Service Manual E80 Excavator: S/N AETB11001 & Above S/N AET311001 & Above

Download as pdf or txt
Download as pdf or txt
You are on page 1of 879
At a glance
Powered by AI
The document provides maintenance and service information for the Bobcat E80 excavator, including safety precautions that must be followed when working on the machine. It also lists various components and systems that are covered in the service manual.

The document mentions several important safety precautions regarding servicing the excavator, such as having good ventilation when welding or grinding painted parts, avoiding contact with leaking hydraulic fluid or diesel fuel under pressure, and wearing eye protection when engines are running or tools are used.

Some of the components listed in the service manual contents include the hydraulic system, undercarriage, travel control valve, travel motor, and upperstructure.

Service Manual

E80 Excavator

S/N AETB11001 & Above


S/N AET311001 & Above

Dealer Copy -- Not for Resale

6987194 (2-11) Printed in U.S.A. © Bobcat Company 2011

1 of 879
2 of 879
Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

P-90216 B-19964 B-19959


Never service the Bobcat Excavator Use the correct procedure to lift Cleaning and maintenance are
without instructions. and support the excavator. required daily.
WRONG WRONG WRONG

Dealer Copy -- Not for Resale


B-19965 B-19960 B-19966
Have good ventilation when Vent exhaust to outside when Always lower the bucket and
welding or grinding painted parts. engine must be run for service. blade to the ground before doing
Wear dust mask when grinding Exhaust system must be tightly any maintenance.
painted parts. Toxic dust and gas sealed. Exhaust fumes can kill Never modify equipment or add
can be produced. without warning. attachments not approved by
Bobcat Company.

WRONG WRONG WRONG

B-19962 B-19958 B-19798


Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, electrical flammable and explosive gases.
checking fluids. contact, hot parts and exhaust. Keep arcs, sparks, flames and
Never service or adjust machine Wear eye protection to guard from lighted tobacco away from
with the engine running unless battery acid, compressed springs, batteries.
instructed to do so in the fluids under pressure and flying Batteries contain acid which
manual. debris when engines are running burns eyes or skin on contact.
Avoid contact with leaking or tools are used. Use eye Wear protective clothing. If acid
hydraulic fluid or diesel fuel protections approved for type of contacts body, flush well with
under pressure. It can penetrate welding. water. For eye contact flush well
the skin or eyes. Keep tailgate closed except for and get immediate medical
Never fill fuel tank with engine service. Close and latch tailgate attention.
running, while smoking, or when before operating the excavator.
near open flame.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW28-0409

1-1
3 of 879
4 of 879
1-2
Dealer Copy -- Not for Resale
CONTENTS

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 70-01

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 879 1-3 E80 Service Manual


Dealer Copy -- Not for Resale

6 of 879 1-4 E80 Service Manual


FOREWORD

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12


Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Spark Arrestor Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14


Excavator Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Dealer Copy -- Not for Resale


DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

BOBCAT EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7 of 879 1-5 E80 Service Manual


Dealer Copy -- Not for Resale

8 of 879 1-6 E80 Service Manual


SAFETY
FOREWORD
This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the excavator has had service or repair:
1. Check that the ROPS/TOPS/ 9. Safety treads must be in good
FOPS is in good condition condition.
and is not modified.

2. Check that ROPS/TOPS 10. Check for correct function of


mounting hardware is indicator lamps.
tightened and is Bobcat
approved.

3. The seat belt must be 11. Check hydraulic fluid level,


correctly installed, functional engine oil level and fuel
and in good condition. supply.

Dealer Copy -- Not for Resale


4. Machine signs (decals) must 12. Inspect for fuel, oil or
be legible and in the correct hydraulic fluid leaks.
location.

5. Travel levers, control levers 13. Lubricate the excavator.


and foot pedals must return to
neutral. Check that the pedal
locks are in working order.

6. Check for correct function of 14. Check the condition of the


the work lights. battery and cables.

7. Enclosure door latches must 15. Inspect the air cleaner for
open and close freely. damage or leaks. Check the
condition of the element.

8. Attachment locking pins must 16. Check the electrical charging


function correctly and be in system.
good condition.

FW EXC-0509 SM

9 of 879 1-7 E80 Service Manual


17. Check tracks for wear and 21. Check the control console
tension. Use only approved interlocks for correct function.
tracks.

18. Inspect for loose or broken 22. Inspect the X-Change™ for
parts or connections. wear or damage. Repair or
replace damaged parts.

19. Check for any field 23. Check function or condition of


modification not completed. all equipped options and
accessories (examples:
special applications kit,
motion alarm, etc.).
20. Operate the machine and 24. Recommend to the owner
check all functions. that all necessary corrections
be made before the machine

Dealer Copy -- Not for Resale


is returned to service.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.

FW EXC-0509 SM

10 of 879 1-8 E80 Service Manual


Dealer Copy -- Not for Resale

11 of 879 1-9 E80 Service Manual


SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

Dealer Copy -- Not for Resale


operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.

• The Compact Excavator Operator Training Course is

DANGER available through your local dealer or at


www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Bobcat excavator. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 • Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

WARNING • The Bobcat compact excavator Safety Video is


available from your Bobcat dealer or at
The signal word WARNING on the machine and in the www.training.bobcat.com or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI EXC-0308 SM

12 of 879 1-10 E80 Service Manual


SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner / operator review the


recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.

Cutting or drilling concrete containing sand or rock


containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.

Call Before You Dig


Dial 811 (USA Only)

Dealer Copy -- Not for Resale


1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).

SI EXC-0308 SM

13 of 879 1-11 E80 Service Manual


FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage


and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.

Maintenance Always clean fluid spills. Do not use gasoline or diesel


fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed


regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.

Dealer Copy -- Not for Resale


cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.

Do not use the machine where exhaust, arcs, sparks or


hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.

Check the spark arrestor exhaust system regularly to


make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.

Battery gas can explode and cause serious injury. Use


the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.

SI EXC-0308 SM

14 of 879 1-12 E80 Service Manual


FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect


the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.

Have good ventilation when grinding or welding painted


parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as


hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Dealer Copy -- Not for Resale


Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.

SI EXC-0308 SM

15 of 879 1-13 E80 Service Manual


SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the excavator when Figure 2


requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation. 1

Excavator Serial Number

Figure 10-141-1

P-86268

The engine serial number (Item 1) [Figure 2] is located


on the top cover.

Dealer Copy -- Not for Resale


P-86914

The excavator serial number plate (Item 1) [Figure 10-


141-1] is located on the swing frame on the front of the
upperstructure.

Explanation of Excavator Serial Number:


XXXX XXXXX

Module 2. - Production
Sequence (Series)

Module 1. - Model / Engine


Combination

1. The four digit Model / Engine Combination Module


number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies


the order which the excavator is produced.

16 of 879 1-14 E80 Service Manual


DELIVERY REPORT

Figure 3

B-16315

The delivery report [Figure 3] must be completed by the


dealer and signed by the owner or operator when the
Bobcat excavator is delivered. An explanation of the form
must be given to the owner.

Dealer Copy -- Not for Resale

17 of 879 1-15 E80 Service Manual


BOBCAT EXCAVATOR IDENTIFICATION

ARM CYLINDER OPERATOR’S


HANDBOOK
MIRROR

OPERATOR SEAT
With SEAT BELT

BUCKET
CYLINDER
BOOM
CONTROL
ARM LEVERS
(JOYSTICKS)
AUXILIARY
QUICK
BOOM
COUPLERS
CYLINDER

BUCKET

Dealer Copy -- Not for Resale


LINK

BLADE
TIE DOWNS/ CYLINDER
[1] BUCKET LIFT POINTS

LIFT
POINTS

[2] CAB
RIGHT SIDE
COVER
REAR COVER

UPPERSTRUCTURE
BLADE

TRACK TRACK FRAME

TIE
DOWN
B23930
TRACK B23931

[1] BUCKET - Several different buckets and other attachments are available for the Bobcat Excavator.
[2] Model E80 S/N AETB11235 & Above has a ROPS / TOPS as standard equipment. (ROPS / TOPS - Roll Over
Protective Structure per ISO 12117-2: 2008, and Tip Over Protective Structure per ISO 12117: 2000.)

18 of 879 1-16 E80 Service Manual


SAFETY & MAINTENANCE

LIFTING AND BLOCKING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Front Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Right Side Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Heating, Ventilation And Air Conditioning Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5

TRANSPORTING THE EXCAVATOR ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1


Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Dealer Copy -- Not for Resale


RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1


Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

CENTER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1


Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1


Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1


Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing The Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

CAB FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1


Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1


Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-2

19 of 879 10-01 E80 Service Manual


FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1


Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1


Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Hydraulic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
Removing And Replacing Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-6
Checking Swing Motor Gear Box Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-7
Removing And Replacing Swing Motor Gear Box Fluid . . . . . . . . . . . . . . . . . . . . . 10-140-8

Dealer Copy -- Not for Resale


LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1


Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1


Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1


Right Rear Side Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

CAB TILT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1


Tilting The Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

TOWING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-1

20 of 879 10-02 E80 Service Manual


LIFTING AND BLOCKING THE EXCAVATOR

Procedure

Figure 10-10-1
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

WARNING
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
P-86926 or fall and result in injury or death.
W-2218-1195

Raise one side of the machine (approximately 101,6 mm


[4 in]) using the boom and arm [Figure 10-10-1].

Dealer Copy -- Not for Resale


Figure 10-10-2

1
1
P-86416

Fully raise the blade and install jackstands (Item 1)


[Figure 10-10-2] under the blade and track frame. Lower
the boom until all machine weight is on the jackstands.

Stop the engine.

21 of 879 10-10-1 E80 Service Manual


Dealer Copy -- Not for Resale

22 of 879 10-10-2 E80 Service Manual


LIFTING THE EXCAVATOR Figure 10-20-2

Procedure
2 1
Figure 10-20-1 1

1 P-87278A

Fasten chains to the ends of the blade (Item 1) [Figure


10-20-1] and [Figure 10-20-2] and up to a lifting device
above the cab. Place protective material between the
chains and the cab and the upperstructure to prevent
damage.
P-86334A

Fasten chains to the boom (Item 2) [Figure 10-20-1] and


Fully extend the cylinders of the bucket, arm, and boom [Figure 10-20-2] and up to a lifting device above the cab.
so that the excavator is in the position as shown [Figure Place protective material between the chains and the cab

Dealer Copy -- Not for Resale


10-20-1]. and the upperstructure to prevent damage.

Raise the blade fully. Figure 10-20-3

Put all the control levers in neutral.

WARNING 45°

AVOID INJURY OR DEATH


• Use a lifting fixture with sufficient capacity for the
weight of the excavator plus any added
attachments.
• Maintain center of gravity and balance when
lifting.
• Do not swing boom or upperstructure.
• Never lift with operator on machine.
W-2434-0502

B-23947A

The maximum angle between the front and rear chains


must not exceed 45° [Figure 10-20-3].

23 of 879 10-20-1 E80 Service Manual


Dealer Copy -- Not for Resale

24 of 879 10-20-2 E80 Service Manual


OPERATOR CAB Cab Door

Description Figure 10-30-1

S/N AETB11235 & Above And AE7311235 & Above

The Bobcat excavator has an operator cab (ROPS / 1


TOPS) as standard equipment to provide protection if the
excavator is tipped over. The seat belt must be worn for
ROPS / TOPS protection.
2
Check the ROPS / TOPS cab, mounting and hardware
for damage. Never modify the ROPS / TOPS cab.
Replace the cab and hardware if damaged.

ROPS / TOPS - Roll Over Protective Structure per ISO


12117-2: 2008, and Tip Over Protective Structure per
ISO 12117: 2000. P-86952

S/N AETB11001 - AETB11234 And AET311001 -


AET311234 The cab door can be locked (Item 1) [Figure 10-30-1]
with the same key as the starter switch.
The Bobcat excavator has an operator cab as standard
equipment. The door can be held in the open position. Push the door

Dealer Copy -- Not for Resale


all the way open until the latch (Item 2) [Figure 10-30-1]
engages to hold the door in the open position.

Figure 10-30-2
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

P-86238A

When the door is in the open position, push down on the


latch (Item 1) [Figure 10-30-2] and close the door.

From inside the cab, open the door using the handle
(Item 2) [Figure 10-30-2].

25 of 879 10-30-1 E80 Service Manual


OPERATOR CAB (CONT’D) Figure 10-30-5

Front Window

Opening The Front Window

Figure 10-30-3

P-86954

1
When the window is fully raised, push up on the window
slightly until the two latch pins (Item 1) (both sides)
engage into the bracket (Item 2) [Figure 10-30-5] to lock
P-86225 the window in the open position. Pull down slightly on the
window to make sure the latch pins are properly seated
to hold the window securely in the open position.

Dealer Copy -- Not for Resale


Rotate the front window latch pins (Item 1) [Figure 10-
30-3] (Both sides). Closing The Front Window

Figure 10-30-4 Support the window while rotating both window latch pins
(Item 1) [Figure 10-30-5] to the unlocked position.

Using both window grab handles, pull the window


forward and down to the closed position [Figure 10-30-
4].

When the window is fully lowered, push in on the window


slightly until the two latch pins (Item 1) [Figure 10-30-3]
(both sides) engage into the bracket to lock the window in
the closed position.

P-86322

Use both window grab handles to pull the top of the


window in [Figure 10-30-4].

Continue moving the window in and up over the


operator’s head until the window is fully raised.

26 of 879 10-30-2 E80 Service Manual


OPERATOR CAB (CONT’D) Window Washer Reservoir

Front Wiper Figure 10-30-8

Figure 10-30-6

P-86908

P-86249
The window washer reservoir (Item 1) [Figure 10-30-8]
is located under the right side cover and to the front of
The front window is equipped with a wiper (Item 1) the radiator. (When the temperature is 0°C (32°F) or
[Figure 10-30-6] and washer. lower, fill the washer reservoir with washer fluid specified

Dealer Copy -- Not for Resale


for freezing conditions. If the washer bottle is filled with
Figure 10-30-7 water, it will freeze and damage the washer reservoir.)

1 2

2
1

P-86945A

The wiper switch (Item 1) [Figure 10-30-7] has three


positions, OFF, intermittent wiper mode and full speed.

The window washer switch (Item 2) activates the front


window washer. (The wiper switch (Item 1) must be
activated before the washer switch (Item 2) [Figure 10-
30-7] will allow washer fluid to be sprayed on the front
window.)

27 of 879 10-30-3 E80 Service Manual


OPERATOR CAB (CONT’D)

Right Side Window

Opening The Right Front Window

Figure 10-30-9

P-86228

Dealer Copy -- Not for Resale


Press the latch / handle (Item 1) [Figure 10-30-9]
together and pull back on the latch / handle to open the
right side window.

Closing The Right Front Window

Push the latch / handle (Item 1) [Figure 10-30-9] forward


until the latch / handle lock the window in the closed
position.

28 of 879 10-30-4 E80 Service Manual


OPERATOR CAB (CONT’D) Figure 10-30-12

Heating, Ventilation And Air Conditioning Duct

Figure 10-30-10

1
1

P-86951

P-86229
The excavator is equipped with seven air vents (Item 1)
[Figure 10-30-10], [Figure 10-30-11] and [Figure 10-30-
Figure 10-30-11 12] that can be adjusted to deflect air flow to the desired
area of the cab.

Figure 10-30-13

Dealer Copy -- Not for Resale


1

P-86230

P-86953

Use the one of the five buttons (Item 1) [Figure 10-30-


13] located in the left console to control which air ducts
are active.

29 of 879 10-30-5 E80 Service Manual


Dealer Copy -- Not for Resale

30 of 879 10-30-6 E80 Service Manual


TRANSPORTING THE EXCAVATOR ON A TRAILER Fastening
Figure 10-40-2
Loading And Unloading

When transporting the machine, observe the rules, motor


vehicle laws, and vehicle limit ordinances. Use a
transport and towing vehicle of adequate length and
capacity.

Secure the parking brakes and block the wheels of the


transport vehicle.

Align the ramps with the center of the transport vehicle.


1
Secure the ramps to the truck bed and be sure ramp
angle does not exceed 15 degrees.

Use metal loading ramps with a slip resistant surface.

Use ramps that are the correct length and width and can P-87269
support the weight of the machine.

The rear of the trailer must be blocked or supported when Figure 10-40-3
loading or unloading the machine to prevent the front of
the transport vehicle from raising.

Determine the direction of the track movement before 1


moving the machine (blade forward).

Dealer Copy -- Not for Resale


Figure 10-40-1

P-87267

NOTE: A clevis may be used at the chain holes for the


chains to be routed through for clearance.

Fasten chains to both corners of the blade (Item 1)


[Figure 10-40-2] and to the tie down loop at the rear of
P-86910A
the track frame (Item 1) [Figure 10-40-3] to prevent it
from moving when going up or down slopes or during
sudden stops.
NOTE: When loading or unloading the machine,
disengage the auto idle feature and place the Use chain binders to tighten the chains and then safely
two speed travel in low range. tie the chain binder levers to prevent loosening.

Move the machine forward onto the transport vehicle


[Figure 10-40-1].

Do not change direction of the machine while it is on the WARNING


ramps.

Lower the boom, arm, bucket, and blade to the transport AVOID SERIOUS INJURY OR DEATH
vehicle. Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
Stop the engine and remove the key. loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
Put blocks at the front and rear of the tracks. W-2058-0807

31 of 879 10-40-1 E80 Service Manual


Dealer Copy -- Not for Resale

32 of 879 10-40-2 E80 Service Manual


RIGHT SIDE COVER Adjusting The Latch

Opening And Closing Figure 10-50-2

Figure 10-50-1

P-86943

P-86256
The right side cover latch (Item 1) [Figure 10-50-2] can
be adjusted.
Pull the latch (Item 1) [Figure 10-50-1] and raise the right
side cover. Loosen the nut (Item 2) [Figure 10-50-2] and adjust the

Dealer Copy -- Not for Resale


latch. Tighten the nut after the adjustment is made.
NOTE: The right side cover can be locked using the
start key. Close the right side cover before operating the excavator.

33 of 879 10-50-1 E80 Service Manual


Dealer Copy -- Not for Resale

34 of 879 10-50-2 E80 Service Manual


REAR COVER

Opening And Closing

The hydraulic tank breather / filter and hydraulic oil fill


cover is located under the rear cover.

Figure 10-60-1

P-86257

Dealer Copy -- Not for Resale


Use the start key to unlock and open the rear cover (Item
1) [Figure 10-60-1].

Close and lock the rear cover when the service


procedure is completed.

35 of 879 10-60-1 E80 Service Manual


Dealer Copy -- Not for Resale

36 of 879 10-60-2 E80 Service Manual


CENTER COVER

Opening And Closing

The window washer bottle, breaker valve, circuit breaker,


fusible links, some relays and the swing motor are
located under the center cover.

Figure 10-70-1

P-89349

Dealer Copy -- Not for Resale


Use the start key to unlock and open the center cover
(Item 1) [Figure 10-70-1].

Close and lock the center cover when the service


procedure is completed.

37 of 879 10-70-1 E80 Service Manual


Dealer Copy -- Not for Resale

38 of 879 10-70-2 E80 Service Manual


SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Excavator.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

SERVICE SCHEDULE HOURS


ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000 2000
Engine Coolant Check coolant level. Add premixed coolant as needed.
Engine Oil Check the engine oil level and add as needed.
Hydraulic Fluid, Hoses and Check the hydraulic fluid level and add as needed. Check for damage
Tubelines, Reservoir Breather Cap and leaks. Repair or replace as needed.
Engine Air Filter and Air System Check condition indicator and empty dust cup as needed. Check air
system for leaks.
Tracks Check and adjust track tension as needed.
Indicators and Lights Check for correct operation of all indicators and lights.
Operator Cab Check condition. Check mounting hardware.
Seat Belt Check condition. Check mounting hardware.
Console Lockout Check console lockout for proper operation. Repair or replace as needed.
Safety Signs Check for damaged signs (decals). Replace any signs that are damaged.

Dealer Copy -- Not for Resale


Fuel Tank And Filter Drain water and sediment from fuel / water separator.
Swing Motor Reduction Gearbox Check oil level and add as needed.
Swing Circle Grease the fitting. [1]
Pivot Points Grease blade, boom swing and boom swing cylinder pivot points and the [1]
front attachment pins. [2]
Battery Check battery, cables, connections and electrolyte level. Add distilled
water as needed.
Fuel Tank Drain water and sediment from fuel tank.
Spark Arrester Muffler Clean spark chamber.
Belts Check and adjust if required. [3]
Pivot Pins Grease boom pins, arm pins, and attachment link pins. [1]
[2]
Fuel Filters Clean fuel / water separator screen. Replace as needed [3]
Engine Oil and Filter Replace oil and filter. Use CI-4 or better grade oil and Bobcat filter. [3]
Travel Motor Check the oil level in both travel motors
Swing Circle Pinion Grease the fitting.
Radiator, Oil Cooler, A/C Clean debris from the radiator fins.
Accessory Drive Belt Check condition of belt and idlers. Adjust as needed. [4]
Fuel Filter Replace fuel filter.
Primary Hydraulic Filter and Replace the primary hydraulic filter and the reservoir breather filter. [5]
Reservoir Breather Filter
Alternator And Starter Check the alternator and starter connections. [4]
Cab Heater Air Filters Clean the filter. Replace as needed.
Hydraulic Oil Suction Filter Clean the suction filter. [5] [6]
Travel Motor Replace the oil in both travel motors. [4] [6]
Engine Valves Check and adjust the engine valve clearance.
Swing Reduction Gear Replace the oil in the gearbox. [4] [6]
Swing Reduction Gear Grease the fitting. [6]
Hydraulic System Replace the hydraulic fluid and filters. Clean the reservoir. [6]
Engine Cooling System Drain and flush the cooling system. Replace the coolant. Every two years. [7]

[1] Service every 10 hours when operating in water.


[2] Service every 10 hours for the first 100 hours, then as scheduled.
[3] Service at the first 50 hours, then as scheduled.
[4] Service at the first 100 hours, then as scheduled.
[5] Service at the first 250 hours, then as scheduled.
[6] Or every 12 months.
[7] Service at the first year, then as scheduled.

