TM2356 - 27D Excavator Repair

Foreword

Foreword

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified
in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of
the manual.

CAUTION:

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

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

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.

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Technical Information Feedback Form

Technical Information Feedback Form

We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments,
ideas and improvements.

-: Technical Manual Fax

SEND TO: John Deere Dubuque Works

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

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

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:
THANK YOU!

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Recognize Safety Information

Recognize Safety Information

T133555-UN: Safety Alert Symbols

T133588-19: Safety Alert Symbols

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

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most
serious hazards.

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

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Follow Safety Instructions

Follow Safety Instructions

T133556-UN: Follow Safety Instructions

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them
frequently.

Be sure all operators of this machine understand every safety message. Replace operator's manual and safety labels
immediately if missing or damaged.

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Operate Only If Qualified

Operate Only If Qualified

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

Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the
machine in an open area before starting to work.

Know and observe all safety rules that may apply to every work situation and work site.

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Wear Protective Equipment

Wear Protective Equipment

TS206-UN: Protective Equipment

Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable
loud noises.

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Avoid Unauthorized Machine Modifications

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute
genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or
hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any
John Deere warranty.

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability,
and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the
electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or
its performance.

Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of
the machine, or that alter machine controls, performance or reliability.

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Add Cab Guarding for Special Uses

Add Cab Guarding for Special Uses

Special work situations or machine attachments may create an environment where special additional guarding is needed to
protect the operator.

Special screens or guarding should be installed to prevent machine damage. Contact your authorized dealer for information on
devices intended to provide protection in special work situations.

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Inspect Machine

Inspect Machine

T6607AQ-UN: Inspect Machine

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

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

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Stay Clear of Moving Parts

Stay Clear of Moving Parts

T133592-UN: Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair
is complete.

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Avoid High-Pressure Fluids

Avoid High-Pressure Fluids

X9811-UN: High Pressure

Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

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

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-
8262 or +1 309-748-5636.

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Avoid High-Pressure Oils

Avoid High-Pressure Oils

T133509-UN: Avoid High Pressure Oils

T133840-UN: Avoid High-Pressure Oils

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

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

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

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Prevent Fires

Prevent Fires

T133552-UN: Handle Fuel Safely

T133553-UN: Clean Machine Regularly

T133554-UN: Carry A Fire Extinguisher

Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks
or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines,
hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine
compartment.

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine
electrical wiring and connectors frequently for damage.

Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.

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Prevent Battery Explosions

Prevent Battery Explosions

TS204-UN: Battery Explosions

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

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

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

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Handle Chemical Products Safely

Handle Chemical Products Safely

T133580-UN: Handle Chemical Products Safely

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and
adhesives used with this machine may be hazardous.

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data
Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use
procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle
chemical products safely.

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Dispose of Waste Properly

Dispose of Waste Properly

T133567-UN: Dispose Of Waste Properly

Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may
be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center
to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for
more information.

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Prepare for Emergencies

Prepare for Emergencies

TS291-UN: First Aid Kit

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.

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Use Steps and Handholds Correctly

Use Steps and Handholds Correctly

T133468-UN: Use Handholds and Steps

Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use
machine controls as handholds.

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never
jump when exiting machine. Never mount or dismount a moving machine.

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Start Only From Operator's Seat

Start Only From Operator's Seat

T133715-UN: Operate Only From Operators Seat

Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure all controls and working tools
are in proper position for a parked machine.

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

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Use and Maintain Seat Belt

Use and Maintain Seat Belt

T133716-19: Use and Maintain Seat Belt

Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during
other uses.

Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does
not function properly.

The complete seat belt assembly should be replaced every 3 years, regardless of appearance.

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Prevent Unintended Machine Movement

Prevent Unintended Machine Movement

T216779-UN: Unintended Machine Movement

Be careful not to accidentally actuate control levers when coworkers are present. Pull pilot shutoff lever to locked (UP) position
during work interruptions. Pull pilot shutoff lever to locked (UP) position and stop engine before allowing anyone to approach
machine.

Always lower work equipment to the ground and pull pilot shutoff lever to locked (UP) position before standing up or leaving
the operator's seat. Stop engine before exiting.

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Avoid Work Site Hazards

Avoid Work Site Hazards

T134986-UN: Work Site Hazards

T133650-UN: Work Site Hazards

T133549-UN: Work Site Hazards

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all
underground utilities before you dig.

Prepare work site properly . Avoid operating near structures or objects that could fall onto the machine. Clear away debris
that could move unexpectedly if run over.

Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or
load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

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

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

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

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Keep Riders Off Machine

Keep Riders Off Machine

T120807-UN: Keep Riders Off Machine

Only allow operator on machine.

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.

Riders may obstruct operator’s view or impair his ability to operate machine safely.

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Avoid Backover Accidents

Avoid Backover Accidents

T120806-UN: Backover Warning

Before moving machine, be sure all persons are clear of both travel and swing paths. Turn around and look directly for
best visibility. Keep windows clean, adjusted, and in good repair.

Be certain travel alarm is working properly.

Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all
times. Use prearranged hand signals to communicate.

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Avoid Machine Tip Over

Avoid Machine Tip Over

T133716-19: Use Seat Belt

T133545-UN: Unloading Machine

T133803-UN: Do Not Jump

Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading
ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.

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

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

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

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Use Special Care When Lifting Objects

Use Special Care When Lifting Objects

T133839-UN: Use Special Care When Lifting Objects

Never use this machine to lift people.

Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave
the seat when there is a raised load.

Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over
undercarriage side may cause machine to tip over.

Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition.
Use tether lines to guide loads and prearranged hand signals to communicate with co-workers.

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Add and Operate Attachments Safely

Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect
machine stability or reliability and may create a hazard for others near the machine.

Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify that all connections are secure and attachment responds properly to controls.

Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions,
carefully operate attachment to learn its characteristics and range of motion.

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Park and Prepare for Service Safely

Park and Prepare for Service Safely

T133332-19: Do Not Operate Tag

TS229-UN: Support Machine Properly

Warn others of service work. Always park and prepare your machine for service or repair properly.

l Park machine on a level surface and lower equipment and attachments to the ground.
l Place pilot shutoff lever in “lock” position. Stop engine and remove key.
l Attach a “Do Not Operate” tag in an obvious place in the operator's station.

Securely support machine or attachment before working under it.

l Do not support machine with boom, arm, or other hydraulically actuated attachments.
l Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
l Do not support machine with a single jack or other devices that may slip out of place.

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

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Service Cooling System Safely

Service Cooling System Safely

TS281-UN: Cooling System

Explosive release of fluids from pressurized cooling system can cause serious burns.

Do not service radiator through the radiator cap. Only fill through the surge tank filler cap.

Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve
pressure before removing completely.

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Remove Paint Before Welding or Heating

Remove Paint Before Welding or Heating

TS220-UN: Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

l Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
l If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
l If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding
or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

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Make Welding Repairs Safely

Make Welding Repairs Safely

T133547-UN: Avoid Heating Near Pressurized Fluid Lines

IMPORTANT:

Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable.
Separate harness connectors to engine and vehicle microprocessors.

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

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure
there is good ventilation. Wear eye protection and protective equipment when welding.

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Drive Metal Pins Safely

Drive Metal Pins Safely

T133738-UN: Hardened Metal Parts

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering
hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer and object to prevent chipping.

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Metric Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

-: Metric Bolt and Cap Screw Torque Values

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

TORQ2-UN: Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Thread Size LubricatedaNm (lb-ft) Dryb LubricatedaNm (lb-ft) Dryb LubricatedaNm (lb-ft) Dryb LubricatedaNm (lb-ft) Dryb
Nm (lb-ft) Nm (lb-ft) Nm (lb-ft) Nm (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.

-: Metric Bolt and Cap Screw Torque Value Instructions

Fasteners should be replaced with the same or higher property class. If higher property class fasteners
are used, these should only be tightened to the strength of the original.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent
CAUTION: them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown
Use only metric tools on metric hardware. Other tools may not fit properly. Tool in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full
may slip and cause injury. torque value.

DO NOT use these values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical
property class.

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Additional Metric Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

T6873AA-UN: T-Bolt

T6873AB-UN: H-Bolt

T6873AC-UN: M-Bolt

CAUTION:

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

Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different
torque value or tightening procedure is listed for a specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

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

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when
tightening.

Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.

-: Metric Cap Screw Torque Values

METRIC CAP SCREW TORQUE VALUES [Torque tolerance is ±10%.]

T-Bolt H-Bolt M-Bolt
Nominal Dia N˙m lb-ft N˙m lb-ft N˙m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687

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Unified Inch Bolt and Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

-: Unified Inch Bolt and Cap Screw Torque Values

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

TORQ1A-UN: Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings

Grade 1 (No Mark) Grade 2 a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Thread Size b
Lubricated N˙m (lb-ft) Dry c
Lubricated b N˙m (lb-ft) Dry c Lubricated b N˙m (lb-ft) Dry c Lubricated b N˙m (lb-ft) Dry c
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.

-: Unified Inch Bolt and Cap Screw Torque Value Instructions

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

OUT3035,TORQUE1-19-20040114
TM2356 - 27D Excavator Repair
Check Oil Lines and Fittings

Check Oil Lines and Fittings

CAUTION:

X9811-UN: High-Pressure Fluids

T85401-UN: Two Wrenches Used To Tighten Connections

Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by
relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high
pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call
the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.
Check all oil lines, hoses and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure
hoses are not twisted or touching machine parts which are moving.

Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately.

IMPORTANT:

Tighten fittings as specified in torque chart.

When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.

T82,FLMA,AI-19-19900314
TM2356 - 27D Excavator Repair
Service Recommendations for O-Ring Boss Fittings

Service Recommendations for O-Ring Boss Fittings

Straight Fitting

T6243AE-UN: Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and
into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.

Angle Fitting
T6520AB-UN: Angle Fitting

1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washer contacts face of boss.

3. Turn fitting head-end counterclockwise to proper index (maximum of one turn).

4. NOTE:

Do not allow hoses to twist when tightening fittings.

Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.

-: Straight Fitting or Special Nut Torque Chart

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N˙m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160

NOTE:
Torque tolerance is ± 10%.

04T,90,K66-19-19990929
TM2356 - 27D Excavator Repair
Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

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

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

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

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

IMPORTANT:

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

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

-: O-ring Seal Fitting Torque

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.

04T,90,K67-19-20000302
TM2356 - 27D Excavator Repair
Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

T6234AC-UN: Cone Seat Connector

1. Inspect flare and flare seat. They must be free of dirt or obvious defects.

2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.

3. Align tube with fitting before attempting to start nut.

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

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.

-: Straight Fitting or Special Nut Torque Chart

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N˙m lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160

NOTE:

Torque tolerance is ± 10%.

T82,BHMA,EL-19-19990929
TM2356 - 27D Excavator Repair
Service Recommendations For Flared Connections—Straight or Tapered
Threads

Service Recommendations For Flared Connections—Straight or Tapered Threads

T6873AE-UN: Straight Thread

T6873AD-UN: Tapered Thread

1. Inspect flare and flare seat. They must be free of dirt or obvious defects.

2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.

3. Align the tube with the fitting before attempting to start the nut.

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

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings.

-: Torque Chart

TORQUE CHART [Torque tolerance is ±10%.]

Straight Thread [With seat face.] Tapered Thread
Thread Size N˙m lb-ft N˙m lb-ft
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434

NOTE:

If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately
10%.

04T,90,M171-19-19920128
TM2356 - 27D Excavator Repair
Service Recommendations For Inch Series Four Bolt Flange Fittings

Service Recommendations For Inch Series Four Bolt Flange Fittings

T6890BB-UN: Flange Fittings

LEGEND:

A - Sealing Surface
B - Split Flange
C - Pinched O-Ring
D - Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion.
If defects cannot be polished out, replace component.

2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand
tighten cap screws to hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on
port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

-: Four Bolt Flange Fittings Torque

TORQUE CHART
N˙m lb-ft
Nominal Flange Size Cap Screw Size Min Max Min Max
1/2 5/16-18 UNC 20 31 15 23
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 UNC 47 85 35 63
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

04T,90,K174-19-19940801
TM2356 - 27D Excavator Repair
Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB-UN: Metric Series Four Bolt Flange Fitting

LEGEND:

A - Sealing Surface
B - Split Flange
C - Pinched O-Ring
D - Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal
extrusion. If defects cannot be polished out, replace component.

2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port.
Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally
located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring.

5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the
diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart
below.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

-: Torque Chart

TORQUE CHART [Tolerance ± 10%. The torques given are enough for the given size connection with the
recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange
and cap screw bending and connection failures.]
Thread [Metric standard thread.] 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 421 318

04T,90,K175-19-19990929
TM2356 - 27D Excavator Repair
Track Roller Remove and Install

Track Roller Remove and Install

1.
T121510-UN: Boom-to-Arm Angle and Bucket Position

Swing upperstructure 90° and lower bucket to raise track off ground. Keep angle between boom and arm 90—110° and position
round side of bucket on ground.

2.

CAUTION:

Prevent possible injury from unexpected machine movement. Put shop stands under frame to support
machine while removing track roller.

Item Measurement Specification

Excavator—Canopy Approximate Weight 2800 kg

6160 lb

Excavator—Cab Approximate Weight 2950 kg

6490 lb

Excavator—Canopy Long Arm Approximate Weight 3010 kg

6620 lb

Excavator—Cab Long Arm Approximate Weight 3160 kg

6950 lb

Place shop stands under machine.

3.

CAUTION:

Prevent possible injury from high-pressure grease. Do not remove grease fitting (2) from valve (1).

T121512-UN: Track Adjuster Valve

T121513-UN: Track Adjuster and Track Roller

LEGEND:
 1 - Track Adjuster Valve
2 - Grease Fitting
3 - Track Roller
4 - Cap Screw (2 used)

IMPORTANT:

If gravel or mud is packed between sprocket and track, it must be removed before loosening track.

Loosen track adjuster valve (1) slowly to release grease.

4. Remove cap screws (4) and track roller (3).

5. Measure track roller tread diameter. (See specification for new and allowable limit for wear.)

Item Measurement Specification

Track Roller Tread—New OD 85 mm

3.35 in.

Track Roller Tread—Used OD Allowable Limit 77 mm

3.03 in.

6. Repair or replace parts as necessary.

7. Apply PM38654 Thread Lock and Sealer (high strength) to threads of cap screws (4).

8. Install track roller and tighten cap screws (4).

Item Measurement Specification

Track Roller-to-Frame Cap Screw Torque 245 N˙m

180 lb-ft

9. Perform Adjusting Track Sag . (Operator's Manual.)

LOCTITE is a trademark of Loctite Corp. MM61211,0000A28-19-20060103

TM2356 - 27D Excavator Repair
Track Roller Oil Leakage Test

Track Roller Oil Leakage Test

T217231A-UN: Track Roller Oil Leakage Test Components

LEGEND:

1 - Stopper Plug, Barbed Adapter and Connector

2 - JT03001 Tee Fitting 7/16-20 M 37° x 7/16-20 F 37° SW x 7/16-20 M 37°
3 - Hose (2 used)
4 - Pressure Gauge
5 - Snubber (Needle) Valve
6 - Air Pressure Regulator

1. Hold the shaft and turn roller several turns to seat metal face seals.

2. Remove threaded plug from track roller.

3. Connect test components (1—6) to track roller.

The stopper plug, barbed adapter, and connector (1) are from D05361ST Rubber Stopper / Leak Detector Kit.

4. While holding the stopper plug so it does not push out, slowly pressurize oil cavity using regulated air pressure.

Item Measurement Specification

Track Roller Oil Cavity Air Test Pressure 92—128 kPa

0.8—1.4 bar
12—20 psi

5. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has
decreased.

6. If there is leakage, disassemble roller and replace parts as necessary.

 7. Remove test equipment.

8. Apply PM37509 Cure Primer and PM37397 Pipe Sealant to threads of plug. Install and tighten plug to specification.

Item Measurement Specification

Track Roller Plug Torque 9.8 N˙m

87 lb-in.

LOCTITE is a trademark of Henkel Group. MM61211,0000A32-19-20090218

TM2356 - 27D Excavator Repair
Track Roller Disassemble and Assemble

Track Roller Disassemble and Assemble

1.
T121516-UN: Track Roller

LEGEND:

1 - Stopper Ring
2 - Plug
3 - Collar
4 - Metal Face Seal (2 used)
5 - Bushing (2 used)
6 - Roller
7 - O-Ring
8 - Axle

Remove plug (2) and drain oil.

2. Remove stopper ring (1).

3. Remove collar (3) using a bearing puller attachment and adapters from D01047AA Puller Set.

4. IMPORTANT:

Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a
set because of wear patterns on seal ring face.

Remove metal face seal (4) from roller and collar. Keep seal rings together as a matched set with seal ring faces
together to protect surfaces.

5. Inspect metal face seals. See Inspect Metal Face Seals . (Group 0130.) For seals that will be reused, put a piece of
cardboard between seal rings to protect seal face.

6. Remove axle (8) from roller (6).

7. NOTE:

If bushings (5) are worn or damaged, complete roller must be replaced.

Inspect track roller bushings (5). Replace track roller if worn or damaged.

8. Apply a thin film of oil to new bushings (5) and install.

9. IMPORTANT:

O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-rings do not slip when roller is
turning.

Thoroughly clean O-ring and seat surfaces using volatile, non-petroleum base solvent and lint-free tissues.
 10. Wipe fingerprints and foreign material off seal ring face using clean oil and lint-free tissues.

11. Apply a thin film of oil to each seal ring face.

12. Install metal face seals (4), collar (3), roller (6), and axle assembly (8). Apply equal pressure with fingers at four equally
spaced points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore. A volatile, non-
petroleum base solvent or talcum powder may be used as a lubricant.

13. Install axle to roller using press.

14. Install stopper ring (1).

15. Fill roller with 35 mL (1.2 oz) of SAE 30 oil meeting API Service GL-5 (MIL-L-2105B or MIL-L-2105C).

Item Measurement Specification

Track Roller Oil Capacity 35 mL

1.2 oz

16. Clean threads of plug. Apply PM37509 Primer.

17. Apply PM37398 Thread Sealant (high temperature) to plug threads and install plug.

Item Measurement Specification

Track Roller Plug Torque 9.8 N˙m

87 lb-in.

LOCTITE is a trademark of Loctite Corp. MM61211,0000A33-19-20060103

TM2356 - 27D Excavator Repair
Inspect Metal Face Seals

Inspect Metal Face Seals

T85079-UN: Ring Sealing Area

LEGEND:

A - Seal Ring
B - Worn Area (shaded area)
C - Seal Ring Face
D - Outer Half of Seal Ring Face
E - Sealing Area (dark line)

1. Inspect for the following conditions to determine if seals can be reused:

a. The narrow, highly polished sealing area (E) must be in the outer half of seal ring face (D).

b. Sealing area must be uniform and concentric with the ID and OD of seal ring (A).

c. Sealing area must not be chipped, nicked, or scratched.

2.
T85080-UN: Metal Face Seals

LEGEND:

A - Seal Ring
B - Worn Area (shaded area)
C - Inner Half of Seal Ring Face
D - Sealing Area (dark line)

Illustration shows examples of worn seal rings (A).

I—Sealing area (D) is in inner half of seal ring face (C).

II—Sealing area (D) not concentric with ID and OD of seal ring.

3.
T82840-UN: No Scraper on Seal Face

LEGEND:

A - Seal Face

Clean reusable seals by removing all foreign material from seal rings, except seal face (A), using a scraper or a stiff
bristled fiber brush.

4. Wash seal rings and O-rings using a volatile, non-petroleum base solvent to remove all oil. Thoroughly dry parts using
a lint-free tissue.

Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape.

T47,0130,5939HQ-19-20050223
TM2356 - 27D Excavator Repair
Measure Track Carrier Roller Wear

Measure Track Carrier Roller Wear

NOTE:

Track carrier roller can be measured for wear without being removed.

1.
T209403A-UN: Track Carrier Roller

LEGEND:

1 - Track Carrier Roller

2 - Caliper

Measure roller tread outer diameter using a caliper.

2. If not within specifications, replace roller. See Track Carrier Roller Remove and Install . (Group 0130.)

Item Measurement Specification

Carrier Roller Tread OD 70 mm

2.76 in.

MM61211,0000900-19-20050308
TM2356 - 27D Excavator Repair
Track Carrier Roller Remove and Install

Track Carrier Roller Remove and Install

T121510-UN: Boom-to-Arm Angle and Bucket Position

1. Swing upperstructure 90° and lower bucket to raise track off ground. Keep angle between boom and arm 90—110° and position
round side of bucket on ground.

2.

CAUTION:

Prevent possible injury from unexpected machine movement. Put shop stands under frame to support
machine while removing track carrier roller.

Item Measurement Specification

Excavator—Canopy Approximate Weight 2800 kg

6160 lb

Excavator—Cab Approximate Weight 2950 kg

6490 lb

Excavator—Canopy Long Arm Approximate Weight 3010 kg

6620 lb

Excavator—Cab Long Arm Approximate Weight 3160 kg

6950 lb

Put shop stands under machine.

3.

CAUTION:

High-pressure grease is in track adjuster cylinder. Do not loosen track adjuster valve (1) quickly or too much.
High-pressure grease may cause serious injury. Never loosen grease fitting (2) to release grease.

IMPORTANT:

If gravel or mud is packed between sprocket and track, it must be removed before loosening track (6).

T121512-UN: Track Adjuster Valve

 T121514-UN: Loosen Track Adjuster Valve

T121515-UN: Jack Track for Carrier Roller Removal

LEGEND:

1 - Track Adjuster Valve

2 - Grease Fitting
3 - Track Frame
4 - Hydraulic Jack
5 - Track Carrier Roller
6 - Track
7 - Cap Screw

Loosen track adjuster valve (1) slowly to discharge grease.

4. IMPORTANT:

Place pads between track frame (3) and hydraulic jack (4) when jacking to prevent jack from slipping.

Using hydraulic jack (4), jack up track (6) until clearance between track and track carrier roller (5) is enough to allow removal. Place
wooden blocks on track frame (3) to support track (6).

5. Remove cap screw (7) and track carrier roller (5).

6. Replace parts as necessary.

7. Install track carrier roller (5) and cap screw (7) and tighten.

Item Measurement Specification

Track Roller-to-Frame Cap Screw Torque 88 N˙m

65 lb-ft

8. Remove pads and jack.

9. Perform Adjusting Track Sag . (Operator's Manual.)

MM61211,0000A34-19-20090218
TM2356 - 27D Excavator Repair
Measure Rubber Track Lugs

Measure Rubber Track Lugs

TX1078996-UN: Rubber Track Height

LEGEND:

1 - Minimum Lug Height

3 - Link Pitch
5 - Lug
6 - Lower Roller
7 - Rubber Track

Measure lug height (1) where indicated.

Replace rubber track if measurement is less than specification.

Measure link pitch (3) where indicated.

TX1078652A-UN: Rubber Track Dimensions Location (35D shown)

LEGEND:

2 - Shoe Width
3 - Link Pitch
4 - Link Amount

Rubber track dimensions (2—4) are imprinted on the inside of the track.

-: Rubber Track Dimensions

Minimum Lug Height 27D Shoe Width 27D Link Pitch 27D Link Quantity 27D
5 mm 300 mm 52.5 mm 80
0.2 in. 11.81 in. 2.07 in.

MM61211,0000A36-19-20100628
TM2356 - 27D Excavator Repair
Rubber Track Remove and Install

Rubber Track Remove and Install

T121510-UN: Boom-to-Arm Angle and Bucket Position

1. Swing upperstructure 90° and lower bucket to raise track off ground. Keep angle between boom and arm 90—110° and position
round side of bucket on ground.

2.

CAUTION:

Prevent possible injury from unexpected machine movement. Put shop stands under frame to support
machine while removing track carrier roller.

Item Measurement Specification

Excavator—Canopy Approximate Weight 2800 kg

6160 lb

Excavator—Cab Approximate Weight 2950 kg

6490 lb

Excavator—Canopy Long Arm Approximate Weight 3010 kg

6620 lb

Excavator—Cab Long Arm Approximate Weight 3160 kg

6950 lb

Put shop stands under machine.

3.

CAUTION:

High-pressure grease is in track adjuster cylinder. Do not loosen track adjuster valve (1) quickly or too much.
High-pressure grease may cause serious injury. Never loosen grease fitting (2) to release grease.

IMPORTANT:

If gravel or mud is packed between sprocket and track, it must be removed before loosening track.

T121512-UN: Track Adjuster Valve

 T121514-UN: Trade Adjuster Valve Location

T121522-19: Rubber Track

LEGEND:

1 - Track Adjuster Valve

2 - Grease Fitting
3 - Front Idler
4 - Rubber Track
5 - Track Frame
6 - Steel Pipe (3 used)

Loosen track adjuster valve (1) slowly to discharge grease. Allow track to lower completely.

4. Install three steel pipes (6) into gaps between rubber track (4) and track frame (5).

5.

CAUTION:

Adjust engine speed to the slowest speed. Stand clear of steel pipes while moving sprocket to prevent injury.

Rotate sprocket in reverse direction until rubber track (4) is raised off of front idler (3) by the three steel pipes.

6.

CAUTION:

Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

Item Measurement Specification

Excavator Weight 113 kg

250 lb

Slide rubber track (4) away from track frame (5) and remove.

7. Inspect lugs and area between lugs for cracks that exceed 3 mm (0.1 in.) in depth, reach steel core, or exceed 30 mm (1.2 in.) in
length. Inspect for any signs of exposed steel core. Inspect roller side of track for cracks that reach steel core. Inspect for separation
of steel core anywhere on track.

8. Repair or replace as necessary.

9. Install rubber track (4) on sprocket teeth, and hand other end over front idler (3).

10. Rotate sprocket in reverse direction to sufficiently mesh rubber track onto sprocket.
11.

CAUTION:

Adjust engine speed to the slowest speed. Stand clear of steel pipe while moving sprocket to prevent injury.

IMPORTANT:

Make sure rubber track is securely engaged on sprocket and front idler.

T121533-19: Rubber Track Installation

LEGEND:

3 - Front Idler
4 - Rubber Track
5 - Track Frame
7 - Steel Pipe

Install one steel pipe (7) into gap between rubber track (4) and track frame (5). Rotate sprocket to position rubber track completely
onto front idler.

12. Perform Adjusting Track Sag . (Operator's Manual.)

MM61211,0000A35-19-20090218
TM2356 - 27D Excavator Repair
Steel Track Components Inspection

Steel Track Components Inspection

Measure Track Shoe Grouser Wear

1. Minimum used is the maximum allowable wear for rebuilding grouser bars with weld.

2. Measure grouser height of several track shoes to find an average using a depth gauge.

Item Measurement Specification

Grouser—New Height 22.0 mm

0.87 in.

Grouser—Used Min. Height 16.5 mm

0.65 in.

Measure Track Chain Link Wear

NOTE:

Track chain link height can be measured for wear without being removed.

T82864-UN: Track Chain Link

 1. Measure height of several links to find an average using a depth gauge.

2. Minimum used is the maximum allowable wear for rebuilding links.

Item Measurement Specification

Track Chain Link Wear—New Height 60 mm

2.36 in.

Track Chain Link Wear—Used Min. Height 55 mm

2.17 in.

Measure Track Chain Bushing Wear

NOTE:

Track chain bushing wear can be measure, without being removed.

T82865-UN: Track Chain Bushing

1. Measure bushing outer diameter at the two worn places using a caliper.

2. Minimum used is the maximum allowable wear for turning pins and bushings.

Item Measurement Specification

Track Chain Bushing Wear—New OD 32.2 mm

1.27 in.

Track Chain Bushing Wear—Used OD Allowable Limit 29.2 mm

1.15 in.

Measure Track Chain Pitch

NOTE:

Track chain pitch can measured without being removed.

T6813AL-UN: Track Chain Pitch

1. Remove slack by putting a wooden block between sprocket and chain, then slowly move machine in reverse to tighten
chain.

2. Measure pitch across several four-link sections as shown, except section on either side of master pin, to find average
chain wear.

Maximum used is the maximum allowable wear for turning pins and bushings.

Item Measurement Specification

Track Chain—New Pitch 406.4 mm

16.0 in.

Track Chain—Used Max. Pitch 412.0 mm

16.22 in.

TX,01,VV2526-19-20050223
TM2356 - 27D Excavator Repair
Track Shoe Remove and Install

Track Shoe Remove and Install

T121510-UN: Boom-to-Arm Angle and Bucket Position

1. Swing upperstructure 90° and lower bucket to raise track off ground. Keep angle between boom and arm 90—110° and position
round side of bucket on ground.

2.

CAUTION:

Prevent possible injury from unexpected machine movement. Put shop stands under frame to support
machine while removing track carrier roller.

Item Measurement Specification

Excavator—Canopy Approximate Weight 2800 kg

6160 lb

Excavator—Cab Approximate Weight 2950 kg

6490 lb

Excavator—Canopy Long Arm Approximate Weight 3010 kg

6620 lb

Excavator—Cab Long Arm Approximate Weight 3160 kg

6950 lb

Put shop stands under machine.

3. NOTE:

The track shoe and track chain are a welded assembly. Removal of track shoe involves removal of track pins on
either side of shoe.

T121512-UN: Track Adjuster Valve

T126403-UN: Track Shoe—Removal and Installation

LEGEND:
 1 - Track Adjuster Valve
2 - Grease Fitting
3 - Track Pin
4 - Track Pin
5 - Track Pin Bushing
6 - Track Shoe

Rotate sprocket to position track shoe (6) over front idler.

4.

CAUTION:

High-pressure grease is in track adjuster cylinder. Do not loosen track adjuster valve (1) quickly or too much.
High-pressure grease may cause serious injury. Never loosen grease fitting (2) to release grease.

IMPORTANT:

If gravel or mud is packed between sprocket and track, it must be removed before loosening track.

Loosen track adjuster valve (1) slowly to discharge grease. Allow track to lower completely.

5. Put wooden blocks in front of front idler and under track to prevent track from falling when track pin is removed.

6. Remove one track pin (4) and lower track to ground.

7. Remove remaining track pin (3) and remove track shoe (6).

8. Check track pin bushing (5) for wear.

9. Repair or replace as necessary.

10. Place track shoe (6) in position and install track pin (3).

11. Pull ends of track together and install track pin (4).

12. Perform Adjusting Track Sag . (Operator's Manual.)

MM61211,0000A37-19-20090218
TM2356 - 27D Excavator Repair
Steel Track Remove and Install

Steel Track Remove and Install

T121510-UN: Boom-to-Arm Angle and Bucket Position

1. Swing upperstructure 90° and lower bucket to raise track off ground. Keep angle between boom and arm 90—110° and position
round side of bucket on ground.

2.

CAUTION:

Prevent possible injury from unexpected machine movement. Put shop stands under frame to support
machine while removing track carrier roller.

Item Measurement Specification

Excavator—Canopy Approximate Weight 2800 kg

6160 lb

Excavator—Cab Approximate Weight 2950 kg

6490 lb

Excavator—Canopy Long Arm Approximate Weight 3010 kg

6620 lb

Excavator—Cab Long Arm Approximate Weight 3160 kg

6950 lb

Put shop stands under machine.

3. NOTE:

The track master pin (3) has drilled center holes on both sides of pin. It also has a head that is larger in diameter
than the rest of pin.

T121512-UN: Track Adjuster Valve

T126555-UN: Track Master Pin

LEGEND:
 1 - Track Adjuster Valve
2 - Grease Fitting
3 - Track Master Pin

Rotate sprocket to position master pin (3) over front idler.

4.

CAUTION:

High-pressure grease is in track adjuster cylinder. Do not loosen track adjuster valve (1) quickly or too much.
High-pressure grease may cause serious injury. Never loosen grease fitting (2) to release grease.

IMPORTANT:

If gravel or mud is packed between sprocket and track, it must be removed before loosening track.

Loosen track adjuster valve (1) slowly to discharge grease. Allow track to lower completely.

5. Put wooden blocks in front of front idler and under track to prevent track from falling when master pin is removed.

6. Remove master pin (3).

7. Slowly turn sprocket in reverse direction to remove track from machine.

8. Repair or replace as necessary.

9. Position track on ground beneath front idler and sprocket.

10. Install end of track on sprocket teeth and slowly turn sprocket in forward direction to pull track across top of track frame to front idler.

11. Pull ends of track together and install master pin (3).

12. Perform Adjusting Track Sag . (Operator's Manual.)

MM61211,0000A38-19-20060103
TM2356 - 27D Excavator Repair
Sprocket Remove and Install

Sprocket Remove and Install

T216904-UN: Sprocket

LEGEND:

1 - Cap Screw (12 used)

2 - Lock Washer (12 used)
3 - Sprocket

1. Remove track. To remove rubber track, see Rubber Track Remove and Install . (Group 0130.) To remove steel track,
see Steel Track Remove and Install . (Group 0130.)

2. Remove cap screws (1) and lock washers (2).

3. Remove sprocket (3).

4. Repair or replace parts as necessary.

5. Install sprocket (3), cap screws (1), and lock washers (2). Tighten cap screws.

Item Measurement Specification

Sprocket Cap Screw Torque 108 N˙m

80 lb-ft

6. Install track. To install rubber track, see Rubber Track Remove and Install . (Group 0130.) To install steel track, see
Steel Track Remove and Install . (Group 0130.)

MM61211,0000A39-19-20051128
TM2356 - 27D Excavator Repair
Front Idler Remove and Install

Front Idler Remove and Install

T121683-UN: Front Idler on Track Frame

T121684-UN: Front Idler Removed from Track Frame

1. Remove track. To remove rubber track, see Rubber Track Remove and Install . (Group 0130.) To remove steel track, see Steel
Track Remove and Install . (Group 0130.)

2.

CAUTION:

Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

Item Measurement Specification

Front Idler Approximate Weight 26 kg

59 lb

CAUTION:

The front idler may be under spring force from track adjuster and can be pushed out from track frame. Make
sure area in front of idler is clear.

Using a shop hoist, remove front idler from track frame.

3. Repair or replace as necessary.

4. Clean and apply grease to sliding surfaces inside track frame.

5. Install front idler into track frame.

6. Install track. To install rubber track, see Rubber Track Remove and Install . (Group 0130.) To install steel track, see Steel Track
Remove and Install . (Group 0130.)

MM61211,0000A3A-19-20051128
TM2356 - 27D Excavator Repair
Front Idler Disassemble and Assemble

Front Idler Disassemble and Assemble

T206787-UN: Front Idler Components

LEGEND:

1 - Cap Screw (2 used)

2 - Washer (2 used)
3 - Seal (2 used)
4 - O-Ring (2 used)
5 - Axle
6 - Bushing (2 used)
7 - Idler
8 - Yoke (2 used)
9 - Cap Screw (4 used)
10 - Plate

1. IMPORTANT:

Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a
set because of wear pattern on seal ring face.

Inspect metal face seals. See Inspect Metal Face Seals . (Group 0250.)

2. Measure axle (5) and bushings (6) for wear or damage. (See specification for new and allowable limit for wear.)

Item Measurement Specification

Front Idler Axle—New OD 35.0 mm

1.3 in.

Front Idler Axle—Used OD Allowable Limit 34.2 mm

1.3 in.

Front Idler Bushing—New ID 35.0 mm

1.3 in.

Front Idler Bushing—Used ID Allowable Limit 36.0 mm

1.4 in.

Front Idler Bushing Flange—New Thickness 3.5 mm

0.14 in.

Front Idler Flange—Used Thickness Allowable Limit 2.7 mm

0.1 in.

3. NOTE:

Remove bushings only if replacement is necessary.

Remove bushing using a 2-jaw puller and adapter from 17-1/2 and 30-ton puller set.
 4. Apply a thin film of oil on bushings. If removed, install bushings with flange tight against shoulder of idler.

5. IMPORTANT:

O-rings and O-ring grooves must be clean, dry, and free of oil to prevent O-rings from slipping when idler
is turning.

Apply a thin layer of PT569 NEVER-SEEZ® Anti-Seize Lubricant or equivalent to both ends of axle from O-ring
grooves, bore of yokes, and spring pins.

6. Assemble and tighten cap screws.

7. Fill front idler with SAE 30 oil meeting API Service GL-5 (MIL-L-2105E).

Item Measurement Specification

Front Idler Capacity 20 mL

0.67 oz

Yoke Cap Screw Torque 175 N˙m

130 lb-ft

NEVER-SEEZ is a trademark of Emhart Chemical Group. MM61211,0000A3B-19-20060104

TM2356 - 27D Excavator Repair
Measure Front Idler Wear

Measure Front Idler Wear

T121638-UN: Front Idler

LEGEND:

1 - Front Idler Diameter

2 - Guide Width

Measure front idler diameter (1) and guide width (2).

Item Measurement Specification

Front Idler Wear—New Diameter 300 mm

11.8 in.

Front Idler Wear—Used Diameter Allowable Limit 291 mm

11.5 in.

Front Idler Guide Width 28 mm

1.1 in.

MM61211,0000A3C-19-20051128
TM2356 - 27D Excavator Repair
Track Adjuster and Recoil Spring Remove and Install

Track Adjuster and Recoil Spring Remove and Install

T121675-UN: Track Adjuster Removed from Track Frame

T121676-UN: Track Adjuster Correctly Sealed on Plate

T121677-UN: Spring Guide

LEGEND:

1 - Track Adjuster
2 - Track Frame
3 - Spring Guide
4 - Plate

1. Remove front idler. See Front Idler Remove and Install . (Group 0130.)

2.

CAUTION:

Spring or rod may break if dropped while handling, transporting, or disassembling. Nicks or weld craters
in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may
result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering
around spring assembly when handling, transporting, or disassembling.

Slide track adjuster (1) and recoil spring out of track frame (2).

3. Repair or replace parts as necessary.

4. IMPORTANT:

When installing track adjuster (1) with recoil spring into track frame (2), make sure that flat bottom of plate faces
down and top radius of plate aligns with spring guide (3).

Install track adjuster (1) with recoil spring into track frame (2) and push into place until track adjusting valve protrudes from hole in
plate (4).

5. Install front idler. See Front Idler Remove and Install . (Group 0130.)

TX,01,VV2537-19-20050223
TM2356 - 27D Excavator Repair
Track Adjuster and Recoil Spring Disassemble and Assemble

Track Adjuster and Recoil Spring Disassemble and Assemble

1.

CAUTION:

Spring or rod may break if dropped while handling, transporting, or disassembling. Nicks or weld craters in
spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in
immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring
assembly when handling, transporting, or disassembling track adjuster.

A compression tool must be used for disassembly and assembly because of the extreme preload on spring.

CAUTION:

Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

Item Measurement Specification

Track Recoil Spring Disassembly Approximate Weight 225 kg

and Assembly Tool 496 lb

T6557DY-UN: ST4920 Track Recoil Spring Tool

LEGEND:

A - ST4920 Track Recoil Spring Disassembly and Assembly Tool

B - Nut (8 used)
C - Top Plate

Place an 18-t (20-ton) jack on bottom of ST4920 Track Recoil Spring Disassembly and Assembly Tool (A). Remove nuts (B) and top
plate (C). See ST4920 Track Recoil Spring Disassembly and Assembly Tool for instructions to make tool. (Group 9900.)

NOTE:

It is not necessary to remove the recoil spring to replace wear ring and U-ring packing on piston. To replace O-
ring in the cylinder, remove recoil spring and rod.

2. Remove nuts (B). Remove top plate (C).

3. Put track adjuster (A) in disassembly and assembly tool with cylinder end on spacer (B).
 T121701-UN: Installing Track Adjuster in Disassembly and Assembly Tool

LEGEND:

A - Track Adjuster
B - Disassembly and Assembly Spacer

4.
T7720AG-UN: Track Recoil Spring Guard Tool

LEGEND:

A - Top Plate
B - Nut (8 used)
C - Valve
D - Nut
E - Special Plug
F - DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (F). See DFT1087 Track Recoil Spring Disassembly
and Assembly Guard Tool for instructions to make tool. (Group 9900.)

5. Install top plate (A) and nuts (B) with smallest opening to allow access to nut (D).

6. Extend jack ram to provide enough travel to release spring.

7. Tighten nuts (B) so plate is tight against retainer plate.

8. Remove valve (C) and special plug (E).

9.
T7720AH-UN: DFT1087 Track Recoil Spring Guard Tool

LEGEND:

A - Top Plate
B - Nut (8 used)
D - Nut
F - DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
 Raise upper half of guard tool (F). Tighten T-handles.

10. Operate jack to compress spring just enough so nut (D) can be removed.

11. Lower jack ram to release spring force.

12. Repair or replace parts as necessary.

13. If disassembly of track adjuster cylinder is necessary, see Track Adjuster Cylinder Disassemble and Assemble . (Group 0130.)

14. Put track adjuster cylinder in assembly tool with cylinder end on spacer.

15. Install spacer on rod.

16. Install retainer plate.

17. Install guard tool.

18. Install top plate (A). Install nuts (B).

19. Raise upper half of guard tool. Tighten T-handles.

20. Operate jack to compress spring.

21. NOTE:

Align nut (4) with correct hole position in rod (5).

TX1080913-UN: Track Adjuster

LEGEND:

1 - Cap Screw and Washer

2 - Hole Position (rubber track)
3 - Hole Position (steel track)
4 - Nut
5 - Rod

Install nut (4) so threaded hole is aligned with proper hole position in rod (5). Hole position (2) is for rubber track and hole position (3)
is for steel track.

22. Install cap screw and washer (1). Tighten to specification.

Item Measurement Specification

Cap Screw Torque 14.5 N˙m

128 lb-in.

23. Install and tighten valve.

MM61211,00008F0-19-20100901
TM2356 - 27D Excavator Repair
Track Adjuster Cylinder Disassemble and Assemble

Track Adjuster Cylinder Disassemble and Assemble

T159834-UN: Track Adjuster Cylinder

LEGEND:

1 - Socket Head Cap Screw (3 used)

2 - Dust Seal
3 - Flange
4 - Piston Rod
5 - Wear Ring
6 - U-Ring Packing
7 - Retaining Ring
8 - Rod
9 - Cylinder
10 - O-Ring
11 - Plug
12 - Valve
13 - Nut
14 - Retainer Plate
15 - Recoil Spring

CAUTION:

Spring or rod may break if dropped while handling, transporting, or disassembling. Nicks or weld
craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak
spots may result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put
a heavy protective covering around spring assembly when handling, transporting, or disassembling.

