242)
38 -24 38.10 (1.500) 2-12 — 326 (240) 60 374 (276)
Continued on next page
TM10091 (11JAN08) 00-0003-16 160DLC Excavator Repair011108
PN=38
Torque Values
00000317
OUT3035,0000421 –19–14JAN04–2/2
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600KPA (275.8 BAR) (4,000 PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Size Steel or Gray Iron Torque
mm. mm mm N•m (lb-ft)
M8 x 1 12 12 8 (6)
M10 x 1 14 14 15 (11)
M12 x 1.5 17 17 35 (26)
M14 x 1.5 19 19 45 (33)
M16 x 1.5 22 22 55 (41)
M18 x 1.5 24 24 70 (52)
M22 x 1.5 27 27 100 (74)
M27 x 2 32 32 170 (125)
M30 x 2 36 36 215 159)
M33 x 2 41 41 260 (192)
M38 x 2 46 46 320 (236)
M42 x 2 50 50 360 (266)
M48 x 2 55 55 420 (310)a Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.b Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
1. Inspect fitting and connector sealing surfaces andthe O-rings. They must be free of dirt, scratches,nicks, and burrs. O-ring must be free of dirt, cuts,cracks, swelling or flatten condition.
2. Back the stud end hex nut off as far as possible.Push backup washer towards the nut to fullyexpose the turn down section. Washer must fitturned down section and not be too loose
3. Lubricate O-rings using a thin film of clean hydraulicoil or as needed, petroleum jelly to hold O-ring inplace.
Install O-ring into groove making sure it is seated atthe bottom. Excess petroleum jelly will preventseating of O-ring and cause it to pop out.
To protect an O-ring from threads, wrap electricaltape over the threads. Slide O-ring over the tapeinto the turned down section. Remove the tape.
4. Turn fitting into the boss by hand until face of nut orwasher squeezes the O-ring into the seat andcontacts face of boss. Loosen adjustable fittings nomore than one turn for alignment.
Hold connections together while tightening nut toensure O-ring remains in place.
5. Tighten fitting or nut to torque value shown. Use asecond wrench to hold the fitting in position or tokeep hose from twisting while tightening nut.
TM10091 (11JAN08) 00-0003-17 160DLC Excavator Repair011108
PN=39
Torque Values
000003
18
04T,90,K175 –19–29SEP99–1/1
Service Recommendations for Metric Series Four Bolt Flange Fitting
T68
90B
B–U
N–0
1MA
R90
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.
2. Install the correct O-ring (and backup washer ifrequired) into groove using petroleum jelly to hold itin place.
3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to the port. Hand tighten cap screwsto hold parts in place. Do not pinch O-ring (C).
4. Single piece flange (D): Place hydraulic line incenter of flange and install four cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.
5. After components are properly positioned and capscrews are hand tightened, tighten one cap screw,
then tighten the diagonally opposite cap screw.Tighten two remaining cap screws. Tighten all capscrews as specified in the chart below.
DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.
TORQUE CHARTa
Threadb N•m lb-ft
M6 12 9
M8 30 22
M10 57 42
M12 95 70
M14 157 116
M16 217 160
M18 334 246
M20 421 318aTolerance ± 10%. The torques given are enough for the givensize connection with the recommended working pressure.Increasing cap screw torque beyond these amounts will result inflange and cap screw bending and connection failures.bMetric standard thread.
TM10091 (11JAN08) 00-0003-18 160DLC Excavator Repair011108
PN=40
Torque Values
00000319
04T,90,K174 –19–01AUG94–1/1
Service Recommendations For Inch Series Four Bolt Flange Fittings
T68
90B
B–U
N–0
1MA
R90
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.
2. Install O-ring (and backup washer if required) intogroove using petroleum jelly to hold it in place.
3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to port. Hand tighten cap screws tohold parts in place. Do not pinch O-ring (C).
4. Single piece flange (D): Place hydraulic line incenter of flange and install cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.
5. Tighten one cap screw, then tighten the diagonallyopposite cap screw. Tighten two remaining capscrews. Tighten all cap screws as specified in thechart below.
DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.
TORQUE CHART
N•m lb-ft
Nominal Cap ScrewFlange Size
Size Min Max Min Max
1/2 5/16-18 20 31 15 23UNC
3/4 3/8-16 UNC 28 54 21 40
1 3/8-16 UNC 37 54 27 40
1-1/4 7/16-14 47 85 35 63UNC
1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
2-1/2 1/2-13 UNC 107 131 79 97
3 5/8-11 UNC 158 264 117 195
3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5 5/8-11 UNC 158 264 117 195
TM10091 (11JAN08) 00-0003-19 160DLC Excavator Repair011108
PN=41
Torque Values
000003
20
OUT3035,0000422 –19–14JAN04–1/1
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
T68
90B
B–U
N–0
1MA
R90
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa(414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—
Tolerance is ± 10% unless otherwise specified
Nominal Cap Screw Sizea Min—Max TorqueFlange Size
in. in. N•m (lb-ft)b
1/2 5/16-18 UNC 20—31 (15—23)
3/4 3/8-16 UNC 34—54 (25—40)
1 7/16-14 UNC 57—85 (42—63)
1-1/4 1/2-13 UNC 85—131 (63—97)
1-1/2 5/8-11 UNC 159—264 (117—195)
2 3/4-10 UNC 271—468 (200—345)a JDM A17D, SAE Grade 5 or better cap screws with platedhardware.Lock washers are permissible but not recommended.b Minimum torques given are enough for the given size connectionwith the recommended working pressure. Torques can beincreased to the maximum shown for each cap screw size ifdesired. Increasing cap screw torque beyond the maximum willresult in flange and cap screw bending and connection failures.
1. Clean sealing surfaces (A). Inspect. Scratches,nicks, and burrs cause leaks. Roughness causesO-ring wear. Out-of-flat causes O-ring extrusion. Ifimperfection cannot be polished out, replacecomponent.
2. Install the O-ring (and backup ring, if used) intogroove. Use petroleum jelly to hold it in place.
IMPORTANT: DO NOT use air wrenches. DO NOTtighten one cap screw fully beforetightening the others. DO NOT overtighten.
3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to port. Hand tighten cap screws tohold flange halves and line in place. Do not pinchO-ring (C).
Single piece flange (D): Make sure flange iscentrally located on port and line is centered inflange. Install the cap screws. Hand tighten capscrews to hold flange and line in place. Do notpinch O-ring.
4. Tighten one cap screw and then the diagonallyopposite cap screw. Tighten the two remaining capscrews. Tighten cap screws within the specifiedtorque values.
TM10091 (11JAN08) 00-0003-20 160DLC Excavator Repair011108
PN=42
Section 01Tracks
Contents 01
Page
Group 0130—Track SystemTrack Roller Remove and Install . . . . . . . . . .01-0130-1Track Roller Disassemble and Assemble . . .01-0130-3Track Roller Pressure Test . . . . . . . . . . . . . .01-0130-5Track Carrier Roller Remove and Install . . . .01-0130-6Metal Face Seals Repair . . . . . . . . . . . . . . . .01-0130-8Track Shoe Remove and Install . . . . . . . . .01-0130-11Track Chain Remove and Install . . . . . . . . .01-0130-11Track Chain Disassemble and Assemble . .01-0130-16Track Chain Repair . . . . . . . . . . . . . . . . . . .01-0130-17Sprocket Remove and Install. . . . . . . . . . . .01-0130-19Front Idler Remove and Install . . . . . . . . . .01-0130-20Front Idler Disassemble and Assemble . . . .01-0130-21Track Adjuster and Recoil Spring Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .01-0130-23Track Adjuster and Recoil Spring
Disassemble and Assemble. . . . . . . . . . .01-0130-25Track Adjuster Cylinder Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-30
TM10091 (11JAN08) 01-1 160DLC Excavator Repair011108
PN=1
Contents
01
TM10091 (11JAN08) 01-2 160DLC Excavator Repair011108
PN=2
Group 0130Track System
0101301
OUO6046,00022F1 –19–03APR07–1/3
Track Roller Remove and Install
1. Swing upperstructure 90° and lower bucket to raisetrack off ground. Keep angle between boom and arm90—110° and position round side of bucket on ground.
CAUTION: Prevent possible injury fromunexpected machine movement. Position shopstands under frame to support machine whileremoving lower track roller.
SpecificationMachine—Weight (Approximate) 18 151 kg................................................
39 980 lb
2. Put shop stands under machine.
OUO6046,00022F1 –19–03APR07–2/3
T73
96D
Z–U
N–2
8NO
V90
A—Grease FittingB—ValveC—Bleed Hole
CAUTION: Prevent possible injury from highpressure grease. Do not remove grease fitting(A) from valve (B).
3. Loosen valve (B) one to two turns to release greasethrough bleed hole (C).
Continued on next page
TM10091 (11JAN08) 01-0130-1 160DLC Excavator Repair011108
PN=45
Track System
010130
2
OUO6046,00022F1 –19–03APR07–3/3
T65
85T
N–U
N–2
5OC
T88
A—Cap Screw (4 used)B—Track Roller
CAUTION: Heavy component; use appropriatelifting device.
SpecificationTrack Roller—Weight 35 kg........................................................................
77 lb
4. Attach appropriate lifting device to track roller (B).Remove cap screws (A) and track roller (B).
5. Measure track roller tread diameter. See 160DLCTrack Roller Tread Diameter. (SP326 UndercarriageAppraisal Manual.)
6. Repair or replace parts as necessary. See Track RollerDisassemble and Assemble. (Group 0130.)
7. Install track roller and tighten cap screws tospecification.
SpecificationRoller-to-Frame Cap Screw—Torque 460 N•m..........................................................................................
340 lb-ft
8. If equipped, install track roller guard and tighten capscrews to specification.
SpecificationTrack Roller Guard Cap Screw—Torque 460 N•m..........................................................................................
340 lb-ft
9. Tighten valve on track adjuster to specification.
SpecificationTrack Adjuster Valve—Torque 88 N•m.......................................................
65 lb-ft
10. Check and adjust track sag. See Check and AdjustTrack Sag. (Operator’s Manual.)
TM10091 (11JAN08) 01-0130-2 160DLC Excavator Repair011108
PN=46
Track System
0101303
OUO6046,00022F2 –19–19APR07–1/2
Track Roller Disassemble and Assemble
T83
10A
H–U
N–2
1SE
P94
A—Plug (2 used) C—Pin (2 used) E—Metal Face Seal (2 used) G—RollerB—Bracket (2 used) D—O-Ring (2 used) F—Bushing (2 used) H—Axle
1. Remove plug (A) and drain oil.
2. Remove pin (C).
3. Remove bracket (B) using a bearing pullerattachment and adapters from puller set.
IMPORTANT: Metal face seals can be reused ifthey are not worn or damaged. Aused seal must be kept together as aset because of wear patterns on sealring face.
4. Remove metal face seal (E) from roller and bracket.Keep seal rings together as a matched set with sealring faces together to protect surfaces.
5. Inspect metal face seals. See Metal Face SealsRepair. (Group 0130.)
6. Remove axle (H) from roller.
NOTE: Only remove bushings if replacement isnecessary.
7. Remove bushings (F) using a 2-jaw puller andadapters from puller set.
8. Replace parts as necessary.
Apply a thin film of oil to bushings (F) and install.
IMPORTANT: O-rings and seat surfaces forO-rings must be clean, dry, and oilfree so O-rings do not slip whenroller is turning.
9. Thoroughly clean O-rings and seat surfaces inbrackets (B) and in seal rings using volatile,non-petroleum base solvent and lint-free tissues.
10. Install seals (E) in brackets (B) and in roller (G).Apply equal pressure with fingers at four equallyspaced points on seal face. Seal must “pop” downinto place so O-ring is tight against seal bore. Avolatile, non-petroleum base solvent or talcumpowder may be used as a lubricant.
TM10091 (11JAN08) 01-0130-3 160DLC Excavator Repair011108
PN=47
Continued on next page
Track System
010130
4
OUO6046,00022F2 –19–19APR07–2/2
11. Wipe finger prints and foreign material off seal ringface using clean oil and lint-free tissues. Apply athin film of oil to each seal ring face.
12. Install axle (H) to bracket (B).
13. Install roller (G) onto axle (H).
14. Install opposite side bracket (B) on rollerassembly.
15. Apply TY24811NEVER-SEEZ anti-seize lubricantor equivalent to pins (C). Install pins (C) even withflat surface of brackets (B).
16. Fill roller to specification.
SpecificationLower Track Roller—Capacity 260 mL.................................................
8.8 oz
17. Apply PM37509 Cure Primer and PM37398 PipeSealant to threads of plug. Install and tighten plug.
SpecificationPlug—Torque 30 N•m...........................................................................
22 lb-ft
NEVER-SEEZ is a trademark of Bostik Findley, Inc.
TM10091 (11JAN08) 01-0130-4 160DLC Excavator Repair011108
PN=48
Track System
0101305
OUO6046,00022F3 –19–19APR07–1/1
Track Roller Pressure Test
T10
9691
B–U
N–0
2JU
N97
A—Plug, Barbed Adapter and ConnectorB—JT03001 Tee Fitting 7/16-20 M 37° x 7/16-20 F
37° SW x 7/16-20 M 37°C—Hose (2 used)D—Pressure GaugeE—Needle ValveF—Air Pressure Regulator
1. Hold shaft and turn shell of roller several turns to seatmetal face seals.
2. Remove the drain plug.
NOTE: Plug, barbed adapter, and connector (A) are fromleak detector kit D05361ST.
3. Install parts (A—F).
4. Tighten plug. Slowly pressurize oil cavity to testpressure specification.
SpecificationTrack Roller Oil Cavity—Pressure 110 ± 28 kPa.......................................
16 ± 4 psi
5. Close valve. Wait for 30 seconds. Check for oil leaksor pressure decrease.
6. If leakage, disassemble roller and replace parts asnecessary. See Track Roller Disassemble andAssemble. (Group 0130.)
7. Apply PM37509 Cure Primer and PM37398 PipeSealant to threads of plug. Install and tighten plug tospecification.
SpecificationPlug—Torque 30 N•m..................................................................................
22 lb-ft
TM10091 (11JAN08) 01-0130-5 160DLC Excavator Repair011108
PN=49
Track System
010130
6
OUO6046,00022F4 –19–05MAR07–1/3
Track Carrier Roller Remove and Install
T73
96D
Z–U
N–2
8NO
V90
A—Grease FittingB—ValveC—Bleed Hole
CAUTION: Prevent possible injury from highpressure grease. Do not remove grease fitting(A) from valve (B).
1. Loosen valve (B) one to two turns to release greasethrough bleed hole (C).
OUO6046,00022F4 –19–05MAR07–2/3
TX
1006
136A
–UN
–07A
PR
06
1—Track Frame2—Carrier Roller3—Track Chain4—Wood Block
2. Raise track chain (3), using a jack, enough to permitcarrier roller (2) removal.
CAUTION: Prevent accidental lowering of trackby securely supporting track before attemptingservice procedure.
3. Install wooden block (4) between track chain (3) andtrack frame (1).
Continued on next page
TM10091 (11JAN08) 01-0130-6 160DLC Excavator Repair011108
PN=50
Track System
0101307
OUO6046,00022F4 –19–05MAR07–3/3
TX
1018
018A
–UN
–26J
AN
07
1—Cap Screw (4 used)2—Carrier Roller
4. Remove cap screws (1) and carrier roller (2).
5. Measure track carrier roller tread diameter. See160DLC Carrier Roller Tread Diameter. (SP326Undercarriage Appraisal Manual.)
IMPORTANT: Carrier roller replaced as assemblyonly.
6. Replace carrier roller as necessary.
SpecificationCarrier Roller—Weight 21 kg......................................................................
46 lb
7. Install carrier roller and cap screws (1).
8. Tighten carrier roller cap screws (1) to specification.
SpecificationCarrier Roller-to-Frame CapScrew—Torque 270 N•m.............................................................................
200 lb-ft
9. Remove wooden blocks and jack.
10. Tighten valve on track adjuster to specification.
SpecificationTrack Adjuster Valve—Torque 88 N•m.......................................................
65 lb-ft
11. Check and adjust track sag. See Check and AdjustTrack Sag. (Operator’s Manual.)
TM10091 (11JAN08) 01-0130-7 160DLC Excavator Repair011108
PN=51
Track System
010130
8
OUO6046,00022F5 –19–05MAR07–1/4
Metal Face Seals Repair
T85
079
–UN
–24A
UG
93
A—Seal RingB—Worn Area (Shaded Area)C—Seal Ring FaceD—Outer Half of Seal Ring FaceE—Sealing Area (Dark Line)
Inspect Metal Face Seals
IMPORTANT: If seals are to be reused, keep sealrings together as a matched set withseal ring faces together. Insert a pieceof cardboard to protect surfaces.
1. Inspect for the following conditions to determine ifseals can be reused:
a. The narrow, highly polished sealing area (E) mustbe in the outer half of seal ring face (D).
b. Sealing area must be uniform and concentric withthe ID and OD of seal ring (A).
c. Sealing area must not be chipped, nicked, orscratched.
OUO6046,00022F5 –19–05MAR07–2/4
T85
080
–UN
–05D
EC
96
A—Seal RingB—Worn area (Shaded Area)C—Inner Half of Seal Ring FaceD—Sealing Area (Dark Line)
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 ofseal ring.
TM10091 (11JAN08) 01-0130-8 160DLC Excavator Repair011108
PN=52
Continued on next page
Track System
0101309
OUO6046,00022F5 –19–05MAR07–3/4
T82
840
–UN
–23F
EB
89
A—Seal Face
3. Clean reusable seals by removing all foreign materialfrom seal rings, except seal face (A), using a scraperor a stiff bristled fiber brush.
4. Wash seal rings and O-rings using a volatile,non-petroleum base solvent to remove all oil.Thoroughly dry parts using a lint-free tissue.
Continued on next page
TM10091 (11JAN08) 01-0130-9 160DLC Excavator Repair011108
PN=53
Track System
010130
10
OUO6046,00022F5 –19–05MAR07–4/4
TX
1018
110
–UN
–26J
AN
07T
X10
1811
2–U
N–2
6JA
N07
A—O-RingB—Mating FaceC—Ring SurfaceD—DistanceE—Distance
Assemble Metal Face Seals
IMPORTANT: If incorrectly assembled, oil leakage ordamage will occur.
1. Check that the O-ring (A) is not twisted and that it isinstalled correctly on seal ring.
2. After installing seal, check that seal ring surface (C) isparallel with seal mating face (B) by measuringdistances (D) and (E), as shown. If these distancesdiffer, correct O-ring seating.
TM10091 (11JAN08) 01-0130-10 160DLC Excavator Repair011108
PN=54
Track System
01013011
OUO6046,00022F6 –19–05MAR07–1/1
Track Shoe Remove and Install
T67
94A
M–U
N–2
3FE
B89
T63
52A
H–U
N–2
3FE
B89
A—Rounded EdgeB—Chamfered Edge
1. Measure grouser height. See 160DLC Three BarGrouser Height. (SP326 Undercarriage AppraisalManual.)
2. Apply a light coat of oil to cap screw threads and installshoe.
3. Install all track shoe nuts with rounded corners (A)against the link and chamfered edges (B) away fromthe link. Be sure nut is properly positioned in the linkso there is full contact between the nut and the link.
4. Tighten cap screws in pattern shown.
SpecificationShoe-to-Link Cap Screw—Torque 804 N•m...............................................
593 lb-ft
OUO6046,00022F7 –19–03APR07–1/4
Track Chain Remove and Install
1. Swing upperstructure to side. Lower boom to raisetrack off the ground.
Keep the angle between boom and arm at 90—110°with the round side of bucket on the ground.
CAUTION: Prevent possible injury fromunexpected machine movement. Put blocks orshop stands under machine frame to supportmachine while measuring track sag.
SpecificationMachine—Weight 18 151 kg.......................................................................
39 980 lb
2. Place blocks or shop stands under the machine tosupport machine.
TM10091 (11JAN08) 01-0130-11 160DLC Excavator Repair011108
PN=55
Continued on next page
Track System
010130
12
OUO6046,00022F7 –19–03APR07–2/4
T73
96D
Z–U
N–2
8NO
V90
A—Grease FittingB—ValveC—Bleed Hole
CAUTION: Prevent possible injury from highpressure grease. Do not remove grease fitting(A) from valve (B).
3. Loosen valve (B) one to two turns to release greasethrough bleed hole (C).
Continued on next page
TM10091 (11JAN08) 01-0130-12 160DLC Excavator Repair011108
PN=56
Track System
01013013
OUO6046,00022F7 –19–03APR07–3/4
T14
3215
B–U
N–2
0JU
L01
1—Bushing (2 used)2—Master Pin3—Dimple
NOTE: Master pin (2) and master link are identified bylarge dimple (3) and snap ring on master pin.
4. Move track chain so master pin (2) is over front idler orsprocket.
5. Remove track shoe on each side of master pin. SeeTrack Shoe Remove and Install. (Group 0130.)
6. If removing chain at idler, put wooden blocks in front ofidler and under chain so chain does not fall whenmaster pin is removed.
7. Remove snap ring.
IMPORTANT: Master pin can be removed in only onedirection.
8. Remove master pin using a 50-Ton Master Pin PusherInstaller.
9. If chain was disconnected at idler, slowly operate travellever in reverse direction to remove chain from top oftrack frame.
CAUTION: Heavy component; use appropriatelifting device.
SpecificationTracks—Weight 1180 kg.............................................................................
2602 lb
10. Remove track chain.
11. Measure track chain link, bushing, and pitch. (SeeSP326 Undercarriage Appraisal Manual.)
12. Replace parts as necessary.
13. Position track chain so section on ground has pinboss on links toward rear of machine.
14. Install end of chain on sprocket and slowly turnsprocket in forward direction to pull chain across topof frame to front idler.
15. Remove stand and lower machine.
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Track System
010130
14
OUO6046,00022F7 –19–03APR07–4/4
IMPORTANT: Master pin can be installed in only onedirection.
16. Pull ends of chain together. Install master pin using50-Ton Master Pin Pusher Installer.
IMPORTANT: Replace snap ring with new one.
17. Install snap ring.
18. Install track shoe. See Track Shoe Remove andInstall. (Group 0130.)
19. Tighten valve in track adjuster to specification.
SpecificationTrack Adjuster Valve—Torque 88 N•m.......................................................
65 lb-ft
20. Check and adjust track sag. See Check and AdjustTrack Sag. (Operator’s Manual.)
TM10091 (11JAN08) 01-0130-14 160DLC Excavator Repair011108
PN=58
Track System
01013015
TM10091 (11JAN08) 01-0130-15 160DLC Excavator Repair011108
PN=59
Track System
010130
16
OUO6046,00022F8 –19–03APR07–1/2
Track Chain Disassemble and Assemble
T16
2713
–UN
–15J
AN
03
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Track System
01013017
OUO6046,00022F8 –19–03APR07–2/2
1—Track Link (42 used) 7—Master Pin 12—Nut (172 used) 16—Master Bushing2—Master Track Link 8—Spacer (2 used) 13—Shoe (43 used) 17—Track Chain Without3—Pin (42 used) 9—Snap Ring 14—Track Link (42 used) Shoes5—Seal (84 used) 10—Cap Screw (172 used) 15—Bushing (42 used)
1. Measure track components (1—17). See 160DLCStandard Bushing Outer Diameter. (SP326Undercarriage Appraisal Manual.)
2. Turn pins (3 and 7) and bushings (15 and 16) asrequired.
3. Clean any dust or rust from surfaces of track linkpin bores, counterbores, and ends of bushings.
4. Apply grease to counterbore in track links, theseals, and ends of bushings.
5. For each joint, fill clearance between pin OD andbushing ID with grease.
6. Install seal (5) so tapered side is toward bushing.
OUO6046,00022F9 –19–05MAR07–1/4
Track Chain Repair
T58
21A
G–U
N–2
6OC
T88
A—Cut LocationsB—Broken Link
1. Remove track shoes from each side of broken linkassembly. See Track Shoe Remove and Install. (Group0130.)
IMPORTANT: When making cuts using cutting torch,be careful not to cut or gouge goodparts.
2. Cut links, bushing, and pin at points (A) to removebroken link (B).
OUO6046,00022F9 –19–05MAR07–2/4
T58
21A
H–U
N–2
6OC
T88
A—Bushing
3. Grind ends of bushing (A) even with links to make itinto a master bushing.
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Track System
010130
18
OUO6046,00022F9 –19–05MAR07–3/4
T58
21A
I–U
N–2
6OC
T88
A—Pin StubB—Hammer
4. Burn holes through center of pin stubs (A).
5. Hold a heavy hammer (B) against link while pin stub isbeing driven out.
OUO6046,00022F9 –19–05MAR07–4/4
T58
21A
J–U
N–2
4MA
Y89
A—Master PinB—SpacerC—Right LinkD—Master BushingE—Left Link
6. Install links (C and E) on master bushing (D). Checkcap screw hole spacing using a track shoe.
7. Instal spacers (B) into counterbore of links.
8. Install link assembly. Install master pins (A).
9. Install track shoes. See Track Shoe Remove andInstall. (Group 0130.)
TM10091 (11JAN08) 01-0130-18 160DLC Excavator Repair011108
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Track System
01013019
OUO6046,00022FA –19–19APR07–1/1
Sprocket Remove and Install
T14
5912
B–U
N–0
1FE
B02
1—Cap Screw (16 used)
IMPORTANT: Sprocket must be replaced when thetooth tips become excessively rounded,worn, or chipped to prevent excessivewear to chain. If machine is driven inone direction a majority of the time,wear will be on one side of teeth. Toextend service life, change sprocketsfrom one side of machine to the other.
1. Disconnect track chain. See Track Chain Remove andInstall. (Group 0130.)
2. Lift side of machine so sprocket teeth clear chain.
CAUTION: Heavy component; use appropriatelifting device.
SpecificationSprocket—Weight (approximate) 46 kg......................................................
100 lb
3. Remove cap screws (1) and sprocket.
4. Apply PM37509 Cure Primer and PM37421 ThreadLock and Sealer (High Strength) to threads of capscrews (B).
5. Install sprocket and tighten cap screws (1).
SpecificationSprocket-to-Travel Gearbox CapScrew—Torque 500 N•m.............................................................................
369 lb-ft
6. Lower machine.
7. Install track chain. See Track Chain Remove andInstall. (Group 0130.)
TM10091 (11JAN08) 01-0130-19 160DLC Excavator Repair011108
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Track System
010130
20
OUO6046,00022FB –19–05MAR07–1/1
Front Idler Remove and Install
T68
76B
U–U
N–2
5OC
T88
A—Front Idler
1. Disconnect track chain. See See Track Chain Removeand Install. (Group 0130.)
2. Slide front idler (A) forward, using pry bar.
CAUTION: Heavy component; use appropriatelifting device.
SpecificationFront Idle—Weight 119 kg...........................................................................
260 lb
3. Attach appropriate lifting device to front idler andremove from frame.
4. Measure front idler wear. See Front Idler FlangeHeight. (SP326 Undercarriage Appraisal Manual.)
5. Repair or replace idler as necessary. See Front IdlerDisassemble and Assemble. (Group 0130.)
6. Install front idler.
7. Connect track chain. See Track Chain Remove andInstall. (Group 0130.)
TM10091 (11JAN08) 01-0130-20 160DLC Excavator Repair011108
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Track System
01013021
OUO6046,00022FC –19–19APR07–1/2
Front Idler Disassemble and Assemble
T115165
A
A
E
E
H
B
BC
D
D
JI
GF
F G
T11
5165
–UN
–21A
PR
06
A—Pin (2 used) D—Drain Plug (2 used) G—O-Ring (2 used) I—YokeB—Bushing (2 used) E—Bracket (2 used) H—Axle J—Cap Screw (4 used)C—Idler F—Metal Face Seal (2 used)
1. Remove cap screws (J) and yoke (I).
2. Remove drain plug (D) and drain oil.
IMPORTANT: Metal face seals (F) can be reused ifthey are not worn or damaged. Aused seal must be kept together as aset because of wear patterns on sealring face.
IMPORTANT: Put matching marks on brackets (E)and axle (H).
3. Remove pins (A), brackets (E), O-rings (G) andmetal face seals (F).
4. Inspect metal face seals (F). See Metal Face SealsRepair. (Group 0130.) Keep seal rings together as
a matched set with seal ring faces together toprotect surfaces.
5. Remove axle (H). Inspect axle (H) and bushings (B)for scoring or excessive wear.
NOTE: Remove bushings (B) only if replacement isnecessary.
6. Remove bushing (B) using a 2-jaw puller andadapters from 17-1/2 and 30-ton puller set.
7. Apply a thin film of oil to new bushings (B). Installbushings (B) so flange is tight against shoulder ofidler (C).
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Track System
010130
22
OUO6046,00022FC –19–19APR07–2/2
8. Apply a thin layer of anti-seize lubricant orequivalent to end of axle (H) and to bore inbrackets (E).
IMPORTANT: Seat surfaces for O-rings must beclean, dry, and oil free so O-rings donot slip when idler is turning.
9. Thoroughly clean seat surfaces in idler (C),brackets (E), and seal rings using volatile,non-petroleum base solvent and lint-free tissues.
NOTE: A volatile, non-petroleum base solvent ortalcum powder may be used as a lubricant.
10. Install metal face seal (F) in bracket (E). Applyequal pressure with fingers at four equally spacedpoints on seal face. Seal must "pop" down intoplace so O-ring is tight against seal bore.
11. Wipe finger prints and foreign material off seal ringface using clean oil and lint-free tissues. Apply athin film of oil to each seal face.
NOTE: Repeat steps 12 and 13 for installing oppositeside metal face seal (F) and bracket (E) inidler.
12. Install axle (H) into idler.
13. Install O-rings (G) on axle.
14. Install brackets (E) onto axle (H).
15. Apply anti-seize lubricant or equivalent to pins (A).Install pins.
16. Add oil through plug holes on bearing brackets (E)to specification.
SpecificationFront Idler Oil—Capacity 265 mL.........................................................
8.96 oz
17. Apply PM37509 Cure Primer to threads of drainplug (D).
18. Apply PM37418 Thread Lock and Sealer (MediumStrength) to threads of plug.
19. Install and tighten plug (D) to specification.
SpecificationFront Idler Plug—Torque 30 N•m.........................................................
22 lb-ft
20. Install yoke (I). Tighten cap screws (J) tospecification.
SpecificationYoke-to-Bracket Cap Screw—Torque 206 N•m....................................................................................
150 lb-ft
TM10091 (11JAN08) 01-0130-22 160DLC Excavator Repair011108
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Track System
01013023
OUO6046,00022FD –19–10APR07–1/2
Track Adjuster and Recoil Spring Removeand Install
1. Remove track chain. See Track Chain Remove andInstall. (Group 0130.)
2. Remove front idler. See Front Idler Remove and Install.(Group 0130.)
CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot. Weak spots may resultin immediate or eventual failure creating a riskof personal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling trackadjuster.
A compression tool must be used fordisassembly and assembly because of theextreme preload on spring.
Continued on next page
TM10091 (11JAN08) 01-0130-23 160DLC Excavator Repair011108
PN=67
Track System
010130
24
OUO6046,00022FD –19–10APR07–2/2
T65
57C
X–U
N–2
5OC
T88
A—Track Adjuster
3. Slide track adjuster (A) forward, using a pry bar.
CAUTION: Heavy component; use appropriatelifting device.
SpecificationTrack Adjuster Cylinder andRecoil Spring—Weight 125 kg....................................................................
280 lb
4. Attach appropriate lifting device to track adjuster andremove from frame.
5. Repair or replace parts as necessary. See TrackAdjuster and Recoil Spring Disassemble andAssemble. (Group 0130.)
6. Install front idler. See Front Idler Remove and Install.(Group 0130.)
7. Install track chain. See Track Chain Remove andInstall. (Group 0130.)
TM10091 (11JAN08) 01-0130-24 160DLC Excavator Repair011108
PN=68
Track System
01013025
OUO6046,00022FE –19–05MAR07–1/5
Track Adjuster and Recoil SpringDisassemble and Assemble
T65
57D
Y–U
N–2
5OC
T88
A—ST4920 Track Recoil Spring Disassembly andAssembly Tool
B—NutC—Top Plate
CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot. Weak spots may resultin immediate or eventual failure creating a riskof personal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling trackadjuster.
A compression tool must be used fordisassembly and assembly because of theextreme preload on spring.
CAUTION: Heavy component; use appropriatelifting device.
SpecificationTrack Recoil Spring Disassemblyand Assembly Tool—Weight 225 kg...........................................................
496 lb
1. Place an 18-t (20-ton) jack on bottom of ST4920 TrackRecoil Spring Disassembly and Assembly Tool (A).Remove nuts (B) and top plate (C). See ST4920 TrackRecoil Spring Disassembly and Assembly Tool. (Group9900.)
NOTE: It is not necessary to remove the recoil spring toreplace wear ring and U-ring packing on piston.To replace O-ring in the cylinder, remove recoilspring and rod.
2. Remove nuts (B). Remove top plate (C).
Continued on next page
TM10091 (11JAN08) 01-0130-25 160DLC Excavator Repair011108
PN=69
Track System
010130
26
OUO6046,00022FE –19–05MAR07–2/5
T77
20A
F–U
N–2
8AP
R92
A—Lifting StrapB—Track AdjusterC—DFT1110 Spacer
CAUTION: Heavy component; use appropriatelifting device.
SpecificationTrack Adjuster Cylinder andRecoil Spring—Weight 125 kg....................................................................
280 lb
3. Connect appropriate lifting device to track adjuster (B)using a lifting strap (A).
4. Put track adjuster in assembly tool with cylinder end onDFT1110 Spacer (C). See DFT1110 Spacer. (Group9900.)
5. Remove lifting strap.
Continued on next page
TM10091 (11JAN08) 01-0130-26 160DLC Excavator Repair011108
PN=70
Track System
01013027
OUO6046,00022FE –19–05MAR07–3/5
T77
20A
G–U
N–2
8AP
R92A—Top Plate
B—Nut (8 used)C—ValveD—NutE—Special PlugF—DFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool
6. Install DFT1087 Track Recoil Spring Disassembly andAssembly Guard Tool (F). See DFT1087 Track RecoilSpring Disassembly and Assembly Guard Tool. (Group9900.)
7. Install plate top (A) and nuts (B) with smallest openingto allow access to nut (D).
8. Extend jack ram to provide enough travel to releasespring to the approximate free length.
SpecificationRecoil Spring—Free Length 606 mm..........................................................
23.9 in.
9. Tighten nuts (B) so top plate (A) is tight againstretainer plate.
10. Remove valve (C) and special plug (E).
Continued on next page
TM10091 (11JAN08) 01-0130-27 160DLC Excavator Repair011108
PN=71
Track System
010130
28
OUO6046,00022FE –19–05MAR07–4/5
T77
20A
H–U
N–2
8AP
R92
A—Top PlateB—Nut (8 used)D—NutF—DFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool
11. Raise upper half of guard tool (F). Tighten T-handles.
12. Operate jack to compress spring just enough so nut(D) can be removed.
13. Lower jack ram to release spring force.
14. Repair or replace parts as necessary. See TrackAdjuster Cylinder Disassemble and Assemble. (Group0130.)
15. Put track adjuster cylinder in assembly tool withcylinder end on spacer.
16. Install spacer on rod.
17. Install spring using appropriate lifting device and liftingstrap.
SpecificationRecoil Spring—Weight 65 kg......................................................................
145 lb
18. Install retainer plate.
19. Install guard tool.
20. Install top plate. Install nuts.
21. Raise upper half of guard tool. Tighten T-handles.
22. Operate jack to compress spring to the compressedlength.
SpecificationRecoil Spring—CompressedLength 490 mm............................................................................................
19.3 in.
23. Install nut (D) so hole is aligned with hole in rod.Install special plug.
24. Tighten special plug to specification.
SpecificationSpecial Plug—Torque 15 N•m.....................................................................
133 lb-in.
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Track System
01013029
OUO6046,00022FE –19–05MAR07–5/5
25. Tighten valve.
SpecificationTrack Adjuster and Recoil SpringValve—Torque 88 N•m................................................................................
65 lb-ft
TM10091 (11JAN08) 01-0130-29 160DLC Excavator Repair011108
PN=73
Track System
010130
30
OUO6046,00022FF –19–05MAR07–1/2
Track Adjuster Cylinder Disassemble and Assemble
TX
1004
754
–UN
–17M
AR
06
1—Holder 4—U-Ring 7—Spring 10—Plug2—Piston Rod 5—Cylinder 8—Spacer 11—Nut3—Dust Seal 6—Rod 9—Washer 12—Grease Valve
CAUTION: Spring or rod may break ifdropped while handling, transporting ordisassembling. Nicks or weld craters inspring and rod assembly can cause stressconcentration resulting in a weak spot. Weakspots can result in immediate or eventualfailure of spring or rod creating a risk ofpersonal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling.
A compression tool must be used fordisassembly and assembly because of theextreme preload on spring.
NOTE: It is not necessary to remove the recoil springto replace dust seal (3) and U-ring packing (4).It is necessary to remove the recoil spring toreplace rod (6).
1. Remove piston rod (2) from cylinder (5).
2. Remove holder (1) from piston rod (2) using apress.
IMPORTANT: Do not damage dust seal (3) andU-ring (4).
3. Remove dust seal (3) and U-ring (4) from cylinder(5).
4. Remove recoil spring if necessary. See TrackAdjuster and Recoil Spring Remove and Install.(Group 0130.)
5. Remove rod (6) from cylinder (5).
6. Repair or replace parts as necessary.
7. Install rod (6) into cylinder (5).
TM10091 (11JAN08) 01-0130-30 160DLC Excavator Repair011108
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Track System
01013031
OUO6046,00022FF –19–05MAR07–2/2
8. Install spring (7), spacer (8), washer (9), plug (10),nut (11), and grease valve (12). See Track Adjusterand Recoil Spring Disassemble and Assemble.(Group 0130.)
9. Apply grease to inner surfaces of U-ring (4) anddust seal (3)
NOTE: Install U-ring (4) with lip towards inside ofcylinder (5).
10. Install U-ring (4) and dust seal (3) into cylinder (5).
11. Press holder (1) into piston rod (2).
12. Install piston rod (2) assembly into cylinder (5).
TM10091 (11JAN08) 01-0130-31 160DLC Excavator Repair011108
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Track System
010130
32
TM10091 (11JAN08) 01-0130-32 160DLC Excavator Repair011108
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Section 02Axles, Differentials and Suspension Systems
Contents
Page
Group 0250—Axle Shaft, Bearings, and ReductionGears 02
Travel Gearbox Remove and Install . . . . . . .02-0250-1Travel Gearbox Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-4
Group 0260—Hydraulic SystemTravel Motor and Park Brake Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-2Travel Motor and Park Brake Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . .02-0260-10Counterbalance Valve Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-13Crossover Relief Valve Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-15Make-Up Check Valve Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-17Travel Speed Change Valve Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-19Travel Motor and Park Brake Start-Up
Procedure . . . . . . . . . . . . . . . . . . . . . . . .02-0260-21
TM10091 (11JAN08) 02-1 160DLC Excavator Repair011108
PN=1
Contents
02
TM10091 (11JAN08) 02-2 160DLC Excavator Repair011108
PN=2
Group 0250Axle Shaft, Bearings, and Reduction Gears
0202501
OUO6046,0002300 –19–16APR07–1/3
Travel Gearbox Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
1. Disconnect track chain. See Track Chain Repair.(Group 0130.)
2. Remove sprocket. See Sprocket Remove and Install.(Group 0130.)
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
3. Push pressure release button (1).
4. Remove cover from track frame.
5. Drain oil from travel gearbox. The approximatecapacity of travel gearbox is 6.8 L (1.8 gal).
6. Drain oil from hydraulic oil tank or pull vacuum inhydraulic oil tank using vacuum pump. See ApplyVacuum to Hydraulic Oil Tank. (Group 3360.) Theapproximate capacity of hydraulic oil tank is 120.4 L(31.8 gal).
7. Tag and disconnect lines. Close all open lines andfittings using caps and plugs.
Continued on next page
TM10091 (11JAN08) 02-0250-1 160DLC Excavator Repair011108
PN=79
Axle Shaft, Bearings, and Reduction Gears
020250
2
OUO6046,0002300 –19–16APR07–2/3
T14
2702
B–U
N–1
5JU
N01
1—Cap Screw (14 used)
CAUTION: Heavy component; use appropriatelifting device.
8. Attach JDG909 Lifting Bracket to gearbox as shown.
SpecificationTravel Gearbox and MotorAssembly—Approximate Weight 325 kg.....................................................
717 lb
NOTE: Make alignment marks between travel gearboxand undercarriage to aid in installation.
9. Remove cap screws (1). Remove travel gearbox andmotor assembly.
10. Repair or replace parts as necessary. See TravelGearbox Disassemble and Assemble. (Group 0250.)
NOTE: Align marks made during removal.
11. Install travel gearbox and motor assembly. Tightencap screws (1).
SpecificationTravel Gearbox-to-Frame CapScrew—Torque 630 N•m.............................................................................
465 lb-ft
12. Connect lines. See Travel Hydraulic System LineConnection. (Group 9025-15.)
13. Fill travel gearbox with oil. See Check Travel GearboxOil Level. (Operator’s Manual.)
14. Do Travel Motor and Park Brake Start-Up Procedure.(Group 0260.)
15. Install cover. Tighten cap screws to specification.
SpecificationTravel Gearbox Cover CapScrews—Torque 140 N•m...........................................................................
103 lb-ft
16. Install sprocket. See Sprocket Remove and Install.(Group 0130.)
17. Connect track chain. See Track Chain Remove andInstall. (Group 0130.)
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Axle Shaft, Bearings, and Reduction Gears
OUO6046,0002300 –19–16APR07–3/3
18. Check and adjust track sag. See Check and AdjustTrack Sag. (Operator’s Manual.)
0202503
TM10091 (11JAN08) 02-0250-3 160DLC Excavator Repair011108
PN=81
Axle Shaft, Bearings, and Reduction Gears
020250
4
OUO6046,0002301 –19–19APR07–1/7
Travel Gearbox Disassemble and Assemble
TX
1021
556
–UN
–03A
PR
07
TM10091 (11JAN08) 02-0250-4 160DLC Excavator Repair011108
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Axle Shaft, Bearings, and Reduction Gears
0202505
OUO6046,0002301 –19–19APR07–2/7
0—Hydraulic Motor and 11—Needle Bearing (6 used) 24—Washer 35—Needle Bearing (3 used)Gearbox Assembly 12—Third Planetary Pinion 25—Planetary Gear (3 used) 36—Plate (6 used)
1—Hydraulic Motor Carrier 26—Needle Bearing (3 used) 37—Spacer (3 used)2—Seal (2 used) 13—Planetary Gear (3 used) 27—Plate (6 used) 38—Spring Pin (3 used)3—Tapered Roller Bearing (2 15—Plate (6 used) 28—Pin Fastener (3 used) 39—Shaft
used) 16—Pin Fastener (3 used) 29—Pin Fastener (3 used) 41—Cover4—Drum 17—Spring Pin (3 used) 30—Second Sun Gear 42—Pin5—Chain Sprocket 18—Third Sun Gear 32—First Planetary Pinion 43—Cap Screw (16 used)6—Cap Screw (16 used) 20—Ring Gear Carrier 44—Fitting Plug (3 used)7—Lock Washer (16 used) 21—Cap Screw (20 used) 33—Spacer —O-Ring9—Bearing Nut 23—Second Planetary Pinion 34—Planetary Gear (3 used)10—Pin Fastener Carrier
1. Remove cap screws (43) and cover (41).
2. Remove shaft (39) and first planetary pinion carrier(32).
3. Remove second sun gear (30) and secondplanetary pinion carrier (23) from ring gear (20).
CAUTION: Heavy component; useappropriate lifting device.
SpecificationRing Gear—ApproximateWeight 40 kg.........................................................................................
88 lb
4. Install JT01748 Lifting Brackets to ring gear (20).Remove cap screws (21) and ring gear from drum(4).
CAUTION: Heavy component; useappropriate lifting device.
SpecificationThird Planetary Pinion Carrier—Approximate Weight 40 kg...................................................................
88 lb
5. Remove third sun gear (13) and third planetarypinion carrier (12).
Continued on next page
TM10091 (11JAN08) 02-0250-5 160DLC Excavator Repair011108
PN=83
Axle Shaft, Bearings, and Reduction Gears
020250
6
OUO6046,0002301 –19–19APR07–3/7
TX
1018
574
–UN
–14F
EB
07
9—Bearing Nut47—DFT1109 Holding Bar48—DF1036A Travel Gearbox Nut Wrench
6. Remove bearing nut (9) from travel motor (1) usingDFT1109 Holding Bar (47) and DFT1036A TravelGearbox Nut Wrench (48). See DFT1109 Holding Bar.See DFT1036A Travel Gearbox Nut Wrench. (Group9900.)
CAUTION: Heavy component; use appropriatelifting device.
SpecificationDrum—Approximate Weight 54 kg..............................................................
120 lb
7. Remove drum (4) using JT01748 Lifting Brackets.
NOTE: Disassembly of first, second, and third planetarypinion carriers are similar. Repeat procedure asrequired.
8. Remove spring pins, pins, thrust plates, needlebearings, and planetary gears.
Clean and inspect parts, replace as necessary. Oilparts with gear oil prior to assembly.
IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. A used sealmust be kept together as a set becauseof wear patterns on seal ring face.
9. Remove metal face seal (2). See Metal Face SealsRepair. (Group 0130.)
10. Replace parts as necessary.
NOTE: Further disassembly is not necessary unlessbearing replacement is required. Bearing will bedestroyed during removal, replace with newbearing.
11. Inspect bearing (3) and race inside drum (4).
Continued on next page
TM10091 (11JAN08) 02-0250-6 160DLC Excavator Repair011108
PN=84
Axle Shaft, Bearings, and Reduction Gears
0202507
OUO6046,0002301 –19–19APR07–4/7
CAUTION: DO NOT heat oil over 182°C (260°F).Oil fumes or oil can ignite above 193°C (380°F).Use a thermometer. DO NOT allow a flame orheating element to come in direct contact withthe oil. Heat the oil in a well-ventilated area.Plan a safe handling procedure to avoid burns.
12. Heat inner bearing cone. Install cone tight againstshoulder.
SpecificationBearing Cone—Temperature 50—70°C....................................................
122—158°F
13. Install drum (4).
IMPORTANT: Metal face seal O-rings and seatsurfaces for O-rings must be clean, dry,and oil free so O-ring does not slip.
14. Thoroughly clean metal face seal O-rings and seatsurfaces in travel motor ring gear, drum, and seal ringusing volatile, non-petroleum base solvent andlint-free tissues.
NOTE: A volatile, non-petroleum base solvent or talcumpowder can be used as a lubricant. Solvent mustnot damage the O-ring or leave an oil residue.
15. Install O-ring and metal face seal on travel motor ringgear and drum. Apply equal pressure with fingers atfour equally spaced points on seal face. Seal must“pop” down into place so O-ring is tight against sealbore and seal ring is installed squarely.
16. Clean seal ring face. Apply a thin film of clean oil.
17. Install drum (4) onto hydraulic motor (1).
18. Apply a thin coat of multi-purpose grease to threadsof bearing nut (9). Install bearing nut with machinedsurface towards bearing.
19. Tighten bearing nut (9) using DFT1109 Holding Barand DFT1036A Travel Gearbox Nut Wrench. SeeDFT1109 Holding Bar. See DFT1036A TravelGearbox Nut Wrench. (Group 9900.) Seat bearings.
TM10091 (11JAN08) 02-0250-7 160DLC Excavator Repair011108
PN=85
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Axle Shaft, Bearings, and Reduction Gears
020250
8 OUO6046,0002301 –19–19APR07–5/7
SpecificationBearing Nut—Torque 800 N•m....................................................................
590 lb-ft
20. To seat bearings, tap on drum using a plastichammer. Then turn drum four-to- five times to theright and left to seat the bearings.
Repeat steps to ensure bearings are seated properly.
OUO6046,0002301 –19–19APR07–6/7
TX1004312
9
10
39
TX
1004
312
–UN
–14M
AR
06
TX1004313
4612
TX
1004
313
–UN
–14M
AR
06
9—Bearing Nut10—Dowel Pin12—Third Planetary Pinion Carrier39—Travel Motor46—Hole
21. Ensure center of dowel pin (10) is aligned with centerof spline on travel motor (39). If centers are notaligned tighten bearing nut (9) until dowel pin centeraligns with center of the next spline.
NOTE: Assembly of first, second, and third planetarypinion carrier assemblies is similar. Repeatprocedure as required.
22. Install needle bearings (11) into planetary gears (13).
IMPORTANT: There is an identification groove on oneside of third planetary gears (16). Besure that this marked side faces thehole for the spring pin.