39 of 879 10-80-1 E80 Service Manual


Dealer Copy -- Not for Resale

40 of 879 10-80-2 E80 Service Manual


AIR CLEANER SERVICE Outer Filter

See the service schedule for the correct service interval. Pull out on the three fasteners (Item 1) and remove the
(See SERVICE SCHEDULE on Page 10-80-1.) cover [Figure 10-90-2].
Daily Check
Clean the dust cup (Item 2) [Figure 10-90-2].
Figure 10-90-1
Figure 10-90-3
1

P-86955A
P-86262

Dealer Copy -- Not for Resale


Check the air cleaner condition indicator icon (Item 1)
[Figure 10-90-1] in the instrument panel. If the icon stays Pull the outer filter (Item 1) [Figure 10-90-3] from the air
ON after the engine is started, the filter needs to be cleaner housing.
replaced.
Check the housing for damage.
Replacing The Filters
Clean the housing and the seal surface. DO NOT use
Open the right side cover to access the air cleaner for compressed air.
service. (See Opening And Closing on Page 10-50-1.)
Install a new filter.
Figure 10-90-2
Install the cover and engage the three fasteners (Item 1)
[Figure 10-90-2].
1
Make sure the dust evacuator cup (Item 3) [Figure 10-
90-2] is in the down position as shown.

Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.

1
2
3
P-86260

Replace the inner filter every third time the outer filter is
replaced or as indicated.

41 of 879 10-90-1 E80 Service Manual


AIR CLEANER SERVICE (CONT’D)

Replacing The Filters (Cont’d)

Inner Filter

Only replace the inner filter under the following


conditions:

• Replace the inner filter every third time the outer filter
is replaced.

• After the outer filter has been replaced, start the


engine. If the air cleaner condition indicator icon (Item
1) [Figure 10-90-3] remains ON, replace the inner
filter.

Figure 10-90-4

Dealer Copy -- Not for Resale


1

P-86261

Remove the air cleaner cover, the outer filter and the
inner filter (Item 1) [Figure 10-90-4].

NOTE: Make sure all sealing surfaces are free of dirt


and debris. DO NOT use compressed air.

Install the new inner filter (Item 1) [Figure 10-90-4].

Install the outer filter and the air cleaner cover.

42 of 879 10-90-2 E80 Service Manual


CAB FILTER Figure 10-100-3

Cleaning And Maintenance

The recirculation filter must be cleaned regularly. The


filter is located at the right of the operator seat. (See
SERVICE SCHEDULE on Page 10-80-1.)
1
The heater filter must be cleaned regularly. The filter is
located at the left of the operator seat. (See SERVICE
SCHEDULE on Page 10-80-1.)

Figure 10-100-1

P-87293

Installation: Install the filter with the arrows that indicate


air flow direction (Item 1) [Figure 10-100-3] pointing
1 towards the heater / A/C housing.

Dealer Copy -- Not for Resale


2

P-86942

Remove the four bolts (Item 1) from the cover (Item 2)


[Figure 10-100-1].

Figure 10-100-2

P-87294

Remove the cover (Item 1) and pull up the filter (Item 2)


[Figure 10-100-2] to remove from the cover.

Use low air pressure to clean the filter. Replace the filter
when very dirty.

43 of 879 10-100-1 E80 Service Manual


Dealer Copy -- Not for Resale

44 of 879 10-100-2 E80 Service Manual


ENGINE COOLING SYSTEM Open the right side cover.

Check the cooling system every day to prevent over- Figure 10-110-2
heating, loss of performance or engine damage.

Cleaning

Open the right side cover. (See Opening And Closing on


Page 10-50-1.)
MA X
Figure 10-110-1

MIN 1

P-86273

Check the coolant level in the coolant recovery tank (Item


1) [Figure 10-110-2].

The coolant level must be between the MINIMUM and

Dealer Copy -- Not for Resale


P-86279 MAXIMUM marks on the coolant recovery tank (Item 1)
[Figure 10-110-2] when the engine is cold.
Use air pressure or water pressure to clean the radiator,
oil cooler and air conditioning condenser (Item 1) [Figure NOTE: The cooling system is factory filled with
10-110-1]. Be careful not to damage fins during cleaning. ethylene glycol. DO NOT mix propylene glycol
with ethylene glycol.
NOTE: Allow the cooling system and engine to cool
before servicing or cleaning the cooling
system.
Checking Level
IMPORTANT
WARNING AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
AVOID BURNS
Do not remove radiator cap when the engine is hot. Too much antifreeze reduces cooling system
You can be seriously burned. efficiency and may cause serious premature engine
W-2070-1203 damage.

Too little antifreeze reduces the additives which


protect the internal engine components; reduces the
boiling point and freeze protection of the system.
WARNING Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
AVOID INJURY OR DEATH engine damage.
Wear safety glasses to prevent eye injury when any I-2124-0497
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

45 of 879 10-110-1 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 10-110-4

Removing And Replacing Coolant

See the Chart for correct service intervals. (See


SERVICE SCHEDULE on Page 10-80-1.)
1
Stop the engine. Open the right side cover. (See Opening
And Closing on Page 10-50-1.)

WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot. P-86275

You can be seriously burned.


W-2070-1203
Open the drain valve (Item 1) [Figure 10-110-4] (located
below the oil filter) and drain the coolant into the
Figure 10-110-3 container.

After all the coolant is removed, close the drain valves.

Dealer Copy -- Not for Resale


Recycle or dispose of the used coolant in an
environmentally safe manner.
1
Mix the coolant in a separate container. (See Capacities
on Page SPEC-10-8.)

NOTE: The cooling system is factory filled with


ethylene glycol. DO NOT mix ethylene glycol
with propylene glycol.

The correct mixture of coolant to provide a -37°C (-34°F)


P-86274 freeze protection is 4 L ethylene glycol mixed with 4 L of
water OR 1 U.S. gal ethylene glycol mixed with 1 U.S. gal
of water.
When the engine is cool, loosen and remove the radiator
cap (Item 1) [Figure 10-110-3].
Add premixed coolant; 50% water and 50% ethylene
glycol to the recovery tank if the coolant level is low.
Rotate the upperstructure 90° to access the lower engine
access cover. Remove the lower engine access cover so
Run the engine until it is at operating temperature. Stop
coolant can be drained into a container.
the engine. Check the coolant level and add as needed.
Be sure the radiator cap is tight.

Add coolant to the recovery tank as needed.

Reinstall the lower engine access cover.

Close the right side cover.

46 of 879 10-110-2 E80 Service Manual


FUEL SYSTEM Biodiesel Blend Fuel

Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using it in this machine:
Use only clean, high quality diesel fuel. Grade No. 2 or
Grade No. 1 with a cetane number of 45 or higher. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures:
• Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE C° (F°) NO. 2 NO. 1
corrosion and plugging of fuel system components.
-9°(+15°) 100% 0%
Down to -29° (-20°) 50% 50% • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as plugged
Below -29° (-20°) 0% 100% fuel filters and deteriorated fuel lines.
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
• Shorter maintenance intervals may be required, such
must be used in this machine.
as cleaning the fuel system and replacing fuel filters
and fuel lines.
The following fuels may also be used in this machine:
• Using biodiesel blended fuels containing more than
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
five percent biodiesel can affect engine life and cause
• Biodiesel Blend Fuel - Must contain no more than five deterioration of hoses, tubelines, injectors, injector
percent biodiesel mixed with low sulfur or ultra low pump and seals.

Dealer Copy -- Not for Resale


sulfur petroleum based diesel. This is commonly
marketed as B5 blended diesel fuel. Apply the following guidelines if biodiesel blend fuel is
used:

• Ensure the fuel tank is as full as possible at all times


WARNING to prevent moisture from collecting in the fuel tank.

AVOID INJURY OR DEATH • Ensure that the fuel tank cap is securely tightened.
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an • Biodiesel blend fuel can damage painted surfaces.
explosion or fire. Remove all spilled fuel from painted surfaces
W-2063-0807 immediately.

• Drain all water from the fuel filter daily before


operating the machine.

WARNING • Do not exceed the engine oil change interval.


Extended oil change intervals can cause engine
damage.
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames, • Before vehicle storage; drain the fuel tank, refill with
sparks or lighted tobacco away from fuel and oil. 100% petroleum diesel fuel, add fuel stabilizer and
Failure to use care around combustibles can cause run the engine for at least 30 minutes.
explosion or fire.
W-2103-0508 NOTE: Biodiesel blend fuel does not have long term
stability and should not be stored for more
than three months.

47 of 879 10-120-1 E80 Service Manual


FUEL SYSTEM (CONT’D)

Filling The Fuel Tank

Figure 10-120-1

P-86941

Remove the fuel fill cap (Item 1) [Figure 10-120-1]


located behind the left corner of the operator cab.

Dealer Copy -- Not for Resale


Figure 10-120-2

P-86263

Inspect the fuel strainer (Item 1) [Figure 10-120-2] for


damage. Replace if damaged. Always have the fuel
strainer installed when filling the fuel tank.

Use a clean, approved safety container to add fuel. Add


fuel only in an area that has a free movement of air and
no flames or sparks. NO SMOKING!

Install and tighten the fuel fill cap.

Clean up any spilled fuel.

48 of 879 10-120-2 E80 Service Manual


FUEL SYSTEM (CONT’D) Replacing Elements

Fuel Filters See the Chart for the service interval for when to replace
the fuel filter. (See Chart on Page 10-80-1.)
Removing Water
Primary Fuel Filter
See the Chart for the service interval for when to remove
water from the fuel filter. (See Chart on Page 10-80-1.) Turn the shut off valve (Item 2) [Figure 10-120-3]
clockwise to the closed position.
Open the right side cover. (See Opening And Closing on
Page 10-50-1.) Remove the filter (Item 3) [Figure 10-120-3].

Figure 10-120-3 Clean the area around the filter housing. Put clean oil on
the seal of the new filter. Install the fuel filter and tighten it
CLOSED 2 by hand.

Turn the shut off valve (Item 2) [Figure 10-120-3]


counterclockwise to the open position.
OPEN
Secondary Fuel Filter

Figure 10-120-4

Dealer Copy -- Not for Resale


1
P-86267A 1

Loosen the drain (Item 1) [Figure 10-120-3] at the


bottom of the filter to drain water from the filter into a
container.

Clean up any spilled fuel.

P-87986

Turn the shut off valve (Item 2) [Figure 10-120-3]


clockwise to the closed position.

Remove the filter (Item 1) [Figure 10-120-4].

Clean the area around the filter housing. Put clean oil on
the seal of the new filter. Install the fuel filter and tighten it
by hand.

Turn the shut off valve (Item 2) [Figure 10-120-3]


counterclockwise to the open position.

Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-120-4.)

49 of 879 10-120-3 E80 Service Manual


FUEL SYSTEM (CONT’D)

Draining The Fuel Tank

See the Chart for the correct service interval. (See


WARNING
SERVICE SCHEDULE on Page 10-80-1.)
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
Figure 10-120-5
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
1 Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
1 from a physician familiar with this injury.
W-2072-0807

Removing Air From The Fuel System

After replacing the fuel filter or when the fuel tank has run
2 out of fuel, air must be removed from the fuel system
before starting the engine.

1 Turn the start key to the ON position for 10 - 15 seconds.


P-86315

Dealer Copy -- Not for Resale


The electric fuel pump will supply fuel under pressure
Loosen one of the bolts and remove two bolts / washers and force air from the system.
(Item 1) and the access cover (Item 2) [Figure 10-120-5]
from below the rear of the excavator. Rotate the cover
out of the way.

Figure 10-120-6

P-86318

Install a drain hose on the drain valve (Item 1) [Figure


10-120-6] at the bottom of the fuel tank. Route the hose
to a container.

Drain the fuel into a container. Tighten the drain valve


after the fuel has been removed.

Reuse, recycle or dispose of the fuel in an


environmentally safe manner.

50 of 879 10-120-4 E80 Service Manual


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil ENGINE OIL
Check the engine oil every day before starting the engine RECOMMENDED SAE VISCOSITY NUMBER
for the work shift. (LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
Figure 10-130-1 Figure 10-130-2

P-86271

Dealer Copy -- Not for Resale


Open the right side cover and remove the dipstick (Item
1) [Figure 10-130-1]. TEMPERATURE RANGE ANTICIPATED BEFORE
NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
Keep the oil level between the marks on the dipstick. CLASSIFICATION CI-4 OR BETTER)
[1] Synthetic Oil - Use recommendation from Synthetic
Oil Manufacturer.

Use good quality engine oil that meets API Service


Classification of CI-4 or better [Figure 10-130-2].

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Install the dipstick and close the right side cover.

51 of 879 10-130-1 E80 Service Manual


ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-130-5

Removing And Replacing Oil And Filter

See the Chart for the service interval for when to replace
the engine oil and filter. (See SERVICE SCHEDULE on
Page 10-80-1.)

Run the engine until it reaches operating temperature.


Rotate the upperstructure 90° for access to the bottom 1
engine cover and the engine oil pan drain plug. Stop the
engine.
Open the right side cover.
Figure 10-130-3
P-86272

2 3 2
2 Remove the oil filter (Item 1) [Figure 10-130-5] and clean
the filter housing surface.

Use a genuine Bobcat replacement filter. Put clean oil on


the filter gasket. Install the filter and tighten it by hand.

Install and tighten the plug (Item 1) [Figure 10-130-4].

Dealer Copy -- Not for Resale


Figure 10-130-6
1 1
2

P-86925

1
From under the machine, loosen the two bolts (Item 1)
and remove four bolts / washers (Item 2) from the access
cover (Item 3) [Figure 10-130-3] from below the engine
area. Remove the access cover.

Figure 10-130-4

P-86268

Remove the fill cap (Item 1) [Figure 10-130-6].

Put the correct amount of oil in the engine. (See


Capacities on Page SPEC-10-8.)

1 Install the fill cap.

Start the engine and let it run for several minutes.

Stop the engine. Check for leaks at the oil filter. Check
P-86924 the oil level.
Add oil as needed if it is not at the top mark on the
Remove the plug (Item 1) [Figure 10-130-4] from the dipstick.
engine oil pan. Drain the oil into a container.
Reinstall the access cover (Item 3) [Figure 10-130-3]
Recycle or dispose of used oil in an environmentally safe and tighten the bolts.
manner.

52 of 879 10-130-2 E80 Service Manual


HYDRAULIC SYSTEM Figure 10-140-2

Checking And Adding Fluid


Put the machine on a level surface. 3
3
Retract the arm and bucket cylinders, put the bucket on
the ground and lower the blade. Stop the engine. 3
3
Open the right side cover. (See Opening And Closing on
Page 10-50-1.)
1 2
Figure 10-140-1

3 3

P-86906
2

Open the rear cover. (See Opening And Closing on Page


10-60-1.)
2
NOTE: When removing the cover (Item 2), there is
1 spring pressure under the cover. Push down
on the cover while removing the bolts (Item 3)

Dealer Copy -- Not for Resale


[Figure 10-140-2].

P-86295
Clean the surface around the reservoir (breather) cap
(Item 1) and cover (Item 2) fully. Press down on the cover
Check the hydraulic fluid level. It must be visible in the (Item 2) and remove the six bolts (Item 3) from the cover
sight gauge (Item 1) between the two red lines (Item 2) (Item 2) [Figure 10-140-2]. Remove the cover.
[Figure 10-140-1].
Add the correct fluid to the reservoir until it is visible in the
sight gauge.

WARNING Check the O-ring under the cover (Item 2) [Figure 10-
140-2]. Replace the O-ring if damaged.

AVOID INJURY OR DEATH Reinstall the cover and align the bolt holes. Press down
Always clean up spilled fuel or oil. Keep heat, flames, on the cover (Item 2) and install the six bolts (Item 3)
sparks or lighted tobacco away from fuel and oil. [Figure 10-140-2]. Tighten the bolts.
Failure to use care around combustibles can cause
explosion or fire. Close the rear cover.
W-2103-0508

Open the rear cover. (See Opening And Closing on Page


10-60-1.)

53 of 879 10-140-1 E80 Service Manual


HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Filters

Hydraulic Fluid Chart Hydraulic Return Filter

RECOMMENDED ISO VISCOSITY GRADE (VG)


AND VISCOSITY INDEX (VI)

Figure 10-140-3
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)

TEMPERATURE RANGE ANTICIPATED Open the rear cover. (See Opening And Closing on Page
DURING MACHINE USE 10-60-1.)
[1] Synthetic Fluid; VG 46; Minimum VI 150
[2] BOBCAT Hydraulic / Hydrostatic Fluid Figure 10-140-4

Dealer Copy -- Not for Resale


Use the correct hydraulic fluid shown in chart [Figure 10- 2
140-3].
2
2
Add hydraulic fluid as needed to bring the level to the
center of sight gauge (Item 1) [Figure 10-140-1 on Page
10-140-1].

Reinstall the cover and align the bolt holes. Press down 1
on the cover (Item 2) and install the four bolts (Item 3)
[Figure 10-140-2 on Page 10-140-1]. Tighten the bolts.
2 2

2
P-86906

NOTE: When removing the cover (Item 1), there is


spring pressure under the cover. Push down
on the cover while removing the bolts (Item 2)
[Figure 10-140-4].

Fully clean the surface around the cover (Item 1) [Figure


10-140-4].

Press down on the cover (Item 1) and remove the six


bolts (Item 2) [Figure 10-140-4] and cover.

54 of 879 10-140-2 E80 Service Manual


HYDRAULIC SYSTEM (CONT’D) Figure 10-140-7

Removing And Replacing Hydraulic Filters (Cont’d)

Hydraulic Return Filter (Cont’d)

Figure 10-140-5

1 1

P-86303

2 Remove the return filter (Item 1) [Figure 10-140-7].

Install the new filter (Item 1) [Figure 10-140-7].


P-86301
Reinstall the valve (Item 1) [Figure 10-140-6].

Dealer Copy -- Not for Resale


Remove the spring (Item 1) [Figure 10-140-5]. Reinstall the spring (Item 1) [Figure 10-140-5].

Inspect the O-ring (Item 2) [Figure 10-140-5] for Reinstall the cover and align the bolt holes. Press down
damage. Replace the O-ring if it is damaged. on the cover (Item 2) and install the six bolts (Item 2)
[Figure 10-140-4 on Page 10-140-2] and tighten the
Figure 10-140-6 bolts.

P-86302

Remove the valve (Item 1) [Figure 10-140-6].

55 of 879 10-140-3 E80 Service Manual


HYDRAULIC SYSTEM (CONT’D) Figure 10-140-9

Removing And Replacing Hydraulic Filters (Cont’d)

Hydraulic Suction Filter

See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)

Open the rear cover. (See Opening And Closing on Page 2 1


10-60-1.)

Figure 10-140-8

2 P-86300
2

2 Remove the spring (Item 1) [Figure 10-140-9].


2
Lift up on the rod (Item 2) [Figure 10-140-9].

3 1
Figure 10-140-10

Dealer Copy -- Not for Resale


2 2

P-86906
1

NOTE: When removing the cover (Item 1), there is


spring pressure under the cover. Push down
on the cover while removing the bolts (Item 2)
2
[Figure 10-140-8].

Fully clean the surface around the reservoir (breather)


cap (Item 3) and cover (Item 1). Remove the four bolts
(Item 2) from the cover (Item 1) [Figure 10-140-8] and P-87308
remove the cover.

Continue to lift up on the rod (Item 1) until the filter (Item


2) [Figure 10-140-10] is removed from the tank.

NOTE: Before removing the filter (Item 2) [Figure 10-


140-10] from the rod (Item 1) [Figure 10-140-
10], measure the distance from the end of the
rod to the end of the filter. Install the new filter
to the same measured distance so that the
spring (Item 1) [Figure 10-140-9] pressure will
keep the filter installed correctly in the tank.

NOTE: When installing the new filter (Item 2) [Figure


10-140-10] into the hydraulic tank, make sure
to get the filter positioned over the outlet port
at the bottom of the hydraulic tank.

56 of 879 10-140-4 E80 Service Manual


HYDRAULIC SYSTEM (CONT’D)

Removing And Replacing Hydraulic Filters (Cont’d)

Hydraulic Breather Filter

See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)

Open the rear cover. (See Opening And Closing on Page


10-60-1.)

Figure 10-140-11

Dealer Copy -- Not for Resale


P-86906

Remove the filter cap (Item 1) [Figure 10-140-11] by


turning the cap counterclockwise.

Figure 10-140-12

P-86296

Remove and replace the breather filter (Item 1) [Figure


10-140-12].

Reinstall the cap (Item 1) [Figure 10-140-11].

57 of 879 10-140-5 E80 Service Manual


HYDRAULIC SYSTEM (CONT’D) Figure 10-140-14

Removing And Replacing Hydraulic Fluid

See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)
1

WARNING
AVOID INJURY OR DEATH 2
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible. P-86317
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention Rotate the cover plate (Item 1) [Figure 10-140-14] to
from a physician familiar with this injury. access the bottom of the hydraulic tank.
W-2072-0807
Remove the drain plug (Item 2) [Figure 10-140-14] from
the bottom of the hydraulic tank.
Retract the arm and bucket cylinders, and lower the
bucket to the ground. Lower the blade to the ground.

Dealer Copy -- Not for Resale


Drain the fluid into a container.
Stop the engine.
Recycle or dispose of the fluid in an environmentally safe
Open the rear cover. (See Opening And Closing on Page
manner.
10-60-1.)

Figure 10-140-13 Reinstall the drain plug (Item 2) [Figure 10-140-14].

Always replace the filters when changing the hydraulic


fluid. (See Removing And Replacing Hydraulic Filters on
1 1 Page 10-140-2.)

1
2

P-86316

From below the rear of the excavator upperstructure,


remove three bolts (Item 1) and loosen the fourth bolt
(Item 2) [Figure 10-140-13].

58 of 879 10-140-6 E80 Service Manual


HYDRAULIC SYSTEM (CONT’D) Checking Swing Motor Gear Box Fluid Level

Removing And Replacing Hydraulic Fluid (Cont’d) Figure 10-140-16

Figure 10-140-15

1
1

P-86904

P-86927
Open the center cover to access the swing motor.