A compression tool must be used for disassembly and assembly because of the extreme preload on
spring.

NOTE:

It is not necessary to remove the recoil spring to replace wear ring (5), U-ring packing (6) and dust seal
(2). To replace O-ring (10), remove recoil spring (15) and rod (8).

1. Remove recoil spring if necessary. See Track Adjuster and Recoil Spring Remove and Install . (Group 0130.)
2.
T121703-UN: Track Adjuster Cylinder Assembly

LEGEND:

1 - Socket Head Cap Screw (3 used)

2 - Dust Seal
3 - Flange
4 - Piston Rod
5 - Wear Ring
6 - U-Ring Packing
7 - Retaining Ring
8 - Rod
9 - Cylinder
10 - O-Ring

If necessary, remove rod (8) from cylinder (9) using a press.

3. Repair or replace parts as necessary.

4. Apply multi-purpose grease to U-ring packing (6), dust seal (2), wear ring (5), and O-ring (10). Fill grooves inside flange
(3) with grease.

5. Install U-ring packing (6) with lip toward inside of cylinder.

6. Tighten cap screws (1).

Item Measurement Specification

Flange-to-Track Adjuster Cylinder Torque 20 N˙m

Cap Screw 177 lb-in.

TX,01,VV2539-19-20050223
TM2356 - 27D Excavator Repair
Travel Gearbox Remove and Install

Travel Gearbox Remove and Install

1. See Rubber Track Remove and Install for removal procedure. (Group 0130.)

See Steel Track Remove and Install for removal procedure. (Group 0130.)

2.

CAUTION:

High pressure release of fluid from pressurized system can cause serious burns or penetrating injury. The
hydraulic fluid tank is pressurized. SLOWLY loosen cap to relieve the air pressure in hydraulic fluid tank.

Slowly loosen cap to relieve the air pressure in hydraulic fluid tank.

3. Remove the travel motor cover.

4.
LEGEND:

1 - Travel Motor Lines

2 - Right Travel Motor and Gearbox
3 - Left Travel Motor and Gearbox
4 - Cap Screw and Lock Washer (12 used)

Put identification tags on lines to aid assembly.

5. Disconnect hydraulic lines. Close all openings using caps and plugs.

6.

CAUTION:

Prevent possible injury from crushing. For a Heavy component; use appropriate lifting device.

Item Measurement Specification

Travel Gearbox and Motor Weight 44 kg

100 lb
 T163399-UN: Travel Gearbox and Motor with Lifting Strap

Connect travel gearbox and motor to a hoist using a lifting strap or a JT01748 Lifting Bracket. Remove a sprocket-to-gearbox cap
screw to install lifting bracket.

7. Remove cap screws and lock washers (4) to remove travel gearbox and motor.

8. Remove sprocket from gearbox.

9. NOTE:

The travel gearbox and motor are removed as an assembly because the motor housing is also the second planet
carrier for the gearbox.

Repair or replace parts as necessary.

See Travel Gearbox Disassemble and Assemble . (Group 0250.)

See Travel Motor Disassemble and Assemble . (Group 0260.)

10. Install travel gearbox and motor.

11. Apply PM38654 Thread Lock and Sealer (high strength) to threads of cap screw.Tighten cap screws and lock washers.

Item Measurement Specification

Frame-to-Gearbox Cap Screw Torque 108 N˙m

80 lb-ft

12. Install sprocket to gearbox.

13. Apply PM38654 Thread Lock and Sealer (high strength) to cap screw threads. Tighten cap screws and lock washers.

Item Measurement Specification

Sprocket-to-Gearbox Cap Screw Torque 108 N˙m

80 lb-ft

14. IMPORTANT:

Prevent damage to travel gearbox and travel motor. Make sure oil is added to gearbox and motor before operating
machine whenever a new gearbox and motor are installed, or whenever oil has been drained from the gearbox and
motor.
 T208611A-UN: Right Travel Motor Shown

T208612A-UN: Gearbox Fill Port

LEGEND:

5 - Travel Motor Fill Port

6 - Gearbox Fill Port
7 - Gearbox Level Port
8 - Gearbox Drain Port

Remove plugs from gearbox fill port (6) and gearbox level port (7). Add gear oil to travel gearbox until oil just starts to flow out
gearbox level port (7). Install plugs. See Checking Travel Gearbox Oil Level . (Operator's Manual.)

15. Add hydraulic fluid to travel motor through fill port (5). Use a funnel with a large diameter neck to allow air to escape. For correct
hydraulic fluid, see Hydraulic Oil . (Operator's Manual.)

16. Connect all hydraulic lines. See Travel Hydraulic System Line Identification (Group 9025-15.)

17. Do break-in operation to prevent travel motors from seizing:

a. Perform Checking Hydraulic Oil Tank Level . (Operator's Manual.)

b. Run engine at slow idle.

c. Operate the travel motors at slow speed for at least 2 minutes.

 18. Install cover. Tighten cap screws and washers.

Item Measurement Specification

Motor Cover-to-Frame Cap Screw Torque 49 N˙m

36 lb-ft

LOCTITE is a trademark of the Henkel Group. MH66O88,0000013-19-20090218

TM2356 - 27D Excavator Repair
Travel Gearbox Disassemble and Assemble

Travel Gearbox Disassemble and Assemble

1. See Travel Gearbox Remove and Install for gearbox and motor removal. (Group 0250.)

See Travel Gearbox Operation for a cross-section of Travel Gearbox. (Group 9020-05.)

2.

CAUTION:

Prevent possible injury from crushing. For heavy component; use appropriate lifting device.

Item Measurement Specification

Travel Gearbox and Motor Weight 44 kg

100 lb

T163440-UN: Travel Gearbox Exploded View

LEGEND:

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

Remove plugs (3) and O-rings (4) to drain oil. See Changing Travel Gearbox Oil . (Operator's Manual.)

3. Remove snap ring (5) to remove cover (6) and O-ring (7).

Remove thrust ring (8) if replacement is necessary.

4.

CAUTION:

Prevent possible injury from unexpected machine movement. Planet gears can turn. Keep fingers away from
gears.

T6639GK-UN: Keep Fingers Away From Gears

Remove input shaft (9).

5. NOTE:

First planet carrier and gears are serviced as an assembly.

Remove first planet carrier and gears (10). Disassemble for inspection and cleaning only. Spring pins (14) and pins (18) cannot be
removed because they are a pressed fit in the carrier.

6. Remove snap rings (21) to remove parts (22—26) for second planet gears. Keep parts for each planet gear together.

7.
T163448-UN: Ring Gear and C-Clamps
 Push the ring gear (29) down slightly using C-clamps or a shop press so the snap ring (26) can be removed.

8. Push housing (33) out of ring gear and bearings (31) using a shop press.

9. IMPORTANT:

Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of
wear patterns on seal ring face.

Remove the metal face seals (32) from ring gear and housing. Keep seal rings together as a matched set with a piece of clean
cardboard between them to protect the seal ring face.

See Inspect Metal Face Seals to determine if seals can be reused. (Group 0130.)

10. NOTE:

New bearings should be installed if removed.

Remove bearings (30) only if replacement is necessary. Bearings are a pressed fit.

11. See Travel Motor Disassemble and Assemble for motor disassembly. (Group 0260.)

12. See Travel Gearbox Operation for a cross-section of Propel Gearbox. (Group 9020-05.)

See Travel Motor Disassemble and Assemble for motor assembly. (Group 0260.)

13.
T163440-UN: Travel Gearbox Exploded View

LEGEND:

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

Install the new bearings (30) so the thicker edge of outer race is against the snap ring (31).

14. IMPORTANT:

The metal face seal O-rings and their seat surfaces must be clean, dry, and oil free so the O-rings do not slip.

Thoroughly clean O-rings, seat surfaces in housing (33), ring gear (29), and seal rings using volatile, non-petroleum base solvent and
lint-free tissues.

15. Install O-rings on seal rings. Check that O-ring is not twisted.

16. NOTE:

A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage
the O-ring or leave an oil residue.

Apply equal pressure with fingers at four equally spaced points on seal ring face. Seal must “pop” down into place so O-ring is tight
against seal bore and seal ring is installed squarely.

17. Wipe fingerprints and foreign material off seal ring face using clean oil and lint-free tissues.

18. Apply a thin film of clean oil on each seal ring face.

19. Install ring gear onto housing. Tap around the top edge of ring gear using a soft-faced hammer to seat the bearings on housing.

20.
T163448-UN: Ring Gear And C-Clamps

Push the ring gear (29) down slightly using C-clamps or a shop press so the snap ring (26) can be installed into groove.

21. Check that ring gear can be turned. If not, disassemble and assemble again because the bearings or metal face seals are not
installed correctly.

22. Install parts (26—21) for second planet gears.

a. Install bushings (25) with the beveled end toward bottom of pin.

b. Install thrust washer with the larger ID (26) over bushing and against machined surface.

c. Install remaining parts.

23. Install first planet carrier and gears (10). Install input shaft (9).

24. Install O-ring (7) to groove in ring gear. Apply grease to O-ring.

25. Add gear oil to gearbox. See Changing Travel Gearbox Oil . (Operator's Manual.)

Install plugs and O-rings (3 and 4) and perform Checking Travel Gearbox Oil Level . (Operator's Manual.)

26. Apply grease to thrust ring (8) to hold it in cover (6).

27. Install cover so plug holes are aligned with notches in ring gear.

28. Install the snap ring (5).

29. Install plugs and O-ring.

Item Measurement Specification

Plug and O-Ring-to-Cover Torque 46—51 N˙m

34—38 lb-ft

Level Check Plug and O-Ring-to- Torque 12—13 N˙m

Cover 107—113 lb-in.

MH66O88,0000014-19-20090219
TM2356 - 27D Excavator Repair
Travel Motor Disassemble and Assemble

Travel Motor Disassemble and Assemble

1.

CAUTION:

Prevent possible injury from crushing. For a heavy component; use appropriate lifting device.

Item Measurement Specification

Travel Gearbox and Motor Weight 44 kg

97 lb

See Travel Gearbox Remove and Install for gearbox and motor removal. (Group 0250.)

See Travel Gearbox Disassemble and Assemble for gearbox disassembly. (Group 0250.)

See Travel Motor and Brake Valve Housing Operation for a cross-section of Travel Motor and Brake Valve Housing. (Group 9025-
05.)

2.

CAUTION:

Brake valve housing contains springs under load. Prevent injury from sudden release by loosen cap screws
evenly.

T163627-UN: Travel Motor Exploded View

LEGEND:

1 - Housing Kit
2 - Travel Motor Housing and Second Planet Carrier
3 - Control Piston
4 - Oil Seal
5 - Ball Bearing
6 - Drive Shaft
7 - Pivot Ball (2 used)
8 - Swash Plate
9 - Rotary Group Kit
10 - Piston and Shoe (9 used)
11 - Retainer (holder)
12 - Ball Guide (holder)
 13 - Pin (3 used)
14 - Cylinder Block
15 - Retainer (2 used)
16 - Spring
17 - Snap Ring
18 - Valve Plate
19 - Spacer
20 - Plate (2 used)
21 - Disk
22 - Backup Ring
23 - O-Ring
24 - Park Brake Piston
25 - O-Ring
26 - Backup Ring
27 - O-Ring
28 - Brake Valve Housing Kit
29 - Ball Bearing
30 - Spring Pin
31 - Brake Valve Housing
32 - Dowel Pin
33 - O-Ring (2 used)
34 - Park Brake Spring (8 used)
35 - Cap Screw (7 used)

Loosen cap screws (35) evenly to release force of park brake springs (34).

3. Before removing the brake valve housing (31), measure and record the distance between it and motor housings as a reference for
assembly.

4. IMPORTANT:

Valve plate can stick to the brake valve housing. Dropping the valve plate can damage the highly machined surfaces.
Use care when removing the brake valve housing.

Remove brake valve housing being careful not to drop the valve plate (18).

Protect machined surfaces of valve plate from damage.

5. Remove ball bearing (29) from brake valve housing only if replacement is necessary. Bearing is a pressed fit. If removed, install new
bearings.

6. Remove park brake piston (24).

7. Hold the housing in a horizontal position and then slid the rotary group (10—17) out of housing and off the drive shaft.

8.

CAUTION:

Cylinder block contains a springs under load. Prevent injury from sudden release by using a press to
compress the spring before removing snap ring.

Disassemble rotary group for inspection and cleaning only. Rotary group is serviced as an assembly.

Compress spring (16) using a press before removing the snap ring (21).

9.
T164706-UN: Piston-To-Shoe Clearance
 T164714-UN: Piston-To-Cylinder Block Bore Clearance

Check the clearance between piston and shoe.

Item Measurement Specification

Piston-to-Shoe Clearance 0.4 mm

0.0157 in.

10. Substract piston diameter from cylinder block bore diameter to check for wear.

Item Measurement Specification

Piston-to-Cylinder Block Bore Clearance 0.4 mm

0.0157 in.

11.
T163669-UN: Brake Valve Housing Exploded View

LEGEND:

31 - Brake Valve Housing

38 - Plug (2 used)
39 - O-Ring (2 used)
40 - Spring (2 used)
41 - Washer (2 used)
42 - Guide (2 used)
43 - O-Ring (2 used)
44 - Spring (2 used)
45 - Check Valve (2 used)
46 - Counterbalance Valve Spool
47 - Plug (2 used)
48 - O-Ring (2 used)
49 - Spring
50 - Travel Speed Change Valve Spool
51 - Plug (2 used)
52 - O-Ring (2 used)
53 - Shuttle Valve Spool
54 - Counterbalance Valve Orifice (4 used)

Brake valve housing (31) is serviced as an assembly except the O-rings (39, 43, 48, and 52) and springs (8 and 9). Disassemble for
inspection and cleaning only.

12. Apply clean hydraulic fluid to all machined surfaces after cleaning.

13. See Travel Motor and Brake Valve Housing Operation for a cross-section of Propel Motor and Brake Valve Housing. (Group 9025-
05.)

See Travel Gearbox Disassemble and Assemble for gearbox assembly. (Group 0250.)

14.
T163669-UN: Brake Valve Housing Exploded View

LEGEND:
 31 - Brake Valve Housing
38 - Plug (2 used)
39 - O-Ring (2 used)
40 - Spring (2 used)
41 - Washer (2 used)
42 - Guide (2 used)
43 - O-Ring (2 used)
44 - Spring (2 used)
45 - Check Valve (2 used)
46 - Counterbalance Valve Spool
47 - Plug (2 used)
48 - O-Ring (2 used)
49 - Spring
50 - Travel Speed Change Valve Spool
51 - Plug (2 used)
52 - O-Ring (2 used)
53 - Shuttle Valve Spool
54 - Counterbalance Valve Orifice (4 used)

Apply clean hydraulic fluidl to all parts before installing.

15. Tighten plugs (38, 47, and 51) to specification.

Item Measurement Specification

Shuttle Valve-to-Housing Plug Torque 11.8—21.5 N˙m

104—190 lb-in.

16.
T163627-UN: Travel Motor Exploded View

LEGEND:

1 - Housing Kit
2 - Travel Motor Housing and Second Planet Carrier
3 - Control Piston
4 - Oil Seal
5 - Ball Bearing
6 - Drive Shaft
7 - Pivot Ball (2 used)
8 - Swash Plate
9 - Rotary Group Kit
10 - Piston and Shoe (9 used)
11 - Retainer (holder)
12 - Ball Guide (holder)
13 - Pin (3 used)
14 - Cylinder Block
15 - Retainer (2 used)
16 - Spring
17 - Snap Ring
18 - Valve Plate
19 - Spacer
20 - Plate (2 used)
21 - Disk
22 - Backup Ring
23 - O-Ring
24 - Park Brake Piston
25 - O-Ring
26 - Backup Ring
27 - O-Ring
28 - Brake Valve Housing Kit
 29 - Ball Bearing
30 - Spring Pin
31 - Brake Valve Housing
32 - Dowel Pin
33 - O-Ring (2 used)
34 - Park Brake Spring (8 used)
35 - Cap Screw (7 used)

Apply petroleum jelly to lip of oil seal. Install oil seal (4) so the sealing lip (spring side) is toward ball bearing (5). Push to the bottom
of bore.

17. Apply clean hydraulic fluid to components before installing.

As needed, apply petroleum jelly to help hold components in place.

18. Install a new ball bearing tight against shoulder on drive shaft (6).

Install shaft into housing so bearing is to the bottom of bore.

19. Install control piston (3) so large diameter end is to the bottom of piston bore.

20. Install swash plate (8) making sure the pivot balls (7) are seated in the holes in housing and swash plate.

21. Assemble the rotary group (10—17).

22. Hold the travel motor housing (2) in a horizontal position. Carefully install the rotary group aligning the splines in ball guide (12) and
cylinder block (14) with the splines on drive shaft.

NOTE:

The valve plate (18) is installed on the brake valve housing.

23. Install spacer (19).

Starting with a plate (20), alternately install two plates and one disk (21).

24. Install O-rings (23 and 25) and backup rings (22 and 26) into grooves of park brake piston (24) making sure the backup rings are to
outer edges.

25. Push park brake piston into housing against the plate.

26. Add approximately 0.2 L (0.2 qt) of hydraulic fluid to housing.

27. Push the new ball bearing (29) to bottom of bore in brake valve housing (31).

28. Install valve plate (18), springs (34), and O-rings (27 and 33) to brake valve housing. Use petroleum jelly to hold parts in place while
installing brake valve housing.

29. Install brake valve housing (2) being careful that the valve plate does not drop off.

30. Measure the distance between the two housings and compare to measurement made at disassembly. If not the same, disassemble
and check for correct assembly.

31. Tighten cap screws (35) in steps to pull housing down evenly against the springs. Tighten cap screws to specification in a diagonal
pattern.

Item Measurement Specification

Brake Valve Housing-to-Housing Torque 51—65 N˙m

Cap Screw 38—48 lb-ft

32. See Travel Gearbox Remove and Install for gearbox and motor installation. (Group 0250.)
MH66O88,0000069-19-20060105
TM2356 - 27D Excavator Repair
Rotary Manifold Disassemble and Assemble

Rotary Manifold Disassemble and Assemble

1.
T217251-UN: Manifold Assembly

LEGEND:

1 - Cap Screws (4 used)

2 - Cover
3 - O-Ring
4 - Retaining Ring
5 - Thrust Washer (ring)
6 - Body
7 - Pin
8 - Lock Washer (4 used) (not shown)
9 - Oil Seal (7 used)
10 - O-Ring
11 - Backup Ring
12 - Dust Seal
13 - Spindle

Take notice of the position of ports in the spindle and flange (13) with respect to the boss on side of body (6) to aid in
assembly.

2. Secure rotary manifold in upright position.

3. Remove cap screws (1) and remove cover (2).

4. Remove retaining ring (4) and thrust washer (5).

5.
T217250-UN: Rotary Manifold Exploded View

LEGEND:

1 - Cap Screw (4 used)

 2 - Cover
3 - O-Ring
4 - Retaining Ring
5 - Thrust Washer (ring)
6 - Body
7 - Pin
8 - Lock Washer (4 used)
9 - Oil Seal (7 used)
10 - O-Ring
11 - Backup Ring
12 - Dust Seal
13 - Spindle

Remove spindle (13) from body (6) using a puller tool.

6. Remove and replace parts (9—12) as necessary.

7. Apply petroleum jelly or hydraulic fluid to seals (9) before installing into grooves. Check that seals are seated in the
groove.

8. Install O-ring (10) into groove of the body so it is toward the seals and backup ring (11) is toward the dust seal end of
body.

9. Install dust seal (12) so lip is toward the bottom end of body. Apply petroleum jelly to seal lip.

10. Put the spindle (13) on a workbench in a vertical position.

11. IMPORTANT:

Seals can be damaged by pushing the body onto the spindle too rapidly. Push body onto the spindle
slowly.

Install body (6) on the spindle (13) so that the boss on the side of the body is aligned with the spindle ports as noted at
disassembly.

Slowly push body (6) down onto the spindle (13) by tapping on end of body using a soft-face hammer.

12. Install the thrust washer (5).

13. Install retaining ring (4) with the flat side toward the thrust washer (5) and the chamfered side toward the cover (2).

Check that retaining ring (4) is seated in the groove.

14. Install O-ring (3) and cover (2). Tighten cap screws to specification.

Item Measurement Specification

Cover-to-Housing Cap Screw Torque 20 N˙m

177 lb-in.

MH66O88,0000016-19-20060105
TM2356 - 27D Excavator Repair
Engine Remove and Install

Engine Remove and Install

1.
TS281-UN: Avoid High-Pressure Fluids

Disconnect negative battery cable.

2. Remove counterweight. See Counterweight Remove and Install . (Group 1749.)

3.

CAUTION:

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to first stop to relieve
pressure, then remove.

Drain coolant. See Draining Cooling System . (Operator's Manual.)

4. Drain hydraulic fluid. See Changing Hydraulic Tank Oil and Cleaning Suction Screen . (Operator's Manual.)
5.
T207062A-UN: Engine Frame

T207063A-UN: Coolant hoses

LEGEND:

1 - Cap Screw (2 used)

2 - Left-Side Frame Bracket
3 - Left-Rear Frame Bracket
4 - Right-Rear Frame Bracket
5 - Frame Cover
6 - Frame Cover
7 - Right-Side Frame Bracket
8 - Fan Guard
9 - Coolant Hoses
10 - Inlet Fuel Line
11 - Return Fuel Line
12 - Speed Control Cable
13 - Ground Strap

Remove two cap screws (1) holding air cleaner housing.

6. NOTE:

Note any shims that may accompany frame brackets for installation.

Remove frame brackets (2-4) and frame cover (5).

 7. Remove right-side frame bracket (7).

8. Remove air cleaner assembly.

9. Remove coolant fan guard (8) and coolant hoses (9).

10. Remove radiator. See Radiator Remove and Install (S.N. —254999) or see Radiator Remove and Install (S.N. 255000— ) . (Group
0510.)

11. Remove fan belt and fan.

12. Disconnect the inlet (10) and return (11) fuel lines.

13. Disconnect speed control cable (12) from engine.

14. Disconnect ground strap (13).

15.
T207064A-UN: Hydraulic pump

T207070A-UN: Starter
 T207122A-UN: Sling and motor mounts

LEGEND:

14 - Hydraulic Pump Hose

15 - Inlet Flange
16 - Cap Screw (2 used)
17 - Hydraulic Pump
18 - Wire Harness-to-Alternator
19 - Wire Harness-to-Starter Motor
20 - Wire Harness Cap Screw (2 used)
21 - JDG23 Lifting Sling
22 - Engine Mount Cap Screw and Washer (4 used)

Disconnect hydraulic pump hose (14) and inlet flange (15).

16. Remove two cap screws (16) and pull hydraulic pump (17) away from engine until drive coupler is disengaged from flywheel and
housing.

17. Disconnect wire harnesses from alternator (18) and starter motor (19).

18. Remove starter motor.

19. Remove two cap screws (20) and fasteners under starter motor securing wiring harness to engine block.

20. Disconnect wiring harnesses from fuel shut-off solenoid, switches, and sensors. Attach identification tags to wiring to aid installation.
See Engine Harness (W10) Component Location . (Group 9015.)

21.

CAUTION:

Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

Item Measurement Specification

Engine Weight 199 kg

440 lb

IMPORTANT:

The recommended method for lifting the engine is using the JDG23 Lifting Sling. The lifting force must be at 90° to the
lifting points.
 Attach engine to a hoist using the JDG23 Lifting Sling (21).

22. Remove engine mount cap screws and washers (22).

23. Repair or replace parts as necessary.

24. Install engine using JDG23 Lifting Sling (21).

25. Install four engine mounts and cap screws (22). Tighten to specifications.

Item Measurement Specification

Engine Mount-to-Isolator Cap Torque 88 N˙m

Screw 65 lb-ft

26. Align hydraulic pump splines to engine coupler. Tighten to specifications.

Item Measurement Specification

Hydraulic Pump-to-Flywheel Torque 88 N��m

Housing Cover Cap Screws 65 lb-ft

27. Connect inlet flange and hydraulic hose to pump. Tighten to specifications.

Item Measurement Specification

Inlet Flange-to-Hydraulic Pump Torque 48 N˙m

36 lb-ft

28. Fill hydraulic system.

29. Bleed hydraulic system. See Bleed Hydraulic System . (Operator's Manual.)

30. NOTE:

Before installing starter motor, install two cap screws and fasteners under starter, securing wiring harness to
engine block.

Install starter motor.

31. Connect engine wire harness. See Engine Harness (W10) Component Location . (Group 9015.)

32. Connect speed control cable to engine.

33. Install ground strap to frame.

34. Install fan and fan belt.

35. Adjust fan belt tension. See Inspect Fan Belt, Check and Adjust Tension . (Operator's Manual.)

36. Install radiator. See Radiator Remove and Install (S.N. —254999) or see Radiator Remove and Install (S.N. 255000— ) . (Group
0510.)

37. Fill radiator and reservoir with coolant. See Cooling System Fill and Deaeration . (Operator's Manual.)

38. Install air cleaner assembly.

39. NOTE:

Make note of any shims that were removed in the disassembly process, and place in same location of removal.

Attach frame brackets to frame.

40. Attach two cap screws from the upper frame bracket-to-air cleaner.

41. Bleed fuel system. See Bleed Fuel System . (Group 0560.)

42. Install counterweight. See Counterweight Remove and Install . (Group 1749.)

43. Connect the negative battery cable.

TW73308,000043C-19-20090219
TM2356 - 27D Excavator Repair
Exhaust Manifold Remove and Install

Exhaust Manifold Remove and Install

1.
T207342A-UN: Heat Shield

T207343A-UN: Exhaust manifold

 T207362A-UN: Gasket

LEGEND:

1 - Muffler Heat Shield Cap Screw (3 used)

2 - Exhaust Manifold Heat Shield Cap Screw (3 used)
3 - Muffler-to-Exhaust Manifold Nut (4 used)
4 - Muffler Bracket Cap Screw (1 used)
5 - Exhaust Manifold Cap Screw (4 used)
6 - Exhaust Manifold Nut (2 used)
7 - Exhaust Manifold
8 - Cylinder Head Mating Surface
9 - Muffler Gasket
10 - Exhaust Manifold Gasket

Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

2. Remove cap screws (1 and 2) and washers. Remove both heat shields.

3. Remove four muffler-to-exhaust manifold nuts (3) and washers.

4. Loosen muffler bracket cap screw (4).

5. Remove four exhaust manifold cap screws (5).

6. Remove two exhaust manifold nuts (6).

7. Clean all gasket material from exhaust manifold (7) and cylinder head mating surfaces (8).

8. Install muffler gasket (9) and exhaust manifold gasket (10).

9. Install exhaust manifold cap screws and nuts. Tighten to specifications.

Item Measurement Specification

Exhaust Manifold-to-Cylinder Head Torque 26 N˙m

Cap Screw and Nut 19 lb-ft

10. Install muffler-to-exhaust manifold nuts and muffler bracket cap screw.
11. Install exhaust manifold heat shield and muffler heat shield.

MM61211,0000A42-19-20060103
TM2356 - 27D Excavator Repair
Muffler Remove and Install

Muffler Remove and Install

1.
T207371A-UN: Exhaust Pipe

T207372A-UN: Muffler

LEGEND:

1 - Frame Bracket
2 - Exhaust Pipe Clamp
3 - Muffler Heat Shield
4 - Exhaust Manifold Heat Shield
5 - Muffler-to-Exhaust Manifold Nut (4 used)
6 - Muffler Bracket Cap Screw
 Park machine on level surface.

2. Remove counterweight. See Counterweight Remove and Install . (Group 1749.)

3. Remove left-side frame bracket (1).

4. Remove exhaust pipe clamp (2).

5. Remove heat shields to muffler (3) and exhaust manifold (4).

6. Remove four muffler-to-exhaust manifold nuts (5) and washers.

7. Remove muffler bracket cap screw (6) and remove muffler.

8. Install muffler gasket and muffler.

9. Install muffler bracket cap screw (6).

10. Install muffler-to-exhaust manifold nuts (5) and tighten.

11. Install heat shields to exhaust manifold (4) and muffler (3).

12. Install exhaust pipe clamp (2).

13. Install counterweight and left-side panels. See Counterweight Remove and Install . (Group 1749.)

MM61211,0000A43-19-20060103
TM2356 - 27D Excavator Repair
Thermostat Remove and Install

Thermostat Remove and Install

M82315A-UN: Thermostat

LEGEND:

A - Cap Screw
B - Cover
C - Cover Gasket
D - Thermostat
E - Gasket

1. Drain engine coolant. See Draining Cooling System . (Operator's Manual.)

2. Remove cap screws (A).

3. Remove cover (B), cover gasket (C), thermostat (D), and gasket (E).

4. Test thermostat. See Engine Thermostat Test . (Group 9010-25.)

5. At installation, replace gaskets.

Item Measurement Specification

Thermostat Cover Cap Screw Torque 20 N˙m

15 lb-ft

OUO1030,00000BC-19-20060105
TM2356 - 27D Excavator Repair
Water Pump Remove and Install

Water Pump Remove and Install

RG8583A-UN: Water Pump

LEGEND:

A - Water Pump
B - Fan-to-Water Pump Cap Screw (4 used)
C - Fan
D - Spacer
E - Pulley
F - Fan Belt
G - Water Pump-to-Cylinder Head Cap Screw (4 used)
H - Gasket
I - O-Ring
J - Gasket
K - Ball Joint
L - Cap Screw (3 used)

1. Remove radiator. See Radiator Remove and Install . (Group 0510.)

2. Remove thermostat and cover. See Thermostat Remove and Install . (Group 0400.)

3. Disconnect coolant temperature sensor leads.

4. Disconnect upper and lower radiator hoses.

5. Remove fan belt (F).

 6. Remove cap screws (B), fan (C), spacer (D), and pulley (E).

7. Remove mounting cap screws (G), water pump (A), and gasket (H).

8. Remove cap screws (L), ball joint (K), gasket (J), and O-ring (I).

9. Installation is done in the reverse order of removal.

IMPORTANT:

At installation, replace all O-rings and copper washers.

Item Measurement Specification

Water Pump Mounting Cap Screws Torque 26 N˙m

230 lb-in.

Water Pump-to-Fan Mounting Cap Torque 11 N˙m

Screws 97 lb-in.

Water Pump Plug Torque 15 N˙m

132 lb-in.

10. Adjust fan belt tension. See Inspect Fan Belt, Check and Adjust Tension . (Operator's Manual.)

11. IMPORTANT:

Air must be expelled from cooling system when system is filled. Loosen coolant temperature sender or plug in thermostat housing
to allow air to escape when filling system. Tighten sender or plug when all the air has been expelled.

Close drain valve and remove coolant temperature sender from engine. Fill radiator with proper coolant until coolant is present at temperature
sender hole. Install temperature sender and continue to fill radiator to top of filler neck.

MM61211,0000A44-19-20060103
TM2356 - 27D Excavator Repair
Intake Manifold Remove and Install

Intake Manifold Remove and Install

T217247A-UN: Intake Manifold

LEGEND:

1 - Breather Tube
2 - Fuel Injection Lines
3 - Intake Manifold Cap Screw (4 used)
4 - Fuel Filter Bracket
5 - Final Fuel Filter Housing
6 - Terminal Connection

1. Remove counterweight. See Counterweight Remove and Install . (Group 1749.)

2. Disconnect crankcase breather tube (1).

3. IMPORTANT:

Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can
damage the pump.

Clean the injection pump lines and area around the nozzles using a parts cleaning solvent or steam cleaner.

4. Loosen fuel injection line (2) connectors-to-nozzles slightly to release pressure in the fuel system.

5. Remove fuel injection lines.

 6. Disconnect fuel filter bracket (4) from intake manifold.

7. Disconnect final fuel filter housing (5) from intake manifold.

8. Disconnect air intake heater terminal (6).

9. Remove intake manifold cap screws (3).

10. Remove intake manifold.

11. Clean cylinder head and intake manifold mounting surfaces.

12. Install intake manifold using new gasket.

13. Tighten cap screws to specification.

Item Measurement Specification

Intake Manifold Cap Screws Torque 11 N˙m

97 lb-in.

14. Connect air intake heater terminal.

15. Connect both fuel filters to intake manifold.

16. Install fuel injection lines.

17. Connect crankcase breather tube.

MM61211,0000A45-19-20060103
TM2356 - 27D Excavator Repair
Fuel Injection Pump Remove and Install

Fuel Injection Pump Remove and Install

Fuel Injection Pump Remove

1. IMPORTANT:

Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can
damage the pump.

Clean injection lines and area around the injection pump with cleaning solvent or a steam cleaner.

2. Remove radiator, fan, and belt. See Radiator Remove and Install (S.N. —254999) or see Radiator Remove and Install
(S.N. 255000— ) . (Group 0510.)

3. Remove intake manifold. See Intake Manifold Remove and Install . (Group 0400.)

4. Lower air conditioning compressor.

5.
RG13396A-UN: Remove Fuel Lines And Coolant Lines.
 RG13397A-UN: Injection Pump Gear Cover

RG13398A-UN: Injection Pump Gear Timing Marks

LEGEND:

A - Fuel Inlet Line

B - Fuel Return Line
C - Injector Return Line
D - Coolant Line
E - Coolant Line
F - Fuel Shutoff Solenoid Wire Connector
G - Foam Spacer
H - Cap Screw (4 used)
I - Pump Gear Timing Mark
J - Idler Gear Timing Mark

Disconnect fuel inlet line (A), fuel return line (B), and injector return line (C).

6. Disconnect coolant lines (D and E).

7. Disconnect fuel shutoff solenoid wire connector (F).

8. Remove foam spacer (G).

 9. Remove cap screws (H) and remove injection pump gear access cover.

10. NOTE:

For all the timing marks to become aligned, engine may need to be rotated up to fifty-two times.

Alignment marks (I and J) are both identified with a stamped letter “B”.

Rotate engine in the direction of rotation until mark (I) on pump gear aligns with mark on idler gear (J) (both identified
by a stamped letter B). Use chalk or paint to mark injection pump gear to idler gear.

11.
RG13399A-UN: Injection Pump Timing Gear

RG13400A-UN: Injection Pump Timing Gear Puller

 RG13401A-UN: Injection Pump Timing Marks

LEGEND:

A - Timing Gear Nut and Washer

B - Cap Screw (4 used)
C - Threaded Puller Holes
D - Puller Cap Screw (2 used)
E - Gear Puller
F - Injection Pump Timing Mark
G - Gear Cover Mounting Plate Timing Mark

Remove gear retaining nut and washer (A).

12. IMPORTANT:

Do not loosen or disturb cap screws (B) securing gear to the hub. Gear to hub adjustment is pre-set to
comply with strict EPA emissions requirements and is not adjustable. This procedure is done at the pump
manufacturer and cannot be duplicated in the field.

Install puller (E) into threaded holes (C) on gear using cap screws (D).

13. IMPORTANT:

Engine must not be rotated when timing gear is removed from injection pump shaft. Engine should only
be rotated when timing gear is securely fastened to pump or engine damage could result.

Remove gear and hub assembly from injection pump shaft. Gear will stay inside timing cover.

14. IMPORTANT:

Marks must be made on the injection pump and the gear cover mounting plate to correctly install the
pump. If marks are not made, there will be no way to properly time the injection pump.

Note position of timing marks on gear cover mounting plate (G) and injection pump (F). Pump must be installed at the
exact same timing mark as when removed. Scribe a line as accurately and straight as possible at the pump flange
mark (F) onto the gear cover mounting plate.
 15.
RG13402A-UN: Injection Pump Mounting Points

LEGEND:

A - External Lube Line

B - Cap Screw
C - Nut (3 used)

Remove external lube line (A) from pump.

16. Remove cap screw (B).

17. IMPORTANT:

Marks must be made on the injection pump and the gear cover mounting plate to properly install pump.
You must also record the injection pump timing number marked on the pump to correctly install the
pump. If marks are not made and the timing number not recorded, there will be no way to properly time
the injection pump.

Remove pump flange mounting nuts (C) and remove pump.

18. NOTE:

The injection pump timing number is stamped on the engine side of the fuel injection pump
housing. Treat this number as though there is a decimal point between the two digits. (Example 68
= 6.8).

Find and record pump timing number stamped on pump. This number will be needed if pump is being replaced or
recalibrated.

IMPORTANT:

DO NOT attempt to service the injection pump or governor. If unit is in need of repair, it must be serviced
by a qualified EPA/CARB certified fuel injection repair shop. If replacement is necessary, replace entire
unit. Do not rotate engine while injection pump is removed. If engine is rotated, the timing gear cover
must be removed to ensure correct timing.

Pump Installation
1.
RG13399A-UN: Injection Pump Timing Gear

LEGEND:

A - Timing Gear Nut and Washer

B - Cap Screw (4 used)
C - Threaded Puller Holes

Install new O-ring on injection pump.

2. Put injection pump onto back of gear cover mounting plate. Install three mounting nuts. Do not tighten. Align key on
shaft with keyway in gear hub. Ensure gear is still aligned to idler gear.

3. Install nut and washer (A) on pump shaft. Tighten nut to specification.

Item Measurement Specification

Fuel Injection Pump Drive Gear Torque 78—88 N˙m

Hub-to-Shaft Retaining Nut 58—65 lb-ft
4.
RG13403A-UN: Injection Pump Timing Marks

RG13415A-UN: Injection Pump Mounting

LEGEND:

A - Injection Pump Timing Mark

B - Gear Cover Mounting Plate Timing Mark
C - Pump Mounting Nut (3 used)
D - Cap Screw
E - External Lube Line

Align timing mark on injection pump (A) with correct mark on gear cover mounting plate (B).

5. Tighten three pump mounting nuts (C) to specification.

Item Measurement Specification

Injection Pump Mounting Nuts Torque 26 N˙m

228 lb-in.
 6. Install cap screw (D). Tighten to specification.

Item Measurement Specification

Injection Pump Mounting Cap Torque 26 N˙m

Screw 228 lb-in.

7. Fill pump with engine oil through external lube line port until oil runs out. Install external lube line. Tighten lube line
fitting (E) to specification.

Item Measurement Specification

Injection Pump External Lube Line Torque 15 N˙m

Fitting 133 lb-in.

8. Install cover for injection pump timing gear.

9.
RG13396A-UN: Install Fuel and Coolant Lines

LEGEND:

A - Fuel Inlet Line

B - Fuel Return Line
C - Injectors Return Line
D - Coolant Line
E - Coolant Line
F - Fuel Shutoff Solenoid Wire Connector
G - Foam Spacer

Install spacer (G) between pump and engine block.

10. Connect fuel shutoff solenoid wire connector (F).

11. Connect fuel lines (A, B, and C).

12. Connect coolant lines (D and E).

 13. Install intake manifold. See Intake Manifold Remove and Install . (Group 0400.)

14. Install radiator, fan, and belt. See Radiator Remove and Install (S.N. —254999) or see Radiator Remove and Install
(S.N. 255000— ) . (Group 0510.)

New, Rebuilt, or Recalibrated Pump Timing

1.
RG13614-UN: Injection Pump Sticker

LEGEND:

A - Middle 0° Line
B - 1° Line
C - 2° Line
D - 0.5° Line

Install timing mark sticker supplied with pump so that the (A) line is exactly in-line with the mark that was made on the
gear cover mounting plate when the pump was removed.

2. IMPORTANT:

Injection pump timing can not be performed without injection pump timing numbers from original and
replacement pumps. There is no way to properly install the injection pump without these numbers.

Calculate the difference between the timing numbers, recorded earlier, from the original and replacement/recalibrated
pumps. This calculated number will be needed to correctly time the pump.

Example: If the timing number on the replacement/recalibrated pump was 6.0, and the timing number on the original
pump is 4.0 (fuel injection angle of replacement/recalibrated pump) - (fuel injection angle of original pump), the
replacement pump should be timed at the +2.0° (advanced) mark (C) on the new timing mark sticker.

3. NOTE:

Rotating the injection pump away from the cylinder block will advance the timing and rotating the
injection pump toward the cylinder block will delay the timing.

Set the pump to the correct timing mark using the calculated number difference between the original and replacement
pumps. Adjust timing accordingly using the new timing mark sticker.

4. Hold the pump at the correct timing mark and tighten three pump mounting nuts and cap screw to specification.

Item Measurement Specification

Injection Pump Mounting Nuts Torque 26 N˙m

228 lb-in.

Injection Pump Mounting Cap Torque 26 N˙m

Screw 228 lb-in.

5. If removed, install timing cover. See Timing Gear Cover Remove and Install . (Group 0400.)
 6.
RG13396A-UN: Install Fuel And Coolant Lines

LEGEND:

A - Fuel Inlet Line

B - Fuel Return Line
C - Injectors Return Line
D - Coolant Line
E - Coolant Line
F - Fuel Shutoff Solenoid Wire Connector
G - Foam Spacer

Install spacer (G) between pump and engine block.

7. Connect fuel shutoff solenoid wire connector (F).

8. Connect fuel lines (A, B, and C).

9. Connect coolant lines (D and E).

10. Install intake manifold. See Intake Manifold Remove and Install . (Group 0400.)

11. Install radiator, fan, and belt. See Radiator Remove and Install (S.N. —254999) or see Radiator Remove and Install
(S.N. 255000— ) . (Group 0510.)

CS33148,0002C7E-19-20090219
TM2356 - 27D Excavator Repair
Fuel Injection Nozzles Remove and Install

Fuel Injection Nozzles Remove and Install

General Nozzle Service Precautions

Before removal, thoroughly remove all dirt from the cylinder head around fuel injection nozzles. Clean with compressed air to
prevent dirt from entering the cylinders. Plug the bore in the cylinder head after each nozzle has been removed. Cap fuel line
openings as soon as they are disconnected.

Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage and getting debris in
fuel system.

Do not bend the fuel delivery lines, as this may affect their durability. When loosening the fuel pressure lines, hold male union
of nozzle line stationary with a backup wrench.

1. IMPORTANT:

Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can
damage the pump.

Clean the injection pump lines and area around the nozzles using a parts cleaning solvent or steam cleaner.

NOTE:

Nozzles are matched to the cylinders. If removing more than one nozzle, tag each nozzle,
according to the cylinder from which it was removed.

2.
RG13407-UN: Fuel Injector Components

LEGEND:

A - Cap Screw and Washer

B - Retaining Plate
C - Hose Clamp
D - Leak-Off Hose
E - Injection Nozzle
F - Ring
G - Heat Protector

Loosen fuel injection line connectors-to-nozzles slightly to release pressure in the fuel system.

3. Loosen line clamp(s) and remove fuel injection lines.

4. Remove clamps (C) and leak-off hoses (D).

 5. Remove cap screw and washer (A) and retaining plate (B).

6. Remove injection nozzle (E), ring (F), and TEFLON® heat protector (G). If ring and protector stay in cylinder head,
thread a cap screw into protector and pull from cylinder head.

7.
M82126A-UN: If Nozzles Stick in Cylinder Head

LEGEND:

A - Large Flat Washer

B - Nut (2 used)
C - Cap Screw
D - Old Injection Line Nut
E - Injection Nozzle

If nozzles are stuck in cylinder head:

Grind the head of a cap screw (C) so it fits inside a nut from an old injection line (D).

Use two nuts (B) to attach a large flat washer (A) to the cap screw.

Install assembly onto nozzle and use a puller and slide hammer to pull nozzle from cylinder head.

8. Test injection nozzles. Perform Fuel Injection Nozzle Check . (Group 9010-25.)

9. Installation is done in the reverse order of removal.

10. Tighten retaining plate nuts.

Item Measurement Specification

Fuel Injection Retaining Plate Cap Torque 24—28 N˙m

Screw 212—248 lb-in

TEFLON is a trademark of Du Pont Co. OUO1030,00000CB-19-20051128

TM2356 - 27D Excavator Repair
Rocker Arm Cover Remove and Install

Rocker Arm Cover Remove and Install

RG13393-UN: Rocker Arm Cover

LEGEND:

A - Special Nut (3 used)

B - Diaphragm Cover
C - Spring
D - Diaphragm
E - Oil Filler Cap
F - Gasket
G - Baffle
H - Baffle Plate
I - Gasket
J - Rocker Arm Cover
K - Crankcase Breather Tube
L - O-Ring
M - Spring Plate

1. Remove the special nuts (A).

2. Disconnect crankcase breather tube (K).

3. Remove rocker arm cover (J) from cylinder head.

4. Remove diaphragm cover (B).

5. Remove and inspect spring (C) and diaphragm (D). Replace if damaged or deteriorated.

6. Remove baffle plate (H) and baffle (G).

7. Wash baffle in solvent and blow dry with compressed air. Replace baffle if it is damaged or deteriorated.

8. Install baffle and baffle plate.

9. Install diaphragm, spring plate (M), spring, and diaphragm cover.

10. Inspect gasket (I) and O-rings (L) before reinstalling rocker arm cover. Replace if damaged.

11. Clean cylinder head surface and install rocker arm cover on cylinder head. Install special nuts and tighten to
specification.

Item Measurement Specification

Rocker Arm Cover Special Nuts Torque 18 N˙m
156 lb-in.

OUO1030,000006C-19-20051128
TM2356 - 27D Excavator Repair
Rocker Arm Shaft Assembly Repair

Rocker Arm Shaft Assembly Repair

Rocker Arm Shaft Disassemble

1.
RG13416-UN: Rocker Arm Shaft Assembly

LEGEND:

A - Nut
B - Adjusting Screw
C - Mounting Cap Screw
D - Nut
E - Stud
F - Rocker Arm End Support
G - Rocker Arm Shaft
H - Push Rod
I - Valve Cap
J - Intake Valve Rocker Arm
K - Exhaust Valve Rocker Arm
L - Mounting Cap Screw
M - Rocker Arm Shaft Spring
N - Rocker Arm Center Support

Remove rocker arm cover. See Rocker Arm Cover Remove and Install . (Group 0400.)

2. Remove rocker arm end support mounting cap screws (C).

3. Remove rocker arm center support mounting cap screws (L).

4. Lift rocker arm assembly from cylinder head and set on bench.

5. NOTE:

When disassembling the rocker arm assembly, replace components in same location on rocker
arm shaft they were removed from.

Slide rocker arm assembly components off rocker arm shaft while noting positions for reassembly.

6. Lift push rods (H) from cylinder head and note order of removal for reassembly in same positions in head.

Rocker Arm Shaft Inspect

1.
M35262A-UN: Measure Rocker Arm Shaft Outer Diameter

M82022A-UN: Measuring Rocker Arm ID

LEGEND:

A - Rocker Arm Shaft

B - Rocker Arm

Measure outer diameter of rocker arm shaft (A) at each rocker arm location.

Item Measurement Specification

Rocker Arm Shaft OD 15.97—15.98 mm

0.6286—0.6293 in.

Wear Limit 15.95 mm

0.6280 in.

Replace rocker arm shaft if less than wear limit.

2. Measure inner diameters of rocker arms (B) and supports.

Item Measurement Specification

Rocker Arm Shaft Support ID 16.00—16.02 mm

0.630—0.631 in.

Wear Limit 16.09 mm

0.633 in.

Rocker Arm Shaft-to-Rocker Arm Wear Limit 0.14 mm

and Shaft Support Clearance 0.006 in.

Replace rocker arms or supports if ID is more than wear limit.

 3.
M82023A-UN: Measure Length and Bending of Push Rod

LEGEND:

A - Push Rod Length

B - Push Rod Bend

Measure length (A) and bending (B) of push rod.

Item Measurement Specification

Push Rod Length 178.2—178.75 mm

7.018—7.037 in.

Push Rod Bend Wear Limit 0.03 mm

0.001 in.

Replace push rod if not within specifications.

Rocker Arm Shaft Assemble

1. NOTE:

Lubricate all parts with clean oil during assembly.

Install push rods in cylinder head with ball-shaped end down in head. Push rods should be in same locations they were
removed from.

2. Assemble rocker arm assembly components in the reverse order of removal.

3. Place rocker arm assembly on cylinder head. Align rocker arms with valves and push rods. Align rocker arm end
supports and center supports with corresponding holes in head.

4. Install rocker arm support mounting cap screws and torque to specification.

Item Measurement Specification

Rocker Arm Support Cap Screws Torque 26 N˙m

230 lb-in.

5. Adjust valve clearance. See Engine Valve Lash (Clearance) Check and Adjustment . (Group 9010-25.)

OUO1030,000006F-19-20060105
TM2356 - 27D Excavator Repair
Cylinder Head Remove and Install

Cylinder Head Remove and Install

Cylinder Head Remove

T207557-UN: Cylinder Head Remove and Install

T217249-UN: Cylinder Head Cap Screw Loosening Sequence

LEGEND:

A - Mounting Cap Screw

B - Cylinder Head
C - Gasket
D - Fan End of Engine

1. Remove rocker arm cover, rocker arm assembly, push rods, and valve caps. See Rocker Arm Cover Remove and
Install . (Group 0400.)

2. Remove exhaust and intake manifolds. See Exhaust Manifold Remove and Install and see Intake Manifold Remove
and Install . (Group 0400.)

3. Remove water pump. See Water Pump Remove and Install . (Group 0400.)

4. Remove fuel injection nozzles. See Fuel Injection Nozzles Remove and Install . (Group 0400.)

5. NOTE:

Loosen cap screws in two steps. First, loosen all cap screws to 54 N˙m (40 lb-ft). Then, loosen
again to remove.

Remove all mounting cap screws.

6. IMPORTANT:

DO NOT use screwdrivers or pry bars between cylinder block and head to loosen head gasket seal.
Screwdrivers or pry bars can damage cylinder head and block gasket surfaces.
 Lift cylinder head from the block.

7. Remove cylinder head gasket. Inspect for possible oil, coolant, or combustion chamber leaks.

8. Clean gasket sealing surface on cylinder head and engine block.

9. If repair to cylinder head is necessary, see Cylinder Head and Valves Disassemble and Assemble . (Group 0400.)

Cylinder Head Flatness Check

T207255-UN: Cylinder Head

M82028A-UN: Measuring Cylinder Head Flatness

LEGEND:

A - Straightedge
B - Feeler Gauge

1. Before inspection, thoroughly clean all components of carbon or dirt.

2. Measure cylinder head distortion.

3. Place D05012ST Precision “Bevelled Edge” Straightedge (A) along each of the four sides and each diagonal. Measure
clearance between straightedge and combustion surface with a feeler gauge (B).

Item Measurement Specification

Cylinder Head Out-of-Flat Maximum 0.05 mm

0.002 in.

Wear Limit 0.15 mm

0.006 in.

4. If distortion exceeds the wear limit, resurface or replace cylinder head. Remove only enough metal to make cylinder
head flat, but do not remove more than 0.20 mm (0.008 in.).

Item Measurement Specification

Maximum Material Removal for Quantity 0.20 mm

Flattening Head 0.008 in.

Measure Piston-to-Cylinder Head Clearance

M82042A-UN: Measure Piston-to-Cylinder Head Clearance

 1. Remove cylinder head. See Cylinder Head Remove and Install . (Group 0400.)

2. Place three 10 mm (0.400 in.) long pieces of 1.50 mm (0.060 in.) diameter soft wire in three positions on the flat part of
the piston head.

3. Install cylinder head and old gasket. Install cylinder head cap screws and tighten in proper sequence to specified
torque. See Cylinder Head Remove and Install . (Group 0400.)

4. Slowly turn crankshaft one complete revolution.

5. Remove cylinder head and gasket.

6. Measure thickness of flattened section of each piece of wire. Calculate average thickness of wires to obtain piston-to-
cylinder head clearance specification shown below:

Item Measurement Specification

Piston-to-Cylinder Head Clearance 0.66—0.78 mm

0.026—0.031 in.

If clearance is less than specifications, replace cylinder head.

Preliminary Cylinder Head and Valve Checks

Make preliminary inspection of cylinder head and valve assembly during disassembly.

Look for the following conditions:

Sticking Valves:

l Carbon deposits on valve stem.

l Worn valve guides.
l Scored valve stems.
l Warped valve stems.
l Misaligned or broken valve springs.
l Worn or distorted valve seats.
l Insufficient lubrication.

Warped, Worn, or Distorted Valve Guides:

l Lack of lubrication.
l Cylinder head distortion.
l Excessive heat.
l Unevenly tightened cylinder head cap screws.

Distorted Cylinder Head and Gasket Leakage:

l Loss of cylinder head cap screw torque.

l Broken cylinder head cap screw(s).
l Overheating from low coolant level operation.
l Insufficient liner standout.
l Coolant leakage into cylinder causing hydraulic failure of gasket.
l Leaking after cooler.
l Cracked cylinder head.
l Cracked cylinder liner.
l Damaged or incorrect gasket.
l Overpowering or overfueling.
l Damaged cylinder head or block surfaces.
l Improper surface finish on cylinder head.
 l Improperly tightened cylinder head cap screws.
l Faulty gasket installation (misaligned).

Worn or Broken Valve Seats:

l Misaligned valves.
l Distorted cylinder head.
l Carbon deposits on seats due to incomplete combustion.
l Valve spring tension too weak.
l Excessive heat.
l Improper valve clearance.
l Improper valve timing.
l Incorrect valve or seat installed.

Burned, Pitted, Worn, or Broken Valves:

l Worn or distorted valve seats.

l Loose valve seats.
l Worn valve guides.
l Insufficient cooling.
l Cocked or broken valve springs.
l Improper engine operation.
l Improper valve train timing.
l Faulty valve rotators.
l Warped or distorted valve stems.
l “Stretched” valves due to excessive spring tension.
l Warped cylinder head.
l Bent push rods.
l Carbon buildup on valve seats.
l Rocker arm failure.
l Incorrect valve or seat installed.
l Incorrect piston-to-valve clearance.

Improper Valve Clearance:

l Inefficient use of fuel.

l Engine starts harder.
l Maximum engine power will not be achieved.
l Shorter service life of valve train.
l Greater chance for engine to overheat.

Excessive Recession:

l Worn valve guides.

l Bent valves.
l Debris passed through valve train.

Cylinder Head Install

1. IMPORTANT:

Oil passage in gasket must be located over oil passage in cylinder block.

T207557-UN: Cylinder Head Remove and Install

 LEGEND:

A - Mounting Cap Screw

B - Cylinder Head
C - Gasket

Place cylinder head gasket (C) on engine block. Dowels in engine block will assist in aligning gasket.

2. Place cylinder head (B) on engine block. Dowels in engine block will again assist in alignment.

3. IMPORTANT:

Cylinder head mounting cap screws must be checked for proper torque after 50 hours of engine
operation.

T217269-UN: Cylinder Head Torque Sequence

LEGEND:

A - Exhaust Manifold Side

B - Timing Gear Case Side
C - Intake Manifold Side
D - Flywheel Side

Dip mounting cap screws in oil. Install and tighten cap screws in the sequence shown, in stages of gradually increasing
torque. See torque specifications below:

Item Measurement Specification

Cap Screw—First Torque 24 N˙m

212 lb-in.

Cap Screw—Second Torque 48 N˙m

36 lb-ft

Cap Screw—Final Torque 88 N˙m

65 lb-ft

4. Install water pump. See Water Pump Remove and Install . (Group 0400.)

5. Install exhaust and intake manifolds. See Exhaust Manifold Remove and Install and see Intake Manifold Remove and
Install . (Group 0400.)

6. Install rocker arm assembly, push rods, and valve caps. See Rocker Arm Cover Remove and Install . (Group 0400.)

7. Install fuel injectors. See Fuel Injection Nozzles Remove and Install . (Group 0400.)
MM61211,0000A46-19-20060105
TM2356 - 27D Excavator Repair
Cylinder Head and Valves Disassemble and Assemble

Cylinder Head and Valves Disassemble and Assemble

Cylinder Head and Valves Disassemble

1.
T207558-UN: Cylinder Head and Valves

LEGEND:

A - Collet Halves
B - Retainer
C - Valve Spring
D - Stem Seal
E - Intake Valve Guide
F - Exhaust Valve Guide
G - Exhaust Valve
H - Intake Valve

Remove valve caps from valves. Valve caps should be installed on the valves they were removed from.

2. Compress valve spring using a valve spring compressor; remove the collet halves, retainer, valve spring, and valve
stem seal for each valve.

3. Intake and exhaust valve guides are press fit. Replace guides only if necessary.

4. Intake and exhaust valve seat inserts are not replaceable. If inspection of cylinder head reveals worn or damaged
valve seats that grinding will not repair, cylinder head must be replaced.

Valve Seats Inspect

M82029A-UN: Measure Valve Seat Width

LEGEND:

A - Valve Seat Width

Measure valve seat width (A).

If necessary, grind valve seats to meet specifications.

Item Measurement Specification

 Intake Valve Seat Width 1.77 mm
0.070 in.

Wear Limit 2.27 mm

0.089 in.

Exhaust Valve Seat Width 1.34 mm

0.053 in.

Wear Limit 1.84 mm

0.072 in.

Grind Valve Seats

M82039A-UN: Grinding Valve Seat

M82040A-UN: Valve Seat Angles

LEGEND:

A - Seat Grinder
B - Lower Seat Surface (70°)
C - Valve Seat Surface (45°)
D - Seat Width
E - Upper Seat Surface (15°)

IMPORTANT:

Valve seats should never be cut. Cutting a valve seat can damage its sealing surface, which may result in leaks
or valve seat failure. Valve seats should be ground and lapped.

NOTE:

Lightly grind valve seats for a few seconds only to avoid excessive valve seat width.

1. Grind valve seats (C) using a seat grinder (A). For intake valve seats, use a 30° seat grinder. For exhaust valve seats
use a 45° grinder. Follow tool manufacturer's instructions.

2. Measure valve seat width (D) after grinding.

3. If seat is too wide after grinding, grind lower seat surface (B) using a 70° seat grinder until seat width is close to
specifications.

Item Measurement Specification

Lower Valve Seat Surface Angle 70°

4. Grind upper seat surface (E) using a 15° seat grinder until seat width is narrowed to specifications.
 Item Measurement Specification

Upper Seat Surface Angle 15°

5. If valve seats are ground, measure valve recession and check contact pattern between the seat and valve with bluing
dye.

6. Lap valves.

If valve recession exceeds maximum specifications or seats cannot be reconditioned, replace valves and/or cylinder
head.

Clean Valves

1. Hold each valve firmly against a soft wire wheel on a bench grinder.

2. IMPORTANT:

Any carbon left on the stem will affect alignment in valve refacer. DO NOT use a wire wheel on plated
portion of valve stem. Polish the valve stem with steel wool or crocus cloth to remove any scratch marks
left by the wire brush.

Make sure all carbon is removed from valve head, face, and unplated portion of stem.

Inspect and Measure Valves

1.
M35307-UN: Measuring Valve for Bend

M82030A-UN: Valve Face Margin and Angles

LEGEND:

A - Valve Face Margin

B - Valve Face Angle

Check valve for out-of-round, bent, or warped condition using a valve inspection center. Replace valve if necessary.

2. If valve faces are worn, burned, or pitted, grind valves to proper face angle. If valve face margin (A) is less than 0.51
mm (0.020 in.) after grinding, replace valve.
 Item Measurement Specification

Intake Valve Face Margin Width 1.24—1.44 mm

0.049—0.057 in.

Wear Limit Minimum 0.50 mm

0.020 in.

Exhaust Valve Face Margin Width 1.35—1.55 mm

0.053—0.061 in.

Wear Limit Minimum 0.50 mm

0.020 in.

3. Measure valve face angles (B).

Item Measurement Specification

Intake Valve Face Angle 30°

Exhaust Valve Face Angle 45°

4.
M82031A-UN: Measure Valve Stem Diameter

LEGEND:

A - Distance from Valve Face to Measure Point C

B - Distance from Measure Point C to Measure Point D
C - First Valve Stem Diameter Measure Point
D - Second Valve Stem Diameter Measure Point

Measure valve stem diameter at the two locations (C) and (D) at the points shown as (A) and (B). Replace valve if
measurement exceeds wear limit.

Item Measurement Specification

First Valve Stem Measure Point Distance 43 mm

1.693 in.

Second Valve Stem Measure Point Distance 60 mm

2.360 in.

Intake Valve Stem OD 7.96—7.98 mm

0.3134—0.3142 in.

Wear Limit 7.90 mm

0.3110 in.

Exhaust Valve Stem OD 7.96—7.97 mm

0.3134—0.3138 in.

Wear Limit 7.90 mm

0.3110 in.
Lap Valves

NOTE:

Use a rubber suction-cup type lapping tool for valves without a lapping tool groove slit.

If seat does not make proper contact, lap the valve into the seat:

1. Apply small amount of fine lapping compound to face of valve.

2.
M82041A-UN: Lap Valves

LEGEND:

A - Valve Lapping Tool

Turn valve lapping tool (A) to lap valve to seat.

3. Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the surface of the valve face.

4. Wash all parts in solvent to remove lapping compound. Dry parts.

5. Check position of lap mark on valve face. Lap mark must be on or near center of valve face. If not, grind valve seat to
relocate contact area.

Check Valve Recess in Cylinder Head

M82032A-UN: Measuring Valve Recession

LEGEND:

A - Valve Recession
B - Cylinder Head
C - Depth Gauge

Measure valve recession (A) using a depth gauge (C). Replace valve or cylinder head (B) if measurement exceeds
specification.

Item Measurement Specification

Intake and Exhaust Valve Depth 0.30—0.50 mm

Recession 0.012—0.020 in.
 Wear Limit 0.80 mm
0.031 in.

Inspect and Measure Valve Guides

1. Clean valve guides with a plastic brush before inspection or repair.

NOTE:

A few drops of light oil or kerosene will help clean the guides.

2. Measure valve guide inside diameter.

Item Measurement Specification

Valve Guide ID-Intake 8.010—8.025 mm

0.3154—0.3159 in.

Wear Limit 8.10 mm

0.319 in.

Valve Guide ID-Exhaust 8.015—8.030 mm

0.3156—0.3161 in.

Wear Limit 8.10 mm

0.319 in.

Valve Stem-to-Valve Guide Clearance-Intake 0.035—0.070 mm

0.0014—0.0028 in.

Clearance-Exhaust 0.045—0.075 mm
0.0018—0.0030 in.

Wear Limit-Intake and Exhaust 0.18 mm

0.279 in.

If diameter exceeds wear limit, knurl or replace guide.

If diameter is less than wear limit, determine guide-to-stem clearance (guide diameter minus stem diameter).

If clearance exceeds 0.15 mm (0.006 in.) but is less than 0.20 mm (0.008 in.), knurl valve guides.

If clearance exceeds 0.20 mm (0.008 in.), replace valve guides.

Knurl valve guides using:

¡ D20019WI Valve Guide Knurler

Ream inside diameter of valve guides using:

¡ D20021WI Valve Guide Reamer

Replace Valve Guides

Replace valve guides using:

l JDE118 Valve Guide Driver

 l Knurl and ream guides.

M82193A-UN: Valve Guide-to-Cylinder Head Distance

LEGEND:

A - Distance from Top of Cylinder Head

Intake and exhaust valve guides are different. The exhaust valve guide has one groove and the intake valve guide has none.
Install valve guides with tapered ends down. Push valve guides down until top of valve guides are a specified distance (A)
from top of cylinder head.

Item Measurement Specification

Valve Guide Height 14.7—15.0 mm

0.578—0.590 in.

Inspect Valve Springs

1. NOTE:

Free length may vary slightly between valve springs.

M82034A-UN: Measure Spring Free Length

M82035A-UN: Measuring Valve Spring Inclination

LEGEND:
 A - Square Gauge
B - Spring Inclination
C - Free Length

Measure spring free length (C). Replace spring if measurement is less than specification.

Item Measurement Specification

Valve Spring Free Length 44.4 mm

1.870 in.

2. Measure spring inclination (B). Replace spring if measurement exceeds specification.

Item Measurement Specification

Valve Spring Inclination 1.2 mm

0.047 in.

Cylinder Head and Valves Assemble

T207558-UN: Cylinder Head and Valves

LEGEND:

A - Collet Halves
B - Retainer
C - Valve Spring
D - Stem Seal
E - Intake Valve Guide
F - Exhaust Valve Guide
G - Exhaust Valve
H - Intake Valve

1. IMPORTANT:

Do not reuse stem seals if removed. Used seals will leak.

Install new valve stem seals over valve guides.

2. Apply clean engine oil on intake and exhaust valve stems during assembly.

3. Install springs with smaller pitch end or paint mark toward cylinder head.

4. Compress valve springs and retainer until collet halves are able to be installed in grooves of valve stem.

5. Carefully release tension on spring compressor.

6. Tap on end of valve with a plastic hammer to ensure collet halves have seated properly on valve stem.

7. Repeat for remaining valves.

8. Measure valve recession if new valves were installed.

OUO1030,000007B-19-20051128
TM2356 - 27D Excavator Repair
Piston and Connecting Rod Remove and Install

Piston and Connecting Rod Remove and Install

Measure Connecting Rod Side Play

M82116A-UN: Checking Connecting Rod Side Play

LEGEND:

A - Feeler Gauge

Use a feeler gauge (A) to measure clearance between connecting rod and crankshaft.

If side play exceeds wear limit, replace connecting rod and connecting rod cap.

Item Measurement Specification

Connecting Rod Side Play Clearance 0.20—0.40 mm

0.0079—0.0157 in.

Wear Limit 0.55 mm

0.022 in.

Measure Connecting Rod Bearing Clearance

1. IMPORTANT:

Connecting rod caps must be installed on the same connecting rod and in the same direction to prevent
crankshaft and connecting rod damage.

Remove connecting rod cap.

2. Wipe oil from bearing insert and crankshaft journal.

3.
M35351-UN: Apply PLASTIGAGE® to Rod Bearing Insert

LEGEND:

A - PLASTIGAGE®

Put a piece of PLASTIGAGE® (A), or an equivalent, along the full width of the bearing insert approximately 6 mm
(0.250 in.) off center.

4. Turn crankshaft approximately 30° from bottom dead center.

5. IMPORTANT:

Do not rotate crankshaft while PLASTIGAGE is installed. Doing so will result in a false reading.

Install connecting rod end cap and original cap screws. Tighten cap screws to specifications.

Item Measurement Specification

Connecting Rod Cap Screw Torque 47 N˙m

35 lb-ft

6.
M82117A-UN: Measure Width of PLASTIGAGE®

LEGEND:

A - PLASTIGAGE
B - Envelope

Remove cap screws and connecting rod cap.

NOTE:

The flattened PLASTIGAGE will be found on either the bearing insert or the crankshaft journal.

7. Use the graduation marks on the envelope (B) to compare the width of the flattened PLASTIGAGE (A) at its widest
point.

8. Determine bearing clearance. The number within the graduation marks indicates the bearing clearance in millimeters
or inches, depending on which side of the envelope is used.
 9. Remove PLASTIGAGE.

Item Measurement Specification

Connecting Rod Bearing-to- Oil Clearance 0.038—0.074 mm

Crankshaft 0.0015—0.0029 in.

Wear Limit 0.15 mm

0.0059 in.

If clearance is not within specification, replace bearing inserts, repair crankshaft, or both.

Piston and Connecting Rod Remove

1.

CAUTION:

Do not drain engine coolant until it cools below operating temperature. Then slowly loosen
cylinder block drain valve to relieve any pressure.

Drain coolant and engine oil.

2. Remove cylinder head. See Cylinder Head Remove and Install . (Group 0400.)

3. Remove camshaft followers and keep in order for reassembly in the same position.

4. Clean all foreign material from cylinder block top deck.

5. NOTE:

Always follow manufacturer's directions provided with ridge reamer.

RG7455-UN: Remove Ridge Using Ridge Reamer

LEGEND:
 A - Ridge Reamer

Remove carbon from cylinder bore with a scraper or ridge reamer (A). Use compressed air to remove loose material
from cylinders.

6.
M82196AB-UN: Piston, Connecting Rod, and Bearings

LEGEND:

A - Piston and Connecting Rod

B - Bearing Inserts
C - Connecting Rod Cap
D - Connecting Rod Cap Screws

Remove oil pan and strainer tube.

7. Measure connecting rod side play.

8. Measure crankshaft end play.

 9. Measure connecting rod bearing clearance.

10. IMPORTANT:

Pistons and rings, connecting rods, and bearings must be installed in the cylinders from which they were
removed.

Mark rods, pistons, and caps to ensure correct assembly in the same location.

11. IMPORTANT:

Keep inserts with their respective caps for rod and main bearings.

Remove all rod caps (C) with bearing inserts (B).

12. IMPORTANT:

Hold onto piston to prevent piston from dropping. Piston will drop once piston rings have cleared
cylinder bore.

Push piston and connecting rod out of cylinder bore using a wooden dowel.

Measure Crankshaft Connecting Rod Journals

M82062A-UN: Measure Crankshaft Connecting Rod Journals

LEGEND:

A - Main Bearing Journal

B - Connecting Rod Journal

Measure crankshaft connecting rod journals. Measure at several places around journal.

NOTE:

If engine has had a previous major overhaul, journals may have been ground and undersized bearing
inserts installed.

If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine shop.

If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.)
undersize.

Item Measurement Specification

Crankshaft Connecting Rod Journal OD 47.952—47.962 mm

1.8879—1.8883 in.

Wear Limit 47.902 mm

1.8859 in.

Connecting Rod Bearing-to- Oil Clearance 0.038—0.074 mm

Crankshaft Journal 0.0015—0.0029 in.

Wear Limit 0.15 mm

 0.0059 in.

Piston and Connecting Rod Install

M82196C-UN: Piston and Connecting Rod Assembly

LEGEND:

A - Piston Mark “M”

B - Fuel Injection Pump Side
C - Flywheel Side
D - Connecting Rod Alignment Mark
E - Connecting Rod Cap Screw
F - Groove
G - Tangs

1. IMPORTANT:

Pistons must be installed in cylinders from which they were removed and in the same direction. Be
careful not to damage crankshaft rod journal while installing piston.
 NOTE:

Apply clean engine oil to all parts during installation.

Never reuse connecting rod cap screws; replace with new.

Coat piston, cylinder bore, and piston ring compressor with clean engine oil.

2. Rotate crankshaft so that connecting rod journal for the cylinder you working on is at bottom dead center.

3. IMPORTANT:

Ensure rings are correctly staggered before installing ring compressor.

Install piston ring compressor over piston and rings, and tighten.

4. Install piston and connecting rod into the cylinder from which it was removed, with alignment mark (D) on connecting
rod and/or with piston size mark (A) on top of piston toward fuel injection pump side of engine.

5. IMPORTANT:

Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface.

Install bearing insert on connecting rod and rod cap, aligning tangs with grooves.

6. Apply clean engine oil to both bearing inserts and crankshaft journal. Carefully pull rod against crankshaft journal.

7. IMPORTANT:

Connecting rod caps must be installed on the same connecting rods they were removed from.

Install cap on connecting rod with match marks on same side.

8. Dip new connecting rod cap screws in clean engine oil. Install cap screws and tighten to specifications.

9. Repeat with remaining cylinders.

Item Measurement Specification

Connecting Rod Cap Screw Torque 47 N˙m

35 lb-ft

10. If a new piston and connecting rod were installed, stamp a number corresponding to the cylinder number on the
connecting rod cap and connecting rod.

11. Install cylinder head. See Cylinder Head Remove and Install . (Group 0400.)

12. Install oil pan and strainer tube. See Oil Pan and Strainer Remove and Install . (Group 0400.)

PLASTIGAGE is a trademark of the DANA Corporation. OUO1030,0000097-19-20051128

TM2356 - 27D Excavator Repair
Preliminary Piston and Rod Checks

Preliminary Piston and Rod Checks

Scuffed or Scored Pistons:

l Insufficient lubrication.
l Insufficient cooling.
l Improper piston-to-cylinder bore clearance.
l Coolant leakage in crankcase.
l Misaligned or bent connecting rod.
l Improperly installed piston.
l Low oil level.
l Improper operation.
l Incorrect connecting rod bearing clearance.
l Carbon build-up in ring groove.
l Improper break-in.
l Worn piston.
l Contaminated oil.

Worn or Broken Compression Rings:

l Insufficient lubrication.
l Insufficient cooling.
l Improper ring installation.
l Improper combustion.
l Improper timing.
l Abrasives in combustion chamber.

Clogged Oil Control Ring:

l Improper oil.
l Excessive blow-by.
l Contaminated oil.
l Improper periodic service.
l Low operating temperature.

Dull Satin Finish and Fine Vertical Scratches on Rings:

l Dirt and abrasives in air intake system.

Stuck Rings:

l Improper oil classification.

l Improper periodic service.
l Poor operating conditions.
l Coolant leakage in crankcase.
l Excessive cylinder bore taper.

Cylinder Wear and Distortion:

l Incorrectly installed compression rings.

l Insufficient lubrication.
l Uneven cooling around cylinder bore.
l Improper piston-to-cylinder bore clearance.
l Cylinder bore damage.
Warped Cylinder Block:

l Insufficient cooling.

Broken Connecting Rod:

l Inadequate piston-to-cylinder bore clearance.

l Worn connecting rod bearing.
l Distorted cylinder bore.
l Piston pin failure.

Piston Pin and Snap Ring Failure:

l Misaligned connecting rod.

l Excessive crankshaft end play.
l Incorrect snap rings.

Mottled, Grayish, or Pitted Compression Rings:

l Internal coolant leaks.

OUO1030,0000094-19-20051128
TM2356 - 27D Excavator Repair
Piston and Connecting Rod Disassemble and Assemble

Piston and Connecting Rod Disassemble and Assemble

Piston and Connecting Rod Disassemble

1. Remove piston rings.

2. IMPORTANT:

Pistons must be installed on the same connecting rod they were removed from.

Put a mark on each piston and connecting rod to aid in assembly.

3. Remove and discard piston pin snap rings and separate piston from connecting rod.

4. Piston pin bushing is press fit in connecting rod. Remove bushing only if replacement is necessary.

Clean Pistons

RG7465-UN: Cleaning Piston Ring Grooves

1.

CAUTION:

Always follow manufacturer's instructions and safety steps exactly.

Clean piston ring grooves using a piston ring groove cleaning tool.

2. IMPORTANT:
 When washing pistons, always use a stiff bristle brush—NOT A WIRE BRUSH—to loosen carbon residue.

DO NOT bead blast ring groove areas.

Clean pistons by any of the following methods:

¡ Immersion-Solvent “D-Part”.
¡ Hydra-Jet Rinse Gun.
¡ Hot water with liquid detergent soap.

If cleaning with hot water and liquid detergent, soak pistons in a 50 percent solution of liquid household detergent and
hot water for 30 to 60 minutes. Use a stiff bristle brush—NOT A WIRE BRUSH—to loosen carbon residue. Dry with
compressed air.

Visually Inspect Pistons

RG3326-UN: (Defects Exaggerated)

LEGEND:

A - Fine Cracks in Piston Head

B - Bent or Broken Ring Lands
C - Cracks in the Skirt

Carefully inspect pistons under magnification. Check for:

l Signs of fatigue.
l Fine cracks in the piston head (A).
l Bent or broken ring lands (B).
l Cracks in the skirt (C) at inner and outer ends of piston pin bore.
l Excessive piston skirt wear (original machining marks must be visible).

If any imperfections are found, replace the piston.

Check Piston Ring Groove Wear

M35360-UN: Measure Piston Ring Groove Clearance

With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston.

Item Measurement Specification

Top Compression Ring Clearance 0.70—0.105 mm

0.0028—0.0041 in.

Wear Limit Can not be accurately measured

due to design

Second Compression Ring Clearance 0.035—0.070 mm

0.0014—0.0028 in.

Wear Limit 0.190 mm

0.0075 in.

Oil Ring Clearance 0.030—0.060 mm

0.0012—0.0024 in.

Wear Limit 0.180 mm

0.0071 in.

Measure Piston Ring End Gap

M82049B-UN: Piston Ring End Gap

LEGEND:

A - End Gap
B - Cylinder Bore
C - Piston Ring
D - Approx. 30 mm (1.181 in.)

Push loose piston ring (C) into cylinder bore, using a piston, until ring is approximately 30 mm (1.181 in.) from bottom of
cylinder bore.

Measure piston ring end gap (A) and compare to specifications.

If end gap exceeds wear limit, replace piston rings.

Item Measurement Specification

All Piston Rings Gap 0.20—0.40 mm

0.008—0.016 in.

Wear Limit 0.490 mm

0.019 in.
Measure Piston Pin Bore

M37683-UN: Measure Piston Pin Bore

Measure piston pin bore diameter in piston.

If piston pin bore is not within specification, replace piston.

If bore clearance (bore ID minus pin OD) exceeds specification, replace piston, piston pin, or both.

Item Measurement Specification

Piston Pin Bore Diameter 26.00—26.009 mm

1.0236—1.0240 in.

Wear Limit 26.039 mm

1.0252 in.

Piston Pin-to-Piston Pin Bore Wear Limit 0.120 mm

0.0047 in.

Oil Clearance 0.000—0.014 mm

0.0000—0.0006 in.

Wear Limit 0.074 mm

0.0029 in.

Measure Piston Diameter

M82200A-UN: Piston Diameter Measurement Height

M82052A-UN: Measure Piston Diameter Perpendicular to Piston Pin Bore

LEGEND:

A - Piston Measure Point

1. Measure piston diameter perpendicular (90°) to piston pin bore at distance (A).

If piston diameter is less than wear limit, install a new piston.

Item Measurement Specification

Measurement Location (A) Distance 24 mm

0.945 in.

Standard Piston Diameter 87.945—87.975 mm

3.4624—3.4636 in.

Wear Limit 87.900 mm

3.4606 in.

0.25 mm (0.010 in.) Oversize Piston Diameter 88.195—88.225 mm

3.4722—3.4734 in.

Wear Limit 88.150 mm

3.4705 in.

Piston-to-Cylinder Bore Clearance 0.040—0.070 mm

0.0016—0.0028 in.

2. NOTE:

If engine has had a previous major overhaul, oversize pistons and rings may have been installed.
Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines.

Measure cylinder bore diameter and compare with piston diameter to determine piston-to-cylinder bore clearance.

If clearance exceeds wear limit, cylinders must be bored oversize.

Inspect Piston Pins and Bushings

RG7466-UN: Inspect Piston Pins and Bushings

LEGEND:

A - Pin

1. Visually inspect piston pin. Pin must be in good condition with no visible wear.

2. IMPORTANT:

Do not attempt to polish or refinish piston pin. Pin has a highly polished surface.

Dip piston pin in clean engine oil.

3. Install pin (A) through piston. Pin should pass through piston using only light thumb pressure.

4. Insert pin from both sides. If pin enters freely, but binds in the center, the bore could be tapered. Pin should not “click”
or need to be forced into bore on opposite side.

Measure Piston Pins

M82050A-UN: Measure Piston Pins

Measure piston pin diameter. Measure diameter at six places.

If pin diameter is less than wear limit, replace pin.

If bore clearance (bore ID minus pin OD) exceeds specification, replace piston pin, piston, or both.

Item Measurement Specification

Piston Pin Diameter 25.995—26.000 mm

1.0234—1.0236 in.
 Wear Limit 25.965 mm
1.0222 in.

Piston Pin-to-Piston Pin Bore Oil Clearance 0.000—0.014 mm

0.0000—0.0006 in.

Wear Limit 0.074 mm

0.0029 in.

Measure Piston Pin Bushings

M82051A-UN: Measure Piston Pin Bushings

Measure piston pin bushing diameter in connecting rod.

If bushing diameter exceeds specification, replace bushing.

NOTE:

When pressing in new bushings in connecting rod end, be sure oil holes are aligned.

If bushing clearance (bushing ID minus pin OD) exceeds specification, replace bushing, piston pin, or both.

Item Measurement Specification

Piston Pin Bushing In Connecting ID 25.025—26.038 mm

Rod 0.9852—1.0251 in.

Wear Limit 26.068 mm

0.9082 in.

Piston Pin-to-Piston Pin Bushing Oil Clearance 0.025—0.043 mm

0.0010—0.0017 in.

Measure Connecting Rod Bearings

M82048A-UN: Measuring Connecting Rod Bearings

Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap screws and tighten to
specifications.

Item Measurement Specification

Connecting Rod Cap Screw Torque 47 N˙m

35 lb-ft
Measure inside diameter of bearing at three places as shown.

If bearing diameter exceeds wear limit, replace bearing inserts.

If bearing clearance with new bearing inserts (bearing ID minus crankshaft journal OD) exceeds specification, grind crankshaft
connecting rod journals and install undersized bearing inserts, or replace bearing inserts and crankshaft.

Item Measurement Specification

Connecting Rod Bearing ID 48.00—48.028 mm

1.888—1.891 in.

Wear Limit 48.07 mm

1.893 in.

Piston and Connecting Rod Assemble

M82198AB-UN: Assemble Piston and Connecting Rod

LEGEND:

A - Piston Mark “M”

B - Piston
C - Piston Pin
D - Snap Ring
E - Connecting Rod
F - Stamped Mark
G - Bearing Insert Groove
 1. IMPORTANT:

Pistons must be installed on the same connecting rod they were removed from, and new piston pin snap
rings must be used.

NOTE:

Apply clean engine oil to all parts during assembly.

Assemble piston to connecting rod with piston identification mark “M” (A) on same side as connecting rod stamped
mark (F). If a new connecting rod is used, assemble piston to connecting rod with piston mark “M” opposite connecting
rod bearing insert groove (G). Be sure oil hole in piston pin bushing is aligned with hole in connecting rod.

2. Install piston pin and new snap rings.

Piston Rings Install

M82046A-UN: Oil Ring Components

M82199A-UN: Piston Assembly

LEGEND:

A - Oil Ring Expander

B - Oil Ring Expander Ends
C - Oil Ring
D - Oil Ring Gap
E - Piston Pin
F - Second Compression Ring
G - First Compression Ring

1. Install oil ring expander (A) in bottom ring groove of piston with ends above either end of piston pin (E).

2. Install oil ring over expander with ring gap (D) opposite (180°) of expander ends (B).

3. Install second compression ring, with manufacturer's mark (near ring gap) toward top of piston, in middle groove. Turn
ring until gap is 120° away from oil ring gap.

4. Install first compression ring (chrome plated), with manufacturer's mark “R”, “T”, or “RN” (near ring gap) toward top of
piston, in top groove. Turn ring until gap is 120° away from second ring gap and oil ring gap.

OUO1030,0000093-19-20051128
TM2356 - 27D Excavator Repair
Cylinder Block Repair

Cylinder Block Repair

Cylinder Block Clean and Inspect

Before inspecting and cleaning cylinder block, remove all of the following:

l Soft plugs
l Oil galley plugs
l All internal and external mounted components

1. IMPORTANT:

If block is cleaned in a hot tank, remove any aluminum parts (such as galley plugs) that can be damaged
by hot tank solutions.

Clean block thoroughly using cleaning solvent, pressure steam, or a hot tank.

2. All passages and crevices must be clear of sludge and grease.

3. All coolant passages must be free of lime deposits and scale.

Measure Camshaft Follower Bores in Block

Measure camshaft follower bores at all bore locations in block.

If any one camshaft follower bore ID or cam follower-to-follower bore clearance exceeds specification, install a new cylinder
block.

Inspect and measure cam followers.

Item Measurement Specification

Camshaft Follower Bore ID 12.00—12.025 mm

0.4724—0.4734 in.

Wear Limit 12.045 mm

0.4742 in.

Camshaft Follower-to-Bore Oil Clearance 0.010—0.050 mm

0.0004—0.0019 in.

Wear Limit 0.090 mm

0.0035 in.