23. Install thrust plates (15) and planetary gears (13) intothird planetary pinion carrier (12).
24. Install pins (16).
Continued on next page
TM10091 (11JAN08) 02-0250-8 160DLC Excavator Repair011108
PN=86
Axle Shaft, Bearings, and Reduction Gears
0202509
OUO6046,0002301 –19–19APR07–7/7
45
TX1004310 16
TX
1004
310
–UN
–14M
AR
06
16—Pin45—Slit
25. Install spring pins (17) with slit (45) toward end ofpins (16).
26. Assemble second and first planetary pinion carrierassemblies.
27. Install third planetary pinion carrier so dowel pin (10)enters hole (46) on third planetary pinion carrier (12).
28. Apply PM38656 Rigid Form-in-Place gasket to flangesurface on ring gear.
29. Install ring gear (20) onto drum (4).
30. Install and tighten cap screws (21).
SpecificationRing Gear-to-Drum Cap Screw—Torque 270 N•m..........................................................................................
199 lb-ft
31. Install second and first planetary pinion carriers, sungears, and shaft.
32. Apply PM38656 Form-in-Place gasket to flangesurface on cover (41).
33. Install cover on ring gear (20).
34. Apply PM37418 Thread Lock and Sealer (mediumstrength) to thread of cap screws (43). Install andtighten cap screws.
SpecificationCover-to-Ring Gear Cap Screw—Torque 110 N•m..........................................................................................
83 lb-ft
TM10091 (11JAN08) 02-0250-9 160DLC Excavator Repair011108
PN=87
Axle Shaft, Bearings, and Reduction Gears
020250
10
TM10091 (11JAN08) 02-0250-10 160DLC Excavator Repair011108
PN=88
Group 0260Hydraulic System
0202601
TM10091 (11JAN08) 02-0260-1 160DLC Excavator Repair011108
PN=89
Hydraulic System
020260
2
FS41334,0000172 –19–10APR07–1/7
Travel Motor and Park Brake Remove and Install
TX
1000
629
–UN
–28N
OV
05
TM10091 (11JAN08) 02-0260-2 160DLC Excavator Repair011108
PN=90
Continued on next page
Hydraulic System
0202603
FS41334,0000172 –19–10APR07–2/7
0—Travel Motor and Gearbox 10—Pin Fastener 23—Second Planetary Pinion 33—SpacerAssembly 11—Needle Bearing (6 used) Carrier 34—Planetary Gear (3 used)
1—Travel Motor 12—Third Planetary Pinion 24—Washer 35—Needle Bearing (3 used)2—Seal (2 used) Carrier 25—Planetary Gear (3 used) 36—Plate (6 used)3—Tapered Roller Bearing (2 13—Planetary Gear (3 used) 26—Needle Bearing (3 used) 37—Spacer (3 used)
used) 15—Plate (6 used) 27—Plate (6 used) 38—Spring Pin (3 used)4—Drum 16—Pin Fastener (6 used) 28—Pin Fastener (3 used) 39—Shaft5—Chain Sprocket 17—Spring Pin (3 used) 29—Pin Fastener (3 used) 41—Cover6—Cap Screw (20 used) 18—Third Sun Gear 30—Second Sun Gear 42—Pin7—Lock Washer (20 used) 20—Ring Gear 32—First Planetary Pinion 43—Cap Screw (12 used)9—Bearing Nut 21—Cap Screw (28 used) Gear 44—Fitting Plug (3 used)
IMPORTANT: Travel motor housing will bedamaged if removal is attemptedwhile travel gearbox is on machine.Travel motor housing is an integralpart of travel gearbox and retained inplace by bearing nut (9).
This procedure is written to showremoval and installation of the travelgearbox from the travel motor. Thisis the recommended repairprocedure for performing majorrepairs to travel motor or park brake.
NOTE: Travel motor and park brake internalcomponents can be replaced with care whilemotor is on machine.
1. Remove travel motor and gearbox assembly frommachine. See Travel Gearbox Remove and Install.(Group 0250.)
CAUTION: Heavy component; use anappropriate lifting device.
IMPORTANT: Weight of travel motor and gearboxassembly can damage motor valveplate. Block travel motor andgearbox assembly so that the motorcover does not carry full weight oftravel motor and gearbox assembly.
2. Position travel motor and gearbox assemblysecurely in a vertical position with the motor valveplate end down.
SpecificationTravel Motor and Gearbox—Weight 310 kg.......................................................................................
685 lb
3. Make alignment marks between cover (41), ringgear (20), and drum (4).
4. Remove cap screws (43) and cover (41).
5. Remove shaft (39) and first stage planetary pinioncarrier (32) from ring gear (20).
6. Remove second stage sun gear (30), second stageplanetary pinion carrier (23), and third stage sungear (18) from ring gear (20).
CAUTION: Heavy component; use anappropriate lifting device.
7. Install JT01748 lifting brackets to ring gear (20).Remove cap screws (21) and ring gear (20) fromdrum (4).
SpecificationRing Gear Approximate—Weight 64 kg.........................................................................................
140 lb
TM10091 (11JAN08) 02-0260-3 160DLC Excavator Repair011108
PN=91
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Hydraulic System
020260
4 FS41334,0000172 –19–10APR07–3/7
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationThird Stage Planetary PinionCarrier Approximate—Weight 40 kg.....................................................
88 lb
8. Remove third stage planetary pinion carrier (12).
Continued on next page
TM10091 (11JAN08) 02-0260-4 160DLC Excavator Repair011108
PN=92
Hydraulic System
0202605
FS41334,0000172 –19–10APR07–4/7
TX
1018
574
–UN
–14F
EB
07
9—Bearing Nut47—DFT1109 Holding Bar48—DFT1036A Travel Gearbox Nut Wrench
9. Remove bearing nut (9) using holding bar (47) andtravel gearbox nut wrench (48). See DFT1109 HoldingBar and See DFT1036A Travel Gearbox Nut Wrench.(Group 9900.)
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationDrum Approximate—Weight 59 kg..............................................................
130 lb
10. Remove drum (4) from travel motor housing usingJT01748 lifting brackets.
IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. A used sealmust be kept together as a set becauseof wear patterns on seal ring surface.
11. Remove metal face seal (2). See Metal Face SealsRepair. (Group 0130.)
12. Repair or replace parts as necessary. See TravelMotor and Park Brake Disassemble and Assemble.(Group 0260.)
13. Clean and oil parts with gear oil prior to assembly.
NOTE: Further disassembly is not necessary unlessbearing replacement is required. Bearing will bedestroyed during removal, replace with a newbearing.
14. Inspect bearings (3) and races inside housing.
15. Replace parts as necessary.
Continued on next page
TM10091 (11JAN08) 02-0260-5 160DLC Excavator Repair011108
PN=93
Hydraulic System
020260
6
FS41334,0000172 –19–10APR07–5/7
CAUTION: DO NOT heat oil over 182 °C (260 °F).Oil fumes or oil can ignite above 193°C (380 °F).Use thermometer to measure. Do Not allow aflame or heating element to come in contactwith the oil. Heat in a well ventilated area. Plana safe handling procedure to avoid burns.
SpecificationBearing Cone—Temperature 50—70 °C....................................................
122—158 °F
16. Heat inner bearing cone. Install cone tight againstshoulder.
IMPORTANT: Metal face seal O-rings and seatsurfaces for O-rings must be clean, dry,and oil free so O-ring does not slip.
17. Thoroughly clean metal face seal O-rings and seatsurfaces in travel motor housing, drum, and seal ring.Use volatile, non-petroleum based solvent andlint-free tissues.
NOTE: A volatile, non-petroleum based solvent or talcumpowder can be used as a lubricant. Solvent mustnot damage the O-ring or leave an oil residue.
18. Install O-ring and metal face seal on travel motorhousing and drum. Apply equal pressure with fingersat four, equally spaced points on seal face.
Seal most “pop” down into place so O-ring is tightagainst seal bore and seal ring is installed squarely.
19. Clean ring seal face. Apply a thin film of clean oil.
20. Install drum (4) onto travel motor. Make sure thatroller bearings are fully installed by checking to seethat clearance between motor and drum is equal.
Continued on next page
TM10091 (11JAN08) 02-0260-6 160DLC Excavator Repair011108
PN=94
Hydraulic System
0202607
FS41334,0000172 –19–10APR07–6/7
IMPORTANT: Install bearing nut with stepped surfacetowards bearing.
21. Apply a thin coat of multi-purpose grease to bearingnut (9). Tighten bearing nut using tools DFT1109 andDFT1036A to specification. See DFT1109 Holding Barand See DFT1036A Travel Gearbox Nut Wrench.(Group 9900.)
SpecificationBearing Nut—Torque 800 N•m....................................................................
590 lb-ft
22. To seat bearings, tap around face of drum with aplastic hammer. Then, rotate drum 4 to 5 times ineach direction. Retighten to specification.
NOTE: If dowel pin does not engage with spline ofhousing, tighten bearing nut (9) until dowel pincenter aligns with center of next spline.
23. Ensure center of dowel pin (10) is aligned with centerof spline on travel motor. If centers are not aligned,tighten bearing nut (9) until dowel pin center alignswith center of next spline.
24. Install planetary gears (13) in third stage planetarypinion carrier (12), if removed.
Continued on next page
TM10091 (11JAN08) 02-0260-7 160DLC Excavator Repair011108
PN=95
Hydraulic System
020260
8
FS41334,0000172 –19–10APR07–7/7
45
TX1004310 16
TX
1004
310
–UN
–14M
AR
06
Spring Pin Installation
16—Pin45—Slit
25. Install spring pinions with slit (45) toward end of pin(16).
26. Install third stage planetary pinion carrier (12) andthird stage sun gear (18).
27. Apply PM38627 Rigid Form-in-Place gasket to flangesurface on ring gear (20) and install ring gear.
28. Apply PM37421 Thread Lock and Sealer (highstrength) to cap screws (21). Tighten to specification.
SpecificationRing Gear-to-Drum Cap Screw—Torque 265 N•m..........................................................................................
195 lb-ft
29. Install second stage planetary pinion carrier (23),washer (24), sun gear (30), first stage planetarypinion carrier (32), washer (33), and shaft (39).
30. Apply PM38656 Rigid Form-in-Place to flange surfaceof ring gear cover (41).
31. Apply PM37418 Thread Lock and Sealer (mediumstrength) to threads of cap screws (43). Tighten tospecification.
SpecificationCover-to-Ring Gear Cap Screw—Torque 110 N•m..........................................................................................
83 lb-ft
32. Install travel motor and gearbox assembly. See TravelGearbox Remove and Install. (Group 0250.)
TM10091 (11JAN08) 02-0260-8 160DLC Excavator Repair011108
PN=96
Hydraulic System
0202609
TM10091 (11JAN08) 02-0260-9 160DLC Excavator Repair011108
PN=97
Hydraulic System
020260
10
FS41334,0000152 –19–08MAR07–1/3
Travel Motor and Park Brake Disassemble and Assemble
TX
1000
643
–UN
–01D
EC
05
TM10091 (11JAN08) 02-0260-10 160DLC Excavator Repair011108
PN=98
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Hydraulic System
02026011
FS41334,0000152 –19–08MAR07–2/3
0—Hydraulic Motor 10—Roller Bearing 22—Plate (4 used) 31—O-Ring (2 used)0A—Housing 14—Piston (9 used) 23—Plate (4 used) 32—Travel Motor Cover1—Seal 16—Retainer 25—Piston 33—Needle Bearing3—Piston 17—Bushing 26—O-Ring 37—Dowel Pin (2 used)7—Shaft 18—Swash Plate 28—O-Ring 39—Valve Plate8—Snap Ring 19—Spring (6 used) 29—Spring 40—Bolt (9 used)9—Pin (2 used) 21—Rotor 30—O-Ring
CAUTION: Heavy component; useappropriate lifting device.
SpecificationTravel Motor—ApproximateWeight 91 kg.........................................................................................
200 lb
IMPORTANT: Use care when removing travelmotor cover (32), valve plate iseasily damaged.
1. Remove travel motor cover (32), and plate (39).
IMPORTANT: Remove needle bearing (33) only ifreplacement is necessary. Do notreuse needle bearing as it may havebeen damaged during removal.
2. Remove needle bearing (33) as required.
3. Remove disc spring (29). Inspect part for wear ordamage.
SpecificationDisc Spring—Height 7.0—6.9 mm.......................................................
0.276—0.272 in.
4. Apply 100—300 kPa (14—43 psi) air pressure tobrake release passage to remove brake piston (25).
5. Remove friction plates (22) and plates (23).
6. Inspect parts for wear or damage.
SpecificationFriction Plate—Height 2.75—2.70 mm.................................................
0.108—0.106 in.
Plate—Height 1.80—1.75 mm..............................................................0.071—0.069 in.
IMPORTANT: Pistons must be installed into thesame bores because of wearpatterns. Mark location of pistonswith respect to bores to aid inassembly.
7. Remove parts (21, 19, 17, 16, and 14).
8. Remove parts (7, 10, 8, and 1) through motor sideof housing (0A).
9. Replace parts as necessary.
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationTravel Motor Housing—Weight 50 kg..................................................
110 lb
10. Apply multi-purpose grease to lip of seal (1) andapply PM38627 Rigid Form-in-Place Gasket toouter surface of seal.
11. Install parts (7, 10, 8, and 1) using D01044AABushing, Bearing and Seal Driver Set.
TM10091 (11JAN08) 02-0260-11 160DLC Excavator Repair011108
PN=99
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Hydraulic System
020260
12
FS41334,0000152 –19–08MAR07–3/3
16
17
TX
1004
978
–UN
–23M
AR
06
17—Bushing16—Retainer
12. Lubricate parts (21, 19, 17, 16, 14, and 18) withhydraulic oil and install. Ensure that pistons (14) areinstalled in their original bores. Install bushing (17)and retainer (16) as shown.
13. Install parts (29, 28, 25, 26, 22, and 23).
14. Install needle bearing (33) into travel motor cover(32).
NOTE: Apply petroleum jelly to mating surface of valveplate to adhere it to travel motor cover duringassembly.
15. Install pins (37) then valve plate (39).
16. Assemble travel motor cover to housing (0A).
17. Install cap screws (40) and tighten.
SpecificationTravel Motor Cover-to-TravelMotor Housing Cap Screw—Torque 300 N•m..........................................................................................
220 lb-ft
TM10091 (11JAN08) 02-0260-12 160DLC Excavator Repair011108
PN=100
Hydraulic System
02026013
FS41334,0000151 –19–13APR07–1/3
Counterbalance Valve Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Relief Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure relief button (1).
1. Push pressure relief button (1).
2. Drain oil from hydraulic oil tank or pull vacuum inhydraulic oil tank using vacuum pump. See ApplyVacuum to Hydraulic Oil Tank. (Group 3360.) Theapproximate capacity of hydraulic oil tank is 120.4 L(31.8 gal).
3. Disconnect battery ground (negative) cable.
4. Remove cover from track frame.
Continued on next page
TM10091 (11JAN08) 02-0260-13 160DLC Excavator Repair011108
PN=101
Hydraulic System
020260
14
FS41334,0000151 –19–13APR07–2/3
TX
1020
307A
–UN
–07M
AR
07
TX
1020
308
–UN
–09M
AR
07
1—Travel Motor Cover2—Spool (2 used)3—Spring (2 used)4—O-Ring (2 used)5—Plug (2 used)6—Valve Spool
NOTE: Valves may be removed with travel motor inmachine.
5. Remove counterbalance valve plugs (5) from travelmotor cover (1).
6. Remove spring (3) and spool (2) from travel motorusing a magnet.
7. Remove valve spool (6) from travel motor using amagnet.
8. Repair or replace parts as needed. Apply a film ofclean hydraulic oil to parts before assembly.
9. Install valve spool (6) halfway into cover (1).
10. Instal spools (2), Springs (3), and plugs (5) on eachside of valve spool (6). Tighten by hand.
11. Tighten counterbalance valve plug (5) on each side tospecification.
SpecificationCounterbalance Valve Plug—Torque 450 N•m..........................................................................................
332 lb-ft
12. Fill hydraulic oil tank. See Check Hydraulic Tank OilLevel. (Operator’s Manual.)
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Procedure must be performed whenevera new pump is installed or oil has beendrained from the pump or hydraulic oiltank.
13. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
14. Connect battery ground (negative) cable.
15. Perform travel motor start-up procedure. See TravelMotor and Park Brake Start-Up Procedure. (Group3360.)
16. Install cover to track frame and torque tospecification.
TM10091 (11JAN08) 02-0260-14 160DLC Excavator Repair011108
PN=102
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Hydraulic System
FS41334,0000151 –19–13APR07–3/3
SpecificationTrack Frame Cover—Torque 50 N•m.........................................................
37 lb-ft
02026015
FS41334,0000159 –19–13APR07–1/4
Crossover Relief Valve Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Relief Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure relief button (1).
1. Push pressure relief button (1).
2. Drain oil from hydraulic oil tank or pull vacuum inhydraulic oil tank using vacuum pump. See ApplyVacuum to Hydraulic Oil Tank. (Group 3360.) Theapproximate capacity of hydraulic oil tank is 120.4 L(31.8 gal).
3. Disconnect battery ground (negative) cable.
4. Remove cover from track frame.
FS41334,0000159 –19–13APR07–2/4
TX
1020
327A
–UN
–07M
AR
07
1—Travel Motor Cover2—Plug (2 used)
NOTE: Valves may be removed with travel motor inmachine.
5. Remove crossover relief valves (10) from travel motorcover (1).
Crossover relief valves retain make-up check valve andspring. For correct reinstallation; See Make-Up CheckValve Remove and Install. (Group 0260.)
TM10091 (11JAN08) 02-0260-15 160DLC Excavator Repair011108
PN=103
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Hydraulic System
020260
16
FS41334,0000159 –19–13APR07–3/4
TX
1020
309
–UN
–09M
AR
07
1—Travel Motor Cover 5—Valve (2 used) 8—Piston (2 used) 11—O-Ring (2 used)2—Sleeve (2 used) 6—Guide (2 used) 9—Back-Up Ring (4 used) 12—Packing (2 used)3—O-Ring (2 used) 7—Spring (2 used) 10—Plug (2 used) 13—Shim (2 used)4—Back-Up Ring (4 used)
IMPORTANT: Disassembly of crossover reliefvalve will alter the set pressure.Adjust after repairs are made.
6. Disassemble crossover relief valves.
7. Repair or replace parts as needed. Apply a film ofclean hydraulic oil to parts before assembly.
8. Assemble crossover relief valves.
9. Install relief valves (10) and tighten to specification.
SpecificationRelief Valve—Torque 450 N•m.............................................................
332 lb-ft
10. Fill hydraulic oil tank. See Check Hydraulic TankOil Level. (Operator’s Manual.)
IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before startingengine. Procedure must beperformed whenever a new pump isinstalled or oil has been drainedfrom the pump or hydraulic oil tank.
11. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
12. Connect battery ground (negative) cable.
13. Perform travel motor start-up procedure. SeeTravel Motor and Park Brake Start-Up Procedure.(Group 0260.)
TM10091 (11JAN08) 02-0260-16 160DLC Excavator Repair011108
PN=104
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Hydraulic System
02026017FS41334,0000159 –19–13APR07–4/4
14. Install cover to track frame.
SpecificationTrack Frame Cover—Torque 50 N•m...................................................
37 lb-ft
15. Perform crossover relief valve test and adjustment.See Travel Motor Crossover Relief Valve Test andAdjustment. (9025-25.)
FS41334,0000158 –19–13APR07–1/2
Make-Up Check Valve Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Relief Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure relief button (1).
1. Push pressure relief button (1).
2. Drain oil from hydraulic oil tank or pull vacuum inhydraulic oil tank using vacuum pump. See ApplyVacuum to Hydraulic Oil Tank. (Group 3360.) Theapproximate capacity of hydraulic oil tank is 120.4 L(31.8 gal).
3. Disconnect battery ground (negative) cable.
4. Remove cover from track frame.
Continued on next page
TM10091 (11JAN08) 02-0260-17 160DLC Excavator Repair011108
PN=105
Hydraulic System
020260
18
FS41334,0000158 –19–13APR07–2/2
TX
1020
327A
–UN
–07M
AR
07T
X10
2091
0A–U
N–2
3MA
R07
1—Travel Motor Cover2—Relief Valve (2 used)3—Spring (2 used)4—Check Valve (2 used)
NOTE: Valves may be removed with travel motor inmachine.
5. Remove relief valves (2) from travel motor cover (1).
6. Remove springs (3) and check valves (4) from travelmotor using a magnet.
7. Repair or replace parts as needed. Apply a film ofclean hydraulic oil to parts before assembly.
8. Install Springs (3) to check valves (4). Install checkvalves into travel motor cover (1).
9. Install relief valves (2) and tighten to specification.
SpecificationRelief Valve—Torque 450 N•m...................................................................
332 lb-ft
10. Fill hydraulic oil tank. See Check Hydraulic Tank OilLevel. (Operator’s Manual.)
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Procedure must be performed whenevera new pump is installed or oil has beendrained from the pump or hydraulic oiltank.
11. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
12. Connect battery ground (negative) cable.
13. Perform travel motor start-up procedure. See TravelMotor and Park Brake Start-Up Procedure. (Group0260.)
14. Install cover to track frame.
SpecificationTrack Frame Cover—Torque 50 N•m.........................................................
37 lb-ft
TM10091 (11JAN08) 02-0260-18 160DLC Excavator Repair011108
PN=106
Hydraulic System
02026019
FS41334,0000157 –19–13APR07–1/2
Travel Speed Change Valve Remove andInstall
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Relief Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure relief button (1).
1. Push pressure relief button (1).
2. Drain oil from hydraulic oil tank or pull vacuum inhydraulic oil tank using vacuum pump. See ApplyVacuum to Hydraulic Oil Tank. (Group 3360.) Theapproximate capacity of hydraulic oil tank is 120.4 L(31.8 gal).
3. Disconnect battery ground (negative) cable.
4. Remove cover from track frame.
Continued on next page
TM10091 (11JAN08) 02-0260-19 160DLC Excavator Repair011108
PN=107
Hydraulic System
020260
20
FS41334,0000157 –19–13APR07–2/2
TX
1019
101A
–UN
–19M
AR
07T
X10
2026
3A–U
N–0
6MA
R07
1—Line2—Valve Spool3—Spring4—Fitting Plug
NOTE: Valves may be removed with travel motor inmachine.
5. Remove fitting plug (4) from travel motor cover.
6. Remove compression spring (3) and valve spool (2)from travel motor cover using a magnet.
7. Repair or replace parts as needed. Apply a film ofclean hydraulic oil to parts before assembly.
8. Install valve spool (2) into cover with shoulder facingspring.
9. Install spring (3) and fitting plug (4). Tighten tospecification.
SpecificationFitting Plug—Torque 35 N•m......................................................................
26 lb-ft
10. Fill hydraulic oil tank. See Check Hydraulic Tank OilLevel. (Operator’s Manual.)
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Procedure must be performed whenevera new pump is installed or oil has beendrained from the pump or hydraulic oiltank.
11. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
12. Connect battery ground (negative) cable.
13. Perform travel motor start-up procedure. See TravelMotor and Park Brake Start-Up Procedure. (Group0260.)
14. Install cover to track frame.
SpecificationTrack Frame Cover—Torque 50 N•m.........................................................
37 lb-ft
15. Perform travel speed solenoid valve test and adjust.Travel Speed Solenoid Valve Test and Adjustment.(Group 9025-25.)
TM10091 (11JAN08) 02-0260-20 160DLC Excavator Repair011108
PN=108
Hydraulic System
02026021
FS41334,0000150 –19–08MAR07–1/1
Travel Motor and Park Brake Start-UpProcedure
TX
1018
694A
–UN
–19M
AR
07
1—Travel Motor Drain Line
IMPORTANT: Travel motor will be damaged if notfilled with oil before operating travelfunction. Procedure must be performedwhenever a new travel motor isinstalled or oil has been drained fromthe motor.
1. Disconnect drain line (1).
2. Fill motor with hydraulic oil until oil reaches top of drainport.
NOTE: Use a funnel with suitable diameter neck to allowair to escape while filling.
3. Connect drain line (1).
TM10091 (11JAN08) 02-0260-21 160DLC Excavator Repair011108
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Hydraulic System
020260
22
TM10091 (11JAN08) 02-0260-22 160DLC Excavator Repair011108
PN=110
Section 04Engine
Contents
Page
Group 0400—Removal and InstallationEngine Remove and Install . . . . . . . . . . . . . .04-0400-1
04
TM10091 (11JAN08) 04-1 160DLC Excavator Repair011108
PN=1
Contents
04
TM10091 (11JAN08) 04-2 160DLC Excavator Repair011108
PN=2
Group 0400Removal and Installation
TJ15698,0000181 –19–11APR07–1/18
Engine Remove and Install
1. Disconnect battery ground (negative) cable.
0404001
TJ15698,0000181 –19–11APR07–2/18
TS
281
–UN
–23A
UG
88
CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns.
Shut off engine. Remove filler cap when cool totouch. Slowly loosen filler cap to first stop torelieve pressure, then remove.
2. Drain coolant from radiator. Approximate capacity is 19L (5 gal).
TJ15698,0000181 –19–11APR07–3/18
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
3. Push pressure release button (1).
4. Pull a vacuum in hydraulic oil tank using a vacuumpump, or drain tank. Approximate oil capacity is 120.4L (31.8 gal). See Apply Vacuum to Hydraulic Oil Tank.(Group 3360.)
5. Close fuel supply valve on bottom of fuel tank.
6. Remove engine cover, muffler cover, and control valvecover.
Continued on next page
TM10091 (11JAN08) 04-0400-1 160DLC Excavator Repair011108
PN=113
Removal and Installation
040400
2
TJ15698,0000181 –19–11APR07–4/18
TX
1021
007A
–UN
–29M
AR
07
1—Upper Intercooler Tube2—Upper Radiator Hose3—Coolant Surge Tank
7. Remove coolant surge tank (3). See Coolant SurgeTank Remove and Install. (Group 0510.)
8. Remove upper intercooler tube (1), upper radiator hose(2), and lower radiator hose.
TJ15698,0000181 –19–11APR07–5/18
TX
1020
192A
–UN
–05A
PR
07
1—Cap Screw (4 used)2—Final Fuel Filter3—Primary Fuel Filter
9. Remove cap screws (1) and set fuel filters (2 and 3)aside.
TJ15698,0000181 –19–11APR07–6/18
TX
1020
874A
–UN
–22M
AR
07
1—Shield2—Cap Screws (6 used)3—Water Drain
10. Remove water drain (3), cap screws (2), and mufflershield (1).
Continued on next page
TM10091 (11JAN08) 04-0400-2 160DLC Excavator Repair011108
PN=114
Removal and Installation
0404003
TJ15698,0000181 –19–11APR07–7/18
TX
1020
754A
–UN
–29M
AR
07
1—Muffler2—Cap Screw (4 used)3—Bracket
CAUTION: Exhaust parts may be hot. Avoidburns by waiting until the parts are cool to thetouch before working on them.
11. Disconnect exhaust pipe from turbocharger.
12. Support pump 1 and 2. Remove cap screws (2) andbracket (3) with muffler (1). Reinstall cap screws.
TJ15698,0000181 –19–11APR07–8/18
TX
1021
000A
–UN
–29M
AR
07
1—Engine Control Unit2—Electrical Connector (2 used)3—Cover4—Bracket5—Air Intake Tube6—Fan Drive Pump Supply Hose7—Alternator
13. Remove air intake tube (5) and bracket (4).
14. Disconnect electrical connectors (2) and removeengine control unit (1).
15. Disconnect electrical connector and wires fromalternator (7).
16. Disconnect fan drive pump supply hose (6) and linefrom pump and engine mount.
17. Close all open hoses and fittings using caps andplugs.
18. Remove cover (3).
Continued on next page
TM10091 (11JAN08) 04-0400-3 160DLC Excavator Repair011108
PN=115
Removal and Installation
TJ15698,0000181 –19–11APR07–9/18
TX
1021
004A
–UN
–29M
AR
07
040400
4
1—Electrical Connector (2 used)
19. Disconnect connectors (1).
TJ15698,0000181 –19–11APR07–10/18
TX
1021
001A
–UN
–29M
AR
07
1—Compressor Mounting Bracket2—Fuel Hose (2 used)3—Lower Intercooler Tube
NOTE: It is not necessary to discharge the airconditioning system.
20. Disconnect air conditioner compressor mountingbracket (1) from engine. Fasten compressor andbracket so it will not interfere with engine removal.
21. Disconnect fuel hoses (2) and close all open fittingsand hoses using caps and plugs.
22. Remove lower intercooler tube (3).
TJ15698,0000181 –19–11APR07–11/18
TX
1021
005A
–UN
–29M
AR
07
1—Starter2—Fuel Hose (2 used)
23. Tag and disconnect fuel hoses (2). Close all openfittings and hoses using caps and plugs.
24. Disconnect wires from starter (1).
Continued on next page
TM10091 (11JAN08) 04-0400-4 160DLC Excavator Repair011108
PN=116
Removal and Installation
TJ15698,0000181 –19–11APR07–12/18
TX
1021
006A
–UN
–29M
AR
07
0404005
1—Fan Drive Pump Outlet Hose2—Heater Hose (2 used)3—Engine Oil Filter Hose (2 used)
25. Tag and disconnect heater hoses (2), hose (1), andoil filter hoses (3).
26. Close all open hoses and fittings using caps andplugs.
TJ15698,0000181 –19–11APR07–13/18
TX
1021
205A
–UN
–02A
PR
07
1—Eyebolt (2 used)2—Lifting Bracket
27. Install JT05550 Lifting Eyebolt (1) and JDG19 LiftingBracket (2) in housing of pump 1 and 2.
TJ15698,0000181 –19–11APR07–14/18
TX
1021
141A
–UN
–29M
AR
07
1—DFT1119 Pump Support2—Lever Block
CAUTION: Heavy component; use appropriatelifting device.
28. Install DFT1119 Pump Support (1) on machine asshown. See DFT1119 Pump Support. (Group 9900.)
SpecificationPump 1 and 2—Weight 190 kg..................................................................
419 lb
29. Attach pump support to machine using C-clamps toprevent movement.
30. Support pump 1 and 2 using DFT1119 Pump Support(1) and a lever block (2). Attach lever block toeyebolts and lifting bracket installed in pump housingusing suitable lifting sling.
TM10091 (11JAN08) 04-0400-5 160DLC Excavator Repair011108
PN=117
Continued on next page
Removal and Installation
040400
6
TJ15698,0000181 –19–11APR07–15/18
TX
1021
109A
–UN
–29M
AR
07
1—Lifting Sling2—Lifting Eye (2 used)
31. Install lifting eyes (2) and lifting sling (1).
CAUTION: Heavy component; use appropriatelifting device.
SpecificationEngine—Approximate Weight 491 kg........................................................
1083 lb
33. Remove cap screws securing pump 1 and 2 and drivegearbox to engine flywheel housing.
Continued on next page
TM10091 (11JAN08) 04-0400-6 160DLC Excavator Repair011108
PN=118
Removal and Installation
0404007
TJ15698,0000181 –19–11APR07–16/18
TX
1021
106A
–UN
–29M
AR
07
Counterweight Side
TX
1021
107A
–UN
–29M
AR
07
Swing Gearbox Side
TX
1021
108A
–UN
–29M
AR
07Bottom Side
1—Cap Screw (14 used)2—Nut (4 used)
34. Remove cap screws (1) and nuts (2).
35. Raise engine slightly. Move engine away from pump1 and 2 and drive gearbox. Lift and remove enginewhen disengaged from hydraulic pump drive coupling.
36. Repair or replace parts as necessary.
CAUTION: Heavy component; use appropriatelifting device.
SpecificationEngine—Approximate Weight 491 kg........................................................
1083 lb
37. Align hydraulic pump and drive gearbox to engine andinstall engine. Install cap screws (1), washers, andnuts (2). Tighten cap screws and nuts to specification.
SpecificationEngine Mount Cap Screw—Torque 110 N•m..........................................................................................
81 lb-ft
SpecificationEngine Isolator Nut—Torque 400 N•m........................................................
295 lb-ft
38. Install pump housing cap screws. Tighten cap screwsto specification.
SpecificationPump 1 and 2Housing-to-Flywheel Housing CapScrew—Torque 65 N•m...............................................................................
48 lb-ft
39. Remove lifting sling and lifting eyes from engine.
40. Connect engine oil filter hoses.
41. Connect heater hoses.
42. Connect hoses to fan drive pump. See Fan DrivePump Remove and Install. (Group 3360.)
43. Connect fuel hoses to fuel transfer pump.
44. Install cover.
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Continued on next page
Removal and Installation
040400
8
TJ15698,0000181 –19–11APR07–17/18
45. Install engine control unit and connect harnessconnectors.
46. Connect starter and alternator wires.
47. Install air conditioning compressor and mountingbracket to engine.
48. Install compressor belt. Inspect and adjustcompressor belt tension. See Check and Adjust A/CBelt. (Operator’s Manual.)
49. Connect fuel hoses to fuel injection pump.
50. Install muffler and bracket. Tighten muffler bracketcap screws to specification.
SpecificationPump 1 and 2Housing-to-Flywheel Housing CapScrew—Torque 65 N•m...............................................................................
48 lb-ft
51. Remove lifting bracket, lifting eyebolt, and pumpsupport from pump 1 and 2.
52. Install covers surrounding muffler.
53. Connect air intake tube.
54. Connect upper and lower radiator hoses. SeeRadiator Remove and Install. (Group 0510.)
55. Install intercooler tubes. See Intercooler Remove andInstall. (Group 0510.)
56. Install fuel filters.
57. Install top covers over control valve and muffler.
58. Open fuel supply valve on bottom of fuel tank.
59. Fill engine with clean engine oil. See Diesel EngineOil. (Operator’s Manual.)
60. Fill cooling system. See Cooling System Fill andDeaeration Procedure. (Operator’s Manual.)
TM10091 (11JAN08) 04-0400-8 160DLC Excavator Repair011108
PN=120
Continued on next page
Removal and Installation
0404009
TJ15698,0000181 –19–11APR07–18/18
61. Fill and check hydraulic oil level. Approximate oilcapacity is 120.4 L (31.8 gal).
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
62. If hydraulic oil tank was drained, perform pumpstart-up procedure. See Pump 1 and 2 Start-UpProcedure. (Group 3360.)
63. Bleed fuel system. See Bleed Fuel System.(Operator’s Manual.)
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Removal and Installation
040400
10
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PN=122
Section 05Engine Auxiliary SystemContents
Page
Group 0510—Cooling SystemRadiator Remove and Install . . . . . . . . . . . . .05-0510-1Hydraulic Oil Cooler Remove and Install . . . .05-0510-4Intercooler Remove and Install . . . . . . . . . . .05-0510-6Fuel Cooler Remove and Install . . . . . . . . .05-0510-11Cooling Package Remove and Install . . . . .05-0510-11Fan, Fan Guard, and Fan Shroud Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .05-0510-19Coolant Surge Tank Remove and Install . . .05-0510-24
Group 0520—Intake SystemAir Cleaner Remove and Install. . . . . . . . . . .05-0520-1
05Group 0560—External Fuel Supply SystemFuel Tank Remove and Install. . . . . . . . . . . .05-0560-1Primary Fuel Filter (Water Separator)
Remove and Install . . . . . . . . . . . . . . . . . .05-0560-3Final Fuel Filter Remove and Install . . . . . . .05-0560-4
TM10091 (11JAN08) 05-1 160DLC Excavator Repair011108
PN=1
Contents
05
TM10091 (11JAN08) 05-2 160DLC Excavator Repair011108
PN=2
Group 0510Cooling System
LD30992,0000598 –19–18APR07–1/7
Radiator Remove and Install
1. Remove batteries. See Battery Remove and Install.(Group 9015-20).
0505101
LD30992,0000598 –19–18APR07–2/7
TS
281
–UN
–23A
UG
88
CAUTION: Prevent possible injury from hotspraying water. DO NOT remove surge tank capunless engine is cool. Then remove cap slowly.
2. Remove surge tank filler cap to relieve pressure.
3. Open drain valve and drain coolant into suitablecontainer.
SpecificationCooling System—Capacity 19.0 L...............................................................
5.0 gal
4. Remove coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
5. Remove fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)
LD30992,0000598 –19–18APR07–3/7
TX
1020
785A
–UN
–23M
AR
07
1—Cap Screw (4 used)2—Condenser3—Connector
NOTE: It is not necessary to discharge air conditioningsystem.
6. Disconnect wiring harness connector (3) fromreceiver-dryer.
7. Remove any clamps attaching air conditioning lines toframe or panels.
IMPORTANT: Use caution when repositioningcondenser to avoid damagingcondenser fins.
8. Remove cap screws (1). Lay condenser (2) aside andsecure in place.
TM10091 (11JAN08) 05-0510-1 160DLC Excavator Repair011108
PN=125
Continued on next page
Cooling System
LD30992,0000598 –19–18APR07–4/7
TX
1020
784A
–UN
–23M
AR
07
050510
2
1—Cap Screw (4 used)2—Fan Drive Motor Assembly
9. Support fan drive motor assembly (2). Remove capscrews (1) and fan drive motor assembly (2).
LD30992,0000598 –19–18APR07–5/7
TX
1020
802A
–UN
–19M
AR
07
1—Lower Radiator Hose2—Cap Screw
10. Loosen clamp and disconnect lower radiator hose (1).
11. Remove cap screw (2).
Continued on next page
TM10091 (11JAN08) 05-0510-2 160DLC Excavator Repair011108
PN=126
Cooling System
0505103
LD30992,0000598 –19–18APR07–6/7
TX
1020
803A
–UN
–19M
AR
07
1—Radiator2—Cap Screw (16 used)
CAUTION: Heavy component; use a hoist.
SpecificationRadiator—Weight 27 kg..............................................................................
60 lb
12. Attach suitable lifting device to radiator (1).
13. Remove cap screws (2), washers, and nuts attachingradiator to intercooler and hydraulic oil cooler.
14. Remove radiator. Repair or replace as necessary.
15. Ensure all foam seals are in place and install radiator.Tighten cap screws to specification.
SpecificationRadiator-to-Hydraulic Oil CoolerCap Screws—Torque 37 N•m.....................................................................
27 lb-ftRadiator-to-Intercooler CapScrews—Torque 37 N•m.............................................................................
27 lb-ftRadiator-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................
41 lb-ft
16. Connect lower radiator hose.
17. Install fan drive motor assembly. Tighten cap screwsto specification.
SpecificationFan Drive Motor Assembly CapScrews—Torque 73 N•m.............................................................................
54 lb-ft
18. Install condenser assembly.
19. Connect wiring harness connector to receiver-dryer.
20. Install fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)
21. Install coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
22. Install batteries. See Battery Remove and Install.(Group 9015-20).
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Continued on next page
Cooling System
LD30992,0000598 –19–18APR07–7/7
23. Fill cooling system. See Cooling System Fill andDeaeration Procedure. (Operator’s Manual.)
LD30992,0000599 –19–18APR07–1/6
Hydraulic Oil Cooler Remove and Install
1. Remove radiator. See Radiator Remove and Install.(Group 0510.)
050510
4
LD30992,0000599 –19–18APR07–2/6
TX
1020
824A
–UN
–23M
AR
07
1—Cap Screw2—Cap Screws3—Fuel Cooler
2. Remove cap screw (1) from upper mounting bracket.
IMPORTANT: Use caution when repositioning fuelcooler to avoid damaging fuel coolerfins.
3. Remove cap screws (2). Lay fuel cooler (3) andmounting bracket aside and secure in place.
LD30992,0000599 –19–18APR07–3/6
TX
1020
827A
–UN
–23M
AR
07
1—Hydraulic Hose2—Cover
4. Drain hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).
5. Remove cap screws from cover (2) to gain furtheraccess to fitting on lower oil cooler hydraulic hose (1).
6. Disconnect lower oil cooler hydraulic hose (1). Applycaps and plugs to close all openings.
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Continued on next page
Cooling System
LD30992,0000599 –19–18APR07–4/6
TX
1020
826A
–UN
–23M
AR
07
0505105
1—Hydraulic Oil Cooler-to-Frame Lower Cap Screw2—Mounting Bracket-to-Frame Cap Screws
CAUTION: Heavy component; use a hoist.
SpecificationHydraulic Oil Cooler—Weight 42 kg............................................................
92 lb
7. Attach suitable lifting device to hydraulic oil cooler.
8. Remove cap screws (1) and (2).
LD30992,0000599 –19–18APR07–5/6
TX
1020
828A
–UN
–23M
AR
07
1—Hydraulic Oil Cooler
9. Move hydraulic oil cooler (1) toward rear of machineuntil hydraulic fitting in lower port clears access hole inside panel.
10. Remove hydraulic oil cooler.
Continued on next page
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PN=129
Cooling System
050510
6
LD30992,0000599 –19–18APR07–6/6
2
1
43
65
TX
1021
207
–UN
–27M
AR
07
1—Hydraulic Oil Cooler2—Mounting Bracket3—Washer (8 used)4—Cap Screw (8 used)5—Nut (8 used)6—Washer (8 used)
11. Remove washers (3 and 6), nuts (5), cap screws (4),and mounting bracket (2) from hydraulic oil cooler (1).
12. Install mounting bracket onto new hydraulic oil cooler.
13. Install hydraulic oil cooler. Tighten cap screw tospecification.
SpecificationHydraulic Oil Cooler-to-FrameLower Cap Screw—Torque 55 N•m............................................................
41 lb-ft
14. Connect lower hydraulic hose.
15. Install fuel cooler and mounting bracket.
16. Install upper mounting bracket cap screw.
17. Install radiator. See Radiator Remove and Install.(Group 0510.)
18. Fill and check hydraulic oil level. See 160DLC Drainand Refill Capacities. (Operator’s Manual.)
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
19. Perform pump start-up procedure. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
LD30992,000059A –19–10APR07–1/9
Intercooler Remove and Install
1. Remove batteries. See Battery Remove and Install.(Group 9015-20).
2. Remove coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
3. Remove fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)
TM10091 (11JAN08) 05-0510-6 160DLC Excavator Repair011108
PN=130
Continued on next page
Cooling System
LD30992,000059A –19–10APR07–2/9
TX
1020
785A
–UN
–23M
AR
07
1—Cap Screw (4 used)2—Condenser3—Connector
NOTE: It is not necessary to discharge air conditioningsystem.
4. Disconnect wiring harness connector (3) fromreceiver-dryer.
5. Remove any clamps attaching air conditioning lines toframe or panels.
IMPORTANT: Use caution when repositioningcondenser to avoid damagingcondenser fins.
6. Remove cap screws (1). Lay condenser (2) aside andsecure in place.
0505107
LD30992,000059A –19–10APR07–3/9
TX
1020
786A
–UN
–23M
AR
07
1—Mounting Bracket2—Cap Screws
7. Remove cap screws (2) and condenser mountingbracket (1).
LD30992,000059A –19–10APR07–4/9
TX
1020
787A
–UN
–23M
AR
071—Cap Screw
8. Remove cap screw (1) from upper mounting uppermounting bracket.
Continued on next page
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PN=131
Cooling System
LD30992,000059A –19–10APR07–5/9
TX
1020
784A
–UN
–23M
AR
07
050510
8
1—Cap Screw (4 used)2—Fan Drive Motor Assembly
9. Support fan drive motor assembly (2). Remove capscrews (1) and fan drive motor assembly (2).
LD30992,000059A –19–10APR07–6/9
TX
1020
788A
–UN
–23M
AR
07
1—Mounting Bracket-to-Frame Cap Screws2—Intercooler-to-Frame Lower Cap Screw3—Lower Intercooler Tube
10. Remove cap screws (1) and (2) from bottom ofintercooler.
11. Loosen clamps and disconnect lower intercooler tube(3).
LD30992,000059A –19–10APR07–7/9
TX
1020
789A
–UN
–23M
AR
07
1—Intercooler2—Cap Screw (8 used)
CAUTION: Heavy component; use a hoist.
SpecificationIntercooler—Weight 27 kg...........................................................................
60 lb
12. Attach suitable lifting device to intercooler (1).
13. Remove cap screws (2), washers, and nuts from eachside of intercooler.
14. Remove intercooler.
Continued on next page
TM10091 (11JAN08) 05-0510-8 160DLC Excavator Repair011108
PN=132
Cooling System
LD30992,000059A –19–10APR07–8/9
TX
1020
790A
–UN
–23M
AR
07
0505109
1—Mounting Bracket2—Intercooler
15. Remove cap screws and mounting bracket (1) fromintercooler (2).
16. Install mounting bracket onto new intercooler. Tightencap screws to specification.
SpecificationMounting Bracket-to-IntercoolerCap Screws—Torque 37 N•m.....................................................................
27 lb-ft
Continued on next page
TM10091 (11JAN08) 05-0510-9 160DLC Excavator Repair011108
PN=133
Cooling System
050510
10
LD30992,000059A –19–10APR07–9/9
TX
1020
791A
–UN
–23M
AR
07
1—Wiring Harness
IMPORTANT: Ensure wiring harness (1) is securedbehind foam and mounting bracketbefore fully lower intercooler.
17. Ensure all foam seals are in place and installintercooler. Tighten cap screws to specification.
SpecificationIntercooler-to-Radiator CapScrews—Torque 37 N•m.............................................................................
27 lb-ftIntercooler-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................
41 lb-ft
18. Install upper mounting bracket cap screw.
19. Install fan drive motor assembly. Tighten cap screwsto specification.
SpecificationFan Drive Motor Assembly CapScrews—Torque 73 N•m.............................................................................
54 lb-ft
20. Install condenser assembly.
21. Connect wiring harness connector to receiver-dryer.
22. Install fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)
23. Install coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
24. Install batteries. See Battery Remove and Install.(Group 9015-20).
TM10091 (11JAN08) 05-0510-10 160DLC Excavator Repair011108
PN=134
Cooling System
OUO1073,0002101 –19–13MAR07–1/1
Fuel Cooler Remove and Install
TX
1019
245A
–UN
–15F
EB
07
05051011
1—Fuel Return Hose2—Fuel Cooler3—Cap Screws (4 used)4—Fuel Supply Hose
1. Tag and disconnect fuel hoses (1 and 4).
2. Remove cap screws (3) and fuel cooler (2).
3. Repair or replace as necessary.
4. Install cooler and connect hoses.
5. Install air filter assembly.
LD30992,000059C –19–18APR07–1/16
Cooling Package Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
Continued on next page
TM10091 (11JAN08) 05-0510-11 160DLC Excavator Repair011108
PN=135
Cooling System
050510
12
LD30992,000059C –19–18APR07–2/16
TS
281
–UN
–23A
UG
88
CAUTION: Prevent possible injury from hotspraying water. DO NOT remove surge tank capunless engine is cool. Then remove cap slowly.
2. Remove surge tank filler cap to relieve pressure.
3. Open drain valve and drain coolant into suitablecontainer.
SpecificationCooling System—Capacity 19.0 L...............................................................
5.0 gal
4. Remove batteries. See Battery Remove and Install.(Group 9015-20).
5. Remove coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
6. Remove access panels on bottom of machine.
LD30992,000059C –19–18APR07–3/16
TX
1021
548A
–UN
–03A
PR
07T
X10
2154
9A–U
N–0
3AP
R07
1—Hood Support Rod2—Cap Screws3—Hood
7. Raise engine hood.
8. Remove retaining pin and disconnect hood support rod(1).
CAUTION: Heavy component; use a hoist.
SpecificationEngine Hood—Weight 36 kg.......................................................................
80 lb
9. Attach appropriate lifting device to hood.
10. Remove cap screws (2) and hood (3).
TM10091 (11JAN08) 05-0510-12 160DLC Excavator Repair011108
PN=136
Continued on next page
Cooling System
LD30992,000059C –19–18APR07–4/16
TX
1021
073A
–UN
–02A
PR
07
05051013
1—Intercooler Tube2—Radiator Hose3—Hydraulic Hose4—Hydraulic Hose5—Cover6—Cover
11. Loosen clamps and disconnect upper intercooler tube(1) and upper radiator hose (2).
12. Drain hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).
13. Disconnect hydraulic hoses (3 and 4) to hydraulic oilcooler. Apply caps and plugs to close all openings.
14. Remove covers (5 and 6).
LD30992,000059C –19–18APR07–5/16
TX
1020
785A
–UN
–23M
AR
07
1—Cap Screw (4 used)2—Condenser3—Connector
NOTE: It is not necessary to discharge air conditioningsystem.
15. Disconnect wiring harness connector (3) fromreceiver-dryer.
16. Remove any clamps attaching air conditioning lines toframe or panels.
IMPORTANT: Use caution when repositioningcondenser to avoid damagingcondenser fins.