After the hydraulic fluid has been drained from the The swing motor gear box (Item 1) has a dipstick (Item 2)
excavator or after the hydraulic pump has been serviced, [Figure 10-140-16] for checking the swing motor gear

Dealer Copy -- Not for Resale


the hydraulic pump must be flooded with hydraulic oil. box oil level.
Allow sufficient time for the hydraulic fluid to gravity feed
into the hydraulic pump before starting the machine. Keep the oil level between the marks on the dipstick.

Remove the case drain line (Item 1) [Figure 10-140-15]


to see if hydraulic fluid is at the plug opening. If oil is
present the pump has been flooded. Reinstall the case
drain line.

If fluid is not at the opening, install the case drain line


(Item 1). Start the engine and run at low idle for one
minute. Remove the case drain line (Item 1) [Figure 10-
140-15] and verify fluid is at the opening. Reinstall case
drain line before operating.

Recycle or dispose of the fluid in an environmentally safe


manner.

Start the engine and operate the machine through the


hydraulic functions. Stop the engine. Check the fluid level
and add as needed.

Install new Bobcat hydraulic fluid. (See Hydraulic Fluid


Chart on Page 10-140-2.)

59 of 879 10-140-7 E80 Service Manual


HYDRAULIC SYSTEM (CONT’D)

Removing And Replacing Swing Motor Gear Box


Fluid

Figure 10-140-17

P-87254

The swing motor carrier drain plug is located below the

Dealer Copy -- Not for Resale


engine area by the hydraulic tank drain plug.

Remove the plug (Item 1) [Figure 10-140-17] and drain


the swing motor carrier. Reinstall the drain plug.

Remove the dipstick (Item 1) [Figure 10-140-16] and


add gear lube (SAE 80-90) until it is at the correct mark
on the dipstick.

60 of 879 10-140-8 E80 Service Manual


LUBRICATING THE EXCAVATOR Figure 10-150-2

Lubrication Locations

Lubricate the excavator as specified in the Chart for the


best performance of the machine. (See Chart on Page
10-80-1.)
4
Record the operating hours each time you lubricate the
excavator.

Always use a good quality lithium based multipurpose


grease when lubricating the machine. Apply the lubricant
until extra grease shows.

Figure 10-150-1 P-86309

1 4. Boom Cylinder Rod End (1) [Figure 10-150-2]

Figure 10-150-3
3 3

Dealer Copy -- Not for Resale


5

2
5
P-86313

6
Ref Description (# of Fittings)

1. Blade Cylinder Rod End (1) P-86310

2. Blade Cylinder Base End (1)


5. Boom Swing Pin (2)
3. Blade Pivots (2) [Figure 10-150-1]
6. Boom Swing Cylinder Base End (1) [Figure 10-150-
3]

61 of 879 10-150-1 E80 Service Manual


LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-150-6

Lubrication Locations (Cont’d)

Figure 10-150-4

7 9

P-86308

9. Arm Cylinder Base End (1) [Figure 10-150-6]


P-86311
Figure 10-150-7

7. Boom Pivot (1) [Figure 10-150-4]

Dealer Copy -- Not for Resale


Figure 10-150-5

10

8 P-86307

10. Arm Pivot (1) [Figure 10-150-7]


P-87302A

8. Boom Cylinder Rod End (1) [Figure 10-150-5]

62 of 879 10-150-2 E80 Service Manual


LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-150-10

Lubrication Locations (Cont’d)

Figure 10-150-8

15
11

16 15

P-86304
12

15. Link Pivot Pin (2)


P-86306
16. Arm (1) [Figure 10-150-10]

11. Arm Cylinder Rod End (1) Figure 10-150-11

Dealer Copy -- Not for Resale


12. Bucket Cylinder Base End (1) [Figure 10-150-8]
19 18
Figure 10-150-9 20
17

13

14
P-86905

Lubricate the following locations on the hydraulic


P-86305 Excavator per the SERVICE SCHEDULE for the correct
lubrication intervals. (See SERVICE SCHEDULE on
Page 10-80-1.)
13. Bucket Cylinder Rod End (1)
17. Boom Swing Cylinder Base End (1)
14. Bucket Link (1) [Figure 10-150-9]
18. Swing Motor Reduction Gear (1)

19. Slew Circle Bearing (1)

20. Slew Pinion (1). (Install 3 to 4 pumps of grease then


rotate the upperstructure 90°. Install 3 to 4 pumps of
grease and again rotate the upperstructure 90°.
Repeat this until the slew pinion has been greased at
four positions.) [Figure 10-150-11].

63 of 879 10-150-3 E80 Service Manual


LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-150-13

Lubrication Locations (Cont’d)

Articulated Boom (Optional)

Figure 10-150-12

21
25

S37512
22
23
25. Articulated Boom Pivot (1) [Figure 10-150-13].

24
S37506

Dealer Copy -- Not for Resale


21. Articulated Boom Cylinders Base End (2).

22. Articulated Boom Cylinders Base End Pivot (1).

23. Articulated Boom Cylinders Rod End (2).

24. Articulated Boom Cylinders Rod End Pivot (1).


[Figure 10-150-12]

64 of 879 10-150-4 E80 Service Manual


PIVOT PINS

Inspection And Maintenance

Figure 10-160-1

1
1

P-86923

The boom, arm and bucket cylinder pivots have a large


pivot pin (Item 1) [Figure 10-160-1] held in position with

Dealer Copy -- Not for Resale


a bolt and nut.

Check that the bolt and nut are securely tightened and
are not damaged.

65 of 879 10-160-1 E80 Service Manual


Dealer Copy -- Not for Resale

66 of 879 10-160-2 E80 Service Manual


TRAVEL MOTOR Removing And Replacing Oil

Checking And Adding Oil For the correct service interval. (See Chart on Page 10-
80-1.)
Figure 10-170-1
Park the excavator on a level surface with plugs (Item 1,
2 and 3) in the position shown. Remove plugs (Item 2
and 3) [Figure 10-170-1] and drain the lubricant into a
container.
2

WARNING
3 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
P-86327
explosion or fire.
W-2103-0508

Park the excavator on a level surface with the plugs (Item


1, 2 and 3) [Figure 10-170-1] in the position as shown. Install the bottom plug (Item 3). Add lubricant (80W-90)

Dealer Copy -- Not for Resale


through the top plug (Item 2) until the lube level is at the
Remove the plug (Item 1) [Figure 10-170-1]. The lube bottom edge of the plug hole (Item 1) [Figure 10-170-1].
level must be at the bottom edge of the hole.
Install the plugs (Item 1 and 2) [Figure 10-170-1].
Add lubricant (80W-90) through hole (Item 2) [Figure 10-
170-1] if the lube level is low. Repeat the procedure for the opposite travel motor.

67 of 879 10-170-1 E80 Service Manual


Dealer Copy -- Not for Resale

68 of 879 10-170-2 E80 Service Manual


SPARK ARRESTER MUFFLER Figure 10-180-1

Cleaning Procedure

See the Chart for the correct service interval. (See


SERVICE SCHEDULE on Page 10-80-1.)

WARNING
1
AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
P-91994
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
Remove the plug (Item 1) [Figure 10-180-1] from the
bottom of the muffler.

Start the engine and let it run for about 10 seconds while
a second person, wearing safety glasses, holds a piece
WARNING of wood over the outlet of the muffler. The carbon

Dealer Copy -- Not for Resale


deposits will be forced out of the muffler plug hole.
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles. Stop the engine. Install and tighten the plug.
Failure to obey can cause serious injury.
W-2011-1285 Close the right side cover.

WARNING
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285

WARNING
When the engine is running during service, the
steering levers must be in neutral.

Failure to do so can cause injury or death.


W-2203-0595

Do not operate the excavator with a defective exhaust


system.

Stop the engine. Open the tailgate.

69 of 879 10-180-1 E80 Service Manual


Dealer Copy -- Not for Resale

70 of 879 10-180-2 E80 Service Manual


EMERGENCY EXIT Figure 10-190-3

The door, the right side rear window and the front window
provide emergency exits.

Right Rear Side Window

Figure 10-190-1

P-86325
1

Exit through the right rear side window [Figure 10-190-


3].

Front Window
P-86217
Figure 10-190-4

Dealer Copy -- Not for Resale


If emergency exit requires breaking a window, use the
supplied hammer (Item 1) [Figure 10-190-1] located on
the left side of the operator cab.

Figure 10-190-2

P-86322

Open the front window and exit [Figure 10-190-4].

NOTE: If the excavator has a FOGS Kit installed, the


P-86218 front window is NOT an emergency exit.

Remove the hammer from the storage position and strike


the glass with the pointed end of the hammer [Figure 10-
190-2].

Use the hammer to remove broken glass from the edge


of the window before exiting.

71 of 879 10-190-1 E80 Service Manual


Dealer Copy -- Not for Resale

72 of 879 10-190-2 E80 Service Manual


SEAT BELT Figure 10-200-1

Inspection And Maintenance

WARNING
Failure to properly inspect and maintain the seat belt
can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703

Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly yearly, or more


often if the machine is exposed to severe environmental
conditions or applications.

The seat belt system should be repaired or replaced if it


shows cuts, fraying, extreme or unusual wear, significant
discolorations due to ultraviolet (UV) rays from the sun,
dusty/dirty conditions, abrasion to the seat belt webbing,

Dealer Copy -- Not for Resale


or damage to the buckle, latch plate, retractor (if
equipped), or hardware.

B-22283

The items below are referenced in [Figure 10-200-1].

1. Check the webbing. If the system is equipped with a


retractor, pull the webbing completely out and inspect
the full length of the webbing. Look for cuts, wear,
fraying, dirt and stiffness.

2. Check the buckle and latch for correct operation.


Make sure that the latch plate is not excessively worn
or deformed, that the buckle is not damaged and that
the casing is not broken.

3. Check the retractor web storage device (if equipped)


by extending the webbing to determine if it looks
correct and that it spools out and retracts the webbing
correctly.

4. Check webbing in areas exposed to ultraviolet (UV)


rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have deteriorated.

See your Bobcat dealer for approved seat belt system


replacement parts for your machine.

73 of 879 10-200-1 E80 Service Manual


Dealer Copy -- Not for Resale

74 of 879 10-200-2 E80 Service Manual


CAB TILT PROCEDURE Figure 10-210-3

Tilting The Cab


1
Figure 10-210-1 1

1 2
4 3

P-86920

Remove the bolts (Item 1) and cover (Item 2). Remove


P-87898 the bolt (Item 3), loosen the bolt (Item 4) and pivot the
cover (Item 5) [Figure 10-210-3].

Remove the nut (Item 1) [Figure 10-210-1] and washer Figure 10-210-4
from the right rear cab mount.

Dealer Copy -- Not for Resale


Figure 10-210-2

1
2
1

P-87893

P103402 Install a 27 mm socket and ratchet (Item 1) [Figure 10-


210-4] on the tilt assembly. Raise the cab.

Remove the nut (Item 1) [Figure 10-210-2] and washer NOTE: Do not use an impact wrench to raise / lower
from the left rear cab mount. the cab. Damage to the tilt assembly will
result.
For S/N AETB11235 & Above and AET311001 & Above
remove the bolt (Item 2) [Figure 10-210-2] and washer
from the left rear cab mount using a 36 mm socket.

Installation: Tighten the bolt to 931 N•m (688 ft-lb)


torque.

75 of 879 10-210-1 E80 Service Manual


CAB TILT PROCEDURE (CONT’D)

Tilting The Cab (Cont’d)

Figure 10-210-5

P-87896

Remove the bolt (Item 1) [Figure 10-210-5] from the cab


support.

Dealer Copy -- Not for Resale


Figure 10-210-6

P-87895

Lower the cab support (Item 1) [Figure 10-210-6] onto


the mount, and lower the cab until the weight of the cab is
resting on the support.

WARNING
AVOID INJURY OR DEATH
Never work under the excavator cab without
installing an approved cab support device.
W-2435-0502

76 of 879 10-210-2 E80 Service Manual


CONTROL CONSOLE LOCKOUTS

Inspection And Maintenance

Figure 10-220-1

P-86321

When the left console is raised [Figure 10-220-1] the


hydraulic control levers (joysticks and traction system)

Dealer Copy -- Not for Resale


must not function.

Sit in the operator's seat, fasten the seat belt and start
the engine.

Raise the left console.

Move the joystick control levers. There should be no


movement of the boom, arm, slew or bucket.

Move the travel control levers. There should be no


movement of the excavator.

Service the system if these controls do not deactivate


when the left control console is raised.

77 of 879 10-220-1 E80 Service Manual


Dealer Copy -- Not for Resale

78 of 879 10-220-2 E80 Service Manual


TOWING THE EXCAVATOR

Procedure

There is not a recommended towing procedure for the


excavators.

• The excavator can be lifted onto the transport vehicle.

• The excavator can be skidded a short distance for


service (EXAMPLE: Move onto a transport vehicle)
without damage to the hydraulic system. (The tracks
will not turn.) There might be slight wear to the tracks
when the excavator is skidded.

• The towing chain (or cable) must be rated at 1.5 times


the weight of the excavator. (See Performance on
Page SPEC-10-6.)

Dealer Copy -- Not for Resale

79 of 879 10-230-1 E80 Service Manual


Dealer Copy -- Not for Resale

80 of 879 10-230-2 E80 Service Manual


HYDRAULIC SYSTEM

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1


Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Troubleshooting The Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Swing (Slew) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-9

CYLINDER (BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-16

CYLINDER (ARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6

Dealer Copy -- Not for Resale


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-15

CYLINDER (BOOM SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-13

CYLINDER (BUCKET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-14

CYLINDER (BLADE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-14

81 of 879 20-01 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-12

VALVES (RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

VALVES (PORT RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1


Testing And Adjusting The Port Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

VALVE (PILOT PRESSURE RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1


Testing And Adjusting The Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4

Dealer Copy -- Not for Resale


Inlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Boom, Arm And Bucket Valve Section Disassembly And Assembly . . . . . . . . . . . . 20-40-12
Left Travel, Right Travel And Blade Valve Section Disassembly And Assembly . . 20-40-16
Auxiliary And Slew Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . 20-40-20
Boom Swing Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-40-24
Articulated Boom Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . 20-40-27

PUMP (HYDRAULIC PISTON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1


Hydraulic Pump Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-14
Torque Limiter Valve Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-16
Torque Limiter Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17
Torque Limiter Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-18
Torque Limiter Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-22
Initial Torque Limiter Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-26
Pump Control Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-28
Pump Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-29
Pump Control Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-30
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-35
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-36
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-44

PUMP (GEAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-1


Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-1
Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-5

82 of 879 20-02 E80 Service Manual


MANIFOLD ASSEMBLY / ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Parts Identification Gear Reduction Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-18

SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-6

SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3

Dealer Copy -- Not for Resale


Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4

SWING MOTOR (DRIVE CARRIER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-3

CONTROL PATTERN SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-5

RIGHT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-2
Joystick Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-5
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-6

LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Joystick Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-5
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-6

83 of 879 20-03 E80 Service Manual


BLADE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-3

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

DIRECT TO TANK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2

AUXILIARY BREAKER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-3

Dealer Copy -- Not for Resale


BOOM SWING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-3

AUXILIARY HYDRAULIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-3

ARTICULATED BOOM VALVE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-3

TRAVEL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-4

AUTO IDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1


Testing And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-2

84 of 879 20-04 E80 Service Manual


HYDRAULIC/HYDROSTATIC SCHEMATIC
E80 (S/N AETB11001 AND ABOVE)
Printable Version Click Here

(PRINTED AUGUST 2010)


V-1315NAlegend

LEGEND
1 HYDRAULIC RESERVOIR (PRESSURIZED) 17 PORT RELIEF / ANTI-CAVITATION VALVE – (2) 32 RELIEF VALVE – Slew Motor Brake 48 MINIMUM PUMP DISPLACEMENT
Reservoir Volume – (87 L) 23 Gal. (2nd Auxiliary – If Equipped) - (On Stroke Piston)
Oil Volume – (127 L) 35.5 Gal. (250 bar) 3626 PSI 33 SHUTTLE VALVE (Motion Alarm – If
Equipped)
2 18 3rd AUXILIARY QUICK COUPLERS – 49 TORQUE LIMITER (280 bar) 4061 PSI
MAIN FILTER - 10 MICRON
With (2,5 bar) 36 PSI By-Pass Valve Male / Female (If Equipped) 34 SHUTTLE VALVE (Slew Motor Brake Valve)
50 SHUTTLE VALVE – Auxiliary Hydraulic
3 19 MANUAL DIRECTIONAL CONTROL 35 SOLENOID ACTIVATED DIRECTIONAL
SUCTION FILTER - 150 MICRON
VALVE (Bucket Cylinder – 3rd Auxiliary CONTROL VALVE (2) (2nd Auxiliary) 51 BREATHER FILTER
Couplers) – (If Equipped)
4 CHECK VALVE - (2.5 bar) 36 PSI 36 ACCUMULATOR 52 PRESSURE SWITCH – Auto Idle
20 PILOT ACTIVATED DIRECTIONAL Nitrogen (10.2 bar) 148 PSI Precharged Activation – (24,8 bar) 360 PSI
CHECK VALVE - (3 bar) 44 PSI CONTROL VALVE (Load Holding valve) –
5
SOLENOID ACTIVATED DIRECTIONAL De-activation – (20 bar) 290 PSI
Boom 37
6 CONTROL VALVE (Two Speed) 53 PRESSURE REDUCING VALVE:
OIL COOLER 21 RELIEF VALVE - (Load Holding valve) –
Boom SOLENOID ACTIVATED DIRECTIONAL
38 Auto Idle Switch – (30 bar) 435 PSI
7 LOAD CHECK Dealer Copy -- NotCONTROL VALVE (Breaker)
for Resale PILOT ACTIVATED DIRECTIONAL
22 54
CHECK VALVE With Restriction - (Load 39
BACK-UP RELIEF VALVE: SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (Load Holding valve) –
8 Holding valve) – Boom
(340 bar) 4931 PSI CONTROL VALVE - (Console Lockout / Pilot Arm
23 LOCK VALVES – BLADE CYLINDER (2) Cut off)
9 FLUSHING VALVE: (25 bar) 362 PSI 55 RELIEF VALVE - (Load Holding valve) –
(If Equipped) 40 FILTER - Pilot Pressure Arm
10 LOAD SENSE BLEED VALVE 24 AUXILIARY QUICK COUPLERS – Male / Female
41 PRESSURE REDUCING VALVE - 56 CHECK VALVE With Restriction - (Load
11 LOAD SENSE RELIEF VALVE: 25 BRAKE RELEASE VALVE – Travel Motor (32 bar) 464 PSI Holding valve) – Arm
(280 bar) 4060 PSI (6,3 bar) 91 PSI 42 CHECK VALVE (0,5 bar) 7.25 PSI 57 2nd AUXILIARY QUICK COUPLERS –
12 PORT RELIEF / ANTI-CAVITATION VALVE 26 TWO SPEED SHIFT SPOOL – Travel Motor Male / Female (If Equipped)
(2) - (Boom Cylinder) - (310 bar) 4496 PSI 43 HYDRAULIC GEAR PUMP
27 CROSS PORT RELIEF VALVE (22 L/min.) 5.8 GPM at High Idle 58 HOSE - Accumulator (Used for vibration
13 PORT RELIEF / ANTI-CAVITATION VALVE and sound reduction)
(Travel Motor) (280 bar) 4061 PSI
(2) - (Bucket Cylinder) - (310 bar) 4496 PSI 44 HYDRAULIC PISTON PUMP
28 COUNTERBALANCE SPOOL (Travel Motor) (144 L/min.) 38 GPM at High Idle
14 PORT RELIEF / ANTI-CAVITATION VALVE
(2) - (Arm Cylinder) - (310 bar) 4496 PSI 45 TORQUE LIMITER SUPPLY SPOOL
29 BRAKE RELEASE VALVE - Slew Motor
(20 bar) 290 PSI
15 PORT RELIEF / ANTI-CAVITATION VALVE - (19 bar) 276 PSI
(Auxiliary – Two Way - Breaker) - 46 DESTROKE PISTON
30 CROSS PORT RELIEF VALVE - Slew Motor
(310 bar) 4496 PSI
(220 bar) 3190 PSI
47 PUMP MARGIN SPOOL (15 bar) 218 PSI
16 ANTI-CAVITATION VALVE- Boom Swing (2) 31 ANTI-CAVITATION VALVE – Slew Motor
NOTE: Unless otherwise specified
springs have NO significant
pressure value.