Measure Camshaft Bushing and Bores in Block

M82072-UN: Camshaft Bushing at Gear Housing End

LEGEND:

A - Camshaft Bushing
B - Oil Hole

1. NOTE:

Replaceable camshaft bushing (A) is installed in front camshaft bore only. Remaining bores in
cylinder block act as camshaft bushings.

Measure camshaft bushing diameter at gear housing end.

If bushing diameter is not within specification, replace bushing.

2. To replace bushing:

a. Remove bushing using a chisel. Be careful not to push bushing inside of engine.

b. Align oil holes in new bushing and cylinder block. Install bushing using a driver set.

3.
M35287A-UN: Flywheel End Plug
 M82073-UN: Intermediate and Flywheel Bores

LEGEND:

A - Plug
B - Intermediate Bores
C - Flywheel-End Bore

Remove flywheel housing. See Flywheel Housing Remove and Install . (Group 0400.)

4. Remove plug (A) using a long wooden dowel. Insert wooden dowel through gear housing side.

5. Measure intermediate (B) and flywheel-end (C) camshaft bore diameters. If bore diameter exceeds specification,
replace cylinder block.

6. Apply PM38657 Flexible Form-in-Place Gasket on outer edge of plug. Install plug until it bottoms in bore.

7. Install flywheel housing. See Flywheel Housing Remove and Install . (Group 0400.)

Item Measurement Specification

Gear Housing End (Bushing) ID 44.990—45.055 mm

1.771—1.774 in.

Wear Limit 45.13 mm

1.777 in.

Intermediate and Flywheel-End ID 45.00—45.025 mm

Bores 1.772—1.773 in.

Wear Limit 45.10 mm

1.776 in.

Camshaft Journal-to-Bushing—Gear Oil Clearance 0.040—0.130 mm

Housing End 0.0016—0.0051 in.

Wear Limit 0.240 mm

0.0094 in.

Camshaft Journal-to-Block— Oil Clearance 0.065—0.115 mm

Intermediate 0.0026—0.0045 in.

Wear Limit 0.225 mm

0.0089 in.

Camshaft Journal-to-Block— Oil Clearance 0.050—0.100 mm

Flywheel End 0.0020—0.0039 in.
 Wear Limit 0.210 mm
0.0083 in.

Inspect and Measure Cylinder Bore

M82053A-UN: Inspect and Measure Cylinder Bore

LEGEND:

A - Top Position
B - Middle Position
C - Bottom Position
D - Direction of Crankshaft Rotation
E - Direction of Crankshaft Centerline

Measure cylinder bore diameter at three positions: top, middle, and bottom. At these three positions, measure in both
directions: along crankshaft centerline and in direction of crankshaft rotation.

NOTE:

If engine has had a previous major overhaul, oversize pistons and rings may have been installed.

Slightly uneven wear, flaws, or minor damage may be corrected by deglazing.

If cylinder bore exceeds wear limit, replace cylinder block or have cylinder rebored.

If cylinder is rebored, oversize pistons and rings must be installed. Pistons and rings are available in 0.25 mm (0.010 in.)
oversize.

If clearance (cylinder bore ID minus piston OD) exceeds specification, replace cylinder block, piston, or both; or rebore cylinder
and install oversize piston and rings.

Item Measurement Specification

Standard Bore Diameter 88.00—88.03 mm

3.4646—3.4657 in.

Wear Limit 88.20 mm

3.472 in.

0.25 mm (0.010 in.) Oversize Bore Diameter 88.25—88.28 mm

3.4744—3.4756 in.

Wear Limit 88.45 mm

3.482 in.

Piston-to-Cylinder Bore Clearance 0.040—0.070 mm

0.0016—0.0028 in.

Cylinder Bore Out-of-Round 0.01 mm

0.0004 in.
 Wear Limit 0.03 mm
0.0012 in.

Cylinder Bore Taper 0.01 mm

0.0004 in.

Wear Limit 0.03 mm

0.0012 in.

Deglaze Cylinder Bores

M82054A-UN: 30°—40° Crosshatch Pattern

If cylinder bores have slightly uneven wear, minor flaws, or damage, they can possibly be corrected by deglazing.

1. IMPORTANT:

If cylinder bores are to be deglazed with crankshaft installed in engine, put clean shop towels over
crankshaft to protect journal and bearing surfaces from any abrasives.

Deglaze cylinder bores using a flex-hone with 300 grit stones.

2. Use flex-hone as instructed by manufacturer to obtain a 30°—40° crosshatch pattern as shown.

3. IMPORTANT:

Do not use gasoline, kerosene, or commercial solvents to clean cylinder bores. Solvents will not remove
all abrasives from cylinder walls.

Remove excess abrasive residue from cylinder walls using a clean, dry rag. Clean cylinder walls using clean white rags
and warm, soapy water. Continue to clean cylinder until white rags show no discoloration.

Rebore Cylinder Bores

NOTE:

The cylinder block can be rebored to use oversize pistons and rings. Pistons and rings are available in
0.25 mm (0.010 in.) oversize for all engines.

1. Align center of bore to drill press center.

2. IMPORTANT:

Check stone for wear or damage. Use a rigid hone with 180 grit stones.

Adjust hone so lower end is even with lower end of cylinder bore.

3. Adjust rigid hone stones until they contact narrowest point of cylinder.

4. Coat cylinder with honing oil. Hone should turn by hand. Adjust if too tight.
 5.
M52959-UN: Using Rigid Hone

Run drill press at about 250 rpm. Move hone up and down in order to obtain a 30°—40° crosshatch pattern.

6. NOTE:

Measure bore when cylinder is cool.

Stop press and check cylinder diameter.

7. NOTE:

Finish should not be smooth. It should have a 30°—40° crosshatch pattern.

Remove rigid hone when cylinder is within 0.03 mm (0.001 in.) of desired size.

8. Use a flex hone with 300 grit stones for honing to final size.

9. Check bore for size, taper, and out-of-round.

10. IMPORTANT:

Do not use solvents to clean cylinder bore. Solvents will not remove all metal particles and abrasives
produced during honing.

Clean cylinder thoroughly using warm, soapy water until clean white rags show no discoloration.

11. Dry cylinder and apply engine oil.

LOCTITE is a trademark of Loctite Corp. MM61211,0000A47-19-20060105

TM2356 - 27D Excavator Repair
Check Engine Rotation for Excessive Tightness

Check Engine Rotation for Excessive Tightness

1. Rotate crankshaft several revolutions to be sure engine rotates without excessive tightness.

2. Check cylinder bores for deep scratches caused by an improperly installed or broken piston ring.

3. Check side clearance of connecting rods.

OUO1030,000007F-19-20051128
TM2356 - 27D Excavator Repair
Crankshaft and Main Bearing Failure Analysis

Crankshaft and Main Bearing Failure Analysis

Scored Main Bearing: (Diagnosis also applies to connecting rod bearing.)

l Oil starvation.
l Contaminated oil.
l Engine parts failure.
l Excessive heat.
l Poor periodic service.

Galled or “Wiped” Bearings:

l Fuel in lubricating oil (incomplete combustion).

l Coolant in lubrication system (cracked block).
l Leaking water pump (Seal with plugged hole).
l Insufficient bearing oil clearance.
l Parts not lubricated prior to engine operation.
l Wrong bearing size.

Inconsistent Wear Pattern

l Misaligned or bent connecting rod.

l Warped or bowed crankshaft.
l Distorted cylinder block.

Broken Main Bearing Caps:

l Improper installation.
l Dirt between bearing and crankshaft journal.
l Low oil pressure.
l Oil pump failure.

Cracked, Chipped or Broken Bearings:

l Overspeeding.
l Excessive idling.
l Lugging.
l Excessive oil clearance.
l Improper installation.

OUO1030,00000B4-19-20051128
TM2356 - 27D Excavator Repair
Replace Crankshaft Front Oil Seal

Replace Crankshaft Front Oil Seal

M82203A-UN: Timing Gear Cover and Oil Seal

LEGEND:

A - Timing Gear Cover

B - Oil Seal

1. Remove timing gear cover (A). See Timing Gear Cover Remove and Install . (Group 0400.)

2. Replace oil seal (B) using a driver set. Install seal with lip toward inside of gear housing cover. Install seal flush with
surface of cover.

OUO1030,00000B3-19-20051128
TM2356 - 27D Excavator Repair
Measure Crankshaft End Play

Measure Crankshaft End Play

M82118A-UN: Measure Crankshaft End Play

LEGEND:

A - Dial Indicator
B - Crankshaft

NOTE:

Crankshaft end play can be measured at front end or rear end of crankshaft. Procedure shown is
performed from the rear end. The flywheel is removed to show detail.

1. Fasten dial indicator(A) to engine, and position indicator tip on end of crankshaft.

2. IMPORTANT:

Do not use excessive force when moving crankshaft to avoid damaging bearings.

Push crankshaft (B) toward rear as far as possible.

3. Zero the dial indicator.

4. Using a bar, gently pry the crankshaft as far forward as possible.

Item Measurement Specification

Crankshaft End Play 0.13—0.23 mm

0.005—0.009 in.

Wear Limit 0.28 mm

0.011 in.

If end play exceeds wear limit, replace thrust bearings.

OUO1030,00000B2-19-20051128
TM2356 - 27D Excavator Repair
Flywheel Remove and Install

Flywheel Remove and Install

T207259A-UN: Flywheel Remove and Install

LEGEND:

1 - Cap Screw (6 used)

2 - Flywheel

1. Remove dampener drive (flex coupler). See Dampener Drive (Flex Coupling) Remove and Install . (Group 3360.)

2. Remove mounting cap screws (1) and flywheel (2).

3. Examine flywheel ring gear for worn or broken teeth.

4. Replace flywheel if defective.

5. IMPORTANT:

Never reuse flywheel mounting cap screws. Always install new cap screws.

Apply clean engine oil to flywheel mounting cap screws.

6. Tighten to specification.

Item Measurement Specification

Flywheel Cap Screw Torque 83 N˙m

61 lb-ft

OUO1030,00000AF-19-20060105
TM2356 - 27D Excavator Repair
Crankshaft Rear Oil Seal Replace

Crankshaft Rear Oil Seal Replace

M82349A-UN: Crankshaft Rear Oil Seal Components

LEGEND:

A - Rear Oil Seal

B - Oil Seal Case-to-Cylinder Block Cap Screw
C - Oil Seal Case
D - Flexible Form-In-Place Gasket
E - Oil Seal Case-to-Crankcase Extension Cap Screw

1. Remove flywheel. See Flywheel Remove and Install . (Group 0400.)

2. Remove rear oil seal case (C).

3. Replace oil seal (A) using a driver set. Install seal, with lip toward cylinder block. Install seal flush with surface of oil
seal case.

NOTE:

If crankshaft is grooved at oil seal contact point, seal can be installed 3 mm (0.120 in.) farther into
oil seal case.

4. Apply PM38657 Flexible Form-In-Place Gasket to oil seal case mounting surface.

5. Install rear oil seal case and tighten cap screws securely.

LOCTITE is a trademark of Loctite Corp. MM61211,0000A48-19-20051130

TM2356 - 27D Excavator Repair
Crankcase Extension Housing Remove and Install

Crankcase Extension Housing Remove and Install

M82056-UN: Flywheel Housing, Rear Oil Seal Case

RG10855A-UN: Gasket Assembly

LEGEND:

A - Flywheel Housing
B - Rear Oil Seal Case
C - Cap Screw (Flywheel Housing-to-Crankcase Extension Housing)
D - Cap Screw (Rear Oil Seal Case-to-Crankcase Extension Housing)
E - Flexible Form-In-Place Gasket
F - Cap Screw (Crankcase Extension Housing-to-Timing Gear Cover)
G - Crankcase Extension Housing
H - Cap Screw (Crankcase Extension Housing-to-Cylinder Block)

1. Remove flywheel. See Flywheel Remove and Install . (Group 0400.)

2. Remove oil pan. See Oil Pan and Strainer Remove and Install . (Group 0400.)

3. Remove rear oil seal case-to-crankcase extension housing cap screws (D) and flywheel housing-to-crankcase
extension housing cap screws. (C).

4. Remove crankcase extension housing cap screws (F and H) and crankcase extension housing (G).

5. Inspect crankcase extension housing for cracks.

6. Apply PM38657 Flexible Form-In-Place Gasket in a continuous 2—4 mm (0.080—0.157 in.) bead to crankcase
extension housing.

7. Install extension housing and tighten cap screws to specification.

Item Measurement Specification

Rear Oil Seal Case-to-Crankcase Torque 21 N˙m

Extension Housing Cap Screws 186 lb-in.

Flywheel Housing-to-Crankcase Torque 49 N˙m

Extension Housing Cap Screws 36 lb-ft

Crankcase Extension Housing-to- Torque 27 N˙m

Cylinder Block Cap Screws 20 lb-ft

Crankcase Extension Housing-to- Torque 22 N˙m

Timing Gear Cover Cap Screws 195 lb-in.

LOCTITE is a trademark of Loctite Corp. OUO1030,00000AD-19-20051130

TM2356 - 27D Excavator Repair
Flywheel Housing Remove and Install

Flywheel Housing Remove and Install

M82288A-UN: Flywheel Housing

LEGEND:

A - Flywheel Housing-to-Cylinder Block Cap Screw

B - Flywheel Housing
C - Flexible Form-In-Place Gasket
D - Plug
E - Flywheel Housing-to-Crankcase Extension Cap Screw

1. Remove flywheel. See Flywheel Remove and Install . (Group 0400.)

2. Remove starting motor.

3. Remove cap screws (A and E) and remove flywheel housing.

4. When installing, apply a bead of PM38657 Flexible Form-In-Place Gasket to mounting flange of flywheel housing.

5. Tighten cap screws (A and E) to specification.

Item Measurement Specification

Flywheel Housing-to-Cylinder Block Torque 49 N˙m

Cap Screw 36 lb-ft

Flywheel Housing-to-Crankcase Torque 49 N˙m

Extension Cap Screw 36 lb-ft

LOCTITE is a trademark of Loctite Corp. MM61211,0000A49-19-20051130

TM2356 - 27D Excavator Repair
Crankshaft and Main Bearings Repair

Crankshaft and Main Bearings Repair

Crankshaft and Main Bearings Remove

1. Drain oil from crankcase.

2. Check crankshaft end play. See Measure Crankshaft End Play . (Group 0400.)

3. Remove rear oil seal. See Crankshaft Rear Oil Seal Replace . (Group 0400.)

4. Remove flywheel housing. See Flywheel Housing Remove and Install . (Group 0400.)

5. Remove oil pan and crankcase extension housing. See Crankcase Extension Housing Remove and Install . (Group
0400.)

6. Remove timing gear cover and mounting plate or housing. See Timing Gear Cover Remove and Install . (Group 0400.)

7. Check crankshaft main bearing clearance.

8. IMPORTANT:

Connecting rod caps must be installed on the same connecting rods from which they were removed. Note
alignment marks on caps and rods.

Remove connecting rod cap screws and caps. See Piston and Connecting Rod Remove and Install . (Group 0400.)

9. Push pistons and connecting rods away from crankshaft.

10. IMPORTANT:

Main bearing caps must be installed on the same main bearings from which they were removed.

T207254-UN: Crankshaft and Main Bearings

LEGEND:

A - Crankshaft
B - Smooth Bearing Inserts
C - Main Bearing Cap Screw
D - Main Bearing Cap
E - Tangs
F - Bearing Cap Thrust Bearing
G - Cylinder Block Thrust Bearing
H - Grooved Bearing Inserts
I - Flywheel End of Crankshaft
 Remove main bearing cap screws (C), caps (D), and cap thrust bearings (F and G). Visually inspect condition of
bearing inserts and crankshaft journals as bearing caps are removed.

11. Remove crankshaft (A).

12. Remove cylinder block thrust bearing (G) and main bearing inserts (B and H).

13. Inspect all parts for wear or damage.

Inspect Crankshaft and Main Bearings

M82284A-UN: Measure Crankshaft Bend

M82060A-UN: Connecting Rod Journal, Main Bearing Journal

LEGEND:

A - Dial Indicator
B - V-Blocks
C - Key
D - Crankshaft Gear
E - Timing Mark “A”

1. Inspect crankshaft gear for chipped or broken teeth. Replace if necessary.

2. If necessary, remove crankshaft gear from crankshaft using a knife-edge puller and a press.

3. To install crankshaft gear, heat new gear to approximately 150°C (300°F). Install gear (D) with timing mark “A” (E)
toward end of crankshaft. Align slot in gear with key (C) in shaft. Press crankshaft into gear until gear is tight against
crankshaft shoulder.

4. Inspect crankshaft for bend using V-blocks (B) and a dial indicator(A). Turn crankshaft slowly and read runout on
indicator. If runout is greater than specification, replace crankshaft.

Item Measurement Specification

Crankshaft Radial Runout Maximum 0.02 mm

 0.0007 in.

5.
M82062A-UN: Connecting Rod and Main Bearing Journal

LEGEND:

A - Main Bearing Journal

B - Crankshaft Connecting Rod Journal

Measure crankshaft connecting rod journal (B) and main bearing journal (A) diameters. Measure several places around
each journal.

NOTE:

If engine has had a previous major overhaul, journals may have been ground and undersized
bearing inserts installed.

Item Measurement Specification

Connecting Rod Journal OD 47.952—47.962 mm

1.8879—1.8883 in.

Wear Limit 47.902 mm

1.8859 in.

Main Bearing Journal OD 53.952—53.962

2.1241—2.1245 in.

Wear Limit 53.902

2.1221 in.

If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine
shop.

If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.)
undersize.
 6.
M82063-UN: Measure Main Bearing Inner Diameter

Install bearing inserts and main bearing cap on main bearing. Tighten main bearing cap screws to specifications.

Item Measurement Specification

Main Bearing Cap Screw Torque 98 N˙m

72 lb-ft

7. Measure main bearing inner diameter as shown.

Item Measurement Specification

Main Bearing Insert ID 54.000—54.020 mm

2.1260—2.1268 in.

If bearing diameter exceeds wear limit, replace bearing inserts.

If bearing clearance (bearing ID minus crankshaft main bearing journal OD) exceeds specification, replace bearing
inserts and crankshaft or have crankshaft journals ground undersize by a qualified machine shop and install
undersized bearing inserts.

Item Measurement Specification

Main Bearing-to-Crankshaft Clearance 0.038—0.068 mm

0.0015—0.0027 in.

Wear Limit 0.150 mm

0.0059 in.

Bearing inserts are available in 0.25 mm (0.010 in.) undersize.

8. Clean and inspect oil passages in main bearing journals, connecting rod journals, and main bearing bores in cylinder
block.

9. Inspect crankshaft for cracks or damage. Replace if necessary.

Measure Crankshaft Main Bearing Clearance

M35382-UN: Graduation Marks

LEGEND:

A - PLASTIGAGE

IMPORTANT:

Main bearing caps must be installed on the same main bearing and in the same direction to prevent crankshaft
and main bearing damage.

1. Remove main bearing cap.

2. Wipe oil from bearing insert and crankshaft journal.

3. Put a piece of PLASTIGAGE® (A), or an equivalent, along the full width of the bearing insert approximately 6 mm
(0.250 in.) off center.

4. IMPORTANT:

Do not rotate crankshaft while PLASTIGAGE is installed. Doing so will result in a false reading.

Install main bearing cap and cap screws. Tighten cap screws to specifications.

Item Measurement Specification

Main Bearing Cap Screw Torque 98 N˙m

72 lb-ft

5. Remove cap screws and main bearing cap.

NOTE:

The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal.
 6.
M82117B-UN: Graduation Marks

LEGEND:

A - Graduation Marks
B - PLASTIGAGE

Use the graduation marks (A) on the envelope to compare the width of the flattened PLASTIGAGE (B) at its widest
point.

7. Determine main bearing clearance. The number within the graduation marks indicates the bearing clearance in
millimeters or inches, depending on which side of the envelope is used.

8. Remove PLASTIGAGE.

Item Measurement Specification

Main Bearing Clearance 0.038—0.068 mm

0.0015—0.0027 in.

Wear Limit 0.150 mm

0.0059 in.

If clearance exceeds specification, replace bearing inserts.

Crankshaft and Main Bearings Install

1.
T207254-UN: Crankshaft and Main Bearings

LEGEND:

A - Crankshaft
B - Smooth Bearing Inserts
C - Main Bearing Cap Screw
D - Main Bearing Cap
E - Tangs
F - Bearing Cap Thrust Bearing
G - Cylinder Block Thrust Bearing
H - Grooved Bearing Insert
I - Flywheel End of Crankshaft
 Apply clean engine oil to all parts during installation.

2. IMPORTANT:

Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface.

Install grooved bearing inserts (H) in crankshaft bearing bores, aligning tangs with slots in bores. Ensure oil holes align
with oil passages in cylinder block.

3. Install cylinder block thrust bearings with oil grooves facing away from engine block.

4. Install crankshaft.

5. Install smooth bearing inserts (B) in main bearing caps, aligning tangs with slots in caps.

6. NOTE:

Main bearing caps have “raised arrows” that are stamped with numbers. Both correspond to their
location on the engine block. Install all bearing caps with the “arrow” toward the flywheel end.
Install bearing caps beginning with thrust bearing cap (no number), number 1, then 2, etc. The
main bearing cap at gear train end does not have a number.

Install bearing cap thrust bearings, with oil grooves facing away from cap.

7. IMPORTANT:

DO NOT use high-speed power tools or air wrenches to tighten main bearing cap screws.

Install main bearing caps (D) in their original locations with arrows pointing toward flywheel side of engine.

8. Dip entire main bearing cap screws in clean engine oil. Install cap screws and tighten. DO NOT tighten to
specifications.

9. Using a soft-faced hammer, tap the front end of the crankshaft, then the rear end of the crankshaft, to align the thrust
bearings.

10. Tighten main bearing cap screws to specifications. When tightening, start at center main bearing cap and work your
way out, alternating to the ends. Turn crankshaft by hand. If it does not turn easily, disassemble the parts and find the
cause.

Item Measurement Specification

Main Bearing Cap Screw Torque 98 N˙m

72 lb-ft

11. IMPORTANT:

Connecting rod caps must be installed on the same connecting rods they were removed from.

Never reuse connecting rod cap screws, replace with new.

Match the connecting rod caps to the rods, using alignment marks. Install caps.

12. Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to specifications.

Item Measurement Specification

 Connecting Rod Cap Screw Torque 47 N˙m
35 lb-ft

PLASTIGAGE is a trademark of DANA Corp. OUO1030,00000AA-19-20051128

TM2356 - 27D Excavator Repair
Measure Valve Lift

Measure Valve Lift

1.
T6333DTA-UN: Measuring Valve Lift

LEGEND:

A - Dial Indicator
B - Valve Spring Retainer

Remove rocker arm cover.

2. Adjust valve clearance. See Engine Valve Lash (Clearance) Check and Adjustment . (Group 9010-25.)

3. Fasten dial indicator(A) to engine, and position indicator tip on valve spring retainer (B). Valve must be fully closed and
rocker arm must move freely.

4. Zero the dial indicator.

5. Manually turn crankshaft pulley clockwise (from fan end).

6. Observe dial indicator as valve is moved to the full open position.

Item Measurement Specification

Intake and Exhaust Valve Lift Minimum 5.1 mm

0.201 in.

7. Repeat for each valve.

OUO1030,00000A5-19-20060105
TM2356 - 27D Excavator Repair
Timing Gear Cover Remove and Install

Timing Gear Cover Remove and Install

T207257-UN: Timing Gear Cover

LEGEND:

A - Oil Fill Cap

B - O-Ring
C - O-Ring
D - Cover
E - Gasket
F - Auxiliary Drive Cover
G - Front Crankshaft Oil Seal
H - Injection Pump Gear Cover
I - Crankshaft Pulley
J - Washer
K - Cap Screw, Crankshaft Pulley
L - Form-in-Place Gasket
M - Timing Gear Cover
N - Pipe Plug
O - Pipe Plug
P - Form-in-Place Gasket

1. Remove engine. See Engine Remove and Install . (Group 0400.)

2. Remove alternator and belt.

3. Remove fan, spacer, and pulley.

4. Remove cap screw and washer securing crankshaft pulley.

5. Remove crankshaft pulley using puller.

6. NOTE:

When removing timing gear cover, it is not necessary to remove auxiliary drive cover and gasket,
end cover and O-ring, or fuel injection pump gear cover.

Remove mounting cap screws and timing gear cover.

7. Apply PM38657 Flexible Form-in-Place Gasket where indicated on illustrations.

8. Install timing gear cover.

9. Tighten cap screws to specification.

10. Install crankshaft pulley and tighten to specification.

11. Install fan, spacer, fan pulley, alternator, and belt.

 12. Install engine. See Engine Remove and Install . (Group 0400.)

Item Measurement Specification

Timing Gear Cover-to-Front Plate Torque 26 N˙m

229 lb-in.

End Cover-to-Timing Gear Cover Torque 26 N˙m

229 lb-in.

Injection Pump Gear Cover-to- Torque 26 N˙m

Timing Gear Cover 229 lb-in.

Oil Pan-to-Timing Gear Cover Torque 22 N˙m

192 lb-in.

Crankshaft Pulley-to-Crankshaft Torque 115 N˙m

85 lb-ft

LOCTITE is a trademark of Loctite Corp. MM61211,0000A4A-19-20060105

TM2356 - 27D Excavator Repair
Camshaft End Play Check

Camshaft End Play Check

M37512-UN: Camshaft End Play Check

1. Remove timing gear cover. See Timing Gear Cover Remove and Install . (Group 0400.)

2. Fasten dial indicatorto engine, and position indicator tip on end of camshaft.

3. Push camshaft toward the rear as far as possible.

4. Zero the dial indicator.

5. Pull camshaft forward as far as possible.

If end play exceeds wear limit, remove camshaft and replace thrust plate. See Camshaft Remove and Install . (Group
0400.)

Item Measurement Specification

Camshaft End Play 0.05—0.20 mm

0.002—0.008 in.

Wear Limit 0.30 mm

0.012 in.

OUO1030,00000A3-19-20060105
TM2356 - 27D Excavator Repair
Timing Gear Backlash Check

Timing Gear Backlash Check

T207256-UN: Timing Gear Arrangement

LEGEND:

A - Fuel Injection Pump Gear-to-Idler Gear

B - Camshaft Gear-to-Idler Gear
C - Idler Gear-to-Crankshaft Gear

Measure backlash between meshing gears at points (A—D and G). If backlash exceeds wear limit, replace meshing gears as
a set.

Item Measurement Specification

Timing Gear Backlash Backlash 0.07—0.15 mm

0.002—0.006 in.

Wear Limit 0.17 mm

0.007 in.

OUO1030,00000A2-19-20051128
TM2356 - 27D Excavator Repair
Camshaft Remove and Install

Camshaft Remove and Install

Camshaft Remove

T207559A-UN: Timing Gear Arrangement

LEGEND:

A - Timing Marks
B - Camshaft Mounting Cap Screws
C - Camshaft and Gear

1. Drain engine oil and coolant if not done previously.

2. Remove rocker arm assembly and push rods. See Rocker Arm Cover Remove and Install . (Group 0400.)

3. Remove timing gear cover. See Timing Gear Cover Remove and Install . (Group 0400.)

4. Check camshaft end play. See Camshaft End Play Check . (Group 0400.)

5. Check backlash of timing gears. See Timing Gear Backlash Check . (Group 0400.)

6. NOTE:

If a magnetic follower holder kit is not available, turn engine until oil pan is upward, to hold cam
followers away from camshaft.

Hold cam followers away from camshaft using a magnetic follower holder kit such as D15001NU.

7. NOTE:

Due to the odd number of teeth on the idler gear, timing marks will only align periodically.
 Rotate crankshaft and align timing marks (A).

8. IMPORTANT:

DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces can be
damaged.

Remove two cap screws (B) and remove camshaft with gear.

9. Inspect camshaft for wear or damage.

10. Inspect camshaft followers.

11. Inspect camshaft follower bores in block and inspect camshaft bushing and bores in block.

Inspect Camshaft

M82067A-UN: Measure Camshaft Side Play

LEGEND:

A - Camshaft Gear
B - Thrust Plate
C - Camshaft
D - Side Gap

1. If camshaft end play was not checked before removing camshaft, check clearance (side gap) between camshaft and
camshaft thrust plate using a feeler gauge.

If side gap exceeds wear limit, remove camshaft gear and replace thrust plate.

Item Measurement Specification

Camshaft-to-Thrust Plate Clearance 0.05—0.20 mm

0.002—0.008 in.

Wear Limit 0.30 mm

0.012 in.

2.
M82068A-UN: Camshaft Components

LEGEND:

A - Camshaft Gear
B - Thrust Plate
C - Camshaft
D - Key
 Inspect gear (A) for chipped or broken teeth. Replace if necessary.

3. If necessary, remove gear (A) and thrust plate (B) from camshaft (C) using a knife-edge pullerand a press.

4.

CAUTION:

DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a
thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat
the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns.

Heat gear in oil to approximately 150°C (300°F).

5. IMPORTANT:

Be sure thrust plate is not between camshaft gear and camshaft shoulder while installing gear. Thrust
plate must spin freely on camshaft after installation of gear.

Install thrust plate (B) if removed. Install gear with timing mark “C” facing away from end of camshaft. Align slot in gear
with key (D) in shaft. Press camshaft into gear until gear is tight against camshaft shoulder.

6.
M82291A-UN: Measure Camshaft Bend

LEGEND:

A - Dial Indicator
B - Camshaft Central Bearing Areas
C - V-Block

Measure camshaft bend using V-blocks and a dial indicator(A). Turn camshaft slowly and read variation on indicator. If
variation exceeds wear limit, replace camshaft.

Item Measurement Specification

 Camshaft Bend Radial Runout maximum 0.02 mm
0.0008 in.

Wear Limit 0.05 mm

0.0020 in.

7.
RG11086A-UN: Measure Camshaft Lobe Height

LEGEND:

A - Camshaft Lobe Height

Measure camshaft lobe height (A).

If lobe height is less than wear limit, replace camshaft.

Item Measurement Specification

Camshaft Lobe Height 38.600—38.800 mm

1.5197—1.5276 in.

Wear Limit 38.35 mm

1.5098 in.
 8.
M82292A-UN: Measure Camshaft Journal OD

LEGEND:

A - Flywheel-End Journal
B - Intermediate Journals
C - Gear-End Journal

Measure camshaft journal OD at both flywheel- and gear-end journals (A and C), and at intermediate journals (B).

If journal diameter is less than wear limit, replace camshaft.

Item Measurement Specification

Camshaft End Journals OD 44.925—44.950 mm

1.7687—1.7697 in.

Wear Limit 44.890 mm

1.7673 in.

Camshaft Intermediate Journal OD 44.910—44.935 mm

1.7681—1.7691 in.

Wear Limit 44.875 mm

1.7667 in.

9. Measure camshaft bushing and camshaft bores in cylinder block.

10. Inspect cam followers.

11. Inspect cam follower bores in cylinder block.

Inspect Cam Followers

1. IMPORTANT:

Cam followers must be installed in the same bores from which they were removed.

Put a mark on each cam follower and cylinder block bore to aid in installation.

2. Remove cam followers.

3. Inspect all parts for wear or damage.

 4.
T207560-UN: Inspect Cam Follower

T207561-UN: Measure Cam Follower

LEGEND:

A - Abnormal Wear Surface

B - Normal Contact Surface

Inspect cam follower contact surface for abnormal wear (A). Replace if necessary. A normal contact surface is shown in
(B).

5. Measure cam follower diameter.

Item Measurement Specification

Cam Follower OD 11.975—11.990 mm

0.471—0.472 in.

Wear Limit 11.955 mm

0.4707 in.

If diameter is less than wear limit, replace cam follower.

6. Measure cam follower bore diameter in cylinder block and determine if clearance is within specification.

If cam follower bore diameter exceeds wear limit, replace cylinder block.

If bore clearance (bore ID minus follower OD) exceeds specification, replace cam follower, cylinder block, or both.

Camshaft Install
T207559A-UN: Timing Gear Arrangement

LEGEND:

A - Timing Marks
B - Camshaft Mounting Cap Screws
C - Camshaft and Gear

NOTE:

Apply clean engine oil to all parts during installation.

Due to the odd number of teeth on the idler gear, timing marks will only align periodically.

1. Rotate crankshaft to align timing marks (A).

2. IMPORTANT:

DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Machined surfaces can be
damaged.

Install camshaft (C).

3. Install and tighten cap screws (B) to specification.

Item Measurement Specification

Camshaft Mounting Cap Screw Torque 26 N˙m

228 lb-in.

4. Install timing gear cover. See Timing Gear Cover Remove and Install . (Group 0400.)

5. Install push rods and rocker arm assembly. See Rocker Arm Cover Remove and Install . (Group 0400.)

OUO1030,00000A1-19-20051128
TM2356 - 27D Excavator Repair
Idler Gear Remove and Install

Idler Gear Remove and Install

Idler Gear Remove

RG13595A-UN: Idler Gear

LEGEND:

C - Idler Gear
D - Cap Screw
E - Idler Gear Shaft

1. Remove timing gear cover. See Timing Gear Cover Remove and Install . (Group 0400.)

2. Check backlash of timing gears. See Timing Gear Backlash Check . (Group 0400.)

3. NOTE:

Due to the odd number of teeth on the idler gear, timing marks will only align periodically. When all
timing marks on gears align, the piston closest to the coolant pump is at TDC on compression
stroke. No. 1 cylinder is closest to the flywheel.

Rotate crankshaft and align timing marks.

4. Remove three cap screws (D), shaft (E), and gear (C).

5. Inspect all parts for wear or damage.

Inspect Idler Gear

RG10849A-UN: Idler Gear

LEGEND:

A - Idler Gear Shaft

B - Idler Gear Bushing
C - Idler Gear

1. Inspect gear (C) for chipped or broken teeth. Replace if necessary.

2. Measure outside diameter of idler gear shaft (A).

If shaft diameter is less than wear limit, replace idler gear shaft.

Item Measurement Specification

Idler Gear Shaft OD 45.950—45.975 mm

1.809—1.810 in.

Wear Limit 45.93 mm

1.808 in.

3. Measure idler gear bushing (B) inside diameter.

If bushing diameter exceeds wear limit, replace bushing.

Item Measurement Specification

Idler Gear Bushing ID 46.00—46.025 mm

1.811—1.812 in.

Wear Limit 46.08 mm

1.814 in.

Oil Clearance 0.025—0.075 mm

0.001—0.003 in.

Wear Limit 0.18 mm

0.007 in.

If bushing oil clearance (bushing ID minus shaft OD) exceeds specification, replace bushing, shaft, or both.

Replace bushing using a universal driver set.Align oil holes in bushing and idler gear. Install bushing flush with surface
of idler gear.
Idler Gear Install

1. Install idler gear and ensure all timing marks are aligned.

2. Install cap screws.

3. Install timing gear cover and crankshaft pulley. See Timing Gear Cover Remove and Install . (Group 0400.)

OUO1030,000009D-19-20051128
TM2356 - 27D Excavator Repair
Timing Gear Cover Mounting Plate Remove and Install

Timing Gear Cover Mounting Plate Remove and Install

RG8578A-UN: Timing Gear Cover Mounting Plate

LEGEND:

A - Timing Gear Cover Mounting Plate

B - Cap Screws
C - O-Rings
D - Stud
E - Form-in-Place Gasket

1. Remove camshaft. See Camshaft Remove and Install . (Group 0400.)

2. Remove idler gear. See Idler Gear Remove and Install . (Group 0400.)

3. Remove fuel injection pump. See Fuel Injection Pump Remove and Install . (Group 0400.)

4. Remove mounting cap screws (B) and plate (A).

5. Install new O-rings (C).

6. Apply a bead of PM38657 Flexible Form-In-Place Gasket to the cylinder block and plate mating surfaces.
 7. Install plate (A) and tighten cap screws (B) to specification.

Item Measurement Specification

Timing Gear Cover Mounting Plate Torque 25 N˙m

Cap Screws 221 lb-in.

8. Install camshaft, idler gear, oil pump, fuel injection pump, fuel supply pump, and coolant pump.

LOCTITE is a trademark of Loctite Corp. MM61211,0000A4B-19-20060105

TM2356 - 27D Excavator Repair
Oil Pan and Strainer Remove and Install

Oil Pan and Strainer Remove and Install

M82362A1-UN: Oil Pan Installation

LEGEND:

A - Gasket
B - Oil Strainer
C - Cap Screws
D - Form-in-Place Gasket
E - Oil Pan
F - Cap Screws
G - Drain Plug
H - Washer
I - Spacer Plate (if equipped)

1. Drain engine oil from crankcase.

2. Remove cap screws (F) and oil pan (E).

3. Remove oil strainer (B).

 4. Replace gasket on oil strainer.

5. Install oil strainer and tighten cap screws (C) to specification.

Item Measurement Specification

Oil Strainer Cap Screw Torque 26 N˙m

230 lb-in.

6. Apply PM38657 Flexible Form-in-Place Gasket to oil pan rail.

7. Install oil pan (E) and spacer plate (I) (if equipped), and tighten cap screws to specification.

Item Measurement Specification

Oil Pan Cap Screw Torque 26 N˙m

230 lb-in.

8. Replace drain washer as necessary.

NOTE:

Install washer with raised center against plug.

9. Fill engine crankcase with correct grade and viscosity of engine oil. See Diesel Engine Oil . (Operator's Manual.)

LOCTITE is a trademark of Loctite Corp. MM61211,0000A4C-19-20060105

TM2356 - 27D Excavator Repair
Oil Pump Remove and Install

Oil Pump Remove and Install

RG13414A-UN: Oil Pump Mounting Screw

LEGEND:

A - Timing Gear Cover

B - Oil Pump Cover
C - Screw (7 used)

1. Remove timing gear cover. See Timing Gear Cover Remove and Install . (Group 0400.)

2. Remove oil pressure regulating valve. See Oil Pressure Regulating Valve Remove and Install . (Group 0400.)

3. Remove oil pump cover mounting cap screws (C) and remove oil pump cover (B).

4. Inspect all parts for wear or damage. See Oil Pump Disassemble, Inspect, and Assemble . (Group 0400.)

5. Install timing gear cover. See Timing Gear Cover Remove and Install . (Group 0400.)

OUO1030,00000B9-19-20090218
TM2356 - 27D Excavator Repair
Oil Pump Disassemble, Inspect, and Assemble

Oil Pump Disassemble, Inspect, and Assemble

RG13408A-UN: Rotor Recess

RG13409A-UN: Rotor-to-Rotor Clearance

RG13410A-UN: Rotor-to-Housing Clearance

LEGEND:

A - Outer Rotor
B - Inner Rotor
C - Pump Housing

1. Check rotor recess. If rotors are below face of pump housing more than specification, replace rotor assembly.

Item Measurement Specification

Oil Pump Rotor Recess 0.02—0.07 mm

0.001—0.003 in.

Wear Limit 0.12 mm

0.005 in.

2. Check inner-to-outer rotor clearance. If clearance is more than specification, replace rotor assembly.

Item Measurement Specification

Oil Pump Inner-to-Outer Rotor Clearance Maximum 0.16 mm

0.006 in.

3. Check outer rotor-to-pump body clearance. If clearance is more than wear limit, replace entire assembly.

Item Measurement Specification

Oil Pump Outer Rotor-to-Housing Clearance 0.12—0.21 mm

0.005—0.008 in.

Wear Limit 0.30 mm

0.012 in.
4.
RG13411A-UN: Inner Rotor Flats

RG13412A-UN: Crankshaft Gear

LEGEND:

A - Inner Rotor Diameter

B - Inner Rotor Flat-to-Flat
C - Crankshaft Gear Outer Diameter
D - Crankshaft Gear Flat-to-Flat

Measure inner rotor diameter (A). If measurement is less than specification, replace rotor assembly.

Item Measurement Specification

Oil Pump Inner Rotor Inner Diameter 53.05—53.15 mm

2.088—2.093 in.

5. Measure distance between flats (B) of inner rotor. If measurement is less than specification, replace rotor assembly.
 Item Measurement Specification

Oil Pump Inner Rotor Flat-to-Flat Distance 49.95—50.05 mm

1.967—1.974 in.

6. Measure crankshaft gear outer diameter (C). If measurement is less than specification, replace crankshaft gear.

Item Measurement Specification

Crankshaft Gear Outer Diameter 53.45—53.55 mm

2.104—2.108 in.

7. Measure distance between flats (D) of crankshaft gear. If measurement is less than specification, replace crankshaft
gear.

Item Measurement Specification

Crankshaft Gear Flat-to-Flat Distance 49.45—49.75 mm

1.947—1.959 in.

8.
RG13413A-UN: Oil Pump Rotor Installation

LEGEND:

A - Alignment Marks

Install rotors with alignment marks (A) facing out.

9. Apply PM37418 Thread Lock and Sealer (medium strength) to pump cover mounting cap screws. Install cap screws
and tighten to specification.

Item Measurement Specification

Oil Pump Cover Mounting Cap Torque 7 N˙m

Screw 61 lb-in.
 10. Install oil pump. See Oil Pump Remove and Install . (Group 0400.)

LOCTITE is a trademark of Loctite Corp. MM61211,0000A4D-19-20060105

TM2356 - 27D Excavator Repair
Oil Pressure Regulating Valve Remove and Install

Oil Pressure Regulating Valve Remove and Install

RG13404A-UN: Oil Pressure Regulating Valve

LEGEND:

A - Valve Cap
C - Spring
D - Valve

Remove parts as follows:

1. Remove cap (A) and add shims. Each 1 mm (0.039 in.) of shim thickness increases oil pressure 10.9 kPa (1.6 psi).

2. NOTE:

Valve components are not serviced individually. Replace complete regulating valve if any components
are defective.

Inspect all parts for wear or damage and replace parts or complete valve as needed.