17. Remove cap screws (1). Lay condenser (2) aside andsecure in place.
LD30992,000059C –19–18APR07–6/16
TX
1020
786A
–UN
–23M
AR
07
1—Mounting Bracket2—Cap Screws
18. Remove cap screws (2) and condenser mountingbracket (1).
TM10091 (11JAN08) 05-0510-13 160DLC Excavator Repair011108
PN=137
Continued on next page
Cooling System
LD30992,000059C –19–18APR07–7/16
TX
1020
787A
–UN
–23M
AR
07
050510
14
1—Cap Screw
19. Remove cap screw (1) from upper mounting bracket.
LD30992,000059C –19–18APR07–8/16
TX
1021
622A
–UN
–05A
PR
07
1—Cap Screw2—Cap Screws3—Fuel Cooler
20. Remove cap screw (1) from upper mounting bracket.
IMPORTANT: Use caution when repositioning fuelcooler to avoid damaging fuel coolerfins.
21. Remove cap screws (2). Lay fuel cooler (3) andmounting bracket aside and secure in place.
Continued on next page
TM10091 (11JAN08) 05-0510-14 160DLC Excavator Repair011108
PN=138
Cooling System
05051015
LD30992,000059C –19–18APR07–9/16
TX
1021
074A
–UN
–02A
PR
07
1—Air Filter Assembly2—Fan Drive Control Valve3—Panel4—Cold Weather Starting Aid
22. Remove cap screws attaching air filter assembly (1)to panel (3). Secure air filter to side panel behind rearof cab.
23. Disconnect wiring harness connectors from fan drivecontrol valve (2).
NOTE: Hydraulic hoses do not need to be disconnectedfrom fan control valve.
24. Remove cap screws attaching fan control valve (2) topanel (3). Lay fan control valve on floor panel.
25. Disconnect hose from cold weather starting aid (4).
26. Disconnect wiring harness connector from coldweather starting aid.
27. Remove any clamps attaching wiring harness to panel(3).
28. Remove mounting cap screws from panel. Lift panel(3) and remove.
LD30992,000059C –19–18APR07–10/16
TX
1021
075A
–UN
–02A
PR
07
1—Cap Screw (4 used)2—Hydraulic Hose
29. Remove cap screws (1) and disconnect lower oilcooler hydraulic hose (2). Apply caps and plugs toclose all openings.
LD30992,000059C –19–18APR07–11/16
TX
1020
211A
–UN
–07M
AR
07
1—Cap Screws
30. Remove cap screws (1) and cover.
TM10091 (11JAN08) 05-0510-15 160DLC Excavator Repair011108
PN=139
Continued on next page
Cooling System
050510
16
LD30992,000059C –19–18APR07–12/16
TX
1020
687A
–UN
–22M
AR
07T
X10
2068
8A–U
N–2
2MA
R07
1—Hydraulic Hose (to Fan Drive Motor)2—Cap Screw
31. Disconnect fan drive motor hydraulic hose (1) fromhydraulic oil tank. Apply caps and plugs to close allopenings.
32. Remove cap screw (2) and hose clamp.
33. Route hydraulic hose back through opening in side offan shroud.
LD30992,000059C –19–18APR07–13/16
TX
1020
690A
–UN
–22M
AR
07
1—Hydraulic Hose2—Hydraulic Hose
34. Tag and disconnect hydraulic hoses (1 and 2). Applycaps and plugs to close all openings.
35. Route hoses through opening in side of fan shroud.
Continued on next page
TM10091 (11JAN08) 05-0510-16 160DLC Excavator Repair011108
PN=140
Cooling System
LD30992,000059C –19–18APR07–14/16
TX
1021
077A
–UN
–02A
PR
07
05051017
1—Cooling Package
CAUTION: Heavy component; use a hoist.
SpecificationCooling Package—ApproximateWeight 126 kg..............................................................................................
278 lb
IMPORTANT: Do not use lifting eyes on individualcooling package components(intercooler, radiator, and hydraulic oilcooler) to lift entire cooling package.
36. Attach suitable lifting device to cooling package (1).
Continued on next page
TM10091 (11JAN08) 05-0510-17 160DLC Excavator Repair011108
PN=141
Cooling System
050510
18
LD30992,000059C –19–18APR07–15/16
TX
1021
076A
–UN
–02A
PR
07
1—Cap Screws2—Intercooler Tube3—Cap Screw4—Cap Screw5—Cap Screw6—Radiator Hose
37. Disconnect lower intercooler tube (2) and lowerradiator hose (6).
38. Remove cap screws (3—5) from cooling packagecomponents.
39. Remove cap screws (1) and cooling package.
40. Replace components as necessary.
41. Install cooling package. Tighten cap screws (3—5) tospecification.
SpecificationIntercooler-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................
41 lb-ftRadiator-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................
41 lb-ftHydraulic Oil Cooler-to-FrameLower Cap Screw—Torque 55 N•m............................................................
41 lb-ft
42. Connect upper and lower intercooler tubes.
43. Connect upper and lower radiator hoses.
44. Connect upper and lower hydraulic oil cooler hoses.
45. Install panel, air filter assembly, fan drive controlvalve, and cold weather starting aid.
46. Route and connect fan drive motor hydraulic hoses.
47. Connect wiring harness connectors to cold weatherstarting aid.
48. Connect cold weather starting aid hose.
49. Connect wiring harness connectors to fan drivecontrol valve.
50. Install air conditioning condenser and fuel cooler.
51. Connect wiring harness connector to receiver-dryer.
52. Install cooling package upper mounting bracket capscrews.
TM10091 (11JAN08) 05-0510-18 160DLC Excavator Repair011108
PN=142
Continued on next page
Cooling System
05051019
LD30992,000059C –19–18APR07–16/16
53. Install covers.
54. Install hood.
55. Install batteries. See Battery Remove and Install.(Group 9015-20).
56. Fill cooling system. See Cooling System Fill andDeaeration Procedure. (Operator’s Manual.)
57. Fill and check hydraulic oil level. See 160DLC Drainand Refill Capacities. (Operator’s Manual.)
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
58. Perform pump start-up procedure. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
OUO1073,0002103 –19–10APR07–1/9
Fan, Fan Guard, and Fan Shroud Removeand Install
Remove and Install Fan and Fan Guard
1. Remove coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
OUO1073,0002103 –19–10APR07–2/9
TX
1020
695A
–UN
–22M
AR
07
1—Cap Screw (4 used)2—Fan Guard
2. Remove cap screws (1) and fan guard (2).
TM10091 (11JAN08) 05-0510-19 160DLC Excavator Repair011108
PN=143
Continued on next page
Cooling System
050510
20
OUO1073,0002103 –19–10APR07–3/9
TX
1021
215A
–UN
–27M
AR
07
1—Fan2—Cap Screw (6 used)
3. Loosen clamps and remove upper radiator hose.
4. Remove cap screws (2), washers, and fan (1).
5. Install fan, washers, and cap screws. Tighten capscrews to specification.
SpecificationFan Cap Screws—Torque 37 N•m..............................................................
27 lb-ft
6. Install upper radiator hose.
7. Install fan guard and cap screws. Tighten cap screwsto specification.
SpecificationFan Guard Cap Screws—Torque 37 N•m..................................................
27 lb-ft
8. Install coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
Remove and Install Fan Shroud
OUO1073,0002103 –19–10APR07–4/9
TX
1020
196A
–UN
–07M
AR
071—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
Continued on next page
TM10091 (11JAN08) 05-0510-20 160DLC Excavator Repair011108
PN=144
Cooling System
05051021
OUO1073,0002103 –19–10APR07–5/9
TX
1021
548A
–UN
–03A
PR
07T
X10
2154
9A–U
N–0
3AP
R07
1—Hood Support Rod2—Cap Screws3—Hood
2. Raise engine hood.
3. Remove retaining pin and disconnect hood support rod(1).
CAUTION: Heavy component; use a hoist.
SpecificationEngine Hood—Weight 36 kg.......................................................................
80 lb
4. Attach appropriate lifting device to hood.
5. Remove cap screws (2) and hood (3).
6. Remove fan and fan guard.
7. Remove access covers on bottom of machine.
8. Pull a vacuum in hydraulic oil tank using a vacuumpump. See Apply Vacuum to Hydraulic Oil Tank.(Group 3360.)
OUO1073,0002103 –19–10APR07–6/9
TX
1020
211A
–UN
–07M
AR
07
1—Cap Screws
9. Remove cap screws (1) and cover.
Continued on next page
TM10091 (11JAN08) 05-0510-21 160DLC Excavator Repair011108
PN=145
Cooling System
050510
22
OUO1073,0002103 –19–10APR07–7/9
TX
1020
687A
–UN
–22M
AR
07T
X10
2068
8A–U
N–2
2MA
R07
1—Hydraulic Hose (to Fan Drive Motor)2—Cap Screw
10. Disconnect fan drive motor hydraulic hose (1) fromhydraulic oil tank. Apply caps and plugs to close allopenings.
11. Remove cap screw (2) and hose clamp.
12. Route hydraulic hose back through opening in side offan shroud.
OUO1073,0002103 –19–10APR07–8/9
TX
1020
690A
–UN
–22M
AR
07
1—Hydraulic Hose2—Hydraulic Hose
13. Tag and disconnect fan drive motor hydraulic hoses(1 and 2). Apply caps and plugs to close all openings.
14. Route hoses through opening in side of fan shroud.
Continued on next page
TM10091 (11JAN08) 05-0510-22 160DLC Excavator Repair011108
PN=146
Cooling System
05051023
OUO1073,0002103 –19–10APR07–9/9
TX
1020
691A
–UN
–27M
AR
07
1—Cap Screw (8 used)2—Fan Shroud3—Hydraulic Hose4—Hydraulic Hose5—Fan Drive Motor Shaft6—Upper Intercooler Tube
15. Loosen clamps and remove upper intercooler tube(6).
16. Disconnect hydraulic oil cooler hoses (3 and 4). Applycaps and plugs to close all openings.
NOTE: Lower shroud cap screws can be accessed byremoving access panel on bottom ofupperstructure.
17. Remove cap screws (1) and washers from fan shroud(2).
IMPORTANT: To prevent damage to fan shroud, usean additional technician to help guideshroud past fan drive motor shaft (5)from below.
18. Lift fan shroud up, tilt toward left-hand side ofmachine, and remove.
19. Install fan shroud, washers, and cap screws. Tightencap screws to specification.
SpecificationFan Shroud Cap Screws—Torque 37 N•m.................................................
27 lb-ft
20. Connect hydraulic oil cooler hoses.
21. Install upper intercooler cooler tube.
22. Route hydraulic hoses back through opening in fanshroud and connect.
23. Install access covers.
24. Install fan and fan guard.
25. Install upper radiator hose.
26. Install hood.
27. Fill cooling system. See Cooling System Fill andDeaeration Procedure. (Operator’s Manual.)
28. Check hydraulic oil level. Fill as necessary. See160DLC Drain and Refill Capacities. (Operator’sManual.)
TM10091 (11JAN08) 05-0510-23 160DLC Excavator Repair011108
PN=147
Cooling System
OUO1073,0002102 –19–18APR07–1/2
Coolant Surge Tank Remove and Install
TS
281
–UN
–23A
UG
88
CAUTION: Prevent possible injury from hotspraying water. DO NOT remove surge tank capunless engine is cool. Then remove cap slowly.
1. Remove surge tank filler cap to relieve pressure.
050510
24
OUO1073,0002102 –19–18APR07–2/2
TX
1020
677A
–UN
–22M
AR
07
1—Hose (to Engine)2—Hose3—Hose (to Radiator)4—Cap Screw (4 used)5—Hose6—Coolant Surge Tank
2. Drain coolant until level is below surge tank.
3. Loosen hose clamps and disconnect hoses (1, 2, and3).
4. Remove cap screws (4) from coolant surge tank (5).Reposition coolant surge tank to access lower hose(5).
5. Loosen hose clamp and disconnect lower hose (6).
6. Remove coolant surge tank. Replace as necessary.
7. Install coolant surge tank and cap screws.
8. Connect hoses and tighten clamps.
9. Fill cooling system. See Cooling System Fill andDeaeration Procedure. (Operator’s Manual.)
TM10091 (11JAN08) 05-0510-24 160DLC Excavator Repair011108
PN=148
Group 0520Intake System
0505201
LD30992,00005A0 –19–04APR07–1/1
Air Cleaner Remove and Install
TX
1021
229
–UN
–04A
PR
07
1—Cap Screw (4 used) 8—Hose 15—Intake Air Temperature 21—Nut2—Washer (4 used) 9—Hose Clamp Sensor 22—Air Cleaner Dust Valve3—Brackets 10—Mounting Bracket 16—Hose Clamp 23—Air Filter Housing4—Air Filter Restriction Switch 11—Washer (3 used) 17—Hose 24—Safety Element5—Intake Tube 12—Cap Screw (3 used) 18—Hose Clamp 25—Primary Air Cleaner6—Mounting Bracket 13—Cap Screw (4 used) 19—Cap Screw Element7—Hose Clamp 14—Washer (4 used) 20—Screen
TM10091 (11JAN08) 05-0520-1 160DLC Excavator Repair011108
PN=149
Intake System
050520
2
TM10091 (11JAN08) 05-0520-2 160DLC Excavator Repair011108
PN=150
Group 0560External Fuel Supply System
0505601
TJ15698,000012F –19–11APR07–1/4
Fuel Tank Remove and Install
TX
1020
209A
–UN
–07M
AR
07
1—Cover2—Step3—Handrail4—Toolbox
1. Drain fuel from tank. Approximate capacity is 320 L (85gal).
NOTE: Two cap screws for panel (1) are located intoolbox (4).
CAUTION: Heavy component; use a hoist.
2. Disconnect and remove wiring harness from inside oftoolbox.
3. Remove step (2), cover (1), handrail (3), and toolbox(4).
SpecificationToolbox—Weight 33 kg...............................................................................
72 lb
TJ15698,000012F –19–11APR07–2/4
TX
1020
212A
–UN
–07M
AR
07
1—Cap Screw (3 used)2—Panel Latch Bracket
4. Remove cap screws (1) and bracket (2).
5. Remove control valve cover.
Continued on next page
TM10091 (11JAN08) 05-0560-1 160DLC Excavator Repair011108
PN=151
External Fuel Supply System
050560
2
TJ15698,000012F –19–11APR07–3/4
TX
1020
200A
–UN
–07M
AR
07T
X10
2019
7A–U
N–0
7MA
R07
1—Cap Screws (4 used)2—Fuel Return Hose3—Clamp4—Electrical Connector
6. Disconnect electrical connector (4) and return hose (2).
7. Disconnect fuel supply hose from bottom of tank.
CAUTION: Heavy component; use a hoist.
8. Remove cap screws (1) and fuel tank.
SpecificationFuel Tank—Weight 97 kg approximate without fuel....................................
214 lb approximate without fuel
9. Repair or replace as necessary.
10. Install fuel tank and tighten mounting cap screws tospecification.
SpecificationFuel Tank Mounting CapScrews—Torque 270 N•m...........................................................................
199 lb-ft
11. Connect fuel supply hose, return hose, and electricalconnector.
12. Install control valve cover and side panel latchbracket.
Continued on next page
TM10091 (11JAN08) 05-0560-2 160DLC Excavator Repair011108
PN=152
External Fuel Supply System
0505603
TJ15698,000012F –19–11APR07–4/4
TX
1020
209A
–UN
–07M
AR
07
1—Cover2—Step3—Handrail4—Toolbox
13. Install handrail (3), toolbox (4), cover (1), and step(2).
14. Fill tank with fuel.
15. Bleed fuel system. See Bleed Fuel System.(Operator’s Manual.)
TJ15698,000012D –19–11APR07–1/1
Primary Fuel Filter (Water Separator) Removeand Install
TX
1020
198A
–UN
–07M
AR
07
1—Cap Screw (2 used)2—Fuel Hose
1. Loosen drain valve on bottom of filter and drain fuelinto a container.
2. Disconnect electrical connector from bottom of filter.
3. Tag and disconnect fuel hoses (2).
4. Remove cap screws (1) and primary fuel filterassembly.
5. Install primary fuel filter assembly and tighten capscrews.
6. Connect fuel hoses and electrical connector.
7. Bleed fuel system. See Bleed Fuel System. (Operator’sManual.)
TM10091 (11JAN08) 05-0560-3 160DLC Excavator Repair011108
PN=153
External Fuel Supply System
TJ15698,000012E –19–11APR07–1/1
Final Fuel Filter Remove and Install
TX
1020
210A
–UN
–07M
AR
07
1—Cap Screw (2 used)2—Fuel Hose3—Electrical Connector
1. Loosen drain valve on bottom of filter and drain fuelinto a container.
2. Disconnect electrical connector (3).
3. Tag and disconnect fuel hoses (2).
4. Remove cap screws (1) and final fuel filter assembly.
5. Install final fuel filter assembly and tighten cap screws.
6. Connect fuel hoses and electrical connector.
7. Bleed fuel system. See Bleed Fuel System. (Operator’sManual.)
050560
4
TM10091 (11JAN08) 05-0560-4 160DLC Excavator Repair011108
PN=154
Section 07Dampener Drive (Flex Coupling)
Contents
Page
Group 0752—ElementsDampener Drive (Flex Coupling) Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1
07
TM10091 (11JAN08) 07-1 160DLC Excavator Repair011108
PN=1
Contents
07
TM10091 (11JAN08) 07-2 160DLC Excavator Repair011108
PN=2
Group 0752Elements
0707521
FS41334,0000145 –19–10APR07–1/3
Dampener Drive (Flex Coupling) Remove andInstall
TX
1019
969
–UN
–02M
AR
07
1—Hub2—Set Screw (2 used)3—Flex Coupling4—Cap Screw (4 used)5—Insert (4 used)6—Guide Pins (4 used)7—Cap Screw (4 used)8—Insert (4 used)
1. Remove engine or hydraulic pump. See EngineRemove and Install. (Group 0400.) or See Pump 1 and2 Remove and Install. (Group 3360.)
NOTE: Flex coupling may come off with pump or stay onengine flywheel.
2. Remove parts (1—8).
3. Inspect and replace parts as necessary.
IMPORTANT: Do not use steel hammer to installguide pins (2). Use only rubber orplastic mallet.
4. If guide pins in engine flywheel are damaged, removeand replace pins. Use new pins and install intoflywheel using a plastic or rubber mallet.
5. Install each insert so index hole is aligned with guidepin, installed in previous step.
FS41334,0000145 –19–10APR07–2/3
TX
1019
893A
–UN
–19M
AR
07
1—Engine Flywheel2—Insert (4 used)3—Cap Screw (4 used)4—Flex Coupling
6. Apply PM37418 Thread Lock and Sealer (MediumStrength) to cap screws (3). Tighten to specification.
SpecificationFlex Coupling-to-Flywheel CapScrew—Torque 137 N•m.............................................................................
101 lb-ft
7. Install flex coupling (4) onto flywheel inserts (2) asshown.
TM10091 (11JAN08) 07-0752-1 160DLC Excavator Repair011108
PN=157
Continued on next page
Elements
070752
2
FS41334,0000145 –19–10APR07–3/3
TX
1019
891A
–UN
–19M
AR
07
1—Hydraulic Pump Housing2—Insert (4 used)3—Set Screw (2 used)4—Cap Screw (4 used)5—Hub6—Pump Shaft
8. Clean face of hydraulic pump housing (1).
9. Apply PM37418 Thread Lock and Sealer (MediumStrength) to threads of cap screws (4).
10. Install inserts (2) onto hub (5) using cap screws (4)and tighten to specification.
SpecificationPump Insert Cap Screws—Torque 137 N•m..........................................................................................
101 lb-ft
CAUTION: Install hub assembly so face is flushwith end of pump shaft. It cannot rub or hitpump housing or shaft oil seal when rotated.
11. Install hub (5) onto splines of pump shaft (6). Positionhub so face is flush with pump shaft end. Spacebetween hub and pump housing is approximately 2mm (0.08 in.).
12. Apply PM37418 Thread Lock and Sealer (MediumStrength) to set screws (3).
13. Tighten set screws (3) to specification.
SpecificationHub-to-Pump Shaft Set Screw—Torque 108 N•m..........................................................................................
80 lb-ft
14. Install engine or hydraulic pump. See Engine Removeand Install. (Group 0400.) or See Pump 1 and 2Remove and Install. (Group 3360.)
TM10091 (11JAN08) 07-0752-2 160DLC Excavator Repair011108
PN=158
Section 17Frame or Supporting Structure
Contents
Page
Group 1740—Frame InstallationWelding On Machine. . . . . . . . . . . . . . . . . . .17-1740-1Welding Repair of Major Structure. . . . . . . . .17-1740-3
Group 1749—Chassis WeightsCounterweight Remove and Install . . . . . . . .17-1749-1
17
TM10091 (11JAN08) 17-1 160DLC Excavator Repair011108
PN=1
Contents
17
TM10091 (11JAN08) 17-2 160DLC Excavator Repair011108
PN=2
Group 1740Frame Installation
OUO1073,0002105 –19–09APR07–1/4
Welding On Machine
IMPORTANT: Electrical current traveling from thewelder through the machine electricalsystem may damage the machineelectrical system, including battery,engine control unit (ECU), informationcontroller (ICF) and main controller(MCF). Disconnect battery cables andECU, ICF and MCF electrical connectorsbefore welding on the machine.
Before welding on the machine, follow the steps listedbelow to protect the machine electrical system.
1717401OUO1073,0002105 –19–09APR07–2/4
TX
1003
378A
–UN
–07F
EB
06
1—Electrical Connectors2—Main Controller (MCF)
1. Disconnect battery ground and positive cables.
2. Remove rear console cover behind seat. See RearCover Remove and Install. (9015-20.)
3. Disconnect electrical connectors (1) from MCF (2). SeeCab Harness (W1) Component Location (9015-10.)
OUO1073,0002105 –19–09APR07–3/4
TX
1003
380A
–UN
–01M
AR
061—Electrical Connector (2 used)2—Information Controller (ICF)
4. Disconnect electrical connectors (1) from ICF (2). SeeCab Harness (W1) Component Location. (9015-10.)
Continued on next page
TM10091 (11JAN08) 17-1740-1 160DLC Excavator Repair011108
PN=161
Frame Installation
OUO1073,0002105 –19–09APR07–4/4
TX
1021
721A
–UN
–10A
PR
07
1—Engine Control Unit (ECU)2—Electrical Connectors
NOTE: Engine Control Unit (ECU) is located in the enginecompartment.
6. Disconnect electrical connectors (2) from enginecontrol unit (ECU) (1). See Engine Interface Harness(W5) Component Location. (9015-10.)
171740
2
TM10091 (11JAN08) 17-1740-2 160DLC Excavator Repair011108
PN=162
Frame Installation
1717403
OUO1073,0002106 –19–28MAR07–1/1
Welding Repair of Major Structure
CAUTION: Avoid potentially toxic fumes anddust. Hazardous fumes can be generatedwhen paint is heated by welding, soldering,or using a torch. Do all work outside or in awell ventilated area. Dispose of paint andsolvent properly.
If you sand or grind paint, avoid breathingthe dust. Wear an approved respirator. If youuse solvent or paint stripper, removestripper with soap and water before welding.Remove solvent or paint stripper containersand other flammable material from area.Allow fumes to disperse at least 15 minutesbefore welding or heating.
1. Remove paint before welding or heating.
IMPORTANT: Disconnect battery ground strap andpositive cables. Also disconnect thewiring harness connectors to themain controller (MCF), informationcontroller (ICF) and engine controlunit (ECU). See Welding on Machine.(Group 1740.)
Have only a qualified welder do thisjob. Connect welder ground clampclose to each weld area so electricalcurrent does not pass through anybearings. Remove or protect all partsthat can be damaged by heat or weldsplatter.
2. Use one of the following weld processes:
• AWS-E-7018 covered electrode with shieldedmetal arc welding (SMAW) process.
• AWS-ER-70S-3 wire electrode with gas metal arcwelding (GMAW) process.
• AWS-E70T-1 or E71T-1 wire electrode with fluxcore arc welding (FCAW) process.
Welding Repair of Major Structure—SpecificationWeld Metal—Tensile Strength 482.6 mPa (70,000 psi).......................Yield Strength 413.7 mPa (60,000 psi)................................................Elongation 22%.....................................................................................
IMPORTANT: Area to be repaired must bepreheated to allow better weldpenetration.
3. To repair weld metal failure, remove failed weldmetal using arc or grinding equipment. Thoroughlyclean area to be welded. Preheat structuralassemblies to a minimum of 38°C (100°F). Preheatground engaging tools (cutting edges, skid shoes,and teeth shanks) to 177°C (350°F).
To repair base metal failure remove enoughmaterial to allow weld to penetrate to the bottom ofcrack. Preheat structural assemblies to a minimumof 38°C (100°F). Preheat ground engaging tools(cutting edges, skid shoes, and teeth shanks) to177°C (350°F).
Welding Repair of Major Structure—SpecificationStructural Assemblies—PreheatTemperature 38°C (100°F)...................................................................Ground Engaging Tools—Preheat Temperature 177°C (350°F)....................................................
TM10091 (11JAN08) 17-1740-3 160DLC Excavator Repair011108
PN=163
Frame Installation
171740
4
TM10091 (11JAN08) 17-1740-4 160DLC Excavator Repair011108
PN=164
Group 1749Chassis Weights
1717491
TJ15698,0000144 –19–29MAR07–1/1
Counterweight Remove and Install
T14
3043
–UN
–20J
UL0
1T
1430
44–U
N–0
3SE
P02
T14
3045
–UN
–20J
UL0
1
1—Plastic Cap (2 used)2—Lifting Device3—Spreader Bar4—Cap Screw and Washer (4 used)
1. Park machine on level ground.
2. Remove two plastic caps (1) from top of counterweight.
CAUTION: Heavy component; use appropriatelifting device.
The lifting capacity of a lifting eyeboltdecreases as the lift angle increases fromvertical. A spreader bar should be used toobtain, as close as possible, a vertical lift fromeyebolts.
SpecificationCounterweight—Weight 3310 kg.................................................................
7299 lb
3. Connect counterweight to an appropriate lifting device(2) using a spreader bar (3).
4. Remove cap screws and washers (4).
5. Remove counterweight.
6. Repair or replace as necessary.
7. Install counterweight onto machine using appropriatelifting device.
8. Install cap screws and washers (4). Tighten tospecification.
SpecificationFrame-to-Counterweight CapScrew—Torque 1150 N•m...........................................................................
830 lb-ft
TM10091 (11JAN08) 17-1749-1 160DLC Excavator Repair011108
PN=165
Chassis Weights
171749
2
TM10091 (11JAN08) 17-1749-2 160DLC Excavator Repair011108
PN=166
Section 18Operator’s Station
Contents
Page
Group 1800—Removal and InstallationCab Remove and Install . . . . . . . . . . . . . . . .18-1800-1
Group 1810—Operator EnclosureSliding Windows Remove and Install. . . . . . .18-1810-1Windowpanes Remove and Install . . . . . . . .18-1810-2Windowpanes Dimensions . . . . . . . . . . . . . .18-1810-3
Group 1821—Seat and Seat BeltSeat Remove and Install . . . . . . . . . . . . . . . .18-1821-1Seat Belt Remove and Install . . . . . . . . . . . .18-1821-2Mechanical Suspension Seat Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-3Air Suspension Seat Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-4Left and Right Console Covers Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-5
Group 1830—Heating and Air ConditioningRefrigerant Cautions and Proper
Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1Flush and Purge Air Conditioner System. . . .18-1830-3R134a Refrigerant Oil Information . . . . . . . . .18-1830-6R134a Refrigerant Recovery/Recycling
and Charging Station InstallationProcedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7
Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-8Evacuate R134a System. . . . . . . . . . . . . . . .18-1830-9Charge R134a System . . . . . . . . . . . . . . . .18-1830-10
18Compressor Remove and Install . . . . . . . . .18-1830-11Condenser Remove and Install . . . . . . . . . .18-1830-11Heater and Air Conditioner Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13Receiver-Dryer Remove and Install . . . . . . .18-1830-17
TM10091 (11JAN08) 18-1 160DLC Excavator Repair011108
PN=1
Contents
18
TM10091 (11JAN08) 18-2 160DLC Excavator Repair011108
PN=2
Group 1800Removal and Installation
OUO1073,0002100 –19–03APR07–1/17
Cab Remove and Install
1. Disconnect battery ground (-) cable.
OUO1073,0002100 –19–03APR07–2/17
TX
1020
462A
–UN
–16M
AR
07
1—Door
2. Remove door (1).
OUO1073,0002100 –19–03APR07–3/17
TX
1020
458A
–UN
–16M
AR
07
1818001
1—Cover
3. Remove cover (1).
OUO1073,0002100 –19–03APR07–4/17
TX
1020
459A
–UN
–16M
AR
07
1—Hose Clamp
4. Loosen hose clamp (1).
Continued on next page
TM10091 (11JAN08) 18-1800-1 160DLC Excavator Repair011108
PN=169
Removal and Installation
OUO1073,0002100 –19–03APR07–5/17
TX
1020
460A
–UN
–16M
AR
07
1—Air Filter Assembly2—Windshield Washer Reservoir3—Hose4—Diagnostic Connector5—Cap Screw (4 used)
5. Disconnect hose (3) from windshield washer reservoir(2).
6. Disconnect wiring harness from windshield washerreservoir (2).
7. Lift windshield washer reservoir (2) off of mountingbracket and remove.
8. Remove cap screws attaching diagnostic connector (4)to air filter assembly mounting bracket. Lay connectoraside.
9. Remove cap screws (5) and air filter assembly (1).Close air tube openings.
OUO1073,0002100 –19–03APR07–6/17
TX
1020
461A
–UN
–16M
AR
07
181800
2
1—Panel2—Panel
NOTE: Lower mounting hardware for panel (1) can beaccessed by removing access panels on bottomof machine.
10. Remove panels (1 and 2) to access rear of cab.
OUO1073,0002100 –19–03APR07–7/17
TX
1020
388A
–UN
–19M
AR
07
1—Connector2—Connector3—Connector4—Connector5—Ground
11. Disconnect cab wiring harness connectors (1—4).
12. Disconnect ground wires (5) from frame.
13. Remove seat. See Seat Remove and Install. (Group1821.)
14. Remove cab floor mat.
TM10091 (11JAN08) 18-1800-2 160DLC Excavator Repair011108
PN=170
Continued on next page
Removal and Installation
OUO1073,0002100 –19–03APR07–8/17
TX
1020
391
–UN
–16M
AR
07
1—Bracket2—Cap Screw (3 used)3—Cab Frame4—Seat Mount
15. Remove cap screws (2) and bracket (1) from cabframe (3) and seat mount (4).
OUO1073,0002100 –19–03APR07–9/17
TX
1020
272A
–UN
–08M
AR
07
1818003
1—Cover2—Screws3—Cap Screws4—Panel
16. Remove cover (1) from rear panel.
17. Remove screws (2) and cap screws (3) from rearpanel (4).
18. Pull rear panel forward. Disconnect wiring harnessfrom lighter and power outlet and remove panel.
OUO1073,0002100 –19–03APR07–10/17
TX
1020
347A
–UN
–08M
AR
07
1—Screw2—Panel3—Air Duct
19. Remove screws (1), panel (2), and air duct (3).
Continued on next page
TM10091 (11JAN08) 18-1800-3 160DLC Excavator Repair011108
PN=171
Removal and Installation
OUO1073,0002100 –19–03APR07–11/17
TX
1020
275A
–UN
–08M
AR
07
1—Inlet Duct2—Cap Screw
20. Remove cap screws (2), mounting bracket, and freshair inlet duct (1).
181800
4
OUO1073,0002100 –19–03APR07–12/17
TX
1020
387A
–UN
–19M
AR
07T
X10
2039
4A–U
N–1
9MA
R07
1—Cap Screw2—Cab Wiring Harness3—Cap Screw4—Bracket5—Cap Screws
21. Remove cap screw (1) behind 12 volt powerconverter.
22. Remove cap screw (3), cap screws (5) and bracket(4).
23. Disconnect cab wiring harness (2) from left and rightconsoles and air conditioning module. See CabHarness (W1) Component Location . (Group9015-10).
24. Remove any clamps or tie bands securing cabharness to floor or consoles.
OUO1073,0002100 –19–03APR07–13/17
TX
1021
236A
–UN
–27M
AR
07
1—Monitor Controller2—Cup Holder3—Panel
25. Remove monitor controller (1). See Monitor ControllerRemove and Install. (Group 9015-20.)
26. Remove cup holder (2) and panel (3).
TM10091 (11JAN08) 18-1800-4 160DLC Excavator Repair011108
PN=172
Continued on next page
Removal and Installation
OUO1073,0002100 –19–03APR07–14/17
TX
1020
389A
–UN
–19M
AR
07
Rear Anchor Bolt
TX
1020
390A
–UN
–19M
AR
07
Front Anchor Bolt
1818005
1—Ground Wire2—Anchor Bolt
27. Remove access covers from bottom of cab.
28. Remove anchor bolts (1), spacers, and washers.
29. Remove cap screw and disconnect ground (1) fromframe.
OUO1073,0002100 –19–03APR07–15/17
21 2
1
3
45
63
4
57
8
3
46
TX
1020
393
–UN
–19M
AR
07
1—Lock Nut (4 used)2—Washer (4 used)3—Socket Head Cap Screw (4 used)4—Washer (4 used)5—Cap Screw (6 used)6—Washer (6 used)7—Socket Head Cap Screw8—Washer
30. Remove socket head cap screws (3 and 7), capscrews (5), and isolator lock nuts (1) to separate cabframe from floor. Discard lock nuts.
Continued on next page
TM10091 (11JAN08) 18-1800-5 160DLC Excavator Repair011108
PN=173
Removal and Installation
181800
6
OUO1073,0002100 –19–03APR07–16/17
TX
1003
209A
–UN
–14M
AR
06
1—Lifting Brackets
CAUTION: Heavy component; use appropriatelifting device.
SpecificationCab—Weight 380 kg...................................................................................
838 lb
31. Use lifting straps and connect appropriate liftingdevice to lifting brackets (1) on roof of cab.
IMPORTANT: Before lifting cab, ensure all wiringharness connectors and ducts havebeen disconnected.
32. Remove cab.
33. Repair or replace parts as necessary.
IMPORTANT: Ensure all wiring harnesses and othercomponents are out of the way beforeinstalling cab.
34. Install cab. Tighten cab mounting hardware tospecification.
SpecificationCab-to-Floor Socket Head CapScrews—Torque 50 N•m.............................................................................
37 lb-ft
SpecificationCab-to-Floor Cap Screws—Torque 50 N•m............................................................................................
37 lb-ft
SpecificationCab Isolator Lock Nuts—Torque 210 N•m..................................................
155 lb-ft
SpecificationCab Anchor Bolts—Torque 550 N•m..........................................................
406 lb-ft
35. Install access covers on bottom of cab. Tighten capscrews to specification.
SpecificationCab Access Cover Cap Screws—Torque 50 N•m............................................................................................
37 lb-ft
TM10091 (11JAN08) 18-1800-6 160DLC Excavator Repair011108
PN=174
Continued on next page
Removal and Installation
OUO1073,0002100 –19–03APR07–17/17
36. Connect cab wiring harness connectors. See CabHarness (W1) Component Location . (Group9015-10).
37. Connect ducts to heater and air conditioning module.
38. Install monitor controller. See Monitor ControllerRemove and Install. (Group 9015-20.)
39. Install seat. See Seat Remove and Install. (Group1821.)
40. Install panels behind cab.
41. Install air filter assembly.
42. Install windshield washer reservoir and connect hose.
43. Install diagnostic connector to air filter assemblymounting bracket.
44. Install door.
1818007
TM10091 (11JAN08) 18-1800-7 160DLC Excavator Repair011108
PN=175
Removal and Installation
181800
8
TM10091 (11JAN08) 18-1800-8 160DLC Excavator Repair011108
PN=176
Group 1810Operator Enclosure
RO33873,0000A5E –19–03APR07–1/1
Sliding Windows Remove and Install
T14
0968
–UN
–30A
PR
01
1—Window Frame2—Bottom Spacer (4 used)3—Molding4—Adhesive
1. Remove molding (3) from inside of window.
2. Use putty knife to cut adhesive (4) between cab flangeand window frame (1).
IMPORTANT: Work carefully to avoid damaging frameand windowpane. Two technicians arerequired during window removal; one topush window out of cab, and one toprevent window from falling.
3. Carefully remove window frame from cab.
4. Lift frame slightly at top-center to remove and installwindowpanes.
5. Apply PM37391 Instant Gel Adhesive to cab flange.
6. Install windows and frame with spacers (2) at thebottom.
7. Using water as lubricant, push window frame tightagainst cab flange.
8. Install molding (3) around window and cab flange.
1818101
TM10091 (11JAN08) 18-1810-1 160DLC Excavator Repair011108
PN=177
Operator Enclosure
181810
2
RO33873,0000A5F –19–03APR07–1/1
Windowpanes Remove and Install
The adhesive used to secure windowpanes is a urethaneadhesive used on automobile windshields. Urethaneadhesive manufactured by Henkel Corporation orequivalent is recommended. DO NOT use any other typeof adhesive. It is recommended that an auto glass dealerinstall windowpanes.
IMPORTANT: Windowpanes must include anultraviolet barrier around edge toprevent adhesive deterioration.Windowpanes ordered through JohnDeere Parts include ultraviolet barrier. Ifwindowpane is purchased throughglass dealer, the dealer mustincorporate ultraviolet barrier on theglass. DO NOT paint border of glass.
If auto glass dealer does not install windowpanes,proceed as follows:
1. Remove windowpane frame from cab.
2. Scrape any broken glass off existing adhesive. DONOT remove adhesive from window frame or cab.
IMPORTANT: Adhesive will not bond to bare metal.
3. If existing adhesive is removed and paint is scraped,paint window frame. Paint must fully cure beforeinstalling windowpane.
4. Trim existing adhesive to form a smooth surface.
IMPORTANT: Follow manufacturer’s instructions forusing adhesive.
5. Apply 6 mm (1/4 in.) bead of adhesive over existingadhesive.
6. Position windowpane in cab frame. Use hand pressureto force windowpane down until edges are even withmetal frame.
7. Secure windowpane with duct tape until adhesivecures. Allow adhesive to cure for 24 hours beforeoperating machine.
TM10091 (11JAN08) 18-1810-2 160DLC Excavator Repair011108
PN=178
Operator Enclosure
1818103
OUO1073,0002108 –19–17APR07–1/5
Windowpanes Dimensions
TX
1021
276
–UN
–04A
PR
07
Cab Door Glass
TM10091 (11JAN08) 18-1810-3 160DLC Excavator Repair011108
PN=179
Continued on next page
Operator Enclosure
181810
4
OUO1073,0002108 –19–17APR07–2/5
TX
1018
573
–UN
–23F
EB
07
Cab Right-Hand Glass
TM10091 (11JAN08) 18-1810-4 160DLC Excavator Repair011108
PN=180
Continued on next page
Operator Enclosure
1818105
OUO1073,0002108 –19–17APR07–3/5
TX
1021
275
–UN
–04A
PR
07
Cab Rear and Left-Hand Rear Glass
TM10091 (11JAN08) 18-1810-5 160DLC Excavator Repair011108
PN=181
Continued on next page
Operator Enclosure
181810
6
OUO1073,0002108 –19–17APR07–4/5
TX
1018
570
–UN
–23F
EB
07
Cab Front Glass
TM10091 (11JAN08) 18-1810-6 160DLC Excavator Repair011108
PN=182
Continued on next page
Operator Enclosure
OUO1073,0002108 –19–17APR07–5/5
1—Black Ceramic Coating 2—Black Ceramic CoatingRange Surface
NOTE: Dimensions shown are in millimeters.
1818107
TM10091 (11JAN08) 18-1810-7 160DLC Excavator Repair011108
PN=183
Operator Enclosure
181810
8
TM10091 (11JAN08) 18-1810-8 160DLC Excavator Repair011108
PN=184
Group 1821Seat and Seat Belt
1818211
OUO1073,00020FF –19–17APR07–1/1
Seat Remove and Install
TX
1020
303A
–UN
–08M
AR
07T
X10
2030
4A–U
N–0
8MA
R07
1—Cap Screw2—Socket Head Cap Screw3—Cap Screws4—Stop5—Socket Head Cap Screws
1. Slide seat forward.
2. Remove cap screws (1), lock washers, and lower seatbelts from each side of seat.
3. Remove socket head cap screws (2) from rear of seat.
4. Slide seat rearward.
5. Remove socket head cap screws (5) from front of seat.
CAUTION: Heavy component; use a hoist.
SpecificationSeat—Weight 40 kg....................................................................................
90 lb
6. Remove seat through front window using lifting strapand hoist.
7. Repair or replace parts as necessary.
8. Install seat.
9. Tighten seat mounting hardware to specification.
SpecificationSeat Mount Socket Head CapScrews—Torque 20 N•m.............................................................................
177 lb-in.
10. Install lower seat belt, lock washer and cap screw oneach side of seat. Tighten cap screw to specification.
SpecificationLower Seat Belt Mount CapScrews—Torque 50 N•m.............................................................................
37 lb-ft
TM10091 (11JAN08) 18-1821-1 160DLC Excavator Repair011108
PN=185
Seat and Seat Belt
OUO1073,00020E8 –19–10APR07–1/1
Seat Belt Remove and Install
TX
1018
443A
–UN
–09F
EB
07T
1889
88B
–UN
–26M
AR
0318
18212
1—Lower Seat Belt2—Cap Screw3—Upper Seat Belt4—Cap Screw
1. Slide seat forward. Remove cap screw (2), lock washerand lower seat belt (1) from each side of seat.
2. Remove cap screw (4) and upper seat belt (3) fromeach side of seat.
3. Repair or replace parts as necessary.
4. Install seat belts and cap screws (4).
5. Install lower seat belt to lower mount on each side ofseat using cap screw (4), lock washer and cap screw.Tighten cap screw to specification.
SpecificationLower Seat Belt Mount CapScrews—Torque 50 N•m.............................................................................
37 lb-ft
TM10091 (11JAN08) 18-1821-2 160DLC Excavator Repair011108
PN=186
Seat and Seat Belt
1818213
RO33873,0000A6B –19–16MAR06–1/1
Mechanical Suspension Seat Disassemble and Assemble
TX
1004
008
–UN
–21F
EB
06
0—Seat Assembly 6—Frame 12—Adjuster 17—Cover2—Cushion Cover 7—Cable 13—Lever 20—Bushing3—Support 8—Stand 14—Seat Suspension 21—Link4—Cushion 10—Spring 15—Seat Slide Track Kit 24—Seat Kit5—Pad 11—Torsional Damper 16—Handle 25—Head Restraint
TM10091 (11JAN08) 18-1821-3 160DLC Excavator Repair011108
PN=187
Seat and Seat Belt
181821
4
RO33873,0000A6C –19–16MAR06–1/1
Air Suspension Seat Disassemble and Assemble
TX
1004
009
–UN
–21F
EB
06
0—Seat Assembly 8—Handle 16—Compressor 22—Seat Suspension2—Cushion Cover 9—Stand 17—Lever 23—Seat Suspension Boot Kit3—Pad 10—Spring 18—Torsional Damper 24—Seat Adjustment Cable Kit4—Cushion 11—Seat Slide Track Kit 19—Air Spring Seat Kit 25—Wiring Lead5—Pad 14—Lever Kit 20—Valve 26—Head Restraint6—Frame 15—Bearing Kit 21—Kit 27—Heater7—Cable
TM10091 (11JAN08) 18-1821-4 160DLC Excavator Repair011108
PN=188
Seat and Seat Belt
LD30992,00004F1 –19–28MAR07–1/3
Left and Right Console Covers Remove andInstall
TX
1018
700A
–UN
–08F
EB
07
1—Pilot Control Shutoff Lever2—Cap Screws and Washers (8 used)
1. Remove pilot control shutoff lever (1).
2. Remove cap screws (2) from pilot control boot.
Continued on next page
1818215
TM10091 (11JAN08) 18-1821-5 160DLC Excavator Repair011108
PN=189
Seat and Seat Belt
181821
6
LD30992,00004F1 –19–28MAR07–2/3
TX
1000
801
–UN
–15D
EC
05
TM10091 (11JAN08) 18-1821-6 160DLC Excavator Repair011108
PN=190
Continued on next page
Seat and Seat Belt
LD30992,00004F1 –19–28MAR07–3/3
0—Cover 9—Cap Screw, Washer, and 18—Cover 26—Cover4—Screw (4 used) Lock Washer 19—Cap Screw, Washer, and 27—Cap Screw, Washer, and5—Cap Screw, Washer, and 11—Cover Lock Washer (3 used) Lock Washer (4 used)
Lock Washer 12—Cap Screw, Washer, and 22—Cover 28—Cap (2 used)7—Cover Lock Washer 23—Cap Screw, Washer, and 30—Label8—Cap Screw, Washer, and 15—Cover Lock Washer (2 used) 31—Label
Lock Washer (2 used) 16—Screw (4 used) 24—Cap Screw, Washer, andLock Washer
3. Remove:
• Caps (28)• Screws (4 and 16)• Cap Screws (5, 8, 9, 12, 19, 23, 24, and 27)• Covers (0, 7, 11, 15, 18, 22, and 26)
4. Repair or replace parts as necessary.
5. Install covers, cap screws, screws, and caps.
6. Install pilot control shutoff lever and pilot controlboot cap screws.
1818217
TM10091 (11JAN08) 18-1821-7 160DLC Excavator Repair011108
PN=191
Seat and Seat Belt
181821
8
TM10091 (11JAN08) 18-1821-8 160DLC Excavator Repair011108
PN=192
Group 1830Heating and Air Conditioning
1818301
TX,9031,DY5073 –19–21JUL06–1/2
Refrigerant Cautions and Proper Handling
CAUTION: DO NOT allow liquid refrigerant tocontact eyes or skin. Liquid refrigerant willfreeze eyes or skin on contact. Weargoggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DONOT rub the area. Splash large amounts ofCOOL water on affected area. Go to aphysician or hospital immediately fortreatment.
DO NOT allow refrigerant to contact openflames or very hot surfaces such as electricwelding arc, electric heating element andlighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) ina closed container. Heated refrigerant willdevelop high pressure which can burst thecontainer.
Keep refrigerant containers away from heatsources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant containerwith your bare hands. Skin may freeze tocontainer. Wear gloves.
If skin freezes to container, pour COOLwater over container to free the skin. Go to aphysician or hospital immediately fortreatment.
IMPORTANT: To meet government standardsrelating to the use of refrigerants,
R134a is used in the air conditioningsystem. Because it does not containchlorine, R134a is not detrimental tothe ozone in the atmosphere.However, it is illegal to dischargeany refrigerant into the atmosphere.It must be recovered using theappropriate recovery stations.
Use correct refrigerant recovery,recycling and charging stations.Never mix refrigerants, hoses,fittings, components or refrigerantoils.
Use only John Deere approvedR134a refrigerant products. Mixing ofproducts not compatible will causesystem damage and contaminaterecovery, recycling and chargingstation equipment. Care must betaken to identify and use equipment,refrigerant oil and refrigerantdesigned only for R134a refrigerantsystems. Refrigerant should betested for type and purity beforerecovery, recycling or charging ofsystem. JT02167A refrigerant testinstrument should be used beforeany testing or repair to system ispreformed.
Continued on next page
TM10091 (11JAN08) 18-1830-1 160DLC Excavator Repair011108
PN=193
Heating and Air Conditioning
TX,9031,DY5073 –19–21JUL06–2/2
Prism Pro Refrigerant IdentificationInstrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A
To safely identify type and check purity of refrigerantprior to recovery, recycling and recharging of A/Csystems.
181830
2
TM10091 (11JAN08) 18-1830-2 160DLC Excavator Repair011108
PN=194
Heating and Air Conditioning
1818303
OUO1073,00020F4 –19–10APR07–1/3
Flush and Purge Air Conditioner System
CAUTION: Liquid refrigerant will freeze eyesor skin on contact. Wear goggles, glovesand protective clothing.
See Refrigerant Cautions and ProperHandling. (Group 1830.)
NOTE: Flushing can be performed on machine.
1. Recover refrigerant from system. See RecoverR134a Refrigerant. (Group 1830.)
Add flushing solvent to system with JT02075Flusher and JT02098 Flusher Fitting Kit.
2. Remove and discard receiver/dryer.
3. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102 Adapter.
4. Fill flusher tank with solvent and fasten allconnections. Dispose of solvent properly.
SpecificationFlusher Tank—Capacity 4 L.................................................................
1 gal
NOTE: Air pressure must be at least at specificationfor flushing and purging.
SpecificationAir Pressure—MinimumPressure 620 kPa for flushing and
purging........................................................