Printed in U.S.A. V-1315legend (7-29-10)


85 of 879
LEFT TRAVEL MOTOR RIGHT TRAVEL MOTOR
HYDRAULIC/HYDROSTATIC SCHEMATIC
E80 (S/N AETB11001 AND ABOVE) 26 26
D1 D2 D1
P2 P3 P2 P3
(PRINTED AUGUST 2010) 25 25
V-1315 P P

Printable Version Click Here 29

27 27
SH S1
28 28 PG

23 P1 P2 P2 P1 30
Dr
23 REVERSE FORWARD REVERSE FORWARD 32
C2

18 M 55 30
C2
E
M
21
E 54
Mu
T V2
56 MALE FEMALE B A
T V2
20 22 Pa3 (LEFT)
31
(RIGHT)
Pb1
19
SWIVEL 24
58 57
JOINT A D A SWIVEL F T P B E
C
B P JOINT

LS M pb1 pb2 pb3 pb4 pb5 pb6 pb7 pb8 P2 pb9 pb10

BUCKET

7 7 7 7 7 7 7 7
7 7
B

2 UP P T DOWN 1

Pa4 Pb4
11
8 9 10

T B A T T B A T T B A T T B A T T B A T T B A T

BOOM SWING VALVE


16
12 13 14 15 17

T1 pa1 pa2 pa3 pa4 pa5 pa6 pa7 pa8 pa9 pa10
58

2 LEFT P T RIGHT 1

Pa8 Pb8

AUTO IDLE 52
SWITCH PW
5 53
T

P
PRESSURE Dealer Copy -- Not for Resale
REDUCING VALVE

P-T BLOCK (1)


4

2nd AUXILIARY
HYDRAULIC VALVE
Pb10
51 AUXILIARY pb5
HYDRAULICS R1 Pi1 R2 Pi2 R2 Pi2
Pa10
VALVE A B
45 T
2

50
1 P T 2
47
X Pa5 1 SWING 3 2 ARM 4 1 BUCKET 3 2 BOOM 4 1
LEFT
2 3
RIGHT
4 P1
TRAVEL TRAVEL
49 LEFT RIGHT OUT RETRACT UP REVERSE REVERSE
IN DOWN 35
B1 EXTEND FORWARD FORWARD
40
Pb2 Pa2
46 B2 37 38 39 C1
33
D1 A1
33
B1
1
P 33

A3 A2 A1
HYDRAULIC 43 MOTION ALARM
3 Dr1 8 7 6 5 VALVE
RESERVOIR 44
Dr2 (IF EQUIPPED)
C2 D2 E A2 B2

4 3 2 1 Pb6 Pa6 Pb7 Pa7

T1
Pb9 Pa9
Pb3 Pa3
41 42 34
HYDRAULIC S1 L1 L S2
48 Pa1 Pb1
PUMP B1 A1 MOTION ALARM
T PV PRESSURE SWITCH
SLEW MOTOR (IF EQUIPPED)
BRAKE VALVE
36
B2 S1 A2

86 of 879
Printed in U.S.A. ACCUMULATOR V-1315NA (7-29-10)
HYDRAULIC/HYDROSTATIC SCHEMATIC
E80 (S/N AET311001 AND ABOVE)
Printable Version Click Here

(PRINTED AUGUST 2010)


V-1315EMEAlegend

LEGEND
1 HYDRAULIC RESERVOIR (PRESSURIZED) 17 PORT RELIEF / ANTI-CAVITATION VALVE – (2) 32 RELIEF VALVE – Slew Motor Brake 48 MINIMUM PUMP DISPLACEMENT
Reservoir Volume – (87 L) 23 Gal. (2nd Auxiliary – If Equipped) - (On Stroke Piston)
Oil Volume – (127 L) 35.5 Gal. (250 bar) 3626 PSI 33 SHUTTLE VALVE (Motion Alarm – If
Equipped)
2 18 3rd AUXILIARY QUICK COUPLERS – 49 TORQUE LIMITER (280 bar) 4061 PSI
MAIN FILTER - 10 MICRON
With (2,5 bar) 36 PSI By-Pass Valve Male / Female (If Equipped) 34 SHUTTLE VALVE (Slew Motor Brake Valve)
50 SHUTTLE VALVE – Auxiliary Hydraulic
3 19 MANUAL DIRECTIONAL CONTROL 35 SOLENOID ACTIVATED DIRECTIONAL
SUCTION FILTER - 150 MICRON
VALVE (Bucket Cylinder – 3rd Auxiliary CONTROL VALVE (2) (2nd Auxiliary) 51 BREATHER FILTER
Couplers) – (If Equipped)
4 CHECK VALVE - (2.5 bar) 36 PSI 36 ACCUMULATOR 52 PRESSURE SWITCH – Auto Idle
20 PILOT ACTIVATED DIRECTIONAL Nitrogen (10.2 bar) 148 PSI Precharged Activation – (24,8 bar) 360 PSI
CHECK VALVE - (3 bar) 44 PSI CONTROL VALVE (Load Holding valve) –
5
SOLENOID ACTIVATED DIRECTIONAL De-activation – (20 bar) 290 PSI
Boom 37
6 CONTROL VALVE (Two Speed) 53 PRESSURE REDUCING VALVE:
OIL COOLER 21 RELIEF VALVE - (Load Holding valve) –
Boom SOLENOID ACTIVATED DIRECTIONAL
38 Auto Idle Switch – (30 bar) 435 PSI
7 LOAD CHECK Dealer Copy -- NotCONTROL VALVE (Breaker)
for Resale PILOT ACTIVATED DIRECTIONAL
22 54
CHECK VALVE With Restriction - (Load 39
BACK-UP RELIEF VALVE: SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (Load Holding valve) –
8 Holding valve) – Boom
(340 bar) 4931 PSI CONTROL VALVE - (Console Lockout / Pilot Arm
23 LOCK VALVES – BLADE CYLINDER (2) Cut off)
9 FLUSHING VALVE: (25 bar) 362 PSI 55 RELIEF VALVE - (Load Holding valve) –
(If Equipped) 40 FILTER - Pilot Pressure Arm
10 LOAD SENSE BLEED VALVE 24 AUXILIARY QUICK COUPLERS – Male / Female
41 PRESSURE REDUCING VALVE - 56 CHECK VALVE With Restriction - (Load
11 LOAD SENSE RELIEF VALVE: 25 BRAKE RELEASE VALVE – Travel Motor (32 bar) 464 PSI Holding valve) – Arm
(280 bar) 4060 PSI (6,3 bar) 91 PSI 42 CHECK VALVE (0,5 bar) 7.25 PSI 57 2nd AUXILIARY QUICK COUPLERS –
12 PORT RELIEF / ANTI-CAVITATION VALVE 26 TWO SPEED SHIFT SPOOL – Travel Motor Male / Female (If Equipped)
(2) - (Boom Cylinder) - (310 bar) 4496 PSI 43 HYDRAULIC GEAR PUMP
27 CROSS PORT RELIEF VALVE (22 L/min.) 5.8 GPM at High Idle 58 HOSE - Accumulator (Used for vibration
13 PORT RELIEF / ANTI-CAVITATION VALVE and sound reduction)
(Travel Motor) (280 bar) 4061 PSI
(2) - (Bucket Cylinder) - (310 bar) 4496 PSI 44 HYDRAULIC PISTON PUMP
(144 L/min.) 38 GPM at High Idle 59 PORT RELIEF / ANTI-CAVITATION VALVE
28 COUNTERBALANCE SPOOL (Travel Motor) (2) - (Articulated Boom Cylinder - Option) -
14 PORT RELIEF / ANTI-CAVITATION VALVE
(2) - (Arm Cylinder) - (310 bar) 4496 PSI 45 TORQUE LIMITER SUPPLY SPOOL (310 bar) 4496 PSI
29 BRAKE RELEASE VALVE - Slew Motor
(20 bar) 290 PSI
15 PORT RELIEF / ANTI-CAVITATION VALVE - (19 bar) 276 PSI
(Auxiliary – Two Way - Breaker) - 46 DESTROKE PISTON
30 CROSS PORT RELIEF VALVE - Slew Motor
(310 bar) 4496 PSI
(220 bar) 3190 PSI
47 PUMP MARGIN SPOOL (15 bar) 218 PSI
16 ANTI-CAVITATION VALVE- Boom Swing (2) 31 ANTI-CAVITATION VALVE – Slew Motor
NOTE: Unless otherwise specified
springs have NO significant
pressure value.

Printed in Europe V-1315legend (7-29-10)


87 of 879
HYDRAULIC/HYDROSTATIC SCHEMATIC
E80 (S/N AET311001 AND ABOVE) 26 26
D1 D2 D1
P2 P3 P2 P3
(PRINTED AUGUST 2010) 25 25
V-1315EMEA P P 29

Printable Version Click Here SH S1


PG

27 27
28 28
30
Dr 32

30
23 P1 P2 P2 P1
23 REVERSE FORWARD REVERSE FORWARD
C2

18 M Mu
C2 E 55
M A
21 31
(LEFT) (RIGHT)
E
C2 C2
54 T V2 M M
56 E E
MALE FEMALE
T V2 Pa3
20 22
V2 T V2 T
Pb1
19
SWIVEL 24 pb10

A SWIVEL
58
JOINT A D F C T P B E
2 UP P T DOWN 1

B P JOINT Pa4 Pb4

57

BOOM SWING VALVE


LS M pb1 pb2 pb3 pb4 pb5 pb6 pb7 pb8 P2 pb9 pa10 pb11

BUCKET

7 7 7 7 7 7 7 7 7 2 LEFT P T RIGHT 1
7 7
B Pa8 Pb8

11
8 9 10

ARTICULATED
T B A T T B A T T B A T T B A T T B A T T T B A T BOOM VALVE
T B A
(OPTION)

16
12 13 14 15 17
59
T1 pa1 pa2 pa3 pa4 pa5 pa6 pa7 pa8 pa9 pb10 pa11
58

2 UP P T DOWN 1

Pa10 Pb10

AUTO IDLE 52
SWITCH PW
5 53
T

P
PRESSURE
REDUCING VALVE
Dealer Copy -- Not for Resale
6

P-T BLOCK (1)


4

2nd AUXILIARY
HYDRAULIC VALVE
Pb11
51 AUXILIARY pb5
HYDRAULICS R1 Pi1 R2 Pi2 R2 Pi2
Pa11
VALVE A B
45 T
2

50
1 P T 2
47
X Pa5 1 SWING 3 2 ARM 4 1 BUCKET 3 2 BOOM 4 1
LEFT
2 3
RIGHT
4 P1
TRAVEL TRAVEL
49 LEFT RIGHT OUT RETRACT REVERSE REVERSE
IN UP DOWN 35
B1 EXTEND FORWARD FORWARD
40
Pa3 Pb2 Pa2 Pa1
46 B2 37 38 39 Pb3 Pb1
C1
33
D1 A1
33
B1
1
P 33

A3 A2 A1
HYDRAULIC 43 MOTION ALARM
3 Dr1 VALVE
RESERVOIR 44
Dr2 (IF EQUIPPED)
C2 D2 E A2 B2

Pb6 Pa6 Pb7 Pa7

T1
Pb9 Pa9

41 42 34
HYDRAULIC S1 L1 L S2
48
PUMP B1 A1 MOTION ALARM
T PV PRESSURE SWITCH
SLEW MOTOR (IF EQUIPPED)
BRAKE VALVE
36
B2 S1 A2

88 of 879
Printed in Europe ACCUMULATOR V-1315EMEA (7-29-10)
HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols

Dealer Copy -- Not for Resale

MS-1892-1
MC 2340 (6-2-98)

89 of 879 20-10-1 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

Dealer Copy -- Not for Resale

MS-1892-2
MC 2340-2 (6-2-98)

90 of 879 20-10-2 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

Dealer Copy -- Not for Resale

MS-1892-3
MC 2340-3 (6-2-98)

91 of 879 20-10-3 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Hydraulic Circuit

PROBLEM CAUSE CORRECTION


No hydraulic operation at one or more Hydraulic oil level low. Refill with correct oil.
circuits. Hydraulic pump drive coupling Replace
damaged.
Hydraulic pump defective. Repair or replace.
Pump pressure too low. Readjust or replace.
Hydraulic power insufficient to one or Pump pressure setting incorrect. Readjust or replace.
more circuits.
All hydraulic speed too slow. Torque limiter supply spool set too low. Readjust.
Hydraulic oil level or viscosity incorrect. Fill to correct level. Use correct
viscosity oil.
Pump margin too low. Test and adjust.
Engine rpm reduced. Readjust or replace.
Torque limiter set too low/high. Test and adjust.
Hydraulic pump volume low. Check repair or replace.

Dealer Copy -- Not for Resale


Oil temperature too high. Oil cooler or radiator fins plugged. Clean oil cooler external surface.
Hydraulic oil level low. Fill to correct level.
Non recommended hydraulic oil. Replace.
One or more port relief valves not set Readjust or replace.
correctly.
Extreme operating conditions. High
ambient temperature. (IE: Enclosed
structure).
Fan belt loose. Tighten fan belt.
Piston pump margin too high.
Pump (Piston) response slow. Pump minimum displacement set too Readjust.
low.

92 of 879 20-10-4 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Cylinder Circuit

PROBLEM CAUSE CORRECTION


Cylinder inoperable. Pump torque limiter supply spool not Repair or replace.
shifting.
Control console raised. Lower control console.
Loose fittings or broken hoses. Repair or replace.
Low psi at joystick. Check, repair or replace pressure
reducing valve.
Control console lockout switch. Readjust or replace.
Cylinder internal leakage excessive. Repair or replace.
Joystick pressure reducing valve Repair or replace.
defective.
Joystick internal leakage excessive. Repair or replace.
Pump margin spool not shifting. Repair or replace.
Load sense relief valve set too low. Repair or replace.
Cylinder force insufficient. Lever linkage incorrectly adjusted. Readjust.

Dealer Copy -- Not for Resale


. Pump pressure too low. Readjust or replace.
Pump torque limiter too low. Readjust or replace.
Cylinder speed too slow. Engine rpm low. Check rpm or increase engine speed.
Cylinder internal leakage excessive. Repair or replace.
Joystick pressure reducing valve Repair or replace.
defective.
Control valve internal leakage Repair or replace.
excessive.
Joystick internal leakage excessive. Repair or replace.
Low or dirty fluid. Add or replace the hydraulic fluid.
Load sense relief valve malfunctioning. Readjust or replace.
Pump margin too low. Repair or replace.
Pump torque limiter too low. Readjust or replace.

93 of 879 20-10-5 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Swing (Slew) Circuit

PROBLEM CAUSE CORRECTION


Swing not operating. Swing brake not releasing. Repair or replace.
Lower control console. Lower control console.
Control console lockout switch Readjust or replace.
incorrectly adjusted or defective.
Swing motor gear defective. Repair or replace.
Joystick internal leakage excessive. Repair or replace.
Swing motor defective. Repair or replace.
Swing force. Pump pressure set too low. Readjust or replace.
Swing motor relief valve pressure too Readjust or replace.
low.
Swing speed too slow. Swing brake not releasing. Repair, replace or adjust.
Engine rpm low. Adjust.
Pump flow low. (Gear pump) Check, repair or adjust.
Blocked or restricted line to swing Replace.
motor.

Dealer Copy -- Not for Resale


Joystick internal leakage excessive. Repair or replace.
Control valve internal leakage Repair or replace.
excessive. (Three spool valve)
Swing motor internal leakage Repair or replace.
excessive.
Swing over run excessive. Control valve spool sticking. Repair or replace.
Joystick spool sticking. Repair or replace.
Swing motor relief valve set too low. Repair or replace.
Swing motor internal leakage Repair or replace.
excessive.
Swing motor seal leakage. Return line plugged. Inspect, clean or replace.

94 of 879 20-10-6 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Travel Circuit

PROBLEM CAUSE CORRECTION


Travel system inoperable. Pilot pressure too low. Repair or readjust.
Console switch not closed. Repair or replace.
Track tension too tight. Readjust.
Defective pump. (Piston pump) Check, repair or replace.
Travel motor counter balance spool Repair or replace.
sticking.
Travel motor internal leakage Repair or replace.
excessive.
Travel motor defective. Repair or replace.
Travel motor gears defective. Repair or replace.
Swivel joint defective. Repair or replace.
Pump pressure too low. Readjust.
Travel power. Track tension too tight. Readjust.
Travel motor check valve leaking. Readjust or replace.

Dealer Copy -- Not for Resale


Pump pressure too low. Readjust.
Torque limiter too low. Readjust.
Swivel joint leaking. Repair or replace.
Travel motor counterbalance spool Repair or replace.
sticking.
Travel speed too slow. Engine rpm low. Readjust.
Pilot pressure low. Readjust.
Pump margin too low. Readjust.
Swivel joint internal leakage excessive. Repair or replace.
Control valve internal leakage Repair or replace.
excessive.
Low pump pressure. Check, repair or replace.
Travel motor internal leakage Repair or replace.
excessive.
Travel motor seal leakage. Case drain line plugged. Inspect, clean or replace.

95 of 879 20-10-7 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Travel Circuit (Cont’d)

PROBLEM CAUSE CORRECTION


Machine not running straight. Track tension not equal. Readjust.
Travel motor internal leakage not equal. Repair or replace.
Travel motor counter balance spool Repair or replace.
sticking.
Pump pressure set too low. Repair or replace.
Swivel joint internal leakage excessive. Repair or replace.
Control valve internal leakage not Repair or replace.
equal.
Machine will not hold on slope or while Valve compensators not equal. Repair or replace.
digging. Travel motor counterbalance valve Repair or replace.
leakage excessive.
Blade drops while machine is moving. Cylinder internal leakage excessive. Repair or replace.
Control valve internal leakage Repair or replace.
excessive.
Swivel joint internal leakage from travel Repair or replace.

Dealer Copy -- Not for Resale


motor pressure circuit into blade
cylinder circuit.
High / low gear switch inoperative Control valve defective. Replace.
(2-speed). Torque limiter set too low. Readjust.
Pump pressure set too low. Readjust.
Switch defective. Replace.
Faulty pressure reducing valve. Repair or replace.
Bad solenoid. Replace.

96 of 879 20-10-8 E80 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D) Figure 20-10-1

Description

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,


clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-86566
The hydraulic system has two separate hydraulic circuits.

The piston pump circuit supplies fluid to the hydraulic Figure 20-10-2
control valve.

The hydraulic control valve contains the boom, bucket,


arm, blade, auxiliary, left and right travel, boom swing
and upperstructure swing valve sections.

Dealer Copy -- Not for Resale


1

P-86558

A load sense relief valve (Item 1) [Figure 20-10-1] and


safety relief valve (Item 1) [Figure 20-10-2] protect the
valve from high pressure.

The gear pump circuit supplies fluid to the manifold


assembly / accumulator.

97 of 879 20-10-9 E80 Service Manual


Dealer Copy -- Not for Resale

98 of 879 20-10-10 E80 Service Manual


CYLINDER (BOOM) Figure 20-20-3

Testing

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.

Remove one articulated boom cylinder. (See Removal


And Installation on Page 20-25-3.) (Optional)
1
Figure 20-20-1

P-86898

Figure 20-20-4

1 Articulated Boom

Dealer Copy -- Not for Resale


P-87019

1
Figure 20-20-2
Articulated Boom
1 S37540

Install a sling (Item 1) [Figure 20-20-3] or [Figure 20-20-


4] and a lifting device to the rod end of the boom cylinder.

S37539

Support the boom with a chain hoist (Item 1) [Figure 20-


20-1] or [Figure 20-20-2].

99 of 879 20-20-1 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-7

Testing (Cont’d)

Figure 20-20-5

2 1

2
P-87000

Lower the cylinder (Item 1) [Figure 20-20-7].


P-86897
Start the engine and fully retract the cylinder rod (Item 2)
[Figure 20-20-7].
Figure 20-20-6
Articulated Boom Stop the engine. Relieve hydraulic pressure.

Dealer Copy -- Not for Resale


2
3
WARNING
1 Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
S37541

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


20-5] or [Figure 20-20-6].

Remove the rod end pivot pin (Item 3) [Figure 20-20-5]


or [Figure 20-20-6].

100 of 879 20-20-2 E80 Service Manual


CYLINDER (BOOM) (CONT’D)

Testing (Cont’d)

Figure 20-20-8

P-86896

Remove the hose from the base end of the cylinder. Cap
the hose (Item 1) [Figure 20-20-8].

Dealer Copy -- Not for Resale


Start the engine and retract the boom cylinder.

If there is any oil leakage from the base end fitting (Item
1) [Figure 20-20-8], remove the cylinder for repair or
replacement.

101 of 879 20-20-3 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-11

Removal And Installation

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.

Remove one articulated boom cylinder. (See Removal


And Installation on Page 20-25-3.) (Optional)
1
Figure 20-20-9

P-86898

Figure 20-20-12
Articulated Boom
1

Dealer Copy -- Not for Resale


P-87019

Figure 20-20-10 1

Articulated Boom
S37540

1
Install a sling (Item 1) [Figure 20-20-11] or [Figure 20-
20-12] and a lifting device to the rod end of the boom
cylinder.

S37539

Support the boom with a chain hoist (Item 1) [Figure 20-


20-9] or [Figure 20-20-10].

102 of 879 20-20-4 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-15

Removal And Installation (Cont’d)


2
Figure 20-20-13
3

1
P-86839

Figure 20-20-16
P-86896
Articulated Boom

Figure 20-20-14 2
3

Dealer Copy -- Not for Resale


1 1

S37541

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


P-86897 20-15] or [Figure 20-20-16].

Remove the rod end pivot pin (Item 3) [Figure 20-20-15]


Remove the hoses (Item 1) [Figure 20-20-13] and or [Figure 20-20-16].
[Figure 20-20-14].

103 of 879 20-20-5 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-19

Removal And Installation (Cont’d)

Figure 20-20-17
2

1
1

P-87926

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


P-87000 20-19].

Remove the base end pivot pin (Item 3) [Figure 20-20-


Lower the cylinder (Item 1) [Figure 20-20-17] until it rests 19].
on the blade.

Dealer Copy -- Not for Resale


Figure 20-20-20

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,


clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-20-18

P-87008

Remove the cylinder (Item 1) [Figure 20-20-20].

P-87001

Remove the shims (Item 1) [Figure 20-20-18] from both


sides.

104 of 879 20-20-6 E80 Service Manual


CYLINDER (BOOM) (CONT’D)

Parts Identification

1. Bolt 1
2. Washer 2
3. O-ring 4
4. Tubeline 5
5. Seal 3
6
6. U-bolt
8
7. Nut
8. Grease Fitting
9. Bushing 7 1 20
10. Set Screw 2
11. Piston 9
12. Back-up Ring 4 2
13. Wear Ring 5
14. Seal Assembly
15. Cushion Ring
16. Snap Ring 1 6 2
17. Head 7
18. Wiper Seal 2
19. Rod
10

Dealer Copy -- Not for Resale


20. Housing 11
3
3
13
13

15
7
3
12

1 5
14
5

12
16
9

17
5
5
18
16 8
19

5 MS-2790S

105 of 879 20-20-7 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-23

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook


1
Hold the hydraulic cylinder over a drain pan and slowly
move the rod in and out to remove the fluid from the
cylinder.

Figure 20-20-21

P-87090

Remove the O-ring (Item 1) [Figure 20-20-23] from the


tubeline.
1
Figure 20-20-24

Dealer Copy -- Not for Resale


P-87085

Remove the two nuts (Item 1) [Figure 20-20-21], lock


washers and U-bolt. 1

Figure 20-20-22

P-87087
2

Remove the two nuts (Item 1) [Figure 20-20-24], lock


1 washers and U-bolt.

P-87086

Remove the four bolts (Item 1) and the tubeline (Item 2)


[Figure 20-20-22].

106 of 879 20-20-8 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-27

Disassembly (Cont’d)

Figure 20-20-25

1 1
P-86848

Support the cylinder with a block (Item 1) [Figure 20-20-


P-87088 27].