3. Installation is done in the reverse order of removal.

4. Stake valve cap to valve body.

Item Measurement Specification

Oil Pressure Regulating Valve Filter Torque 27 N˙m

Housing Cap Screws 20 lb-ft

Oil Pressure Regulating Valve Body Torque 30 N˙m

Retaining Nut 22 lb-ft

OUO1030,00000B6-19-20051128
TM2356 - 27D Excavator Repair
Oil Filter Adapter Remove and Install

Oil Filter Adapter Remove and Install

T207258-UN: Oil Filter Adapter

LEGEND:

A - Oil Filter
B - Adapter
C - Gasket
D - Cap Screw (3 used)

1. Remove oil filter (A).

2. Remove three cap screws (D), oil filter adapter (B), and gasket (C).

3. Installation is done in the reverse order of removal.

4. Tighten cap screws to specification.

Item Measurement Specification

Oil Filter Adapter Cap Screws Torque 27 N˙m

20 lb-ft

OUO1030,00000B5-19-20051128
TM2356 - 27D Excavator Repair
Radiator Remove and Install (S.N. —254999)

Radiator Remove and Install (S.N. —254999)

CAUTION:

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap
to first stop to relieve pressure before removing completely.

TS281-UN: Cooling System

T207062A-UN: Engine Frame

T207277A-UN: Fan guard

LEGEND:

1 - Cap Screw (2 used)

2 - Left-Side Frame Bracket
3 - Left-Rear Frame Bracket
4 - Right-Rear Frame Bracket
5 - Frame Cover
6 - Frame Cover
7 - Right-Side Frame Bracket
8 - Fan Guard
9 - Upper Radiator Hose
10 - Lower Radiator Hose
11 - Cap Screw (4 used)

1. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

2. Remove counterweight. See Counterweight Remove and Install . (Group 1749.)

 3. Remove two cap screws (1) holding air cleaner housing.

4. NOTE:

Note any shims that may accompany frame brackets for installation.

Remove frame brackets (2–4) and frame cover (5).

5. Remove right-side frame bracket (7).

6. Remove air cleaner assembly.

7. Drain coolant from radiator. See Draining Cooling System . (Operator's Manual.)

8. Remove fan guard (8). Remove upper radiator hose (9) and lower radiator hose (10).

9. Remove four cap screws (11) securing fan shroud. Carefully move away from radiator.

10.
T217316A-UN: Oil Cooler Mounts
 T207274A-UN: Lower Drain Hose

T207275A-UN: Fan Guard #2

LEGEND:

12 - Cap Screw (2 used)

13 - Cap Screw (2 used)
14 - Overflow Hose
15 - Cap Screw (2 used)
16 - Radiator
17 - Fan Shroud
18 - Drain Hose
19 - Fan Guard
20 - Upper Radiator Hose
21 - Lower Radiator Hose

Remove lower drain hose.

11. Remove cap screws (12 and 13).

12. Disconnect overflow hose (14).

13. Remove cap screws (15) and remove brackets.

14. Remove radiator. Carefully move oil cooler and lines away from radiator when removing radiator.

15. Remove fan shroud (17).

16. Remove two lower bushings from the bottom of the radiator.

17. Replace parts as necessary.

18. Install two lower bushings.

19. Temporarily position fan shroud over fan.

20. Install radiator (16).

21. Install fan shroud (17) to radiator with four cap screws.

22. Install drain hose (18) to bottom of radiator.

23. Position fan guard (19) and install cap screws.

24. Install upper radiator hose (20) and lower radiator hose (21) and tighten clamps.

25.
T217317A-UN: Oil Cooler

LEGEND:

22 - Cap Screw (4 used)

23 - Overflow Hose
24 - Bracket (2) used.

Install four cap screws (22) connecting oil cooler to radiator.

26. Connect overflow hose (23).

27. Install brackets and two cap screws (24).

28. Fill radiator with coolant. See Cooling System Fill and Deaeration . (Operator's Manual.)

29. Install air cleaner assembly.

30. Install frame brackets.

31. Install counterweight. See Counterweight Remove and Install . (Group 1749.)

32. Install engine covers.

MH66O88,000002E-19-20090219
TM2356 - 27D Excavator Repair
Radiator Remove and Install (S.N. 255000— )

Radiator Remove and Install (S.N. 255000— )

CAUTION:

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap
to first stop to relieve pressure before removing completely.

TS281-UN: Cooling System

1. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

2.

CAUTION:

Avoid crushing injury. Use appropriate lifting device when lifting component.
 TX1056076-UN: Counter Weights and Covers

LEGEND:

1 - Counter Weight
2 - Lower Cover
3 - Middle Cover
4 - Upper Cover

Remove counterweight (1).

3. Remove covers (2—4).

4. Remove air intake tube.

5. Drain coolant from radiator. See Draining Cooling System . (Operator's Manual.)

6.
TX1056077-UN: Radiator

LEGEND:

5 - Upper Radiator Hose

6 - Lower Radiator Hose
7 - Fan Shroud
8 - Upper Radiator Mounting Bracket
9 - Radiator

Remove upper radiator hose (5) and lower radiator hose (6).

7. Remove cap screws securing fan shroud (7).

8. Remove overflow hose from radiator and upper radiator mounting bracket (8).

9. Remove upper radiator mounting bracket (8).

10. Remove radiator (9).

11. Repair or replace radiator as necessary.

12. Install radiator.

13. Install upper radiator mounting bracket.

14. Install overflow hose.

15. Install fan shroud.

16. Install upper and lower radiator hoses.

17. Fill radiator with coolant. See Cooling System Fill and Deaeration . (Operator's Manual.)

18. Install air intake tube.

19. Install counterweight.

20. Install engine covers.

21. Return operator station to original position. See Tilting the Operator Station . (Operator's Manual.)

PM10405,0000358-19-20090219
TM2356 - 27D Excavator Repair
Fuel Tank Remove and Install

Fuel Tank Remove and Install

T217315A-UN: Battery

T207592A-UN: Battery box

LEGEND:

1 - Positive Battery Cable

2 - Negative Battery Cable
3 - Battery Securing Bracket
4 - Fuel Level Sender Harness
6 - Battery Box Outer Side Plate
7 - Maintenance Cover Clip, Washer, and Cable
8 - Battery Box Cap Screw (5 used)
9 - Battery Box
 1. Lift maintenance cover.

2. Remove right-side covers.

3. Disconnect negative battery cable (2) and positive battery cable (1).

4. Remove battery securing bracket (3) and rods.

5. Disconnect fuel level sender harness (4).

6. Remove outer side plate (6) of battery box.

7. Carefully remove battery from battery box.

8. Remove clip, washer, and cable (7) to maintenance cover.

9. Remove five cap screws (8) and remove battery box (9).

10. Remove fuel tank strap.

11.
T207594A-UN: Fuel Drain
 T207593A-UN: Fuel Tank

LEGEND:

10 - Inspection Plate
11 - Fuel Drain Valve
12 - Pick-Up Hoses
13 - Fuel Tank
14 - Fuel Tank Strap

Remove inspection plate (10) under fuel tank.

12. NOTE:

Residual fuel may drain from tank when removing hoses. Place drain on track prior to
disconnecting fuel hoses to tank.

Drain fuel using valve (11). See Fuel Tank . (Operator's Manual.)

13. Disconnect pick-up hoses (12).

14. Remove fuel tank (13).

15. Replace parts as necessary.

16. Position fuel tank (13) and tank strap (14).

17. Connect pick-up hoses (12).

18. Install inspection plate (10) under fuel tank.

19. Install battery box (9).

20. Install five cap screws (8) securing battery box.

21. Install clip, washer, and cable (7) to maintenance cover.

22. Carefully install battery in battery box.

23. Install outer side plate (6) to battery box.

24. Connect fuel level sender harness (4).

25. Install battery securing bracket (3) to battery.

26. Connect positive battery cable (1) and negative battery cable (2).

27. Install right-side covers.

28. Fill fuel tank.

29. Bleed fuel system by turning fuel shutoff valve to the ON position.

30. Turn the key switch to ON for 10—15 seconds to engage automatic bleeding. Do not start engine.

31. Start engine. Stop engine. Check for fuel leakage.

TW73308,000043D-19-20090218
TM2356 - 27D Excavator Repair
Primary Fuel Filter (Water Separator) Remove and Install

Primary Fuel Filter (Water Separator) Remove and Install

TX1055232A-UN: Water Separator

LEGEND:

1 - Fuel Shutoff Valve

2 - Water Separator

1. Close fuel shutoff valve (1) on top of water separator (2).

2. Turn water separator counterclockwise to remove.

3. Remove element and dispose.

4. Install new element. Turn water separator clockwise by hand until O-ring touches mounting surface.

5. Open fuel shutoff valve.

6. Bleed fuel system. See Bleed Fuel System . (Group 0560.)

PM10405,0000350-19-20090218
TM2356 - 27D Excavator Repair
Final Fuel Filter Remove and Install

Final Fuel Filter Remove and Install

1.
TX1055231A-UN: Fuel Shut Off Valve

TX1047309A-UN: Final Fuel Filter

LEGEND:

1 - Fuel Shutoff Valve

2 - Fuel Filter

Close fuel shutoff valve (1).

2. Remove fuel filter (2). Dispose of waste properly.

3. Clean mounting surface for fuel filter.

4. Fill new filter with fuel and install.

5. Turn fuel shutoff valve to ON.

6. Bleed fuel system. See Bleed Fuel System . (Group 0560.)

7. Start engine and run for 2-3 minutes checking for leakage. Stop engine.

PM10405,000034F-19-20090218
TM2356 - 27D Excavator Repair
Bleed Fuel System

Bleed Fuel System

IMPORTANT:

Air in the fuel system will cause the engine to start hard and/or run rough. Be sure to bleed air from system after
replacing fuel filter or draining fuel tank.

Bleeding Procedure (Automatic Bleeding Device)

1. Confirm that fuel level is more than one half of tank capacity. If lower, automatic bleeding cannot be accomplished. Add
fuel.

2. Loosen plug in the final fuel filter head to bleed air. Tighten plug when fuel flows from the hole.

3. Turn key switch to ON and hold for 10—15 seconds to engage automatic bleeding.

4. Start engine and check for fuel leakage.

MH66O88,0000032-19-20051202
TM2356 - 27D Excavator Repair
Welding on Machine

Welding on Machine

IMPORTANT:

Electrical current traveling from the welder through the machine electrical system can damage the machine
electrical system, including the battery, and any electronic control units. Before welding on the machine,
disconnect the battery ground cable and wiring harness connectors to any electronic control units.

Electrical current traveling from the welder through a bearing can arc inside the bearing causing damage. The
welder ground clamp must be connected as close to each weld area as possible so electrical current does not
pass through any bearings.

Disconnect the battery ground cable.

Disconnect wiring harness connectors to any electronic control units.

Connect the welder ground clamp as close to the weld area as possible.

OUO1030,00000D4-19-20050303
TM2356 - 27D Excavator Repair
Welding Repair of Major Structure

Welding Repair of Major Structure

1.

CAUTION:

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use
solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or
paint stripper containers and other flammable material from area. Allow fumes to disperse at least
15 minutes before welding or heating.

Remove paint before welding or heating.

2. IMPORTANT:

Disconnect battery ground strap or turn battery disconnect switch to “OFF”. Also disconnect the wiring
harness connectors to the engine and pump controller.

Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so
electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by
heat or weld splatter.

Use one of the following weld processes:

¡ AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.
¡ AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process.
¡ AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

Item Measurement Specification

Weld Metal Tensile Strength 482.6 mPa

70,000 psi

Yield Strength 413.7 mPa

60,000 psi

Elongation 22%

3. IMPORTANT:

Area to be repaired must be preheated to allow better weld penetration.

To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be
welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges,
skid shoes, and teeth shanks) to 177°C (350°F).
To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural
assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks)
to 177°C (350°F).

Item Measurement Specification

Structural Assembly Preheat Temperature 38°C

100°F

Ground Engaging Tool Preheat Temperature 177°C

350°F

OUT1738,0000074-19-20050310
TM2356 - 27D Excavator Repair
Counterweight Remove and Install

Counterweight Remove and Install

1.

CAUTION:

Prevent possible injury. Heavy component; ensure side cover is properly supported before
removing.

T217010A-UN: Left Side Panels

 T217009A-UN: Right Side Panels

LEGEND:

1 - Left-Side Upper Panel

2 - Left-Side Middle Panel
3 - Left-Side Lower Panel
4 - Maintenance Cover
5 - Right-Side Middle Panel
6 - Right-Side Lower Panel

Park machine on a level surface.

2. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

3. Remove left-side panels (1, 2 and 3) from main frame.

4. Open maintenance cover (4).

5. Remove right-side panels (5 and 6) from main frame.

6.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

The lifting capacity of a lifting eyebolt decreases as the lift angle increases from vertical. A load
positioning sling should be used to obtain, as close as possible, a vertical lift from lifting
eyebolts.

Remove two plastic plugs located at top of counterweight. Install M20 x 2.5 lifting eyebolts (6) such as JT05552 Metric
Lifting Eyebolts to threaded holes in counterweight.

Item Measurement Specification

Counterweight Weight 281 kg

620 lb
7.
T206932A-UN: Lifting Eyebolts and Chains Attached to Counterweight

T206933A-UN: Counterweight Cap Screws

 T206934A-UN: Counterweight Removed

LEGEND:

8 - Chains
9 - Counterweight Cap Screws (3 used)
10 - Main Frame

Attach appropriate lifting device and chains (8) to eyebolts.

8. Remove three cap screws (9) from bottom side of counterweight.

9. Lift counterweight slightly, then slide counterweight rearward. Remove counterweight from main frame.

10. Replace parts as necessary.

11. Install counterweight by lower counterweight so it just touches main frame (10), then slide counterweight forward into
position.

12. Install three cap screws to bottom side of counterweight. Tighten to specification.

Item Measurement Specification

Counterweight-to-Frame Cap Screw Torque 550 N˙m

410 lb-ft

13. Remove chains and lifting device.

14. Remove eyebolts.

15. Install plastic plugs into threaded holes at top of counterweight.

16. Install outer access panels.

17. Close maintenance cover.

18. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)
MM61211,0000997-19-20060131
TM2356 - 27D Excavator Repair
Cab Remove and Install

Cab Remove and Install

1.
T208922-UN: Air Duct and Cab

LEGEND:

1 - Air Duct Cover

2 - Air Duct
3 - Front Cap Screw (3 used)
4 - Side Cap Screw (4 used)
5 - Cap Screw Cover (2 used)
6 - Cap Screw (2 used)
7 - Cap Screw (3 used)
8 - Lifting Point (3 used)

Disconnect negative battery (-) cable.

2. Remove air duct cover (1) and disconnect wires to accessory outlet.

3. Remove air duct (2).

4. Disconnect wires and hose to windshield pump motor.

5. Disconnect wires to monitor.

6. Disconnect cab harness-to-floor harness connector located below right control lever.

7. Remove front (3) and side (4) cap screws.

8. Remove cap screw covers (5) and cap screws (6 and 7).

9.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Cab Weight approximate 120 kg

265 lb

Attach hoist to cab lifting points using lifting straps.

10. Slowly lift cab from platform. Cab must be moved forward while being raised to allow front of cab to clear front of propel pedals.

11. Repair or replace parts as necessary.

12. IMPORTANT:
 Make sure that hydraulic lines and wiring harnesses do not get pinched when lowering cab into position.

Lower cab into position.

13. Install and tighten cap screws (3, 4, 6, and 7). Install cap screw covers (5).

Item Measurement Specification

Front and Side Cab Cap Screw Torque 50 N˙m

37 lb-ft

Rear Cab Cap Screw Torque 90 N˙m

66 lb-ft

14. Connect cab harness-to-floor harness connector.

15. Connect wires to monitor.

16. Connect wires and hose to windshield pump motor. Install air duct (2).

17. Connect wires to accessory outlet and install air duct cover (1).

18. Connect negative battery (-) cable.

MH66O88,0000026-19-20051130
TM2356 - 27D Excavator Repair
Canopy Remove and Install

Canopy Remove and Install

1.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Canopy Weight approximate 68 kg

150 lb

T208894-UN: Canopy

LEGEND:

1 - Chain
2 - Canopy Lifting Point (4 used)
3 - Side Panel
4 - Front Cover
5 - Side Cover
6 - Canopy

Attach hoist and chain (1) to canopy lifting points (2).

2. Remove side panel (3), front cover (4), and side cover (5).

3.
 T208895A-UN: Front Cap Screws

T208896A-UN: Rear Cap Screws

LEGEND:

7 - Front Cap Screw (5 used)

8 - Side Cap Screw (2 used)
9 - Rear Cap Screw (5 used)

Remove front (7) and side (8) cap screws.

4. Remove rear cap screws (9).

5. Remove canopy (6).

6. Repair or replace parts as necessary.

7. IMPORTANT:

Make sure that hydraulic lines and wiring harnesses do not get pinched when lowering canopy into position.

Lower canopy (6) into position.

8. Install front (7), side (8), and rear (9) cap screws.

Item Measurement Specification

Front and Side Canopy Mount Cap Torque 50 N˙m

Screw 37 lb-ft

Rear Canopy Mount Cap Screw Torque 90 N˙m

66 lb-ft

9. Install side panel (3), front cover (4), and side cover (5).

MH66O88,0000027-19-20060131
TM2356 - 27D Excavator Repair
Platform Remove and Install

Platform Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine. Slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

2. Disconnect negative battery (-) cable.

3. Remove canopy or cab. See Cab Remove and Install or see Canopy Remove and Install . (Group 1800.)

4. Tilt the operator station. See Tilting the Operator Station . (Operator's Manual.)

5.

CAUTION:

Explosive release of fluids from a pressurized cooling system can cause serious burns.

Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing it completely.

TS281-UN: Explosive Release of Fluid

If equipped with a heater, close the heater hose shut-off valve on engine or drain coolant. See Draining Cooling System . (Operator's
Manual.)
 6.
T217314A-UN: Platform

LEGEND:

1 - Heater Hose (2 used)

2 - Air Conditioning Line (2 used)
3 - Drain Hose (2 used)
4 - Wire Harness and Horn
5 - Quick Coupler Hydraulic Line

Disconnect heater hoses (1) at bracket.

7. If equipped with air conditioning, perform the following:

a. Purge A/C system. See R134A Refrigerant Recovery / Recycling and Charging Station Installation Procedure . (Group 1830.)

b. IMPORTANT:

Close A/C lines with caps or plugs immediately after disconnecting to prevent contamination of system. If
system is left open, receiver-dryer must be replaced before charging system.

Disconnect air conditioning lines (2). Close all openings using caps and plugs.

c. Disconnect A/C compressor wire connector located at bracket.

8. Cut tie band to air conditioning drain hoses (3).

9. Disconnect wire harness and horn (4).

10. Disconnect quick coupler for hydraulic lines (5) at the bracket. Label lines to aid in assembly.

11.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Platform with Heater, Pilot Controls, Weight (approximate) 95 kg

and Seat Assembly 210 lb
 NOTE:

Four JT01748 Lifting Brackets are required to lift platform.

Attach a hoist to rear platform using JT01748 lifting brackets.

12. Disconnect tilt assembly and lower the operator station.

13.
T217313A-UN: Platform Mounts

LEGEND:

1 - Cap Screw (2 used)

2 - Front Cover
3 - Hinge Cap Screw (3 used)

Loosen cap screws (1) and lift front cover (2). Remove hinge cap screws (3).

14. IMPORTANT:

Make sure all hydraulic lines and wiring harnesses are disconnected before removing platform.

Carefully lift and remove platform while making sure that hydraulic lines and wiring do not get caught on platform.

15. Repair or replace parts as necessary.

16. IMPORTANT:

Make sure that hydraulic lines and wiring harnesses do not get pinched when lowering platform into position.

Install platform and hinge cap screws (3). Fasten front cover (2).

Item Measurement Specification

Platform Hinge Cap Screws Torque 140 N˙m

103 lb-ft

17. Raise operator station and install tilt assembly.

18. Connect hydraulic lines, wire harness, and horn. Install tie bands where needed.

19. If equipped with A/C, connect heater hose, air conditioning lines, and wire to A/C compressor.
20. Lower operator station and install cab or canopy.

21. Connect negative battery (-) cable.

22. NOTE:

If equipped with a heater, open shut-off valve for heater hoses at the engine.

Fill radiator with coolant. See Cooling System Fill and Deaeration . (Operator's Manual.)

23. If equipped with A/C, evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System .
(Group 1830.)

24. Check oil level in hydraulic tank. Add hydraulic oil if necessary. See Hydraulic Oil . (Operator's Manual.)

MH66O88,0000029-19-20090218
TM2356 - 27D Excavator Repair
Seat Remove and Install

Seat Remove and Install

T208367A-UN: Rear Seat Bracket

T208368A-UN: Front Bracket

LEGEND:

1 - Rear Seat Bracket Nut (2 used)

2 - Front Seat Bracket Nut (2 used)

1. Park machine on a flat level surface.

2. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)
3. Remove rear seat bracket nuts (1) from rear of seat base.

4. Tilt operator station back to normal position.

5. Remove seat bracket nuts (2) from front of seat base.

6. Remove seat.

7. Replace parts as necessary.

8. Install seat.

MH66O88,000002B-19-20051130
TM2356 - 27D Excavator Repair
Seat Base Remove and Install

Seat Base Remove and Install

1.
T208439A-UN: Floor Panel

T208437A-UN: Vent Cover

 T208435A-UN: Lever

LEGEND:

1 - Floor Plate
2 - Access Panel
3 - Air Vent Cover
4 - Power Outlet Wire Harness
5 - Heater Control Valve Cap Screw (2 used)
6 - Pilot Control Shut-Off Lever Cap Screw (4 used)
7 - Cap Screw
8 - Seat Base

Disconnect battery negative (-) cable.

2. Remove seat. See Seat Remove and Install . (Group 1821.)

3. Remove floor mat.

4. Remove floor plate (1).

5. Remove access panel (2).

6. Remove air vent cover (3).

7. Remove and disconnect power outlet wire harness (4).

8. Remove heater control valve cap screws (5).

9. Remove four pilot control shut-off lever cap screws (6).

10. Remove cap screw (7) on upperstructure of seat base (8).

11.
T208438A-UN: Blower

T208449A-UN: Relay panel

LEGEND:

9 - Cap Screw (5 used) Air Conditioner Relay Panel

10 - Cap Screw (4 used) Lower Structure Seat Base

Remove cap screws (9) to air conditioner relay panel.

12. Remove cap screws (10) on lower structure of seat base.

13. Remove seat base from platform.

14. Replace parts as necessary.

15. Install seat base

16. Install air conditioner relay panel

17. Connect electrical harnesses.

18. Install air vent cover

19. Install seat.

20. Install access cover and floor plate.

21. Connect battery negative (-) cable.

MH66O88,000002A-19-20051130
TM2356 - 27D Excavator Repair
Seat Belt Remove and Install

Seat Belt Remove and Install

1.
T208369A-UN: Belt latch

T208370A-UN: Seat Belt

LEGEND:

1 - Cap Screw (1 used)

2 - Seat Belt Latch
3 - Cap Screw (1 used)
4 - Seat Belt

Remove seat. See Seat Remove and Install . (Group 1821.)

2. Remove cap screw (1) and spacer. Remove seat belt latch (2).

3. Remove cap screw (3) and spacer. Remove seat belt (4).

4. Replace as needed.

5. Install seat belt and seat belt latch.

6. Install seat.

MH66O88,000002C-19-20051130
TM2356 - 27D Excavator Repair
Refrigerant Cautions and Proper Handling

Refrigerant Cautions and Proper Handling

CAUTION:

DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on
contact. Wear goggles, gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water
on affected area. Go to a physician or hospital immediately for treatment.

DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc,
electric heating element and lighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high
pressure which can burst the container.

Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.

DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear
gloves.

If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or
hospital immediately for treatment.

IMPORTANT:

To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning system.
Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is
illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery
stations.

Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.

Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system
damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and
use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be
tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument
should be used before any testing or repair to system is performed.

Prism Pro Refrigerant Identification

Instrument.......JT02167A
To safely identify type and check purity of refrigerant prior
to recovery, recycling and recharging of A/C systems.

TX,9031,DY5073-19-20011119
TM2356 - 27D Excavator Repair
Flush and Purge Air Conditioner System

Flush and Purge Air Conditioner System

CAUTION:

Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

See Refrigerant Cautions and Proper Handling . (Group 1830.)

NOTE:

Flushing can be performed on machine.

1. Perform Recover R134a Refrigerant . (Group 1830.)

Add flushing solvent to system with JT02075 Flusher and JT02098 Flusher Fitting Kit.

2. Remove and discard receiver-dryer.

3. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

4. Fill flusher tank with solvent and fasten all connections. Dispose of solvent properly.

Item Measurement Specification

A/C Flusher Tank Capacity 4L

1 gal

5. NOTE:

Air pressure must be at least at specification for flushing and purging.

Item Measurement Specification

A/C Flusher Tank Air Pressure Minimum Pressure 620 kPa for flushing and purging
6.2 bar for flushing and purging
90 psi for flushing and purging

Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

6. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with burned oil or metal particles.

7. Clean compressor as follows:

a. Remove compressor and measure oil drained from both manifold ports.

b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

c. Pour flushing solvent into suction port and discharge port. Plug both ports in compressor manifold, using JT02099 and JT03194 Caps.

Item Measurement Specification

A/C Flushing Solvent in Suction Port Volume 240 mL

8 fl oz
 A/C Flushing Solvent in Discharge Volume 120 mL
Port 4 fl oz

d. Turn compressor end for end and roll it side to side.

e. Remove both plugs from manifold ports and drain solvent from compressor.

f. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders.

g. Invert compressor. Roll end for end and side to side. Drain thoroughly.

h. Repeat previous two steps at least three times.

8. Divide system into two circuits:

¡ Condenser circuit, including inlet and outlet hoses.

¡ Evaporator circuit, including inlet and outlet hoses.

9. Condenser:

a. IMPORTANT:

DO NOT attempt to flush through compressor or receiver-dryer. Flushing through expansion valve is acceptable if
refrigerant oil has a normal odor and appearance.

Flush / Purge Condenser:

b. Remove and discard receiver-dryer.

c. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

d. Fill flusher tank with solvent and fasten all connections.

Item Measurement Specification

A/C Flusher Tank Capacity 4L

1 gal

e. NOTE:

Air pressure must be at least to specification for flushing and purging.

Item Measurement Specification

A/C Flusher Tank Air Pressure Minimum Pressure 620 kPa for flushing and purging.
6.2 bar for flushing and purging.
90 psi for flushing and purging.

Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

f. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing
cycles are required if system is heavily contaminated with burned oil or metal particles.

g. Attach return hose and aerator nozzle to end of receiver-dryer inlet hose using JT03197 Adapter. Put nozzle in container to collect
flushing solvent.

h. NOTE:

Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.

Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to piece of cardboard; continue purging until
cardboard is dry.

10. See Flush evaporator, if evaporator requires flushing.

If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. See following steps to flush evaporator
through expansion valve, if oil appears normal.
11. Flush evaporator:

a. Remove evaporator and expansion valve. See Air Conditioner / Heater Module Remove and Install . (Group 1830.)

b. Force flushing solvent through evaporator inlet with 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 of receiver-dryer outlet hose using JT03188 adapter.

b. Fill flusher tank and fasten all connections.

Item Measurement Specification

A/C Flusher Tank Capacity 4L

1 gal

c. NOTE:

Air pressure must be at least to specification for flushing and purging.

Item Measurement Specification

A/C Flusher Tank Air Pressure Minimum Pressure 620 kPa for flushing and purging.
6.2 bar for flushing and purging.
90 psi for flushing and purging.

Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

d. Attach hose and aerator nozzle to compressor inlet line using JT02101 adapter. Put nozzle in container to collect solvent.

13. NOTE:

Purging evaporator circuit takes 12—15 minutes to thoroughly remove solvent.

Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to piece of cardboard and continue purging until cardboard
is dry.

14. Install new receiver-dryer compatible with R134a refrigerant. Fasten connections and mounting bracket. See Receiver-Dryer Remove and
Install . (Group 1830.)

15. Add required oil. See R134a Refrigerant Oil Information . (Group 1830.)

16. Install compressor and connect refrigerant lines to manifold.

17. Connect clutch coil wire and install drive belt.

TX,18,DU2461-19-20090218
TM2356 - 27D Excavator Repair
R134a Refrigerant Oil Information

R134a Refrigerant Oil Information

IMPORTANT:

Refrigerant oil easily absorbs moisture and can become contaminated with moisture. DO NOT leave system or
R134a compressor oil containers open. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil
will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental
mixing of different oils.

Compressors can be divided into three categories when determining correct oil charge for system.

l New compressor from service parts

l Used compressor removed from operation
l Compressor internally washed with flushing solvent

CAUTION:

New compressors with oil are charged with a mixture of nitrogen, R134a refrigerant and TY22101
(R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible
injury.

New compressor from service parts must be checked for oil. Check oil level, which is visible through suction port is normally
below drive shaft. See Air Conditioner Compressor Remove and Install . (Group 1830.)

When complete system, lines, and components are flushed add correct amount of oil as described.

If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz
per ft) to determine correct amount of oil to be added.

Connect battery power to compressor clutch coil.

Drain compressor oil into graduated container while rotating compressor shaft and record amount.

If oil drained from compressor removed from operation is very black or amount of oil is less than 6 mL (0.2 fl oz), perform the
following and discard oil properly:

□ Determine if R134a leakage was detected, remove component and repair or replace component.
□ Remove and discard receiver-dryer.
□ Flush complete system with TY25601 Air Conditioning Flushing Solvent. See Flush and Purge Air Conditioner System .
(Group 1800.)

If component is serviceable, pour flushing solvent in ports.

Connect battery power to compressor clutch coil and internally wash out old oil. Finish draining compressor by rotating
compressor shaft, discard oil properly.

Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
 IMPORTANT:

Add correct amount of R134a compressor oil to prevent compressor damage and for system efficiency. Lack of
oil will damage compressor and too much oil will reduce maximum cooling efficiency. A new compressor must
have oil removed and measured, then reinstalled to match system requirements.

Install required amount of TY22101 Refrigerant Oil in compressor.

Item Measurement Specification

Refrigerant Oil Compressor 100 mL

3.38 fl oz

Connect all components. Perform Evacuate R134a System and Perform Charge R134a System . (Group 1830.)

KV70328,00001FE-19-20101207
TM2356 - 27D Excavator Repair
R134a Refrigerant Recovery / Recycling and Charging Station Installation
Procedure

R134a Refrigerant Recovery / Recycling and Charging Station Installation Procedure

CAUTION:

Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

See Refrigerant Cautions and Proper Handling . (Group 1830.)

IMPORTANT:

Use only John Deere approved refrigerant recovery / recycling and charging stations. DO NOT mix refrigerant, hoses,
fittings, components or refrigerant oils.

Use only John Deere approved R134a refrigerant products. Mixing of non-compatible products will cause system
damage and contaminate recovery / recycling and charging station equipment.

T204413-UN: R134a Recovery and Charging Station Installation

LEGEND:

1 - Low Pressure Test Port

2 - High Pressure Test Port
3 - Blue Hose
4 - Red Hose
5 - Refrigerant Recovery / Recycling and Charging Station

1. Follow procedures. See Refrigerant Cautions and Proper Handling . (Group 1830.)

2. Close both high-side and low-side valves on refrigerant recovery / recycling and charging station (5).

3. Remove caps from low pressure and high pressure test ports (1 and 2).

4. Connect blue hose (3) from refrigerant recovery / recycling and charging station to low pressure test port (1).

5. Connect red hose (4) from refrigerant recovery / recycling and charging station to high pressure test port (2).

6. Follow the manufacturer's instructions when using refrigerant recovery / recycling and charging station.

OUO1010,00006B3-19-20041022
TM2356 - 27D Excavator Repair
Recover R134a Refrigerant

Recover R134a Refrigerant

CAUTION:

Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

See Refrigerant Cautions and Proper Handling . (Group 1830.)

IMPORTANT:

Use correct refrigerant recovery / recycling and charging stations. DO NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.

1. Run air conditioning system for three minutes to help in recovery process. Turn air conditioning system off before
proceeding with recovery steps.

2. With engine OFF, identify refrigerant type using JT02167A Refrigerant Identification Instrument.

3. Connect refrigerant recovery system. See R134a Refrigerant Recovery / Recycling and Charging Station Installation
Procedure . (Group 1830.)

4. Follow manufacturer's instructions when using refrigerant recovery / recycling and charging station.

OUO1010,00006C6-19-20041029
TM2356 - 27D Excavator Repair
Evacuate R134a System

Evacuate R134a System

CAUTION:

Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

See Refrigerant Cautions and Proper Handling . (Group 1830.)

1. Connect refrigerant recovery system. See R134a Refrigerant Recovery / Recycling and Charging Station Installation Procedure .
(Group 1830.)

2. Open low-side and high-side valves on refrigerant recovery / recycling and charging station.

3. Follow manufacturer's instructions and evacuate system.

4. NOTE:

Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980
mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

Item Measurement Specification

Evacuate System Vacuum Subtract 3.4 kPa from 98 kPa for

each 300 m elevation above sea
level
Subtract 34 mbar from 980 mbar for
each 300 m elevation above sea
level
Subtract 1 in. Hg from 29 in. Hg for
each 1000 ft elevation above sea
level

Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.

Item Measurement Specification

Evacuate System Vacuum 98 kPa

980 mbar
29 in. Hg

If above specification vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Test . (Group 9031-
25.)

5. When vacuum reaches above specification, close low-side and high-side valves. Turn vacuum pump off.

6. If vacuum decreases more than specification in 5 minutes, there is a leak in system.

Item Measurement Specification

Evacuate System Vacuum 3.4 kPa

34 mbar
1 in. Hg
 7. Repair leak.

8. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached.

9. Close low-side and high-side valves. Stop evacuation.

10. Perform Charge R134a System . (Group 1830.)

OUO1010,00006C7-19-20041029
TM2356 - 27D Excavator Repair
Charge R134a System

Charge R134a System

CAUTION:

Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

See Refrigerant Cautions and Proper Handling . (Group 1830.)

IMPORTANT:

Use only John Deere approved refrigerant recovery / recycling and charging stations. DO NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.

1. Identify refrigerant type using JT02167A Refrigerant Identification Instrument.

2. Connect R134a Refrigerant Recovery / Recycling and Charging Station. See R134a Refrigerant Recovery / Recycling and Charging
Station Installation Procedure . (Group 1830.)

3. Perform Evacuate R134a System . (Group 1830.)

4. NOTE:

Before beginning to charge air conditioning system, the following conditions must exist:

¡ Engine STOPPED
¡ Pump used must be capable of pulling at least 28.6 in. Hg vacuum (sea level)
¡ Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation
above sea level

Item Measurement Specification

Evacuate System Vacuum Subtract 3.4 kPa from 98 kPa for

each 300 m elevation above sea
level
Subtract 34 mbar from 980 mbar for
each 300 m elevation above sea
level
Subtract 1 in. Hg from 29 in. Hg for
each 1000 ft elevation above sea
level

Follow manufacturer’s instructions and charge system.

5. Add refrigerant to system.

Item Measurement Specification

R134a Air Conditioning System Refrigerant Quantity 794 g

Refrigerant 1.75 lb

6. Check air conditioning for proper function. See Diagnose Air Conditioning System Malfunctions . (Group 9031-25.)

OUO1010,00006C8-19-20120306
TM2356 - 27D Excavator Repair
Air Conditioner Compressor Remove and Install

Air Conditioner Compressor Remove and Install

T208185A-UN: Air Conditioner Compressor

LEGEND:

1 - Wire Harness Connector

2 - Low Pressure Input Line
3 - High Pressure Output Line
4 - Cap Screw (3 used)
5 - A/C Compressor

1. Park machine on a flat level surface.

2. Recover refrigerant. Perform Recover R134a Refrigerant . (Group 1830.)

3. IMPORTANT:

Close A/C lines with caps or plugs immediately after disconnecting to prevent contamination of system. If
system is left open, receiver-dryer must be replaced before charging system.

Disconnect high and low pressure lines (2 and 3).

4. Remove compressor belt.

5. Disconnect wire harness connector (1).

6. Remove cap screws (4) washers, and lock nuts to remove A/C compressor (5).

Repair or replace parts as necessary.

7. If original compressor is reused:

 ¡ Connect battery power to compressor clutch coil.
¡ Drain compressor oil into graduated container while rotating compressor shaft and record amount.
¡ If oil drained from compressor removed from operation is very black or amount of oil is less than 6 mL (0.2 fl
oz), perform the following and discard oil properly:
¡ Pour flushing solvent in ports and internally wash out old oil while rotating compressor shaft. Discard oil
properly.
¡ Determine if R134a leakage was detected, remove component and repair or replace component.
¡ Flush complete system with TY25601 Air Conditioning Flushing Solvent. See Flush and Purge Air Conditioner
System . (Group 1800.)

If a new compressor is installed:

¡ Connect battery power to compressor clutch coil.

¡ Drain compressor oil into graduated container while rotating compressor shaft.

8. Install required amount of TY22101 Refrigerant Oil in compressor.

Item Measurement Specification

Refrigerant Oil Compressor 100 mL

3.38 fl oz

9. Install A/C compressor.

10. Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)

11. Install compressor belt and connect wire harness connector.

12. Connect high and low pressure lines to A/C compressor.

Item Measurement Specification

A/C Compressor High and Low Torque 29 N˙m

Pressure Output Line Cap Screw 21 lb-ft

13. Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System . (Group
1830.)

MM61211,00008BD-19-20101207
TM2356 - 27D Excavator Repair
Receiver-Dryer Remove and Install

Receiver-Dryer Remove and Install

T208210A-UN: Receiver dryer

LEGEND:

1 - A/C Refrigerant Lines

2 - Receiver-Dryer
3 - Cap Screws and Retainer
4 - High / Low Pressure Switch
5 - Wire Harness Connector

1. Park machine on a flat level surface.

2. Recover refrigerant. Perform Recover R134a Refrigerant . (Group 1830.)

3. Disconnect refrigerant lines (1).

4. Disconnect wire harness connector (5).

5. Remove high / low pressure switch (4) if receiver-dryer is to be replaced.

6. Remove retainer cap screws (3) and remove receiver-dryer (2).

7. Repair or replace parts as necessary.

8. Install receiver-dryer.

9. Install high / low pressure switch, if removed.

10. Connect refrigerant lines.

 Item Measurement Specification

Receiver-Dryer Refrigerant Lines Torque 16 N˙m

144 lb-in.

11. Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System . (Group
1830.)

MM61211,00008BE-19-20050210
TM2356 - 27D Excavator Repair
Condenser Remove and Install

Condenser Remove and Install

1. Park machine on a flat level surface.

2. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

3.
T217393A-UN: Right Side Panels

LEGEND:

1 - Right Side Panel

2 - Right Side Panel

Remove right-side panels (1 and 2).

4. Recover refrigerant. Perform Recover R134a Refrigerant . (Group 1830.)

5. IMPORTANT:

Close A/C lines with caps or plugs immediately after disconnecting to prevent contamination of system. If
system is left open, receiver-dryer must be replaced before charging system.
 T217394A-UN: Air Conditioner Condenser

LEGEND:

3 - High Pressure Liquid Output Line

4 - High Pressure Gas Input Line
5 - Cap Screw (2 used)
6 - Nut (3 used)
7 - Air Conditioner Condenser

Disconnect high pressure liquid output line (3).

6. Disconnect high pressure gas input line (4).

7. Remove cap screws (5) washers, and lock nuts to remove condenser (6).

8. Repair or replace parts as necessary.

9. Install condenser.

10. Connect high pressure liquid output line and high pressure gas input line.

Item Measurement Specification

Refrigerant Lines Torque 16 N˙m

144 lb-in.

11. Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System . (Group
1830.)

MM61211,0000A4E-19-20051201
TM2356 - 27D Excavator Repair
Air Conditioner / Heater Module Remove and Install

Air Conditioner / Heater Module Remove and Install

1.
T208297A-UN: Air vent cover

T208298A-UN: Auxiliary Pedals

LEGEND:

1 - Air Vent Cover

2 - Cap Screw (1 used)
3 - Screw (4 used)
4 - Power Outlet Wire Harness
5 - Floor Plate
6 - Rubber Mat
7 - Pedal Covers
 8 - Auxiliary Control Pedals
9 - Bracket
10 - Screw (2 used)

Park machine on a flat level surface.

2. Recover refrigerant. Perform Recover R134a Refrigerant . (Group 1830.)

3.

CAUTION:

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure before removing completely.

NOTE:

Heater core and heater hoses contain coolant. Properly dispose of coolant.

Drain coolant from system and to heater hoses. See Draining Cooling System . (Operator's Manual.)

4. Disconnect heater hoses.

5. Remove screws (3). And cap screw (2) from air duct cover (1).

6. Disconnect wire harness from power outlet (4).

7. Remove floor plate (5).

8. Remove rubber pad (6) and remove auxiliary control pedals (8) and pedal covers (7).

9. Remove bracket (9) under auxiliary pedals.

10. Remove two air duct cover screws (10).

11.
T208299A-UN: Coolant Lines

T208300A-UN: Module

LEGEND:

11 - Screw (3 used)
12 - Access Panel
13 - Cap Screw (1 used)
14 - Refrigerant Lines
15 - Module
16 - Heater Hoses
17 - Cap Screw (2 used)
18 - Blower Motor Cover
19 - Cap Screw (2 used)
20 - Wire Harness Connector

Remove air vent screws (11).

12. Remove access panel (12).

13. Remove cap screw (13).

14. IMPORTANT:

Close A/C lines with caps or plugs immediately after disconnecting to prevent contamination of system. If
system is left open, receiver-dryer must be replaced before charging system.

NOTE:

Refrigerant lines-to-expansion valve connections are located under the cab floor, just to the rear of
the brake valve.

Disconnect refrigerant lines (14) from module (15).