90 psi for flushing and purging6.2 bar for flushing and purging
5. Connect supply line of moisture-free compressedair or dry nitrogen to flusher air valve.
6. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty when hosepulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.
7. Clean compressor as follows:
a. Remove compressor and measure oil drainedfrom both manifold ports.
b. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102Adapter.
c. Pour flushing solvent into suction port anddischarge port. Plug both ports in compressormanifold, using JT02099 and JT03194 Caps.
SpecificationFlushing Solvent in SuctionPort—Volume 240 mL...........................................................................
8 fl ozFlushing Solvent in DischargePort—Volume 120 mL...........................................................................
4 fl oz
d. Turn compressor end for end and roll it side toside.
e. Remove both plugs from manifold ports anddrain solvent from compressor.
f. Connect battery power to compressor clutch coil.Rotate pulley at least five revolutions to movesolvent out of cylinders.
g. Invert compressor. Roll end for end and side toside. Drain thoroughly.
h. Repeat previous two steps at least three times.
8. Divide system into two circuits:
• Condenser circuit, including inlet and outlethoses.
• Evaporator circuit, including inlet and outlethoses.
9. Condenser:
TM10091 (11JAN08) 18-1830-3 160DLC Excavator Repair011108
PN=195
Continued on next page
Heating and Air Conditioning
181830
4
OUO1073,00020F4 –19–10APR07–2/3
IMPORTANT: DO NOT attempt to flush throughcompressor or receiver/dryer.Flushing through expansion valve isacceptable if refrigerant oil has anormal odor and appearance.
a. Flush/Purge Condenser:
b. Remove and discard receiver/dryer.
c. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102Adapter.
d. Fill flusher tank with solvent and fasten allconnections.
SpecificationFlusher Tank—Capacity 4 L.................................................................
1 gal
NOTE: Air pressure must be at least to specificationfor flushing and purging.
SpecificationAir Pressure—MinimumPressure 620 kPa for flushing and
purging.........................................................
90 psi for flushing and purging.6.2 bar for flushing and
purging.
e. Connect supply line of moisture-free compressedair or dry nitrogen to flusher air valve.
f. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty whenhose pulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.
g. Attach return hose and aerator nozzle to end ofreceiver/dryer inlet hose using JT03197 Adapter.
Put nozzle in container to collect flushingsolvent.
NOTE: Purging the condenser circuit takes 10—12minutes to thoroughly remove solvent.
h. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to piece ofcardboard; continue purging until cardboard isdry.
10. See flush evaporator, if evaporator requiresflushing.
If system is contaminated with burned refrigerantoil or debris, remove and bench flush evaporator.See following steps to flush evaporator throughexpansion valve, if oil appears normal.
11. Flush evaporator:
a. Remove evaporator and expansion valve. SeeHeater and Air Conditioner Remove and Install.(Group 1830.)
b. Force flushing solvent through evaporator inletwith compressed air.
c. Purge system until dry.
d. Install evaporator and then go to step 13.
12. Flush evaporator through expansion valve:
a. Connect flusher outlet hose to connection ofreceiver/dryer outlet hose using JT03188adapter.
b. Fill flusher tank and fasten all connections.
SpecificationFlusher Tank—Capacity 4 L.................................................................
1 gal
TM10091 (11JAN08) 18-1830-4 160DLC Excavator Repair011108
PN=196
Continued on next page
Heating and Air Conditioning
OUO1073,00020F4 –19–10APR07–3/3
NOTE: Air pressure must be at least to specificationfor flushing and purging.
SpecificationAir Pressure—MinimumPressure 620 kpa for flushing and
purging.........................................................
90 psi for flushing and purging.6.2 bar for flushing and
purging.
c. Connect supply line of moisture-freecompressed air or dry nitrogen to flusher airvalve.
d. Attach hose and aerator nozzle to compressorinlet line using JT02101 adapter. Put nozzle incontainer to collect solvent.
NOTE: Purging evaporator circuit takes 12—15minutes to thoroughly remove solvent.
13. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to piece ofcardboard and continue purging until cardboard isdry.
14. Install new receiver/dryer compatible with R134arefrigerant. Fasten connections and mountingbracket. See Receiver-Dryer Remove and Install.(Group 1830.)
15. Add required oil. See R134a Refrigerant OilInformation. (Group 1830.)
16. Install compressor and connect refrigerant lines tomanifold.
17. Connect clutch coil wire and install drive belt.
1818305
TM10091 (11JAN08) 18-1830-5 160DLC Excavator Repair011108
PN=197
Heating and Air Conditioning
181830
6
OUO1073,00020F5 –19–04APR07–1/1
R134a Refrigerant Oil Information
CAUTION: All new compressors are chargedwith a mixture of nitrogen, R134a refrigerantand TY22025 (R134a) refrigerant oil. Wearsafety goggles and discharge thecompressor slowly to avoid possible injury.
IMPORTANT: Do not add any more oil thanrequired or maximum cooling will bereduced.
DO NOT leave system or R134acompressor oil containers open.Refrigerant oil easily absorbsmoisture. DO NOT spill R134acompressor oil on acrylic or ABSplastic. This oil will deteriorate thesematerials rapidly. Identify R134a oilcontainers and measures toeliminate accidental mixing ofdifferent oils.
New compressor from parts depot contains new oil. Oillevel visible through suction port normally is belowdrive shaft.
Normal operating oil level of compressor removed fromoperation cannot be seen through suction port ofcompressor.
Compressors can be divided into three categorieswhen determining correct oil charge for system.
• New compressor from parts depot• Used compressor removed from operation• Compressor internally washed with flushing solvent
Determine amount of system oil charge prior toinstallation of compressor on machine.
When complete system, lines, and components areflushed add correct amount of oil as described.
SpecificationOil—Volume 180 mL.............................................................................
6.09 fl ozR134a—Weight 950 ± 50 g...................................................................
2.09 ± 0.1 lb
If any section of hose is removed and flushed orreplaced, measure length of hose and use formula 3mL per 30 cm (0.1 fl oz per ft ) to determine correctamount of oil to be added.
Drain compressor oil into graduated container whilerotating compressor shaft and record amount.
If oil drained from compressor removed from operationis very black or amount of oil is less than 6 mL (0.2 floz), perform the following and discard oil properly:
❒ Determine if R134a leakage was detected, removecomponent and repair or replace component.
❒ Remove and discard receiver/dryer.❒ Flush complete system with TY16134 Air
Conditioning Flushing Solvent.
If component is serviceable, pour flushing solvent inports and internally wash out old oil and discard oilproperly.
Install new receiver-dryer.See Receiver-Dryer Removeand Install. (Group 1830.)
Install required amount of TY22025 Refrigerant Oil incompressor.
Connect all components. Evacuate and charge system.See Evacuate R134a System and See Charge R134aSystem. (Group 1830.)
TM10091 (11JAN08) 18-1830-6 160DLC Excavator Repair011108
PN=198
Heating and Air Conditioning
1818307
OUO1073,00020F6 –19–05MAR07–1/1
R134a Refrigerant Recovery/Recycling andCharging Station Installation Procedure
T81
18A
G–U
N–0
6DE
C93
A—High Pressure Hose Charge Port CapB—Red HoseC—Blue HoseD—High Pressure Relief ValveE—Refrigerant Recovery/Recycling and Charging
Station
CAUTION: Liquid refrigerant will freeze eyes orskin on contact. Wear goggles, gloves andprotective clothing.
See Refrigerant Cautions and Proper Handling.(Group 1830.)
IMPORTANT: Use only John Deere approved R134arefrigerant products. Mixing of productsnot compatible will cause systemdamage and contaminate recovery,recycling and charging stationequipment.
CAUTION: Do not remove high pressure reliefvalve (D). Air conditioning station will dischargerapidly causing possible injury.
IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling andcharging stations. DO NOT mixrefrigerant, hoses, fittings, componentsor refrigerant oils.
1. Follow procedures. See Refrigerant Cautions andProper Handling. (Group 1830.)
2. Close both high-side and low-side valves on refrigerantrecovery/recycling and charging station (E).
3. Remove cap from low-side charge port.
4. Connect blue hose (C) from refrigerantrecovery/recycling and charging station (E) to low-sidetest port.
5. Remove cap (A) from charge port on high pressurehose and connect red hose (B).
6. Follow the manufacturers’ instructions when usingrefrigerant recovery/recycling and charging station.
TM10091 (11JAN08) 18-1830-7 160DLC Excavator Repair011108
PN=199
Heating and Air Conditioning
181830
8
OUO1073,00020F7 –19–05MAR07–1/1
Recover R134a Refrigerant
CAUTION: Liquid refrigerant will freeze eyes orskin on contact. Wear goggles, gloves andprotective clothing.
See Refrigerant Cautions and Proper Handling.(Group 1830.)
CAUTION: Do not remove high pressure reliefvalve. Air conditioning system will dischargerapidly causing possible injury.
IMPORTANT: Use correct refrigerantrecovery/recycling and chargingstations. DO NOT mix refrigerant,hoses, fittings, components orrefrigerant oils.
1. Run air conditioning system for three minutes to help inrecovery process. Turn air conditioning system offbefore proceeding with recovery steps.
2. With engine OFF identify refrigerant type usingJT02167A Refrigerant Identification Instrument.
3. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and Charging StationInstallation Procedure. (Group 1830.)
4. Follow manufacturers’ instructions when usingrefrigerant recovery/recycling and charging station.
TM10091 (11JAN08) 18-1830-8 160DLC Excavator Repair011108
PN=200
Heating and Air Conditioning
1818309
OUO1073,00020F8 –19–05MAR07–1/1
Evacuate R134a System
CAUTION: Liquid refrigerant will freeze eyesor skin on contact. Wear goggles, glovesand protective clothing.
See Refrigerant Cautions and ProperHandling. (Group 1830.)
Do not remove high pressure relief valve. Airconditioning system will discharge rapidlycausing possible injury.
1. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and ChargingStation Installation Procedure. (Group 1830.)
2. Open low-side and high-side valves on refrigerantrecovery/recycling and charging station.
3. Follow manufacturers’ instructions and evacuatesystem.
NOTE: Vacuum specifications listed are for sea levelconditions. Subtract 3.4 kPa (34 mbar) (1 in.Hg) from 98 kPa (980 mbar) (29 in. Hg) foreach 300 m (1000 ft) elevation above sealevel.
SpecificationEvacuate System—Vacuum Subtract 3.4 kPa from 98 kPa
for each 300 m elevation abovesea level
................
Subtract 34 mbar from 980mbar for each 300 m elevation
above seal levelSubtract 1 in. Hg from 29 in.Hg for each 1000 ft elevation
above sea level
4. Evacuate system until low-side gauge registers 98kPa (980 mbar) (29 in. Hg) vacuum.
SpecificationEvacuate System—Vacuum 98 kPa.....................................................
980 kPa29 in. Hg
If above specification vacuum cannot be obtained in 15minutes, test the system for leaks. See RefrigerantLeak Test. (Group 9031-25.)
5. When vacuum reaches above specification, closelow-side and high-side valves. Turn vacuum pumpoff.
6. If vacuum decreases more than specification in 5minutes, there is a leak in system.
SpecificationEvacuate System—Vacuum 3.4 kPa....................................................
34 mbar1 in. Hg
7. Repair leak.
8. Evacuate system for 30 minutes after 98 kPa (980mbar) (29 in. Hg) vacuum is reached.
9. Close low-side and high-side valves. Stopevacuation.
10. Charge system. See Charge R134a System.(Group 1830.)
TM10091 (11JAN08) 18-1830-9 160DLC Excavator Repair011108
PN=201
Heating and Air Conditioning
181830
10
OUO1073,00020F9 –19–27MAR07–1/1
Charge R134a System
CAUTION: Liquid refrigerant will freeze eyesor skin on contact. Wear goggles, glovesand protective clothing.
See Refrigerant Cautions and ProperHandling. (Group 1830.)
IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling andcharging stations. DO NOT mixrefrigerant, hoses, fittings,components or refrigerant oils.
1. Identify refrigerant type using JT02167A RefrigerantIdentification Instrument.
2. Connect R134a Refrigerant Recovery/Recyclingand Charging Station. See R134a RefrigerantRecovery/Recycling and Charging StationInstallation Procedure. (Group 1830.)
3. Evacuate system. See Evacuate R134a System .(Group 1830.)
NOTE: Before beginning to charge air conditioningsystem, the following conditions must exist:Engine STOPPED, the pump must be capableof pulling at least 28.6 in. Hg vacuum (sea
level). Subtract 3.4 kPa (34 mbar) (1 in. Hg)from 98 kPa (980 mbar) (29 in. Hg) for each300 m (1000 ft) elevation above sea level.
SpecificationEvacuate System—Vacuum Subtract 3.4 kPa from 98 kPa
for each 300 m elevation abovesea level
................
Subtract 34 mbar from 980mbar for each 300 m elevation
above seal levelSubtract 1 in. Hg from 29 in.Hg for each 1000 ft elevation
above sea level
4. Follow manufacturer’s instructions and chargesystem.
5. Add refrigerant to system.
SpecificationAir Conditioning SystemRefrigerant—RefrigerantQuantity .95 kg......................................................................................
2.09 lb
6. Check air conditioning for proper function. SeeDiagnose Air Conditioning System Malfunctions.(Group 9031-15.)
TM10091 (11JAN08) 18-1830-10 160DLC Excavator Repair011108
PN=202
Heating and Air Conditioning
18183011
OUO1073,00020FA –19–03APR07–1/1
Compressor Remove and Install
TX
1020
173A
–UN
–07M
AR
07
1—Cap Screws2—Low Pressure Line3—High Pressure Line4—Connector5—Cap Screw (4 used)6—Compressor7—Belt
1. Recover refrigerant from system. See See RecoverR134a Refrigerant. (Group 1830.)
2. Remove compressor drive belt (7).
3. Disconnect wiring harness connector (4).
4. Remove cap screws (1) and disconnect low pressureline (2) and high pressure line (3). Close all open linesand fittings using caps and plugs.
5. Remove cap screws (5) and compressor (6).
6. Install compressor. Tighten cap screws to specification.
SpecificationAir Conditioning Compressor CapScrew—Torque 30 N•m...............................................................................
22 lb-ft
7. Connect harness connector.
8. Connect high and low pressure lines. Install andtighten cap screws (1).
SpecificationPressure Line Cap Screw—Torque 28 N•m............................................................................................
21 lb-ft
9. Install compressor belt. Inspect and adjust compressorbelt tension. See See Check and Adjust A/C Belt.(Operator’s Manual.)
10. Evacuate and charge system. See Evacuate R134aSystem and See Charge R134a System. (Group1830.)
OUO1073,00020FB –19–27MAR07–1/2
Condenser Remove and Install
1. Recover refrigerant from system. See Recover R134aRefrigerant. (Group 1830.)
TM10091 (11JAN08) 18-1830-11 160DLC Excavator Repair011108
PN=203
Continued on next page
Heating and Air Conditioning
181830
12
OUO1073,00020FB –19–27MAR07–2/2
TX
1020
174A
–UN
–07M
AR
07
1—Condenser2—High Pressure Liquid Input Line3—Electrical Connector4—High Pressure Gas Input Line5—High Pressure Gas Output Line6—Receiver-Dryer7—Cap Screw8—Bracket9—Cap Screws (4 used)
2. Disconnect electrical connector (3).
3. Remove cap screws and disconnect high pressureliquid input line (2) and high pressure liquid output line(5) from receiver-dryer (6).
4. Loosen cap screw (7) and remove receiver-dryer (6)from bracket.
5. Remove cap screw and disconnect high pressure gasinput line (4) from condenser (1).
6. Remove cap screws (9) and condenser (1).
7. Remove cap screws and receiver-dryer mountingbracket (8) from condenser.
8. Install condenser.
9. Connect high pressure gas input line (4) to condenser.Tighten cap screw to specification.
SpecificationHigh Pressure Gas Input LineCap Screw—Torque 23 N•m.......................................................................
17 lb-ft
10. Install receiver-dryer.
11. Connect high-pressure output line and high pressureinput line cap screw to receiver-dryer. Tighten capscrews to specification.
SpecificationReceiver-Dryer Input and OutputLine Cap Screws—Torque 5 N•m...............................................................
44 lb-in.
12. Install air filter assembly.
13. Evacuate and charge system. See Evacuate R134aSystem and See Charge R134a System. (Group1830.)
TM10091 (11JAN08) 18-1830-12 160DLC Excavator Repair011108
PN=204
Heating and Air Conditioning
OUO1073,00020FE –19–13APR07–1/8
Heater and Air Conditioner Remove andInstall
1. Recover refrigerant from system. See Recover R134aRefrigerant. (Group 1830.)
2. Remove seat. See Seat Remove and Install. (Group1821.)
OUO1073,00020FE –19–13APR07–2/8
TX
1020
272A
–UN
–08M
AR
07
18183013
1—Cover2—Screws3—Cap Screws4—Panel
3. Remove cover (1) from rear panel.
4. Remove screws (2) and cap screws (3) from rear panel(4).
5. Pull rear panel forward. Disconnect wiring harnessfrom lighter and power outlet and remove panel.
OUO1073,00020FE –19–13APR07–3/8
TX
1020
273A
–UN
–08M
AR
07
1—Air Duct2—Bracket3—Monitor Warning Alarm4—Mounting Bracket5—Cover
6. Remove screws and air duct (1).
7. Remove screws and bracket (2).
8. Remove monitor warning alarm (3) from mountingbracket (4).
9. Remove screws and mounting bracket (4).
10. Remove cover (5).
TM10091 (11JAN08) 18-1830-13 160DLC Excavator Repair011108
PN=205
Continued on next page
Heating and Air Conditioning
OUO1073,00020FE –19–13APR07–4/8
TX
1020
274A
–UN
–08M
AR
07
1—Cap Screws2—Relay Block3—12 Volt Power Converter4—Cap Screw5—Cap Screws6—Information Controller (ICF)7—Panel8—Cab Wiring Harness
11. Remove screws attaching relay block (2) to panel (7).
NOTE: Panel (7) may be removed with power converterand information controller installed on panel.
12. Disconnect 12 volt power converter (3) andinformation controller (ICF) (6) from cab wiringharness.
13. Remove clamps and hold-downs attaching cab wiringharness (8) to panel (7).
14. Remove cap screws (1 and 5).
15. Disconnect cab wiring harness (8) from and rightconsole, security alarm, and ground locations onpanel (7). See Cab Harness (W1) ComponentLocation . (Group 9015-10.)
16. Lift cab wiring harness (8). Slide out panel (7) andremove.
181830
14
OUO1073,00020FE –19–13APR07–5/8
TX
1020
275A
–UN
–08M
AR
07
1—Inlet Duct2—Cap Screw
17. Remove cap screws (2) and fresh air inlet duct (1).
Continued on next page
TM10091 (11JAN08) 18-1830-14 160DLC Excavator Repair011108
PN=206
Heating and Air Conditioning
OUO1073,00020FE –19–13APR07–6/8
TX
1020
276A
–UN
–08M
AR
07
1—Screw2—Panel3—Air Duct4—Mounting Bracket
18. Remove screws (1), panel (2), and air duct (3).
19. Remove cap screws and mounting bracket (4).
Continued on next page
18183015
TM10091 (11JAN08) 18-1830-15 160DLC Excavator Repair011108
PN=207
Heating and Air Conditioning
181830
16
OUO1073,00020FE –19–13APR07–7/8
TX
1020
277A
–UN
–08M
AR
07
1—Air Conditioner2—Air Duct3—Engine Coolant Hoses4—Air Conditioner Refrigerant Lines5—Air Duct6—Cap Screw (6 used)7—Screws
20. Clamp off engine coolant hoses (3). Disconnectengine coolant hoses from air conditioner (1). Plugengine coolant lines to minimize coolant loss.
21. Remove air conditioner refrigerant lines (4) from airconditioner (1).
22. Disconnect wiring harness from air conditioner (1).
23. Remove screws (7) and air duct (5).
24. Remove cap screws (6). Separate air conditioner (1)from air duct (2) and remove.
25. Repair or replace parts as necessary.
26. Install air conditioner and cap screws.
27. Connect wiring harness.
28. Connect air ducts.
29. Connect engine coolant hoses and refrigerant lines.
30. Install mounting bracket, rear panel, and air duct.
31. Install fresh air inlet duct.
32. Install rear panel and cap screws.
33. Connect cab wiring harness. See Cab Harness (W1)Component Location . (Group 9015-10.)
34. Attach wiring harness to panel using clamps andhold-downs.
35. Install air duct, mounting brackets, and monitorwarning alarm.
36. Connect wiring harness to lighter and power outletand install rear panel.
37. Install seat. See Seat Remove and Install (Group1821.)
38. Evacuate and charge system. See Evacuate R134aSystem and See Charge R134a System. (Group1830.)
TM10091 (11JAN08) 18-1830-16 160DLC Excavator Repair011108
PN=208
Continued on next page
Heating and Air Conditioning
OUO1073,00020FE –19–13APR07–8/8
39. Check engine coolant level. Add coolant asnecessary. See Cooling System Fill and DeaerationProcedure. (Operator’s Manual.)
18183017
OUO1073,00020FC –19–05MAR07–1/1
Receiver-Dryer Remove and Install
TX
1018
622A
–UN
–22F
EB
07
1—Electrical Connector2—High Pressure Liquid Input Line3—Cap Screws4—High Pressure Liquid Output Line5—Cap Screw6—Receiver-Dryer
1. Recover refrigerant from system. See Recover R134aRefrigerant. (Group 1830.)
2. Disconnect electrical connector (1).
3. Remove cap screws (3) and disconnect high pressureliquid input line (2) and high pressure liquid output line(4).
4. Loosen cap screw (5) and remove receiver-dryer (6)from bracket.
5. Install receiver-dryer.
6. Tighten high-pressure output line cap screw and highpressure input line cap screw.
SpecificationReceiver-Dryer Input and OutputLine Cap Screws—Torque 5 N•m...............................................................
44 lb-in
7. Connect electrical connector.
8. Evacuate and charge system. See Evacuate R134aSystem and See Charge R134a System. (Group 1830.)
TM10091 (11JAN08) 18-1830-17 160DLC Excavator Repair011108
PN=209
Heating and Air Conditioning
181830
18
TM10091 (11JAN08) 18-1830-18 160DLC Excavator Repair011108
PN=210
Section 33Excavator
Contents
Page Page
Group 3302—Buckets Pilot Valve (Left and Right) Remove andBucket Remove and Install . . . . . . . . . . . . . .33-3302-1 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-47Bucket Pin-Up Data. . . . . . . . . . . . . . . . . . . .33-3302-2 Pilot Valve (Left and Right) Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-50Group 3340—FramesTravel Pilot Valve Remove and Install . . . . .33-3360-52Bucket Links Remove and Install . . . . . . . . .33-3340-1Travel Pilot Valve Disassemble andArm Remove and Install . . . . . . . . . . . . . . . .33-3340-3
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-54Boom Remove and Install . . . . . . . . . . . . . . .33-3340-6Pilot Signal Manifold Remove and Install. . .33-3360-56Inspect Pins, Bushings and Bosses—FrontPilot Signal Manifold Disassemble andAttachment . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-58Bushings and Seal Remove and Install . . . .33-3340-14Control Valve Remove and Install . . . . . . . .33-3360-61Control Valve (5-Spool) Disassemble andGroup 3360—Hydraulic System
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63Apply Vacuum to Hydraulic Oil Tank . . . . . . .33-3360-1Control Valve (4-Spool) Disassemble andHydraulic Oil Cleanup Procedure Using
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-71Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-3Hydraulic Oil Tank Remove and Install . . . .33-3360-76Pump 1 and 2 Remove and Install . . . . . . . .33-3360-4Hydraulic Oil Tank Disassemble andPump 1 and 2 Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-80Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-10Restriction Valve Remove and Install . . . . .33-3360-81Pump 1 and 2 Inspection . . . . . . . . . . . . . .33-3360-22Hydraulic Oil Cooler Bypass Valve RemovePump 1 and 2 Start-Up Procedure . . . . . . .33-3360-25
and Install . . . . . . . . . . . . . . . . . . . . . . . .33-3360-83Pump 1 and 2 Regulator Remove andBoom Cylinder Remove and Install . . . . . . .33-3360-85Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-26Boom Cylinder Disassemble andPump 1 and 2 Regulator Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-89Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-28Arm Cylinder Remove and Install . . . . . . . .33-3360-91Pilot Pump Remove and Install . . . . . . . . . .33-3360-30Arm Cylinder Disassemble andPilot Pump Disassemble and Assemble . . .33-3360-32
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-96Pilot Pump Drive Shaft Remove andBucket Cylinder Remove and Install . . . . . .33-3360-99Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-34Bucket Cylinder Disassemble andPilot Pressure Regulating Valve and Filter
Assemble. . . . . . . . . . . . . . . . . . . . . . . .33-3360-103Remove and Install . . . . . . . . . . . . . . . . .33-3360-35Hydraulic Cylinder Bleed Procedure . . . . .33-3360-106Pilot Pressure Regulating Valve and Filter
Disassemble and Assemble. . . . . . . . . . .33-3360-36Pilot Shutoff Solenoid Valve Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3633Pilot Shutoff Solenoid Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-38Fan Drive Pump Remove and Install . . . . . .33-3360-39Fan Drive Motor Remove and Install . . . . . .33-3360-40Fan Drive Control Valve Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-43Solenoid Valve Manifold Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-44Solenoid Valve Remove and Install—Power
Dig (SG), Travel Speed (SI), BoomMode (SC), and Boom Flow Rate(SF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-46
TM10091 (11JAN08) 33-1 160DLC Excavator Repair011108
PN=1
Contents
33
TM10091 (11JAN08) 33-2 160DLC Excavator Repair011108
PN=2
Group 3302Buckets
3333021
TJ15698,0000128 –19–11APR07–1/1
Bucket Remove and Install
5
4
53
81
2
3
7
3
6
4
32
1
T142450
T14
2450
–UN
–24J
UL0
1
1—Bushing (2 used) 3—O-Ring (4 used) 5—Pin (2 used) 7—Pin2—Seal (2 used) 4—Ring (2 used) 6—Pin 8—Bucket
CAUTION: Heavy component; use a hoist.
SpecificationBucket—Weight 1018 kg approximate.................................................
2245 lb approximate
1. Position bucket (8) on level surface.
2. Remove parts (4, 5, 6, and 7).
3. Remove bucket.
4. Repair or replace parts as necessary.
5. Align pin bores and install pins (6 and 7).
6. Adjust bucket to arm joint. See Adjusting Bucket toArm Joint. (Operator’s Manual.)
TM10091 (11JAN08) 33-3302-1 160DLC Excavator Repair011108
PN=213
Buckets
TJ15698,0000183 –19–29MAR07–1/2
Bucket Pin-Up Data
Section A Section B
87
17
9 14
1312
11
10 1615
1
65
3
4
2
A
B
TX1003797
TX
1003
797
–UN
–07M
AR
06
333302
2
Continued on next page
TM10091 (11JAN08) 33-3302-2 160DLC Excavator Repair011108
PN=214
Buckets
3333023
TJ15698,0000183 –19–29MAR07–2/2
IMPORTANT: If the front attachment of a previousmodel machine is used, use thegrease intervals for previous modelmachine.
Item
1 370 mm14.6 in.
2 10 mm0.4 in.
3 540 mm21.2 in.
4 520 mm20.4 in.
5 400 mm15.7 in.
6 1430 mm56.3 in.
7 433 mm17 in.
8 326 mm12.8 in.
9 80 mm3.2 in.
10 400 mm15.7 in.
11 31 mm1.2 in.
12 433 mm17 in.
13 307 mm12.1 in.
14 80 mm3.1 in.
15 0°
16 0°
17 449 mm17.7 in.
TM10091 (11JAN08) 33-3302-3 160DLC Excavator Repair011108
PN=215
Buckets
333302
4
TM10091 (11JAN08) 33-3302-4 160DLC Excavator Repair011108
PN=216
Group 3340Frames
3333401
TJ15698,0000129 –19–13APR07–1/2
Bucket Links Remove and Install
TX
1020
202
–UN
–04A
PR
07
1—Nut (4 used) 6—Thrust Plate (4 used) 9—Center Link (2 used) 14—O-Ring (2 used)2—Cap Screw (2 used) 7—Bucket Cylinder Rod 10—Right Side Link 15—Pin3—Thrust Plate (2 used) End-to-Side and Center 11—Left Side Link 16—Ring4—Dust Seal (2 used) Links Pin 12—Side Links-to-Arm Pin5—Bushing (2 used) 8—Wood Block 13—Bucket-to-Center Links
Pin
NOTE: Removal of bucket is not necessary forremoval of bucket links.
1. Connect hoist to center links (9) using lifting strap.Put wood block (8) between bucket cylinder andarm to hold cylinder up when cylinder pin (7) isremoved.
2. Remove parts (1—5).
As cylinder pin (7) is removed, lower links (10 and11) to ground.
3. Remove ring (16) and pin (15).
4. Remove pins (12 and 13) and remove side andcenter links.
Continued on next page
TM10091 (11JAN08) 33-3340-1 160DLC Excavator Repair011108
PN=217
Frames
333340
2
TJ15698,0000129 –19–13APR07–2/2
TX
1020
201
–UN
–07M
AR
07
1—Dust Seal (6 used) 3—Center Link 5—Dust Seal (2 used) 7—Spacer2—Bushing (4 used) 4—Lubrication Fitting (2 used) 6—Bushing (2 used)
5. Inspect bushings (2 and 6) and dust seals (1 and5). See Inspect Pins, Bushings and Bosses—FrontAttachment. (Group 3340.)
6. Replace parts as necessary.
7. Before installing pins, align pin bores to preventdamage to dust seal when pins are installed.
8. Tighten nuts against each other allowing capscrews to be free to turn in hole.
9. Apply multi-purpose grease to all pivot joints. SeeTrack Adjuster, Working Tool Pivot, Swing Bearing,And Swing Bearing Gear Grease. (Operator’sManual.)
TM10091 (11JAN08) 33-3340-2 160DLC Excavator Repair011108
PN=218
Frames
TJ15698,000012A –19–11APR07–1/7
Arm Remove and Install
1. Remove bucket. See Bucket Remove and Install.(Group 3302.)
2. Retract arm cylinder.
3. Put floor stand under end of boom, so load is onboom, not on arm cylinder. Extend arm cylinder justenough to put end of arm on ground.
TJ15698,000012A –19–11APR07–2/7
TX
1020
196A
–UN
–07M
AR
07
3333403
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
4. Push pressure release button (1).
TJ15698,000012A –19–11APR07–3/7
X98
11–U
N–2
3AU
G88
CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.
5. Loosen bucket cylinder hydraulic hoses to release anyresidual pressure.
NOTE: Remove bucket cylinder and linkage only ifnecessary to repair arm.
7. Remove bucket links and bucket cylinder. See BucketLinks Remove and Install (Group 3340.) See BucketCylinder Remove and Install. (Group 3360.)
TM10091 (11JAN08) 33-3340-3 160DLC Excavator Repair011108
PN=219
Continued on next page
Frames
TJ15698,000012A –19–11APR07–4/7
T66
26JC
–UN
–31O
CT
88
Arm With Bucket Cylinder
CAUTION: Heavy component; use appropriatelifting device. Weight of boom, arm and bucketassembly and components will vary dependingon machine configuration.
SpecificationBoom, Arm and BucketAssembly—Approximate Weight 2900 kg...................................................
6395 lbBucket Cylinder—Weight 120 kg.................................................................
265 lbArm Cylinder—Weight 205 kg.....................................................................
452 lb
8. Attach appropriate lifting device to arm.
333340
4
TJ15698,000012A –19–11APR07–5/7
TX
1003
794A
–UN
–19A
PR
06
1—Nut (2 used)2—Pin3—Cap Screw4—Arm5—Arm Cylinder
9. Put wooden block between arm cylinder (5) and boomto hold cylinder up when cylinder pin (2) is removed.
10. Remove nuts (1), cap screw (3) and pin (2).
Continued on next page
TM10091 (11JAN08) 33-3340-4 160DLC Excavator Repair011108
PN=220
Frames
TJ15698,000012A –19–11APR07–6/7
TX
1003
793A
–UN
–15M
AR
06
1—Cap Screw2—Pin3—Hydraulic Hose
11. Tag and disconnect hydraulic hoses (3). Close allopen lines and fittings using caps and plugs.
12. Remove cap screw (1) and boom-to-arm pin (2).
13. Remove arm and lower to floor.
14. Inspect bushings and dust seals. See Inspect Pins,Bushings and Bosses—Front Attachment. (Group3340.)
15. Repair or replace parts as necessary. See Bushingsand Seal Remove and Install. (Group 3340.)
Continued on next page
3333405
TM10091 (11JAN08) 33-3340-5 160DLC Excavator Repair011108
PN=221
Frames
TJ15698,000012A –19–11APR07–7/7
4
5
6
4
1
3
2
T14
2652
–UN
–27S
EP
01
710
11
12
13 12
89
T14
2653
–UN
–24J
UL0
1
333340
6
1—Nut (2 used)2—Stopper3—Cap Screw4—Thrust Plate (2 used)5—Thrust Plate6—Cylinder Pin7—Cap Screw8—Washer9—Plate10—Block11—Pin12—Thrust Plate (2 used)13—Thrust Plate
16. Install thrust plates (4 and 12) equally on each side ofarm to get minimal amount of clearance betweenboom and arm.
17. Install boom-to-arm pin (11), block (10), plate (9),washer (8) and cap screw (7).
18. Connect arm cylinder by inserting cylinder pin (6), capscrew (3) and nuts (1).
19. Connect hoses. See Hydraulic System LineConnections. (Group 9025-15.)
20. Apply multi-purpose grease to all lubrication fittings.
21. Install bucket. See Bucket Remove and Install.(Group 3302.)
TJ15698,000012C –19–11APR07–1/10
Boom Remove and Install
1. Remove bucket and arm. See Bucket Remove andInstall (Group 3302.) See Arm Remove and Install.(Group 3340.)
2. Lower boom to ground.
3. Disconnect wiring harness.
TM10091 (11JAN08) 33-3340-6 160DLC Excavator Repair011108
PN=222
Continued on next page
Frames
TJ15698,000012C –19–11APR07–2/10
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
4. Push pressure release button (1).
3333407
TJ15698,000012C –19–11APR07–3/10
X98
11–U
N–2
3AU
G88
TX
1003
795A
–UN
–09M
AR
06
1—Hydraulic Hoses (4 used)
CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.
5. Slowly loosen hydraulic hoses (1) to relieve anyresidual pressure; then disconnect hoses. Close allopen lines and fittings using caps and plugs.
6. Remove arm cylinder only if necessary to repair boom.See Arm Cylinder Remove and Install. (Group 3360.)
Continued on next page
TM10091 (11JAN08) 33-3340-7 160DLC Excavator Repair011108
PN=223
Frames
TJ15698,000012C –19–11APR07–4/10
T10
5828
–UN
–30D
EC
96
F—Boom Cylinder (2 used)
CAUTION: Heavy component; use appropriatelifting device.
SpecificationBoom Cylinder—Weight 155 kg..................................................................
342 lb
7. Attach appropriate lifting device to boom cylinder (F)using lifting strap.
TJ15698,000012C –19–11APR07–5/10
TX
1003
796A
–UN
–17F
EB
06
333340
8
1—Cap Screw (2 used)2—Lubrication Hoses (2 used)3—Retainer (2 used)
8. Disconnect lubrication hoses (2), nuts, cap screws (1),and retainers (3).
TJ15698,000012C –19–11APR07–6/10
T14
2979
–UN
–24J
UL0
1
1—Nut (4 used)2—Retainer (2 used)3—Cap Screw (2 used)4—Boom Cylinder Rod End-to-Boom Pin5—Thrust Plate (4 used)6—Boom Cylinder (2 used)
9. Push boom cylinder-to-boom pin (4) into boom.
10. Lower boom cylinder (6) onto floor stand. Repeatprocedure for second boom cylinder.
TM10091 (11JAN08) 33-3340-8 160DLC Excavator Repair011108
PN=224
Continued on next page
Frames
TJ15698,000012C –19–11APR07–7/10
T66
26JW
–UN
–31O
CT
88
CAUTION: Heavy component; use appropriatelifting device. Weight of boom, arm, and bucketassembly and components will vary dependingon machine configuration.
SpecificationBoom, Arm and BucketAssembly—Approximate Weight 2900 kg...................................................
6395 lbBucket Cylinder—Weight 120 kg.................................................................
265 lbArm Cylinder—Weight 205 kg.....................................................................
452 lb
11. Attach appropriate lifting device to boom. Useprotective covering to prevent damage to pin if chainis used.
IMPORTANT: Arm end of boom is heavy end with armcylinder installed. Frame end is heavyend when arm cylinder is removed.
3333409
TJ15698,000012C –19–11APR07–8/10
TX
1020
209A
–UN
–07M
AR
07
1—Cover2—Step3—Handrail4—Toolbox
CAUTION: Heavy component; use a hoist.
NOTE: Two cap screws for cover (1) are located intoolbox (4).
12. Remove step (2), cover (1), and toolbox (4).
SpecificationToolbox—Weight 33 kg...............................................................................
72 lb
Disconnect and remove wiring harness from inside oftoolbox.
TM10091 (11JAN08) 33-3340-9 160DLC Excavator Repair011108
PN=225
Continued on next page
Frames
TJ15698,000012C –19–11APR07–9/10
TX
1003
791A
–UN
–19A
PR
06
1—Cap Screw2—Spacer3—Boom-to-Frame Pin
13. Remove cap screw (1), washer, and spacer (2).
14. Insert bar between plate of boom-to-frame pin (3) andbracket. Pull plate out.
15. Remove boom-to-frame pin (3). Remove washers.
16. Remove boom.
17. Inspect bushings and dust seals. See Inspect Pins,Bushings and Bosses—Front Attachment. (Group3340.)
18. Repair or replace parts as necessary. See Bushingsand Seal Remove and Install. (Group 3340.)
19. Install washers equally on each side of boom to getminimal amount of clearance between boom andframe.
20. Install boom. Tighten boom-to-frame cap screw (1).
SpecificationBoom-to-Frame Cap Screw—Torque 392 N•m..........................................................................................
290 lb-ft
21. Install toolbox, cover, and step.
333340
10
Continued on next page
TM10091 (11JAN08) 33-3340-10 160DLC Excavator Repair011108
PN=226
Frames
TJ15698,000012C –19–11APR07–10/10
TX
1003
796A
–UN
–17F
EB
06
1—Cap Screw (2 used)2—Lubrication Lines (2 used)3—Retainer (2 used)
22. Connect rod end of boom cylinders. Install thrustplates equally on each side to get minimum amountof clearance between boom and cylinder rod end.
23. Install retainers (3) and cap screws (1).
24. Tighten nuts against each other allowing cap screw(1) to be free to turn in hole.
SpecificationBoom Cylinder Rod End-to-BoomPin Retainer Nut—Torque 550 N•m (tighten nut against nut).....................
405 lb-ft (tighten nut against nut)
25. Connect lubrication hoses (2).
26. Connect hydraulic hoses. See Hydraulic System LineConnections. (Group 9025-15.)
27. Apply multi-purpose grease to all pivot joints. SeeTrack Adjuster, Working Tool Pivot, Swing Bearing,and Swing Bearing Gear Grease. (Operator’sManual.)
33334011
TJ15698,0000184 –19–29MAR07–1/3
Inspect Pins, Bushings and Bosses—FrontAttachment
TX1004442
2
13
6 5 7
8 10
4
119
TX
1004
442
–UN
–06M
AR
06
1—Boom-to-Frame Joint2—Boom Cylinder Head End-to-Frame Joint3—Boom Cylinder Rod End-to-Boom Joint4—Boom-to-Arm Joint5—Arm Cylinder Rod End-to-Arm Joint6—Arm Cylinder Head End-to-Boom Joint7—Bucket Cylinder Head End-to-Arm Joint8—Bucket Cylinder Rod End-to-Side and Bucket
Links Joint9—Side Links-to-Arm Joint10—Bucket Link-to-Bucket Joint11—Bucket-to-Arm Joint
Continued on next page
TM10091 (11JAN08) 33-3340-11 160DLC Excavator Repair011108
PN=227
Frames
333340
12
TJ15698,0000184 –19–29MAR07–2/3
Pins, Bushings, and Bosses
Item Standard Allowable Limit Remedy
1 Pin 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Boss (Main Frame) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
Bushing 80 mm 81.5 mm Replace3.15 in. 3.21 in.
2 Pin 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Boss (Main Frame) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
Bushing (Boom Cylinder) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
3 Pin 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Bushing (Boom Cylinder) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
Boss (Boom) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
4 Pin 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Boss (Boom) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
Bushing (Arm) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
5 Pin 71 mm 70.0 mm Replace2.80 in. 2.77 in.
Boss (Arm) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
Bushing (Arm Cylinder) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
6 Pin 71 mm 70.0 mm Replace2.80 in. 2.77 in.
Boss (Boom) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
Bushing (Arm Cylinder) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
7 Pin 65 mm 64.0 mm Replace2.56 in. 2.52 in.
Boss (Arm) 65 mm 66.5 mm Replace2.56 in. 2.62 in.
Bushing (Bucket Cylinder) 65 mm 66.5 mm Replace2.56 in. 2.62 in.
8 Pin 71 mm 70.0 mm Replace2.80 in. 2.77 in.
TM10091 (11JAN08) 33-3340-12 160DLC Excavator Repair011108
PN=228
Continued on next page
Frames
TJ15698,0000184 –19–29MAR07–3/3
Pins, Bushings, and Bosses
Item Standard Allowable Limit Remedy
Boss (Link B) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
Bushing (Link A) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
Bushing (Bucket Cylinder) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
9 Pin 71 mm 70.0 mm Replace2.80 in. 2.76 in.
Boss (Arm) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
Bushing (Arm) 71 mm 72.5 mm Replace2.80 in. 2.85 in.
10 Pin 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Boss (Bucket) 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Bushing (Link A) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
11 Pin 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Boss (Arm) 80 mm 79.0 mm Replace3.15 in. 3.11 in.
Bushing (Arm) 80 mm 81.5 mm Replace3.15 in. 3.21 in.
33334013
TM10091 (11JAN08) 33-3340-13 160DLC Excavator Repair011108
PN=229
Frames
TJ15698,000012B –19–05MAR07–1/1
Bushings and Seal Remove and Install
T95
237
–UN
–01N
OV
88T
6641
CW
–UN
–31O
CT
88
333340
14
A—Hydraulic RamB1—Pipe—Minimum ID to Clear Bushing ODB2—Pipe—Maximum ODB3—Pipe—Length of BushingC—BushingD—DisksE—Bushing Stop (Disk)F—Pilot (Disk)G—Ram Stop (Disk)H—Thickness of Dust Seal
IMPORTANT: Only install bushings using press asshown. Bushings will be damaged ifinstalled with driver.
NOTE: Bushing can also be removed by welding three tofive weld beads on the inside of bushing. Bushingwill shrink enough to permit removal using ahammer.
1. Remove bushings (C) and dust seals using bushing,bearing, and seal driver set.
2. Install bushings with lubrication hole aligned withlubrication passage in pivot.
3. Install bushing to a depth equal to thickness of dustseal (H).
4. Install dust seals with lip toward outside of component.
TM10091 (11JAN08) 33-3340-14 160DLC Excavator Repair011108
PN=230
Group 3360Hydraulic System
FS41334,000014E –19–05MAR07–1/3
Apply Vacuum to Hydraulic Oil Tank
Applying vacuum to hydraulic oil tank eliminates the needto drain tank prior to servicing of hydraulic systemcomponents.
FS41334,000014E –19–05MAR07–2/3
TX
1020
196A
–UN
–07M
AR
07
3333601
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
Continued on next page
TM10091 (11JAN08) 33-3360-1 160DLC Excavator Repair011108
PN=231
Hydraulic System
FS41334,000014E –19–05MAR07–3/3
TX
1000
587A
–UN
–17N
OV
05T
X10
0332
9A–U
N–0
6FE
B06
333360
2
3—Cap Screws (4 used)
2. Use 5 mm hex wrench to remove cap screws (3) andcover.
3. Assemble fittings and hydraulic oil tank adapter fromD15032NU Vacuum Pump Kit, and JT07085A VacuumPump Set. Install in hydraulic tank opening as shown.Refer to pump instructions for operating information.
TM10091 (11JAN08) 33-3360-2 160DLC Excavator Repair011108
PN=232
Hydraulic System
3333603
FS41334,000014D –19–10APR07–1/1
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
SPECIFICATIONS
Hydraulic Oil Tank Capacity 120 L approximate31.8 gal approximate
Hydraulic Oil Tank Filtering 11 minutes approximateTime
Hydraulic System Capacity 220 L approximate58 gal approximate
Hydraulic System Filtering Time 35 minutes approximate
SERVICE EQUIPMENT AND TOOLS
JDG1724A Super Caddy
JT05679 Hose 3.7 m (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 MNPT Ends (2 used)
JTO5751A Suction Wand
JTO5750A Discharge Wand
1. Install new return filter elements.
NOTE: For a failure that creates a lot of debris,remove access cover from hydraulic tank.Drain hydraulic tank. Connect filter caddysuction line to drain port. Add a minimum of 19L (5 gal) of oil to reservoir. Operate filter caddyand wash out the hydraulic tank.
IMPORTANT: The minimum ID for a connector is13 mm (1/2 in.) to prevent cavitationof filter caddy pump.
2. Put filter caddy suction and discharge wands intohydraulic tank filler hole so ends are as far apart aspossible to obtain a thorough cleaning of oil.
3. Start the filter caddy. Check to be sure oil is flowingthrough the filters.
Operate filter caddy until all the oil in hydraulic tankhas been circulated through the filter a minimum offour times.
SpecificationHydraulic Oil Tank—Capacity 120 L approximate................................
31.8 gal approximateHydraulic Oil Tank—FilteringTime 11 minutes approximate...............................................................
NOTE: Filtering time for hydraulic tank is 0.089 minutex number of liters (0.33 minutes x number ofgallons).
4. Leave filter caddy operating for the next step.
5. Start the engine and run it at fast idle.
IMPORTANT: For the most effective results,cleaning procedure must start withthe smallest capacity circuit thenproceed to the next larger capacitycircuit.
6. Starting with the smallest capacity circuit, operateeach function through a complete cycle.
Repeat procedure until the total system capacityhas circulated through filter caddy seven times.Each function must go through a minimum of threecomplete cycles for a thorough cleaning of oil.
SpecificationHydraulic System—Capacity 220 L approximate.................................
58 gal approximateHydraulic System—FilteringTime 35 minutes approximate...............................................................
NOTE: Filtering time for complete hydraulic system is0.158 minute x number of liters (0.6 minute xnumber of gallons). Filtering time for machineswith auxiliary hydraulic functions must beincreased because system capacity is larger.
7. Stop the engine. Remove the filter caddy.
8. Install new return filter elements.
9. Check hydraulic oil level. See Check HydraulicTank Oil Level. (Operator’s Manual.)
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Pump 1 and 2 Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Drain hydraulic oil tank. Approximate capacity is 120.4L (31.8 gal).
3. Drain pump drive gearbox. Approximate oil capacity is0.9 L (1.0 qt).
4. Remove hydraulic compartment cover and mufflercover.
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TX
1020
192A
–UN
–05A
PR
07
1—Cap Screws (4 used)2—Final Fuel Filter3—Primary Fuel Filter
5. Remove cap screws (1) and set fuel filters (2 and 3)aside. Protect against damage to hoses and filters.
FS41334,000014C –19–13APR07–3/13
TX
1020
366A
–UN
–19M
AR
07
1—Oil Filter Assembly2—Cap Screw (2 used)
6. Remove cap screws (2) and set engine oil filterassembly (1) aside. Protect against damage to hosesand filter.
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Hydraulic System
FS41334,000014C –19–13APR07–4/13
TX
1020
874A
–UN
–22M
AR
07
1—Shield2—Cap Screws (6 used)3—Water Drain
7. Remove cap screws (2), water drain (3), and mufflershield (1).
CAUTION: Exhaust parts may be hot. Avoidburns by waiting until the parts are cool to thetouch before working on them.
8. Support muffler using appropriate lifting device.
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1020
749A
–UN
–19M
AR
07
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1—Clamp2—Tube3—Muffler
9. Loosen clamp (1) and move onto muffler tube (2).
FS41334,000014C –19–13APR07–6/13
TX
1020
923A
–UN
–23M
AR
07
1—Muffler2—U-Bolt Nut (8 used)3—Support
10. Remove nuts (2) and U-bolts from muffler support (3).
11. Remove muffler (1).
12. Disconnect electrical connectors.
13. Disconnect lines.
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Hydraulic System
FS41334,000014C –19–13APR07–7/13
TX
1020
397
–UN
–12M
AR
07
1—Lift Point (3 used)
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationHydraulic Pump and DriveGearbox—Approximate Weight 168 kg.......................................................