Figure 20-20-28
Remove the four bolts (Item 1), lock washers and
tubeline (Item 2) [Figure 20-20-25].
1

Dealer Copy -- Not for Resale


Figure 20-20-26

1
P-86849

Remove the eight bolts (Item 1) [Figure 20-20-28].


P-87089

Remove the O-ring (Item 1) [Figure 20-20-26] from the


tubeline.

Clamp the base end of the cylinder in a vise.

Be careful not to damage the cylinder housing.

107 of 879 20-20-9 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-31

Disassembly (Cont’d)

Figure 20-20-29

P-86850

Remove the set screw (Item 1) [Figure 20-20-31].


P-87077
Figure 20-20-32

Remove the rod assembly (Item 1) [Figure 20-20-29]


from the cylinder housing.

Dealer Copy -- Not for Resale


1
Remove the cylinder housing from the vise.

Figure 20-20-30

P-86851

Apply moderate heat to the nut (Item 1) [Figure 20-20-


32].

Remove the nut.


P-86852

Clamp the rod end (Item 1) in a vise [Figure 20-20-30].

108 of 879 20-20-10 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-35

Disassembly (Cont’d)
1
Figure 20-20-33

P-87032

Remove the wear ring (Item 1) [Figure 20-20-35] from


P-86853 the piston.

Figure 20-20-36
Remove the piston (Item 1) [Figure 20-20-33].
1

Dealer Copy -- Not for Resale


Figure 20-20-34

P-87031

P-86542 Remove the seal (Item 1) [Figure 20-20-36].

Remove the seal (Item 1) [Figure 20-20-34] from the


piston.

109 of 879 20-20-11 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-39

Disassembly (Cont’d)

Figure 20-20-37

P-87028

Remove the seal (Item 1) [Figure 20-20-39] from the


P-87030 piston.

Figure 20-20-40
Remove O-ring (Item 1) [Figure 20-20-37] from the
piston.

Dealer Copy -- Not for Resale


Figure 20-20-38 1

P-86862

Remove the O-ring (Item 1) [Figure 20-20-40] from the


P-87029 piston.

Remove the wear ring (Item 1) [Figure 20-20-38] from


the piston.

110 of 879 20-20-12 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-43

Disassembly (Cont’d)
1
Figure 20-20-41

P-86861

Remove the head (Item 1) [Figure 20-20-43] from the


P-87011 rod.

Figure 20-20-44
Remove the back-up ring (Item 1) [Figure 20-20-41]
from the piston.

Dealer Copy -- Not for Resale


Figure 20-20-42

1
1

P-86864

Remove the O-ring (Item 1) [Figure 20-20-44].


P-86860

Remove the cushion ring (Item 1) [Figure 20-20-42] from


the rod.

111 of 879 20-20-13 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-47

Disassembly (Cont’d)

Figure 20-20-45 1

P-86867

Remove the snap ring (Item 1) [Figure 20-20-47].

P-86865 Figure 20-20-48

Remove the back-up ring (Item 1) [Figure 20-20-45].


1

Dealer Copy -- Not for Resale


Figure 20-20-46

P-86868

Remove the wiper seal (Item 1) [Figure 20-20-48].

P-86866

Remove the O-ring (Item 1) [Figure 20-20-46].

112 of 879 20-20-14 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-51

Disassembly (Cont’d)
2
Figure 20-20-49
1

P-887014
1
Remove the seal (Item 1) (both sides) and bushing (Item
P-87754 2) [Figure 20-20-51] from the rod end.

Figure 20-20-52
Remove the two seals (Item 1) [Figure 20-20-49].

Dealer Copy -- Not for Resale


Figure 20-20-50

1
2

P-87015

P-86870 Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-20-52] from the base end.

Remove the snap ring (Item 1) and bushing (Item 2)


[Figure 20-20-50].

Remove the rod from the vise.

113 of 879 20-20-15 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-54

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander


MEL1033 - Rod Seal Installation Tool 2
1
MEL1369-2 - Piston Ring Compressor

Wash the cylinder parts in clean solvent and dry with


compressed air.

Inspect the cylinder parts for nicks, scratches and other


damage. Replace any damaged parts.
P-86870
Always install new O-rings and seals during assembly.

Lubricate all O-ring and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-20-54] into the head.

Clamp the rod end in a vise. Figure 20-20-55

Figure 20-20-53

Dealer Copy -- Not for Resale


1

P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-20-55] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-20-53].

114 of 879 20-20-16 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-58

Assembly (Cont’d)

Figure 20-20-56

P-86866

Install the O-ring (Item 1) [Figure 20-20-58] onto the


P-86868 head.

Figure 20-20-59
Install the wiper seal (Item 1) [Figure 20-20-56] into the
head.

Dealer Copy -- Not for Resale


Figure 20-20-57

P-86865

Install the back-up ring (Item 1) [Figure 20-20-59] onto


P-86867 the head.

Install the snap ring [Figure 20-20-57] into the head.

115 of 879 20-20-17 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-62

Assembly (Cont’d)

Figure 20-20-60 1

1
P86860

Install the cushion ring (Item 1) [Figure 20-20-62] onto


P-86864 the rod.

Figure 20-20-63
Install the O-ring (Item 1) [Figure 20-20-60].

Dealer Copy -- Not for Resale


Figure 20-20-61

P-87011

P-86861 Install the back-up ring (Item 1) [Figure 20-20-63] into


the piston.

Install the head (Item 1) [Figure 20-20-61] onto the rod.

116 of 879 20-20-18 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-66

Assembly (Cont’d)

Figure 20-20-64

1 P-87029

Install the wear ring (Item 1) [Figure 20-20-66] onto the


P-86862 piston.

Figure 20-20-67
Install the O-ring (Item 1) [Figure 20-20-64] into the
piston.

Dealer Copy -- Not for Resale


Figure 20-20-65

P-87030

Figure 20-20-68
P-87028

Install the seal (Item 1) [Figure 20-20-65] onto the


piston.

P-87031

Install the O-ring (Item 1) [Figure 20-20-67] and seal


(Item 2) [Figure 20-20-68] onto the piston.

117 of 879 20-20-19 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-71

Assembly (Cont’d)

Figure 20-20-69 2

1
P-86853

Install the piston (Item 1) [Figure 20-20-71] onto the rod.


P-87032
Figure 20-20-72

Install the wear ring (Item 1) [Figure 20-20-69] onto the


piston.

Dealer Copy -- Not for Resale


Figure 20-20-70
1

2
P-86851

Install the nut (Item 1) [Figure 20-20-72].

P-87033 Tighten the nut until the bore (Item 2) [Figure 20-20-72]
of the set screw is aligned with the groove (Item 2)
[Figure 20-20-71] of the rod.
Install the seal (Item 1) [Figure 20-20-70] onto the
piston.

118 of 879 20-20-20 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-75

Assembly (Cont’d)

Figure 20-20-73

1
P-87077

Install the rod assembly (Item 1) [Figure 20-20-75] into


P-86850 the cylinder housing.

Figure 20-20-76
Install the set screw (Item 1) [Figure 20-20-73] into the
nut. 1

Dealer Copy -- Not for Resale


Use a center punch to deform the threads of the set
screw bore.

Figure 20-20-74
1

1
P-86849

Install the head (Item 1) using the eight bolts (Item 2)


[Figure 20-20-76].

1 Tighten the bolts to 190 - 210 N•m (140 - 155 ft-lb)


P-87013 torque.

Remove the rod end from the vise.

Support the housing with a block (Item 1) [Figure 20-20-


74].

119 of 879 20-20-21 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-79

Assembly (Cont’d)

Figure 20-20-77

P-87087

Install the U-bolt, lock washers and nuts (Item 1) [Figure


P-87089 20-20-79].

Figure 20-20-80
Install the O-ring (Item 1) [Figure 20-20-77] into the
tubeline.

Dealer Copy -- Not for Resale


Figure 20-20-78

1
2

P-87090

2
Install the O-ring (Item 1) [Figure 20-20-80] into the
P-7088 tubeline.

Install the tubeline (Item 1), lock washers and bolts (Item
2) [Figure 20-20-78] onto the cylinder housing.

120 of 879 20-20-22 E80 Service Manual


CYLINDER (BOOM) (CONT’D) Figure 20-20-83

Assembly (Cont’d)
1
Figure 20-20-81 2

P-87014

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


P-87086 20-83] into both sides of the rod end of the cylinder.

Figure 20-20-84
Install the tubeline (Item 1) using the four bolts (Item 2)
[Figure 20-20-81] and lock washers.

Dealer Copy -- Not for Resale


Figure 20-20-82
1
2

P-36183

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


P-87085 20-84] into both sides of the base end of the cylinder.

Install the U-bolt, washers and nuts (Item 1) [Figure 20-


20-82].

121 of 879 20-20-23 E80 Service Manual


Dealer Copy -- Not for Resale

122 of 879 20-20-24 E80 Service Manual


CYLINDER (ARM) Figure 20-21-3

Testing 1

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.

Figure 20-21-1

P-87020
1

Support the arm cylinder (Item 1) [Figure 20-21-3].

Figure 20-21-4

Dealer Copy -- Not for Resale


1
P-87019

Figure 20-21-2
Articulated Boom

1 3

P-87076

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


21-4] from the rod end pivot pin.

Remove the rod end pivot pin (Item 3) [Figure 20-21-4].

S37544 Start the engine and fully retract the cylinder rod.

Support the boom with a chain hoist (Item 1) [Figure 20-


21-1] or [Figure 20-21-2].

123 of 879 20-21-1 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-7

Testing (Cont’d)

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290 P-86831

Figure 20-21-5 Install a plug (Item 1) [Figure 20-21-7] on the hose.

Start the engine and retract the cylinder.

1 If there is any leakage from the base end fitting, remove


the cylinder for repair or replacement.

Dealer Copy -- Not for Resale


P-86830

Figure 20-21-6
Articulated Boom

S37542

Remove the hose (Item 1) [Figure 20-21-5] or [Figure


20-21-6] from the base end of the cylinder.

124 of 879 20-21-2 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-10

Removal And Installation 1

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.

Figure 20-21-8

P-887020

1 Support the arm cylinder (Item 1) [Figure 20-21-10].

Figure 20-21-11

Dealer Copy -- Not for Resale


P-87019

Figure 20-21-9
Articulated Boom
1 2
1
3

P-87076

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


21-11].

Remove the rod end pivot pin (Item 3) [Figure 20-21-11].

S37439

Support the boom with a chain hoist (Item 1) [Figure 20- IMPORTANT
21-8] or [Figure 20-21-9].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

125 of 879 20-21-3 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-14

Removal And Installation (Cont’d) 1

Figure 20-21-12

P-87078

1
1
Install a sling (Item 1) [Figure 20-21-14] on both ends of
P-87018 the cylinder.

Remove the hoses (Item 1) [Figure 20-21-12].

Dealer Copy -- Not for Resale


Figure 20-21-13

P-87093

Remove the hose (Item 1) [Figure 20-21-13].

126 of 879 20-21-4 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-17

Removal And Installation (Cont’d)

Figure 20-21-15

2 3 1
P-87095

Remove the cylinder (Item 1) [Figure 20-21-17].


P-87016
Remove the shims (Item 2) [Figure 20-21-17] from both
sides of the base end of the cylinder.
Figure 20-21-16
Articulated Boom

Dealer Copy -- Not for Resale


1
2
3

S37543

Remove the nuts (Item 1), bolt (Item 2) and base end
pivot pin (Item 3) [Figure 20-21-15] or [Figure 20-21-
16].

127 of 879 20-21-5 E80 Service Manual


CYLINDER (ARM) (CONT’D)

Parts Identification

1
1. U-Bolt
2. Tubeline
7
3. Bolt 8
4. Washer
5. O-ring
6. Nut
2
7. Seal
8. Grease Fitting 4 9
9. Bushing 6
10. Check Valve 2 7
10
11. Spring 14
12. Spring Support 3 11
13. Plug 4 12
14. Housing 4 13
15. Cushion Plunger 5 3
16. Ring Stop
17

Dealer Copy -- Not for Resale


17. Set Screw 18
18. Piston 15
19. Wear Ring
20. Seal Assembly 19
21. Back-up Ring 19
22. Cushion Ring 5
16
23. Snap Ring 22
5 6
24. Head
25. Wiper Seal
26. Rod
7
20
3 7
21
21
23
9

24
7
7
25
23 8
26

7 MS-2793S

128 of 879 20-21-6 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-20

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

Hold the hydraulic cylinder over a drain pan and slowly 1


move the rod in and out to remove the fluid from the
cylinder.

Figure 20-21-18

P-87098

Remove the O-ring (Item 1) [Figure 20-21-20] from the


tubeline.
1 Figure 20-21-21

Dealer Copy -- Not for Resale


P-87096

Remove the two nuts (Item 1) [Figure 20-21-18], lock 1


washers and U-bolt.

Figure 20-21-19

P-87096

Remove the two nuts (Item 1) [Figure 20-21-21], lock


2 washers and U-bolt.

1
1

P-87097

Remove the four bolts (Item 1) and tubeline (Item 2)


[Figure 20-21-19].

129 of 879 20-21-7 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-24

Disassembly (Cont’d)

Figure 20-21-22

1
P-86848
2

Support the cylinder with a block (Item 1) [Figure 20-21-


1
P-87099 24].

Figure 20-21-25
Remove the four bolts (Item 1), lock washers and hose
(Item 2) [Figure 20-21-22].
1

Dealer Copy -- Not for Resale


Figure 20-21-23

1
P-86849

Remove the eight bolts (Item 1) [Figure 20-21-25].


P-87100

Remove the O-ring (Item 1) [Figure 20-21-23] from the


tubeline.

Clamp the base end of the cylinder in a vise.

Be careful not to damage the cylinder housing.

130 of 879 20-21-8 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-28

Disassembly (Cont’d)

Figure 20-21-26

P-86850

1 Remove the set screw (Item 1) [Figure 20-21-28].


P-87077
Figure 20-21-29

Remove the rod assembly (Item 1) [Figure 20-21-26]


from the cylinder housing. 1

Dealer Copy -- Not for Resale


Remove the cylinder housing from the vise.

Figure 20-21-27

P-86851

Apply moderate heat to the nut (Item 1) [Figure 20-21-


29].

Remove the nut.


P-86852

Clamp the rod end (Item 1) [Figure 20-21-27] in a vise.

Support the end of the rod with a block.

131 of 879 20-21-9 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-32

Disassembly (Cont’d)

Figure 20-21-30
1

P-87032

Remove the wear ring (Item 1) [Figure 20-21-32] from


P-86853 the piston.

Figure 20-21-33
Remove the piston (Item 1) [Figure 20-21-30].

Dealer Copy -- Not for Resale


Figure 20-21-31

1
1

P-87031

P-87033 Remove the seal (Item 1) [Figure 20-21-33].

Remove the seal (Item 1) [Figure 20-21-31] from the


piston.

132 of 879 20-21-10 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-36

Disassembly (Cont’d)

Figure 20-21-34

P-87028

Remove the seal (Item 1) [Figure 20-21-36] from the


P-87030 piston.

Figure 20-21-37
Remove the O-ring (Item 1) [Figure 20-21-34] from the
piston.

Dealer Copy -- Not for Resale


Figure 20-21-35 1

P-86862

Remove the O-ring (Item 1) [Figure 20-21-37] from the


P-87029 piston.

Remove the wear ring (Item 1) [Figure 20-21-35] from


the piston.

133 of 879 20-21-11 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-40

Disassembly (Cont’d)

Figure 20-21-38 1

P-86861

Remove the head (Item 1) [Figure 20-21-40] from the


P-87011 rod.

Figure 20-21-41
Remove the back-up ring (Item 1) [Figure 20-21-38].

Dealer Copy -- Not for Resale


Figure 20-21-39

1 1

P-86864

P-86860 Remove the O-ring (Item 1) [Figure 20-21-41].

Remove the cushion ring (Item 1) [Figure 20-21-39] from


the rod.

134 of 879 20-21-12 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-44

Disassembly (Cont’d)

Figure 20-21-42 1

P-86867

Remove the snap ring (Item 1) [Figure 20-21-44].

P-86865 Figure 20-21-45

Remove the back-up ring (Item 1) [Figure 20-21-42]. 1

Dealer Copy -- Not for Resale


Figure 20-21-43

1
P-86868

Remove the wiper seal (Item 1) [Figure 20-21-45].

P-86866

Remove the O-ring (Item 1) [Figure 20-21-43].

135 of 879 20-21-13 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-48

Disassembly (Cont’d) 2

Figure 20-21-46
1

P-887014
1
Remove the seal (Item 1) (both sides) and bushing (Item
P-87754 2) [Figure 20-21-48] from the rod end.

Figure 20-21-49
Remove the two seals (Item 1) [Figure 20-21-46].

Dealer Copy -- Not for Resale


Figure 20-21-47

1
2

P-87015

P-86870 Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-21-49] from the base end.

Remove the snap ring (Item 1) and bushing (Item 2)


[Figure 20-21-47].

Remove the rod from the vise.

136 of 879 20-21-14 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-51

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander


MEL1033 - Rod Seal Installation Tool 2
1
MEL1396-2 - Piston Ring Compressor

Wash the cylinder parts in clean solvent and dry with


compressed air.

Inspect the cylinder parts for nicks, scratches and other


damage. Replace any damaged parts.
P-86870
Always install new O-rings and seals during assembly.

Lubricate all O-ring and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-21-51] into the head.

Clamp the rod end in a vise. Figure 20-21-52

Figure 20-21-50

Dealer Copy -- Not for Resale


1

P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-21-52] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-21-50].

137 of 879 20-21-15 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-55

Assembly (Cont’d)

Figure 20-21-53

P-86866

Install the O-ring (Item 1) [Figure 20-21-55] onto the


P-86868 head.

Figure 20-21-56
Install the wiper seal (Item 1) [Figure 20-21-53] into the
head.

Dealer Copy -- Not for Resale


Figure 20-21-54

P-86865

Install the back-up ring (Item 1) [Figure 20-21-56] onto


P-86867 the head.

Install the snap ring (Item 1) [Figure 20-21-54] into the


head.

138 of 879 20-21-16 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-59

Assembly (Cont’d)

Figure 20-21-57 1

1
P86860

Install the cushion ring (Item 1) [Figure 20-21-59] on the


P-86864 rod.

Figure 20-21-60
Install the O-ring (Item 1) [Figure 20-21-57].

Dealer Copy -- Not for Resale


Figure 20-21-58 1

P-87011

P-86861 Install the back-up ring (Item 1) [Figure 20-21-60] into


the piston.

Install the head (Item 1) [Figure 20-21-58] onto the rod.

139 of 879 20-21-17 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-63

Assembly (Cont’d)

Figure 20-21-61

1 1

P-87029

Install the wear ring (Item 1) [Figure 20-21-63] onto the


P-86862 piston.

Figure 20-21-64
Install the O-ring (Item 1) [Figure 20-21-61] into the
piston.

Dealer Copy -- Not for Resale


Figure 20-21-62

1
1

P-87030

Figure 20-21-65
P-87028

Install the seal (Item 1) [Figure 20-21-62] onto the


piston.

P-87031

Install the O-ring (Item 1) [Figure 20-21-64] and seal


(Item 2) [Figure 20-21-65] onto the piston.

140 of 879 20-21-18 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-68

Assembly (Cont’d)

Figure 20-21-66 2

1
1
P-86853

Install the piston (Item 1) [Figure 20-21-68] onto the rod.


P-87032
Figure 20-21-69

Install the wear ring (Item 1) [Figure 20-21-66] onto the


piston.

Dealer Copy -- Not for Resale


Figure 20-21-67
1

1
P-86851

Install the nut (Item 1) [Figure 20-21-69].

P-87033 Tighten the nut until the bore (Item 2) [Figure 20-21-69]
of the set screw is aligned with the groove (Item 2)
[Figure 20-21-68] of the rod.
Install the seal (Item 1) [Figure 20-21-67] onto the
piston.

141 of 879 20-21-19 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-72

Assembly (Cont’d)

Figure 20-21-70

1 2

1
P-87077

Install the rod assembly (Item 1) into the cylinder housing


P-86850 (Item 2) [Figure 20-21-72].

Figure 20-21-73
Install the set screw (Item 1) [Figure 20-21-70] into the
nut. 2

Dealer Copy -- Not for Resale


Use a center punch to deform the threads of the set
screw bore.
1
Remove the rod end from the vise.
2
Figure 20-21-71

2
P-86849

Install the head (Item 1) using the eight bolts (Item 2)


[Figure 20-21-73].

Tighten the bolts to 123 - 149 N•m (91 - 110 ft-lb) torque.

2
P-87013

Install the base end of the cylinder housing (Item 1)


[Figure 20-21-71] in a vise.

Support the housing with a block (Item 2) [Figure 20-21-


71].

142 of 879 20-21-20 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-76

Assembly (Cont’d)

Figure 20-21-74

1
1

P-87098

Install the O-ring (Item 1) [Figure 20-21-76] into the


P-86847 tubeline.

Figure 20-21-77
Install the O-ring (Item 1) [Figure 20-21-74] into the
hose.

Dealer Copy -- Not for Resale


Figure 20-21-75

2 1

2
2

P-87097
1
Install the tubeline (Item 1) using the four bolts (Item 2)
2
P-87099 [Figure 20-21-77] and lock washers.

Install the hose (Item 1), lock washers and bolts (Item 2)
[Figure 20-21-75] onto the cylinder housing.

143 of 879 20-21-21 E80 Service Manual


CYLINDER (ARM) (CONT’D) Figure 20-21-80

Assembly (Cont’d)

Figure 20-21-78
1
2

P-36183

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


P-87096 21-80] into both sides of the base end of the cylinder.

Install the U-bolt, washers and nuts (Item 1) [Figure 20-


21-78].

Dealer Copy -- Not for Resale


Figure 20-21-79

P-87014

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


21-79] into both sides of the rod end of the cylinder.

144 of 879 20-21-22 E80 Service Manual


CYLINDER (BOOM SWING) Figure 20-22-3

Testing

Swing the boom to the right, fully extending the boom


offset cylinder.

Lower the boom / bucket to the ground.

Stop the engine.