15. Disconnect heater hoses (16) from module (15).

16. Remove cap screws (17) from module.

17. Remove blower motor cover (18).

18. Remove cap screws (19) under blower motor cover.

19. Disconnect A/C thermostat / blower harness connector (20).

20. Carefully remove A/C-heater module (15).

21. Repair or replace parts as necessary.

22. Install A/C-heater module. Add insulation as necessary around module and refrigerant lines.

23. Connect heater hoses (16).

24. Install air vent, and air duct.

25. Connect all wire harness connectors.

26. Install air duct cover (1).

27. Connect refrigerant lines to module using new O-rings.

Item Measurement Specification

Refrigerant Lines Torque 16 N˙m

144 lb-in.

28. Evacuate air conditioning system and charge. See Evacuate R134a System and see Charge R134a System . (Group
1830.)

29. Fill cooling system to proper level. See Cooling System Fill and Deaeration . (Operator's Manual.)

30. Start engine and check heater hoses for leaks.

31. Check air conditioning system for leaks. See Refrigerant Leak Test . (Group 9031-25.)

32. Install access panel (12).

33. Install floor plate (5) and auxiliary control pedal assembly (8).
34. Install rubber floor mat (6).

MM61211,00008C0-19-20090218
TM2356 - 27D Excavator Repair
Heater Control Valve Remove and Install

Heater Control Valve Remove and Install

1.
T208344A-UN: Seat Assembly

T208345A-UN: Pattern control valve

 T208346A-UN: Bracket

LEGEND:

1 - Cap Screw (3 used)

2 - Wire Harness (2 used)
3 - Heater Hose (2 used)
4 - Heater Control Valve
5 - Control Lever Pattern Conversion Cap Screw (2 used)
6 - Control Lever Pattern Conversion Bracket Cap Screw (2 used)
7 - Bracket Nut (2 used)

Drain cooling system. See Draining Cooling System . (Operator's Manual.)

2. Remove three cap screws (1).

3. Disconnect wire harnesses (2).

4. Disconnect both heater hoses (3) from control valve (4).

5. Remove control lever pattern conversion cap screws (5).

6. Remove control lever pattern conversion bracket cap screw (6).

7. Remove bracket nuts (7) on back side of cab.

8. Remove heater control valve (4). Replace if necessary.

9. Connect hoses to control valve using new hose clamps.

10. Install cap screws (1).

11. Install nuts (7) on back side of cab, but do not tighten.

12. Install control lever pattern conversion bracket cap screw (6).

13. Install control lever pattern conversion cap screws (5).

14. Tighten all cap screws and nuts.

15. Fill cooling system to proper level. See Cooling System Fill and Deaeration . (Operator's Manual.)

16. Start engine and check for leaks.

17. Stop engine.

MM61211,0000A4F-19-20090219
TM2356 - 27D Excavator Repair
Blade Remove and Install

Blade Remove and Install

1.
T119390-UN: Attaching Hoist to Blade

LEGEND:

1 - Hoist
2 - Lifting Holes (2 used)
3 - Blade

Lower all equipment to ground.

2. Stop engine.

3.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Blade Weight approximate 205 kg

450 lb

Attach chains or lifting straps to lifting holes (2) of blade (3) and to hoist (1).

4.
T208280-UN: Blade and Pins

LEGEND:

1 - Blade
2 - Hydraulic Cylinder
3 - Cap Screw (2 used)
4 - Washer (2 used)
5 - Locking Plate
6 - Cylinder Pin
7 - Cylinder Shim (as needed)
8 - Cap Screw (4 used)
9 - Washer (4 used)
10 - Locking Plate (2 used)
11 - Arm Pin (2 used)
12 - Arm Shim (as needed)

Put support stands under the rear arms of blade (1) and front of hydraulic cylinder (2).
 5. Remove cap screws (3), washers (4), and locking plate (5).

6. NOTE:

Cylinder shims (7) may fall out as cylinder pin (6) is removed.

Remove cylinder pin (6) using a brass punch and hammer. Remove cylinder shims (7).

7. Remove cap screws (8), washers (9), and locking plates (10).

8. NOTE:

Arm shims (12) may fall out as blade (1) is removed.

Remove arm pins (11) using a brass punch and hammer. Remove arm shims (12).

9. Remove blade and replace parts as necessary.

10. Clean and apply grease to all pins (6 and 11).

11. Align holes in blade arms with mounting holes in undercarriage frame. Install arms pins (11) with equal number of shims (12) at each
side of blade arm.

12. NOTE:

It may be necessary to rotate the cylinder pin so the keyway aligns with the locking plate.

Install locking plates (10), washers (9), and cap screws (8). Tighten cap screws to specification.

Item Measurement Specification

Blade Arm Pin Locking Plate Cap Torque 140 N˙m

Screw 103 lb-ft

13. Connect blade cylinder to blade by installing cylinder pin (6) with equal number of shims (7) at each side.

14. NOTE:

It may be necessary to rotate the cylinder pin so the keyway aligns with the locking plate.

Install locking plate (5), washer (4), and cap screw (3). Tighten cap screw to specification.

Item Measurement Specification

Blade Cylinder Pin Locking Plate Torque 140 N˙m

Cap Screw 103 lb-ft

15. Check oil level. See Checking Hydraulic Oil Tank Level . (Operator's Manual.) Add oil as necessary. See Hydraulic Oil . (Operator's
Manual.)

MM61211,0000A50-19-20090218
TM2356 - 27D Excavator Repair
Blade Disassemble and Assemble

Blade Disassemble and Assemble

T125452-UN: Blade Bushings and Dust Seals

LEGEND:

1 - Blade
2 - Dust Seal (4 used)
3 - Bushing (2 used)

Repair or replace parts as needed.

See Welding on Machine . (Group 1740.)

See Welding Repair of Major Structure before welding on the blade. (Group 1740.)

OUO1030,0000122-19-20050218
TM2356 - 27D Excavator Repair
Blade Cylinder Remove and Install

Blade Cylinder Remove and Install

1. Lower blade to ground.

2. Stop engine.

3.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Slowly loosen hydraulic tank cap to release air pressure in hydraulic tank.

4.
T217399A-UN: Blade Cylinder Removal

LEGEND:

1 - Cap Screw (2 used)

2 - Washer (2 used)
3 - Cylinder Guard
4 - Hydraulic Lines
5 - Cap Screw (4 used)
6 - Washer (4 used)
7 - Locking Plate (2 used)
8 - Cylinder Pin (2 used)
9 - Blade Cylinder

Remove cap screws (1), washers (2), and cylinder guard (3).

5. Identify, tag, then disconnect hydraulic lines (4). Close all openings using caps and plugs.

6.
 CAUTION:

Prevent possible injury from crushing. For a heavy component, use appropriate lifting device.

Item Measurement Specification

Blade Cylinder Weight (approximate) 19 kg

42 lb

Attach a hoist and lifting straps to blade cylinder (9).

7. Remove cap screws (5), washers (6), and locking plates (7).

8. Remove cylinder pins (8) using a brass punch and hammer.

9. Remove blade cylinder (9).

10. Repair or replace blade cylinder as necessary. See Blade and Boom Swing Cylinder Disassemble and Assemble . (Group 3360.)

11. Apply grease to cylinder pins (8).

12. Line up blade cylinder (9) mounts and install cylinder pins (8).

13. NOTE:

It may be necessary to rotate the cylinder pin so the keyway aligns with the locking plate.

Install locking plates (7), washers (6), and cap screws (5). Tighten cap screws to specification.

Item Measurement Specification

Blade Cylinder Pin Locking Plate Torque 140 N˙m

Cap Screw 103 lb-ft

14. Connect hydraulic lines.

15. Install cylinder guard (3), washers (2), and cap screws (1). Tighten cap screws (1).

16. Check fluid level. See Checking Hydraulic Oil Tank Level . (Operator's Manual.) Add oil as necessary. See Hydraulic Oil . (Operator's
Manual.)

MH66O88,0000073-19-20090218
TM2356 - 27D Excavator Repair
Blade Pilot Controller Remove and Install

Blade Pilot Controller Remove and Install

1. Lower blade to ground.

2. Stop engine.

3.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic tank cap to relieve air pressure in hydraulic tank.

Slowly loosen hydraulic tank cap to release air pressure in hydraulic tank.

4. NOTE:

Open access panel (26) to ease the removal of the cover (25).

T208342A-UN: Blade Pilot Control Lever

LEGEND:

22 - Control Lever
23 - Screw (4 used)
24 - Cap Screw
25 - Cover
26 - Access Panel
 Remove screws (23), and cap screw (24) to remove cover (25). Disconnect wire leads to 12-volt power outlet.

5.
T208341-UN: Blade Pilot Controller

LEGEND:

22 - Lever
27 - Cap Screws (2 used)
28 - Hydraulic Line (4 used)
29 - Cap Screw (2 used)
30 - Blade Pilot Controller

Remove cap screws (27) and lever (22).

6. Identify, tag, then disconnect hydraulic lines (28). Close all openings using caps and plugs.

7. Remove cap screws (29) and blade pilot controller (30).

8. Replace parts as necessary.

9. Install blade pilot controller.

10. Connect hydraulic lines. For line identification, see Blade Hydraulic System Line Identification . (Group 9025-15.)

11. Install lever (22) using cap screws (27).

12. Connect wire leads to 12-volt power outlet.

13. Install cover (25), cap screw (24), and screws (23).

MH66O88,0000074-19-20060105
TM2356 - 27D Excavator Repair
Blade Pilot Controller Disassemble and Assemble

Blade Pilot Controller Disassemble and Assemble

1. IMPORTANT:

The pilot controller must be replaced if cam (3), bracket (8), push rods (12), spools (17), or housing (21)
are damaged.

NOTE:

Note location of parts with respect to mating parts for assembly purposes.

T160028-UN: Blade Pilot Controller

LEGEND:

1 - Boot
2 - Set Screw
3 - Cam
4 - Steel Ball (2 used)
5 - Cap Screw (2 used)
6 - Bushing (2 used)
7 - Shaft
8 - Bracket
9 - Packing (2 used)
10 - Plug (2 used)
11 - O-Ring (2 used)
12 - Push Rod (2 used)
13 - Spring Seat (2 used)
14 - Inner Spring (2 used)
15 - Shim (2 used)
16 - Washer (2 used)
17 - Spool (2 used)
18 - Outer Spring (2 used)
19 - Plug
20 - O-Ring
21 - Housing

Remove set screw (2). Medium strength thread lock and sealer is used on the threads of set screws .

2. Remove shaft (7) to remove cam (3). Steel balls (4) are not removable.

3. Loosen cap screws (5) to relieve spring tension. Remove bracket (8) from housing (21).

4. Remove packing (9), plugs (10), O-rings (11), and push rods (12).

5. IMPORTANT:
 The spool assemblies are adjusted for equal pressure using shims. Keep the shims and washers with
their respective spools.

Prevent premature wear of Identify the port each spool is removed from. Spools must be installed into the
same ports from which they were removed.

Remove spool assemblies (13—17) and outer springs (18). Keep parts for each spool assembly together.

6. Clean and repair or replace parts as necessary.

7. Install washer (16), shim (15), and inner spring (14) onto spool (17).

Compress the spring just enough to insert head of spool (17) through large diameter hole of spring seat (13). Move
head of spool to the small center hole to lock spring seat into position.

8. Install the outer spring (18).

9. Carefully install spool assemblies into the same ports from which they were removed.

10. Install O-rings (11) on plugs (10).

11. Apply grease to packing (9). Install packing into plugs so lip is toward O-ring end of plug.

12. Apply hydraulic fluid to push rods (12) before pushing rod through the packing in plugs (10). Install plug and push rod
into housing.

13. Install bracket (8). Tighten cap screws (5) to specification.

Item Measurement Specification

Blade Pilot Controller Cover-to- Torque 5.0 N˙m

Housing Cap Screw 44 lb-in

14. Install cam (3). Install the shaft (7) through cover and cam so hole in shaft aligns with tapped hole in cam.

15. Apply PM37509 Cure Primer then PM37477 Thread Lock and Sealer (medium strength) to threads of set screw (2).
Tighten set screw to specification.

Item Measurement Specification

Blade Pilot Controller Cam-to-Shaft Torque 5.0 N˙m

Set Screw 44 lb-in

LOCTITE is a trademark of Henkel Group. MH66O88,0000075-19-20060105

TM2356 - 27D Excavator Repair
Tooth Shank Remove and Install

Tooth Shank Remove and Install

1. IMPORTANT:

Take all precautions and move vehicle into safe work area.

T197606-UN: Bucket Tooth Shank

LEGEND:

0 - Bucket Assembly
1 - Tooth
2 - Cap Screw
3 - Nut

Adjust the bucket to comfortable working height. Stop engine.

2. Remove nut (3), cap screw (2), and tooth (1).

3. Replace as necessary.

4. Install tooth (1), cap screw (2), and nut (3). Tighten nut (3) to specification.

Item Measurement Specification

Tooth Shank Torque 150 N˙m

115 lb-ft

MH66O88,0000077-19-20060131
TM2356 - 27D Excavator Repair
Bucket Pin-Up Data

Bucket Pin-Up Data

TX1110081-UN: Bucket Pin-Up Data

LEGEND:

1 - Bucket Pin A to Guide Link Arm Pin Distance

2 - Guide Link Arm Pin to Arm Centerline Offset
3 - Guide Link Length
4 - Bucket Link Length
5 - Bucket Pin Distance
6 - Bucket Arm Pin to Bucket Tooth Tip Distance
7 - Bucket Pin A Cap Screw Hole to Pin End (minimum—without shim)
8 - Bucket Pin A Bucket Ear Bushing Inner Distance
9 - Bucket Pin A Bucket Ear Bushing Bore Size
10 - Bucket Pin Distance (bucket resting flat on ground)
11 - Bucket Pin Vertical Offset (bucket resting flat on ground)
12 - Bucket Pin B Cap Screw Hole to Pin End (minimum)
13 - Bucket Pin B Bucket Ear Bushing Inner Distance
14 - Bucket Pin B Bucket Ear Bushing Bore Size
15 - Bucket Pin A Locking Cap Screw Angle
16 - Bucket Pin B Locking Cap Screw Angle

-: Bucket Pin-Up Data

Item Measurement (mm) Measurement (in.)

1 152 5.98
2 13 0.51
3 244 9.61
4 230 9.06
5 185 7.28
6 640 25.20
7 234.5 9.23
8 140.5 5.53
9 35 1.38
10 185 7.28
11 0 0
12 234.5 9.23
13 140.5 5.53
14 35 1.38
15 90° 90°
16 90° 90°

ML82895,00006CE-19-20120323
TM2356 - 27D Excavator Repair
Bucket Link Remove and Install

Bucket Link Remove and Install

T217440-UN: Bucket Links

LEGEND:

1 - Nut (4 used)
2 - Left Side Link
3 - O-Ring (2 used)
4 - Plate (washer) (6 used)
5 - Plate (washer) (6 used)
6 - Center Link
7 - Cap Screw (2 used)
8 - Links-to-Arm Pin
9 - Lubrication Fitting (2 used)
10 - Cylinder Pin
11 - Right Side Link

NOTE:

Removal of bucket is not necessary for the removal of just the bucket links. Remove the bucket if the arm
is also being removed. See Installing Bucket with Quick Coupler . (Operator's Manual.)

1. Connect hoist and lifting strap to center link (6). Put a wood block between bucket cylinder and arm to hold cylinder
when pin (8) is removed.

2. Remove nuts (1) and cap screws (7).

3. NOTE:

As pin (8) is removed, grasp side links (2 and 11) and lower each one to the ground .

Remove pin (8).

4.
T208458-UN: Bushings and Dust Seals

LEGEND:

1 - O-Ring (2 used)
 2 - Plate (washer) (4 used)
3 - Center Link
4 - Bushing (2 used)
5 - Dust Seal (2 used)
6 - Dust Seal (4 used)
7 - Bushing (2 used)

Inspect bushings (4 and 7) and dust seals (5 and 6). See Inspect Arm, Boom, Bucket, and Boom Swing Pins and
Bushings . (Group 3340.)

Replace parts as necessary.

5. Install plates (washers) (2) equally on each side of joint to get a minimal amount of clearance in the joints. There must
be some clearance in the joints.

6. Before installing pins, align pin bores so as not to damage dust seal when pins are installed.

7. Install cap screws and nuts.

8. Apply multi-purpose grease to pivot joints.

MH66O88,0000079-19-20060131
TM2356 - 27D Excavator Repair
Arm Remove and Install

Arm Remove and Install

T217439-UN: Arm And Cylinder

LEGEND:

1 - Bushing
2 - Cap Screw
3 - Washer
4 - Arm-to-Boom Pin
5 - Link
6 - Stop (2 used)
7 - Link
8 - Shim (4 used)
9 - Arm-to-Arm Cylinder Pin
10 - Arm-to-Bucket Cylinder Pin
11 - Pin
12 - Pin
13 - Bucket-to-Arm Pin
14 - Bucket-to-Center Link Pin
15 - Plug (6 used)
16 - Cap Screw (4 used)
17 - Nut (8 used)
21 - Lubrication Fitting (4 used)
22 - O-Ring (4 used)
24 - Cap Screw
25 - Bushing
26 - Cap Screw
27 - Bushing
29 - Shim (3 used)
30 - Shim (8 used)
31 - Shim (8 used)
35 - Adapter (2 used)
36 - O-Ring (2 used)
37 - Hydraulic Hose (2 used)
39 - Plug (4 used)
40 - Plug (2 used)

1. Remove bucket. See Installing Bucket with Quick Coupler . (Operator's Manual.)

2. Fully retract arm cylinder.

3. Lower boom onto a floor stand making sure load is on the boom, not on arm or arm cylinder.

4. Stop engine.

5.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.
 Slowly loosen cap to relieve the air pressure in hydraulic tank.

6.

CAUTION:

To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting
or connecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811-UN: High-Pressure Fluid

Loosen bucket cylinder hydraulic lines to release any residual pressure.

7. Disconnect hydraulic lines. Close all opening using caps and plugs.

8.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Arm Weight approximate 96 kg

210 lb

NOTE:

Remove bucket cylinder and linkage only if necessary to repair arm.

Attach hoist and lifting strap to arm.

9. Put a wood block between arm cylinder and boom to keep cylinder off hydraulic lines.
 10.
T124955-UN: Remove Arm

LEGEND:

1 - Cap Screw
2 - Bushing
3 - Arm-to-Arm Cylinder Pin
4 - Cap Screw
5 - Bushing
6 - Boom-to-Arm Pin

Remove parts (1—6). Remove arm.

11. Repair or replace parts as necessary.

12. Install arm.

Install shims equally on each side of joint to get a minimal amount of clearance in the joints. There must be some clearance in the
joints.

Item Measurement Specification

Arm and Cylinder Joints Clearance 0.5 mm or less

0.020 in. or less

13. Install parts (1—6). Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to threads of cap screws.
Tighten cap screws (1 and 4) to specification.

Item Measurement Specification

Arm-to-Arm Cylinder Pin Cap Screw Torque 90 N˙m

66 lb-ft

Boom-to-Arm Pin Cap Screw Torque 210 N˙m

154 lb-ft

14. Remove wood block.

15. Remove hoist.

16. Install bucket cylinder if removed.

17. Connect bucket cylinder hydraulic lines.

18. Install bucket links if removed.

19. Install bucket. See Installing Bucket with Quick Coupler . (Operator's Manual.)

20. Check hydraulic fluid level and add hydraulic fluid if necessary. See Hydraulic Oil . (Operator's Manual.)

21. Apply multi-purpose grease to all joints.

22. Perform Hydraulic Cylinder Bleed Procedure . (Group 3360.)

LOCTITE is a trademark of Henkel Group. MH66O88,000007A-19-20090218

TM2356 - 27D Excavator Repair
Boom Remove and Install

Boom Remove and Install

T159763-UN: Boom

LEGEND:

1 - Boom-to-Arm Cylinder Pin

2 - Arm-to-Boom Pin
3 - Shim (2 used)
4 - Shim (2 used)
5 - Shim (7 used)
6 - Boom-to-Boom Cylinder Pin
7 - Bushing
8 - Cap Screw
9 - Bushing
10 - Cap Screw
11 - Bushing
12 - Cap Screw
13 - Lock Washer
14 - Lubrication Fitting
15 - Plug (5 used)
16 - Bushing (2 used)
17 - Seal (2 used)

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen cap to relieve the air pressure in hydraulic tank.

2. Remove bucket. See Installing Bucket with Quick Coupler . (Operator's Manual.)

3. Remove arm. See Arm Remove and Install . (Group 3340.)

4. Lower boom so the end is resting on a support stand.

5.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

 Boom Cylinder Weight approximate 31 kg
70 lb

Attach a hoist and lifting strap to boom cylinder.

6. NOTE:

Removal of boom cylinder cover (1) is only necessary if cylinder is being removed.

T124958-UN: Boom-To-Cylinder Pin

LEGEND:

1 - Boom Cylinder Cover

2 - Cap Screw and Washer
3 - Shim (2 used)
4 - Shim (2 used)
5 - Boom-to-Boom Cylinder Pin
6 - Cap Screw
7 - Bushing

Remove cap screw (6), bushing (7), pin (5), and shims (3 and 4). Lower rod-end of boom cylinder onto a support stand.

7. Remove arm cylinder if boom repair or cylinder replacement is necessary.

8.

CAUTION:

To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting
or connecting hydraulic or other lines. Tighten all connections before applying pressure.
 X9811-UN: High-Pressure Fluid

LEGEND:

1 - Cover
2 - Hydraulic Lines
3 - Cap Screw and Nuts
4 - Boom-to-Frame Pin
5 - Shims (2 used)

Remove cover (1).

9. Identify, tag, then disconnect hydraulic lines (2). Close all openings using caps and plugs.

10. Disconnect wires for boom light.

11.

CAUTION:
 Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Boom Weight Weight approximate 213 kg

470 lb

Attach hoist and lifting strap to boom.

12. Remove cap screw and nuts (3). Remove the pin (4) and shims (5).

13. Remove boom.

14. Repair or replace parts as necessary.

15. Align boom to machine frame and install pin (4) with equal number of shims (5) on each side of joint to get a minimal amount of
clearance in the joint. There must be some clearance in the joint.

Item Measurement Specification

Boom, Arm, and Cylinder Joints Clearance 0.5 mm

0.020 in.

16. Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to threads of cap screw and nuts (3).

Install cap screw and nuts (3). Tighten the nuts against each other, not the boss, until torque and clearance are to specification. Cap
screw must be free to turn in hole.

Item Measurement Specification

Boom-to-Frame Pin Cap Screw and Torque 90 N˙m

Nuts 66 lb-ft

Boom Pin Nut-to-Boss Clearance 3—5 mm

0.12—0.20 in.

17.
T124958-UN: Boom Cylinder and Pin

LEGEND:

1 - Boom Cylinder Cover

2 - Cap Screw and Washer
3 - Shim (2 used)
4 - Shim (2 used)
5 - Boom Cylinder-to-Boom Pin
6 - Cap Screw
 7 - Bushing

Raise rod-end of boom cylinder into position. Install pin (5) with equal number of shims (3 and 4) at each side of joint to get a minimal
amount of clearance in the joint. There must be some clearance in the joint.

18. Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to threads of cap screw (6).

Install bushing (7) and cap screw (6). Tighten cap screw to specification.

Item Measurement Specification

Boom Cylinder Pin-to-Boom Frame Torque 90 N˙m

Cap Screw 66 lb-ft

19. Connect hydraulic lines. For line identification, see Main Hydraulic Working System Line Identification . (Group 9025-15.)

20. Install boom cylinder cover (1) if removed. Tighten cap screw and washer (2) to specification.

Item Measurement Specification

Boom Cylinder Protector Cap Screw Torque 50 N˙m

37 lb-ft

21. Install arm. See Arm Remove and Install . (Group 3340.)

22. Install arm cylinder if removed. See Arm Cylinder Remove and Install . (Group 3360.)

23. Install bucket. See Installing Bucket with Quick Coupler . (Operator's Manual.)

24. Check fluid level and add hydraulic fluid if necessary. See Hydraulic Oil . (Operator's Manual.)

25. Apply multi-purpose grease to all joints.

26. Perform Hydraulic Cylinder Bleed Procedure . (Group 3360.)

LOCTITE is a trademark of Henkel Group. MH66O88,000007B-19-20090219

TM2356 - 27D Excavator Repair
Boom Swing Remove and Install

Boom Swing Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic tank cap to relieve air pressure in hydraulic tank.

X9811-UN: High Pressure Fluid

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

2. Remove boom. See Boom Remove and Install . (Group 3340.)

3.
T217438-UN: Swing Post

LEGEND:
 1 - Cap Screw (3 used)
2 - Cover
3 - Cap Screw (2 used)
4 - Cover
5 - Cap Screw (2 used)
6 - Cover
7 - Nut (2 used)
8 - Cap Screw
9 - Pin
10 - Nut (2 used)
11 - Cap Screw
12 - Pin
13 - Shim (2 used)
14 - Shim
15 - Nut (2 used)
16 - Cap Screw
17 - Pin
18 - Shim (2 used)
19 - Shim
20 - Screw (3 used)
21 - Guide
22 - Nut (2 used)
23 - Cap Screw
24 - Pin
25 - Bushing
26 - Thrust Washer
27 - Swing Frame

Remove cap screws (1) and cover (2).

4. Remove cap screws (3) and cover (4).

5. Remove cap screws (5) and cover (6).

6. Remove nuts (7), cap screw (8), and pin (9) to disconnect boom swing cylinder.

7.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Attach a hoist and lifting strap to boom swing frame (27).

8. Remove nuts (22), cap screws (23), and pin (24).

9. Remove thrust washer (26) and bushing (25).

10. NOTE:

Remove and reinstall guide (21) if replacing swing frame (27).

Remove swing frame (27).

11. Make repairs or replace parts as necessary.

12. Install swing frame (27).

 13. Install thrust washer (26), bushing (25), and pin (24).

14. Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to the threads of nuts (22).Install
cap screw (23) and tighten nuts (22) against each other, not the boss. There must be clearance between nuts and
boss. Cap screw must be free to turn in hole.

Item Measurement Specification

Nut-to-Boss Clearance 3—5 mm

0.12—0.20 in.

Item Measurement Specification

Swing Frame Cap Screw and Nuts Torque 50 N˙m

37 lb-ft

15. Install guide (21) and screws (20).

16. Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to the threads of nuts (7).Connect
swing boom cylinder using pin (9), cap screw (8), and nuts (7).

17. Install boom. See Boom Remove and Install . (Group 3340.)

18. Check fluid level and add hydraulic fluid if necessary. See Hydraulic Oil . (Operator's Manual.)

19. Apply multi-purpose grease to all joints.

LOCTITE is a trademark of Henkel Group. MH66O88,000007C-19-20090218

TM2356 - 27D Excavator Repair
Inspect Arm, Boom, Bucket, and Boom Swing Pins and Bushings

Inspect Arm, Boom, Bucket, and Boom Swing Pins and Bushings

T124959-UN: Arm, Boom, Boom Swing Pins and Bushings

LEGEND:

A - Boom Cylinder Head End-to-Frame Joint

B - Boom-to-Frame Joint
C - Boom Cylinder Rod End-to-Boom Joint
D - Arm Cylinder Head End-to-Boom Joint
E - Arm Cylinder Rod End-to-Arm Joint
F - Boom-to-Arm Joint
G - Bucket Cylinder Head End-to-Arm Joint
H - Side Links-to-Arm Joint
I - Bucket Cylinder Rod End-to-Boom Joint
J - Center Link-to-Bucket Joint
K - Bucket-to-Arm Joint
L - Boom Swing-to-Frame Joint
M - Boom Swing Cylinder Rod End-to-Boom Swing Joint
N - Frame-to-Boom Swing Cylinder Head End Joint

Item Measurement Specification

Boom Cylinder Head End-to-Frame OD (nominal) 40.0 mm

Joint Pin 1.57 in.

OD (limit of use) 39.0 mm

1.54 in.

Boom Cylinder Head End-to-Frame ID (nominal) 40.0 mm

Joint Bushing 1.58 in.

ID (limit of use) 41.5 mm

1.63 in.

Boom Cylinder Rod End-to-Boom OD (nominal) 40.0 mm

Joint Pin 1.58 in.

OD (limit of use) 39.0 mm

1.54 in.

Boom Cylinder Rod End-to-Boom ID (nominal) 40.0 mm

Joint Bushing 1.58 in.

ID (limit of use) 41.5 mm

1.63 in.

Boom-to-Frame Joint Pin OD (nominal) 45.0 mm

1.77 in.

OD (limit of use) 44.0 mm

1.73 in.

Boom-to-Frame Joint Bushing ID (nominal) 45.0 mm

 1.77 in.

ID (limit of use) 46.5 mm

1.83 in.

Boom-to-Arm Joint Pin OD (nominal) 45.0 mm

1.77 in.

OD (limit of use) 44.0 mm

1.73 in.

Boom-to-Arm Joint Bushing ID (nominal) 45.0 mm

1.77 in.

ID (limit of use) 46.5 mm

1.83 in.

Boom Swing-to-Frame Pin OD (nominal) 71.0 mm

2.80 in.

OD (limit of use) 70.0 mm

2.76 in.

Boom Swing-to-Frame Bushing ID (nominal) 71.0 mm

2.80 in.

ID (limit of use) 72.5 mm

2.85 in.

Boom Swing Cylinder-to-Boom OD (nominal) 40.0 mm

Swing Pin 1.57 in.

OD (limit of use) 39.0 mm

1.54 in.

Boom Swing Cylinder-to-Boom ID (nominal) 40.0 mm

Swing Bushing 1.57 in.

ID (limit of use) 41.5 mm

1.63 in.

Frame-to-Boom Swing Cylinder Pin OD (nominal) 40.0 mm

1.57 in.

OD (limit of use) 39.0 mm

1.54 in.

Frame-to-Boom Swing Cylinder ID (nominal) 40.0 mm

Bushing 1.57 in.

ID (limit of use) 41.5 mm

1.63 in.

Arm Cylinder Head End-to-Boom OD (nominal) 40.0 mm

Joint Pin 1.57 in.

OD (limit of use) 40.0 mm

1.57 in.

Arm Cylinder Head End-to-Boom ID (nominal) 40.0 mm

Joint Bushing 1.57 in.

ID (limit of use) 41.5 mm

1.63 in.

Arm Cylinder Rod End-to-Arm Joint OD (nominal) 40.0 mm

Pin 1.57 in.

OD (limit of use) 39.0 mm

 1.54 in.

Arm Cylinder Rod End-to-Arm Joint ID (nominal) 40.0 mm

Bushing 1.57 in.

ID (limit of use) 41.5 mm

1.63 in.

Bucket Cylinder Head End-to-Arm OD (nominal) 35.0 mm

Joint Pin 1.38 in.

OD (limit of use) 34.0 mm

1.33 in.

Bucket Cylinder Head End-to-Arm ID (nominal) 35.0 mm

Joint Bushing 1.38 in.

ID (limit of use) 36.5 mm

1.44 in.

Bucket Cylinder Rod End-to-Side OD (nominal) 35.0 mm

and Center Links Joint Pin 1.38 in.

OD (limit of use) 34.0 mm

1.33 in.

Bucket Cylinder Rod End-to-Side ID (nominal) 35.0 mm

and Center Links Joint Bushing 1.38 in.

ID (limit of use) 36.5 mm

1.44 in.

Side Links-to-Arm Joint Pin OD (nominal) 35.0 mm

1.38 in.

OD (limit of use) 34.0 mm

1.33 in.

Side Links-to-Arm Joint Bushing ID (nominal) 35.0 mm

1.38 in.

ID (limit of use) 36.5 mm

1.44 in.

Center Link-to-Bucket Joint Pin OD (nominal) 35.0 mm

1.38 in.

OD (limit of use) 34.0 mm

1.33 in.

Center Link-to-Bucket Joint ID (nominal) 35.0 mm

Bushing— 1.38 in.

ID (limit of use) 36.5 mm

1.44 in.

Bucket-to-Arm Joint Pin OD (nominal) 35.0 mm

138 in.

OD (limit of use) 34.0 mm

1.33 in.

Bucket-to-Arm Joint Bushing ID (nominal) 35.0 mm

1.38 in.

ID (limit of use) 36.5 mm

1.44 in.
MH66O88,000007D-19-20051214
TM2356 - 27D Excavator Repair
Bushing and Seal Remove and Install

Bushing and Seal Remove and Install

T95237-UN: Pipe Dimensions

T6641CW-UN: Dust Seal Thickness

LEGEND:

A - Hydraulic Ram
B1 - Pipe—Minimum ID to Clear Bushing OD
B2 - Pipe—Maximum OD
B3 - Pipe—Length of Bushing
C - Bushing
D - Disks
E - Bushing Stop (disk)
F - Pilot (disk)
G - Ram Stop (disk)
H - Thickness of Dust Seal

1. NOTE:

Bushing can also be removed by welding three to five weld beads on the inside of bushing.
Bushing will shrink enough to permit removal using a hammer.

Remove bushings (C) and dust seals using bushing, bearing, and seal driver set.

2. Install bushings with lubrication hole aligned with lubrication passage in pivot.

3. Install bushing to a depth equal to thickness of dust seal (H).

4. Install dust seals with lip toward outside of component.

MH66O88,000007E-19-20051214
TM2356 - 27D Excavator Repair
Hydraulic Pump Remove and Install

Hydraulic Pump Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

2. Drain hydraulic tank. See Changing Hydraulic Tank Oil and Cleaning Suction Screen . (Operator's Manual.)

3. Remove left side covers to access hydraulic pump.

4.

CAUTION:

To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting
or connecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811-UN: High-Pressure Fluid

 T217404A-UN: Hydraulic Pump

LEGEND:

1 - Hydraulic Line
2 - Hydraulic Line
3 - Hydraulic Line
4 - Hydraulic Line
5 - Washer (2 used)
6 - Cap Screw (2 used)
7 - Hydraulic Line (air conditioning only)
8 - Hydraulic Pump
9 - Hose

Disconnect lines (1—4) and (7) if equipped. Close openings using caps and plugs.

5. Loosen clamp and disconnect line (9).

6.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Hydraulic Pump

Hydraulic Pump Weight approximate 21 kg

46 lb

Attach hoist and lifting strap to hydraulic pump. Remove cap screws (6) and lock washers (5). Remove hydraulic pump (8).

7. See Hydraulic Pump Disassemble (Group 3360.)

See Hydraulic Pump Assemble for procedure. (Group 3360.)

8. Install hydraulic pump (8), lock washers (5) and cap screws (6). Tighten cap screws to specification.

Item Measurement Specification

Hydraulic Pump-to-Flywheel Torque 90 N˙m

Housing Cover Cap Screw 67 lb-ft
 9. Connect hose (9) and tighten clamp.

10. Connect lines (1—4) and (7) if equipped.

11. IMPORTANT:

Hydraulic pump will be damaged if not filled with fluid before starting engine. Procedure must be performed whenever
the pump is installed or fluid has been drained from the pump or hydraulic tank.

Perform Hydraulic Pump Start-Up Procedure . (Group 3360.)

MH66O88,000004E-19-20090219
TM2356 - 27D Excavator Repair
Hydraulic Pump Disassemble

Hydraulic Pump Disassemble

T207937-UN: Hydraulic Pump Cross Section

LEGEND:

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

1.
T125691-UN: Hydraulic Pump Hose Fitting

LEGEND:

15 - Hose Fitting
48 - Cap Screw (4 used)
49 - O-Ring

Remove cap screws (48), hose fitting (15), and O-ring (49).

2. NOTE:

Bushing (43) and coupling (44) may come off with hydraulic pump 3 (45) or remain on hydraulic
pump.

T125692-UN: Hydraulic Pump 3 Cap Screw

 T125693-UN: Hydraulic Pump Coupling and O-rings

LEGEND:

35 - Sealing Washer
36 - Adjusting Screw
37 - Nut
38 - Lock Washer (5 used)
39 - Cap Screw (5 used)
40 - O-Ring
41 - O-Ring
42 - O-Ring
43 - Bushing
44 - Coupling
45 - Hydraulic Pump 3
46 - Washer (2 used)
47 - Cap Screw (2 used)

Remove cap screws (47) and washers (46) to remove hydraulic pump 3 (45).

3. Remove bushing (43) and coupling (44).

4. Remove O-rings (40—42).

5. NOTE:

Adjusting screw controls the maximum pump flow rate. Removal will require a test and adjustment
to get the correct setting for maximum pump flow rate.

Remove nut (37), sealing washer (35), and adjusting screw (36) for inspection or replacement only. Measure length of
adjusting screw from pump housing to end of screw to aid assembly.

6. Remove cap screws (39) and lock washers (38).

7. IMPORTANT:

When separating pump housing, use care not to drop the valve plate.
 T125694-UN: Hydraulic Pump Halves

LEGEND:

9 - Pump Housing
10 - Gasket
26 - Valve Plate
34 - Pump Housing

Separate pump housing (9 and 34).

8. Remove gasket (10) and valve plate (26).

9.
T125695-UN: Pump Housing Bearing and Spring Seat

LEGEND:

27 - Spring Pin
28 - Bearing
31 - Spring Seat
33 - O-Ring (2 used)

Remove spring pin (27), spring seat (31), and O-ring (33).

10. Remove bearing (28) for replacement only. Bearing is press fit.
11.
T125696-UN: Pump Housing Spring and Spring Seat

LEGEND:

29 - Spring Seat
30 - Spring
33 - O-Ring (2 used)

Remove spring (30), spring seat (29), and O-ring (33).

12. IMPORTANT:

When removing rotary group, use care not to damage cylinder block and piston assembly.

The original pistons must be installed into the same bores of original cylinder block because of wear
patterns.

T125697-UN: Rotary Group

LEGEND:

18 - Piston (10 used)

19 - Retainer
20 - Bushing
21 - Pin (3 used)
22 - Cylinder Block

Mark pistons (18) with respect to cylinder block (22) bores for assembly. Remove parts (18—22).
13.

CAUTION:

Prevent possible injury. Spring is under load. Spring must be compressed before removing snap
ring.

T125698-UN: Cylinder Block, Washers, Spring

LEGEND:

23 - Washer (2 used)
24 - Spring
25 - Snap Ring

Remove snap ring (25), washers (23), and spring (24) for inspection or replacement only. Apply force to outer washer
using a press. Remove snap ring.

14.
T164706-UN: Piston-To-Shoe Clearance

T164714-UN: Piston-To-Cylinder Block Bore Clearance

Check the clearance between piston and shoe.

Item Measurement Specification

Piston-to-Shoe Clearance 0.2 mm or less

0.00787 in. or less

Substract piston diameter from cylinder block bore diameter to check for wear.

Item Measurement Specification

Piston-to-Cylinder Block Bore Clearance 0.050 mm or less

0.00197 in. or less
15.
T207939A-UN: Swash Plate, Stoppers and Ceramic Balls

LEGEND:

6 - O-Ring (2 used)
7 - Plug (2 used)
11 - Disk Spring (4 used)
12 - Pin (stop, short)
13 - Rod
14 - Swash Plate
16 - Pin (stop, long)
17 - Ceramic Ball (2 used)
50 - Rod (air conditioning only)

Remove swash plate (14) and ceramic balls (17).

16. NOTE:

Pin (16) has two cavities and is longer than pin (12). Note location of pins to aid in assembly.

Remove parts (11—13, 16 and 50).

17. Remove plugs (7) and O-rings (6).

18.
T125700-UN: Shaft Snap Ring

LEGEND:
 5 - Snap Ring

Remove snap ring (5).

19.
T125701-UN: Press and Shaft

LEGEND:

3 - Shaft

Remove shaft (3) using a press.

20.
T125702-UN: Seal and Snap Ring
 T125703-UN: Bearing and Pins

LEGEND:

1 - Snap Ring
2 - Seal
4 - Bearing
8 - Pin
32 - Pin

Remove snap ring (1). Remove seal (2).

21. Remove bearing (4) for replacement only. Bearing is press fit in pump housing.

22. Remove pins (8 and 32) for replacement only.

23. See Hydraulic Pump Assemble .

MH66O88,000004F-19-20051206
TM2356 - 27D Excavator Repair
Hydraulic Pump Assemble

Hydraulic Pump Assemble

T207938-UN: Hydraulic Pump Exploded View

LEGEND:

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

1.
T125702-UN: Seal and Snap Ring

T125703-UN: Bearing and Pins

LEGEND:

1 - Snap Ring
2 - Seal
4 - Bearing
8 - Pin
32 - Pin

Install pins (8 and 32).

2. Install bearing (4) using a press.

3. Install seal (2).

4. Install snap ring (1).

5.
T125701-UN: Shaft

LEGEND:

3 - Shaft

Install shaft (3) using a press.

6.
T125700-UN: Shaft Snap Ring

LEGEND:

5 - Snap Ring

Install snap ring (5).

 7.
T207939A-UN: Swash Plate, Pins (stops) and Ceramic Balls

LEGEND:

6 - O-Ring (2 used)
7 - Plug (2 used)
11 - Disk Spring (4 used)
12 - Pin (stop, short)
13 - Rod
14 - Swash Plate
16 - Pin (stop, long)
17 - Ceramic Ball (2 used)
50 - Rod (air conditioning only)

Install O-rings (6) and plugs (7).

8. Install disk springs (11) so convex side is against head of pins (12 and 16).

9. Install pins (12 and 16) into their original bores.

10. NOTE:

Rod (50) is only installed in the machine if equipped with air conditioning.

Install rods (13 and 50) so the larger diameter end is toward the swash plate (14).

11. Install ceramic balls (17) and swash plate (14).

12.
T125698-UN: Cylinder Block, Washers, Spring

LEGEND:

23 - Washer (2 used)
24 - Spring
25 - Snap Ring

Install washers (23) and spring (24).

13. Apply force to outer washer to compress spring. Install snap ring (25).
14.
T125697-UN: Rotary Group

LEGEND:

18 - Piston (10 used)

19 - Retainer
20 - Bushing
21 - Pin (3 used)
22 - Cylinder Block

Install pins (21), bushing (20), retainer (19), and pistons (18) into cylinder block (22) so marks on pistons and cylinder
block are aligned.