370 lb
14. Install JT05550 Lifting Eyebolt and JDG19 LiftingBracket to pump (1). Connect an appropriate liftingdevice to eyebolt and lifting bracket using liftingstraps.
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TX
1020
354
–UN
–09M
AR
07
1—Hydraulic Pump Drive Gearbox2—Bracket3—Support4—Cap Screw (8 used)
15. Remove cap screws (4), muffler support (3), and hosebracket (2) from hydraulic pump gearbox (1).
16. Pull pump assembly (1) away from flywheel housingto disengage damper drive (flex coupler).
17. Remove hydraulic pump and drive gearbox frommachine.
18. Repair or replace as necessary.
IMPORTANT: Align flex coupler on drive gearbox withmating part on engine flywheel.
19. Align damper drive and install pump assembly toflywheel housing.
20. Install muffler support (3), hose bracket (2), and pumpassembly with cap screws (1). Tighten tospecification.
SpecificationPump Drive Gearbox-to-FlywheelHousing Cap Screw—Torque 65 N•m.........................................................
48 lb-ft
21. Connect lines. See Pump 1, Pump 2, and Pilot PumpLine Identification. (Group 9025-15.)
22. Connect electrical connectors. See Pump Harness(W8) Component Location. (Group 9015-10.)
23. Install split flange and tighten cap screws.
SpecificationSplit Flange 8 mm Cap Screw—Torque 50 N•m............................................................................................
37 lb-ftSplit Flange 10 mm Cap Screw—Torque 90 N•m............................................................................................
67 lb-ft
24. Apply pipe sealant to pump drive gearbox pipe plugthreads, if removed.
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Hydraulic System
FS41334,000014C –19–13APR07–9/13
TX
1020
923A
–UN
–23M
AR
07
1—Muffler2—U-Bolt Nut (8 used)3—Support
25. Install muffler (1) to support using U-bolts and nuts(2). Hand tighten for next step.
FS41334,000014C –19–13APR07–10/13
TX
1020
749A
–UN
–19M
AR
07
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1—Clamp2—Tube3—Muffler
NOTE: Clamp torque is 8.5 N•m (75 lb-in.) with maximumtorque of 20 N•m (177 lb-in.).
26. Install clamp (1) and tighten.
27. Tighten muffler U-bolt nuts to specification.
SpecificationMuffler U-Bolt Nut—Torque 50 N•m............................................................
37 lb-ft
FS41334,000014C –19–13APR07–11/13
TX
1020
874A
–UN
–22M
AR
07
1—Shield2—Cap Screw (6 used)3—Water Drain
28. Install muffler shield (1) using cap screws (2).
29. Install and route water drain (3) down through mufflershield.
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TX
1020
366A
–UN
–19M
AR
07
1—Engine Oil Filter2—Cap Screw (2 used)
30. Install engine oil filter (1) assembly using cap screws(2).
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TX
1020
192A
–UN
–05A
PR
07
1—Cap Screw (4 used)2—Final Fuel Filter3—Primary Fuel Filter
31. Install fuel filters (2 and 3) using cap screws (1).
32. Install muffler cover and hydraulic compartment cover.
33. Fill and check hydraulic oil level. See 160DLC Drainand Refill Capacities. (Operator’s Manual.)
IMPORTANT: Hydraulic pump and drive gearbox willbe damaged if not filled with oil beforestarting engine. Start-up proceduremust be performed whenever a newpump or gearbox is installed or oil hasbeen drained from the pump, gearboxor hydraulic oil tank.
34. Fill pump housing and pump drive gearbox with oil.See Pump 1 and 2 Start-Up Procedure. (Group3360.)
35. Check pump regulator adjustments.
For minimum flow:
• See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)
For maximum flow:
• See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)
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Pump 1 and 2 Disassemble and Assemble
7 8 9
10
11
6
12
5
13
4
13
14
1516
1718
19 2021
22 23
24
2322
2125
1826
1716
15
2728
2930
2827
3132
1
23
33
37
3635
3456
5554
57
58
44
35
3840
41
42
5153 52
5150
49
48
4746
45
39
43
32
20
T142373
T14
2373
–UN
–20J
UL0
1
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1—Pump Housing 16—Roller Bearing (2 used) 29—O-Ring 43—Drain Plug2—Lock Washer (6 used) 17—Ring (2 used) 30—Special Fitting 44—O-Ring3—Cap Screw (6 used) 18—Roller Bearing (2 used) 31—Spring Pin (2 used) 45—Cap Screw (2 used)4—Spring Pin (4 used) 19—Hydraulic Pump 1 (Front) 32—Oil Seal (2 used) 46—Lock Washer (2 used)5—O-Ring (10 used) Drive Shaft 33—Snap Ring (2 used) 47—Washer (2 used)6—O-Ring (2 used) 20—Pin (2 used) 34—Fill Plug 48—Pilot Pump7—Cap Screw (4 used) 21—Center Shaft (2 used) 35—Snap Ring (2 used) 49—Snap Ring8—Hydraulic Pump 1 (Front) 22—Spring (2 used) 36—Hydraulic Pump 1 Driven 50—Snap Ring
Regulator 23—Piston (14 used) Gear 51—Ball Bearing9—Cap Screw (2 used) 24—Cylinder Block (Rotor) 37—Gasket 52—Pilot Pump Drive Gear10—Cap Screw (2 used) (2 used) 38—Cap Screw (2 used) 53—Pilot Pump Drive Shaft11—Cap Screw (2 used) 25—Hydraulic Pump 2 (Rear) 39—Hydraulic Pump 2 Drive 54—Snap Ring12—Hydraulic Pump 2 (Rear) Drive Shaft Gear 55—Oil Seal
Regulator 26—Hydraulic Pump 2 Spacer 40—Dipstick 56—Pump Drive Gearbox13—O-Ring (4 used) Ring 41—Dipstick Tube 57—Set Screw (2 used)14—O-Ring (6 used) 27—O-Ring (2 used) 42—Gasket 58—Dampener Drive Coupling15—Bearing Nut (2 used) 28—Plug (2 used)
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12
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82
82
59
60
61
60
6660
81
80
79
77
78
76
69
67
68
70
71
72
73
74
71
75
6263
6563
6260
6263
6463
62
60
66
59
6061
60
T142375
T14
2375
–UN
–20J
UL0
1
59—Dowel Pin 65—Hydraulic Pump 2 Valve 71—O-Ring (4 used) 77—Servo Piston (2 used)60—Snap Ring (12 used) Plate 72—Cap Screw (8 used) 78—Pin (2 used)61—Dowel Pin (2 used) 66—Dowel Pin (4 used) 73—Cover (2 used) 79—O-Ring (2 used)62—Lever (4 used) 67—Back-Up Ring 74—O-Ring (2 used) 80—Stop (2 used)63—Dowel Pin (4 used) 68—O-Ring 75—Cap Screw (12 used) 81—Cap Screw (8 used)64—Hydraulic Pump 1 Valve 69—Spring Pin (2 used) 76—Set Screw (2 used) 82—Feedback Link (2 used)
Plate 70—Cylinder Head (Cover)
1. Remove plug (43) from pump gearbox. Drain gearoil. Approximate oil capacity is 0.9 L (1.0 qt).
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CAUTION: Heavy component; use anappropriate lifting device.
SpecificationHydraulic Pump Housing andGearbox—Approximate Weight 168 kg................................................
370 lb
2. Loosen set screws (57) and remove dampenerdrive coupling (58).
3. Remove pilot pump (48). For repair: See PilotPump Disassemble and Assemble. (Group 3360.)
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationPump Housing Assembly—Approximate Weight 105 kg.................................................................
230 lb
4. Remove cap screws (3) and lock washers (2) toremove pump housing (1) from pump drive gearbox(56).
5. Remove parts (49-53). For removal of pilot pumpdrive shaft: See Pilot Pump Drive Shaft Removeand Install. (Group 3360.)
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Hydraulic System
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–UN
–07F
EB
07
35—Snap Ring (2 used)36—Driven Gear39—Drive Gear83—Driven Gear-to-Drive Gear Timing Mark84—Pump 2 (Rear) Drive Shaft-to-Drive Gear
Timing Mark85—Pump 1 (Front) Drive Shaft-to-Driven Gear
Timing Mark
NOTE: The gears are not interchangeable. To aid inreassembly, make timing marks on drive shafts at(84) and (85), and mark (83) on drive gear (39)and driven gear (36).
6. Make timing marks on pump gears to aid inreassembly.
7. Measure amount of backlash between gears, usingspecification, to determine limit of use.
SpecificationPump Drive and Driven Gear—Backlash 0.68 mm (0.027 in.) nominal........................................................
1.50 mm (0.059 in.) limit of use
8. Remove snap rings (35) and remove gears (36 and39).
9. Remove pump regulators (8 and 12). For repair: SeePump 1 and 2 Regulator Disassemble and Assemble.(Group 3360.)
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationCylinder Head—ApproximateWeight 30 kg................................................................................................
66 lb
IMPORTANT: Valve plates (64 and 65) are connectedto the feedback linkage and mustremain on the cylinder blocks (24).Valve plates and end of cylinder blockshave highly machined surfaces and canbe damaged.
10. Remove cap screws (75) and carefully removecylinder head (70).
11. Remove servo pistons (77) only if replacement isnecessary.
Disassemble servo piston using following procedure:
• Heat set screw (76) to loosen thread lock andsealer. (Medium strength thread lock used.)
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Hydraulic System
FS41334,000015A –19–13APR07–6/13
• Remove set screw. (Use a 6 mm hex key wrench.)• Remove pin (78).
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)(65) valve plates are notinterchangeable. Take notice of thelocation and position of ports in plate.The inlet port in valve plate is locatedtowards the center and top of pumphousing.
12. Remove hydraulic pump 1 (64) and hydraulic pump 2(65) valve plates. Protect machined surfaces of platesfrom damage.
13. Remove special fittings (30) before removinghydraulic pump 1 (19) and hydraulic pump 2 (25)drive shafts.
14. Remove hydraulic pump 2 spacer ring (26) from bore.
15. Remove bearing nut (15) using JDG769 SpannerWrench.
16. Remove roller bearings (16 and 18) from pump 1 (19)and pump 2 (25) drive shafts using a knife edgepuller and a press.
17. Clean and inspect parts. Repair or replace parts asnecessary. See Pump 1 and 2 Inspection. (Group3360.)
18. Assemble hydraulic pump in reverse order, using thefollowing information.
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Hydraulic System
FS41334,000015A –19–13APR07–7/13
TX
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493
–UN
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EB
07T
X10
1849
4–U
N–0
7FE
B07
333360
16
15—Bearing Nut16—Roller Bearing17—Spacer Ring18—Roller Bearing19—Pump 1 (Front) Drive Shaft25—Pump 2 (Rear) Drive Shaft
CAUTION: DO NOT heat oil over 182°C (360°F).Oil fumes or oil can ignite above 193°C (380°F).Use a thermometer. Do not allow a flame orheating element to come in direct contact withthe oil. Heat the oil in a well-ventilated area.Plan a safe handling procedure to avoid burns.
19. Heat roller bearings (16 and 18).
SpecificationRoller Bearing Heat—Temperature 50—80°C................................................................................
122—176°F
20. Apply oil to bearing. Push roller bearing (18) on driveshaft so inner race is tight against shoulder.
21. Install spacer ring (17) and roller bearing (16).
22. Apply oil to threads of bearing nut (15).
23. Tighten bearing nut using JDG769 Spanner Wrench.
SpecificationPump Drive Shaft Bearing Nut—Rolling Drag Torque 1.96 ± 0.49 N•m.........................................................
17 ± 4 lb-in.
FS41334,000015A –19–13APR07–8/13
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–UN
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07
26—Spacer Ring
24. Install hydraulic pump 2 spacer ring (26) into housingbore.
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FS41334,000015A –19–13APR07–9/13
TX
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EB
07
19—Drive Shaft25—Drive Shaft30—Special Fitting (2 used)
25. To help installation of drive shafts (19 and 25), heatpump housing using a heat gun such as the JT07010Two Temperature Heat Gun.
SpecificationHydraulic Pump Housing Heat—Temperature 50—80°C................................................................................
122—176°F
26. Apply a film of oil to outer race of bearings. Install thedrive shafts.
NOTE: Allow housing to cool to the touch, to safelyhandle after drive shaft installation.
27. Install and tighten special fittings (30).
SpecificationSpecial Plug-to-Hydraulic PumpHousing Special Fitting—Torque 34 N•m....................................................
25 lb-ft
28. Apply multi-purpose grease to lips of oil seals (32).Install oil seals with lip (spring side) toward inside ofhousing. Install snap rings (33).
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7FE
B07
19—Pump 1 (Front) Drive Shaft25—Pump 2 (Rear) Drive Shaft35—Snap Ring (2 used)36—Driven Gear39—Drive Gear83—Driven Gear-to-Drive Gear Timing Mark84—Pump 2 (Rear) Drive Shaft-to-Drive Gear
Timing Mark85—Pump 1 (Front) Drive Shaft-to-Driven Gear
Timing Mark86—JDG1054 Aligning Bar (Pump Timing Tool)87—Socket88—Socket89—Socket Alignment Dowel90—Socket Alignment Dowel91—M8-1.25 Cap Screw (2 used)
29. Install drive (39) and driven (36) gears usingprocedure:
For original parts;
• Install drive (39) and driven (36) gears on shafts sotiming marks (83, 84, and 85) are aligned. Installsnap rings (35).
For new parts;
• Install the JDG1054 Aligning Bar on the socket (87and 88) end of drive shafts.
• Install aligning bar so end marked “Long ShaftSide” is to pump 2 (rear) drive shaft (25). Turnshafts so socket alignment dowels (89 and 90)engage a socket in drive shafts. The socket forpump 1 (front) drive shaft is slightly below thecenter-line of socket for pump 2 (rear) drive shaftwhen shafts are timed correctly.
• Install cap screws (91) to hold bar in position.• From the spline end of shafts, turn shafts to the left
to remove any play between socket alignmentdowels and sockets.
• Install gear on pump 2 (rear) drive shaft. Install thesnap ring.
• Install gear on pump 1 (front) drive shaft. Asnecessary, turn shaft slightly or turn gear to anotherposition so teeth on gears engage. Install snap ring.
30. Apply oil to center shaft (21), pistons (23), andcylinder blocks (24). Use petroleum jelly to hold pin(20) in hole in center shaft.
31. Install cylinder block so pin engages slot in cylinderblock.
32. Apply thread lock and sealer (medium strength) tothreads of dowel pins (63). Tighten dowel pins intopump 1 (front) (64) and pump 2 (rear) (65) valveplates.
SpecificationDowel Pin-to-Pump 1 (Front) andPump 2 (Rear) Valve Plate—Torque 9.8 N•m...........................................................................................
86 lb-in.
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Hydraulic System
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FS41334,000015A –19–13APR07–11/13
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)(65) valve plates are notinterchangeable. The inlet port in valveplate is located toward the center andtop of pump housing.
33. Install valve plates using procedure:
• Apply oil to valve plates.• Install valve plates so inlet port is toward the center
and top of pump housing.• Connect levers (62) for feedback linkage to valve
plates.
34. Install servo pistons (77) and pins (78). If set screwwas removed, install using procedure:
• Apply thread lock and sealer (medium strength) tothreads of set screw (76).
• Tighten set screw (76) using a 6 mm hex keywrench.
SpecificationServo Piston-to-Pin Set Screw—Torque 34 N•m............................................................................................
25 lb-ft
35. Tighten cap screws (72 and 81) for stop (80) andcover (73) to specification.
SpecificationStop and Cover-to-Cylinder HeadCap Screw—Torque 19.5 N•m....................................................................
180 lb-in.
CAUTION: Heavy component; user anappropriate lifting device.
36. Install cylinder head (70) checking to be sure thatpins engage middle hole in valves plates.
SpecificationCylinder Head—ApproximateWeight 30 kg................................................................................................
66 lb
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Hydraulic System
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FS41334,000015A –19–13APR07–12/13
Tighten cap screws (75) to specification.
SpecificationCylinder Head-to-Hydraulic PumpHousing Cap Screw—Torque 108 N•m.......................................................
80 lb-ft
37. Install regulators:
• Remove air bleed plugs from pump regulators (8and 12).
• Install regulators, making sure groove in remotecontrol sleeve and load sleeve engage dowel pin(61) in feedback link (82). Check, through hole, thatgroove in sleeves engage dowel pin.
• Reinstall air bleed plugs to avoid contamination tohydraulic pump during installation.
• Tighten cap screws to specification.
SpecificationRegulator-to-Hydraulic PumpHousing Cap Screw—Torque 49 N•m.........................................................
36 lb-ft
38. Install and tighten pump pressure sensors tospecification.
SpecificationPump PressureSensor-to-Hydraulic PumpHousing—Torque 98 N•m............................................................................
72 lb-ft
39. Install parts (49-53). For installation of pilot pumpdrive shaft: See Pilot Pump Drive Shaft Remove andInstall. (Group 3360.)
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationHydraulic Pump HousingAssembly—Approximate Weight 105 kg.....................................................
230 lb
40. Install pump housing assembly (1) to gearbox (56).
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Hydraulic System
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Tighten cap screws (3) to specification.
SpecificationHydraulic PumpHousing-to-Gearbox Housing CapScrew—Torque 147 N•m.............................................................................
109 lb-ft
41. Apply rigid form-in-place gasket to mounting surfacefor pilot pump (48).
Tighten cap screws (45) to specification.
SpecificationPilot Pump-to-Gearbox CapScrew—Torque 49 N•m...............................................................................
36 lb-ft
42. Apply multi-purpose grease to lips of oil seal (55).Install oil seal with lip (spring side) toward inside ofhousing.
CAUTION: Install damper drive coupling hub soface is flush with end of pump shaft. It cannotrub or hit gearbox housing or shaft oil sealwhen rotated.
43. Install damper drive coupling (58) onto splines ofpump shaft (25). Position so hub face is flush withpump shaft end. Space between coupling andgearbox housing (56) is approximately 2 mm (0.08in.).
44. Apply thread lock and sealer (medium strength) tothreads of set screws (57).
Tighten set screws (57) to specification. For assemblyof dampener drive: See Dampener Drive (FlexCoupling) Remove and Install. (Group 0752.)
SpecificationDampener Drive Hub-to-Pump 2(Rear) Drive Shaft Set Screw—Torque 108 N•m..........................................................................................
80 lb-ft
45. Fill pump and pump drive gearbox with oil. See Pump1 and 2 Start-Up Procedure. (Group 3360.)
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FS41334,000014A –19–11APR07–1/6
Pump 1 and 2 Inspection
T10
5725
–UN
–09J
AN
97
A—Oil Seal Contact SurfaceB—Oil Seal Contact SurfaceC—Pump 2 (Rear) Drive ShaftD—Oil Seal Contact SurfaceE—Pump 1 (Front) Drive Shaft
1. Measure diameter of oil seal contact surfaces (A, B,and D) on pump 1 (front) (E) and pump 2 (rear) (C)drive shafts.
SpecificationPump 2 (Rear) Drive Shaft OilSeal Contact Surface (A)—OD 45 mm nominal.........................................
1.77 in. nominal44.8 mm limit of use
1.76 in. limit of usePump 2 (Rear) Drive Shaft OilSeal Contact Surface (B)—OD 55 mm nominal.........................................
2.17 in. nominal54.8 mm limit of use
2.16 in. limit of usePump 1 (Front) Drive Shaft OilSeal Contact Surface—OD 55 mm nominal...............................................
2.17 in. nominal54.8 mm limit of use
2.16 in. limit of use
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5726
–UN
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AN
97
F—Piston Connecting RodG—Rear Drive ShaftH—Play
2. Measure play (H) between piston connecting rod (F)and socket in front and rear drive shafts (G).
SpecificationPiston-to-Drive Shaft Socket—Play 0.058 mm nominal...............................................................................
0.0023 in. nominal0.400 mm limit of use0.0157 in. limit of use
Continued on next page
TM10091 (11JAN08) 33-3360-22 160DLC Excavator Repair011108
PN=252
Hydraulic System
FS41334,000014A –19–11APR07–3/6
T65
57E
M–U
N–1
8OC
T88
T65
57E
N–U
N–1
8OC
T88
3. Measure ID of cylinder block piston bore. Measure ODof piston. Subtract the OD from the ID for clearance.
SpecificationCylinder Block Bore-to-Piston—Clearance 0.043 mm nominal.....................................................................
0.0017 in. nominal0.080 mm limit of use0.0032 in. limit of use
FS41334,000014A –19–11APR07–4/6
T65
57E
K–U
N–1
8OC
T88
4. Clamp the connecting rod end of a piston in a vise withsoft-jaw faces. Measure play between connecting rodand piston.
SpecificationPiston-to-Connecting Rod—Play 0.150 mm nominal..................................
0.0059 in. nominal0.400 mm limit of use0.0157 in. limit of use
33336023
Continued on next page
TM10091 (11JAN08) 33-3360-23 160DLC Excavator Repair011108
PN=253
Hydraulic System
FS41334,000014A –19–11APR07–5/6
T10
5727
–UN
–19D
EC
96
333360
24
A—Cylinder HeadB—IDC—ODD—Servo Piston
5. Measure OD (C) of small and large end of servo piston(D). Measure ID (B) of small and large end of bore incylinder head (A). Subtract the OD from the ID forclearances.
SpecificationServo Piston-to-Cylinder HeadBore—Clearance 0.079 mm nominal..........................................................
0.0033 in. nominal0.200 mm limit of use0.0078 in. limit of use
FS41334,000014A –19–11APR07–6/6
T10
5729
–UN
–09J
AN
97
A—Valve PlateB—Piston PinC—ODD—ID
6. Measure OD (C) of servo piston pin (B). Measure ID(D) of bore in valve plate (A). Subtract the OD from theID for the clearance.
SpecificationServo Piston Pin-to-Valve PlateBore—Clearance 0.051 mm nominal..........................................................
0.0020 in. nominal0.300 mm limit of use0.0118 in. limit of use
TM10091 (11JAN08) 33-3360-24 160DLC Excavator Repair011108
PN=254
Hydraulic System
33336025
FS41334,0000149 –19–10APR07–1/1
Pump 1 and 2 Start-Up Procedure
TX
1020
193A
–UN
–06M
AR
07T
1450
92–U
N–3
1AU
G01
TX
1020
374A
–UN
–19M
AR
071—Dipstick2—Fill Plug3—Air Bleed Plug (2 used)
IMPORTANT: Hydraulic pump and drive gearbox willbe damaged if not filled with oil beforestarting engine. Procedure must beperformed whenever a new pump orgearbox is installed or oil has beendrained from the pump, gearbox orhydraulic oil tank.
Procedure is to ensure the pumps andgearbox are filled with oil and air is bledfrom suction side of pumps to preventcavitation.
1. Fill pump drive gearbox with oil through fill plug (2) solevel is above “H” mark on dipstick (1). See PumpGearbox Oil. (Operator’s Manual.)
2. Remove air bleed plugs (3) from the top of pumpregulators to allow housing to fill with oil from thehydraulic oil tank and to let air escape.
3. When pump housing is full of oil, install plugs.
4. As necessary, add oil to hydraulic oil tank until it isbetween marks on sight glass. See Hydraulic Oil.(Operator’s Manual.) Tighten tank cap. Tighten ventplug.
5. Start engine and run at slow idle. Slowly raise boom tofull height and then lower to pressurize hydraulic oiltank.
6. Purge air from the hydraulic system by slowlyoperating each function through three cycles. Air inpilot circuits are purged automatically.
TM10091 (11JAN08) 33-3360-25 160DLC Excavator Repair011108
PN=255
Hydraulic System
FS41334,0000148 –19–13APR07–1/2
Pump 1 and 2 Regulator Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
NOTE: Pump 1 (front) and pump 2 (rear) regulators aresimilar in design. Removal of pump 2 (rear)regulator is shown.
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) Hydraulic oil tankcapacity is approximately 120.4 L (31.8 gal).
3. Disconnect lines.
4. Disconnect electrical connectors.
333360
26
Continued on next page
TM10091 (11JAN08) 33-3360-26 160DLC Excavator Repair011108
PN=256
Hydraulic System
FS41334,0000148 –19–13APR07–2/2
TX
1003
224A
–UN
–06F
EB
06
1—Cap Screw (8 used)2—Hydraulic Pump Regulator (2 used)
5. Remove cap screws (1) and regulator (2).
6. Repair or replace parts as necessary.
7. Install regulators making sure groove in remote controlsleeve and load sleeve engage dowel pin in feedbacklink. Check through hole that groove in sleeves engagedowel pin.
8. Tighten cap screws (1) to specification.
SpecificationPump 1 (Front) and Pump 2(Rear) Regulator-to-PumpHousing Cap Screw—Torque 49 N•m.........................................................
36 lb-ft
9. Connect lines. See Pump 1, Pump 2, and Pilot PumpLine Identification. (Group 9025-15.)
10. Connect electrical connectors. See Pump Harness(W8) Component Location. (Group 9015-10.)
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Procedure must be performed whenevera new pump is installed or oil has beendrained from the pump or hydraulic oiltank.
11. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
33336027
TM10091 (11JAN08) 33-3360-27 160DLC Excavator Repair011108
PN=257
Hydraulic System
333360
28
FS41334,0000147 –19–10APR07–1/2
Pump 1 and 2 Regulator Disassemble and Assemble
T14
2272
B–U
N–1
6FE
B07
Pump 2 (Rear) Regulator Shown
1—Cap Screw (4 used) 8—O-Ring (3 used) 15—Spring (2 used) 22—Piston2—Nut 9—Load Adjusting Screw 16—Remote Control Spool 23—Load Piston3—Nut (2 used) (Stop) 17—Remote Control Sleeve 24—Cylinder4—Minimum Flow Adjusting 10—Regulator Body 18—O-Ring 25—Load Sleeve
Screw 11—Cap Screw (4 used) 19—Backup Ring 26—Load Spool5—Cover 12—End Plate 20—O-Ring 27—Inner Spring6—Nut (2 used) 13—Flow Adjusting Cartridge 21—Cylinder7—Load Adjusting Cartridge 14—Maximum Flow Adjusting
Screw (Stop)
NOTE: Pump 1 (front) and pump 2 (rear) regulatorsare similar. Pump 2 (rear) regulator is shown.
IMPORTANT: Removal of adjusting screws (4, 9and 14) and cartridges (7 and 13)from end plate (12) and cover (5) willrequire the adjustment of pumpregulators. Only remove parts fromend plate and cover if replacement isnecessary.
1. Remove end plate (12) and cover (5) with adjustingscrews and cartridges installed.
2. Repair or replace parts as necessary.
3. Tighten cap screws (1 and 11).
SpecificationPump 1 (Front) and Pump 2(Rear) End Plate andCover-to-Housing Cap Screw—Torque 19.8 N•m...................................................................................
180 lb-in.
TM10091 (11JAN08) 33-3360-28 160DLC Excavator Repair011108
PN=258
Continued on next page
Hydraulic System
33336029
FS41334,0000147 –19–10APR07–2/2
T10
5706
–UN
–09J
AN
97
2—Load Sleeve 13—Load Adjusting Screw 24—Maximum Flow Adjusting 34—Nut3—Load Spool (Stop) Screw (Stop) 35—End Plate5—Cylinder 15—Spring 27—Remote Control Sleeve 36—Cover6—Load Piston 16—Nut (2 used) 28—Remote Control Spool 37—Cap Screw (8 used)12—Load Adjusting Cartridge 17—Nut (2 used) 29—Minimum Flow Adjusting 47—Outer Spring
(Stop) 20—Piston Screw 48—Inner Spring—Flow Adjusting Cartridge 21—Cylinder
(Stop)
4. Tighten cap screws.
5. Tighten air bleed plug.
SpecificationPump 1 (Front) and Pump 2(Rear) Air BleedPlug-to-Housing—Torque 78 N•m........................................................
58 lb-ft
IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before startingengine. Procedure must beperformed whenever a new pump isinstalled or oil has been drainedfrom the pump or hydraulic oil tank.
6. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
7. Check pump regulator adjustments.
For minimum flow:
• See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)
For maximum flow:
• See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)
TM10091 (11JAN08) 33-3360-29 160DLC Excavator Repair011108
PN=259
Hydraulic System
FS41334,0000146 –19–10APR07–1/3
Pilot Pump Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Drain pump drive gearbox. Approximate oil capacity is0.9 L (1.0 qt).
3. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) and See 160DLCDrain and Refill Capacities. (Operator’s Manual.)
FS41334,0000146 –19–10APR07–2/3
TX
1020
192A
–UN
–05A
PR
07
333360
30
1—Cap Screw (4 used)2—Final Fuel Filter3—Primary Fuel Filter
4. Remove cap screws (1) and set fuel filters (2 and 3)aside. Protect against damage to hoses and filters.
Continued on next page
TM10091 (11JAN08) 33-3360-30 160DLC Excavator Repair011108
PN=260
Hydraulic System
FS41334,0000146 –19–10APR07–3/3
TX
1020
294A
–UN
–19M
AR
07
1—Pilot Pump2—Cap Screw (2 used)3—Adapter (2 used)4—Pump Drive Gearbox
5. Tag and disconnect lines and hoses. Close all openlines and fittings using caps and plugs.
6. Remove adapters (3).
7. Remove cap screws (2) and pilot pump (1) fromgearbox (4).
8. Repair or replace parts as necessary.
9. Apply T43514 Rigid Form-In-Place Gasket to mountingsurface for pilot pump.
10. Tighten cap screws (2) to specification.
SpecificationPilot Pump-to-Pump DriveGearbox Cap Screw—Torque 49 N•m........................................................
36 lb-ft
11. Install adapters (3) and O-ring.
12. Connect lines. See Pump 1, Pump 2, and Pilot PumpLine Identification. (Group 9025-15.)
13. Fill pump drive gearbox so level is above “H” mark ondipstick. See Change Pump Drive Gearbox Oil.(Operator’s Manual.)
33336031
TM10091 (11JAN08) 33-3360-31 160DLC Excavator Repair011108
PN=261
Hydraulic System
333360
32
TJ15698,0000113 –19–11APR07–1/3
Pilot Pump Disassemble and Assemble
TX
1000
393
–UN
–16N
OV
05
TM10091 (11JAN08) 33-3360-32 160DLC Excavator Repair011108
PN=262
Continued on next page
Hydraulic System
TJ15698,0000113 –19–11APR07–2/3
0—Pilot Pump 6—Seal (2 used) 13—Driven Gear 26—Bushing1—Housing 7—End Cover 14—Drive Gear 27—Bushing2—Flange 9—Backup Retainer (2 used) 15—Washer (4 used) 28—Pin (4 used)3—Oil Seal 10—Key (2 used) 16—Cap Screw (4 used) 30—Seal Kit5—Snap Ring 12—O-Ring (2 used)
TJ15698,0000113 –19–11APR07–3/3
T76
85IX
–UN
–13M
AY
92
A—Drive GearB—Keys (2 used)C—Driven GearD—Bushing
IMPORTANT: Be careful not to lose keys (B).
1. Check bushings (D). If inside diameter and surfacetoward gear are rough or worn, replace pump.
2. Check gears (A and C) and housing. If gear teeth,shaft, and inside of housing is rough or worn, replacepump.
IMPORTANT: Apply clean hydraulic oil to all parts.Pump failure can result if pump isassembled dry.
3. Apply clean hydraulic oil to all parts.
4. Apply multi-purpose grease to lip of oil seal. Install oilseal with lip (spring side) towards inside of housing.
5. Tighten cap screws.
SpecificationCover-to-Flange Cap Screw—Torque 41 N•m............................................................................................
30 lb-ft
6. Check pilot pressure setting. See See Pilot PressureRegulating Valve Test and Adjustment. (Group9025-25.)
33336033
TM10091 (11JAN08) 33-3360-33 160DLC Excavator Repair011108
PN=263
Hydraulic System
FS41334,000014F –19–02MAR07–1/1
Pilot Pump Drive Shaft Remove and Install
T10
5640
–UN
–12D
EC
96T
1056
57–U
N–1
2DE
C96
T14
2290
–UN
–20J
UL0
1
333360
34
1—Pump Drive Gearbox Case3—Pilot Pump Drive Gear4—Pilot Pump Drive Shaft5—Ball Bearing (2 used)6—Snap Ring7—Snap Ring
1. Remove snap rings (6 and 7).
2. Remove pilot pump drive shaft (4) and outer ballbearing (5) using a blind-hole puller or an internalpuller. Ball bearings are a press fit on drive shaft andin housing.
3. Remove pilot pump drive gear (3) through opening forhydraulic pump.
4. Repair or replace as needed.
5. Assemble in reverse order.
TM10091 (11JAN08) 33-3360-34 160DLC Excavator Repair011108
PN=264
Hydraulic System
TJ15698,0000138 –19–11APR07–1/2
Pilot Pressure Regulating Valve and FilterRemove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
33336035
TJ15698,0000138 –19–11APR07–2/2
TX
1020
241A
–UN
–07M
AR
07
1—Hydraulic Hose2—Pilot Pressure Regulating Valve3—Filter4—Cap Screw (2 used)
2. Tag and disconnect hoses (1).
3. Close all open hoses and fittings using caps and plugs.
4. Remove cap screws (4) and remove pilot pressureregulating valve (2) and filter (3).
5. Repair or replace as necessary.
6. Install cap screws (4).
SpecificationFilter Head-to-Support CapScrew—Torque 49 N•m...............................................................................
36 lb-ft
7. Replace pilot filter element (3).
SpecificationPilot Filter ElementHousing-to-Filter Head—Torque 25 N•m...................................................
220 lb-in.
8. Connect hoses. See Hydraulic System LineConnections. (Group 9025-15.)
9. Check pilot pressure setting. See Pilot PressureRegulating Valve Test and Adjustment. (Group9025-25.)
TM10091 (11JAN08) 33-3360-35 160DLC Excavator Repair011108
PN=265
Hydraulic System
TJ15698,0000139 –19–06MAR07–1/1
Pilot Pressure Regulating Valve and FilterDisassemble and Assemble
1
23
45
6
TX
1003
402
–UN
–07F
EB
06
1—Pilot Pressure Regulating Valve Housing2—Poppet3—Shim (as required)4—Spring5—O-Ring6—Plug
1. Remove plug (6) with O-ring (5).
2. Remove parts (2—4).
3. Inspect, clean and replace parts as necessary.
4. Check that poppet (2) slides smoothly in pilot pressureregulating valve housing.
5. Tighten plug (6).
SpecificationPlug-to-housing—Torque 49 N•m................................................................
36 lb-ft
333360
36
TJ15698,0000130 –19–18APR07–1/3
Pilot Shutoff Solenoid Valve Remove andInstall
1. Turn upperstructure 90° to tracks.
TJ15698,0000130 –19–18APR07–2/3
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
2. Push pressure release button (1).
Continued on next page
TM10091 (11JAN08) 33-3360-36 160DLC Excavator Repair011108
PN=266
Hydraulic System
TJ15698,0000130 –19–18APR07–3/3
TX
1003
407A
–UN
–07F
EB
06T
X10
0340
6A–U
N–0
7FE
B06
33336037
1—Cap Screw (2 used)2—Connector
3. Tag and disconnect hoses and lines. Close all openlines and fittings using caps and plugs.
4. Disconnect solenoid connector (2).
5. Remove cap screws (1) and valve.
6. Repair or replace parts as necessary.
7. Install valve. Tighten cap screws.
SpecificationPilot Shutoff ValveHousing-to-Cab Platform CapScrew—Torque 49 N•m...............................................................................
36 lb-ft
8. Connect lines. See Pilot Shutoff Solenoid ValveOperation. (Group 9025-05.)
TM10091 (11JAN08) 33-3360-37 160DLC Excavator Repair011108
PN=267
Hydraulic System
333360
38
TJ15698,0000114 –19–18APR07–1/2
Pilot Shutoff Solenoid Valve Disassemble and Assemble
TX
1000
413
–UN
–16N
OV
05
TM10091 (11JAN08) 33-3360-38 160DLC Excavator Repair011108
PN=268
Continued on next page
Hydraulic System
TJ15698,0000114 –19–18APR07–2/2
1—Spring 5—Screen 9—Screw (2 used) 12—O-Ring (2 used)2—Plate 6—Solenoid 10—Screw (2 used) 13—Valve, Pilot Shutoff3—Housing 8—Plug (2 used) 11—O-Ring Solenoid4—Spool
1. Clamp housing (3) in a vise.
2. Scribe a line on housing (3) and solenoid (6).
3. Remove screws (9), solenoid (6), and O-ring (11).
4. Remove plug (8), O-ring (12), spring (1), and spool(4), from housing.
5. Remove screen (5).
6. Clean and inspect all parts. Replace worn ordamaged parts as necessary. Use new O-ringswhen assembling.
7. Install spool (4), spring (1), plug (8), and O-ring(12). Tighten plug to specification.
SpecificationShutoff Solenoid Valve HousingPlug—Torque 28 N•m...........................................................................
246 lb-in.
8. Install screen (5).
9. Install O-ring (11) to solenoid (6).
10. Align scribe marks and install solenoid (6) tohousing (3), using screws (9). Tighten screws tospecification.
SpecificationSolenoid-to-Housing Screws—Torque 4 N•m........................................................................................
36 lb-in.
33336039
OUO6046,0002328 –19–10APR07–1/2
Fan Drive Pump Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump, or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) Approximate capacity ofhydraulic oil tank it 120.4 L (31.8 gal).
Continued on next page
TM10091 (11JAN08) 33-3360-39 160DLC Excavator Repair011108
PN=269
Hydraulic System
OUO6046,0002328 –19–10APR07–2/2
TX
1020
830A
–UN
–23M
AR
07T
X10
2082
9A–U
N–2
3MA
R07
1—Cold Weather Starting Aid Line2—Inlet Hose3—Outlet Hose4—Cap Screws (2 used)
3. Disconnect cold weather starting aid line (1).
4. Loosen clamp and disconnect inlet hose (2).
5. Disconnect outlet hose (3). Close all open lines andfittings using caps and plugs.
6. Remove cap screws (4), washers, pump (3), andgasket.
7. If installing new pump, remove fittings and top capscrew from existing pump and install onto new pumpusing new O-rings on fittings.
8. Install pump and new gasket.
9. Tighten cap screws.
10. Connect inlet and outlet hoses.
11. Tighten fittings and clamp.
12. Fill and check hydraulic oil level. See 160DLC Drainand Refill Capacities. (Operator’s Manual.)
333360
40
OUO6046,0002327 –19–04APR07–1/3
Fan Drive Motor Remove and Install
1. Remove coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
2. Remove fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)
Continued on next page
TM10091 (11JAN08) 33-3360-40 160DLC Excavator Repair011108
PN=270
Hydraulic System
OUO6046,0002327 –19–04APR07–2/3
TX
1020
784A
–UN
–23M
AR
07
1—Cap Screw (4 used)2—Fan Drive Motor Assembly
3. Support fan drive motor assembly (2). Remove capscrews (1) and fan drive motor assembly (2).
Continued on next page
33336041
TM10091 (11JAN08) 33-3360-41 160DLC Excavator Repair011108
PN=271
Hydraulic System
333360
42
OUO6046,0002327 –19–04APR07–3/3
TX
1021
112A
–UN
–30M
AR
07
1—Hub2—Lock Nut3—Cap Screws4—Hydraulic Hose5—Fan Drive Motor6—Hydraulic Hose7—Hydraulic Hose
4. Disconnect hydraulic hoses (4, 6, and 7).
5. Remove lock nut (2) and washer. Discard lock nut.
6. Remove hub (1) from motor shaft using suitable puller.
7. Remove cap screws (3), nuts, washers, and fan drivemotor (5).
8. Replace motor as necessary.
9. Install motor into mounting bracket.
10. Install cap screws, washers, and nuts. Tighten capscrews to specification.
SpecificationFan Drive Motor-to-MountingBracket Cap Screws—Torque 73 N•m........................................................
54 lb-ft
11. Install hub on fan shaft.
12. Install washer and new lock nut onto fan shaft.Tighten lock nut to specification.
SpecificationFan Motor Shaft Lock Nut—Torque 50 N•m............................................................................................
37 lb-ft
13. Connect hydraulic hoses.
14. Install fan drive motor assembly. Tighten cap screwsto specification.
SpecificationFan Drive MotorAssembly-to-Cooling PackageCap Screws—Torque 73 N•m.....................................................................
54 lb-ft
15. Install fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)
16. Install coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)
TM10091 (11JAN08) 33-3360-42 160DLC Excavator Repair011108
PN=272
Hydraulic System
OUO1073,0002104 –19–18APR07–1/2
Fan Drive Control Valve Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump. See Apply Vacuum to Hydraulic Oil Tank.(Group 3360.)
33336043
OUO1073,0002104 –19–18APR07–2/2
TX
1021
223A
–UN
–27M
AR
07
1—Connectors2—Cap Screw (2 used)3—Fan Drive Control Valve
NOTE: Reversing control valve shown, standard valvesimilar.
3. Disconnect wiring harness connectors (1).
4. Tag and disconnect hydraulic hoses. Close all openlines and fittings using caps and plugs.
5. Remove cap screws (2) and fan drive control valve (3).
6. Install valve and cap screws.
7. Connect hydraulic hoses. See Fan Drive SystemComponent Location. (Group 9025-15.)
8. Connect wiring harness connectors.
9. Fill and check hydraulic oil level. See 160DLC Drainand Refill Capacities. (Operator’s Manual.)
TM10091 (11JAN08) 33-3360-43 160DLC Excavator Repair011108
PN=273
Hydraulic System
TJ15698,0000131 –19–11APR07–1/2
Solenoid Valve Manifold Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) Approximate oilcapacity is 120.4 L (31.8 gal).
Continued on next page
333360
44
TM10091 (11JAN08) 33-3360-44 160DLC Excavator Repair011108
PN=274
Hydraulic System
TJ15698,0000131 –19–11APR07–2/2
TX
1020
239A
–UN
–07M
AR
07
1—Solenoid Valve Manifold2—Cap Screws (2 used)
3. Tag and disconnect electrical connectors.
4. Tag and disconnect hoses and lines.
5. Close all open lines, hoses, and fittings using caps andplugs.
6. Remove cap screws (2) and solenoid valve manifold(1).
7. Repair or replace as necessary.
8. Install manifold and tighten cap screws to specification.
SpecificationSolenoid Valve Manifold CapScrews—Torque 50 N•m.............................................................................
37 lb-ft
9. Connect hoses and lines.
10. Connect electrical connectors.
11. Fill hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
12. Perform pump 1 and 2 start-up procedure. See Pump1 and 2 Start-Up Procedure. (Group 3360.)
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TM10091 (11JAN08) 33-3360-45 160DLC Excavator Repair011108
PN=275
Hydraulic System
TJ15698,0000132 –19–11APR07–1/2
Solenoid Valve Remove and Install—PowerDig (SG), Travel Speed (SI), Boom Mode(SC), and Boom Flow Rate (SF)
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
333360
46
TJ15698,0000132 –19–11APR07–2/2
TX
1020
240A
–UN
–07M
AR
07
1—Cap Screw (8 used)2—Solenoid Valve Coil (4 used)3—Electrical Connector (4 used)
2. Disconnect electrical connector (3).
3. Remove cap screws (1) and remove solenoid valve coil(2). Be careful not to lose spring and O-ring.
4. Keep parts for each individual solenoid valve together.
5. Install solenoid valve coil (2) with O-ring and spring.
6. Tighten cap screws (1).
SpecificationSolenoid Valve Coil-to-ManifoldCap Screws—Torque 6 N•m.......................................................................
53 lb-in.
7. Connect electrical connectors (3).
8. Check pressure setting of solenoid valves. See PowerDigging Solenoid Valve Test and Adjustment. SeeTravel Speed Solenoid Valve Test and Adjustment.See Arm Regenerative Solenoid Valve Test andAdjustment. See Dig Regenerative Solenoid Valve Testand Adjustment. (Group 9025-25.)
TM10091 (11JAN08) 33-3360-46 160DLC Excavator Repair011108
PN=276
Hydraulic System
TJ15698,0000133 –19–11APR07–1/3
Pilot Valve (Left and Right) Remove andInstall
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Remove seat. See Seat Remove and Install. (Group1821.)
3. Remove console covers. See Left and Right ConsoleCovers Remove and Install. (Group 1821.)
Continued on next page
33336047
TM10091 (11JAN08) 33-3360-47 160DLC Excavator Repair011108
PN=277
Hydraulic System
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48
TJ15698,0000133 –19–11APR07–2/3
TX
1018
524
–UN
–05F
EB
071—Handle (2 used) 5—Boot (2 used) 8—Cap Screw and Washer (6 10—Cap Screw (2 used)2—Tie Band (2 used) 6—Washer (8 used) used) 11—Washer (2 used)3—Nut (4 used) 7—Tie Band (2 used) 9—Spring Pin (2 used) 12—Pilot Valve (2 used)4—Shaft (2 used)
4. Disconnect wiring harness and remove handles (1).Handles are threaded onto shaft (4).
5. Remove cap screws (8 and 10) and remove pilotvalves (12) from console.
6. Tag and disconnect hoses. Close all open hosesand fittings using caps and plugs.
7. Repair or replace parts as necessary.
8. Connect hoses. See Pilot Control Valve-to-PilotSignal Manifold Component Location—ExcavatorPattern. (Group 9025-15.)
NOTE: Position cap screw (10) with spring pin (9), inlower left hole of left pilot valve, and lowerright hole of right pilot valve.
9. Install pilot valves (12) and tighten cap screws (8and 10).
TM10091 (11JAN08) 33-3360-48 160DLC Excavator Repair011108
PN=278
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Hydraulic System
TJ15698,0000133 –19–11APR07–3/3
SpecificationPilot Valve-to-Console CapScrew—Torque 20 N•m........................................................................
177 lb-in.
10. After pilot valve is installed, check operation of allfunctions. See Control Lever Pattern Operation.(Operator’s Manual.)
11. Install console covers. See Left and Right ConsoleCovers Remove and Install. (Group 1821.)
12. Install seat. See Seat Remove and Install. (Group1821.)
33336049
TM10091 (11JAN08) 33-3360-49 160DLC Excavator Repair011108
PN=279
Hydraulic System
333360
50
TJ15698,0000116 –19–03APR07–1/3
Pilot Valve (Left and Right) Disassemble and Assemble
TX
1000
262
–UN
–16N
OV
05
TM10091 (11JAN08) 33-3360-50 160DLC Excavator Repair011108
PN=280
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Hydraulic System
33336051
TJ15698,0000116 –19–03APR07–2/3
0—Housing and Spools 11—Snap Ring (4 used) 21—Plate 27—O-Ring3—Shim (4 used) 14—Pusher B (2 used) 22—Universal Joint 28—Snap Ring4—Spacer (4 used) 15—Pusher A (2 used) 23—Cam 33—Return Spring (2 used)6—Balance Spring (2 used) 17—Sleeve (4 used) 24—Coupling 34—Return Spring (2 used)8—Balance Spring (2 used) 19—O-Ring (4 used) 26—Plug 35—Pilot Valve10—Guide (4 used)
IMPORTANT: The housing and spools (0) arereplaced as an assembly becausethe spools are select fitted to boresin housing.
Some parts from ports 1 and 3 aredifferent than parts from ports 2 and4. Parts for each port must be kepttogether and installed into the sameport from which it was removed. Theport numbers are stamped on thehousing.
Remove universal joint (22) only ifnecessary.
Note port location and quantity ofshims (3) when removing. Samenumber of shims must be used wheninstalling.
1. Remove:
• Coupling (24)• Cam (23)• Universal Joint (22)• Plate (21)
NOTE: Sleeves (17) cannot be disassembled. Do notattempt to remove oil seal from sleeve.
2. Remove sleeves (17).
3. Remove:
• Pusher (14 and 15)• Snap Ring (11)• Guide (10)• Spring (6 and 8)• Spring (33 and 34)• Shim (3)
• Spacer (4)• Spools (0)• Snap Ring (28)• O-Ring (27)• Plug (26)
4. Repair or replace parts as necessary.
5. Install O-ring (27) onto plug (26).
6. Install plug (26) and snap ring (28).
IMPORTANT: Components are select fit to bores.Install components in the same borethat they were removed from.
7. Install spools (0).
IMPORTANT: Ports 1 and 3 use short balancesprings. Ports 2 and 4 use longbalance springs.
8. Install spacers (4), shims (3), and balance springs(6 and 8).
IMPORTANT: Ports 1 and 3 use short returnsprings. Ports 2 and 4 use longreturn springs.
9. Install return springs (33 and 34).
10. Install guides (10) with protrusion facing upward.
11. Install snap rings (11).
IMPORTANT: Ports 1 and 3 use pushers with 1outer groove. Ports 2 and 4 usepushers with 2 outer grooves.