Remove the left upperstructure side cover. (See Removal


And Installation on Page 40-20-1.)
1
Figure 20-22-1
P-87411

1 Place a board (Item 1) [Figure 20-22-3] between the


cylinder and the excavator frame.
2
Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

Figure 20-22-4

Dealer Copy -- Not for Resale


1
P-87409

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


22-1].

Figure 20-22-2

P-87412

Remove the base end hose (Item 1) [Figure 20-22-4].


1
Install a plug on the hose.

Lower the cab.

Start the engine.

Retract the cylinder.


P-87410
If there is any oil leakage from the base end fitting (Item
1) [Figure 20-22-4] on the cylinder, remove the cylinder
Remove the pivot pin (Item 1) [Figure 20-22-2]. for repair or replacement.

145 of 879 20-22-1 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-7

Removal And Installation

Swing the upperstructure 90° to the left or right.

Swing the boom to the right, fully extending the boom


offset cylinder.

Lower the boom / bucket to the ground.

Stop the engine.


1
Figure 20-22-5

P-87411

1
Place a board (Item 1) [Figure 20-22-7] between the
2
cylinder and the excavator frame.

Figure 20-22-8

Dealer Copy -- Not for Resale


P-87409

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


22-5].

Figure 20-22-6 1

P-87417

Start the excavator and fully retract the cylinder (Item 1)


[Figure 20-22-8].

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

P-87410

Remove the pivot pin (Item 1) [Figure 20-22-6].

146 of 879 20-22-2 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-11

Removal And Installation (Cont’d)


2
Figure 20-22-9

1
1
1

P-87413

Remove the two bolts (Item 1) and the retaining plate


P-87412 (Item 2) [Figure 20-22-11].

Figure 20-22-12
Remove the hoses (Item 1) [Figure 20-22-9].

Dealer Copy -- Not for Resale


Figure 20-22-10

1
1

P-87415

P-89344 Remove the pin (Item 1) [Figure 20-22-12].

Install a sling (Item 1) [Figure 20-22-10] and a lifting


device on the rod end of the cylinder.

147 of 879 20-22-3 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-15

Removal And Installation (Cont’d)

Figure 20-22-13

1 1

P-89345

Install a sling (Item 1) [Figure 20-22-15] and lifting


P-87416 device on the base end of the cylinder.

Figure 20-22-16
Slide the cylinder out of the front of the excavator until the
cable tie (Item 1) [Figure 20-22-13] can be removed.

Dealer Copy -- Not for Resale


Remove the cable tie.

Figure 20-22-14

P-89347

1 Remove the grease hose (Item 1) [Figure 20-22-16].

Remove the cylinder.


P-89346

Continue sliding the cylinder out until the second cable tie
(Item 1) [Figure 20-22-14] can be removed.

Remove the cable tie.

148 of 879 20-22-4 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D)

Parts Identification

1. Seal 1
2. Bushing
3. Rod
4. Grease Fitting
2
5. Snap Ring
6. Wiper
7. Head
3
8. Lock Ring
9. O-ring
4
10. Back-up Ring
11. Piston
12. Wear Ring
13. Set Screw
14. Nut
15. Housing
16. Fitting 5 1
6
1
7

Dealer Copy -- Not for Resale


5
8
9
10
9
9
11

1
12
13

14

15 1

16
1

MS-2795S

149 of 879 20-22-5 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-19

Disassembly

Use the following tools to disassemble the cylinder:

MEL 1074- O-ring Seal Hook

Hold the cylinder over a drain pan and slowly move the
rod in and out to remove the oil from the cylinder.
1
Figure 20-22-17

1 P-87421

Straighten the lock ring tab (Item 1) [Figure 20-22-19].

Figure 20-22-20

Dealer Copy -- Not for Resale


1
P-87419
1

Clamp the base end (Item 1) [Figure 20-22-17] of the


cylinder in a vise.

Figure 20-22-18

1 P-87422

Insert the adjustable gland nut wrench into the notches


(Item 1) [Figure 20-22-20] and loosen the head.

P-87420

Support the cylinder with a block (Item 1) [Figure 20-22-


18]. Be careful not to damage the cylinder housing.

150 of 879 20-22-6 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-23

Disassembly (Cont’d)

Figure 20-22-21
2

1
1

P-87425

Remove the seal (Item 1) (both sides) and bushing (Item


P-87423 2) [Figure 20-22-23].

Figure 20-22-24
Remove the rod assembly (Item 1) [Figure 20-22-21]
from the housing.

Dealer Copy -- Not for Resale


Remove the cylinder from the vise.

Figure 20-22-22

P-87390

1 Clamp the rod end in a vise. Support the rod with a block
(Item 1) [Figure 20-22-24].

P-87424

Remove the fitting (Item 1) [Figure 20-22-22].

151 of 879 20-22-7 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-27

Disassembly (Cont’d)

Figure 20-22-25

1 P-87429

Remove the piston (Item 1) [Figure 20-22-27].


P-87428
Figure 20-22-28

Loosen the set screw (Item 1) [Figure 20-22-25].

Dealer Copy -- Not for Resale


Figure 20-22-26

1
1

P-87430

Remove the seal (Item 1) [Figure 20-22-28].


P-87427

Apply moderate heat to the nut (Item 1) [Figure 20-22-


25].

Remove the nut.

152 of 879 20-22-8 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-31

Disassembly (Cont’d)

Figure 20-22-29

P-87433

Remove the O-ring (Item 1) [Figure 20-22-31].


P-87431
Figure 20-22-32

Remove the wear ring (Item 1) [Figure 20-22-29].

Dealer Copy -- Not for Resale


Figure 20-22-30

P-87446

Remove the seal (Item 1) [Figure 20-22-32].


P-87432

Remove the seal (Item 1) [Figure 20-22-30].

153 of 879 20-22-9 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-35

Disassembly (Cont’d)

Figure 20-22-33
1

P-87436

Remove the O-ring (Item 1) [Figure 20-22-35].


P-87434
Figure 20-22-36

Remove the O-ring (Item 1) [Figure 20-22-33].

Dealer Copy -- Not for Resale


Figure 20-22-34

P-87437

Remove the back-up ring (Item 1) [Figure 20-22-36].


1
P-87435

Remove the head (Item 1) [Figure 20-22-34].

154 of 879 20-22-10 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-39

Disassembly (Cont’d)

Figure 20-22-37
1

P-87440

Remove the snap ring (Item 1) [Figure 20-22-39].


P-87438
Figure 20-22-40

Remove the O-ring (Item 1) [Figure 20-22-37].


2

Dealer Copy -- Not for Resale


Figure 20-22-38

P-87444

Remove the wiper seal (Item 1) and inner seal (Item 2)


P-87439 [Figure 20-22-40].

Remove the lock ring (Item 1) [Figure 20-22-38].

155 of 879 20-22-11 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-43

Disassembly (Cont’d)

Figure 20-22-41 1

P-87445

Remove the seal (Item 1) (both sides) and bushing (Item


P-87442 2) [Figure 20-22-43].

Remove the snap ring (Item 1) [Figure 20-22-41].

Dealer Copy -- Not for Resale


Figure 20-22-42

P-87443

Remove the bushing (Item 1) [Figure 20-22-42].

156 of 879 20-22-12 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Install the bushing (Item 1) [Figure 20-22-45] into the
head.
Assembly
Figure 20-22-46
Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander


MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
1
Wash the cylinder parts in clean solvent and dry with
compressed air.

Inspect the cylinder parts for nicks, scratches and other


damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.

Lubricate all O-ring and seals with hydraulic oil during P-87442
installation.

Figure 20-22-44 Install the snap ring (Item 1) [Figure 20-22-46].

Dealer Copy -- Not for Resale


2

P-87445

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


22-44]. (Both sides)

Figure 20-22-45

P-87443

157 of 879 20-22-13 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-49

Assembly (Cont’d)

Figure 20-22-47
1

P-87439
2

Install the lock ring (Item 1) [Figure 20-22-49].


P-87444
Figure 20-22-50

Install the inner seal (Item 1) and wiper seal (Item 2)


[Figure 20-22-47].

Dealer Copy -- Not for Resale


Figure 20-22-48
1

P-87438

Install the O-ring (Item 1) [Figure 20-22-50].

P-87440 Figure 20-22-51

Install the snap ring (Item 1) [Figure 20-22-48].

P-87437

Install the back-up ring (Item 1) [Figure 20-22-51].

158 of 879 20-22-14 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-54

Assembly (Cont’d)

Figure 20-22-52
1

P-87434

Install the O-ring (Item 1) [Figure 20-22-54] in the piston.


P-87436
Figure 20-22-55

Install the O-ring (Item 1) [Figure 20-22-52].

Dealer Copy -- Not for Resale


Clamp the rod end in a vise. Support the rod with a block.
Be careful not to damage the rod.
1
Figure 20-22-53

P-87446

Install the seal (Item 1) [Figure 20-22-55].

1
P-87435

Install the head (Item 1) [Figure 20-22-53].

159 of 879 20-22-15 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-58

Assembly (Cont’d)

Figure 20-22-56

P-87431

Install the wear ring (Item 1) [Figure 20-22-58].


P-87433
Figure 20-22-59

Figure 20-22-57

Dealer Copy -- Not for Resale


1
1

P-87430

P-87439
Install the seal (Item 1) [Figure 20-22-59].

Install the O-ring (Item 1) [Figure 20-22-56] and seal


(Item 1) [Figure 20-22-57].

160 of 879 20-22-16 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-62

Assembly (Cont’d)

Figure 20-22-60

P-87428

1
Install the set screw (Item 1) [Figure 20-22-61].
P-87429
Use a center punch to deform the threads of the set
screw bore.
Install the piston (Item 1) [Figure 20-22-60].
Figure 20-22-63

Dealer Copy -- Not for Resale


Figure 20-22-61
1

1
P-87426
P-87427

Remove the rod end (Item 1) [Figure 20-22-63] from the


Install the nut (Item 1) [Figure 20-22-61]. vise.

Tighten the nut until the bore (Item 2) [Figure 20-22-61]


of the set screw is aligned with the groove (Item 2)
[Figure 20-22-60] of the rod.

161 of 879 20-22-17 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-66

Assembly (Cont’d)

Figure 20-22-64

2 1

P-87423

Install the rod assembly (Item 1) [Figure 20-22-66] into


P-87425 the housing.

Figure 20-22-67
Install the bushing (Item 1) and seal (Item 2) [Figure 20-
22-64] (both sides) into the rod end.

Dealer Copy -- Not for Resale


Figure 20-22-65 1

P-87422
1

Tighten the head (Item 1) [Figure 20-22-67].


P-87424

Install the fitting (Item 1) [Figure 20-22-65].

Clamp the base end of the cylinder housing in a vise.

162 of 879 20-22-18 E80 Service Manual


CYLINDER (BOOM SWING) (CONT'D)

Assembly (Cont’d)

Figure 20-22-68

P-87421

Bend the lock ring tab (Item 1) [Figure 20-22-68] into the
groove on the head.

Dealer Copy -- Not for Resale


Figure 20-22-69

P-87420

Remove the cylinder (Item 1) [Figure 20-22-69] from the


vise.

163 of 879 20-22-19 E80 Service Manual


Dealer Copy -- Not for Resale

164 of 879 20-22-20 E80 Service Manual


CYLINDER (BUCKET) Removal And Installation

Testing Fully retract the bucket cylinder.

Fully retract the bucket and arm cylinders. Lower the boom until the bucket is on the ground.

Lower the boom to the ground. Figure 20-23-3

With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.

Figure 20-23-1 1

1
P-87021

Dealer Copy -- Not for Resale


Support the arm with a chain hoist (Item 1) [Figure 20-
23-3].
P-86828
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
Remove the hydraulic hose (Item 1) [Figure 20-23-1]
from the base end of the bucket cylinder.

Figure 20-23-2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
1 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-86829

Install a plug (Item 1) [Figure 20-23-2] on the hose.

Start the engine and retract the bucket cylinder.

If there is any oil leakage from the base end fitting (Item
2) [Figure 20-23-2] on the bucket cylinder, remove the
cylinder for repair or replacement.

165 of 879 20-23-1 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-6

Removal And Installation (Cont’d)


2
Figure 20-23-4

2 1

P-86832

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


P-86828 23-6] from the base end pivot pin.

Figure 20-23-7
Remove the hose (Item 1) [Figure 20-23-4] from the
base end.

Dealer Copy -- Not for Resale


Remove the hose (Item 2) [Figure 20-23-4] from the rod
end. 2

Figure 20-23-5

P-86833

1 Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


23-7] from the rod end pivot pin.

P-86834

Install a strap (Item 1) [Figure 20-23-5] and a lifting


device on the cylinder.

166 of 879 20-23-2 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-10

Removal And Installation (Cont’d)

Figure 20-23-8
1

1 P-86835

Remove the base end pivot pin (Item 1) [Figure 20-23-


P-86836 10] and the shims.

Figure 20-23-11
Remove the rod end pivot pin (Item 1) [Figure 20-23-8].

Dealer Copy -- Not for Resale


Figure 20-23-9

P-86838
1

P-86837 Remove the cylinder (Item 1) [Figure 20-23-11].

Remove the shims (Item 2) [Figure 20-23-11] (Both


Remove the shims (Item 1) [Figure 20-23-9] (Both sides).
sides).

167 of 879 20-23-3 E80 Service Manual


CYLINDER (BUCKET) (CONT’D)

Parts Identification

1. Bolt
2. Lockwasher 1
3. O-ring
4. Tubeline 2
5. Seal 4
6. Grease Fitting 3
8 3
7. Bushing
6
8. U-Bolt
9 1
9. Nut
10. Housing 2 2
11. Set Screw
7
12. Piston 4
13. Wear Ring
14. Seal Assembly 10
1
15. Back-up Ring 2 8
16. Cushion Ring 2 5
17 Snap Ring
18. Head
21
19. Wiper Seal
20. Rod
11

Dealer Copy -- Not for Resale


21. Spacer
3 13
3 13
15
16
3 9
17 12
5
1 14
5
3

3
15
7

18
5
5
19
17
6
20

7
5
MS-2794S

168 of 879 20-23-4 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-14

Disassembly

Use the following tools to disassemble the cylinder:


1
MEL1074 - O-ring Seal Hook

Hold the hydraulic cylinder over a drain pan and slowly


move the rod in and out to remove the fluid from the
cylinder.

Figure 20-23-12

P-86843

Remove the O-ring (Item 1) [Figure 20-23-14] from the


spacer.

Figure 20-23-15
1

Dealer Copy -- Not for Resale


1
P-86839

Remove the two nuts (Item 1) [Figure 20-23-12], lock


washers and U-bolt.

Figure 20-23-13

P-86842

Remove the O-ring (Item 1) [Figure 20-23-15] from the


tubeline.

1 1

P-86840

Remove the four bolts (Item 1), tubeline (Item 2) [Figure


20-23-13] and spacer.

169 of 879 20-23-5 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-18

Disassembly (Cont’d)

Figure 20-23-16

1 1

P86847

2
Remove the O-ring (Item 1) [Figure 20-23-18] from the
P-86844 tubeline.

Clamp the base end of the cylinder in a vise.


Remove the two nuts (Item 1), lock washers and U-bolt
(Item 2) [Figure 20-23-16]. Be careful not to damage the cylinder housing.

Dealer Copy -- Not for Resale


Figure 20-23-17 Figure 20-23-19

1
2
1

P-86845
1
P-86848

Remove the four bolts (Item 1), lock washers and Support the cylinder with a block (Item 1) [Figure 20-23-
tubeline (Item 2) [Figure 20-23-17]. 19].

170 of 879 20-23-6 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-22

Disassembly (Cont’d)
1
Figure 20-23-20

P-86852

1 Clamp the rod end (Item 1)[Figure 20-23-22] in a vise.


P-86849 Support the end of the rod with a block.

Figure 20-23-23
Remove the eight bolts (Item 1) [Figure 20-23-20].

Dealer Copy -- Not for Resale


Figure 20-23-21

P-86850
1

P-87077 Remove the set screw (Item 1) [Figure 20-23-23].

Remove the rod assembly (Item 1) [Figure 20-23-21]


from the cylinder housing.

Remove the cylinder housing from the vise.

171 of 879 20-23-7 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-26

Disassembly (Cont’d)

Figure 20-23-24
1

P-86542

Remove the seal (Item 1) [Figure 20-23-26] from the


P-86851 piston.

Figure 20-23-27
Apply moderate heat to the nut (Item 1) [Figure 20-23-
24].

Dealer Copy -- Not for Resale


Remove the nut. 1

Figure 20-23-25

P-87032

Remove the wear ring (Item 1) [Figure 20-23-27] from


the piston.

P-86853

Remove the piston (Item 1) [Figure 20-23-25].

172 of 879 20-23-8 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-30

Disassembly (Cont’d)

Figure 20-23-28

P-87029

Remove the wear ring (Item 1) [Figure 20-23-30] from


P-87031 the piston.

Figure 20-23-31
Remove the seal (Item 1) [Figure 20-23-28].

Dealer Copy -- Not for Resale


Figure 20-23-29

P-87028

P-87030 Remove the seal (Item 1) [Figure 20-23-31] from the


piston.

Remove the O-ring (Item 1) [Figure 20-23-29] from the


piston.

173 of 879 20-23-9 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-34

Disassembly (Cont’d)

Figure 20-23-32
1

P-86860

Remove the cushion ring (Item 1) [Figure 20-23-34] from


P-86862 the rod.

Figure 20-23-35
Remove the O-ring (Item 1) [Figure 20-23-32] from the
piston.

Dealer Copy -- Not for Resale


1
Figure 20-23-33

P-86861

Remove the head (Item 1) [Figure 20-23-35] from the


P-87011 rod.

Remove the back-up ring (Item 1) [Figure 20-23-33]


from the piston.

174 of 879 20-23-10 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-38

Disassembly (Cont’d)

Figure 20-23-36

P-86866

Remove the O-ring (Item 1) [Figure 20-23-38].


P-86864
Figure 20-23-39

Remove the O-ring (Item 1) [Figure 20-23-36].


1

Dealer Copy -- Not for Resale


Figure 20-23-37

P-86867

Remove the snap ring (Item 1) [Figure 20-23-39].

P-86865

Remove the back-up ring (Item 1) [Figure 20-23-37].

175 of 879 20-23-11 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-42

Disassembly (Cont’d)

Figure 20-23-40

1 1
2

P-86870

P-86868 Remove the snap ring (Item 1) and bushing (Item 2)


[Figure 20-23-42].

Remove the wiper seal (Item 1) [Figure 20-23-40]. Remove the rod from the vise.

Figure 20-23-41 Figure 20-23-43

Dealer Copy -- Not for Resale


1 1

2
1

P-87754 P-887014

Remove the two seals (Item 1) [Figure 20-23-41]. Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-23-43] from the rod end.

176 of 879 20-23-12 E80 Service Manual


CYLINDER (BUCKET) (CONT’D)

Disassembly (Cont’d)

Figure 20-23-44

2
1

P-87015

Remove the seal (Item 1) (both sides) and bushing (Item


2) [Figure 20-23-44] from the base end.

Dealer Copy -- Not for Resale

177 of 879 20-23-13 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-46

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander


MEL1033 - Rod Seal Installation Tool 2
1
MEL1396-2 - Piston Ring Compressor

Wash the cylinder parts in clean solvent and dry with


compressed air.

Inspect the cylinder parts for nicks, scratches and other


damage. Replace any damaged parts.
P-86870
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-23-46] into the head.

Clamp the rod end in a vise. Figure 20-23-47

Figure 20-23-45

Dealer Copy -- Not for Resale


1

P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-23-47] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-23-45].

178 of 879 20-23-14 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-50

Assembly (Cont’d)

Figure 20-23-48

P-86866

Install the O-ring (Item 1) [Figure 20-23-50] onto the


P-86868 head.

Figure 20-23-51
Install the wiper seal (Item 1) [Figure 20-23-48] into the
head.

Dealer Copy -- Not for Resale


Figure 20-23-49

P-86865

Install the back-up ring (Item 1) [Figure 20-23-51] onto


P-86867 the head.

Install the snap ring [Figure 20-23-49] into the head.

179 of 879 20-23-15 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-54

Assembly (Cont’d)

Figure 20-23-52 1

1
P86860

Install the cushion ring (Item 1) [Figure 20-23-54] on the


P-86864 rod.

Figure 20-23-55
Install the O-ring (Item 1) [Figure 20-23-52].

Dealer Copy -- Not for Resale


Figure 20-23-53

P-87011

P-86861 Install the back-up ring (Item 1) [Figure 20-23-55] in the


piston.

Install the head (Item 1) [Figure 20-23-53] onto the rod.

180 of 879 20-23-16 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-58

Assembly (Cont’d)

Figure 20-23-56

1
1

P-87029

Install the wear ring (Item 1) [Figure 20-23-58] onto the


P-86862 piston.

Figure 20-23-59
Install the O-ring (Item 1) [Figure 20-23-56] into the
piston.

Dealer Copy -- Not for Resale


Figure 20-23-57

P-87030

Figure 20-23-60
P-87028

Install the seal (Item 1) [Figure 20-23-57] onto the


piston.

P-87031

Install the O-ring (Item 1) [Figure 20-23-59] and seal


(Item 1) [Figure 20-23-60] onto the piston.

181 of 879 20-23-17 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-63

Assembly (Cont’d)
2
Figure 20-23-61

1
P-86853

Install the piston (Item 1) [Figure 20-23-63] onto the rod.


P-87032
Figure 20-23-64

Install the wear ring (Item 1) [Figure 20-23-61] onto the


piston.

Dealer Copy -- Not for Resale


Figure 20-23-62

1 1

P-86851

Install the nut (Item 1) [Figure 20-23-64].

P-87033 Tighten the nut until the bore (Item 2) [Figure 20-23-64]
of the set screw is aligned with the groove (Item 2)
[Figure 20-23-64] of the rod.
Install the seal (Item 1) [Figure 20-23-62] onto the
piston.

182 of 879 20-23-18 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-67

Assembly (Cont’d)

Figure 20-23-65

1
P-87077

Install the rod assembly (Item 1) [Figure 20-23-67] into


P-86850 the cylinder housing.