15. Install cylinder block (22).

16.
T125696-UN: Pump Housing Spring and Spring Seat

LEGEND:

29 - Spring Seat
30 - Spring
33 - O-Ring (2 used)

Install O-ring (33), spring seat (29), and spring (30).

17.
T125695-UN: Pump Housing Bearing and Spring Seat

LEGEND:

27 - Spring Pin
28 - Bearing
31 - Spring Seat
33 - O-Ring

Install bearing (28) using a press.

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

19. IMPORTANT:

Valve plate has highly machined surfaces and can be damaged. Do not drop valve plate.

T125694-UN: Hydraulic Pump Halves

LEGEND:

9 - Pump Housing
10 - Gasket
26 - Valve Plate
34 - Pump Housing

Apply petroleum jelly to valve plate (26) to help hold it in place on pump housing (34).
20. Install gasket (10).

21. Join pump housing (9 and 34). Pull the housing together against the spring using M10 x 65 mm cap screw.

22.
T125693-UN: Coupling, Bushing, and O-rings

T125692-UN: Hydraulic Pump 3 Cap Screw

LEGEND:

35 - Sealing Washer
36 - Adjusting Screw
37 - Nut
38 - Lock Washer (5 used)
39 - Cap Screw (5 used)
40 - O-Ring
41 - O-Ring
42 - O-Ring
43 - Bushing
44 - Coupling
45 - Hydraulic Pump 3
46 - Washer (2 used)
47 - Cap Screw (2 used)

Install lock washers (38) and cap screws (39). Tighten cap screws.

Item Measurement Specification

 Housing-to-Housing Cap Screw Torque 59 N˙m
44 lb-ft

23. Install adjusting screw (36), sealing washer (35), and nut (37) so screw is to the measurement taken at disassembly.
See Hydraulic Pumps 1 and 2 Regulator Test and Adjustment—Engine Pulldown to check maximum pump flow rate
after pump is installed. (Group 9025-25.)

24. Install O-rings (40—42).

25. Install bushing (43) and coupling (44).

26. Install hydraulic pump 3 (45), washers (46), and cap screws (47). Tighten cap screws.

Item Measurement Specification

Hydraulic Pump 3-to-Pump Housing Torque 12 N˙m

Cap Screw 108 lb-in

27. Install O-ring, hose fitting, and cap screws.

MH66O88,0000050-19-20060131
TM2356 - 27D Excavator Repair
Hydraulic Pump Start-Up Procedure

Hydraulic Pump Start-Up Procedure

T217403A-UN: Hydraulic Pump

LEGEND:

1 - Air Bleed Plug

IMPORTANT:

Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed
whenever a new hydraulic pump is installed or oil has been drained from the pump or hydraulic tank.

Procedure is performed to ensure pump is filled with hydraulic fluid and air is bled from suction side of pump to
prevent cavitation.

1. Add hydraulic fluid until it is between marks on hydraulic tank sight glass.

2. Remove air bleed plug (1) from the top of pump housing. Fill pump housing with hydraulic fluid.

3. Install plug after pump housing is full of hydraulic fluid.

4. Check hydraulic fluid level in hydraulic tank. Add hydraulic fluid as necessary. Tighten hydraulic tank cap.

5. Start engine and run at slow idle. Slowly raise boom to full height and then lower to pressurize hydraulic tank.

6. Purge air from the hydraulic system by starting engine and run at slow idle. Slowly loosen air bleed plug (1) allowing air
to escape. Tighten plug when hydraulic fluid appears.

MH66O88,0000051-19-20060130
TM2356 - 27D Excavator Repair
Dampener Drive (Flex Coupling) Remove and Install

Dampener Drive (Flex Coupling) Remove and Install

1. Remove engine. See Engine Remove and Install . (Group 0400.)

2.
T207302A-UN: Flywheel Housing

T207260A-UN: Flex Dampener

LEGEND:

1 - Flywheel Cover
2 - Cap Screw (8 used)
3 - Socket Head Cap Screw (3 used)
 4 - Dampener

Remove eight cap screws (2).

3. Remove flywheel cover (1).

4. Remove three socket head cap screws (3).

5. Remove dampener (4).

6. Install dampener (4).

7. Apply PM37509 Cure Primer then PM37477 Thread Lock and Sealer (medium strength) to socket head cap screws
(3). Install cap screws and tighten to specification.

Item Measurement Specification

Flex Coupling-to-Flywheel Cap Torque 83—92 N˙m

Screw 61—68 lb-ft

8. Install flywheel cover (1), and cap screws (2).

Item Measurement Specification

Cover-to-Flywheel Housing Cap Torque 49 N˙m

Screw 36 lb-ft

9. Install engine. See Engine Remove and Install . (Group 0400.)

LOCTITE is a trademark of Henkel Group. MH66O88,0000052-19-20060131

TM2356 - 27D Excavator Repair
Solenoid Valve Manifold Disassemble and Assemble

Solenoid Valve Manifold Disassemble and Assemble

T164374-UN: Solenoid Valve Manifold Exploded View

LEGEND:

1 - Guide
2 - O-Ring
3 - Washer
4 - Spring
5 - Washer
6 - Spool
7 - Nut
8 - Solenoid
9 - Tube
10 - O-Ring
11 - Spool
12 - Spring
13 - Manifold

Remove and replace parts as necessary.

Item Measurement Specification

Pilot Pressure Regulating Valve-to- Torque 74—88 N˙m

Manifold Guide 55—65 lb-ft

Solenoid-to-Manifold Tube Torque 47—74 N˙m

35—55 lb-ft

Solenoid-to-Tube Nut Torque 4.9 N˙m

3.6 lb-ft

MH66O88,0000054-19-20051206
TM2356 - 27D Excavator Repair
Pilot Controller Remove and Install

Pilot Controller Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic oil tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic oil tank cap to first stop to relieve pressure in hydraulic oil tank.

T208557-UN: Left Side Pilot Controller Shown

LEGEND:

1 - Grip
2 - Boot
3 - Jam Nut (2 used per side)
4 - Rod
5 - Upper Cover
6 - Cap (4 used per side)
7 - Screw (5 used per side)
8 - Gasket (2 used per side)
9 - Pilot Controller
10 - Insulator
11 - Tie Strap
12 - Lower Cover
13 - Cap Screw (4 used per side)
14 - Grip
15 - Bracket (2 used per side)
16 - Gasket
17 - Cap Screw (4 used)

Stop engine. Relieve pressure in hydraulic oil tank.

2. Remove caps (6), screws (7 and 13), and brackets (15).

3. Lift up boot (2), loosen lower jam nut (3) and remove rod (4) with boot and grip (1). If removing right-side controller,
disconnect wire connector for horn.

4. Remove upper and lower covers (5 and 12).

5.
 CAUTION:

To avoid injury from escaping fluid under pressure, relieve the pressure in the system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.

Identify and disconnect hydraulic lines from pilot controller (9). Close all openings using caps and plugs.

6. NOTE:

Right-side pilot controller has a pin inserted in the center of one of the cap screws (17), which is
used to route the wire harness for the horn switch so it will not interfere with the movement of the
pilot controller. The cap screw with the pin must be installed in the same location it was removed
from, and harness must be routed around the pin.

Remove cap screws (17) and pilot controller (9).

7. Repair or replace parts as necessary.

8. Install pilot controller and cap screws (17). Tighten cap screws to specification.

Item Measurement Specification

Pilot Controller Cap Screws Torque 20 N˙m

177 lb-in

9. Connect hydraulic hoses. For line identification, see Pilot Controller to Pattern Conversion Valve Line Connection and
see Main Hydraulic Pilot System Line Identification or see Main Hydraulic Pilot System Line Identification . (Group
9025-15.)

10. Connect wire for horn, if removed

11. Install upper and lower covers.

12. Install rod, jam nut, boot, and grip.

13. Install brackets, screws, and caps.

14. Check hydraulic oil level.

MH66O88,0000055-19-20100923
TM2356 - 27D Excavator Repair
Pilot Controller Disassemble and Assemble

Pilot Controller Disassemble and Assemble

TX1000262-UN: Pilot Control Valve

LEGEND:

0 - Housing and Spools

3 - Shim (4 used)
4 - Spacer (4 used)
6 - Balance Spring (2 used)
8 - Balance Spring (2 used)
10 - Guide (4 used)
11 - Snap Ring (4 used)
14 - Pusher B (2 used)
15 - Pusher A (2 used)
17 - Sleeve (4 used)
19 - O-Ring (4 used)
21 - Plate
22 - Universal Joint
23 - Cam
24 - Coupling
26 - Plug
27 - O-Ring
28 - Snap Ring
33 - Return Spring (2 used)
34 - Return Spring (2 used)
35 - Pilot Valve

1. IMPORTANT:

The housing and spools (0) are replaced as an assembly because the spools are select fitted to bores in
housing.

NOTE:

Some parts from ports 1 and 3 are different than parts from ports 2 and 4. Parts for each port must
be kept together and installed into the same port from which it was removed. The port numbers are
stamped on the housing.

NOTE:

Remove universal joint (22) only if necessary.

Remove parts coupling (24), cam (23), universal joint (22), and plate (21).

2. NOTE:

Sleeves (17) cannot be disassembled. Do not attempt to remove oil seal from sleeve.
 Remove sleeves (17).

3. IMPORTANT:

Note port location and quantity of shims (3) when removing. Same number of shims must be used when
installing.

Remove pusher (14 and 15), snap ring (11), guide (10), springs (6, 8, 33 and 34), shim (3), spacer (4), spools (0), snap
ring (28), O-ring (27), and plug (26).

4. Inspect and replace parts as necessary.

5. Install O-ring (27) onto plug.

6. Install (26) and snap ring (28).

7. IMPORTANT:

Components are select fit to bores. Install components in the same bore that they were removed from.

Install spools (0).

8. IMPORTANT:

Ports 1 and 3 use short balance springs. Ports 2 and 4 use long balance springs.

Install spacers (4), shims (3), and balance springs (6 and 8).

9. IMPORTANT:

Ports 1 and 3 use short return springs. Ports 2 and 4 use long return springs.

Install return springs (33 and 34).

10. Install guides with protrusion facing upward.

11. Install snap rings.

12. IMPORTANT:

Ports 1 and 3 use pushers with 1 outer groove. Ports 2 and 4 use pushers with 2 outer grooves.

Install pushers A and pushers B.

13. Apply clean multipurpose grease to ball at ends of pushers A and pushers B.

14. Apply clean multipurpose grease to joint of universal joint (22) and to inner surface of sleeve (17) seals.

15. Install O-rings (19) and sleeves.

16. Apply PM37479 Thread Lock (high strength) to threads of universal joint.

17. IMPORTANT:

Align cap screw hole in plate (21) with cap screw hole in housing (0).

Install plate and universal joint. Tighten universal joint to specification.

 Item Measurement Specification

Universal Joint Torque 24.5 N·m

217 lb-in.

18. Install cam (23) on universal joint. Adjust clearance between pushers A and pushers B and cam.

Item Measurement Specification

Cam-to-Pusher A and Pusher B Clearance 0—0.20 mm

0—0.008 in.

19. Hold cam and tighten coupling (24) to specification.

Item Measurement Specification

Coupling-to-Cam and Universal Torque 69 N˙m

Joint 51 lb-ft

LOCTITE is a trademark of Henkel Corporation PM10405,0000352-19-20090203

TM2356 - 27D Excavator Repair
Travel Pilot Controller Remove and Install

Travel Pilot Controller Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic tank cap to relieve air pressure in hydraulic tank.

T208785A-UN: Hydraulic Lines for Travel Pilot Controller

T208786A-UN: Travel Pilot Controller

LEGEND:
 1 - Wire Connector
2 - Pressure Switch
3 - Fitting
4 - Fitting
5 - Socket Head Cap Screw (2 used)

Stop engine, then slowly loosen hydraulic tank cap to release air pressure in hydraulic tank.

2. Remove front section of floor mat.

3. Remove pedal lever assemblies from pilot controller.

4. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

5. Disconnect wire connector (1) and remove pressure switch (2).

6. Identify, tag, then disconnect hydraulic lines. Close all openings using caps and plugs.

7. Remove fittings (3 and 4).

8. Remove socket head cap screws (5) and remove controller.

9. Repair or replace parts as necessary.

10. Install controller using two socket head cap screws (5). Tighten to specification.

Item Measurement Specification

Travel Pilot Controller Socket Head Torque 50 N˙m

Cap Screws 37 lb-ft

11. Install fittings (3 and 4) and pressure switch (2).

12. Connect hydraulic lines. For line identification, see Travel Hydraulic System Line Identification . (Group 9025-15.)

13. Connect wire connector (1).

14. Lower operator station. See Tilting the Operator Station . (Operator's Manual.)

15. Install front section of floor mat.

16. Install pedal / lever assemblies.

MH66O88,0000057-19-20090219
TM2356 - 27D Excavator Repair
Travel Pilot Controller Disassemble and Assemble

Travel Pilot Controller Disassemble and Assemble

1. IMPORTANT:

Spools (24) are matched to the bores in the spool housing (23). If spools are removed, they must be
installed in the same housing they were removed from. The quantity of shims (27) has been determined
during performance testing at the factory. Keep the shims together with the spool they were removed
from.

T208792-UN: Disassemble and Assemble Travel Pilot Controller

LEGEND:

1 - Cap Screw (2 used)

2 - Cover
3 - Spring Pin (2 used)
4 - Spring Pin (2 used)
5 - Cam (2 used)
6 - Bushing (4 used)
7 - Housing
8 - Spring Washer (4 used)
9 - Socket Head Screw (4 used)
10 - Spring Pin (2 used)
11 - Bracket
12 - Spring Pin (2 used)
13 - Spring Pin (2 used)
14 - O-Ring (4 used)
15 - Sleeve (4 used)
16 - Pusher (4 used)
17 - Spring Guide (4 used)
18 - Balance Spring (4 used)
19 - O-Ring (2 used)
20 - Plug (2 used)
21 - Plug (2 used)
22 - O-Ring (2 used)
23 - Spool Housing
24 - Spool (4 used)
25 - Return Spring (4 used)
26 - Spacer (4 used)
27 - Shim (12 used)
28 - Seal (4 used)
29 - Spring Washer (2 used)
30 - Socket Head Screw (2 used)
31 - Rubber Seal (2 used)
32 - Damper (2 used)
33 - Ring (2 used)
34 - O-Ring (2 used)
35 - Pin (2 used)
 Remove cap screws (1) and remove cover (2).

2. Remove pins (35) and cams (5).

3. Remove socket head screws (30) and housing (7).

4. Repair or replace parts as required.

5. Apply grease to the top of pushers (16).

6. Install sleeves (15), O-rings (14), and seals (28).

7. Install housing (7) using cap screws (30).

Item Measurement Specification

Travel Pilot Controller Cam Housing Torque 7 N˙m

Socket Head Screws 62 lb-in

8. Install cams (5), pins (35), and dampers (32).

9. Install cover (2) with cap screws (1). Tighten to specification.

Item Measurement Specification

Travel Pilot Controller Cover Cap Torque 5 N˙m

Screws 44 lb-in

MH66O88,0000058-19-20070604
TM2356 - 27D Excavator Repair
Boom Swing or Auxiliary Pilot Controller Remove and Install

Boom Swing or Auxiliary Pilot Controller Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic tank cap to relieve air pressure in hydraulic tank.

T208811A-UN: Boom or Auxiliary Pilot Controller

LEGEND:

1 - Cap Screw
2 - Plate
3 - Cap Screw (2 used)
4 - Pedal
5 - Socket Head Cap Screw (2 used)
6 - Pedal Bracket
7 - Cap Screw (2 used)
8 - Bracket

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.
 2. Remove front section of floor mat.

3. Remove cap screw (1) and plate (2).

4. Remove cap screws (3) and pedal (4).

5. Remove socket head cap screws (5) and pedal bracket (6).

6. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

7. Identify, tag, then disconnect hydraulic lines. Close all openings using caps and plugs.

8. Remove cap screws (7) and bracket (8).

9. Remove boom or auxiliary pilot controller.

10. Repair or replace parts as required.

11. Install pilot controller, bracket (8), and cap screws (7). Tighten to specification.

Item Measurement Specification

Boom or Auxiliary Pilot Controller Torque 30 N˙m

Mounting Cap Screws 22 lb-ft

12. Connect hydraulic lines. For line identification, see Main Hydraulic Pilot System Line Identification . (Group 9025-15.)

13. Lower operator station. See Tilting the Operator Station . (Operator's Manual.)

14. Install pedal bracket and pedal.

15. Install plate.

16. Install front section of floor mat.

MH66O88,0000059-19-20090219
TM2356 - 27D Excavator Repair
Boom Swing or Auxiliary Pilot Controller Disassemble and Assemble

Boom Swing or Auxiliary Pilot Controller Disassemble and Assemble

1. IMPORTANT:

If damage to cam (3), bracket (8), push rods (12), spools (17), or housing (21) is noticed, the pilot
controller must be replaced.

T160028-UN: Boom Swing or Auxiliary Pilot Controller

LEGEND:

1 - Boot
2 - Set Screw
3 - Cam
4 - Steel Ball (2 used)
5 - Cap Screw (2 used)
6 - Bushing (2 used)
7 - Shaft
8 - Bracket
9 - Packing (2 used)
10 - Plug (2 used)
11 - O-Ring (2 used)
12 - Push Rod (2 used)
13 - Spring Seat (2 used)
14 - Inner Spring (2 used)
15 - Shim (2 used)
16 - Washer (2 used)
17 - Spool (2 used)
18 - Outer Spring (2 used)
19 - Plug
20 - O-Ring
21 - Housing

Take notice of part location with respect to its mating part for assembly.

2. NOTE:

Medium strength thread lock and sealer is used on the threads of set screws.

Remove set screw (2).

Remove shaft (7) to remove cam (3) from bracket (8). Steel balls (4) cannot be removed.

3. Loosen the cap screws (5) to relieve the slight spring force. Remove bracket (8) from housing (21).

4. Remove packing (9), plugs (10), O-rings (11), and push rods (12).
 5. IMPORTANT:

The spool assemblies are adjusted for equal pressure using shims. The shims and washers must be kept
with their respective spool.

The spools must be installed into the same port from which they were removed.

Remove spool assemblies (13—17) and outer springs (18). Keep parts for each spool together.

6. Clean and repair or replace parts as necessary.

7. Install washer (16), shim (15), and inner spring (14) onto their original spool (17).

Compress the spring just enough to install spring seats (13) onto spools through the larger diameter hole.

8. Install the outer spring (18).

9. Carefully install spool assemblies into the same ports from which they were removed.

10. Install O-rings (11) on plugs (10).

11. Apply grease to packing (9). Install packing in plugs with lip toward O-ring end of plug.

12. Apply hydraulic fluid to push rods (12) before pushing rod through the packing in plugs (10). Install plug and push rod
into housing.

13. Install bracket (8). Tighten cap screws (5).

Item Measurement Specification

Cover-to-Housing Cap Screw Torque 23.5 N˙m

208 lb-in

14. Install cams (3). Install the shafts (7) through cover and cam so hole in shaft aligns with tapped hole in cam.

15. Apply PM37509 Cure Primer then PM37477 Thread Lock and Sealer (medium strength) to threads of set screw (2).
Tighten set screw.

Item Measurement Specification

Cam-to-Shaft Set Screw Torque 5.0 N˙m

44 lb-in

LOCTITE is a trademark of Henkel Group. MH66O88,000005A-19-20070112

TM2356 - 27D Excavator Repair
Control Valve Remove and Install

Control Valve Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

2. Induce a vacuum in hydraulic tank or drain hydraulic tank. See Changing Hydraulic Tank Oil and Cleaning Suction Screen .
(Operator's Manual.)

3. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

4.

CAUTION:

To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting
or connecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811-UN: High-Pressure Fluid

 T217402A-UN: Control Valve

T208921A-UN: Main Frame Plate

LEGEND:

1 - Control Valve
2 - Cap Screw (4 used)

Identify, tag, then disconnect hydraulic lines from control valve (1). Close all openings using caps and plugs.

5. Remove four cap screws (2) from underside of main frame .

6.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Control Valve Weight 58 kg

130 lb
 Install a lifting strap under cap on control valve and attach to a hoist. Carefully lift control valve (1) off the main frame plate.

7. Repair or replace parts as necessary. See Control Valve Disassemble and Assemble . (Group 3360.)

8. Install control valve and fasten with cap screws (2).

Item Measurement Specification

Control Valve-to-Main frame Plate Torque 50 N˙m

Cap Screw 37 lb-ft

9. Connect hydraulic lines. For line identification, see Control Valve Operation . (Group 9025-05.)

10. Check hydraulic fluid level in the hydraulic tank. See Checking Hydraulic Oil Tank Level . (Operator's Manual.) Add hydraulic fluid as
necessary. See Hydraulic Oil . (Operator's Manual.)

11. Perform Hydraulic Pump Start-Up Procedure . (Group 3360.)

PM10405,0000354-19-20090219
TM2356 - 27D Excavator Repair
Control Valve Disassemble and Assemble

Control Valve Disassemble and Assemble

T217405-UN: Control Valve—Rear Sections

LEGEND:

1 - Bucket Control Valve

2 - Cover
3 - Cap Screw (2 used)
4 - Guide
5 - Spring
6 - Guide
7 - O-Ring
8 - Spool
9 - Circuit Relief Valve
10 - Plug
11 - O-Ring
12 - Spring
13 - Poppet
14 - Plug
15 - O-Ring
16 - Spring
17 - Poppet
18 - Circuit Relief Valve
19 - O-Ring
20 - Guide
21 - Spring
22 - Guide
23 - Cap Screw (2 used)
24 - Cover
25 - Stud (4 used)
26 - Nut (4 used)
27 - Housing
30 - Boom Control Valve
31 - Cover
32 - Cap Screw (2 used)
33 - Guide
34 - Spring
35 - Guide
36 - O-Ring
37 - Spool
38 - Circuit Relief Valve
39 - Circuit Relief Valve
41 - Plug
42 - O-Ring
43 - Spring
44 - Poppet
51 - O-Ring
52 - Guide
53 - Spring
54 - Guide
71 - Housing
75 - Left Travel Control Valve
76 - Cover
 77 - Cap Screw (2 used)
78 - Guide
79 - Spring
80 - Guide
81 - O-Ring
82 - Spool
83 - Spring
84 - Poppet
85 - Plug
86 - O-Ring
87 - Guide
88 - Spring
89 - Guide
90 - Cap Screw (2 used)
91 - Cover
92 - O-Ring
93 - Housing
95 - Inlet Section
96 - Plug
97 - Filter
98 - Cover
99 - Cap Screw (2 used)
100 - O-Ring
101 - Spool
102 - System Relief Valve
103 - O-Ring
104 - Plug
105 - System Relief Valve
106 - O-Ring
107 - Cap Screw (2 used)
108 - Cover
109 - Plug
110 - O-Ring
111 - Housing

T217406-UN: Control Valve—Middle Sections

LEGEND:

115 - Right Travel Control Valve

116 - Cover
117 - Cap Screw (2 used)
118 - Guide
119 - Spring
120 - Guide
121 - O-Ring
122 - Spool
123 - O-Ring
124 - Plug
125 - O-Ring
126 - Guide
127 - Spring
128 - Guide
129 - Cap Screw (2 used)
130 - Cover
131 - Poppet
132 - Spring
133 - Housing
135 - Arm Control Valve
136 - Cover
137 - Cap Screw (2 used)
138 - Guide
 139 - Spring
140 - O-Ring
141 - Guide
142 - Spool
143 - Circuit Relief Valve
144 - O-Ring
145 - O-Ring
146 - O-Ring
147 - Plug
148 - O-Ring
149 - Spring
150 - Poppet
151 - Circuit Relief Valve
152 - O-Ring
153 - Guide
154 - Spring
155 - Guide
156 - Cap Screw (2 used)
157 - Cover
158 - Plug
159 - Poppet
160 - Spring
161 - O-Ring
162 - Plug
163 - Housing
165 - Auxiliary Control Valve
166 - Cover
167 - Cap Screw (2 used)
168 - Guide
169 - Spring
170 - O-Ring
171 - Guide
172 - Spool
173 - Circuit Relief Valve
174 - O-Ring
175 - Plug
176 - O-Ring
177 - Spring
178 - Poppet
179 - Plug
180 - O-Ring
181 - Spring
182 - Plug
183 - Plug
184 - Circuit Relief Valve
185 - O-Ring
186 - Guide
187 - Spring
188 - Guide
189 - Cap Screw (2 used)
190 - Cover
191 - Housing

T163356-UN: Control Valve—Front Sections

LEGEND:

215 - Boom Swing Control Valve

216 - Cover
217 - Cap Screw (2 used)
218 - Guide
219 - Spring
220 - Guide
221 - O-Ring
222 - Spool
223 - Poppet
224 - Spring
225 - Plug
226 - O-Ring
227 - Spring
228 - Poppet
229 - O-Ring
230 - Guide
231 - Spring
232 - Guide
233 - Cap Screw (2 used)
234 - Cover
235 - O-Ring
236 - Housing
240 - Swing Control Valve
241 - Cover
242 - Cap Screw (2 used)
243 - Guide
244 - Spring
245 - Guide
246 - O-Ring
247 - Spool
248 - Plug
249 - O-Ring
250 - Spring
251 - Poppet
252 - O-Ring
253 - Guide
254 - Spring
255 - Guide
256 - Cap Screw (2 used)
257 - Cover
258 - O-Ring
259 - Housing
265 - Blade Control Valve
266 - Cover
267 - Cap Screw (2 used)
268 - Guide
269 - Spring
270 - Guide
271 - O-Ring
272 - Spool
273 - Plug
274 - O-Ring
275 - Spring
276 - Poppet
277 - O-Ring
278 - Guide
279 - Spring
280 - Guide
281 - Cap Screw (2 used)
282 - Cover
283 - O-Ring
284 - Housing
290 - Flow Combiner Valve
291 - Cover
292 - Cap Screw (2 used)
293 - Guide
294 - Spring
295 - Guide
296 - O-Ring
297 - Spool
298 - System Relief Valve
299 - Nut (4 used)
300 - Plug
301 - O-Ring
302 - Cap Screw (2 used)
303 - Plug
304 - Cover
305 - O-Ring
306 - Housing

1. NOTE:

Complete control valve must be removed from machine to remove individual valve sections.

See Control Valve Remove and Install for removal procedure. (Group 3360.)

2. Remove system relief valves (102, 105, and 298).

3. Remove circuit relief valves (9, 18, 38, 39, 143 ,151, 173 and 184).

4. Remove nuts (26) and studs (25) to disassemble the control valve into sections.

5. IMPORTANT:

Because spools are fitted to a bore and the design is different for each section, spools must be installed into
the same bores from which they were removed for proper operation.

Spools are disassembled for inspection and cleaning only. Each spool and housing is serviced as an assembly.

T163430-UN: Arm Control Valve Section Shown

T163449-UN: Arm Regenerative Valve

LEGEND:

135 - Arm Control Valve Housing

136 - Cover
137 - Cap Screw (2 used)
138 - Guide
139 - Spring
140 - O-Ring
141 - Guide
142 - Spool
147 - Plug
148 - O-Ring
149 - Spring
150 - Lift Check Poppet
152 - O-Ring
153 - Guide
154 - Spring
155 - Guide
 156 - Cap Screw (2 used)
157 - Cover
159 - Arm Regenerative Valve Poppet
160 - Spring
161 - O-Ring
162 - Plug
310 - Orifice

Spool Disassemble and Assemble:

a. Remove parts (136—142, 150, and 152—157).

b. Replace parts as necessary.

c. Install parts.

d. Tighten cap screws (137 and 156).

Item Measurement Specification

Cover-to-Housing Cap Screw Torque 7—10 N˙m

61—87 lb-in

6. Arm Regenerative Valve, Check Valve, and Orifice Disassemble and Assemble:

a. Remove parts (145—150, 159—162, and 310).

b. Replace parts as necessary.

c. Install orifice.

Item Measurement Specification

Arm Regenerative Valve Orifice-to- Torque 2 N˙m

Housing 17 lb-in

d. Apply grease to O-rings.

e. Install parts.

Item Measurement Specification

Arm Regenerative Valve Plug-to- Torque 29.4 N˙m

Housing 22 lb-ft

Lift Check Plug-to-Housing Torque 29.4 N˙m

22 lb-ft

7. Tighten system relief valves (102, 105, and 298).

Item Measurement Specification

System Relief Valve-to-Valve Torque 5.9—6.9 N˙m

Housing 4.3—5.1 lb-ft

8. Tighten circuit relief valves (9, 18, 38, 39, 143, and 151).

Item Measurement Specification

Circuit Relief Valve-to-Valve Torque 5.9—6.9 N˙m

 Housing 4.3—5.1 lb-ft

9. Tighten nuts (26) and studs (25).

Item Measurement Specification

Housing-to-Housing Stud and Nut Torque 26.5—29.4 N˙m

19.5—21.5 lb-ft

10. See Control Valve Remove and Install for installation. (Group 3360.)

MH66O88,0000062-19-20060131
TM2356 - 27D Excavator Repair
Pilot Controller Pattern Conversion Valve Remove and Install

Pilot Controller Pattern Conversion Valve Remove and Install

1.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic tank cap to relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

2.
T208798A-UN: Back Side of Cab
 T208797A-UN: Valve

LEGEND:

1 - Pilot Controller Pattern Conversion Valve Nut (2 used)

2 - Hydraulic Lines (8 used)
3 - Cap Screw (2 used)
4 - Pilot Controller Pattern Conversion Valve

Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

3. Remove two nuts (1) on back of cab.

4. Tilt operator station back to normal position.

5. Identify, tag, then disconnect hydraulic lines (2).

6. Remove two cap screws (3) and pilot controller pattern conversion valve (4).

7. Repair or replace parts as necessary.

8. Connect hydraulic lines. For line identification, see Pilot Control Valve to Pattern Selector Valve Line Connection
(Group 9025-15.)

9. Install cap screws (3).

10. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

11. Install two nuts (1) on back of cab.

12. Check hydraulic fluid level and add hydraulic fluid if necessary. See Hydraulic Oil . (Operator's Manual.)

MH66O88,0000063-19-20090218
TM2356 - 27D Excavator Repair
Pilot Controller Pattern Conversion Valve Disassemble and Assemble

Pilot Controller Pattern Conversion Valve Disassemble and Assemble

1.
T204414-UN: Pilot Controller Pattern Conversion Valve

LEGEND:

0 - Pilot Controller Pattern Conversion Valve

1 - Housing
2 - Spindle
4 - Cover
5 - Cover
6 - Plug
7 - Handle
8 - Spring
9 - Detent Ball
10 - Packing
11 - O-Ring
12 - Packing
13 - Backup Ring
14 - Bolt
15 - Spring Pin
17 - Identification Plate
18 - Ring
19 - Rivet
51 - Housing
52 - Seal Kit

Remove plug (6), spring (8), and detent ball (9) before removing spindle (2) from housing (1).

2. Install spindle (2) into housing (1).

3. Install detent ball (9) and spring (8).

4. Install plug (6).

5. Install Pilot Controller Pattern Conversion Valve. See Pilot Controller Pattern Conversion Valve Remove and Install .
(Group 3360.)

MH66O88,0000064-19-20070226
TM2356 - 27D Excavator Repair
Hydraulic Tank Remove and Install

Hydraulic Tank Remove and Install

1.

CAUTION:

Prevent possible injury. Heavy component; ensure side cover is properly supported before
removing.

T217421A-UN: Hydraulic Tank (S.N.—254999 ) Shown

LEGEND:

1 - Cap Screw (2 used)

2 - Side Cover
3 - Cap Screw (4 used)
4 - Cover Plate
5 - Battery
6 - Cap Screw (6 used)
7 - Cap Screw (2 used)
8 - Coolant Bottle Bracket
9 - Cap
10 - Hydraulic Line (4 used)
11 - Upper and Lower Hoses
12 - Bracket and Clamp (4 used)
13 - Cap Screw (2 used)
14 - Hydraulic Tank

Remove cap screws (1) and side cover (2).

2. Remove cap screws (3) and cover plate (4).

 3. Disconnect battery (5) and remove.

4. Remove cap screws (6) that mount battery tray to hydraulic tank (14).

5. Remove cap screws (7) and coolant bottle bracket (8).

6.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic tank cap to relieve air pressure in hydraulic tank.

Slowly loosen cap (9) to release air pressure in hydraulic tank (14).

7. Drain fluid from hydraulic tank.

8. Identify, tag, then disconnect hydraulic lines (10) at front of tank.

9. Remove upper and lower hydraulic hoses (11).

10. Remove brackets and clamps (12).

11. Remove cap screws (13) and hydraulic tank (14).

12. Repair or replace parts as necessary.

13. Installation is done in the reverse order of removal.

14. Add hydraulic fluid to tank. For procedure and type of hydraulic fluid, see Checking Hydraulic Oil Tank Level and see
Hydraulic Oil . (Operator's Manual.)

15. IMPORTANT:

Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill
pump housing whenever oil has been drained from the pump or hydraulic tank.

Perform Hydraulic Pump Start-Up Procedure . (Group 3360.)

MH66O88,000006A-19-20090223
TM2356 - 27D Excavator Repair
Hydraulic Oil Cooler Remove and Install

Hydraulic Oil Cooler Remove and Install

1.
TS281-UN: Cooling System

Remove right access cover.

2.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from
pressurized system can cause serious burns or penetrating injury. Stop engine. Slowly loosen
hydraulic tank cap to relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

3. NOTE:

If using a vacuum pump to pull vacuum, cap off all disconnected hydraulic lines while hydraulic
cooler is being serviced.

Induce a vacuum in hydraulic tank or drain hydraulic tank. See Changing Hydraulic Tank Oil and Cleaning Suction
Screen . (Operator's Manual.)
4.
T217422A-UN: Cab Shown

LEGEND:

5 - Cap Screw (2 used )

6 - Nut (3 used)
7 - Cap screw (5 used)

If machine is equipped with air conditioning, remove cap screws (5) and move overflow container and mounting
bracket off to the side.

5. Remove nuts (6) and move receiver-dryer and mounting brackets off to the side.

6. Remove cap screws (7). Move A/C condenser back enough to provide clearance to remove hydraulic oil cooler.

T207384A-UN: Canopy Shown

LEGEND:
 1 - Hydraulic Tank Cap (not shown)
2 - Upper Hydraulic Hose
3 - Lower Hydraulic Hose
4 - Cap Screw (2 used)

Disconnect hoses (2 and 3).

7. Remove cap screws (4).

8. NOTE:

When removing hydraulic oil cooler, make certain that cooler does not scrape, rub, or hit the frame
bracket.

Carefully move oil cooler past frame bracket and remove.

9. Inspect hydraulic oil cooler for damage or leakage. Repair or replace cooler as needed.

10. Connect receiver-dryer and its mounting brackets (if equipped).

11. Attach overflow container and its mounting bracket.

12. Install hydraulic oil cooler.

13. Connect hoses (2 and 3) and tighten clamps.

14. Install two cap screws (4).

15. Check fluid level in hydraulic tank. Add hydraulic fluid as necessary. See Hydraulic Oil . (Operator's Manual.)

16. IMPORTANT:

Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill
pump housing whenever oil has been drained from the pump or hydraulic tank.

Perform Hydraulic Pump Start-Up Procedure . (Group 3360.)

TW73308,000043E-19-20090218
TM2356 - 27D Excavator Repair
Boom Cylinder Remove and Install

Boom Cylinder Remove and Install

1. Park machine on firm, level surface.

2. Fully retract arm cylinder and bucket cylinder, then lower boom until open side of bucket is resting on ground.

3.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

4.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Boom Cylinder Weight (approximate) 35 kg

77 lb

Attach hoist and lifting strap to boom cylinder.

5.
T124958-UN: Boom Cylinder Rod End

LEGEND:

1 - Cover
 2 - Cap Screw and Washer
3 - Shim (2 used)
4 - Shim (2 used)
5 - Boom Cylinder-to-Boom Pin
6 - Cap Screw
7 - Bushing

Remove parts (1—7).

6.

CAUTION:

X9811-UN: High-Pressure Fluid

Prevent injury from escaping fluid under pressure. Stop engine and relieve the pressure in the system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

T209070A-UN: Boom Cylinder Removal

LEGEND:

1 - Hydraulic Line
 2 - Hydraulic Line
3 - Nut (2 used)
4 - Cap Screw
5 - Frame-to-Boom Cylinder Pin
6 - Shim (3 used)

Loosen boom cylinder hydraulic lines (1 and 2) at frame end of boom to release any residual pressure.

7. Identify, tag, then disconnect hydraulic lines (1 and 2). Close all openings using caps and plugs.

8. Remove parts (3—6).

9. Lower boom cylinder onto floor stand.

10. Repair or replace parts as necessary. See Boom Cylinder Disassemble and Assemble . (Group 3360.)

11. IMPORTANT:

Prevent hydraulic cylinder cap seal and ring damage. Trapped air suddenly compressed in a cylinder can become
quickly heated and ignite the oil used for assembly. Make sure cylinder rod is fully retracted and the rod end filled with
clean oil before connecting the cylinder rod end and lines. Operate appropriate function to slowly extend cylinder rod.
This will eliminate most of the air and reduce the possibility of damage.

Bleed air at initial start-up, whenever major repairs or maintenance (fluid change) is done on hydraulic system, or
when machine has been in storage for a period of time.

Install boom cylinder. Connect head-end of cylinder to frame using pin (5) and equal number of shims (6) on each side to ensure
minimum amount of clearance in joint.

Item Measurement Specification

Boom, Arm, and Cylinder Joints Clearance 0.5 mm

0.020 in.

12. Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to threads of cap screw (4) and nuts (3). Install
cap screw and nuts. Tighten nuts against each other, not the boss, until torque and clearance is to specification. Cap screw must be
free to turn in hole.

Item Measurement Specification

Boom Cylinder-to-Frame Pin Cap Torque 50 N˙m

Screw and Nuts 37 lb-ft

Boom Cylinder Pin Nut-to-Boss Clearance 3—5 mm

0.12—0.20 in.

13. Connect hydraulic lines (1 and 2). See Main Hydraulic Working System Line Identification . (Group 9025-15.)

14. Start engine and slowly extend boom cylinder until rod-end pin bores are aligned.
 15.
T124958-UN: Boom Cylinder Rod End

LEGEND:

1 - Cover
2 - Cap Screw and Washer
3 - Shim (2 used)
4 - Shim (2 used)
5 - Boom Cylinder-to-Boom Pin
6 - Cap Screw
7 - Bushing

Install pin (5) with equal number of shims (3) and (4) to get minimum amount of clearance between boom frame and rod end of boom
cylinder.

16. Install cap screw (6) and bushing (7). Tighten cap screw to specification.

Item Measurement Specification

Boom-to-Cylinder Pin Cap Screw Torque 140 N˙m

103 lb-ft

17. Install cover (1) and cap screw and washer (2).

Item Measurement Specification

Cover-to-Boom Cylinder Cap Screw Torque 50 N˙m

37 lb-ft

18. Apply grease to all pivot joints. See Grease . (Operator's Manual.)

19. Check hydraulic fluid level. See Checking Hydraulic Oil Tank Level . (Operator's Manual.)

LOCTITE is a trademark of Henkel Group. MH66O88,000005D-19-20090218

TM2356 - 27D Excavator Repair
Arm Cylinder Remove and Install

Arm Cylinder Remove and Install

1. Park machine on firm, level surface.

2. Fully retract arm cylinder and bucket cylinder, then lower boom until open side of bucket is resting on ground.

3.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

4.
X9811-UN: High-Pressure Fluid

T164887-UN: Arm Cylinder

LEGEND:

1 - Cap Screw
2 - Pin
3 - Shims (4 used)
4 - Wood Block
5 - Arm Cylinder
6 - Line (2 used)
7 - Shims (4 used)
 8 - Pin
9 - Cap Screw

Loosen arm cylinder hydraulic lines (6) to release any residual pressure.

5. Identify, tag, then disconnect hydraulic lines. Close all openings using caps and plugs.

6. Support arm cylinder by inserting a wood block (4) between arm cylinder (5) and boom.

7.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Arm Cylinder Weight approximate 34 kg

75 lb

Attach hoist and lifting strap to arm cylinder.

8. NOTE:

Record location of shims (3 and 7) to aid in assembly.

Remove parts (1—3 and 7—9).

9. Repair or replace parts as necessary. See Arm Cylinder Disassemble and Assemble . (Group 3360.)

10. IMPORTANT:

Prevent hydraulic cylinder cap seal and ring damage. Trapped air suddenly compressed in a cylinder can become
quickly heated and ignite the oil used for assembly. Make sure cylinder rod is fully retracted and the rod end filled with
clean oil before connecting the cylinder rod end and lines. Operate appropriate function to slowly extend cylinder rod.
This will eliminate most of the air and reduce the possibility of damage.

Bleed air at initial start-up, whenever major repairs or maintenance (fluid change) is done on hydraulic system, or
when machine has been in storage for a period of time.

T164887-UN: Arm Cylinder

LEGEND:

1 - Cap Screw
2 - Pin
3 - Shims (4 used)
4 - Wood Block
5 - Arm Cylinder
6 - Line (2 used)
7 - Shims (4 used)
8 - Pin
9 - Cap Screw
 Install arm cylinder by connecting head-end of cylinder first. Install pin (8) with equal number of shims (7) at each side to get
minimum amount of clearance in joints. Do not connect other end of cylinder at this time.

11. Install cap screw (9) and tighten to specification.

Item Measurement Specification

Pin Fastener-to-Boom Cap Screw Torque 137 N˙m

101 lb-ft

12. Connect hydraulic lines (6). For line identification, see Main Hydraulic Working System Line Identification . (Group 9025-15.)