12. Install pushers A (15) and pushers B (14).
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Hydraulic System
TJ15698,0000116 –19–03APR07–3/3
13. Apply TY6341 Multi-Purpose SD Polyurea Greaseto ball at ends of pushers A and pushers B.
14. Apply TY6341 Multi-Purpose SD Polyurea Greaseto joint of universal joint (22) and to inner surfaceof sleeve (17) seals.
15. Install O-rings (19) and sleeves (17).
16. Apply LOCTITE 262 Threadlocker (high strength)to threads of universal joint (22).
IMPORTANT: Align cap screw hole in plate (21)with cap screw hole in housing (0).
17. Install plate (21) and universal joint (22). Tightenuniversal joint.
SpecificationUniversal Joint—Torque 24.5 N•m.......................................................
217 lb-in.
18. Install cam (23) on universal joint (22). Adjustclearance between pushers A (15) and pushers B(14) and cam.
SpecificationCam-to-Pusher A and PusherB—Clearance 0—0.20 mm...................................................................
0—0.008 in.
19. Hold cam (23) and tighten coupling (24).
SpecificationCoupling-to-Cam and UniversalJoint—Torque 69 N•m..........................................................................
51 lb-ft
LOCTITE is a trademark of Henkel Corporation
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52
TJ15698,0000134 –19–11APR07–1/2
Travel Pilot Valve Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
Continued on next page
TM10091 (11JAN08) 33-3360-52 160DLC Excavator Repair011108
PN=282
Hydraulic System
TJ15698,0000134 –19–11APR07–2/2
TX
1003
510A
–UN
–16F
EB
06
1—Cap Screw (4 used)2—Cap Screw (2 used)3—Travel Pilot Valve
2. Tag and disconnect hoses underneath of cab.
3. Close all open hoses and fittings using caps and plugs.
4. Remove cap screws (1) and remove pedals and levers.
5. Remove cap screws (2) and remove travel pilot valve(3).
6. Repair or replace parts as necessary.
7. Tighten cap screws (2).
SpecificationValve-to-Cab Platform CapScrew—Torque 50 N•m...............................................................................
37 lb-ft
8. Tighten cap screws (1).
SpecificationTravel Pedal-to-Lever CapScrew—Torque 50 N•m...............................................................................
37 lb-ft
9. Connect hoses. See Travel Hydraulic System LineConnection. (Group 9025-15.)
10. After travel pilot valve is installed, check the operationof all functions to be sure they operate correctly.
33336053
TM10091 (11JAN08) 33-3360-53 160DLC Excavator Repair011108
PN=283
Hydraulic System
333360
54
TJ15698,0000117 –19–16FEB07–1/3
Travel Pilot Valve Disassemble and Assemble
1
235
34
33
32
3031
26
27 2829
10
14
19
20
21
22 23
24
25
13
12
11
9
8
7
6 54
3
18
17
1516
TX
1018
305
–UN
–31J
AN
07
1—Cap Screw (2 used) 10—Holder 19—Spool (4 used) 28—Cap Screw (4 used)2—Cover 11—Oil Seal (4 used) 20—Spring (4 used) 29—Lock Washer (4 used)3—Pin (2 used) 12—O-Ring (4 used) 21—Spacer (4 used) 30—Spring Pin (2 used)4—O-Ring (2 used) 13—Bushing (4 used) 22—Shim (As required) 31—Spring Pin (2 used)5—O-Ring (2 used) 14—Casing 23—Balance Spring (4 used) 32—Bushing (4 used)6—Dampener (2 used) 15—O-Ring 24—Spring Guide (4 used) 33—Cam (2 used)7—Rubber Seat (2 used) 16—Plug 25—Pusher (4 used) 34—Spring Pin (2 used)8—Cap Screw (2 used) 17—Plug 26—Bracket (2 used) 35—Spring Pin (2 used)9—Lock Washer (2 used) 18—O-Ring 27—Spring Pin (2 used)
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Hydraulic System
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TJ15698,0000117 –19–16FEB07–2/3
IMPORTANT: The casing (14) and spools (19) arereplaced as an assembly becausethe spools are select fitted to boresin housing.
Parts for each port must be kepttogether and installed into the sameport from which it was removed. Theport numbers are stamped on thehousing.
Note port location and quantity ofshims (22) when removing. Samenumber of shims must be used wheninstalling.
1. Remove parts from casing. Remember to keepparts removed from each port together. Identifyeach group of parts by port numbers stamped oncasing.
NOTE: Spring pins (30 and 31) are stepped and canonly be removed from one direction.
Remove spring pin (27) and bushings (32) onlyif necessary.
2. Repair or replace parts as necessary.
NOTE: Use same number of shims (22) as wereremoved.
3. Install spools (19), springs (20), spacers (21), shims(22) and balance springs (23) into casing (14).
4. Install spring guides (24) with stepped end facingdown.
5. Apply multi-purpose grease to the end of eachpusher (25) and to oil seals (11).
IMPORTANT: Note direction of insertion for springpins (34 and 35).
6. Assemble cam (33) in holder (10) with spring pins(34 and 35), and pin (3). Install spring pins with slits90° apart.
7. Lock pins (34 and 35) in position by displacing thebore above spring pin using a punch and hammer.
8. Install holder (10) to casing (14) with cap screws(8), lock washers (9) and tighten.
SpecificationHolder-to-Casing Cap Screw—Torque 49 N•m......................................................................................
36 lb-ft
9. Apply multi-purpose grease to O-rings (4 and 5)and install on pin (3).
10. Position rubber seat (7) and dampener (6) on pin(3) with lever facing upward.
11. Install cap screws (28), lock washers (29) andtighten.
SpecificationDampener-to-Holder CapScrew—Torque 7 N•m..........................................................................
62 lb-in.
IMPORTANT: Note direction of insertion for springpins (30 and 31).
Spring pins must be positioned withslits 90° apart.
Align brackets with marks madeduring disassembly.
12. Install brackets (26) and spring pins (30 and 31).
13. Lock pins (30 and 31) in position by displacing thebore above spring pin using a punch and hammer.
14. Install cover (2) and cap screws (1) and tighten.
SpecificationCover-to-Holder Cap Screw—Torque 5 N•m........................................................................................
44.3 lb-in.
15. Apply multi-purpose grease to spring pin (27).
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Hydraulic System
TJ15698,0000117 –19–16FEB07–3/3
16. Install O-ring (18) and plug (17). Tighten plug tospecification.
SpecificationPlug—Torque 10 N•m...........................................................................
89 lb-in.
17. Install O-ring (15) and plug (16). Tighten plug tospecification.
SpecificationPlug—Torque 20 N•m...........................................................................
177 lb-in.
TJ15698,0000135 –19–11APR07–1/2
Pilot Signal Manifold Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) Approximate oilcapacity is 120.4 L (31.8 gal).
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56
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TM10091 (11JAN08) 33-3360-56 160DLC Excavator Repair011108
PN=286
Hydraulic System
TJ15698,0000135 –19–11APR07–2/2
TX
1021
445A
–UN
–02A
PR
07
1—Pilot Signal Manifold2—Bracket3—Cap Screw (4 used)
3. Tag and disconnect hoses and lines.
4. Close all open lines, hoses, and fittings using caps andplugs.
5. Disconnect electrical connectors.
6. Remove cap screws (3).
7. Repair or replace parts as necessary.
8. Position manifold (1) on bracket (2) and tighten capscrews (3).
SpecificationPilot Signal Manifold-to-BracketCap Screw—Torque 50 N•m.......................................................................
37 lb-ft
9. Connect electrical connectors. See System FunctionalSchematic, Component Location, and Wiring DiagramMaster Legend. (Group 9015-10.)
10. Connect hoses and lines. See PilotControllers-to-Pilot Signal Manifold ComponentLocation—Excavator Pattern. See Pilot SignalManifold-to-Control Valve Line Connection. (Group9025-15.)
11. Fill hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).
33336057
TM10091 (11JAN08) 33-3360-57 160DLC Excavator Repair011108
PN=287
Hydraulic System
333360
58
TJ15698,0000118 –19–16FEB07–1/3
Pilot Signal Manifold Disassemble and Assemble
14
13
15
1619
20
1617
19
18
2012
11
1
23
5
4
6 7
22
23
24
21 14
8
9
10
20 14
25
2619
2716
15
28
17
29
19
1716
15
17
A
B
C
D
T143485
T14
3485
–UN
–17J
UL0
1
TM10091 (11JAN08) 33-3360-58 160DLC Excavator Repair011108
PN=288
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Hydraulic System
TJ15698,0000118 –19–16FEB07–2/3
1—Cap Screw (10 used) 9—Gasket 16—O-Ring (7 used) 23—Valve2—Body 10—Body 17—Spring (4 used) 24—O-Ring3—Gasket 11—Name Plate 18—Spring 25—Spring4—Body 12—Screw (4 used) 19—Spring Seat (7 used) 26—Spool5—Gasket 13—Plate 20—Spool (6 used) 27—Spring6—Body 14—Cap Screw (11 used) 21—Plate 28—Spring7—Gasket 15—Plug (7 used) 22—O-Ring 29—Plate8—Body
Continued on next page
33336059
TM10091 (11JAN08) 33-3360-59 160DLC Excavator Repair011108
PN=289
Hydraulic System
333360
60
TJ15698,0000118 –19–16FEB07–3/3
A B
C D
30 32
31
32
31
30
3130
T143486
T14
3486
–UN
–17J
UL0
1
30—Filter (17 used) 31—Shuttle Valve (21 used) 32—Spring (4 used)
TM10091 (11JAN08) 33-3360-60 160DLC Excavator Repair011108
PN=290
Hydraulic System
OUO6046,000231D –19–10APR07–1/3
Control Valve Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump, or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) See 160DLC Drain and RefillCapacities. (Operator’s Manual.)
OUO6046,000231D –19–10APR07–2/3
TX
1020
604A
–UN
–23M
AR
07
33336061
1—Cap Screws2—Pilot Signal Manifold
3. Tag and disconnect hydraulic lines and hoses. Closeall open lines and fittings using caps and plugs.
4. Disconnect electrical connectors.
5. Remove cap screws (1) and washers. Place pilotsignal manifold (2) with bracket to side.
6. Attach an appropriate lifting device to control valveusing lifting straps.
Continued on next page
TM10091 (11JAN08) 33-3360-61 160DLC Excavator Repair011108
PN=291
Hydraulic System
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62
OUO6046,000231D –19–10APR07–3/3
2
2
1
51
3
4
3
TX
1003
909
–UN
–20F
EB
06
1—Cap Screw (4 used)2—Washer (4 used)3—Spacer (4 used)4—Front Mounting Bracket5—Rear Mounting Bracket
CAUTION: Heavy component; use anappropriate lifting device.
SpecificationControl Valve—ApproximateWeight 220 kg..............................................................................................
485 lb
7. Remove cap screws (1), washers (2), and spacers (3).Remove control valve.
8. Replace parts as necessary.
9. Install in reverse order.
10. Tighten cap screws (1) to specification.
SpecificationMounting Bracket-to-ControlValve Cap Screw—Torque 270 N•m...........................................................
200 lb-ft
11. Install pilot signal manifold with bracket. Tighten capscrews to specification.
SpecificationPilot Signal ManifoldBracket-to-Control Valve CapScrew—Torque 140 N•m.............................................................................
103 lb-ft
12. Connect hydraulic hoses and lines. See HydraulicSystem Line Connections. (Group 9025-15.)
13. Connect electrical connectors.
14. Check hydraulic tank oil level. See Check HydraulicTank Oil Level. (Operator’s Manual.)
15. Do Pump 1 and 2 Start-Up Procedure. (Group 3360.)
TM10091 (11JAN08) 33-3360-62 160DLC Excavator Repair011108
PN=292
Hydraulic System
33336063
OUO6046,000231E –19–16APR07–1/8
Control Valve (5-Spool) Disassemble and Assemble
TX
1004
777
–UN
–26A
PR
06
Control Valve End Caps 5-Spool Side
TM10091 (11JAN08) 33-3360-63 160DLC Excavator Repair011108
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Hydraulic System
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64
OUO6046,000231E –19–16APR07–2/8
TX
1004
778
–UN
–25A
PR
06
TM10091 (11JAN08) 33-3360-64 160DLC Excavator Repair011108
PN=294
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Hydraulic System
33336065
OUO6046,000231E –19–16APR07–3/8
1—Housing 33—Spring 68—Poppet 100—O-Ring2—O-Ring 34—Piston 69—Poppet 104—Body3—Plug 35—O-Ring 70—Plug 105—Auxiliary Flow Combiner4—Poppet 36—Plug 71—O-Ring Check Valve5—Spring 37—Poppet 72—Flange 106—Main Relief Valve6—O-Ring (3 used) 38—Spring 73—Spring Isolation Check Valve7—Flange 39—O-Ring 74—Poppet 107—Arm Reduced Leakage8—Cap Screw (22 Used) 40—Spacer 75—Flange (2 Used) Valve9—O-Ring (4 Used) 41—Left Travel Spool 76—Poppet (2 Used) 108—Left Travel Spool10—Plug (4 Used) 42—Spring Seat (10 Used) 77—Auxiliary Flow Rate Spool 109—Auxiliary Spool11—Poppet 43—Spring (5 Used) 78—Spring 110—Boom II Spool12—Spring (2 Used) 44—Bolt (5 Used) 79—Plug 111—Arm I Spool13—O-Ring (5 Used) 45—Auxiliary Spool 80—Spring 112—Swing Spool14—O-Ring 46—Boom 2 Spool 81—Poppet 113—Check Valve15—Backup Ring 47—Arm 1 Spool 82—Poppet 114—Auxiliary Flow Rate16—Plug 48—Spring Seat (2 Used) 83—Poppet Control Valve17—Main Relief and Power 49—Spring 84—Cover (2 Used) 115—Auxiliary Flow Combiner
Digging Valve 50—Swing Spool 85—O-Ring (2 Used) Valve Check Valve18—O-Ring 51—O-Ring (10 Used) 86—Poppet 116—Lift Check (Left Travel19—Arm Out Circuit Relief and 52—Cap Screw (16 Used) 87—Plug Power Passage Check
Anticavitation Valve (2 53—O-Ring 88—O-Ring Valve)Used) 54—Plug 89—Spring 117—Dig Regenerative Check
20—O-Ring (5 Used) 55—Cap 90—Poppet Valve21—O-Ring 56—Plug (2 Used) 91—Socket Bolt (4 Used) 118—Auxiliary Flow Combiner22—Spring 57—O-Ring (2 Used) 92—Cap (2 Used) Valve23—Seat 58—Cap Screw (8 Used) 93—Spring Seat (2 Used) 119—Dig Regenerative Valve24—Poppet 59—Arm 1 Flow Rate Spool 94—Spring 120—Arm Reduced Leakage25—Backup Ring 60—Spring 95—Auxiliary Flow Combiner Valve26—O-Ring 61—Spring Seat (2 Used) Spool 121—Lift Check (Boom 227—O-Ring 62—O-Ring (2 Used) 96—Spring Power Passage)28—Backup Ring 63—Plug (2 Used) 97—Dig Regenerative Spool 122—Arm 1 Flow Rate Control29—Sleeve 64—Sleeve (2 Used) 98—Cap (4 Used) Valve30—Spool 65—Spring (2 Used) 99—Arm In Circuit Relief and 123—Lift Check (Swing Neutral31—O-Ring 66—Plug Anticavitation Valve Passage)32—Body 67—Spring
1. Remove cap screws (52) and bottom pilot caps(98).
2. Remove cap screws (52) and top pilot cap (55).
3. Spool—5 Spool (108—112):
IMPORTANT: The spool (108—112) are select fittedto bores in housing and are adifferent design for each function.Spools must be installed into thesame bores from which they wereremoved for proper operation ofmachine.
NOTE: Hold spool in a vise by the spool end betweenwooden blocks.
a. Remove spools (108—112).
b. Disassemble control valve spools.
c. Inspect control valve spools for wear anddamage.
d. Replace parts as necessary.
e. Assemble in reverse order.
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OUO6046,000231E –19–16APR07–4/8
f. Tighten cap screws (44) to specification.
SpecificationCap Screw-to-Control ValveSpool—Torque 15 N•m.........................................................................
132 lb-in.
NOTE: Apply clean hydraulic oil to spools beforeinstallation.
g. Install spools (108—112) into housing (1) whilerotating them slowly.
h. After installing spools into housing, push themby hand to confirm smoothness.
4. Dig Regenerative Valve (119):
a. Remove cap screws (91) and parts (92, 6, 93,96 and 97).
b. Inspect parts for wear and damage.
c. Replace parts as necessary.
d. Assemble in reverse order.
e. Tighten cap screws (91) to specification.
SpecificationDig RegenerativeValve-to-Housing Cap Screw—Torque 11 N•m......................................................................................
84 lb-in.
5. Lift Check (Left Travel Neutral Passage) (116):
a. Remove plug (10) O-ring (9), spring (38) andpoppet (86).
b. Inspect parts for wear and damage.
c. Replace parts as necessary
d. Assemble in reverse order.
e. Install plug (10) and tighten to specification.
SpecificationLeft Travel NeutralPassage-to-Housing Lift CheckPlug—Torque 76 N•m...........................................................................
56 lb-ft
6. Auxiliary Flow Combiner Valve Check Valve(115):
a. Remove parts (8, 7, 6, 5 and 83).
b. Inspect parts for wear and damage.
c. Assemble in reverse order.
d. Install flange (7) and tighten cap screws (8) tospecification.
SpecificationAuxiliary Flow Combiner ValveCheck Valve-to-Housing CapScrew—Torque 61 N•m........................................................................
46 lb-ft
7. Arm Reduced Leakage Valve (120):
a. Remove cap screws (8) and flange (72).
b. Remove spring (73) and poppet (74).
c. Inspect parts for wear and damage.
d. Replace parts as necessary.
e. Assemble in reverse order.
f. Install flange (72) and tighten cap screws (8).
SpecificationArm Reduced LeakageValve-to-Housing Cap Screw—Torque 61 N•m......................................................................................
46 lb-ft
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8. Lift Check (Boom 2 Power Passage) (121):
a. Remove cap screws (8) and flanges (75).
b. Remove O-ring (13), spring (12) and poppet(76).
c. Inspect parts for wear and damage.
d. Replace parts as necessary.
e. Assemble in reverse order.
f. Install flanges (75) and tighten cap screws (8) tospecification.
SpecificationPower Passage-to-HousingCap Screw—Torque 61 N•m................................................................
46 lb-ft
9. Lift Check (Swing Neutral Passage) (123):
a. Remove cap screws (8) and flanges (75).
b. Remove O-ring (13), spring (12) and poppet(76).
c. Inspect parts for wear and damage.
d. Replace parts as necessary.
e. Assemble in reverse order.
f. Install flanges (75) and tighten cap screws (8) tospecification.
SpecificationNeutral Passage-to-HousingCap Screw—Torque 61 N•m................................................................
46 lb-ft
10. Auxiliary Flow Rate Control Valve (114) andArm I Flow Rate Control Valve (122):
a. Remove cap screws (58) and housing (104).
b. Loosen plugs (56 and 63) from bodies (104).
c. Remove O-rings (20 and 13).
d. Remove plugs (63), spring seats (61), springs(60 and 78) and spools (59 and 77).
e. Remove plugs (56).
f. Remove sleeves (64), springs (65), plugs (66and 79), springs (67 and 80) and poppets (68,69, 81, and 82) from housing (1).
g. Inspect parts for wear and damage.
h. Replace parts as necessary.
i. Assemble in reverse order.
j. Install housing (104) and tighten cap screws(58) to specification.
SpecificationFlow Rate ValveHousing-to-Housing CapScrew—Torque 61 N•m........................................................................
46 lb-ft
k. Tighten plug (63) to specification.
SpecificationFlow Rate Valve HousingPlug—Torque 98 N•m...........................................................................
72 lb-ft
11. Arm Reduced Leakage Valve (107):
a. Remove plug (36).
b. Remove cap screws (8) and body (32).
c. Remove parts (33—35).
d. Remove parts (22—31).
e. Inspects parts for wear and damage.
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f. Replace parts as necessary.
g. Assemble in reverse order.
h. Apply petroleum jelly to valve seat (23) andspring (22) to hold in place.
IMPORTANT: Install spool (30) with the hole sidetowards poppet (24) to ensureproper operation of valve.
i. Install plug (36) loosely.
j. Tighten cap screws (8) to specification.
SpecificationArm Reduced Leakage ValveBody-to-Housing Cap Screw—Torque 62 N•m......................................................................................
46 lb-ft
k. Tighten plug (36) to specification.
SpecificationPlug-to-Arm Reduced LeakageValve—Torque 108 N•m.......................................................................
80 lb-ft
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OUO6046,000231E –19–16APR07–7/8
17
TX1005220
A
B
F
K
M
O
C
D
E
G
H
I
J
L
N
PQ
TX
1005
220
–UN
–24M
AR
06
A—First Adjusting PlugB—O-RingC—PistonD—NutE—Second Adjusting PlugF—O-RingG—Pilot Poppet SpringH—Pilot PoppetI—NutJ—CartridgeK—O-RingL—Pilot Poppet SeatM—Backup RingN—O-RingO—Main Poppet SpringP—Main PoppetQ—Main Poppet Seat
12. Main Relief and Power Digging Valve (17)
NOTE: Disassemble valve for cleaning and inspectiononly. Valve is serviced as an assembly.
a. Disassemble parts (A—Q).
b. Inspect parts for wear and damage.
c. If any part of valve is damaged, replace valve asan assembly.
d. Tighten nuts (D and I) to specification.
Main Relief Valve—SpecificationMain Relief Valve 27 mm Nut(D)—Torque 64 N•m....................................................................................
47 lb-ftMain Relief Valve 32 mm Nut(I)—Torque 83 N•m.....................................................................................
61 lb-ft
e. Tighten valve cartridge (J) to specification.
SpecificationMain Relief ValveCartridge-to-Housing—Torque 83 N•m.......................................................
61 lb-ft
f. Check and adjust pressure setting for system reliefvalve and power boost. See Main Relief and PowerDigging Valve Test and Adjustment. (Group9025-25.)
13. Install top pilot cap (55) and tighten cap screws (52)to specification.
SpecificationTop Pilot Cap-to-Housing CapScrew—Torque 42 N•m...............................................................................
32 lb-ft
14. Install bottom pilot caps (98) and tighten cap screws(52).
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OUO6046,000231E –19–16APR07–8/8
SpecificationBottom Pilot Caps-to-HousingCap Screw—Torque 42 N•m......................................................................
32 lb-ft
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70
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OUO6046,000231F –19–19APR07–1/6
Control Valve (4-Spool) Disassemble and Assemble
TX
1004
704
–UN
–16M
AR
06
4-Spool Control Valve
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TX
1004
708
–UN
–16M
AR
06
Control Valve End Caps (4-Spool Side)
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1—Housing 34—Piston 72—Spring 106—Spring2—Poppet 35—O-Ring 73—Travel Flow Combiner 107—Flange3—Spring (2 used) 36—Plug Spool 108—Poppet4—O-Ring (3 used) 37—Right Travel Spool 74—Circuit Relief and 109—Poppet5—Flange 38—Spring Seat (8 used) Anticavitation Valve (2 110—Spring6—Cap Screw (13 used) 39—Spring (4 used) Used) 111—Plug7—O-Ring (3 used) 40—Body 75—Poppet 112—Poppet8—Plug (3 used) 41—Cap Screw (4 used) 76—Spring 113—Spring9—O-Ring (5 used) 42—Plug 77—O-Ring (5 Used) 114—Plug (3 Used)10—Plug (3 used) 43—Backup Ring (2 used) 78—O-Ring (2 Used) 115—O-Ring (3 Used)11—Poppet 44—O-Ring 79—O-Ring 116—Spring Seat (3 Used)12—Spring 45—Spring 80—Manual Boom Lower 117—Spring13—O-Ring (3 used) 46—Poppet Screw 118—Arm 2 Flow Rate Spool14—O-Ring 47—Bucket Spool 81—O-Ring 119—Plug (3 Used)15—Poppet 48—Plug 82—Plug 120—O-Ring (3 Used)16—Flange 49—Poppet 83—Poppet 121—Spring17—Main Relief Valve Isolation 50—Boom 1 Spool 84—Poppet 122—Arm 2 Flow Rate Spool
Check Valve 51—Arm 2 Spool 85—Spring 123—Body18—Right Travel and Bucket 52—Spring Seat (2 used) 86—Plug 124—Arm 2 Flow Rate Spool
Combined Function Check 53—Spring 87—Spring (3 Used) 125—SpringValve 54—Arm Regenerative Spool 88—Sleeve 126—O-Ring
19—O-Ring (2 used) 55—O-Ring 89—Plug 127—Plug20—Circuit Relief and 56—Backup Ring 90—O-Ring 128—Boom Reduced Leakage
Anticavitation Valve (2 57—Arm Regenerative Spool 91—Body Valveused) 58—Spring 92—Bucket Flow Rate Spool 129—By-Pass Shut-Off Valve
21—Spring 59—O-Ring (8 Used) 93—Spring 130—Right Travel Spool22—Washer 60—O-Ring 94—Spring Seat 131—Bucket Spool23—Poppet 61—Plug 95—O-Ring 132—Boom 1 Spool24—Backup Ring 62—Top Pilot Cap 96—Plug 133—Arm 2 Spool25—O-Ring 63—Cap Screw (14 Used) 97—Cap Screw (12 Used) 134—Arm Regenerative Valve26—O-Ring 64—Bottom Pilot Cap 98—Poppet 135—Travel Flow Combiner27—Arm Regenerative Circuit 65—O-Ring 99—Poppet Valve
Check Valve 66—Plug 100—Spring 136—Boom Reduced Leakage28—Backup Ring 67—Cap (3 Used) 101—Plug Valve29—Sleeve 68—Cap Screw (2 Used) 102—O-Ring 137—Bucket Flow Rate30—Spool 69—Cap 103—Cap Control Valve31—O-Ring 70—Cap Screw 104—Cap Screw (4 Used) 138—Arm 2 Flow Rate Control32—Body 71—Spring Seat (2 Used) 105—By-Pass Shut-Off Spool Valve33—Spring
1. Remove cap screws (63), top pilot cap (62) andO-rings (59) from housing (1).
2. Remove cap screws (63) and bottom pilot caps (67)from housing (1).
3. Spool—4 Spool (130—133):
NOTE: When disassembling spools (131, and 132),heat plugs (46, 48, and 49) to 200—300 °C(392—482 °F) to melt thread lock and sealer.
IMPORTANT: The spools (130—133) are select fitto bores in housing and are adifferent design for each function.Spools must be installed into samebores from which they were removedfor proper operation of machine.
a. Remove spools (130—133).
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NOTE: Hold the spool in a vise by the spool end,using wooden blocks.
b. Remove cap screws (41) and spools.
c. Heat plugs (46, 48, and 49) with heat gun tomelt thread lock and sealer and remove plugs.
d. Inspect parts for wear and damage.
e. Replace parts as necessary.
f. For right travel spool (130) and arm 2 spool(133); install and tighten cap screws (41) tospecification.
SpecificationCap Screw-to-Control ValveSpool—Torque 15 N•m.........................................................................
11 lb-ft
g. For bucket and boom 1 spool (131 and 132):
Apply thread lock and sealer (high strength) toplugs (46, 48, and 49).
h. Install plugs (46, 48, and 49) onto spool (131and 132) and tighten to specification.
SpecificationPlugs-to-Control Valve Spool—Torque 15 N•m......................................................................................
11 lb-ft
i. Install cap screw (41) into spool and tighten tospecification.
SpecificationCap Screw-to-Control ValveSpool—Torque 15 N•m.........................................................................
11 lb-ft
NOTE: Apply hydraulic oil to spools before installation.
j. Install spools (130—133) into housing (1) whilerotating them slowly.
IMPORTANT: After installing spool (130—133) intohousing (1), push them by hand toconfirm smoothness.
4. Travel Flow Combiner Valve (135):
a. Remove cap screws (68) and cap (69).
b. Remove parts (4,70—72).
c. Inspect parts for wear and damage.
d. Replace parts as necessary.
e. Assemble in reverse order.
f. Tighten cap screw (70) to specification.
SpecificationCap Screw-to-Flow CombinerValve Spool—Torque 11 N•m...............................................................
7 lb-ft
g. Install spool (73), cap (69) and tighten capscrews (68) to specification.
SpecificationCap-to-Housing Cap Screw—Torque 10 N•m......................................................................................
7 lb-ft
5. Arm Regenerative Valve (134):
a. Remove parts (4, 54—58).
b. Inspect parts for wear and damage.
c. Replace parts as necessary.
d. Assemble in reverse order.
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e. Install parts (4, 54—58).
6. Arm 2 Flow Rate Control Valve (138):
a. Remove cap screws (97) and body (123).
b. Remove O-rings (77, 13) and poppet (15).
c. Remove plugs (114), spring seats (116), springs(117, 121, 125) and spools (118, 122, 124).
d. Remove plugs (119) and (127).
e. Remove spring (113) and poppet (112).
f. Remove springs (87) and poppets (98, 108).Remove plugs (101, 111), springs (100, 110) andpoppets (99, 109) from poppets (98, 108).
g. Inspect parts for wear and damage.
h. Replace parts as necessary.
i. Install in reverse order and loosely install plugs.
j. Install body (123) to housing (1) using capscrews (97). Tighten to specification.
SpecificationArm 2 Flow Rate Control ValveBody-to-Housing Cap Screw—Torque 61 N•m......................................................................................
45 lb-ft
7. Boom Reduced Leakage Valve (128):
a. Remove plug (36).
b. Remove parts (33—35).
c. Remove cap screws (6) and body (32).
d. Remove parts (21—31).
e. Inspect parts for wear and damage.
f. Replace parts as necessary.
g. Apply petroleum jelly to washer (22) and spring(21) to hold them in place.
h. Install spool (30), with hole side towards poppet(23).
i. Install parts (33—35).
j. Loosely install plug (36).
k. Install and tighten cap screws (6) tospecification.
SpecificationBoom Reduced Leakage ValveBody-to-Housing Cap Screw—Torque 62 N•m......................................................................................
46 lb-ft
l. Tighten plug (36) to specification.
SpecificationBoom Reduced LeakageValve-to-Body Plug—Torque 108 N•m.................................................
80 lb-ft
8. Bucket Flow Rate Valve (137):
a. Remove cap screws (97), housing (91), andO-ring (13).
b. Remove parts (89, 90, 92—96)).
c. Remove (83—88) from housing (1).
d. Inspect parts for wear and damage.
e. Replace parts as necessary.
f. Assemble in reverse order.
g. Install housing (91) and tighten cap screws (97)to specification.
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OUO6046,000231F –19–19APR07–6/6
SpecificationBucket Flow Rate ValveHousing-to-Housing CapScrew—Torque 61 N•m........................................................................
46 lb-ft
h. Tighten plug (96) to specification.
SpecificationFlow Rate Valve HousingPlug—Torque 98 N•m...........................................................................
72 lb-ft
9. Boom Reduced Leakage Valve (136):
a. Remove cap screws (6), housing (40), andO-rings (13).
b. Remove parts (75—78).
c. Inspect parts for wear and damage.
d. Replace parts as necessary.
e. Assemble in reverse order.
f. Install housing (40) and tighten cap screws (6) tospecification.
SpecificationBoom Reduced LeakageValve-to-Housing Cap Screw—Torque 61 N•m......................................................................................
46 lb-ft
10. By-Pass Shut-Off Valve (129):
a. Remove cap screws (6), flange (107) andO-ring (4) from housing (1).
b. Remove spring (106) and spool (105).
c. Inspect parts for wear and damage.
d. Replace parts as necessary.
e. Install O-ring (4) and parts (105—107); thentighten cap screws (6) to specification.
SpecificationBy-Pass Shut-OffValve-to-Housing Cap Screw—Torque 61 N•m......................................................................................
46 lb-ft
11. Install top pilot cap (62) and tighten cap screws(63) to specification.
SpecificationTop Pilot Cap-to-Housing CapScrew—Torque 42 N•m........................................................................
32 lb-ft
12. Install bottom pilot caps (64 and 67) and tightencap screws (63) to specification.
SpecificationBottom Pilot Cap-to-HousingCap Screw—Torque 42 N•m................................................................
32 lb-ft
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TJ15698,000013A –19–11APR07–1/5
Hydraulic Oil Tank Remove and Install
TX
1020
196A
–UN
–07M
AR
07
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
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TX
1020
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–UN
–09M
AR
07
33336077
1—Engine Cover2—Control Valve Cover
2. Remove covers (1 and 2).
3. Drain hydraulic oil tank. Approximate capacity is 120.4L (31.8 gal).
TJ15698,000013A –19–11APR07–3/5
TX
1020
242A
–UN
–07M
AR
07
1—Cap Screw2—Return Line (2 used)3—Hydraulic Hose (4 used)
4. Tag and disconnect hoses (3) and lines (2).
5. Close all open lines and fittings using caps and plugs.
6. Remove cap screw (1).
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TX
1020
243A
–UN
–07M
AR
07
1—Engine Oil Filter Housing2—Panel Latch Bracket3—Pilot Pressure Regulating Valve and Filter
Housing4—Clamps (4 used)5—Cap Screws (4 used)6—Electrical Connector7—Hydraulic Hose
7. Remove bracket (2).
8. Disconnect electrical connector (6).
9. Remove bottom cover and disconnect pump supplyhose.
10. Tag and disconnect hoses (7).
11. Close all open hoses and fittings using caps andplugs.
12. Remove clamps (4) and filter housings (1 and 3) fromtank and support.
13. Remove cap screws (5).
CAUTION: Heavy component; use a hoist.
SpecificationHydraulic Oil Tank—Weight 102 kg approximate.......................................
225 lb approximate
14. Remove hydraulic oil tank using a hoist and liftingstraps.
15. Remove tank components. See Hydraulic Oil TankDisassemble and Assemble. (Group 3360.)
16. Repair or replace parts as necessary.
17. Install tank components. See Hydraulic Oil TankDisassemble and Assemble. (Group 3360.)
18. Install hydraulic oil tank.
19. Tighten tank mounting cap screws to specification.
SpecificationHydraulic Oil Tank-to-Frame CapScrew—Torque 400 N•m.............................................................................
295 lb-ft
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TJ15698,000013A –19–11APR07–5/5
TX
1020
243A
–UN
–07M
AR
07
1—Engine Oil Filter Housing2—Panel Latch Bracket3—Pilot Pressure Regulating Valve and Filter
Housing4—Clamps (4 used)5—Cap Screws (4 used)6—Electrical Connector7—Hydraulic Hose
20. Connect return lines and hoses.
21. Connect electrical connector (6).
22. Install filter housings (1 and 3), hoses (7), clamps (4),and bracket (2).
23. Install covers.
24. Fill hydraulic oil tank. Approximate capacity is 120.4 L(31.8 gal).
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
25. Perform pump 1 and 2 start-up procedure. See Pump1 and 2 Start-Up Procedure. (Group 3360.)
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80
TJ15698,0000137 –19–30MAR07–1/2
Hydraulic Oil Tank Disassemble and Assemble
TX
1020
244
–UN
–07M
AR
07
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TJ15698,0000137 –19–30MAR07–2/2
1—Hydraulic Oil Tank 7A—Housing 13—Washers 21—Elbow Fitting and O-Ring3—O-Ring 7B—Filter Element 14—Hydraulic Oil Temperature 22—Filter Element4—Cap Screw (6 used) 7C—Cover Sensor 23—Cover5—Spring 7D—Nut 15—Gasket 31—Washer (4 used )6—Cover Assembly 7E—Cap 16—Suction Strainer and Rod 32—Cap Screw (4 used)6A—Bracket 8—Packing 16A—Rod 33—Filter Element6B—Cover 9—O-Ring 16B—Suction Strainer 33A—Sealing Ring6C—Cap Screw 10—Screw (4 used) 17—Plug and O-Ring (4 used) 33B—Valve6D—Washer 11—Cap Screw (6 used) 18—Plug and O-Ring 33C—O-Ring6E—Washer 12—Sight Glass 20—Adapter Fitting and 33D—Filter Element7—Filter 12A—Cap Screws O-Ring (3 used)
1. Tighten cap screws (4 and 11).
SpecificationCovers-to-Hydraulic Oil TankCap Screws—Torque 49 N•m..............................................................
36 lb-ft
2. Adjust the length of rod on suction strainer (16).
SpecificationSuction Strainer Rod (Top ofRod-to-Bottom of Strainer)—Length 869 mm....................................................................................
34.2 in
3. Tighten nuts on suction strainer rod.
SpecificationSuction Strainer Rod Nuts—Torque 17 N•m......................................................................................
153 lb-in.
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Restriction Valve Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) Approximate oil capacity is120.4 L (31.8 gal).
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1020
324
–UN
–09M
AR
07
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TJ15698,0000143 –19–11APR07–3/3
1—Cap Screw (4 used) 5—Washer 9—Washer (2 used) 12—O-Ring2—Flange (2 used) 6—Clamp 10—Bracket 13—Restriction Valve3—Oil Cooler Hose 7—Coupling 11—Return Line 14—Snap Ring4—Cap Screw 8—Cap Screw (2 used)
3. Remove clamp (6).
4. Disconnect hose (3) from line (11).
5. Remove snap ring (14) and restriction valve (13).
6. Repair or replace parts as necessary.
7. Install restriction valve (13) and snap ring (14).
8. Connect hose (3) to line (11).
SpecificationHydraulic Oil Tank Return LineCoupling Cap Screw—Torque 90 N•m.................................................
66 lb-ft
9. Fill hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).
IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before starting.Procedure must be performed to fillpump housing whenever oil hasbeen drained from the pump orhydraulic oil tank.
10. Perform pump 1 and 2 start-up procedure. SeePump 1 and 2 Start-Up Procedure. (Group 3360.)
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Hydraulic Oil Cooler Bypass Valve Removeand Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) Approximate oil capacity is120.4 L (31.8 gal).
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1 2
3
4
65
7
TX
1004
061
–UN
–09M
AR
06
1—Control Valve 3—Oil Cooler Bypass Valve 5—Hydraulic Return Line 7—Hydraulic Oil Tank2—O-Ring 4—Socket Head Cap Screws 6—Coupling
3. Loosen cap screws and nuts on coupling (6).
4. Remove socket head cap screws (4) and hydraulicreturn line (5).
5. Remove oil cooler bypass valve (3) and O-ring (2)from control valve (1). Repair or replace asnecessary.
6. Install oil cooler bypass valve (3) and O-ring (2).
7. Install hydraulic line (5).
8. Install socket head cap screws (4). Tighten tospecification.
SpecificationReturn Line Flange-to-ControlValve Socket Head CapScrews—Torque 50 N•m......................................................................
37 lb-ft
9. Tighten nuts on coupling.
SpecificationControl Valve-to-Hydraulic OilTank Return Line CouplingNuts—Torque 11 N•m...........................................................................
97 lb-in.
10. Fill hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).
IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before starting.Procedure must be performed to fillpump housing whenever oil hasbeen drained from the pump orhydraulic oil tank.
11. Perform pump 1 and 2 start-up procedure. SeePump 1 and 2 Start-Up Procedure. (Group 3360.)
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Hydraulic System
OUO6046,0002320 –19–18APR07–1/6
Boom Cylinder Remove and Install
T10
6031
–UN
–10J
AN
97
NOTE: Procedure is the same for both boom cylinders.
1. Park machine on firm, level surface.
2. Retract arm and bucket cylinders and lower bucket toground.
OUO6046,0002320 –19–18APR07–2/6
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
3. Push pressure release button (1).
4. Loosen boom cylinder hydraulic lines at frame end ofboom to release any residual pressure.
5. Disconnect lines. Close all open lines and fittings usingcaps and plugs.
6. Disconnect lubrication line at rod end of cylinder.
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TX
1006
808
–UN
–21A
PR
06
1—Boom Cylinder
CAUTION: Heavy component; use appropriatelifting device.
SpecificationBoom Cylinder—Weight 155 kg..................................................................
342 lb
7. Attach appropriate lifting device to boom cylinder (1)using lifting strap.
TM10091 (11JAN08) 33-3360-85 160DLC Excavator Repair011108
PN=315
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Hydraulic System
OUO6046,0002320 –19–18APR07–4/6
T14
2979
–UN
–24J
UL0
1
1—Nut (2 used)2—Retainer3—Cap Screw4—Boom Cylinder-to-Boom Pin5—Shim (2 used)6—Boom Cylinder
8. Remove parts (1—3, and 5).
9. Push pin (4) into boom.
10. Lower boom cylinder (6) on floor stand.
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86
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Hydraulic System
33336087
OUO6046,0002320 –19–18APR07–5/6
9
107 7
6
11
11
8 8
T14
3048
–UN
–02A
UG
01
6—Boom Cylinder7—Hydraulic Lines8—Shim (as required)9—Cap Screw (2 used)10—Boom Cylinder-to-Frame Pin (2 used)11—Nut (4 used)
11. Disconnect hydraulic lines (7) from head end of boomcylinder (6). Close all open lines and fitting using capsand plugs.
12. Mark location of shims (8) to aid in assembly.
13. Remove parts (8—11) and remove boom cylinder (6).
14. Repair or replace parts as necessary.
15. Install shims equally on each side of cylinder headend to get the minimum amount of clearance in joint.
16. Align pin bores so shims are not damaged as pin (10)is installed.
17. Connect boom cylinder head end to frame.
18. Tighten nuts (11) against each other allowing capscrews (9) to be free to turn in hole.
SpecificationBoom Cylinder-to-Frame PinRetainer Nut—Torque 270 N•m (tighten nut against nut)...........................
200 lb-ft (tighten nut against nut)
19. Connect lines. See Hydraulic System LineConnections. (Group 9025-15.)
20. Tighten boom cylinder hoses.
SpecificationBoom Cylinder Hose Fitting—36mm—Torque 175 N•m.............................................................................
130 lb-ft
SpecificationBoom Cylinder Hose Fitting—41mm—Torque 205 N•m.............................................................................
150 lb-ft
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PN=317
Hydraulic System
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88
OUO6046,0002320 –19–18APR07–6/6
IMPORTANT: Trapped air suddenly compressed in acylinder is heated and ignites the oilused for assembly causing cap seal andring damage. Start with cylinder rodretracted and the rod end filled withclean oil. Connect the cylinder head endand lines. Operate function to slowlyextend rod. Procedure will eliminatemost of the air and reduce thepossibility of damage.
21. Start engine.
22. Slowly extend boom cylinder (6) to align pin bores soshims (5) are not damaged as pin (4) is installed.
23. Install shims to get the minimum amount of clearancebetween boom and boom cylinder rod end.
24. Connect boom cylinder rod end to boom.
25. Tighten nuts (1) against each other allowing capscrew (3) to be free to turn in hole.
SpecificationBoom Cylinder-to-Frame PinRetainer Nut—Torque 550 N•m (tighten nut against nut)...........................
405 lb-ft (tighten nut against nut)
26. Connect lubrication line.
SpecificationBoom Cylinder Pivot LubricationLine—Torque 25 N•m..................................................................................
18 lb-ft
27. Lubricate all pivot joints. See Track Adjuster, WorkingTool Pivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)
28. Bleed air from cylinder. See Hydraulic Cylinder BleedProcedure. (Group 3360.)
29. Check hydraulic oil level. See Check Hydraulic TankOil Level. (Operator’s Manual.)
TM10091 (11JAN08) 33-3360-88 160DLC Excavator Repair011108
PN=318
Hydraulic System
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OUO6046,0002321 –19–05APR07–1/3
Boom Cylinder Disassemble and Assemble
TX
1004
546
–UN
–14M
AR
06
22
18141514
1010
1321
16 17
TX1004547
12 4
5
6
9 113 8 20
712 13
19
TX
1004
547
–UN
–14M
AR
06
1—Rod 7—Cylinder Head 13—Slide Ring (2 used) 18—Set Screw2—Dust Wiper 8—Bushing 14—Wear Ring (2 used) 19—Ball3—Backup Ring 9—Snap Ring 15—Backup Ring (2 used) 20—Piston Nut4—U-Ring 10—Backup Ring 16—O-Ring 21—Cushion Bearing5—Buffer Ring 11—O-Ring 17—Seal Ring 22—Cushion Seal6—Cap Screw (12 used) 12—Barrel
CAUTION: Heavy component; useappropriate lifting device.
SpecificationBoom Cylinder—ApproximateWeight 155 kg.......................................................................................
342 lb
1. Fasten head end of cylinder to JT30043 CylinderService Stand.
2. Pull rod out so piston nut is against cylinder head.
3. Connect rod to appropriate lifting device using alifting strap.
4. Remove cap screws (6) from cylinder head (7).
5. Remove rod, cylinder head and piston nut frombarrel (12).
TM10091 (11JAN08) 33-3360-89 160DLC Excavator Repair011108
PN=319
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Hydraulic System
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OUO6046,0002321 –19–05APR07–2/3
6. Install rod eye in sliding housing and install housingin JT30043 Cylinder Service Stand.
7. Make an alignment mark on piston nut (20) and rod(1).
8. Remove staked material from set screw (18) holeusing a small air grinder or a drill and bit.
9. Remove set screw (18) and steel ball (19).
IMPORTANT: To avoid damaging tapped hole forset screw, cap screw in ST3243 HexPiston Nut Wrench must betightened against a side of nutwithout tapped hole.
To avoid gouging side of nut, installa piece of steel flat stock betweennut and cap screw.
10. Install ST3243 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (20)without tapped hole.
11. Install a piece of steel flat stock between pistonnut and cap screw. Tighten cap screw of pistonnut wrench.
12. Remove piston nut (20) using JT30043 CylinderService Stand.
SpecificationBoom Cylinder Piston Nut—Torque 4000 N•m..................................................................................
2950 lb-ft
IMPORTANT: Note direction of oil groove incushion bearing (21) and notch incushion seal (22) for installation.
13. Remove cushion bearing (21) and cushion seal(22) from rod (1).
14. Remove components (13—17) from piston nut(20).
15. Remove cylinder head (7) from rod (1).
IMPORTANT: Note direction of dust wiper (2) andU-ring (4) for installation.
16. Remove components (2—5) and (9—11) fromcylinder head (7).
17. Remove bushing (8) using ST8019.
18. Inspect dust seals and bushings in rod (1) andbarrel (12) for wear or damage. Repair or replaceparts as necessary. See Inspect Pins, Bushingsand Bosses—Front Attachment. (Group 3340.)
19. Check for rod curvature on V-blocks using dialindicator.
SpecificationBoom Rod—Curvature 0.5 mm per 1 m..............................................
0.020 in. per 3.25 ft
20. Repair or replace parts as necessary.
21. Install bushing (8) into cylinder head (7) usingST8019. Press to bottom of bore.
22. Install snap ring (9).
23. Install backup ring (10) and O-ring (11).
24. Install buffer ring (5).
25. Install U-ring (4) with lip towards bushing (8).
26. Install backup ring (3).
27. Install dust wiper (2) using ST8019 with liptowards outside of cylinder.
28. Install assembled cylinder head (7) on rod (1)using ST8019.
29. Install O-ring (16) and seal ring (17) to piston nut(20) using ST2962 Installer. Adjust seal ring (17)using ST2205 Adjustment Tool.
30. Install backup rings (15) on each side of seal ring.
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PN=320
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Hydraulic System
OUO6046,0002321 –19–05APR07–3/3
31. Install wear rings (14) and slide rings (13) topiston nut (20).
IMPORTANT: Install cushion seal (22) so thatnotch is towards piston.
32. Install cushion seal (22).
IMPORTANT: Note direction of oil groove incushion bearing (21) duringinstallation.
33. Install cushion bearing (21).
34. Align marks made during disassembly and installpiston nut (20).
IMPORTANT: To avoid damaging tapped hole forset screw, cap screw in ST3243 HexPiston Nut Wrench must betightened against a side of nutwithout tapped hole.
To avoid gouging side of nut, installa piece of steel flat stock betweennut and cap screw.
35. Install ST3243 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (20)
without tapped hole. Install a piece of steel flatstock between nut and cap screw. Tighten capscrew of piston nut wrench. Tighten piston nut (20)to specification using JT30043 Cylinder ServiceStand.
SpecificationBoom Cylinder Piston Nut—Torque 4000 N•m..................................................................................
2950 lb-ft
36. Install steel ball (19) and set screw (18).
37. Stake set screw (18) in two places 90° fromprevious stake marks.
38. Apply clean oil to piston nut and seals. Attachappropriate lifting device to rod using a liftingstrap. Carefully install piston nut, rod and cylinderhead into barrel.
39. Install cylinder head cap screws (6). Tighten tospecification.
SpecificationBoom Cylinder Head-to-BarrelCap Screw—Torque 267 N•m..............................................................