Figure 20-23-68
Install the set screw (Item 1) [Figure 20-23-65] into the
nut. 2

Dealer Copy -- Not for Resale


Use a center punch to deform the threads of the set
screw bore. 1

Remove the rod end from the vise.


2
Be careful not to damage the cylinder housing.

Figure 20-23-66

2
P-86849

Install the head (Item 1) using the eight bolts (Item 2)


[Figure 20-23-68].

Tighten the bolts to 70 - 79 N•m (52 - 58 ft-lb) torque.

1
P-87013

Support the housing with a block (Item 1) [Figure 20-23-


66].

183 of 879 20-23-19 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-71

Assembly (Cont’d)

Figure 20-23-69
2

1
P-86844

1
Install the U-bolt (Item 1), lock washers and nuts (Item 2)
P-86847 [Figure 20-23-71].

Figure 20-23-72
Install the O-ring (Item 1) [Figure 20-23-69] into the
tubeline.

Dealer Copy -- Not for Resale


Figure 20-23-70

P-86842

2
Install the O-ring (Item 1) [Figure 20-23-72] into the
P-86845 tubeline.

Install the tubeline (Item 1), lock washers and bolts (Item
2) [Figure 20-23-70] onto the cylinder housing.

184 of 879 20-23-20 E80 Service Manual


CYLINDER (BUCKET) (CONT’D) Figure 20-23-75

Assembly (Cont’d)

Figure 20-23-73

1
2
1

P-86839

Install the U-bolt, washers and nuts (Item 1) [Figure 20-


P-86843 23-75].

Figure 20-23-76
Install the O-ring (Item 1) into the spacer (Item 2) [Figure
20-23-73].
1

Dealer Copy -- Not for Resale


Figure 20-23-74 2

3 3
P-87014

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


P-86840 23-76] (both sides) into the rod end of the cylinder.

Install the spacer (Item 1) and tubeline (Item 2) using the


four bolts (Item 3) [Figure 20-23-74] and lock washers.

185 of 879 20-23-21 E80 Service Manual


CYLINDER (BUCKET) (CONT’D)

Assembly (Cont’d)

Figure 20-23-77

1
2

P-36183

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


23-77] (both sides) into the base end of the cylinder.

Dealer Copy -- Not for Resale

186 of 879 20-23-22 E80 Service Manual


CYLINDER (BLADE)

Testing

Put the bucket on the ground.

Stop the engine.

With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.

Figure 20-24-1

Dealer Copy -- Not for Resale


P-86489

Remove the hydraulic hose (Item 1) [Figure 20-24-1]


from the base end of the blade cylinders.

Figure 20-24-2

P-86490

Install a plug (Item 1) [Figure 20-24-2] on the hose.

Start the engine and retract the blade cylinders.

If there is any oil leakage from the base end fitting (Item
2) [Figure 20-24-2] of the blade cylinders, remove the
cylinder for repair or replacement.

187 of 879 20-24-1 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-4

Removal And Installation

NOTE: The right blade cylinder is shown. The 2


procedure is the same for the left blade
cylinder.

Put the blade on the floor.


1
With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.

IMPORTANT P-86491

When repairing hydrostatic and hydraulic systems, Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-
clean the work area before disassembly and keep all 24-4] from the base end retaining pin.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-24-5
damage the system.
I-2003-0888

Dealer Copy -- Not for Resale


2
Figure 20-24-3

2
1

1
P-86492

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


24-5] from the rod end retaining pin.
P-86489

Remove the hose (Item 1) [Figure 20-24-3] from the


base end of the cylinder.

Remove the hose (Item 2) [Figure 20-24-3] from the rod


end of the cylinder.

188 of 879 20-24-2 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-8

Removal And Installation (Cont’d)

Figure 20-24-6

P-86496

Figure 20-24-9
P-86493

Figure 20-24-7

Dealer Copy -- Not for Resale


1 1

P-86495

Remove the retaining pins (Item 1) [Figure 20-24-8] and


P-86494 [Figure 20-24-9].

Install a sling (Item 1) [Figure 20-24-6] and [Figure 20-


24-7] on the rod end and base end of the cylinder.

189 of 879 20-24-3 E80 Service Manual


CYLINDER (BLADE) (CONT'D)

Removal And Installation (Cont’d)

Figure 20-24-10

P-86498

Figure 20-24-11

Dealer Copy -- Not for Resale


1

P-86497

Raise the hoist and remove the shims (Item 1) [Figure


20-24-10] and [Figure 20-24-11] from both sides of the
rod end and base end of the cylinder.

Remove the cylinder.

190 of 879 20-24-4 E80 Service Manual


CYLINDER (BLADE) (CONT'D)

Parts Identification

1. Grease Fitting
2. Bushing
3. Rod 1
4. Snap Ring
5. Wiper Seal 3
6. Seal
7. Head
8. O-ring 4 2
9. Back-up Ring 5
7
10. Snap Ring
6
11. Piston
12. Seal 8
13. Slipper Seal Assy 9
14. Wear Ring
15. Set Screw 2
10
16. Nut
8
17. Housing
9
11
12

Dealer Copy -- Not for Resale


13
15 14
12

16
17

MS-2796S

191 of 879 20-24-5 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-13

Disassembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-86501
Hold the cylinder over a drain pan and slowly move the
rod in and out to remove the oil from the cylinder.
Straighten the head lock ring (Item 1) [Figure 20-24-13].
Figure 20-24-12
Figure 20-24-14

Dealer Copy -- Not for Resale


1

2 P-86500
P103657

Clamp the base end (Item 1) [Figure 20-24-12] of the


cylinder housing in a vise. Remove the head (Item 1) [Figure 20-24-14] from the
housing.
Be careful to not damage the cylinder housing.

Install a block (Item 2) [Figure 20-24-12] to support the


cylinder.

Remove the fittings (Item 3) [Figure 20-24-12].

192 of 879 20-24-6 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-17

Disassembly (Cont’d)

Figure 20-24-15

P-86504

Remove the set screw (Item 1) [Figure 20-24-17].


P-86503
Figure 20-24-18

Remove the rod assembly (Item 1) [Figure 20-24-15]


from the housing.
1

Dealer Copy -- Not for Resale


Figure 20-24-16

P-86506

1
Apply moderate heat to the nut (Item 1) [Figure 20-24-
18].
P-86505
Remove the nut.

Clamp the rod end in a vise. Support the end of the rod
with a block (Item 1) [Figure 20-24-16].

193 of 879 20-24-7 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-21

Disassembly (Cont’d)

Figure 20-24-19

P-86541

Remove the wear ring (Item 1) [Figure 20-24-21].


P-86508
Figure 20-24-22

Remove the piston (Item 1) [Figure 20-24-19].

Dealer Copy -- Not for Resale


Figure 20-24-20

P-86548

Remove the back-up ring (Item 1) [Figure 20-24-22].


P-86542
NOTE: The slipper seal consists of four separate
pieces that are removed individually.
Remove the seal (Item 1) [Figure 20-24-20].

194 of 879 20-24-8 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-25

Disassembly (Cont’d)

Figure 20-24-23

P-86532

Remove the slipper seal (Item 1) [Figure 20-24-25].


P-86508
Figure 20-24-26

Remove the wear ring (Item 1) [Figure 20-24-23].

Dealer Copy -- Not for Resale


Figure 20-24-24

P-86531

Remove the seal (Item 1) [Figure 20-24-26].


P-86533

Remove the back-up ring (Item 1) [Figure 20-24-24].

195 of 879 20-24-9 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-29

Disassembly (Cont’d)

Figure 20-24-27 1

P-86517

Remove the back-up ring (Item 1) [Figure 20-24-29].


P-86515
Figure 20-24-30

Remove the back-up ring (Item 1) [Figure 20-24-27]


from the inside of the piston.
1

Dealer Copy -- Not for Resale


Figure 20-24-28

P-86518
1

Remove the head (Item 1) [Figure 20-24-30] from the


cylinder rod.
P-86516

Remove the O-ring (Item 1) [Figure 20-24-28].

196 of 879 20-24-10 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-33

Disassembly (Cont’d)

Figure 20-24-31

P-86524
1

Remove the O-ring (Item 1) [Figure 20-24-33].


P-86519
Figure 20-24-34

Remove the O-ring (Item 1) [Figure 20-24-31] from the


head.
1

Dealer Copy -- Not for Resale


Figure 20-24-32

P-86525

Remove the snap ring (Item 1) [Figure 20-24-34] from


the inside of the head.
P-86523

Remove the back-up ring (Item 1) [Figure 20-24-32].

197 of 879 20-24-11 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-37

Disassembly (Cont’d)

Figure 20-24-35

P-86529

Remove the seal (Item 1) [Figure 20-24-37].


P-86508
Figure 20-24-38

Remove the wiper seal (Item 1) [Figure 20-24-35].

Dealer Copy -- Not for Resale


Figure 20-24-36
2 1

1 P-86531

Remove the snap ring (Item 1) and bushing (Item 2)


P-86527 [Figure 20-24-38].

Remove the seal (Item 1) [Figure 20-24-36].

198 of 879 20-24-12 E80 Service Manual


CYLINDER (BLADE) (CONT'D)

Disassembly (Cont’d)

Figure 20-24-39

P-86544

Remove the bushing (Item 1) [Figure 20-24-39] from the


rod.

Dealer Copy -- Not for Resale


Figure 20-24-40

P-86533

Remove the bushing (Item 1) [Figure 20-24-40] from the


base end.

199 of 879 20-24-13 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-42

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander


MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
1
Wash the cylinder parts in clean solvent and dry with
compressed air.

Inspect the cylinder parts for nicks, scratches and other


damage. Replace any damaged parts.
P-86544
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-24-42] into the
assembly. rod.

Figure 20-24-41 Figure 20-24-43

Dealer Copy -- Not for Resale


2 1

P-86543 P-86530

Install the bushing (Item 1) [Figure 20-24-41] into the Install the bushing (Item 1) and snap ring (Item 2)
base end of the housing. [Figure 20-24-43] into the head.

200 of 879 20-24-14 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-46

Assembly (Cont’d)

Figure 20-24-44

1 1

P-86526

Install the wiper seal (Item 1) [Figure 20-24-46].


P-86529
Figure 20-24-47

Install the seal (Item 1) [Figure 20-24-44].

Dealer Copy -- Not for Resale


Figure 20-24-45

1
1

P-86525

Install the snap ring (Item 1) [Figure 20-24-47].


P-86527

Install the seal (Item 1) [Figure 20-24-45].

201 of 879 20-24-15 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-50

Assembly (Cont’d)

Figure 20-24-48

P-86519

Install the O-ring (Item 1) [Figure 20-24-50].


P-8624
Install the rod end in a vise.

Install the O-ring (Item 1) [Figure 20-24-48]. Figure 20-24-51

Dealer Copy -- Not for Resale


Figure 20-24-49

P-86518

P-86523
Install the head (Item 1) [Figure 20-24-51] onto the
cylinder rod.
Install the back-up ring (Item 1) [Figure 20-24-49].

202 of 879 20-24-16 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-54

Assembly (Cont’d)

Figure 20-24-52
1

P-86515

Install the back-up ring (Item 1) [Figure 20-24-54].


P-86517
Figure 20-24-55

Install the back-up ring (Item 1) [Figure 20-24-52].

Dealer Copy -- Not for Resale


Figure 20-24-53

1
1

P-86531

Install the seal (Item 1) [Figure 20-24-55].


P-86516

Install the O-ring (Item 1) [Figure 20-24-53].

203 of 879 20-24-17 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-58

Assembly (Cont’d)

Figure 20-24-56
1

P-86540

Install the wear ring (Item 1) [Figure 20-24-58].


P-86532
Figure 20-24-59

Install the slipper seal (Item 1) [Figure 20-24-56].

Dealer Copy -- Not for Resale


Figure 20-24-57

P-86548

Install the back-up ring (Item 1) [Figure 20-24-59].


P-86533

Install the back-up ring (Item 1) [Figure 20-24-57].

204 of 879 20-24-18 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-62

Assembly (Cont’d)

Figure 20-24-60

1
2

P-86507

Install the piston (Item 1) [Figure 20-24-62] onto the


P-86541 cylinder rod.

Figure 20-24-63
Install the wear ring (Item 1) [Figure 20-24-60].

Dealer Copy -- Not for Resale


Figure 20-24-61

P-86506

P-86542 Install the nut (Item 1) [Figure 20-24-63].

Tighten the nut until the bore of the set screw is aligned
Install the seal (Item 1) [Figure 20-24-61]. with the groove (Item 2) [Figure 20-24-62] of the rod.

205 of 879 20-24-19 E80 Service Manual


CYLINDER (BLADE) (CONT'D) Figure 20-24-66

Assembly (Cont’d)

Figure 20-24-64

P103657

Install the head (Item 1) [Figure 20-24-66] onto the


P-86504 housing.

Figure 20-24-67
Install the set screw (Item 1) [Figure 20-24-64].

Dealer Copy -- Not for Resale


Use a center punch to deform the threads of the set
screw bore.

Remove the rod assembly from the vise.

Clamp the base end of the cylinder housing in a vise.

Figure 20-24-65
1

P-86501
1

Bend the lock ring tab (Item 1) [Figure 20-24-67] into the
groove on the head.

P-86503

Install the rod assembly (Item 1) [Figure 20-24-65] into


the housing.

206 of 879 20-24-20 E80 Service Manual


CYLINDER (BLADE) (CONT'D)

Assembly (Cont’d)

Figure 20-24-68

P-86500

Install the fittings (Item 1) [Figure 20-24-68] into the


housing.

Dealer Copy -- Not for Resale

207 of 879 20-24-21 E80 Service Manual


Dealer Copy -- Not for Resale

208 of 879 20-24-22 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-3

Testing
2
Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.

Figure 20-25-1

1
S37546

Remove the stoppers (Item 1) (both sides), the shims


(both sides) and the rod end pivot pin (Item 2) [Figure
20-25-3].

Figure 20-25-4

Dealer Copy -- Not for Resale


S37544

Support the boom with a chain hoist (Item 1) [Figure 20-


25-1].
1
Figure 20-25-2 2

S37547
1

Lower the cylinders (Item 1) [Figure 20-25-4]. Remove


the shims.

Start the engine and fully retract the cylinder rods (Item 2)
2 [Figure 20-25-4].

S37545 Stop the engine. Relieve hydraulic pressure.

Install a sling (Item 1) [Figure 20-25-2] and lifting device


to the rod end of both cylinders.

Remove the nuts (Item 2) and bolt (Item 3) [Figure 20-


25-3] (Both sides).

209 of 879 20-25-1 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL)
(CONT’D)

Testing (Cont’d)

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

Figure 20-25-5

Dealer Copy -- Not for Resale


1

S37548

Remove the hose (Item 1) [Figure 20-25-5] from the


base end of both cylinders. Cap the hoses.

Start the engine and retract the cylinders.

If there is any oil leakage from the base end fittings (Item
1) [Figure 20-25-5], remove the cylinder for repair or
replacement.

210 of 879 20-25-2 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-8
(CONT’D)
1
Removal And Installation
5
2
NOTE: The left cylinder is shown. The procedure is
the same for the right cylinder. 4

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure. 3

Figure 20-25-6
S37650

1 Remove the hose (Item 1) [Figure 20-25-8].

Remove the bolt (Item 2) [Figure 20-25-8] and washer.

Remove the adapter (Item 3) from the fitting (Item 4)


[Figure 20-25-8].

Dealer Copy -- Not for Resale


Remove the valve (Item 5) [Figure 20-25-8] from the
cylinder housing.

Figure 20-25-9
S37544

2
Support the boom with a chain hoist (Item 1) [Figure 20-
25-6].

Figure 20-25-7

1
3
S37651

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


25-9].

Remove the stopper (Item 3) and shims. [Figure 20-25-


S37549 9].

Install a sling (Item 1) [Figure 20-25-7] and lifting device


to the rod end of the cylinder.

211 of 879 20-25-3 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL)
(CONT’D)

Removal And Installation (Cont’d)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-25-10

Dealer Copy -- Not for Resale


3

1
S37653

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-


25-10].

Remove the stopper (Item 3) and the shims [Figure 20-


25-10].

Remove the cylinder by sliding it off the pivot pins.

212 of 879 20-25-4 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL)
(CONT’D)

Parts Identification

1. Bushing
2. Housing
3. Band
4. Bolt
5. Washer 4
6. Set Screw 3
7. Nut
8. Piston
9. Wear Ring 5
10. Seal
1
11. O-ring
12. Back-up Ring
13. Bushing 4
5
14. Head
15. Inner Seal 6
16. Wiper
17. Snap Ring 3
18. Rod

Dealer Copy -- Not for Resale


2
7

8
9
10
10
11
11
12
17
13
11

14
11
15
16
17

18

NA5527S

213 of 879 20-25-5 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-13
(CONT’D)

Disassembly

Use the following tools to disassemble the cylinder: 1

MEL1074 - O-ring Seal Hook

Hold the hydraulic cylinder over a drain pan and slowly


move the rod in and out to remove the fluid from the
cylinder.

Figure 20-25-11

S37656
1

Straighten the lock ring tab (Item 1) [Figure 20-25-13].

Figure 20-25-14

Dealer Copy -- Not for Resale


S37654

Clamp the base end (Item 1) [Figure 20-25-11] of the


cylinder in a vise.

Figure 20-25-12
S37657

Remove the head (Item 1) [Figure 20-25-14] from the


housing.

Remove the rod assembly from the housing.


1
Remove the cylinder from the vise.

S37655

Support the cylinder with a block (Item 1) [Figure 20-25-


12].

214 of 879 20-25-6 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-17
(CONT’D)

Disassembly (Cont’d)

Figure 20-25-15

P-87390

1
Clamp the rod end in a vise. Support the rod with a block
(Item 1) [Figure 20-25-17].
P-87424
Figure 20-25-18

Remove the fitting (Item 1) [Figure 20-25-15].

Dealer Copy -- Not for Resale


Figure 20-25-16

1
1

S37688

Remove the set screw (Item 1) [Figure 20-25-18].


P-87425

Remove the seal (Item 1) (both sides) and bushing (Item


2) [Figure 20-25-16].

215 of 879 20-25-7 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-21
(CONT’D)

Disassembly (Cont’d)

Figure 20-25-19

S37690

Remove the wear ring (Item 1) [Figure 20-25-21].

S37692 Figure 20-25-22

Apply moderate heat to the nut (Item 1) [Figure 20-25-


19]. Remove the nut.

Dealer Copy -- Not for Resale


Figure 20-25-20

S37689

1 Remove the seal (Item 1) [Figure 20-25-22].

S37687

Remove the piston (Item 1) [Figure 20-25-20].

216 of 879 20-25-8 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-25
(CONT’D)

Disassembly (Cont’d)

Figure 20-25-23

1
P-87435

Remove the head (Item 1) [Figure 20-25-25].

S37691 Figure 20-25-26

Remove the seal (Item 1) [Figure 20-25-23].

Dealer Copy -- Not for Resale


Figure 20-25-24
1

P-87436
1

Remove the O-ring (Item 1) [Figure 20-25-26].

P-87434

Remove the O-ring (Item 1) [Figure 20-25-24].

217 of 879 20-25-9 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-29
(CONT’D)

Disassembly (Cont’d)

Figure 20-25-27
1

P-87439

Remove the lock ring (Item 1) [Figure 20-25-29].

P-87437 Figure 20-25-30

Remove the back-up ring (Item 1) [Figure 20-25-27].

Dealer Copy -- Not for Resale


Figure 20-25-28 1

P-87440

Remove the snap ring (Item 1) [Figure 20-25-30].

P-87438

Remove the O-ring (Item 1) [Figure 20-25-28].

218 of 879 20-25-10 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-33
(CONT’D)

Disassembly (Cont’d)

Figure 20-25-31
1

P-87443

1
Remove the bushing (Item 1) [Figure 20-25-33].

P-87444 Figure 20-25-34

Remove the wiper seal (Item 1) and inner seal (Item 2)


[Figure 20-25-31].

Dealer Copy -- Not for Resale


1
Figure 20-25-32

1 2

P-87445

Remove the seal (Item 1) (both sides) and bushing (Item


2) [Figure 20-25-34].

P-87442

Remove the snap ring (Item 1) [Figure 20-25-32].

219 of 879 20-25-11 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-36
(CONT’D)

Assembly

Use the following tools to assemble the cylinder:


1
MEL1396 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor

Wash the cylinder parts in clean solvent and dry with


compressed air.

Inspect the cylinder parts for nicks, scratches and other


damage. Replace any damaged parts.
P-87443

Always install new O-rings and seals during assembly.


Install the bushing (Item 1) [Figure 20-25-36] into the
Lubricate all O-rings and seals with hydraulic oil during head.
assembly.
Figure 20-25-37
Figure 20-25-35

Dealer Copy -- Not for Resale


1

1
P-87442
P-87445

Install the snap ring (Item 1) [Figure 20-25-37].


Install the bushing (Item 1) and seal (Item 2) [Figure 20-
25-35] (Both sides).

220 of 879 20-25-12 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-40
(CONT’D)

Assembly (Cont’d)

Figure 20-25-38
1

P-87439

1 2
Install the lock ring (Item 1) [Figure 20-25-40].

P-87444 Figure 20-25-41

Install the inner seal (Item 1) and wiper seal (Item 2)


[Figure 20-25-38].

Dealer Copy -- Not for Resale


Figure 20-25-39 1

P-87438

Install the O-ring (Item 1) [Figure 20-25-41].

Figure 20-25-42
P-87440

Install the snap ring (Item 1) [Figure 20-25-39].

P-87437

Install the back-up ring (Item 1) [Figure 20-25-42].

221 of 879 20-25-13 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-45
(CONT’D)

Assembly (Cont’d)

Figure 20-25-43 1

P-87434

Install the O-ring (Item 1) [Figure 20-25-45] in the piston.

P-87436 Figure 20-25-46

Install the O-ring (Item 1) [Figure 20-25-43].

Dealer Copy -- Not for Resale


Clamp the rod end in a vise. Support the rod with a block.
1
Figure 20-25-44

S37691

Install the seal (Item 1) [Figure 20-25-46].

1
P-87435

Install the head (Item 1) [Figure 20-25-44].