13. Start engine and slowly extend arm cylinder until rod-end pin bores are aligned.

14. Install pin (2) with equal number of shims (3) at each side to get minimum amount of clearance in joints.

15. Install cap screw (1) and tighten to specification.

Item Measurement Specification

Pin Fastener-to-Boom Cap Screw Torque 137 N˙m

101 lb-ft

16. Apply grease to all pivot joints. See Grease . (Operator's Manual.)

17. Check hydraulic fluid level. See Checking Hydraulic Oil Tank Level . (Operator's Manual.)

MH66O88,000006E-19-20090218
TM2356 - 27D Excavator Repair
Bucket Cylinder Remove and Install

Bucket Cylinder Remove and Install

1. Park machine on firm, level surface.

2.
T217450-UN: Bucket Position

LEGEND:

1 - Bucket Cylinder
2 - Arm
13 - Wood Block

Fully retract arm cylinder and bucket cylinder. Lower boom so end of arm (2) is resting on a wood block (13) with open side of bucket
on ground as shown.

3.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

4. NOTE:

Use a wire to hold side links (11) and center link (12) to prevent the links from falling when pin (7) is removed.

T217454-UN: Bucket Cylinder Pin

LEGEND:

3 - Shim (8 used)
4 - Nut (2 used)
5 - Cylinder Rod
6 - Cap Screw
7 - Pin
11 - Side Link (2 used)
12 - Center Link

Remove nuts (4), cap screw (6), pin (7), and shims (3). Note shim arrangement for installation purposes.
5.

CAUTION:

Prevent injury from escaping fluid under pressure. Stop engine and relieve the pressure in the system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811-UN: High-Pressure Fluid

T164864-UN: Bucket Cylinder Arm Pin

LEGEND:

1 - Bucket Cylinder
8 - Pin
9 - Cap Screw
10 - Hydraulic Line (2 used)

Disconnect hydraulic lines (10). Close all openings using caps and plugs.

6.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Bucket Cylinder Weight approximate 18 kg

40 lb

Attach hoist and lifting strap to bucket cylinder (1). Remove cap screw (9), pin (8) and shims. Note shim arrangement for installation
purposes.
 7. Remove bucket cylinder.

8. Repair or replace parts as necessary. See Bucket Cylinder Disassemble and Assemble . (Group 3360.)

9. IMPORTANT:

Prevent hydraulic cylinder cap seal and ring damage. Trapped air suddenly compressed in a cylinder can become
quickly heated and ignite the oil used for assembly. Make sure cylinder rod is fully retracted and the rod end filled with
clean oil before connecting the cylinder rod end and lines. Operate appropriate function to slowly extend cylinder rod.
This will eliminate most of the air and reduce the possibility of damage.

Bleed air at initial start-up, whenever major repairs or maintenance (fluid change) is done on hydraulic system, or
when machine has been in storage for a period of time.

Install bucket cylinder by connecting head-end of cylinder first. Install pin with equal number of shims at each side, then tighten pin
cap screw to specification. Do not connect other end of cylinder at this time.

Item Measurement Specification

Bucket Cylinder-to-Arm Pin Cap Torque 90 N˙m

Screw 66 lb-ft

10. Connect hydraulic hoses. For line identification, see Main Hydraulic Working System Line Identification . (Group 9025-15.)

11. With rod end of bucket cylinder disconnected, start engine and slowly extend cylinder rod (5) to align rod hole with links (11 and 12).

12. Install pin and shims. Install cap screw (6) and nuts (4) to specifications.

Item Measurement Specification

Bucket Cylinder-to-Pin Cap Screw Torque 50 N·m

and Nuts 37 lb-ft

Nut-to-Boss Clearance 3—5 mm

0.12—0.20 in.

13. Apply grease to all pivot joints. See Grease . (Operator's Manual.)

14. Check hydraulic fluid level. See Checking Hydraulic Oil Tank Level . (Operator's Manual.)

MH66O88,0000076-19-20090218
TM2356 - 27D Excavator Repair
Boom Swing Cylinder Remove and Install

Boom Swing Cylinder Remove and Install

1. Park machine on firm, level surface.

2. Rotate operator station ninety degrees to the right of the blade.

3. Fully retract arm cylinder and bucket cylinder, then lower boom until open side of bucket is resting on ground.

4.

CAUTION:

Prevent serious injury. The hydraulic tank is pressurized. High pressure release of fluid from pressurized
system can cause serious burns or penetrating injury. Stop engine. Slowly loosen hydraulic tank cap to
relieve air pressure in hydraulic tank.

Stop engine, then slowly loosen hydraulic tank cap to relieve air pressure in hydraulic tank.

5.
T217419A-UN: Boom Swing Cylinder

LEGEND:

1 - Front Cover
2 - Nut (2 used)
3 - Cap Screw
4 - Pin
5 - Boom Swing Cylinder

Remove front cover (1).

6. Support swing cylinder by inserting a wood block between boom swing cylinder (5) and frame.

7. Remove nuts (2), cap screw (3), and pin (4).

 8.

CAUTION:

Prevent injury from escaping fluid under pressure. Stop engine and relieve the pressure in the system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811-UN: High-Pressure Fluid

T217420A-UN: Boom Swing Cylinder Line

LEGEND:

6 - Hydraulic Lines
7 - Cap Screw and Washer
8 - Pin
9 - Boom Swing Cylinder

Remove two access panels located under right side of the operator station.

9. Loosen boom swing cylinder hydraulic line (6) to release any residual hydraulic pressure.

10. Identify, tag, then disconnect hydraulic lines. Close all openings using caps and plugs.
 11.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Boom Swing Cylinder Weight (approximate) 33 kg

73 lb

Attach hoist and lifting strap to rod end of cylinder. Remove cap screw and washer (7). Remove pin (8).

12. Remove boom swing cylinder (9).

13. Repair or replace parts as necessary. See Blade and Boom Swing Cylinder Disassemble and Assemble . (Group 3360.)

14. Install boom swing cylinder (9).

15. Install pin (8) and cap screw (7). Tighten retainer cap screw to specification.

Item Measurement Specification

Retainer Cap Screw Torque 140 N˙m

103 lb-ft

16. Install access panels.

17. Connect hydraulic lines (6). For line identification, see Main Hydraulic Working System Line Identification . (Group 9025-15.)

18. Align rod end and install pin (4).

19. Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to threads of cap screw (3) nuts (2).

20. Install cap screw (3) and nuts (2). Tighten nuts against each other, not against the boss. Tighten to specified torque and clearance.
Cap screw must be free to turn.

Item Measurement Specification

Boom Swing Cap Screw Nut-to-Nut Torque 137 N˙m

101 lb-ft

Nut-to-Boss Clearance 3—5 mm

0.12—0.20 in.

21. Install front cover.

22. Apply grease to all pivot joints. See Grease . (Operator's Manual.)

23. Check hydraulic fluid level. See Checking Hydraulic Oil Tank Level . (Operator's Manual.)

LOCTITE is a trademark of Henkel Group. MH66O88,000006B-19-20090218

TM2356 - 27D Excavator Repair
Boom Cylinder Disassemble and Assemble

Boom Cylinder Disassemble and Assemble

1.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Boom Cylinder Weight approximate 35 kg

77 lb

T159624-UN: Boom Cylinder Cross Section

LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Bushing
8 - Backup Ring
9 - U-Cup Seal
10 - Connector Ring
11 - Snap Ring
12 - Retainer
13 - Backup Ring
14 - O-Ring
15 - Cushion Ring
16 - Spacer
17 - Snap Ring
18 - Cushion
19 - Wear Ring
20 - Piston
21 - Steel Ball
22 - Set Screw
23 - O-Ring
24 - Cap Seal
25 - Wear Ring
26 - Cylinder Barrel

Fasten head end of cylinder to cylinder service stand.

2.
T159623-UN: Boom Cylinder Exploded View

LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Bushing
8 - Backup Ring
9 - U-Cup Seal
10 - Connector Ring
11 - Snap Ring
12 - Retainer
13 - Backup Ring
14 - O-Ring
15 - Cushion Ring
16 - Spacer
17 - Snap Ring
18 - Cushion
19 - Wear Ring
20 - Piston
21 - Steel Ball
22 - Set Screw
23 - O-Ring
24 - Cap Seal
25 - Wear Ring
26 - Cylinder Barrel
27 - Dust Seal (4 used)
28 - Bushing
29 - Grease Fitting
30 - Bushing
31 - Grease Fitting

Bend the crimp from notch in rod guide (3), being careful not to damage the end of cylinder barrel (26).

3. IMPORTANT:

Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly.

Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using JDG28 Spanner Wrench.

4. Attach hoist and lifting strap to cylinder rod.

5. Pull rod and piston (20) from cylinder barrel (26).

6. Remove the staking from piston and set screw (22). Remove set screw and steel ball (21).

7. Remove piston (20) and cushion (18).

8. Remove rod guide.

9. IMPORTANT:

Take care not to damage other parts when removing seals.

Do not reuse wear rings (19 and 25), cap seal (24), or O-ring (23).
 Repair or replace parts as necessary.

10. Clean and dry parts to be reused. Apply a light film of clean hydraulic fluid to all sealing parts and machined surfaces.

11. Install bushing (7) so it is even with the end of rod guide. Bushing is a pressed fit.

12. Install backup ring (8). Install U-cup seal (9) so flat side is toward the rod end.

13. Install wiper seal (2) so lip is toward the outside of rod guide.

14. Install O-ring (6), backup ring (5), and O-ring (4).

15. Install cushion ring (15). Install spacer (16) so notches are toward the cushion ring. Install snap ring (17).

16. Install O-ring (14) and backup ring (13).

17. Install retainer (12), connector ring (10), and snap ring (11).

18. Install O-ring (23) and cap seal (24). Check that O-ring is not twisted.

19. Install wear rings (25 and 19) so the splits are offset.

20. Install rod guide (3) onto rod (1).

21. Install cushion (18), tapered end first. Install piston (20). Tighten piston.

Item Measurement Specification

Piston-to-Rod Torque 1620 N˙m

1200 lb-ft

22. Install steel ball (21) and set screw (22). Tighten set screw. Stake the set screw head in two places to prevent loosening.

Item Measurement Specification

Piston-to-Rod Set Screw Torque 16.7 N˙m

148 lb-in

23. Install rod and piston. Make sure wear rings do not come off while installing rod and piston.

24. Tighten rod guide.

Item Measurement Specification

Rod Guide-to-Cylinder Barrel Torque 490 N˙m

360 lb-ft

Rod Guide-to-Cylinder Barrel— Torque 569 N˙m

420 lb-ft

25. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.

MH66O88,000006C-19-20060131
TM2356 - 27D Excavator Repair
Arm Cylinder Disassemble and Assemble

Arm Cylinder Disassemble and Assemble

1.

CAUTION:

Prevent possible injury from crushing, For a heavy component; use appropriate lifting device.

Item Measurement Specification

Arm Cylinder Weight approximate 33 kg

73 lb

T159627-UN: Arm Cylinder Cross Section

LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Backup Ring
8 - U-Cup Seal
9 - Bushing
10 - Backup Ring
11 - O-Ring
12 - Cushion Ring
13 - Spacer
14 - Snap Ring
15 - Cushion
16 - Wear Ring
17 - Piston
18 - Steel Ball
19 - Set Screw
20 - Cap Seal
21 - O-Ring
22 - Wear Ring
23 - Cushion
24 - Washer
25 - Cap Screw
26 - Cylinder Barrel

Fasten head end of cylinder to cylinder service stand.

 2.
T159625-UN: Arm Cylinder Exploded View

LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Backup Ring
8 - U-Cup Seal
9 - Bushing
10 - Backup Ring
11 - O-Ring
12 - Cushion Ring
13 - Spacer
14 - Snap Ring
15 - Cushion
16 - Wear Ring
17 - Piston
18 - Steel Ball
19 - Set Screw
20 - Cap Seal
21 - O-Ring
22 - Wear Ring
23 - Cushion
24 - Washer
25 - Cap Screw
26 - Cylinder Barrel

Bend the crimp from notch in rod guide (3), being careful not to damage the end of cylinder barrel (26).

3. IMPORTANT:

Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly.

Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using JDG28 Spanner Wrench.

4. Attach hoist and lifting strap to cylinder rod.

5. Pull rod and piston from cylinder barrel (26).

6. Heat cap screw (25) for 10 to 15 seconds to loosen the high strength thread lock and sealer.

Remove cap screw to remove washer (24) and cushion (23).

7. Remove the staking from piston and set screw (19). Remove set screw and steel ball (18).

8. Remove piston (17) and cushion (15).

9. Remove rod guide.

10. IMPORTANT:

Take care not to damage other parts when removing seals.

Do not reuse wear rings (16 and 22), cap seal (20), or O-ring (21).
 Repair or replace parts as necessary.

11. Clean and dry parts to be reused. Apply a light film of clean hydraulic fluid to all sealing parts and machined surfaces.

12. Install bushing (9) to bottom of bore. Bushing is a pressed fit.

13. Install backup ring (7). Install U-cup seal (8) so flat side is toward the rod end.

14. Install wiper ring (2) so lip is toward the outside of rod guide.

15. Install O-ring (6), backup ring (5), and O-ring (4).

16. Install O-ring (11) and backup ring (10).

17. Install cushion ring (12). Install spacer (13) so notches are toward the cushion ring. Install snap ring (14).

18. Install O-ring (21) and cap ring (20). Check that O-ring is not twisted.

19. Install wear rings (22 and 16) so the splits are offset.

20. Install rod guide (3) onto rod (1).

21. Install cushion (15), tapered end first. Install piston (17). Tighten piston.

Item Measurement Specification

Piston-to-Rod Torque 1076 N˙m

790 lb-ft

22. Install steel ball (18) and set screw (19). Tighten set screw. Stake the set screw head in two places to prevent loosening.

Item Measurement Specification

Piston-to-Rod Set Screw Torque 16.7 N˙m

148 lb-in

23. Install cushion (23) so tapered end is toward threaded of rod.

24. Apply PM37509 Cure Primer then PM38654 Thread Lock and Sealer (high strength) to cap screw (25). Install washer (24) and cap
screw. Tighten to specification.

Item Measurement Specification

Cushion-to-Rod Cap Screw Torque 16.7 N˙m

148 lb-in

Cushion-to-Rod Cap Screw Torque 31.2 N˙m

276 lb-in

25. Install rod and piston. Make sure wear rings do not come off while installing rod and piston.

26. Tighten rod guide (3).

Item Measurement Specification

Rod Guide-to-Arm Cylinder Barrel Torque 422 N˙m

310 lb-ft

27. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.
LOCTITE is a trademark of Henkel Group. MH66O88,000006D-19-20060131
TM2356 - 27D Excavator Repair
Bucket Cylinder Disassemble and Assemble

Bucket Cylinder Disassemble and Assemble

1.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Bucket Cylinder Weight approximate 22.5 kg

50 lb

T159629-UN: Bucket Cylinder Cross Section

LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Backup Ring
8 - U-Cup Seal
9 - Bushing
10 - Wear Ring
11 - Piston
12 - Steel Ball
13 - Set Screw
14 - Cap Seal
15 - O-Ring
16 - Wear Ring
17 - Cylinder Barrel
18 - Dust Seal
19 - Bushing
20 - Grease Fitting
21 - Grease Fitting
22 - Bushing

Fasten head end of cylinder to cylinder service stand.

2.
T159628-UN: Bucket Cylinder Exploded View
 LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Backup Ring
8 - U-Cup Seal
9 - Bushing
10 - Wear Ring
11 - Piston
12 - Steel Ball
13 - Set Screw
14 - Cap Seal
15 - O-Ring
16 - Wear Ring
17 - Cylinder Barrel
18 - Dust Seal
19 - Bushing
20 - Grease Fitting
21 - Grease Fitting
22 - Bushing

Bend the crimp from notch in rod guide (3), being careful not to damage the end of cylinder barrel (17).

3. IMPORTANT:

Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly.

Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using JDG28 Spanner Wrench.

4. Attach hoist and lifting strap to cylinder rod.

5. Pull rod from cylinder barrel (17).

6. Remove the staking from piston and set screw (13). Remove set screw and steel ball (12).

7. Remove piston (11).

8. Remove rod guide (3).

9. IMPORTANT:

Take care not to damage other parts when removing seals.

Do not reuse wear rings (10 and 16), cap seal (14), or O-ring (15).

Repair or replace parts as necessary.

10. Clean and dry parts to be reused. Apply a light film of clean hydraulic fluid to all sealing parts and machined surfaces.

11. Install bushing (9) so it is even with the top end of bore. Bushing is a pressed fit.

12. Install backup ring (7). Install U-cup seal (8) so flat side is toward the rod end.

13. Install wiper seal (2) so lip is toward the outside of rod guide.

14. Install O-ring (6), backup ring (5), and O-ring (4).

15. Install O-ring (15) and cap seal (14). Check that O-ring is not twisted.

16. Install wear rings (16 and 10) so the splits are offset.

17. Install rod guide (3) onto rod (1).

18. Install piston (11). Tighten piston.

Item Measurement Specification

Piston-to-Rod Torque 586 N˙m

430 lb-ft

19. Install steel ball (12) and set screw (13). Tighten set screw. Stake the set screw head in two places to prevent loosening.

Item Measurement Specification

Piston-to-Rod Set Screw Torque 16.2 N˙m

143 lb-in

20. Install rod and piston. Make sure wear rings do not come off while installing rod and piston.

21. Tighten rod guide.

Item Measurement Specification

Rod Guide-to-Cylinder Barrel Torque 343 N˙m

255 lb-ft

22. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.

MH66O88,000005F-19-20060131
TM2356 - 27D Excavator Repair
Blade and Boom Swing Cylinder Disassemble and Assemble

Blade and Boom Swing Cylinder Disassemble and Assemble

1.

CAUTION:

Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

Item Measurement Specification

Blade Cylinder Weight 24.2 kg

53 lb

Boom Swing Cylinder Weight 32 kg

71 lb

NOTE:

Disassembly procedure is the same for both blade and boom swing cylinders.

T126379-UN: Cylinder Cross Section

LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Bushing
8 - O-Ring
9 - Backup Ring
10 - Retaining Ring
11 - Wear Ring
12 - Piston
13 - Steel Ball
14 - Set Screw
15 - Cap Seal
16 - O-Ring
17 - Wear Ring
18 - Cylinder Barrel

Fasten head end of cylinder to cylinder service stand.

 2.
T159565-UN: Blade Cylinder Exploded View

LEGEND:

1 - Rod
2 - Wiper Seal
3 - Rod Guide
4 - O-Ring
5 - Backup Ring
6 - O-Ring
7 - Bushing
8 - O-Ring
9 - Backup Ring
10 - Retaining Ring
11 - Wear Ring
12 - Piston
13 - Steel Ball
14 - Set Screw
15 - Cap Seal
16 - O-Ring
17 - Wear Ring
18 - Cylinder Barrel
19 - Seal (4 used)
20 - Bushing (2 used)

Bend the crimp from notch in rod guide (3) being careful not to damage the end of cylinder barrel (18).

3. IMPORTANT:

Carefully remove components so as not to damage piston rod or sliding surfaces during disassembly.

Pull rod (1) out approximately 200 mm (8 in.). Loosen rod guide (3) using a JDG28 Spanner Wrench or equivalent.

4. Attach hoist and lifting strap to cylinder rod.

5. Pull rod from cylinder barrel (18).

6. Remove the staking from piston and set screw (14). Remove set screw and steel ball (13).

7. Remove piston (12).

8. Remove rod guide (3).

9. IMPORTANT:

Take care not to damage other parts when removing seals.

Do not reuse wear rings (11 and 17), cap seal (15), or O-ring (16).

Repair or replace parts as necessary.

10. Clean and dry parts to be reused. Apply a light film of clean hydraulic fluid to all sealing parts and machined surfaces.

11. NOTE:

Assembly procedure is the same for both blade and boom swing cylinders.

Install bushing (7) so it is even with top end of bore. Bushing is a press fit.
12. Install O-ring (6), backup ring (5), and O-ring (4).

13. Install O-ring seal (8) so flat side is toward the rod end. Install backup ring (9) and retaining ring (10).

14. Install wiper seal (2) so lip is toward the outside of rod guide.

15. Install O-ring (16). Check that O-ring is not twisted. Install cap seal (15) using JDG840-3 Installer and JGD840-6 Pusher.

16. Install wear rings (17 and 11) so the splits are offset.

17. Install rod guide (3) onto rod.

18. Install piston (12). Tighten piston.

Item Measurement Specification

Blade Cylinder Piston-to-Rod Torque 1080 N˙m

800 lb-ft

Boom Swing Cylinder Piston-to-Rod Torque 1252 N˙m

920 lb-ft

19. Install steel ball (13) and set screw (14). Tighten set screw. Stake set screw head in two places to prevent loosening.

Item Measurement Specification

Blade Cylinder Piston-to-Rod Set Torque 16.2 N˙m

Screw 143 lb-in

Boom Swing Cylinder Piston-to-Rod Torque 16.2 N˙m

Set Screw 143 lb-in

20. Install rod and piston. Make sure wear rings do not come off while installing rod and piston.

21. Tighten rod guide (3).

Item Measurement Specification

Rod Guide-to-Blade Cylinder Barrel Torque 735 N˙m

540 lb-ft

Rod Guide-to-Boom Swing Cylinder Torque 490 N˙m

Barrel 360 lb-ft

22. Crimp the edge of cylinder barrel into the notch in rod guide using a punch and hammer.

MH66O88,0000066-19-20060131
TM2356 - 27D Excavator Repair
Hydraulic Cylinder Bleed Procedure

Hydraulic Cylinder Bleed Procedure

IMPORTANT:

Prevent hydraulic cylinder cap seal and ring damage. Trapped air suddenly compressed in a cylinder can
become quickly heated and ignite the oil used for assembly. Make sure cylinder rod is fully retracted and the rod
end filled with clean oil before connecting the cylinder rod end and lines. Operate appropriate function to slowly
extend cylinder rod. This will eliminate most of the air and reduce the possibility of damage.

Bleed air at initial start-up, whenever major repairs or maintenance (oil change) is done on hydraulic system, or
when machine has been in storage for a period of time.

1. Run engine at slow idle.

2. Slowly perform function to move cylinder to the most horizontal position possible.

3. Slowly extend and retract cylinder several times to approximately 100 mm (4 in.) from end of stroke.

4. Operate cylinder several times to full stroke.

MH66O88,0000067-19-20060130
TM2356 - 27D Excavator Repair
Swing Gearbox Remove and Install

Swing Gearbox Remove and Install

1. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

2.

CAUTION:

To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

3.
X9811-UN: High-Pressure Fluid

T217442A-UN: Swing Motor and Gearbox Hydraulic Lines and Cap Screws
 T217443A-UN: Hydraulic Lines

LEGEND:

1 - PB to Pilot Control Shut-Off Solenoid Valve

2 - A8 to Right Swing Valve Spool
3 - M to Control Valve
4 - B8 to Left Swing Valve Spool
5 - DB to Rotary Manifold
6 - Cap Screw (6 used)

Record position of hydraulic lines for installation purposes.

4. Disconnect hydraulic lines (1—5). Close all openings using caps and plugs.

5.
T217444A-UN: A/C Lines

LEGEND:

7 - Cap Screw (2 used)

For machines equipped with air conditioning, remove cap screws (7) and move air conditioner lines away from the path of swing
gearbox.

6.
 CAUTION:

Prevent possible injury from crushing. For a heavy component; use appropriate lifting device.

Item Measurement Specification

Swing Motor and Gearbox Weight (approximate) 32 kg

Assembly 70 lb

Remove cap screws (6). Attach swing gearbox to hoist using JT05548 Lifting Eye.

7. NOTE:

When removing the swing gearbox, the swing motor and gearbox are usually removed as a unit. The swing
motor can be removed from the swing gearbox if desired. See Swing Motor and Park Brake Remove and Install .
(Group 4360.)

Remove swing motor and gearbox.

8. Make repairs as necessary.

9. Install the swing motor and gearbox. Tighten cap screws (6) to specification.

Item Measurement Specification

Swing Gearbox Housing-to-Frame Torque 140 N˙m

Cap Screw 103 lb-ft

10. Connect hydraulic lines.

11. Lower and secure operator station.

12. Perform Swing Motor Start-Up Procedure . (Group 4360.)

MM61211,0000A6C-19-20090218
TM2356 - 27D Excavator Repair
Swing Gearbox Disassemble and Assemble

Swing Gearbox Disassemble and Assemble

T126517-UN: Swing Gearbox Exploded View

LEGEND:

1 - Shaft
2 - Collar
3 - Plate
4 - Bearing
5 - Housing
6 - Oil Seal
7 - Bearing
8 - Cap Screw (2 used)
9 - Split Retaining Ring
10 - Collar
11 - Second Planetary Carrier
12 - Thrust Washer (4 used)
13 - Inner Race (4 used)
14 - Needle Bearing (4 used)
15 - Second Planetary Gear (4 used)
16 - Thrust Plate
17 - Cap Screw (4 used)
18 - Second Planetary Sun Gear
19 - First Planetary Carrier
20 - Thrust Washer (4 used)
21 - Inner Race (4 used)
22 - Needle Bearing (4 used)
23 - First Planetary Gear (4 used)
24 - Thrust Plate
25 - First Planetary Sun Gear
26 - O-Ring

1. Remove cap screws (8). Remove swing gearbox from swing motor.

2. Remove first planetary sun gear (25).

3. Remove thrust plate (24), first planetary gear (23), needle bearing (22), inner race (21), thrust washer (20), and first
planetary carrier (19) from housing (5).

4. Remove second planetary sun gear (18) from housing (5).

5. Remove second planetary carrier (11) from housing (5).

6. Remove cap screws (17).

7. Remove thrust plate (16), second planetary gear (15), needle bearing (14), inner race (13), and thrust washer (12) in
this order.
 8. Remove collar (10) and split retaining ring (9) from housing (5).

9. Remove shaft (1) from housing (5) using a press.

10. Remove inner race of bearing (4) using a press. Remove plate (3) and collar (2) from shaft (1).

11. Remove oil seal (6) from housing (5).

12. Remove outer race of bearing (7) from housing (5).

T126516-UN: Swing Gearbox Cross Section

LEGEND:

1 - Shaft
2 - Collar
3 - Plate
4 - Bearing
5 - Housing
6 - Oil Seal
7 - Bearing
8 - Cap Screw (2 used)
9 - Split Retaining Ring
10 - Collar
11 - Second Planetary Carrier
12 - Thrust Washer (4 used)
13 - Inner Race (4 used)
14 - Needle Bearing (4 used)
15 - Second Planetary Gear (4 used)
16 - Thrust Plate
17 - Cap Screw (4 used)
18 - Second Planetary Sun Gear
19 - First Planetary Carrier
20 - Thrust Washer (4 used)
21 - Inner Race (4 used)
22 - Needle Bearing (4 used)
23 - First Planetary Gear (4 used)
24 - Thrust Plate
25 - First Planetary Sun Gear
26 - O-Ring
27 - Swing Motor

1. Install oil seal (6) into housing (5).

2. Install outer race of bearing (7) into housing (5) using a press.

3. Pack inner race of bearing (4) with grease.

4. Install collar (2), plate (3), and inner race of bearing (4) onto shaft (1) using a press.

5. IMPORTANT:

Do not damage oil seal (6) by the spline part of the shaft (1).
 Install shaft (1) into housing (5).

6. Install inner race of bearing (7) into housing (5) using a press.

7. Install split retaining ring (9) and collar (10).

8. Install thrust washer (12), inner race (13), needle bearing (14), second planetary gear (15), and thrust plate (16) on
second planetary carrier (11).

9. Apply PM38654 Thread Lock and Sealer (high strength) to threads of cap screws (17).

10. Tighten cap screws (17) to specification.

Item Measurement Specification

Second planetary Carrier-to-Thrust Torque 4 N˙m

Plate Cap Screw 35 lb-in.

11. Install second planetary carrier assembly into housing (5).

12. Install second planetary sun gear (18).

13. Assemble thrust washer (20), inner race (21), needle bearing (22), first planetary gear (23), and thrust plate (24) on
first planetary carrier (19) in this order.

14. Install first planetary sun gear (25).

15. Install first planetary carrier (19) into housing (5).

16. Install O-ring (26) on swing motor. Install swing motor into housing with cap screws and tighten.

Item Measurement Specification

Swing Motor-to-Gearbox Cap Screw Torque 128 N˙m

94 lb-ft

17. Install swing gearbox. See Swing Gearbox Remove and Install . (Group 4350.)

LOCTITE is a trademark of Henkel Group. CS33148,00008AE-19-20060130

TM2356 - 27D Excavator Repair
Upperstructure Remove and Install

Upperstructure Remove and Install

1. Clean the machine thoroughly.

2. See Canopy Remove and Install for removal procedure. (Group 1800.) See Cab Remove and Install for removal procedure. (Group
1800.)

3. Tilt operator station. See Tilting the Operator Station . (Operator's Manual.)

4. Disconnect hydraulic lines from rotary manifold. Install caps and plugs.

5. Secure operator station.

6.
T6626JK-UN: Swing Bearing and Upperstructure Alignment

LEGEND:

1 - Swing Bearing
2 - Cap Screws and Washer (20 used)

Make alignment marks on swing bearing (A) and upperstructure to aid in assembly.

7. Remove swing bearing-to-upperstructure cap screws and washers (B).

8.

CAUTION:

Prevent possible injury from crushing. For a heavy component; use appropriate lifting device.

Item Measurement Specification

Upperstructure Weight approximate 2164 kg

4770 lb

T209147-UN: Lifting Upperstructure

LEGEND:

1 - Arm Cylinder Mounting Bracket

2 - Chain
3 - Metric Lifting Eyebolt (2 used)
4 - Upperstructure
 Attach upperstructure to a hoist using chains (2), a spreader bar, and M16x2.5 lifting eyebolts such as JT05551 Metric Lifting
Eyebolts (3). Install eyebolts in the rear counterweight. Attach chain to arm cylinder mounting bracket (1).

9. Adjust length of chains as needed to balance the upperstructure (4). Remove all slack from chains.

10. Lift upperstructure (4) slowly from undercarriage.

11. Make repairs as necessary.

12. See Swing Bearing Remove and Install for procedure to remove swing bearing (A). (Group 4350.)

13. Clean mating surfaces of swing bearing and upperstructure (4).

14. Slowly lower upperstructure (4) onto undercarriage while making sure the marks previously made are aligned.

15. Install swing bearing-to-upperstructure (4) cap screws and washers (B). Tighten to specification.

Item Measurement Specification

Swing Bearing-to-Upperstructure Torque 110 N˙m

Cap Screw 81 lb-ft

16. Tilt operator station, connect hydraulic lines, and secure station.

17. Install canopy or cab.

18. Check hydraulic fluid tank level and service as required. See Hydraulic Oil . (Operator's Manual.)

MH66O88,000007F-19-20090218
TM2356 - 27D Excavator Repair
Swing Bearing Remove and Install

Swing Bearing Remove and Install

T164480-UN: Alignment Marks

LEGEND:

1 - Swing Bearing Inner Race

2 - Undercarriage Frame
3 - Alignment Marks

1. Remove upperstructure. See Upperstructure Remove and Install . (Group 4350.)

2.

CAUTION:

Prevent possible injury from crushing. For a heavy component; use appropriate lifting device.

Item Measurement Specification

Swing Bearing Weight (approximate) 40 kg

88 lb

Make alignment marks (3) on swing bearing inner race (1) and undercarriage frame (2).

3.
T207845-UN: Swing Bearing

LEGEND:

1 - Cap Screw (20 used)

2 - Swing Bearing Inner Race

Remove cap screws (1) from swing bearing inner race (2).
 4.
T207846-UN: Lifting Brackets and Hoist

LEGEND:

1 - Lifting Brackets
2 - Swing Bearing

Attach swing bearing to a hoist using lifting brackets (1) such as JT01748 Lifting Brackets. Remove swing bearing (2).

5. Replace parts as necessary.

6. Clean mating surfaces of swing bearing, upperstructure, and undercarriage.

7. Apply PM38656 Rigid Form-in-Place Gasket to mating surfaces on swing bearing.

8. IMPORTANT:

The inner and outer bearing races are marked with the letter “S” to indicate the “soft zone.” The area marked with this
letter must be installed on the left side of machine so the use of that part of swing bearing is minimized.

T164483-UN: S location

LEGEND:

1 - Outer Race “S” Location

2 - Inner Race “S” Location
3 - Front of Machine

Install swing bearing on undercarriage so the area on both inner and outer races marked with an “S” is to the left side of machine at
approximately the 282° position as shown.

9. Install swing bearing-to-undercarriage cap screws. Tighten to specification.

Item Measurement Specification

Swing Bearing-to-Undercarriage Torque 110 N˙m

Cap Screw 81 lb-ft

10. Apply multi-purpose (extreme-pressure) grease to swing bearing teeth and pinion shaft. See Grease . (Operator's Manual.)

11. Install upperstructure. See Upperstructure Remove and Install . (Group 4350.)

LOCTITE is a trademark of Henkel Group. MH66O88,0000080-19-20060130

TM2356 - 27D Excavator Repair
Swing Motor and Park Brake Remove and Install

Swing Motor and Park Brake Remove and Install

1.

CAUTION:

To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the
system before disconnecting or connecting hydraulic or other lines. Tighten all connections
before applying pressure.

X9811-UN: High-Pressure Fluid

Identify lines for assembly purposes.

2.
T217465A-UN: Swing Motor

T217443A-UN: Swing Motor Hydraulic Lines

LEGEND:

1 - PB to Pilot Control Shut-Off Solenoid Valve

2 - A8 to Right Swing Valve Spool
3 - M to Control Valve
4 - B8 to Left Swing Valve Spool
5 - DB to Rotary Manifold
6 - Socket Head Cap Screw (2 used)

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

3. Remove socket head cap screws (6) to remove swing motor.

4. Make repairs as necessary.

5. Install swing motor. Tighten socket head cap screws to specification.

 Item Measurement Specification

Swing Motor-to-Swing Gearbox Cap Torque 128 N˙m

Screw 94 lb-ft

6. Connect hydraulic lines.

7. Lower and secure operator station.

8. Perform Hydraulic Pump Start-Up Procedure . (Group 3360.)

9. Perform Swing Motor Start-Up Procedure . (Group 4360.)

MM61211,0000A75-19-20051216
TM2356 - 27D Excavator Repair
Swing Motor and Park Brake Disassemble and Assemble

Swing Motor and Park Brake Disassemble and Assemble

1.
T126553-UN: Swing Motor Exploded View

LEGEND:

1 - Relief Valve (2 used)

2 - Anti-Cavitation Valve (2 used)
3 - Housing
4 - Bearing
5 - Shaft
6 - Swash Plate
7 - Piston (9 used)
8 - Retainer
9 - Holder
10 - Cap Screw (2 used)
11 - O-Ring
12 - Plug
13 - Orifice
14 - Pin (3 used)
15 - Cylinder Block
16 - Collar
17 - Spring
18 - Washer
19 - Retaining Ring
20 - Disk Plate
21 - O-Ring
22 - O-Ring
23 - Brake Piston
24 - Spring Seat (2 used)
25 - Disk Spring
26 - O-Ring
27 - Valve Plate
28 - Pin
29 - Bearing
30 - Pin
31 - Cover
32 - Cap Screw (5 used)
33 - O-Ring (2 used)
34 - Plug (2 used)
35 - O-Ring (2 used)

Evenly loosen five cap screws (32).

2. IMPORTANT:

Care must be taken when removing cover (31). Valve plate (27) may fall, causing damage to plate.

Remove cap screws, cover (31), valve plate (27), and O-ring (26).
 3. Remove bearing (29) and O-rings (35) from cover (31).

4. Remove disk spring (25) and spring seats (24) from housing (3).

5. Remove brake piston (23) and O-rings (21 and 22) from housing (3).

6. IMPORTANT:

Be careful so as not to damage the sliding surface of swash plate (6) while removing it from housing (3).

Remove cylinder block (15), piston assembly, swash plate (6), and disk plate (20) from housing (3).

7. Remove pistons (7), retainer (8), holder (9), and pins (14) from cylinder block (15).

8.

CAUTION:

Serious injury may result. Washer (18) and spring (17) may fly out if retaining ring (19) is
removed without compressing spring (17). Always use a press to compress spring (17).

Remove retaining ring (19), washer (18), spring (17), and collar (16) from cylinder block (15) using a press.

9. Remove shaft (5) from housing (3) by striking end of shaft with a plastic hammer.

10. Remove bearing (4) from shaft (5) using a press.

11. IMPORTANT:

Apply clean hydraulic fluid to all moving parts during the assembly process.

Repair or replace parts as necessary.

12.
T126564-UN: Swing Motor Shaft

LEGEND:

4 - Bearing
5 - Shaft

Install bearing (4) onto shaft (5) so snap ring is toward shaft splines as shown in illustration.

13. IMPORTANT:

Forcing bearing (4) beyond where snap ring contacts the housing wall will cause snap ring to deform.
 T126552-UN: Swing Motor Cross Section

LEGEND:

1 - Relief Valve (2 used)

2 - Anti-Cavitation Valve (2 used)
3 - Housing
4 - Bearing
5 - Shaft
6 - Swash Plate
7 - Piston (9 used)
8 - Retainer
9 - Holder
10 - Cap Screw (2 used)
11 - O-Ring
12 - Plug
13 - Orifice
14 - Pin (3 used)
15 - Cylinder Block
16 - Collar
17 - Spring
18 - Washer
19 - Snap Ring
20 - Disk Plate
21 - O-Ring
22 - O-Ring
23 - Brake Piston
24 - Spring Seat (2 used)
25 - Disk Spring
26 - O-Ring
27 - Valve Plate
28 - Pin
29 - Bearing
30 - Pin
31 - Cover
32 - Cap Screw (5 used)
33 - O-Ring (2 used)
34 - Plug (2 used)
35 - O-Ring (2 used)

Install shaft and bearing into housing (3) until snap ring on bearing (4) just contacts the housing wall.

14. Install collar (16), spring (17), and washer (18) into cylinder block (15). Beveled side of collar must be toward cylinder
block.

15. Compress spring (17) to install snap ring (19).

16. Apply petroleum jelly to pin (14), and install pin (14) into cylinder block (15).

17. Install holder (9) on pin (14).

18. Install pistons (7) and retainer (8) assembly into cylinder block (15).

19. Install swash plate (6) into housing (3) so beveled side is toward housing and the polished side contacts the cylinder
block pistons.

20. Install cylinder block (15) and piston assembly into housing (3).

21. Install O-rings (21 and 22) onto brake piston (23), then install them into housing (3).
22.
T126565-UN: Disk Spring

LEGEND:

24 - Spring Seat (2 used)

25 - Disk Spring

Install spring seats (24) and disk spring (25) into housing (3) as shown.

23. Install O-ring (26) into housing (3).

24. Install bearing (29) into cover (31).

25. Apply petroleum jelly to mating surfaces of valve plate (27) and cover (31) to hold valve plate in position to prevent it
from falling.

Install O-rings (35) and valve plate (27) onto cover (31).

26. Install cover (31) onto housing (3) using cap screws (32).

27. Evenly tighten cap screws (32) to specification.

Item Measurement Specification

Cover-to-Housing Cap Screw Torque 128 N˙m

94 lb-ft

28. Install swing motor and park brake. See Swing Motor and Park Brake Remove and Install . (Group 4360.)

MH66O88,0000081-19-20081014
TM2356 - 27D Excavator Repair
Swing Motor Start-Up Procedure

Swing Motor Start-Up Procedure

T126424-UN: Swing Motor Drain Line

LEGEND:

1 - Drain Line

IMPORTANT:

Swing motor will be damaged if not filled with fluid before operating swing function. This procedure must be
performed whenever a new swing motor is installed or fluid has been drained from the motor.

This procedure is to ensure the swing motor is filled with fluid before operating the swing function.

1. Disconnect swing motor drain line (1).

2. Fill motor with hydraulic fluid through drain port until fluid reaches the level of drain port. Air must be allowed to escape
from the swing motor while filling. See Hydraulic Oil . (Operator's Manual.)

3. Connect drain line.

MH66O88,0000082-19-20090218
TM2356 - 27D Excavator Repair
ST4920 Track Recoil Spring Disassembly and Assembly Tool

ST4920 Track Recoil Spring Disassembly and Assembly Tool

T6585UY-UN: ST4920 Track Recoil Spring Tool Parts

LEGEND:

A - Nut (12 used)

B - Stud (4 used)
C - Holder
D - Eyebolt (2 used)
E - Supporting Plate
F - Base Plate
G - Base (4 used)
H - Cap Screw (8 used)
I - Lock Washer (8 used)

NOTE:

See DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool that is recommended to be
used with track recoil spring disassembly and assembly tool.

Dimensions given are metric.

Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size
hole for the nut on that track adjuster.

Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring
in track adjuster repair.

Material required:

l 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G).
l “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H).
l “F” Grade (SAE Grade 8) for Studs (B).

Print Numbers:

l A-ST4050 Nut
l B-ST4045 Bolt
l C-ST4035 Holder (plate)
l -ST4036 Holder (plate)
l -ST4037 Holder (Plate)
l D-ST4047 Eyebolt
l E-ST4040 Supporting Base
l F-ST4042 Base Plate
l G-ST4041 Base
 l H-ST4046 Cap Screw
l I-ST4049 Lock Washer

T217469-UN: Track Recoil Spring Tool Dimensions

T7029CH-UN: Track Recoil Spring Tool Dimensions

T7029CG-UN: Track Recoil Spring Tool Dimensions

TX,9900,AA3574-19-19920220
TM2356 - 27D Excavator Repair
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

T7162AF-UN: Recoil Spring Guard Tool Dimensions

LEGEND:

A - 3/16 in. 1020 CR Steel Plate

B - 9/16 in. Hole (2 places)
C - 1/2 in. Nut (2 used)
D - 1/2 x 2 in. Cap Screw (2 used)
E - 1/2 x 3 in. Steel Round Stock (2 used)

Track Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool.

Material required:

l 3/16 in. 1020 CR Steel Plate (A)

l 1/2 in. Nut (C) (2 used)
l 1/2 x 2 in. Cap Screw (D) (2 used)
l 1/2 x 3 in. Steel Round Stock (E) (2 used)

TX,9900,BA499-19-20050826