197 lb-ft
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OUO6046,0002322 –19–05APR07–1/6
Arm Cylinder Remove and Install
T10
6031
–UN
–10J
AN
97
1. Park machine on firm, level surface.
2. Retract arm and bucket cylinders and lower bucket toground.
Continued on next page
TM10091 (11JAN08) 33-3360-91 160DLC Excavator Repair011108
PN=321
Hydraulic System
OUO6046,0002322 –19–05APR07–2/6
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
3. Push pressure release button (1).
4. Loosen arm cylinder hydraulic lines at frame end ofboom to release any residual pressure.
5. Disconnect lines. Close all open lines and fittings usingcaps and plugs.
OUO6046,0002322 –19–05APR07–3/6
T14
3063
–UN
–02A
UG
01
1—Arm Cylinder2—Boom3—Wood Block
6. Insert wood block (3) between arm cylinder (1) andboom (2).
CAUTION: Heavy component; use appropriatelifting device.
SpecificationArm Cylinder—Weight 205 kg....................................................................
452 lb
7. Attach arm cylinder to appropriate lifting device usinglifting straps.
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92
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TM10091 (11JAN08) 33-3360-92 160DLC Excavator Repair011108
PN=322
Hydraulic System
OUO6046,0002322 –19–05APR07–4/6
T14
3064
–UN
–02A
UG
01
1—Nut (2 used)2—Cap Screw3—Shim (as required)4—Arm Cylinder-to-Arm Pin
8. Remove parts (1 and 2).
NOTE: Note location of shims (3) to aid in assembly.
9. Push pin (4) out and remove shims.
10. Disconnect lubrication line.
Continued on next page
33336093
TM10091 (11JAN08) 33-3360-93 160DLC Excavator Repair011108
PN=323
Hydraulic System
333360
94
OUO6046,0002322 –19–05APR07–5/6
T14
3065
–UN
–02A
UG
01
1—Nut (2 used)2—Cap Screw3—Shim (as required)4—Arm Cylinder-to-Boom Pin
11. Remove parts (1 and 2).
NOTE: Note location of shims (3) to aid in assembly.
12. Push pin (4) out and remove shims.
13. Remove arm cylinder
14. Repair or replace parts as necessary.
15. Install shims equally on each side of cylinder to getminimum amount of clearance in joint. There must besome clearance in the joint.
16. Align pin bores so shims are not damaged as pin (4)is installed.
17. Connect lubrication line.
SpecificationArm Cylinder Pivot LubricationLine—Torque 25 N•m..................................................................................
18 lb-ft
18. Connect arm cylinder head end to boom.
19. Tighten nuts (1) against each other allowing capscrew (2) to be free to turn in hole.
SpecificationArm Cylinder-to-Boom PinRetainer Nut—Torque 550 N•m (tighten nut against nut)...........................
405 lb-ft (tighten nut against nut)
IMPORTANT: Trapped air suddenly compressed in acylinder is heated and ignites the oilused for assembly causing cap seal andring damage. Start with cylinder rodretracted and the rod end filled withclean oil. Connect the cylinder head endand lines. Operate function to slowlyextend rod. Procedure will eliminatemost of the air and reduce thepossibility of damage.
20. Slowly extend arm cylinder to align pin bores soshims are not damaged as pin is installed.
21. Connect arm cylinder rod end to arm.
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PN=324
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Hydraulic System
OUO6046,0002322 –19–05APR07–6/6
22. Tighten nuts (1) against each other allowing capscrew (2) to be free to turn in hole.
SpecificationArm Cylinder-to-Arm Pin RetainerNut—Torque 550 N•m (tighten nut against nut)..........................................
405 lb-ft (tighten nut against nut)
23. Connect lubrication line.
SpecificationArm Cylinder Pivot LubricationLine—Torque 25 N•m..................................................................................
18 lb-ft
24. Tighten arm cylinder hoses.
SpecificationArm Cylinder Hose Fitting—36mm—Torque 175 N•m.............................................................................
130 lb-ft
SpecificationArm Cylinder Hose Fitting—41mm—Torque 205 N•m.............................................................................
150 lb-ft
25. Lubricate all pivot joints. See Track Adjuster, WorkingTool Pivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)
26. Bleed air from cylinder. See Hydraulic Cylinder BleedProcedure. (Group 3360.)
27. Check hydraulic oil level. See Check Hydraulic TankOil Level. (Operator’s Manual.)
33336095
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PN=325
Hydraulic System
333360
96
OUO6046,000232A –19–09APR07–1/3
Arm Cylinder Disassemble and Assemble
TX
1004
548
–UN
–14M
AR
06
26 24
22181918
1010
1725
23 1621TX1004549
12 4
5
6
9 113 8 20
14
718
17
13
15
TX
1004
549
–UN
–14M
AR
06
1—Rod 8—Bushing 15—Cushion Seal 21—Seal Ring2—Dust Wiper 9—Snap Ring 16—Snap Ring 22—Set Screw3—Backup Ring 10—Backup Ring 17—Slide Ring (2 used) 23—Ball4—U-Ring 11—O-Ring 18—Wear Ring (2 used) 24—Piston Nut5—Buffer Ring 12—Barrel 19—Backup Ring (2 used) 25—Cushion Bearing6—Cap Screw (12 used) 13—Stopper (2 used) 20—O-Ring 26—Cushion Seal7—Cylinder Head 14—Cushion Bearing
CAUTION: Heavy component; useappropriate lifting device.
SpecificationArm Cylinder—ApproximateWeight 205 kg......................................................................................
452 lb
1. Fasten head end of cylinder to JT30043 CylinderService Stand.
2. Pull rod out so piston nut is against cylinder head.
3. Connect rod to appropriate lifting device using alifting strap.
4. Remove cap screws (6) from cylinder head (7).
5. Remove rod, cylinder head and piston nut frombarrel (12).
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PN=326
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Hydraulic System
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OUO6046,000232A –19–09APR07–2/3
IMPORTANT: Note direction of oil groove incushion bearing (14) and notch incushion seal (15) for installation.
6. Remove stopper (13), cushion bearing (14), cushionseal (15), and snap ring (16).
7. Install rod eye in sliding housing and install housingin JT30043 Cylinder Service Stand.
8. Make an alignment mark on piston nut (24) and rod(1).
9. Remove staked material from set screw (22) holeusing a small air grinder or a drill and bit.
10. Remove set screw (22) and steel ball (23).
IMPORTANT: To avoid damaging tapped hole forset screw, cap screw in ST3245 HexPiston Nut Wrench must betightened against a side of nutwithout tapped hole.
To avoid gouging side of nut, installa piece of steel flat stock betweennut and cap screw.
11. Install ST3245 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (24)without tapped hole.
12. Install a piece of steel flat stock between nut andcap screw. Tighten cap screw of piston nutwrench.
13. Remove piston nut (24) using JT30043 CylinderService Stand.
SpecificationArm Cylinder Piston Nut—Torque 5150 N•m..................................................................................
3799 lb-ft
IMPORTANT: Note direction of oil groove incushion bearing (25) and notch incushion seal (26) for installation.
14. Remove cushion bearing (25) and cushion seal(26) from rod (1).
15. Remove components (17—21) from piston nut(24).
16. Remove cylinder head (7) from rod (1).
IMPORTANT: Note direction of dust wiper (2) andU-ring (4) for installation.
17. Remove components (2—5) and (9—11) fromcylinder head (7).
18. Remove bushing (8) using ST8024.
19. Inspect dust seals and bushings in rod (1) andbarrel (12) for wear or damage. Repair or replaceparts as necessary. See Inspect Pins, Bushingsand Bosses—Front Attachment. (Group 3340.)
20. Check for rod curvature on V-blocks using dialindicator.
SpecificationArm Cylinder Rod—Curvature 0.5 mm per 1 m...................................
0.020 in. per 3.25 ft
21. Repair or replace parts as necessary.
22. Install bushing (8) into cylinder head (7) usingST8024. Press to bottom of bore.
23. Install snap ring (9).
24. Install backup ring (10) and O-ring (11).
25. Install buffer ring (5).
26. Install U-ring (4) with lip towards bushing (8).
27. Install backup ring (3).
28. Install dust wiper (2) using ST8024 with liptowards outside of cylinder.
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Hydraulic System
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29. Install assembled cylinder head (7) on rod (1)using ST8024.
30. Install O-ring (20) and seal ring (21) to piston nut(24) using ST2964 Installer. Adjust seal ring (21)using ST2208 Adjustment Tool.
31. Install backup rings (19) on each side of seal ring.
32. Install slide rings (17) and wear rings (18) topiston nut (24).
IMPORTANT: Install cushion seal (26) so thatnotch is towards piston.
33. Install cushion seal (26).
IMPORTANT: Note direction of oil groove incushion bearing (25) duringinstallation.
34. Install cushion bearing (25).
35. Align marks made during disassembly and installpiston nut (24).
IMPORTANT: To avoid damaging tapped hole forset screw, cap screw in ST3245 HexPiston Nut Wrench must betightened against a side of nutwithout tapped hole.
To avoid gouging side of nut, installa piece of steel flat stock betweennut and cap screw.
36. Install ST3245 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (24)
without tapped hole. Install a piece of steel flatstock between nut and cap screw. Tighten capscrew of piston nut wrench. Tighten piston nut (24)to specification using JT30043 Cylinder ServiceStand.
SpecificationArm Cylinder Piston Nut—Torque 5150 N•m..................................................................................
3799 lb-ft
37. Install steel ball (23) and set screw (22).
38. Stake set screw (22) in two places 90° fromprevious stake marks.
IMPORTANT: Install cushion seal (15) so thatnotch is towards piston.
39. Install snap ring (16) and cushion seal (15).
IMPORTANT: Note direction of oil groove incushion bearing (14) duringinstallation.
40. Install cushion bearing (14) and stopper (13).
41. Apply clean oil to piston nut and seals. Attachappropriate lifting device to rod using a liftingstrap. Carefully install piston nut, rod and cylinderhead into barrel.
42. Install cylinder head cap screws (6). Tighten tospecification.
SpecificationArm Cylinder Head-to-BarrelCap Screw—Torque 267 N•m..............................................................
197 lb-ft
TM10091 (11JAN08) 33-3360-98 160DLC Excavator Repair011108
PN=328
Hydraulic System
OUO6046,000232B –19–09APR07–1/5
Bucket Cylinder Remove and Install
T10
6031
–UN
–10J
AN
97T
X10
0680
7–U
N–2
1AP
R06
33336099
1—Bucket Cylinder2—End of Arm3—Wood Block
1. Park machine on firm, level surface.
2. Retract arm cylinder and bucket cylinder (1) and lowerbucket to ground. Position end of arm (2) on woodblock (3).
OUO6046,000232B –19–09APR07–2/5
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).
3. Push pressure release button (1).
Continued on next page
TM10091 (11JAN08) 33-3360-99 160DLC Excavator Repair011108
PN=329
Hydraulic System
OUO6046,000232B –19–09APR07–3/5
T14
3075
–UN
–02A
UG
01
1—Side and Center Links-to-Bucket Cylinder Pin2—Cap Screw3—Shim (as required)4—Bucket Cylinder Rod End-to-Bucket Section
Top Port Line5—Wood Block6—Nut (2 used)7—Side Link
4. Disconnect lines. Close all open lines and fittings usingcaps and plugs.
5. Connect center link to appropriate lifting device usinglifting strap.
6. Put wood block (5) between bucket cylinder and arm tohold cylinder up when pin (1) is removed.
7. Remove parts (2 and 6).
NOTE: Mark location of shims (3) to aid in assembly.
8. Push pin (1) out and remove shims (3).
Continued on next page
333360,100
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PN=330
Hydraulic System
333360,101
OUO6046,000232B –19–09APR07–4/5
2
1
3
5
4
6
T14
3076
–UN
–02A
UG
01
1—Bucket Cylinder Rod End Hose2—Bucket Cylinder3—Nut (2 used)4—Shim (as required)5—Cap Screw6—Bucket Cylinder-to-Arm Pin
CAUTION: Heavy component; use appropriatelifting device.
SpecificationBucket Cylinder—Weight 120 kg................................................................
265 lb
9. Disconnect bucket cylinder rod end hose (1).
10. Connect bucket cylinder (2) to appropriate liftingdevice using lifting strap.
11. Remove parts (3 and 5).
NOTE: Mark location of shims (4) to aid in assembly.
12. Push pin (6) out and remove shims (4).
13. Remove bucket cylinder.
14. Repair or replace parts as necessary. See BucketCylinder Disassemble and Assemble. (Group 3360.)
15. Install shims equally on each side of bucket cylinderhead end to get minimum amount of clearance injoint.
16. Align pin bores so shims are not damaged as pin isinstalled.
17. Connect bucket cylinder head end to arm.
18. Tighten nuts (3) against each other allowing capscrew (5) to be free to turn in hole.
SpecificationBucket Cylinder-to-Arm PinRetainer Nut—Torque 270 N•m (tighten nut against nut)...........................
200 lb-ft (tighten nut against nut)
19. Connect lines. See Hydraulic System LineConnections. (Group 9025-15.)
20. Tighten bucket cylinder hoses.
SpecificationBucket Cylinder Hose—Torque 175 N•m....................................................
130 lb-ft
TM10091 (11JAN08) 33-3360-101 160DLC Excavator Repair011108
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Hydraulic System
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OUO6046,000232B –19–09APR07–5/5
IMPORTANT: Trapped air suddenly compressed in acylinder is heated and ignites the oilused for assembly causing cap seal andring damage. Start with cylinder rodretracted and the rod end filled withclean oil. Connect the cylinder head endand lines. Operate function to slowlyextend rod. Procedure will eliminatemost of the air and reduce thepossibility of damage.
21. Start engine.
22. Slowly extend bucket cylinder to align pin bores soshims are not damaged as pin is installed.
23. Install shims equally on each side of cylinder rod endand side links to get minimum amount of clearance injoint.
24. Connect bucket cylinder head end to arm.
25. Tighten nuts against each other allowing cap screw tobe free to turn in hole.
SpecificationBucket Cylinder-to-Pin RetainerNut—Torque 550 N•m (tighten nut against nut)..........................................
405 lb-ft (tighten nut against nut)
26. Lubricate all pivot joints. See Track Adjuster, WorkingTool Pivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)
27. Bleed air from cylinder. See Hydraulic Cylinder BleedProcedure. (Group 3360.)
28. Check hydraulic oil level. See Check Hydraulic TankOil Level. (Operator’s Manual.)
TM10091 (11JAN08) 33-3360-102 160DLC Excavator Repair011108
PN=332
Hydraulic System
333360,103
OUO6046,000232C –19–09APR07–1/3
Bucket Cylinder Disassemble and Assemble
TX100455014 17 16 15 13
1 4 5
96
2 37
8 1011
12
13 20 15
1819 14
TX
1004
550
–UN
–09M
AR
06
TX1004551
1
16 17
2 4 5
3 8 9 10
12
11
13 14 14 13 20
18
19
15
76
TX
1004
551
–UN
–09M
AR
06
1—Rod 6—Cap Screw (12 used) 11—O-Ring 16—O-Ring2—Dust Wiper 7—Cylinder Head 12—Barrel 17—Seal Ring3—Backup Ring 8—Bushing 13—Slide Ring (2 used) 18—Set Screw4—U-Ring 9—Snap Ring 14—Wear Ring (2 used) 19—Ball5—Buffer Ring 10—Backup Ring 15—Backup Ring (2 used) 20—Piston Nut
CAUTION: Heavy component; useappropriate lifting device.
SpecificationBucket Cylinder—ApproximateWeight 120 kg......................................................................................
265 lb
1. Fasten head end of cylinder to JT30043 CylinderService Stand.
2. Pull rod out so piston nut is against cylinder head.
3. Connect rod to appropriate lifting device using alifting strap.
4. Remove cap screws (6) from cylinder head (7).
5. Remove rod, cylinder head and piston nut frombarrel (12).
6. Install rod eye in sliding housing and install housingin JT30043 Cylinder Service Stand.
7. Make an alignment mark on piston nut (20) and rod(1).
8. Remove staked material from set screw (18) holeusing a small air grinder or a drill and bit.
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Hydraulic System
333360,104
OUO6046,000232C –19–09APR07–2/3
9. Remove set screw (18) and steel ball (19).
IMPORTANT: To avoid damaging tapped hole forset screw, cap screw in ST3242 HexPiston Nut Wrench must betightened against a side of nutwithout tapped hole.
To avoid gouging side of nut, installa piece of steel flat stock betweennut and cap screw.
10. Install ST3242 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (20)without tapped hole.
11. Install a piece of steel flat stock between nut andcap screw. Tighten cap screw of piston nutwrench.
12. Remove piston nut (20) using JT30043 CylinderService Stand.
SpecificationBucket Cylinder Piston Nut—Torque 4280 N•m..................................................................................
3157 lb-ft
13. Remove components (13—17) from piston nut(20).
14. Remove cylinder head (7) from rod (1).
IMPORTANT: Note direction of dust wiper (2) andU-ring (4) for installation.
15. Remove components (2—5) and (9—11) fromcylinder head (7).
16. Remove bushing (8) using ST8018.
17. Inspect dust seals and bushings in rod (1) andbarrel (12) for wear or damage. Repair or replace
parts as necessary. See Inspect Pins, Bushingsand Bosses—Front Attachment. (Group 3340.)
18. Check for rod curvature on V-blocks using dialindicator.
SpecificationBucket Cylinder Rod—Curvature 0.5 mm per 1 m...................................................................
0.020 in. per 3.25 ft
19. Repair or replace parts as necessary.
20. Install bushing (8) into cylinder head (7) usingST8018. Press to bottom of bore.
21. Install snap ring (9).
22. Install backup ring (10) and O-ring (11).
23. Install buffer ring (5).
24. Install U-ring (4) with lip towards bushing (8).
25. Install backup ring (3).
26. Install dust wiper (2) using ST8018 with liptowards outside of cylinder.
27. Install assembled cylinder head (7) on rod (1)using ST8018.
28. Install O-ring (16) and seal ring (17) to piston nut(20) using ST2977 Installer. Adjust seal ring (17)using ST2332 Adjustment Tool.
29. Install backup rings (15) on each side of seal ring.
30. Install slide rings (13) and wear rings (14) topiston nut (20).
31. Align marks made during disassembly and installpiston nut (20).
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Hydraulic System
OUO6046,000232C –19–09APR07–3/3
IMPORTANT: To avoid damaging tapped hole forset screw, cap screw in ST3242 HexPiston Nut Wrench must betightened against a side of nutwithout tapped hole.
To avoid gouging side of nut, installa piece of steel flat stock betweennut and cap screw.
32. Install ST3242 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (20)without tapped hole. Install a piece of steel flatstock between nut and cap screw. Tighten capscrew of piston nut wrench. Tighten piston nut (20)to specification using JT30043 Cylinder ServiceStand.
SpecificationBucket Cylinder Piston Nut—Torque 4280 N•m..................................................................................
3157 lb-ft
.
33. Install steel ball (19) and set screw (18).
34. Stake set screw (18) in two places 90° fromprevious stake marks.
35. Apply clean oil to piston nut and seals. Attachappropriate lifting device to rod using a liftingstrap. Carefully install piston nut, rod and cylinderhead into barrel.
36. Install cylinder head cap screws (6). Tighten tospecification.
SpecificationBucket Cylinder Head-to-BarrelCap Screw—Torque 267 N•m..............................................................
197 lb-ft
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Hydraulic System
OUO6046,000232D –19–05APR07–1/1
Hydraulic Cylinder Bleed Procedure
IMPORTANT: Trapped air suddenly compressed in acylinder is heated and ignites the oilused for assembly causing cap seal andring damage. Start with cylinder rodretracted and the rod end filled withclean oil. Connect the cylinder head endand lines. Operate function to slowlyextend rod. Procedure will eliminatemost of the air and reduce thepossibility of damage.
NOTE: Bleed air at initial start-up, whenever major repairsor maintenance (oil change) is done on hydraulicsystem, or when machine has been in storage fora period of time.
1. Run engine at slow idle.
2. Slowly operate function to move cylinder to the mosthorizontal position possible.
3. Slowly extend and retract cylinder several times toapproximately 100 mm (4 in.) from end of stroke.
4. Operate cylinder several times to full stroke.
5. Check hydraulic oil level. See Check Hydraulic TankOil Level. (Operator’s Manual.)
333360,106
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Section 43Swing or Pivoting System
Contents
Page
Group 4350—Mechanical Drive ElementsSwing Gearbox Remove and Install . . . . . . .43-4350-1Swing Gearbox Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-4Swing Gearbox Start-Up Procedure . . . . . .43-4350-11Upperstructure Remove And Install . . . . . . .43-4350-11Swing Bearing Remove and Install . . . . . . .43-4350-14Swing Bearing Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .43-4350-16Swing Bearing Upper Seal Install . . . . . . . .43-4350-19Swing Bearing Lower Seal Install . . . . . . . .43-4350-20
Group 4360—Hydraulic SystemCenter Joint Remove and Install . . . . . . . . . .43-4360-1Center Joint Disassemble and Assemble . . .43-4360-4Center Joint Air Test . . . . . . . . . . . . . . . . . . .43-4360-5Swing Motor and Park Brake Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-6Swing Motor and Park Brake
Disassemble . . . . . . . . . . . . . . . . . . . . . .43-4360-10Swing Motor and Park Brake Inspection . . .43-4360-12Swing Motor and Park Brake Assemble . . .43-4360-14Swing Motor and Park Brake Start-Up
Procedure . . . . . . . . . . . . . . . . . . . . . . . .43-4360-16Crossover Relief Valve and Make-Up
Check Valve Remove and Install . . . . . . .43-4360-17Make-Up Check Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .43-4360-18Swing Park Brake Release Valve Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .43-4360-19
43
TM10091 (11JAN08) 43-1 160DLC Excavator Repair011108
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Contents
43
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Group 4350Mechanical Drive Elements
TJ15698,000013B –19–11APR07–1/3
Swing Gearbox Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Pull vacuum in hydraulic oil tank using vacuum pumpor drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) The approximatecapacity of hydraulic oil tank is 120.4 L (31.8 gal).
Continued on next page
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Mechanical Drive Elements
434350
2
TJ15698,000013B –19–11APR07–2/3
TX
1003
159A
–UN
–02F
EB
06
1—Cap Screw and Washer (14 used)2—Electrical Connector
3. Tag and disconnect lines from swing motor. Close allopen lines and fittings using caps and plugs.
CAUTION: Heavy component; use appropriatelifting device.
NOTE: Swing motor may be removed by itself or withswing gearbox. See Swing Motor and Park BrakeRemove and Install. (Group 4360.)
Mark swing gearbox housing to machineupperstructure to aid in installation.
4. Install JT01748 Lifting Brackets and connect toappropriate lifting device.
SpecificationSwing Motor, Brake, andGearbox—Weight 218 kg............................................................................
481 lb
5. Disconnect electrical connector (2).
6. Remove cap screws and washers (1).
7. Remove swing gearbox and motor.
8. Repair or replace parts as necessary. See SwingGearbox Disassemble and Assemble. (Group 4350.)
9. Apply PM38656 Thread Lock and Sealer (HighStrength) to mating surfaces of swing gearbox housingand upperstructure.
10. Install swing gearbox and motor.
11. Tighten cap screws.
SpecificationSwing Gearbox-to-UpperstructureCap Screw—Torque 500 N•m.....................................................................
369 lb-ft
12. Connect electrical connector (2).
13. Connect lines. See Hydraulic System LineConnections. (Group 9025-15.)
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Mechanical Drive Elements
TJ15698,000013B –19–11APR07–3/3
14. See Swing Gearbox Start-Up Procedure. (Group4350.) See Swing Motor and Park Brake Start-UpProcedure. (Group 4360.)
15. If hydraulic oil tank was drained, fill hydraulic oil tank.Approximate oil capacity is 120.4 L (31.8 gal).
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
16. If hydraulic oil tank was drained, perform pumpstart-up procedure. See Pump 1 and 2 Start-UpProcedure. (Group 3360.)
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Mechanical Drive Elements
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4
TJ15698,0000119 –19–11APR07–1/8
Swing Gearbox Disassemble and Assemble
TX
1018
815
–UN
–09F
EB
07
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Mechanical Drive Elements
4343505
TJ15698,0000119 –19–11APR07–2/8
0—Swing Gearbox 9—Plate 17—Spring Pin (3 used) 27—Needle Bearing (3 used)1—Shaft 10—Cap Screw 18—Second Stage Sun Gear 28—Thrust Plate (3 used)2—Sleeve 11—Second Planetary Pinion 20—Ring Gear Housing 29—Spring Pin (3 used)3—O-Ring Carrier 21—Cap Screw (12 used) 30—Snap Ring4—Roller Bearing 12—Washer 23—First Planetary Pinion 31—First Stage Sun Gear5—Seal 13—Pin (2 used) Carrier 33—Line6—Housing 14—Planetary Gear (3 used) 24—Thrust Plate 34—Fitting Plug (2 used)7—Roller Bearing 15—Needle Bearing (6 used) 25—Pin (3 used) 36—Fitting Plug8—Bearing Nut 16—Thrust Plate (3 used) 26—Planetary Gear (3 used)
1. Make alignment marks between swing motor, ringgear housing (20) and housing (6) to aid inassembly.
2. Remove swing motor. See Swing Motor and ParkBrake Remove and Install. (Group 4360.)
CAUTION: Heavy component; useappropriate lifting device.
SpecificationSwing Motor—Weight 48 kg.................................................................
105 lb
3. Remove first planetary pinion carrier assembly(23-29) from ring gear housing (20).
NOTE: First stage sun gear (31) may be removedseparately or along with carrier.
CAUTION: Heavy component; useappropriate lifting device.
SpecificationRing Gear—Weight 23 kg.....................................................................
50 lb
4. Remove cap screws (21) and ring gear housing(20).
5. Remove second planetary pinion carrier assembly(11-18).
NOTE: Second stage sun gear (18) may be removedseparately or with carrier.
6. Disassemble first planetary pinion carrier (23)assembly.
IMPORTANT: Hole for spring pin (29) located onfirst planetary pinion carrier (23) isnot a through hole.
7. Tap spring pin (29) into pin (25) until it reaches thecenter of pin (25).
8. Remove pin (25), planetary gear (26), needlebearing (27), and thrust plate (28) from first planetpinion carrier (23).
9. Inspect needle bearing (27) for wear.
10. Remove thrust plate (24) from carrier.
IMPORTANT: Damaging the surface of pin (25) cancause bearing failure, use care whenhandling pin.
11. Using wood blocks, clamp pin (25) in vise. Tapspring pin (29) out of pin.
12. Disassemble second planetary pinion carrier (11)assembly as in Steps 7-11.
13. Remove cap screws (10) and lock plate (9) frombearing nut (8).
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Mechanical Drive Elements
TJ15698,0000119 –19–11APR07–3/8
8
TX
1004
267
–UN
–01M
AR
06
8—Bearing Nut
14. Remove bearing nut (8) from shaft (1) using DFT1220Swing Gearbox Nut Spanner Wrench. See DFT1220Swing Gearbox Nut Spanner Wrench. (Group 9900.)
CAUTION: Heavy component; use appropriatelifting device.
SpecificationHousing Assembly—Weight 106 kg............................................................
234 lb
15. Install eyebolts into bolt hole on housing (6). Useappropriate lifting device and position housingassembly (6) onto press.
TJ15698,0000119 –19–11APR07–4/8
1
6
TX
1004
268
–UN
–01M
AR
06
1—Shaft6—Housing
NOTE: Bearing and sleeve are pressed onto shaft.
16. Using press, push upper end of shaft (1) and removefrom housing (6). Inner race of roller bearing (4) andsleeve (2) are removed with shaft (1).
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434350
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Mechanical Drive Elements
4343507
TJ15698,0000119 –19–11APR07–5/8
TX1004269
2
1
4
TX
1004
269
–UN
–19A
PR
06
1—Shaft2—Sleeve4—Roller Bearing
17. Inspect shaft (1), roller bearing (4), and sleeve (2).
18. If disassembly is necessary, use press and knife edgebearing puller to push upper end of shaft (1) andremove inner race of roller bearing (4) and sleeve (2).
19. Remove O-ring (3) from sleeve (2).
20. Insert a round bar into oil passage in housing (6). Tapand remove outer race of roller bearing (4).
21. Remove oil seal (5) from housing (6).
NOTE: Oil seal (5) can not be reused.
22. Remove outer race of roller bearing (7) from housing(6) using brass drift and hammer.
23. Repair or replace parts as necessary.
24. Install O-ring (3) in sleeve (2).
25. Install sleeve (2) and inner race of roller bearing (4) toshaft (1) using press and a piece of pipe.
26. Install outer race of roller bearing (4) into housing (6).
27. Apply PM38656 Thread Lock and Sealer (HighStrength) to OD of oil seal (5).
28. Install oil seal (5) so lip (spring side) is toward bottomof bore. Push seal to bottom of bore.
29. Apply grease to ID of oil seal (5).
30. Apply grease to outer surface of sleeve (2) on shaft(1).
CAUTION: Heavy component; use appropriatelifting device.
SpecificationHousing Assembly—Weight 65 kg..............................................................
143 lb
31. Install eyebolts into bolt holes in housing (6).
32. Using appropriate lifting device, slowly lift housing (6)assembly onto shaft (1).
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Mechanical Drive Elements
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8
TJ15698,0000119 –19–11APR07–6/8
IMPORTANT: Align carefully so as not to damage oilseal (5) lip.
33. Install inner race of roller bearing (7) onto shaft (1).
34. Tap inner race of roller bearing (7) until upper end ofinner race reaches two threads for bearing nut (8) onshaft (1).
35. Hand tighten bearing nut (8) to shaft (1) to retainshaft assembly.
36. Install eyebolts into ring gear housing (20) and liftonto housing (6).
37. Remove bearing nut (8) from shaft (1).
38. Press on inner race of roller bearing (7).
39. Apply film of grease on threaded surface of bearingnut (8). Install bearing nut (8) on shaft (1) withstepped side of bearing nut (8) towards roller bearing(7).
40. Tighten bearing nut (8) to specification. Use DFT1220Swing Gearbox Nut Spanner Wrench. See DFT1220Swing Gearbox Nut Spanner Wrench. (Group 9900.)
SpecificationBearing Nut—Torque 490 N•m....................................................................
360 lb-ft
41. Install lock plate (9) to bearing nut (8) with capscrews (10). Tighten to specification.
SpecificationLock Plate-to-Bearing Nut CapScrews—Torque 50 N•m.............................................................................
37 lb-ft
42. If lock plate (9) does not engage with splines of shaft(1), tighten bearing nut until lock plate engages.
43. Assemble planetary gears (14), needle bearings (15),and thrust plates (16).
44. Position gear assemblies (14, 15, 16) into secondplanetary pinion carrier (11).
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Mechanical Drive Elements
TJ15698,0000119 –19–11APR07–7/8
45. Align holes in pins (13) and planetary carrier (11).
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10
TJ15698,0000119 –19–11APR07–8/8
TX1004270
38
13
TX
1004
270
–UN
–19A
PR
06
13—Pin (2 used)38—Slit
46. Install spring pins (17) with slit (38) of spring pinstowards end of pins (13).
NOTE: Procedure for assembly of first and secondplanetary pinion carrier assemblies is identical.
47. Assemble first planetary pinion carrier (23) assemblyfollowing Step 43 through 46.
48. Align the spline of shaft (1) and install the secondplanetary carrier assembly (11).
49. Install thrust plate (12) with oil grooves towardssecond planet pinion carrier (11).
50. Install second stage sun gear (18) into secondplanetary pinion carrier (11) assembly with smallerdiameter of second stage sun gear upward.
51. Apply PM38656 Thread Lock and Sealer (HighStrength) to ring gear housing (20) mounting surfaceof housing (6).
52. Align mating marks and install ring gear housing (20)to housing (6).
53. Apply PM37418 Thread Lock and Sealer (MediumStrength) to cap screws (21). Tighten cap screws (21)to specification.
SpecificationRing Gear Housing-to-HousingCap Screw—Torque 210 N•m.....................................................................
155 lb-ft
54. Align spline of second stage sun gear (18) and installfirst planetary pinion carrier (23) assembly.
55. Install first stage sun gear (31) into first planetarypinion carrier (23) assembly with stepped side of sungear down.
56. Install swing motor. See Swing Motor and Park BrakeRemove and Install. (Group 4360.)
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Mechanical Drive Elements
TJ15698,000013C –19–11APR07–1/1
Swing Gearbox Start-Up Procedure
TX
1001
071A
–UN
–02D
EC
05
1—Dipstick2—Fill Cap
IMPORTANT: Swing gearbox will be damaged if notfilled with oil before operating swingfunction. Procedure must be performedwhenever a new swing gearbox isinstalled or oil has been drained fromthe gearbox.
1. Check that drain line plug is installed.
2. Remove fill cap (2) and add oil. See Swing Gearboxand Travel Gearbox Oils. (Operator’s Manual.)
3. Install fill cap. Check oil level on dipstick (1).
43435011
TJ15698,000017F –19–11APR07–1/4
Upperstructure Remove And Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
1. Clean machine thoroughly.
2. Disconnect negative battery cables.
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
3. Push pressure release button (1).
4. Drain hydraulic oil tank. Approximate capacity is 120.4L (31.8 gal).
5. Remove cab. See Cab Remove and Install. (Group1800.)
6. Remove counterweight. See Counterweight Removeand Install. (Group 1749.)
7. Remove boom. See Boom Remove and Install. (Group3340.)
8. Disconnect center joint hydraulic hoses and removestop. See Center Joint Remove and Install. (Group4360.)
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Mechanical Drive Elements
TJ15698,000017F –19–11APR07–2/4
T18
8539
–UN
–17M
AR
03T
1885
40–U
N–1
7MA
R03
CAUTION: Heavy component; use a hoist.
SpecificationUpperstructure—Weight 4500 kg approximate...........................................
9923 lb approximate
9. Attach chains to counterweight support beams andboom bracket.
IMPORTANT: Make sure chains do not touch engine.
43TJ15698,000017F –19–11APR07–3/4
T10
5961
–UN
–20D
EC
96
Swing Bearing
435012
A—Swing BearingB—Cap Screw (36 used)
10. Put matching marks on the upperstructure and outerrace of the swing bearing to aid in installation. Loosenand remove cap screws (B).
Continued on next page
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Mechanical Drive Elements
43435013
TJ15698,000017F –19–11APR07–4/4
T18
8541
–UN
–17M
AR
03
11. Lift upperstructure from undercarriage using hoist.
12. Repair or replace parts as necessary.
CAUTION: Heavy component; use a hoist.
SpecificationUpperstructure—Weight 4500 kg approximate...........................................
9923 lb approximate
13. Install upperstructure to undercarriage.
14. Align mark on the outer race of swing bearing withmark on upperstructure. Install DFT1144 Guide Pinsto help align holes in swing bearing with holes inupperstructure. See DFT1144 Guide Pin. (Group9900.)
15. Install cap screws (B).
16. Remove chains from upperstructure and tighten capscrews (B).
SpecificationSwing Bearing-to-UpperstructureCap Screws—Torque 510 N•m...................................................................
380 lb-ft
17. Connect center joint hydraulic hoses and install stop.See Center Joint Remove and Install. (Group 4360.)
18. Install boom. See Boom Remove and Install. (Group3340.)
19. Install counterweight. See Counterweight Removeand Install. (Group 1749.)
20. Install cab. See Cab Remove and Install. (Group1800.)
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Start-up procedure must be performedwhenever a new pump is installed or oilhas been drained from the pump orhydraulic oil tank.
21. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)
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Mechanical Drive Elements
TJ15698,0000125 –19–11APR07–1/2
Swing Bearing Remove and Install
T77
64A
B–U
N–0
7MA
Y92
C—JT01748 Lifting BracketsD—Cap Screw and Lock Washer
1. Remove upperstructure. See Upperstructure Removeand Install. (Group 4350.)
CAUTION: Heavy component; use appropriatelifting device.
SpecificationSwing Bearing—Weight 210 kg...................................................................
463 lb
2. Connect swing bearing to appropriate lifting deviceusing lifting brackets (C) such as JT01748 LiftingBrackets.
3. Remove cap screws and lock washers (D) and removeswing bearing.
4. Check and replace swing bearing upper and lowerseals if necessary. See Swing Bearing Upper SealInstall. (Group 4350.) See Swing Bearing Lower SealInstall. (Group 4350.)
5. Replace steel balls and ball supports as necessary.
6. Repair or replace parts as necessary.
7. Clean mating surfaces of swing bearing,upperstructure, and undercarriage.
434350
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Mechanical Drive Elements
TJ15698,0000125 –19–11APR07–2/2
T59
25A
A–U
N–1
1AP
R90
A—ToothB—Loading Plug
IMPORTANT: The tooth marked with the letter “G” or“S” or equivalent is the starting andstopping point for the hardeningprocess. The tooth and the bearingloading plug must be installed on theright side of the machine so the use ofthat part of the swing bearing isminimized.
8. Install swing bearing on undercarriage so tooth (A)marked “G” or “S” or equivalent and bearing loadingplug (B) is to right side of machine.
9. Install cap screws and lock washers and tighten.
SpecificationUndercarriage-to-Swing BearingCap Screw—Torque 510 N•m.....................................................................
376 lb-ft
10. Apply multi-purpose grease to swing bearing teethand pinion shaft. See Track Adjuster, Working ToolPivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)
11. Install upperstructure. See Upperstructure Removeand Install. (Group 4350.)
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Mechanical Drive Elements
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16
TJ15698,000011A –19–11APR07–1/5
Swing Bearing Disassemble and Assemble
TX
1000
479
–UN
–25J
AN
06
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Mechanical Drive Elements
TJ15698,000011A –19–11APR07–2/5
0—Outer Race 2—Steel Ball (121 used) 8—Lower Seal 10—Spacer (121 used)1—Inner Race 5—Lubrication Fitting (2 used) 9—Upper Seal 11—Swing Bearing
1. Check swing bearing upper seal (9) and lower seal(8). If damaged, replace. See Swing Bearing Upper
Seal Install. (Group 4350.) See Swing BearingLower Seal Install. (Group 4350.)
TJ15698,000011A –19–11APR07–3/5
T68
76F
I–U
N–0
7MA
Y92
43435017
A—Tack WeldB—Taper PinC—Loading Plug
2. Grind tack weld (A) off top of taper pin (B).
3. Drive taper pin out from bottom side of bearing.
4. Remove loading plug (C) using an M8-1.25 cap screw.
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Mechanical Drive Elements
TJ15698,000011A –19–11APR07–4/5
T68
76F
K–U
N–0
7MA
Y92
T77
63A
B–U
N–0
7MA
Y92
434350
18
A—Spacer (121 used)B—Steel Ball (121 used)
5. Remove steel balls (A) and spacers (B).
6. Turn inner race to remove remaining steel balls andspacers.
7. Lift outer race off inner race.
8. Replace parts as necessary.
9. Install spacers (B) and steel balls (A). Turn inner raceas needed to install spacers and steel balls.
TJ15698,000011A –19–11APR07–5/5
T68
76F
I–U
N–0
7MA
Y92
A—Tack WeldB—Taper PinC—Loading Plug
10. Install loading plug (C).
11. Install taper pin (B) even with top of swing bearing.
12. Tack weld pin (A) to swing bearing.
13. Add multi-purpose grease to swing bearing throughlubrication fittings. See Track Adjuster, Working ToolPivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)
TM10091 (11JAN08) 43-4350-18 160DLC Excavator Repair011108
PN=356
Mechanical Drive Elements
TJ15698,0000123 –19–11APR07–1/1
Swing Bearing Upper Seal Install
T59
25A
M–U
N–1
1AP
R90
A—Seal
1. Remove upperstructure. See Upperstructure Removeand Install. (Group 4350.)
2. Remove old seal (A).
3. Scrape old adhesive from seal groove. Thoroughlyclean seal groove and new seal using PM37509 CurePrimer.
4. Apply PM37391 Gel Super Glue sparingly to sealgroove.
5. Install seal with lip against inner bearing race. Startabout 76 mm (3 in.) from end of seal using bluntinstrument to force seal into groove. Push seal indirection of portion already installed to avoid stretchingseal.
6. Before bringing ends of seal together, cut off excesslength.
7. Apply PM37391 Gel Super Glue to both ends of seal.Push ends into seal groove making sure they cometogether.
IMPORTANT: To avoid pulling seal out of groove,adhesive must cure for at least 24hours before using swing function.
8. Install upperstructure. See Upperstructure Remove andInstall. (Group 4350.)
43435019
TM10091 (11JAN08) 43-4350-19 160DLC Excavator Repair011108
PN=357
Mechanical Drive Elements
TJ15698,0000124 –19–18APR07–1/1
Swing Bearing Lower Seal Install
T59
36B
A–U
N–1
7MA
Y89
A—SealB—Seal Groove
1. Remove upperstructure. See Upperstructure Removeand Install. (Group 4350.)
NOTE: Part of swing bearing shown cut away to showlower seal in groove.
2. Remove old seal (A).
3. Scrape old adhesive from seal groove (B). Thoroughlyclean seal groove and new seal using PM37509 CurePrimer.
4. Apply PM37391 Gel Super Glue sparingly to sealgroove.
5. Install seal with seal lip against outer race. Start about76 mm (3 in.) from end of seal using blunt instrumentto force seal into groove. Push seal in direction ofportion already installed to avoid stretching seal.
6. Before bringing ends of seal together, cut off excesslength.
7. Apply PM37391 Gel Super Glue to both ends of seal.Push ends into seal groove making sure they cometogether.
IMPORTANT: To avoid pulling seal out of groove,adhesive must cure for at least 24hours before using swing function.
8. Install upperstructure. See Upperstructure Remove andInstall. (Group 4350.)
434350
20
TM10091 (11JAN08) 43-4350-20 160DLC Excavator Repair011108
PN=358
Group 4360Hydraulic System
FS41334,0000144 –19–13APR07–1/4
Center Joint Remove and Install
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Disconnect battery ground (negative) cable.
3. Apply vacuum to hydraulic tank or drain hydraulic tank.See Apply Vacuum to Hydraulic Oil Tank. (Group3360). The approximate capacity of hydraulic oil tank is120.4 L (31.8 gal).
FS41334,0000144 –19–13APR07–2/4
TX
1020
553A
–UN
–19M
AR
07
4343601
1—Bracket2—Cap Screw (2 used)3—Hydraulic Line (4 used)4—Small Hydraulic Line (2 used)
4. Tag and disconnect upper hydraulic lines (3). Close allopen lines and fittings using caps and plugs.
5. Remove cap screws (2) and bracket (1).
6. Disconnect small hydraulic lines (4). Close all openlines and fittings using caps and plugs.
Continued on next page
TM10091 (11JAN08) 43-4360-1 160DLC Excavator Repair011108
PN=359
Hydraulic System
43FS41334,0000144 –19–13APR07–3/4
T76
85JC
–UN
–27A
PR
92
7. Attach the center joint to an appropriate lifting deviceusing a lifting strap. See Center Joint (Rotary Manifold)Lifting Tool (2 used). See (Group 9900.)
8. Tag and disconnect lower hydraulic lines. Close allopen lines and fittings using caps and plugs.
CAUTION: Heavy component; use appropriatelifting device.
SpecificationCenter Joint—Weight 27 kg........................................................................
60 lb
9. Remove four cap screws and lower center joint.
10. Replace parts as necessary. See Center JointDisassemble and Assemble. (Group 4360.)
11. Install center joint. Tighten four cap screws tospecifications.
SpecificationCenter Joint-to-Frame CapScrew—Torque 90 N•m...............................................................................
66 lb-ft
12. Install stop bracket. Tighten cap screws.
SpecificationStop Bracket-to-Frame CapScrew—Torque 140 N•m.............................................................................
103 lb-ft
13. Connect upper and lower hydraulic lines.
14. Fill and check hydraulic oil level. See 160DLC Drainand Refill Capacities. (Operator’s Manual.)
15. Connect battery ground (negative) cable.
43602
Continued on next page
TM10091 (11JAN08) 43-4360-2 160DLC Excavator Repair011108
PN=360
Hydraulic System
FS41334,0000144 –19–13APR07–4/4
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
16. If hydraulic oil tank was drained, perform pumpstart-up procedure. See Pump 1 and 2 Start-UpProcedure. (Group 3360.)
4343603
TM10091 (11JAN08) 43-4360-3 160DLC Excavator Repair011108
PN=361
Hydraulic System
434360
4
FS41334,0000143 –19–02MAR07–1/2
Center Joint Disassemble and Assemble
TX
1018
875
–UN
–12F
EB
07
1—Plug (Ball)2—Spindle3—Dust Seal4—O-Ring5—Bushing6—Oil Seal (6 used)7—Housing8—Ring9—Snap Ring10—O-Ring11—Cover12—Cap Screw (4 used)
CAUTION: Heavy component; use appropriatelifting device.
SpecificationCenter Joint—Weight 27 kg........................................................................
60 lb
1. Make alignment marks on spindle assembly (2),housing (7) and cover (11) to aid in assembly.
2. Remove cover (11), snap ring (9), and ring (8).
3. Install puller to housing (7) using cap screws (12).Carefully remove spindle assembly (2) from housing(7).
4. Remove plug (1) from spindle assembly and cleanport.
NOTE: Bushing (5) can be removed using built-up weld at4 places on its inner diameter, then quenchingbushing to shrink. Cover seal surfaces to protectfrom weld spatter.
5. Remove dust seal (3), bushing (5), and oil seals (6).
6. Inspect and repair or replace parts as necessary.
7. Install bushing (5) into housing (7) using a press.Lubricate bushing with grease or molybdenumdisulfide.
TM10091 (11JAN08) 43-4360-4 160DLC Excavator Repair011108
PN=362
Continued on next page
Hydraulic System
FS41334,0000143 –19–02MAR07–2/2
IMPORTANT: Install dust seal (3) with lip side towardhousing (7).
8. Install dust seal (3) onto spindle (2).
9. Install O-ring (4) and oil seals (6) into housing (7).
IMPORTANT: Install spindle assembly (2) slowly intohousing (7) so oil seals (6) are notdamaged.
10. Lubricate spindle assembly (2) with hydraulic oil andinstall into housing (7). Align reference marks madeduring disassembly.
IMPORTANT: Install ring (8) with chamfered sidefacing spindle assembly (2).
11. Install parts (8—12), aligning reference marks madeduring disassembly.
12. Tighten cap screws (12) to specification.
SpecificationCover-to-Housing Cap Screw—Torque 49 N•m............................................................................................
36 lb-ft
13. Install plug (1).
4343605
FS41334,0000142 –19–02MAR07–1/1
Center Joint Air Test
T65
57JB
–UN
–01N
OV
88
1. Install a plug in one port of a selected passage.
2. Apply shop air pressure, using JDG185 Air Test Plug,to the other port in that passage.
3. Listen for air leaks at other ports on either side ofcenter joint.
4. Repeat test for other passages.
5. Repair or replace if leaks are found. See Center JointDisassemble and Assemble. (Group 4360.)
TM10091 (11JAN08) 43-4360-5 160DLC Excavator Repair011108
PN=363
Hydraulic System
TJ15698,000013D –19–11APR07–1/3
Swing Motor and Park Brake Remove andInstall
TX
1020
196A
–UN
–07M
AR
07
1—Pressure Release Button2—Hydraulic Oil Tank Cover
CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).
1. Push pressure release button (1).
2. Apply vacuum to hydraulic tank or drain hydraulic tank.See Apply Vacuum to Hydraulic Tank. (Group 3360).The approximate capacity of hydraulic oil tank is 120.4L (31.8 gal).
Continued on next page
434360
6
TM10091 (11JAN08) 43-4360-6 160DLC Excavator Repair011108
PN=364
Hydraulic System
43TJ15698,000013D –19–11APR07–2/3
TX
1003
156A
–UN
–19A
PR
06
1—Electrical Connector2—Hydraulic Line3—Main Hydraulic Line4—Hydraulic Line5—Cap Screw (8 used)6—Swing Dampener Valve Hydraulic Lines
3. Tag and disconnect hydraulic lines (2, 3, 4, and 6).
4. Close all open lines and fittings using caps and plugs.
5. Disconnect electrical connector (1).
CAUTION: Heavy component; use appropriatelifting device.
SpecificationSwing Motor and Park Brake—Weight 48 kg................................................................................................
105 lb
6. Remove cap screws (5) to remove swing motor andpark brake.
7. Repair or replace parts as necessary. See SwingMotor and Park Brake Disassemble. (Group 4360.)
8. Install swing motor and park brake.
9. Tighten cap screws (5).
SpecificationSwing Motor-to-Ring Gear CapScrew—Torque 90 N•m...............................................................................
67 lb-ft
10. Connect electrical connector (1).
11. Connect lines. See Hydraulic System LineConnections. (Group 9025-15.)
12. See Swing Motor and Park Brake Start-Up Procedure.(Group 4360.)
13. Check oil level in hydraulic oil tank. See CheckHydraulic Tank Oil Level. (Operator’s Manual). Add oilif necessary. See Hydraulic Oil. (Operator’s Manual).
43607
Continued on next page
TM10091 (11JAN08) 43-4360-7 160DLC Excavator Repair011108
PN=365
Hydraulic System
TJ15698,000013D –19–11APR07–3/3
IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.
14. If hydraulic oil tank was drained, perform pumpstart-up procedure. See Pump 1 and 2 Start-UpProcedure. (Group 3360.)
434360
8
TM10091 (11JAN08) 43-4360-8 160DLC Excavator Repair011108
PN=366
Hydraulic System
4343609
TM10091 (11JAN08) 43-4360-9 160DLC Excavator Repair011108
PN=367
Hydraulic System
434360
10
TJ15698,000011B –19–16FEB07–1/2
Swing Motor and Park Brake Disassemble
TX
1000
252
–UN
–28N
OV
05
TM10091 (11JAN08) 43-4360-10 160DLC Excavator Repair011108
PN=368
Continued on next page
Hydraulic System
43436011
TJ15698,000011B –19–16FEB07–2/2
0—Hydraulic Motor 14—Shoe Plate 43—Fitting Plug (2 used) 76—O-Ring1—Piston (9 used) 15—Valve Plate 44—Make-Up Check Valve 77—O-Ring5—Crossover Relief Valve (2 20—Swing Motor Cover Plug (2 used) 78—Spring (24 used)
used) 30—Housing 45—O-Ring 79—Friction Plates (3 used)8—Piston 35—Poppet (2 used) 47—O-Ring (2 used) 81—Pipe Plug (2 used)10—Shaft 36—Spring (2 used) 48—O-Ring (2 used) 85—Seal Kit11—Cylinder Block 40—Cap Screw (4 used) 49—Seal 87—Spring12—Retainer 41—Roller Bearing 70—Brake Piston 88—Ball13—Plate 42—Roller Bearing 73—Plates (4 used) 89—Packing
IMPORTANT: Do not disassemble crossover reliefvalve (5).
1. Remove crossover relief valves (5) from swingmotor cover (20).
2. Remove make-up check valve plugs (44).
3. Remove springs (36) and poppets (35).
CAUTION: Heavy component; useappropriate lifting device.
SpecificationSwing Motor and Park Brake—Weight 48 kg.........................................................................................
105 lb
CAUTION: Swing motor housing and swingmotor cover is under spring pressure.Remove cap screws evenly to release springforce.
4. Mark alignment of swing motor housing (30) andswing motor cover (20) assembly. Loosen capscrews (40).
IMPORTANT: Do not remove roller bearing (42)unless necessary.
IMPORTANT: Valve plate (15) has a polishedsurface. Valve plate may remain onswing motor cover (20) or stay withcylinder block (11). Valve plate maybe damaged if dropped. Hold valveplate during disassembly.
5. Remove valve plate (15) from cylinder block (11).
6. Remove O-ring (45).
7. Remove springs (78).
8. Remove brake piston (70).
9. Remove O-rings (76, 77) from housing (30).
10. Remove parts (1, 13 and 12) from shaft (10).
11. Remove plates (73) and friction plates (79).
IMPORTANT: Do not damage sliding surface ofshoe plate (14).
12. Remove shoe plate (14).
13. Remove shaft (10) from housing (30) using aplastic hammer.
14. Push out oil seal (49) and remove outer race ofroller bearing (41) from housing (30).
15. Remove inner race of roller bearing (41) fromshaft (10) using a press.
NOTE: Filter and orifice are mounted inside of piston(8). Unless clogged or deformed, do notdisassemble. Do so only when absolutelyneeded. If internal parts need to be replaced,replace piston (8) as an assembly.
16. Remove swing park brake release valve piston (8),packing (89), spring (87), and ball (88).
NOTE: Use seal kit (85) to replace seals and O-rings.
17. Replace parts as necessary.
TM10091 (11JAN08) 43-4360-11 160DLC Excavator Repair011108
PN=369
Hydraulic System
TJ15698,000011C –19–29MAR07–1/4
Swing Motor and Park Brake Inspection
T14
2067
–UN
–22J
UN
01
1. Measure clearance between outer diameter of pistonand inner bore of cylinder.
SpecificationPiston-to-Cylinder—Clearance 0.027 mm new...........................................
0.001 in. new0.052 mm maximum used0.0020 in. maximum used
434360
12
TJ15698,000011C –19–29MAR07–2/4
T14
2069
–UN
–22J
UN
01
2. Measure clearance between piston and slipper.
SpecificationPiston-to-Slipper—Clearance 0.0 mm new.................................................
0.0 in. new0.3 mm maximum used
0.0117 in. maximum used
TM10091 (11JAN08) 43-4360-12 160DLC Excavator Repair011108
PN=370
Continued on next page
Hydraulic System
TJ15698,000011C –19–29MAR07–3/4
T14
2072
–UN
–22J
UN
01
Slipper Thickness
3. Measure thickness of slipper.
SpecificationSlipper—Thickness 5.5 mm new.................................................................
0.214 in. new5.3 mm minimum
0.207 in. minimum
TJ15698,000011C –19–29MAR07–4/4
T14
2073
–UN
–22J
UN
01
Friction Plate Thickness
4. Measure thickness of friction plate.
SpecificationFriction Plate—Thickness 2.0 mm new.......................................................
0.078 in. new1.8 mm minimum
0.070 in. minimum
43436013
TM10091 (11JAN08) 43-4360-13 160DLC Excavator Repair011108
PN=371
Hydraulic System
434360
14
TJ15698,000011D –19–16FEB07–1/3
Swing Motor and Park Brake Assemble
TX
1000
252
–UN
–28N
OV
05
Swing Motor and Park Brake
TM10091 (11JAN08) 43-4360-14 160DLC Excavator Repair011108
PN=372
Continued on next page
Hydraulic System
43436015
TJ15698,000011D –19–16FEB07–2/3
0—Hydraulic Motor 14—Shoe Plate 43—Fitting Plug (2 used) 76—O-Ring1—Piston (9 used) 15—Valve Plate 44—Make-Up Check Valve 77—O-Ring5—Crossover Relief Valve (2 20—Swing Motor Cover Plug (2 used) 78—Spring (24 used)
used) 30—Housing 45—O-Ring 79—Friction Plate (3 used)8—Piston 35—Poppet (2 used) 47—O-Ring (2 used) 81—Pipe Plug (2 used)10—Shaft 36—Spring (2 used) 48—O-Ring (2 used) 85—Seal Kit11—Cylinder Block 40—Cap Screw (4 used) 49—Seal 87—Spring12—Retainer 41—Roller Bearing 70—Brake Piston 88—Ball13—Plate 42—Roller Bearing 73—Plate (4 used) 89—Packing
1. Install ball (88), spring (87), packing (89), andpiston (8) into housing (30).
IMPORTANT: Install inner race of roller bearing(41) with flange facing step side ofshaft (10).
2. Install inner race of roller bearing (41) onto shaft(10) using a press.
3. Install oil seal (49) to housing (30).
4. Install outer race of roller bearing (41) to housing(30).
IMPORTANT: Wind tape onto spline end of shaft(10) to prevent damage to oil seal(49).
5. Install shaft (10) into housing (30).
6. Install shoe plate (14) to housing (30) withchamfered surface toward housing.
7. Align notches on plate (13) and retainer (12). Installpistons (1).
8. Install retainer (12) and plate (13) to pistons (1) withnotches facing shoe plate (14).
9. Apply hydraulic oil into piston holes in cylinder block(11).
10. Insert piston (1) assembly into cylinder block (11).
11. Install cylinder block (11) assembly to shaft (10).
IMPORTANT: There are four notches on outer sideof plates (73) and four notches on
spline teeth side of friction plates(79).
IMPORTANT: Align each notch when installing.
12. Alternately install plates (73) and friction plates(79) to housing (30).
13. Install O-rings (76, 77) to housing (30).
14. Align mating marks and install brake piston (70).
15. Install springs (78) to brake piston (70).
NOTE: Do step 15 only if bearing (42) was removed.
16. Install roller bearing (42) into swing motor cover(20) using plastic hammer.
17. Install O-ring (45) to swing motor cover (20).
18. Install valve plate (15) to swing motor cover (20)with notch in port facing toward cylinder block(11).
19. Apply grease to valve plate (15) to help retain toswing motor cover (20).
20. Apply grease to roller bearing (42) ID to easeshaft (10) installation.
21. Align mating marks on swing motor cover (20) andhousing (30). Install cap screws (40) and tighten tospecification.
SpecificationSwing Motor Cover-to-HousingCap Screw—Torque 431 N•m..............................................................
318 lb-ft
TM10091 (11JAN08) 43-4360-15 160DLC Excavator Repair011108
PN=373
Continued on next page
Hydraulic System
TJ15698,000011D –19–16FEB07–3/3
22. Install poppets (35) and spring (36). Tightenmake-up check valve plug (44) with O-ring (48)attached.
SpecificationMake-Up Check Valve Plug—Torque 334 N•m....................................................................................
246 lb-ft
23. Install crossover relief valves (5) into swing motorcover (20).
SpecificationCrossover Relief Valve—Torque 177 N•m....................................................................................
131 lb-ft
TJ15698,000013E –19–11APR07–1/1
Swing Motor and Park Brake Start-UpProcedure
TX
1003
231A
–UN
–02F
EB
06
1—Hydraulic Line
IMPORTANT: Swing motor will be damaged if notfilled with oil before operating swingfunction. Start-up procedure must beperformed whenever a new swing motoris installed or oil has been drained fromthe motor.
NOTE: Procedure is to ensure swing motor is filled withoil.
1. Disconnect swing motor hydraulic line (1).
2. Fill motor through port until oil reaches level of port.See Hydraulic Oil. (Operator’s Manual.)
NOTE: Air must be allowed to escape from the swingmotor while filling.
3. Connect hydraulic line (1).
434360
16
TM10091 (11JAN08) 43-4360-16 160DLC Excavator Repair011108
PN=374
Hydraulic System
TJ15698,000013F –19–11APR07–1/3
Crossover Relief Valve and Make-Up Check Valve Remove and Install
4
31
2
T139645
T13
9645
–UN
–30A
PR
01
1—Make-Up Check Valve 2—Make-Up Check Valve 3—Crossover Relief Valve 4—Crossover Relief Valve
43436017
TJ15698,000013F –19–11APR07–2/3
TX
1003
161A
–UN
–02F
EB
06
1—Crossover Relief Valve (2 used)
Remove and Install Crossover Relief Valve
1. Remove crossover relief valves (1).
2. Replace crossover relief valves (1) as necessary.
3. Install crossover relief valves (1). Tighten tospecification.
SpecificationCrossover Relief Valve—Torque 177 N•m..................................................
130 lb-ft
4. Check crossover relief valve pressure setting. SeeSwing Motor Crossover Relief Valve Test andAdjustment. (Group 9025-25.)
TM10091 (11JAN08) 43-4360-17 160DLC Excavator Repair011108
PN=375
Continued on next page
Hydraulic System
TJ15698,000013F –19–11APR07–3/3
TX
1003
232A
–UN
–02F
EB
06
1—Make-Up Check Valve (2 used)
Remove and Install Make-Up Check Valve
1. Remove make-up check valves (1).
2. Repair or replace parts as necessary. See Make-UpCheck Valve Disassemble and Assemble. (Group4360.)
3. Install make-up check valves (1). Tighten tospecification.
SpecificationMake-Up Check Valve—Torque 334 N•m...................................................
245 lb-ft
TJ15698,0000140 –19–11APR07–1/2
Make-Up Check Valve Disassemble andAssemble
TX
1003
721A
–UN
–16F
EB
06
1—Make-Up Check Valve (2 used)
1. Remove make-up check valves (1). See CrossoverRelief Valve and Make-Up Check Valve Remove andInstall. (Group 4360.)
Continued on next page
434360
18
TM10091 (11JAN08) 43-4360-18 160DLC Excavator Repair011108
PN=376
Hydraulic System
TJ15698,0000140 –19–11APR07–2/2
TX
1003
722
–UN
–16F
EB
06
43436019
1—Make-Up Check Valve Plug (2 used)2—O-Ring (2 used)3—Spring (2 used)4—Poppet (2 used)5—Cap Screw (4 used)6—Swing Motor Top Plate7—O-Ring
2. Examine O-rings (2), springs (3), and poppets (4) forwear and damage.
3. Replace parts as necessary.
4. Install O-rings (2), springs (3), poppets (4), andmake-up check valve plugs (1).
5. Tighten make-up check valve plugs (1) to specification.See Crossover Relief Valve and Make-Up Check ValveRemove and Install. (Group 4360.)
TJ15698,0000120 –19–11APR07–1/1
Swing Park Brake Release Valve Removeand Install
NOTE: Swing park brake release valve is internallylocated in swing motor. See Swing Motor andPark Brake Disassemble. See Swing Motor andPark Brake Assemble. (Group 4360.)
TM10091 (11JAN08) 43-4360-19 160DLC Excavator Repair011108
PN=377
Hydraulic System
434360
20
TM10091 (11JAN08) 43-4360-20 160DLC Excavator Repair011108
PN=378
Section 9999Dealer Fabricated Tools
Contents
Page
Group 9900—Dealer Fabricated ToolsDF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-1ST4920 Track Recoil Spring Disassembly
and Assembly Tool . . . . . . . . . . . . . . . . . .99-9900-3DFT1087 Track Recoil Spring
Disassembly and Assembly Guard Tool. . .99-9900-7DFT1110 Spacer. . . . . . . . . . . . . . . . . . . . . .99-9900-8DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .99-9900-9DFT1036A Travel Gearbox Nut Wrench . . .99-9900-10DF1038 Torque Adapter . . . . . . . . . . . . . . .99-9900-11DFT1109 Holding Bar . . . . . . . . . . . . . . . . .99-9900-12Center Joint (Rotary Manifold) Lifting
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-13DFT1144 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-13DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-14DFT1220 Swing Gearbox Nut Spanner
Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-16
TM10091 (11JAN08) 99-1 160DLC Excavator Repair011108
PN=1
Contents
99
TM10091 (11JAN08) 99-2 160DLC Excavator Repair011108
PN=2
Group 9900Dealer Fabricated Tools
9999001
TJ15698,0000106 –19–16FEB07–1/2
DF1063 Lift Bracket
T83
18A
C–U
N–2
0SE
P94
Tool is the same as used on other machines. Only the liftbracket of the tool is used for this machine with adapterDFT1130.
Lift Bracket is used to remove and install travel motor.
Material required:
• 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16in.) Square Tube
• 1.3 mm (1/2 in.) 1020 Steel Plate• 1 mm x 38.1 mm (3/8 in. x 1-1/2 in.) Cap Screw with
Nut (4 used)
Continued on next page
TM10091 (11JAN08) 99-9900-1 160DLC Excavator Repair011108
PN=381
Dealer Fabricated Tools
999900
2
TJ15698,0000106 –19–16FEB07–2/2
T72
47B
W–1
9–25
AP
R90
TM10091 (11JAN08) 99-9900-2 160DLC Excavator Repair011108
PN=382
Dealer Fabricated Tools
9999003
TJ15698,0000107 –19–13APR07–1/4
ST4920 Track Recoil Spring Disassembly andAssembly Tool
T65
85U
Y–U
N–2
4MA
R98
A—Nut (12 used)B—Stud (4 used)C—HolderD—Eyebolt (2 used)E—Supporting PlateF—Base PlateG—Base (4 used)H—Cap Screw (4 used)I—Lock Washer (8 used)
NOTE: It is recommended that DFT1087 Track RecoilSpring Disassembly and Assembly Guard Tool beused with track recoil spring disassembly andassembly tool. See DFT1087 Track Recoil SpringDisassembly and Assembly Guard Tool. (Group9900.)
Dimensions given are metric.
Tool is the same as used on other machines except theholder (C). For each track adjuster use the holder with thecorrect size hole for the nut on that track adjuster.
Track Recoil Spring Disassembly and Assembly Tool(compression tool) is used with hydraulic jack to compressrecoil 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),and Cap Screws (H).
• “F” Grade (SAE Grade 8) for Studs (B).
Print Numbers:
• A-ST4050 Nut• B-ST4045 Bolt• C-ST4035 Holder (Plate)• C-ST4036 Holder (Plate)• C-ST4037 Holder (Plate)• D-ST4047 Eyebolt• E-ST4040 Supporting Base• F-ST4042 Base Plate• G-ST4041 Base• H-ST4046 Cap Screw• I-ST4049 Lock Washer
Continued on next page
TM10091 (11JAN08) 99-9900-3 160DLC Excavator Repair011108
PN=383
Dealer Fabricated Tools
999900
4
TJ15698,0000107 –19–13APR07–2/4
T70
29C
I–U
N–0
6JU
L89
Continued on next page
TM10091 (11JAN08) 99-9900-4 160DLC Excavator Repair011108
PN=384
Dealer Fabricated Tools
9999005
TJ15698,0000107 –19–13APR07–3/4
T70
29C
H–U
N–0
6JU
L89
TM10091 (11JAN08) 99-9900-5 160DLC Excavator Repair011108
PN=385
Continued on next page
Dealer Fabricated Tools
999900
6
TJ15698,0000107 –19–13APR07–4/4
T70
29C
G–U
N–0
6JU
L89
TM10091 (11JAN08) 99-9900-6 160DLC Excavator Repair011108
PN=386
Dealer Fabricated Tools
9999007
TJ15698,0000108 –19–13APR07–1/1
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
T71
62A
F–U
N–1
7OC
T89
A—3/16 in. 1020 CR Steel Plate C—1/2 in. Nut (2 used) D—1/2 x 2 in. Cap Screw (2 E—1/2 x 3 in. Steel RoundB—9/16 in. Hole (2 places) used) Stock (2 used)
Track Disassembly and Assembly Guard Tool is usedwith ST4920 Track Recoil Spring Disassembly andAssembly Tool. See ST4920 Track Recoil SpringDisassembly and Assembly Tool. (Group 9900.)
Material required:
• 3/16 in. 1020 CR Steel Plate (A)• 9/16 in. Hole (2 places) (B)• 1/2 in. Nut (2 used) (C)• 1/2 x 2 in. Cap Screw (D) (2 used)• 1/2 x 3 in. Steel Round Stock (E) (2 used)
TM10091 (11JAN08) 99-9900-7 160DLC Excavator Repair011108
PN=387
Dealer Fabricated Tools
999900
8
TJ15698,0000109 –19–13APR07–1/1
DFT1110 Spacer
T77
08A
C–U
N–2
3FE
B92
Spacer is used with ST4920 Track Recoil SpringDisassembly and Assembly Tool. Spacer is installedon the bottom plate so force is applied to spring flangeon cylinder and not to the piston. See ST4920 TrackRecoil Spring Disassembly and Assembly Tool. (Group9900.)
Cut the ends of spacer so they are parallel to eachother.
Material Required:
• 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) HeavyWall Steel Pipe
TM10091 (11JAN08) 99-9900-8 160DLC Excavator Repair011108
PN=388
Dealer Fabricated Tools
9999009
TJ15698,000010A –19–16FEB07–1/1
DFT1130 Adapter
T83
19B
N–U
N–2
0SE
P94
A—Adapter Plate B—Tube C—Stop Plate
Adapter is used with DF1063 Lift Bracket to removeand install travel motor.
Material required:
• 1.3 mm (1/2 in.) 1020 Steel Plate (A)• 38.1 mm x 38.1 mm x .48 mm (1-1/2 in. x 1-1/2 in. x
3/16 in.) Square Tube (B)• .6 mm (1/4 in.) 1020 Steel Plate (C)
TM10091 (11JAN08) 99-9900-9 160DLC Excavator Repair011108
PN=389
Dealer Fabricated Tools
999900
10
TJ15698,000010B –19–13APR07–1/1
DFT1036A Travel Gearbox Nut Wrench
T76
81F
Z–U
N–2
8FE
B92
Travel Gearbox Nut Wrench is used to remove andinstall the hub-to-housing nut in the travel gearbox.
Material required:
• 16 mm (5/8 in.) Flat Bar Stock• M24 (1 in.) Nut• M10-1.5 x 60 mm Cap Screw (2 used)• M10-1.5 Nut (2 used)
TM10091 (11JAN08) 99-9900-10 160DLC Excavator Repair011108
PN=390
Dealer Fabricated Tools
99990011
TJ15698,000010C –19–13APR07–1/1
DF1038 Torque Adapter
T65
57C
H–U
N–2
5OC
T95
Torque Adapter is used to check rolling drag torque onrotor drive shaft.
Material required:
• 17 mm (0.125 in.) hex head driver
TM10091 (11JAN08) 99-9900-11 160DLC Excavator Repair011108
PN=391
Dealer Fabricated Tools
999900
12
TJ15698,000010D –19–11APR07–1/1
DFT1109 Holding Bar
T76
90A
A–U
N–2
7FE
B92
Holding Bar is used with the DF1036A Travel GearboxNut Wrench as a guide when loosening thehub-to-housing nut in the travel gearbox. SeeDF1036A Travel Gearbox Nut Wrench. (Group 9900.)
Material required:
• 16 mm (5/8 in.) Flat Bar Stock
TM10091 (11JAN08) 99-9900-12 160DLC Excavator Repair011108
PN=392
Dealer Fabricated Tools
99990013
TJ15698,000010E –19–13APR07–1/1
Center Joint (Rotary Manifold) Lifting Tool
T66
41D
O–U
N–2
4OC
T88
A—Threads
Tool is used to remove and install center joint.
Drill and tap disk in fitting cap to M8-1.25 mm threads (A).
Material required:
• 38H1416 Cap (—12)• M8-1.25 Lifting Eyebolt such as JT05548 Metric Lifting
Eyebolt
TJ15698,000010F –19–13APR07–1/1
DFT1144 Guide Pin
T66
41E
K–U
N–2
4OC
T88
A—230 mm (9 in.)B—100 mm (4 in.)
Guide pin is used to align cap screw holes in swingbearing and upperstructure.
Remove threads for a distance (B) and then grind a taperon same end.
Material Required:
• M20-2.5 x 230 mm (9 in.) Threaded Rod
TM10091 (11JAN08) 99-9900-13 160DLC Excavator Repair011108
PN=393
Dealer Fabricated Tools
999900
14
TJ15698,0000110 –19–30APR07–1/1
DFT1119 Pump Support
TX1022920
610 mm(24 in.)
76.2 x 76.2 x 6.35 mm(3 x 3 x 0.250 in.)
88.9 x 88.9 x 6.35 mm(3.5 x 3.5 x 0.250 in.)
63.5 x 63.5 x 6.35 mm(2.5 x 2.5 x 0.250 in.)
38 mm (1.5 in.)
104.8 mm (4.125 in.)165 mm (6.5 in.)376 mm (14.8 in.)
233 mm (9.2 in.)
335 mm (13.2 in.)
76 mm (3 in.)152 mm (6 in.)229 mm (9 in.)305 mm (12 in.)380 mm (15 in.)457 mm (18 in.)533 mm (21 in.)610 mm (24 in.)
1524 mm(60 in.)
38 mm(1.5 in.)
9.5 mm(0.375 in.)
9.5 mm(0.375 in.)
Ø12 mm(0.472 in.)5 Places
9.5 mm(0.375 in.)
Ø11 mm(0.438 in.)
457 mm(18 in.)
76 mm(3 in.)114 mm(4.5 in.)
9.5 mm(0.375 in.)
19 mm(0.750 in.)
13 mm(0.5 in.)
13 mm(0.5 in.)
Ø38 mm(1.5 in.)
76 mm(3 in.)
89 mm(3.5 in.)102 mm(4 in.)
Ø11 mm(0.438 in.)12 PLACES76 mm
(3 in.)
TX
1022
920
–UN
–11J
AN
08
Pump support is used with a hand hoist to support apump(s) when an engine is removed.
Two end stands are needed.
Drill the holes through the square steel tubing so theyare centered.
Material required:
• C3 x 5 Steel Channel
• 88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.) SquareSteel Tubing
• 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) SquareSteel Tubing
• 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) SquareSteel Tubing
• 19 mm (3/4 in.) Flat Bar Stock• M10 x 89 mm or 3/8 x 3-1/2 in. D Grade (SAE
Grade 5) Cap Screw (2 used)• M10 or 3/8 in. D Grade (SAE Grade 5) Nut (2 used)
TM10091 (11JAN08) 99-9900-14 160DLC Excavator Repair011108
PN=394
Dealer Fabricated Tools
99990015
TM10091 (11JAN08) 99-9900-15 160DLC Excavator Repair011108
PN=395
Dealer Fabricated Tools
999900
16
TJ15698,0000111 –19–16FEB07–1/2
DFT1220 Swing Gearbox Nut Spanner Wrench
T14
3704
–UN
–17J
UL0
1
TM10091 (11JAN08) 99-9900-16 160DLC Excavator Repair011108
PN=396
Continued on next page
Dealer Fabricated Tools
99990017
TJ15698,0000111 –19–16FEB07–2/2
1—Weld (4 Places)
Material required:
• 159.4 x 82.5 mm (6.275 x 3.25 in.) Steel Tubing
• 159.4 x 38.1 x 6.35 mm (6.65 x 1.5 x .25 in.)
TM10091 (11JAN08) 99-9900-17 160DLC Excavator Repair011108
PN=397
Dealer Fabricated Tools
999900
18
TM10091 (11JAN08) 99-9900-18 160DLC Excavator Repair011108
PN=398
IndexPage Page
A Boom flow rate solenoid valveRemove and install . . . . . . . . . . . . . . . .33-3360-46
Boom mode solenoid valveAir cleanerRemove and install . . . . . . . . . . . . . . . .33-3360-46Remove and install . . . . . . . . . . . . . . . . .05-0520-1
Boom pins and bushingsAir conditionerInspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Condenser, remove and install . . . . . . .18-1830-11
IndxBoom, arm, and bucket bushings and bossesReceiver-dryer, remove and install . . . .18-1830-171Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Air conditioner and heater
Boom, arm, and bucket pinsRemove and install . . . . . . . . . . . . . . . .18-1830-13Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Air conditioner system
BrakeFlush and purge . . . . . . . . . . . . . . . . . . .18-1830-3Swing park, inspection . . . . . . . . . . . . .43-4360-12Refrigerant cautions and properSwing park, remove and install . . . . . . . .43-4360-6handling. . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Air conditioning Brake, park and travel motorCharge R134a system . . . . . . . . . . . . .18-1830-10 Disassemble and assemble . . . . . . . . .02-0260-10Compressor, remove and install . . . . . .18-1830-11 Remove and install . . . . . . . . . . . . . . . . .02-0260-2Evacuate R134a system . . . . . . . . . . . . .18-1830-9 BucketRecover R134a refrigerant . . . . . . . . . . .18-1830-8 Remove and install . . . . . . . . . . . . . . . . .33-3302-1R134a refrigerant oil information . . . . . . .18-1830-6 Bucket cylinderR134a station installation . . . . . . . . . . . .18-1830-7 Bleed procedure . . . . . . . . . . . . . . . . .33-3360-106
Arm Disassemble and assemble . . . . . . . .33-3360-103Remove and install . . . . . . . . . . . . . . . . .33-3340-3 Inspect pins and bushings. . . . . . . . . . .33-3340-11
Arm cylinder Remove and install . . . . . . . . . . . . . . . .33-3360-99Bleed procedure . . . . . . . . . . . . . . . . .33-3360-106 Bucket linksDisassemble and assemble . . . . . . . . .33-3360-96 Remove and install . . . . . . . . . . . . . . . . .33-3340-1Inspect pins and bushings. . . . . . . . . . .33-3340-11 Bucket pinsRemove and install . . . . . . . . . . . . . . . .33-3360-91 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Arm pins and bushings BushingsInspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3340-14
AttachmentsAdding safely . . . . . . . . . . . . . . . . . . . . . .00-01-11Operating safely . . . . . . . . . . . . . . . . . . . .00-01-11
C
CabBRemove and install . . . . . . . . . . . . . . . . .18-1800-1
Cab guarding . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3Backover accidentsCenter jointAvoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Air test . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-5Battery explosionsDisassemble and assemble . . . . . . . . . .43-4360-4Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5Remove and install . . . . . . . . . . . . . . . . .43-4360-1Bearing
Check valve, make-upSwing, disassemble and assemble . . . .43-4350-16Remove and install . . . . . . . . . . . . . . . .02-0260-17Swing, remove and install . . . . . . . . . . .43-4350-14
Chemical productsBleed procedureHandling . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-6Hydraulic cylinder . . . . . . . . . . . . . . . .33-3360-106
Condenser, air conditionerBoomRemove and install . . . . . . . . . . . . . . . .18-1830-11Remove and install . . . . . . . . . . . . . . . . .33-3340-6
Console coversBoom cylinderRemove and install . . . . . . . . . . . . . . . . .18-1821-5Bleed procedure . . . . . . . . . . . . . . . . .33-3360-106
Control valveDissassemble and assemble. . . . . . . . .33-3360-89Arm reduced leakage valve. . . . . . . . . .33-3360-63Inspect pins and bushings. . . . . . . . . . .33-3340-11
Remove and install . . . . . . . . . . . . . . . .33-3360-85 Arm regenerative valve . . . . . . . . . . . . .33-3360-71
TM10091 (11JAN08) Index-1 160DLC Excavator Repair011108
PN=1
Index
Page Page
Auxiliary flow combiner valve check Dvalve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63
Dampener driveAuxiliary flow rate valve . . . . . . . . . . . .33-3360-63Remove and install . . . . . . . . . . . . . . . . .07-0752-1Auxiliary function flow combiner
Dealer fabricated toolsvalve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63Center joint lifting tool . . . . . . . . . . . . . .99-9900-13Boom reduced leakage valve . . . . . . . .33-3360-71DFT1036A travel gearbox nutBucket flow rate valve . . . . . . . . . . . . . .33-3360-71
wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10Bypass shut-off valve . . . . . . . . . . . . . .33-3360-71DFT1087 track recoil spring disassembly and
Indx2
Lift check and orifice (left travel powerassembly guard tool . . . . . . . . . . . . . .99-9900-7
passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-63 DFT1109 holding bar . . . . . . . . . . . . . .99-9900-12Lift check (arm I power passage) . . . . .33-3360-63 DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-8Lift check (boom II power passage) . . .33-3360-63 DFT1119 pump support . . . . . . . . . . . .99-9900-14Lift check (left travel neutral DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9
passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-63 DFT1144 guide pin . . . . . . . . . . . . . . . .99-9900-13Lift check (swing neutral passage) . . . .33-3360-63 DFT1220 swing gearbox nut spannerRemove and install . . . . . . . . . . . . . . . .33-3360-61 wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-16Spool assemblies (4-spool) . . . . . . . . . .33-3360-71 DF1038 torque adapter . . . . . . . . . . . . .99-9900-11Spool assemblies (5 spool) . . . . . . . . . .33-3360-63 DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1
ST4920 track recoil spring disassembly andSystem relief and power boost valve. . .33-3360-63assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3Travel function flow combiner valve . . .33-3360-71
Drive gearbox4-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-71Start-up procedure . . . . . . . . . . . . . . . .33-3360-255-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63
Drive shaft, pilot pumpCooling packageRemove and install . . . . . . . . . . . . . . . .33-3360-34Remove and install . . . . . . . . . . . . . . . .05-0510-11
Driving metal pins. . . . . . . . . . . . . . . . . . . . .00-01-14Cooling systemFan drive motor, remove and install . . .33-3360-40Fan drive pump, remove and install . . .33-3360-39
EFan guard, remove and install. . . . . . . .05-0510-19Fan shroud, remove and install . . . . . . .05-0510-19
Emergency preparation . . . . . . . . . . . . . . . . .00-01-6Fan, remove and install. . . . . . . . . . . . .05-0510-19EngineRadiator, remove and install . . . . . . . . . .05-0510-1
Remove and install . . . . . . . . . . . . . . . . .04-0400-1Surge tank, remove and install . . . . . . .05-0510-24Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . .00-01-5Counterbalance valve, travel motorExplosionRemove and install . . . . . . . . . . . . . . . .02-0260-13
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5Counterweight
Remove and install . . . . . . . . . . . . . . . . .17-1749-1Coupling, flex
FRemove and install . . . . . . . . . . . . . . . . .07-0752-1Crossover relief valve
FanRemove and install . . . . . . . . . . . . . . . .43-4360-17Remove and install . . . . . . . . . . . . . . . .05-0510-19Crossover relief valve, travel motor
Fan drive control valveRemove and install . . . . . . . . . . . . . . . .02-0260-15Remove and install . . . . . . . . . . . . . . . .33-3360-43
Cylinder Fan drive motorArm, disassemble and assemble. . . . . .33-3360-96 Remove and install . . . . . . . . . . . . . . . .33-3360-40Arm, remove and install . . . . . . . . . . . .33-3360-91 Fan drive pumpBleed procedure . . . . . . . . . . . . . . . . .33-3360-106 Remove and install . . . . . . . . . . . . . . . .33-3360-39Boom, disassemble and assemble . . . .33-3360-89 Fan guardBoom, remove and install . . . . . . . . . . .33-3360-85 Remove and install . . . . . . . . . . . . . . . .05-0510-19Bucket, disassemble and asemble . . .33-3360-103 Fan shroud
Remove and install . . . . . . . . . . . . . . . .05-0510-19Bucket, remove and install . . . . . . . . . .33-3360-99
TM10091 (11JAN08) Index-2 160DLC Excavator Repair011108
PN=2
Index
Page Page
Filter, pilot Remove and install . . . . . . . . . . . . . . . . .33-3360-4Start-up procedure . . . . . . . . . . . . . . . .33-3360-25Remove and install . . . . . . . . . . . . . . . .33-3360-35
Fire prevention . . . . . . . . . . . . . . . . . . . . . . . .00-01-5 Hydraulic pump regulatorDisassemble and assemble . . . . . . . . .33-3360-28Flex coupling
Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Remove and install . . . . . . . . . . . . . . . .33-3360-26Front idler
IndxDisassemble and assemble . . . . . . . . .01-0130-213Remove and install . . . . . . . . . . . . . . . .01-0130-20
IFuel coolerRemove and install . . . . . . . . . . . . . . . .05-0510-11
Inch bolt and cap screwFuel filterTorque value. . . . . . . . . . . . . . . . . . . . . .00-0003-4Final, remove and install . . . . . . . . . . . . .05-0560-4
Inch series four bolt flange fittingPrimary, remove and install. . . . . . . . . . .05-0560-3Service recommendation, torque value for highFuel tank
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20Remove and install . . . . . . . . . . . . . . . . .05-0560-1Inspect machine . . . . . . . . . . . . . . . . . . . . . . .00-01-3Inspection
Hydraulic pump. . . . . . . . . . . . . . . . . . .33-3360-22G Intercooler
Remove and install . . . . . . . . . . . . . . . . .05-0510-6Gearbox, travel
Disassemble and assemble . . . . . . . . . .02-0250-4Remove and install . . . . . . . . . . . . . . . . .02-0250-1
L
Lifting objectsH Special care . . . . . . . . . . . . . . . . . . . . . . .00-01-11
Handhold use . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7Hazards
MAvoiding . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9Heater and air conditioner
Remove and install . . . . . . . . . . . . . . . .18-1830-13 Machine inspection. . . . . . . . . . . . . . . . . . . . .00-01-3Machine modificationsHigh-pressure oils
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-4 Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-2Machine movementHydraulic
Fittings, 30° cone seat. . . . . . . . . . .00-0003-5 Unintended . . . . . . . . . . . . . . . . . . . . . . . . .00-01-8Machine tip overFittings, 37° flare . . . . . . . . . . . . . . .00-0003-5
Hydraulic cylinder Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10Make-up check valveBleed procedure . . . . . . . . . . . . . . . . .33-3360-106
Hydraulic fitting Disassemble and assemble . . . . . . . . .43-4360-18Remove and install . . . . . . 02-0260-17, 43-4360-17Flared connections . . . . . . . . . . . . . . . .00-0003-10
Hydraulic oil Manifold, pilot signalRemove and install . . . . . . . . . . . . . . . .33-3360-56Cleanup procedure using portable filter
caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3 Metal face sealsRepair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8Hydraulic oil cooler
Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-14Metric bolt and cap screwHydraulic oil tank
Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1 Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-1MotorDisassemble and assemble . . . . . . . . .33-3360-80
Remove and install . . . . . . . . . . . . . . . .33-3360-76 Swing, assemble. . . . . . . . . . . . . . . . . .43-4360-14Swing, disassemble . . . . . . . . . . . . . . .43-4360-10Hydraulic pump
Disassemble and assemble . . . . . . . . .33-3360-10 Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12Swing, remove and install . . . . . . . . . . . .43-4360-6Inspection . . . . . . . . . . . . . . . . . . . . . . .33-3360-22
TM10091 (11JAN08) Index-3 160DLC Excavator Repair011108
PN=3
Index
Page Page
Motor, travel and park brake Pilot signal manifoldRemove and install . . . . . . . . . . . . . . . .33-3360-56Disassemble and assemble . . . . . . . . .02-0260-10
Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Pilot valve, travelDisassemble and assemble . . . . . . . . .33-3360-54Moving parts
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3 Remove and install . . . . . . . . . . . . . . . .33-3360-52Portable filter caddyServicing. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3
Hydraulic oil cleanup procedure . . . . . . .33-3360-3Power dig solenoid valve
Remove and install . . . . . . . . . . . . . . . .33-3360-46
Indx4
OPressure test . . . . . . . . . . . . . . . . . . . . . . .01-0130-5Protective equipment . . . . . . . . . . . . . . . . . . .00-01-2
O-ring boss fitting in aluminum housing—excavatorsPump regulator, hydraulic
Torque value, serviceDisassemble and assemble . . . . . . . . .33-3360-28
recommendation . . . . . . . . . . . . . . . . .00-0003-8Remove and install . . . . . . . . . . . . . . . .33-3360-26
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6Pump, hydraulic
O-ring face seal fittingDisassemble and assemble . . . . . . . . .33-3360-10
Inch hex nut and stud end for high pressure torqueRemove and install . . . . . . . . . . . . . . . . .33-3360-4
values . . . . . . . . . . . . . . . . . . . . . . . .00-0003-12Pump, pilot
Metric hex nut and stud end for high pressureDisassemble and assemble . . . . . . . . .33-3360-32
torque values. . . . . . . . . . . . . . . . . . .00-0003-16Remove and install . . . . . . . . . . . . . . . .33-3360-30
Metric hex nut and stud end for standard pressuretorque values. . . . . . . . . . . . . . . . . . .00-0003-14
Oil coolerRBypass valve, remove and install . . . . .33-3360-83
Oil informationRadiator
R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6Remove and install . . . . . . . . . . . . . . . . .05-0510-1
Operation qualification . . . . . . . . . . . . . . . . . .00-01-1Receiver-dryer
Remove and install . . . . . . . . . . . . . . . .18-1830-17Refrigerant
P Cautions and proper handling . . . . . . . . .18-1830-1Recover R134a, air conditioning . . . . . . .18-1830-8
Park brake Refrigerant oil informationSwing, disassemble . . . . . . . . . . . . . . .43-4360-10 R134a. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12 Refrigerant recovery/recycling and chargingSwing, remove and install . . . . . . . . . . . .43-4360-6 Charging station installationSwing, start-up procedure . . . . . . . . . . .43-4360-16 procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7
Park brake and travel motor Regulator, hydraulic pumpDisassemble and assemble . . . . . . . . .02-0260-10 Disassemble and assemble . . . . . . . . .33-3360-28Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Remove and install . . . . . . . . . . . . . . . .33-3360-26
Pilot control shut-off lever . . . . . . . . . . . . . . . .00-01-8 Relief valve, crossover, travel motorPilot filter Remove and install . . . . . . . . . . . . . . . .02-0260-15
Remove and install . . . . . . . . . . . . . . . .33-3360-35 Riding machine. . . . . . . . . . . . . . . . . . . . . . . .00-01-9Pilot filter and pilot pressure regulating valve R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8
Remove and install . . . . . . . . . . . . . . . .33-3360-35 R134a refrigerant recovery and charging stationPilot pressure regulating valve and filter Installation procedure . . . . . . . . . . . . . . .18-1830-7
Remove and install . . . . . . . . . . . . . . . .33-3360-35 R134a system charge. . . . . . . . . . . . . . . .18-1830-10Pilot pump R134a system evacuate . . . . . . . . . . . . . . .18-1830-9
Disassemble and assemble . . . . . . . . .33-3360-32Drive shaft, remove and install . . . . . . .33-3360-34Remove and install . . . . . . . . . . . . . . . .33-3360-30 S
Pilot shutoff solenoid valveDisassemble and assemble . . . . . . . . .33-3360-38 Safety
Operator’s seat . . . . . . . . . . . . . . . . . . . . . .00-01-7Remove and install . . . . . . . . . . . . . . . .33-3360-36
TM10091 (11JAN08) Index-4 160DLC Excavator Repair011108
PN=4
Index
Page Page
Welding repairs . . . . . . . . . . . . . . . . . . . . .00-01-14 Lower seal install . . . . . . . . . . . . . . . . .43-4350-20Remove and install . . . . . . . . . . . . . . . .43-4350-14Safety equipment . . . . . . . . . . . . . . . . . . . . . .00-01-2
Safety information Upper seal, install . . . . . . . . . . . . . . . . .43-4350-19Swing gearboxRecognizing . . . . . . . . . . . . . . . . . . . . . . . .00-01-1
Safety instructions . . . . . . . . . . . . . . . . . . . . .00-01-1 Disassemble and assemble . . . . . . . . . .43-4350-4Safety symbols . . . . . . . . . . . . . . . . . . . . . . . .00-01-1 Remove and install . . . . . . . . . . . . . . . . .43-4350-1
IndxSeal, Start-up procedure . . . . . . . . . . . . . . . .43-4350-115Swing bearing lower, install. . . . . . . . . .43-4350-20 Swing motor
Swing bearing upper, install . . . . . . . . .43-4350-19 Assemble . . . . . . . . . . . . . . . . . . . . . . .43-4360-14Disassemble . . . . . . . . . . . . . . . . . . . . .43-4360-10Seals
Remove and install . . . . . . . . . . . . . . . .33-3340-14 Inspection . . . . . . . . . . . . . . . . . . . . . . .43-4360-12Remove and install . . . . . . . . . . . . . . . . .43-4360-6Seals, metal face
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Start-up procedure . . . . . . . . . . . . . . . .43-4360-16Swing park brake release valveSeat
Air suspension, disassemble and Remove and install . . . . . . . . . . . . . . . .43-4360-19assemble. . . . . . . . . . . . . . . . . . . . . . .18-1821-4
Mechanical suspension, disassemble andassemble. . . . . . . . . . . . . . . . . . . . . . .18-1821-3
TRemove and install . . . . . . . . . . . . . . . . .18-1821-1Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7
Remove and install . . . . . . . . . . . . . . . . .18-1821-2 Tank, hydraulic oilApply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1Service recommendation
Inch series four bolt flange fitting for high Tip overAvoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20
O-ring boss fitting in aluminum housing— Torque valueFlared connections . . . . . . . . . . . . . . . .00-0003-10excavators . . . . . . . . . . . . . . . . . . . . . .00-0003-8
O-ring face seal fittings with inch hex nut and Flat face O-ring seal fitting . . . . . . . . . .00-0003-11Inch SAE four bolt flange fitting. . . . . . .00-0003-19stud end for high pressure. . . . . . . . .00-0003-12
O-ring face seal fittings with metric hex nut and Inch series four bolt flange fitting for highpressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20stud end for high pressure. . . . . . . . .00-0003-16
O-ring face seal fittings with metric hex nut and Metric bolt and cap screw . . . . . . . . . . . .00-0003-1Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-2stud end for standard pressure . . . . .00-0003-14
Servicing machine safely . . . . . . . . . . . . . . .00-01-12 Metric four bolt flange fitting . . . . . . . . .00-0003-18O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6Shutoff solenoid valve, pilot
Remove and install . . . . . . . . . . . . . . . .33-3360-36 O-ring boss fitting in aluminum housing—excavators . . . . . . . . . . . . . . . . . . . . . .00-0003-8Sliding window
Remove and install . . . . . . . . . . . . . . . . .18-1810-1 O-ring face seal fittings with inch hex nut andstud end for high pressure. . . . . . . . .00-0003-12Solenoid valve
Boom flow rate, remove and install . . . .33-3360-46 O-ring face seal fittings with metric hex nut andstud end for high pressure. . . . . . . . .00-0003-16Boom mode, remove and install . . . . . .33-3360-46
Power dig, remove and install . . . . . . . .33-3360-46 O-ring face seal fittings with metric hex nut andstud end for standard pressure . . . . .00-0003-14Travel speed, remove and install . . . . .33-3360-46
Sprocket Unified inch bolt and cap screw . . . . . . .00-0003-430° cone seat hydraulic fittings . . . .00-0003-5Remove and install . . . . . . . . . . . . . . . .01-0130-19
Start-up procedure 37° flare hydraulic fittings . . . . . . . .00-0003-5Track adjusterDrive gearbox . . . . . . . . . . . . . . . . . . . .33-3360-25
Hydraulic pump. . . . . . . . . . . . . . . . . . .33-3360-25 Recoil spring, disassemble andassemble. . . . . . . . . . . . . . . . . . . . . .01-0130-25Travel motor and park brake . . . . . . . . .02-0260-21
Steps use . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7 Recoil spring, remove and install . . . . .01-0130-23Track adjuster cylinderSurge tank
Remove and install . . . . . . . . . . . . . . . .05-0510-24 Disassemble and assemble . . . . . . . . .01-0130-30Track carrier rollerSwing bearing
Disassemble and assemble . . . . . . . . .43-4350-16 Remove and install . . . . . . . . . . . . . . . . .01-0130-6
TM10091 (11JAN08) Index-5 160DLC Excavator Repair011108
PN=5
Index
Page Page
Track chain Remove and install . . . . . . . . . . . . . . . .33-3360-52Valve, travel speed changeDisassemble and assemble . . . . . . . . .01-0130-16
Remove and install . . . . . . . . . . . . . . . .01-0130-11 Remove and install . . . . . . . . . . . . . . . .02-0260-19Repair . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-17
Track roller . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5Disassemble and assemble . . . . . . . . . .01-0130-3 WRemove and install . . . . . . . . . . . . . . . . .01-0130-1
Track shoeWaste disposal . . . . . . . . . . . . . . . . . . . . . . . .00-01-6
Remove and install . . . . . . . . . . . . . . . .01-0130-11
Indx6
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3Travel gearbox
Welding precautions . . . . . . . . . . . . . . . . . .17-1740-1Disassemble and assemble . . . . . . . . . .02-0250-4
Window, slidingRemove and install . . . . . . . . . . . . . . . . .02-0250-1
Remove and install . . . . . . . . . . . . . . . . .18-1810-1Travel motor and park brake
WindowpanesDisassemble and assemble . . . . . . . . .02-0260-10
Dimensions . . . . . . . . . . . . . . . . . . . . . . .18-1810-3Remove and install . . . . . . . . . . . . . . . . .02-0260-2
Remove and install . . . . . . . . . . . . . . . . .18-1810-2Start-up procedure . . . . . . . . . . . . . . . .02-0260-21
Work site hazardsTravel motor, counterbalance valve
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9Remove and install . . . . . . . . . . . . . . . .02-0260-13
Travel pilot valveDisassemble and assemble . . . . . . . . .33-3360-54Remove and install . . . . . . . . . . . . . . . .33-3360-52
Travel speed change valveRemove and install . . . . . . . . . . . . . . . .02-0260-19
Travel speed solenoid valveRemove and install . . . . . . . . . . . . . . . .33-3360-46
U
UpperstructureRemove and install . . . . . . . . . . . . . . . .43-4350-11
V
ValveCrossover relief, remove and install . . .43-4360-17Make-up check, disassemble . . . . . . . .43-4360-18Make-up check, remove and install . . . .43-4360-17Pilot pressure regulating, disassemble and
assemble. . . . . . . . . . . . . . . . . . . . . .33-3360-36Swing park brake release, remove and
install . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-19Valve, control
Remove and install . . . . . . . . . . . . . . . .33-3360-61Valve, pilot pressure regulating
Remove and install . . . . . . . . . . . . . . . .33-3360-35Valve, pilot shutoff solenoid
Disassemble and assemble . . . . . . . . .33-3360-38Remove and install . . . . . . . . . . . . . . . .33-3360-36
Valve, travel pilotDisassemble and assemble . . . . . . . . .33-3360-54
TM10091 (11JAN08) Index-6 160DLC Excavator Repair011108
PN=6