222 of 879 20-25-14 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-49
(CONT’D)

Assembly (Cont’d)
2
Figure 20-25-47

S37687

Install the piston (Item 1) [Figure 20-25-49].

S37689 Figure 20-25-50

Install the seal (Item 1) [Figure 20-25-47].

Dealer Copy -- Not for Resale


Figure 20-25-48 1

1
S37692

Install the nut (Item 1) [Figure 20-25-50].

S37690 Tighten the nut until the bore of the set screw is aligned
with the groove (Item 2) [Figure 20-25-49] of the rod.

Install the wear ring (Item 1) [Figure 20-25-48].

223 of 879 20-25-15 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-53
(CONT’D)

Assembly (Cont’d)

Figure 20-25-51 1

1
P-87425

Install the bushing (Item 1) and seal (Item 2) [Figure 20-


25-53] into the rod end (Both sides).
S37688
Figure 20-25-54

Install the set screw (Item 1) [Figure 20-25-51].

Dealer Copy -- Not for Resale


Use a center punch to deform the threads of the set
screw bore.

Figure 20-25-52

P-87424

Install the fitting (Item 1) [Figure 20-25-54].

Clamp the cylinder housing in a vise. Support the cylinder


with a block.
P-87426
Install the rod assembly into the housing.

Remove the rod from the vise [Figure 20-25-52].

224 of 879 20-25-16 E80 Service Manual


CYLINDER (ARTICULATED BOOM) (OPTIONAL) Figure 20-25-57
(CONT’D)

Assembly (Cont’d)

Figure 20-25-55

S37655

Remove the cylinder from the vise [Figure 20-25-57].

S37656

Tighten the head (Item 1) [Figure 20-25-55].

Dealer Copy -- Not for Resale


Figure 20-25-56

S37657

Bend the lock ring tab (Item 1) [Figure 20-25-56] into the
groove on the head.

225 of 879 20-25-17 E80 Service Manual


Dealer Copy -- Not for Resale

226 of 879 20-25-18 E80 Service Manual


VALVES (RELIEF)

Description

Figure 20-30-1

P-86566

Figure 20-30-2

Dealer Copy -- Not for Resale


1

P-86558

The piston pump circuit has one load sense relief valve
(Item 1) [Figure 20-30-1] and one back-up relief valve
(Item 1) [Figure 20-30-2] located on the hydraulic control
valve. The load sense relief valve (Item 1) [Figure 20-30-
1] is factory set at 28000 kPa (280 bar) (4060 psi).

The back-up relief valve (Item 1) [Figure 20-30-2] is set


at 34000 kPa (340 bar) (4931 psi), 3000 kPa (30 bar)
(435 psi) higher than the load sense relief.

The back-up relief valve and load sense relief valve are
tested and adjusted during the piston pump testing and
adjusting. (See Pump Testing on Page 20-50-6.)

227 of 879 20-30-1 E80 Service Manual


Dealer Copy -- Not for Resale

228 of 879 20-30-2 E80 Service Manual


VALVES (PORT RELIEF) Base End (Item 4) [Figure 20-31-1] 31000 kPa (310 bar)
(4495 psi)
Testing And Adjusting The Port Relief Valve
Pressure Arm Port Relief set at:
Rod End (Item 5) [Figure 20-31-1] 31000 kPa (310 bar)
(4495 psi)
Base End (Item 6) [Figure 20-31-1] 31000 kPa (310 bar)
IMPORTANT (4495 psi)

Figure 20-31-2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
3
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 2
I-2003-0888

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

When testing the port relief valves with a hydraulic hand


pump, slowly pressurize the valve. If the hand pump is
pumped fast, the pressure will be altered by as much as
350 kPa (3,5 bar) (50 psi).
1

Dealer Copy -- Not for Resale


When testing the port relief valves with a hydraulic hand P-86423
pump, the valve crack pressure should be observed.

A portable hydraulic hand pump will be used to test the Install the hand pump (Item 1), hose (Item 2) and a
work port relief valves. The hand pump must have clean pressure gauge (Item 3) [Figure 20-31-2] (minimum of
Bobcat hydraulic fluid. 34500 kPa (345 bar) (5000 psi) into the valve section
work port in which the port relief valve is located.
Figure 20-31-1 Pressurize this section with the hand pump until the port
relief valve opens. Record the pressure reading.

If the port relief pressure setting needs to be adjusted,


release the hand pump pressure valve.
4
Figure 20-31-3
2

5
1 P-86413

Boom Port Relief set at:


Rod End (Item 1) [Figure 20-31-1] 31000 kPa (310
bar) (4495 psi) 1
Base End (Item 2) [Figure 20-31-1] 31000 kPa (310 P-86411
bar) (4495 psi)

Bucket Port Relief set at: Remove the protective cap (Item 1) [Figure 20-31-3].
Rod End (Item 3) [Figure 20-31-1] 31000 kPa (310 bar)
(4495 psi)

229 of 879 20-31-1 E80 Service Manual


VALVES (PORT RELIEF) (CONT'D)

Testing And Adjusting The Port Relief Valve


Pressure (Cont’d)

Figure 20-31-4

2
P-86412

Loosen the lock nut (Item 1) [Figure 20-31-4].

Dealer Copy -- Not for Resale


Turn the adjusting screw (Item 2) [Figure 20-31-4]
clockwise to increase the pressure and counterclockwise
to reduce the pressure.

NOTE: One-quarter turn is approximately 6900 kPa


(69 bar) (1000 psi). When the correct pressure
setting is obtained, tighten the locknut while
holding the adjustment screw from turning.

Adjust the port relief valve until the correct setting is


obtained.

Install the protective cap.

230 of 879 20-31-2 E80 Service Manual


VALVE (PILOT PRESSURE RELIEF) Figure 20-32-1

Testing And Adjusting The Pressure Reducing Valve

The pressure reducing valve supplies lower hydraulic


pressure to joysticks.

With the engine off, and the key in the run position, lower 1
the left console and move both joysticks to relieve
hydraulic pressure.

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

WARNING P-86423

AVOID INJURY OR DEATH Install the test fittings and 6900 kPa (69 bar) (1000 psi)
Never work under the excavator cab without gauge (Item 1) [Figure 20-32-1] in between the A-1 port
installing an approved cab support device. fitting and existing hose. Route the gauge to the outside
W-2435-0502 of the excavator.

Lower the cab. (See Tilting The Cab on Page 10-210-1.)


Figure 10-141-1

Dealer Copy -- Not for Resale


Enter the cab, start the engine and warm up the hydraulic
fluid to operating temperature.

1 With the hydraulic fluid at operating temperature, run the


engine at full rpm.
2
The pressure at the gauge should be 3200 kPa (32 bar)
(464 psi).

Move the engine speed control to low idle speed.

Stop the engine.

With the engine off, and the key in the run position, lower
P-86422 the left console and move both joysticks to relieve
hydraulic pressure.
The pressure reducing valve (Item 1) [Figure 10-141-1]
is located on the end of the manifold. If adjustment is needed, remove the center cover. (See
Removal And Installation on Page 40-70-1.)
Remove the hose (Item 2) [Figure 10-141-1] from the A-
1 port.

231 of 879 20-32-1 E80 Service Manual


VALVE (PILOT PRESSURE RELIEF) (CONT'D) If the pressure is still incorrect, relieve hydraulic
pressure, tilt the cab and remove the pressure reducing
Testing And Adjusting The Pressure Reducing Valve valve from the manifold assembly for inspection or repair.
(Cont'd)
If the amount of oil pressure is at or over the service
Figure 20-32-2 limits, it is an indication of worn O-rings and back-up
rings on the pressure reducing valve, or a stuck pressure
reducing valve.

Inspect the port of the pressure reducing valve on the


manifold assembly to verify that there is no damage. If
damaged, replace the manifold assembly.
2
Figure 20-32-4

P-86425

Figure 20-32-3

Dealer Copy -- Not for Resale


P-86427

Inspect the O-rings and back-up rings on the pressure


reducing valve [Figure 20-32-4]. If O-rings and back-up
rings are worn or damaged, replace O-rings and back-up
1
rings. (See Disassembly And Assembly on Page 20-60-
2 2.)

Re-install the pressure reducing valve in the manifold


P-86426 assembly.

Repeat the pressure reducing valve test.


Loosen the nut (Item 1) [Figure 20-32-2] and [Figure 20-
32-3]. If the O-rings and back-rings were not worn or damaged
and the correct pressure could not be achieved, replace
Turn the adjustment screw (Item 2) [Figure 20-32-2] and the pressure reducing valve.
[Figure 20-32-3] clockwise to increase the pressure or
counterclockwise to decrease the pressure.

NOTE: 1/4 turn is approximately 340 kPa (3,4 bar) (50


psi).

Tighten the nut (Item 1) [Figure 20-32-2] and [Figure 20-


32-3].

Retest the pressure reducing valve after adjustment.

NOTE: The valve adjustment is accessible with the


cab lowered. The cab is tilted for photo clarity.

232 of 879 20-32-2 E80 Service Manual


HYDRAULIC CONTROL VALVE Figure 20-40-2

Description

The hydraulic control valve is located between the pump,


cylinders and motors on the oil pressure circuit. Each
component within the hydraulic control valve operates
and controls oil flowing from the main pump. Such control
changes operation, direction or speed of cylinders and
motors.

The hydraulic control valve has three main relief valves


that operate at 30000 kPa (300 bar) (4278 psi). The
bucket, boom 1, arm 1, boom 2 / auxiliary, tilting
(optional) and boom swing sections have 31000 kPa
(310 bar) (4496 psi) work port relief valves. The rotary P-87117
section has a 25000 kPa (250 bar) (3626 psi) work port
relief valve.
Remove the pilot lines from the inboard side of the valve
Removal And Installation [Figure 20-40-2].

Remove the left upperstructure cover. (See Removal And Figure 20-40-3
Installation on Page 40-20-1.)

Dealer Copy -- Not for Resale


Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-87118

Figure 20-40-1
Remove the pilot lines from the outboard side of the
valve [Figure 20-40-3].

P-87116

Mark and remove the hoses from the top of the valve
[Figure 20-40-1].

233 of 879 20-40-1 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-6

Removal And Installation (Cont’d)

Figure 20-40-4

1
1

P-87121

Remove the fitting (Item 1). Remove the bolt (Item 2)


P-87119 [Figure 20-40-6] and washer.

Figure 20-40-7
Remove the bolt (Item 1) [Figure 20-40-4] and washer.

Dealer Copy -- Not for Resale


Figure 20-40-5
2

1
1
1

P-87122

P-87120 Install lifting brackets (Item 1) on both ends of the valve.


Install a chain (Item 2) [Figure 20-40-7] and hoist on the
lifting brackets. Lift and remove the valve.
Remove the two bolts (Item 1) [Figure 20-40-5] and
washers.

234 of 879 20-40-2 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D)

Parts Identification

1. Inlet Valve Section


2. Boom Valve Section
3. Bucket Valve Section
4. Arm Valve Section
5. Blade Valve Section
6. Auxiliary Valve Section
7. Left Travel Valve Section
8. Right Travel Valve Section
9. Boom Swing Valve Section
10. Mid Inlet Valve Section
11. Upperstructure Swing Valve Section
12. Outlet Valve Section
13. Load Sense Relief Valve 28000 kPa (280 bar) (4060 psi)
14. Back-up Relief Valve 34000 kPa (340 bar) (4931 psi)
15. Boom Port Relief Valves 30000 kPa (300 bar) (4350 psi)
16. Bucket Port Relief Valves 30000 kPa (300 bar) (4350 psi)
17. Arm Port Relief Valves 30000 kPa (300 bar) (4350 psi)

Dealer Copy -- Not for Resale


13
15
16 2
17 1
3
4
5 14
6
7
8
9
10
11
12

15
16
17

MS2831S

235 of 879 20-40-3 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-10

Disassembly And Assembly

Figure 20-40-8

1
1

P-87128

Remove the outlet valve section (Item 1) [Figure 20-40-


P-87126 10].

Figure 20-40-11
Remove the bolts (Item 1) [Figure 20-40-8], washers
and mounts.

Dealer Copy -- Not for Resale


1
Figure 20-40-9

1 1

P-87129

Remove the four O-rings (Item 1) [Figure 20-40-11].


1 P-87127

Remove the three nuts (Item 1) [Figure 20-40-9].

Installation: Tighten the nuts to 32 - 38 N•m (24 - 28 ft-


lb) torque.

236 of 879 20-40-4 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-14

Disassembly And Assembly (Cont’d)

Figure 20-40-12
Articulated Boom 1

P-87130

Remove the swing valve section (Item 1) [Figure 20-40-


S37679 14].

Figure 20-40-15
Remove the articulated boom valve section (Item 1)
[Figure 20-40-12]. (If equipped.)

Dealer Copy -- Not for Resale


Figure 20-40-13 1
Articulated Boom

1 1

P-87131

1 1
Remove the four O-rings (Item 1) [Figure 20-40-15].
P-87131

Remove the four O-rings (Item 1) [Figure 20-40-13].

237 of 879 20-40-5 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-18

Disassembly And Assembly (Cont’d)

Figure 20-40-16

1
1

1
1

2
P-87134

Remove the four O-rings (Item 1). Remove the right hand
P-87132 travel valve section (Item 2) [Figure 20-40-18].

Figure 20-40-19
Remove the mid inlet (Item 1) [Figure 20-40-16] valve
section.

Dealer Copy -- Not for Resale


Figure 20-40-17
1

2
1 P-87135

Remove the four O-rings (Item 1). Remove the left hand
2 travel valve section (Item 2) [Figure 20-40-19].
P-87133

Remove the four O-rings (Item 1). Remove the boom


swing valve section (Item 2) [Figure 20-40-17].

238 of 879 20-40-6 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-22

Disassembly And Assembly (Cont’d)

Figure 20-40-20 1

2 1

P-87138
1
Remove the four O-rings (Item 1). Remove the arm valve
P-87136 section (Item 2) [Figure 20-40-22].

Figure 20-40-23
Remove the four O-rings (Item 1). Remove the auxiliary
valve section (Item 2) [Figure 20-40-20].

Dealer Copy -- Not for Resale


Figure 20-40-21 1

1
2

1
P-87139

2 Remove the four O-rings (Item 1). Remove the bucket


P-87137 valve section (Item 2) [Figure 20-40-23].

Remove the four O-rings (Item 1). Remove the blade


valve section (Item 2) [Figure 20-40-21].

239 of 879 20-40-7 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-40-24

P-87140

Remove the four O-rings (Item 1). Remove the boom


valve section (Item 2) [Figure 20-40-24] valve section.

Dealer Copy -- Not for Resale


Figure 20-40-25

2 1

P-87141

Remove the four O-rings (Item 1). Remove the tie rods
(Item 2) [Figure 20-40-25] from the inlet valve section.

240 of 879 20-40-8 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-28

Inlet Valve Section Disassembly And Assembly

Figure 20-40-26 1
1

1 2

P-87144
2

Remove the O-rings (Item 1) and back-up ring (Item 2)


P-87142 [Figure 20-40-28] from the back-up relief valve.

Figure 20-40-29
Remove the load sense relief valve (Item 1) and back-up
relief valve (Item 2) [Figure 20-40-26].

Dealer Copy -- Not for Resale


Installation: Tighten the relief valves to 41 - 49 N•m (30 -
60 ft-lb) torque.

Figure 20-40-27
1

1 1

P-87145

Remove the load sense bleed cartridge (Item 1) [Figure


2 20-40-29].

Installation: Tighten the cartridge to 18 - 22 N•m (13 - 17


P-87143 ft-lb) torque.

Remove the O-rings (Item 1) and back-up ring (Item 2)


[Figure 20-40-27] from the load sense relief valve.

241 of 879 20-40-9 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-32

Inlet Valve Section Disassembly And Assembly


1
(Cont’d)

Figure 20-40-30

P-35277

1
Remove the O-ring (Item 1) [Figure 20-40-32].

P-35275 Figure 20-40-33

Remove the O-rings (Item 1) and back-up ring (Item 2)

Dealer Copy -- Not for Resale


from the flow regulator. Remove the filter (Item 3) [Figure
20-40-30] from the end of the cartridge. 1

Figure 20-40-31

P-87147

Remove the spring (Item 1) [Figure 20-40-33].

P-87146

Remove the plug (Item 1) [Figure 20-40-31].

242 of 879 20-40-10 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D)

Inlet Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-40-34

P-87148

Remove the spool (Item 1) [Figure 20-40-34].

Dealer Copy -- Not for Resale


Figure 20-40-35

P-87149

Remove the shims (Item 1) [Figure 20-40-35] from the


spool.

243 of 879 20-40-11 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-38

Boom, Arm And Bucket Valve Section Disassembly


And Assembly 1

Figure 20-40-36

1
1

P-87156

Remove the plug (Item 1) [Figure 20-40-38].

P-87155 Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-


lb) torque.

Remove the relief valves (Item 1) [Figure 20-40-36]. Figure 20-40-39

Dealer Copy -- Not for Resale


Installation: Tighten the valves to 70 N•m (52 ft-lb)
torque.
1
Figure 20-40-37

1
1

P-35253

2 Remove the O-ring (Item 1) [Figure 20-40-39].

P-35260

Remove the O-rings (Item 1) and back-up ring (Item 2)


[Figure 20-40-37].

244 of 879 20-40-12 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-42

Boom, Arm And Bucket Valve Section Disassembly


And Assembly (Cont’d)

Figure 20-40-40

1
1

P-35279

Remove the O-ring (Item 1) [Figure 20-40-42] from both


covers.
P-87157
Figure 20-40-43

Remove the compensator (Item 1) [Figure 20-40-40].

Dealer Copy -- Not for Resale


Figure 20-40-41

1
1
1
2 2

2
P-35266

1
Remove the centering spring (Item 1) [Figure 20-40-43]
P-87158 from both ends.

Remove the spring seat (Item 2) [Figure 20-40-43] from


Remove the four screws (Item 1) [Figure 20-40-41] from both ends.
both ends of the valve.

Installation: Tighten the screws to 25 N•m (18 ft-lb)


torque.

Remove both covers (Item 2) [Figure 20-40-41].

245 of 879 20-40-13 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
Boom, Arm And Bucket Valve Section Disassembly damaged.
And Assembly (Cont’d)
Figure 20-40-46
Figure 20-40-44

P-87151
P-35267

Record the orientation of the spool (Item 1) [Figure 20- Apply moderate heat to the plug (Item 1) [Figure 20-40-
40-44]. 46] to melt the thread adhesive. Remove the plug from

Dealer Copy -- Not for Resale


both ends of the spool.
Remove the spool (Item 1) [Figure 20-40-44].
Installation: Apply thread adhesive (Loctite® 242) to the
NOTE: The spool is not symmetrical. Incorrect spool plug threads.
installation will cause poor hydraulic valve
performance. Figure 20-40-47

NOTE: The boom spool can be disassembled. Follow


the steps from [Figure 20-40-45] through
[Figure 20-40-48] to disassemble the spool. 1

Figure 20-40-45

Cut

0.5625 Dia
2.0 in

P-87152

Remove the O-ring (Item 1) [Figure 20-40-47] from the


1.500 in plugs.

0.750 in B-14674

To remove the plugs from the boom spool, a holding


fixture will have to be made from a 19 mm thick x 38 mm
wide x 50 mm long (0.750 in thick x 1.500 in wide x 2.0 in
long) piece of hardwood. Drill a 14 mm (0.5625 in) hole in
the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-45].

246 of 879 20-40-14 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-50

Boom, Arm And Bucket Valve Section Disassembly


And Assembly (Cont’d)

Figure 20-40-48

2 3
1

P-35269

3 1
Remove the poppet (Item 1) and spring (Item 2) from the
plug. Remove the O-ring (Item 3) [Figure 20-40-50] from
P-87154 the plug.

Remove the spring (Item 1), sleeve (Item 2) and poppet

Dealer Copy -- Not for Resale


(Item 3) [Figure 20-40-48] from both ends of the spool.

Figure 20-40-49

1
P-35268

Remove the check valves (Item 1) [Figure 20-40-49].

Installation: Tighten the check valves to 27 - 33 N•m (20


- 24 ft-lb) torque.

247 of 879 20-40-15 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-53

Left Travel, Right Travel And Blade Valve Section


Disassembly And Assembly

Figure 20-40-51

1 1

P-87165

Remove the plug (Item 1) [Figure 20-40-53].

P-87164 Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-


lb) torque.

Remove the plugs (Item 1) [Figure 20-40-51]. Figure 20-40-54

Dealer Copy -- Not for Resale


Installation: Tighten the plugs to 70 N•m (52 ft-lb)
torque.
1
Figure 20-40-52

P-35253
1
2
Remove the O-ring (Item 1) [Figure 20-40-54].

P-87160

Remove the O-rings (Item 1) and back up ring (Item 2)


[Figure 20-40-52].

248 of 879 20-40-16 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-57

Left Travel, Right Travel And Blade Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-40-55

P-35279

Remove the O-ring (Item 1) [Figure 20-40-57].

P-87157 Figure 20-40-58

Remove the compensator (Item 1) [Figure 20-40-55].

Dealer Copy -- Not for Resale


Figure 20-40-56
1
2

1
2
2

1 P-35266

1 Remove the centering spring (Item 1) [Figure 20-40-58]


from both ends.
P-87158
Remove the spring seat (Item 2) [Figure 20-40-58] from
both ends.
Remove the four screws (Item 1) [Figure 20-40-56] from
both ends of the valve.

Installation: Tighten the screws to 25 N•m (18 ft-lb)


torque.

Remove both covers (Item 2) [Figure 20-40-56].

249 of 879 20-40-17 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-61

Left Travel, Right Travel And Blade Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-40-59

1 2
1 3

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the


plug. Remove the O-ring (Item 3) [Figure 20-40-61] from
P-35267 the plug.

Figure 20-40-62
Remove the spool (Item 1) [Figure 20-40-59].

Dealer Copy -- Not for Resale


Figure 20-40-60

P-87167

P-35268 Remove the orifice (Item 1) [Figure 20-40-62].

NOTE: The right travel valve section is the only


Remove the check valves (Item 1) [Figure 20-40-60]. section equipped with an orifice.

Installation: Tighten the check valves to 27 - 33 N•m (20


- 24 ft-lb) torque.

250 of 879 20-40-18 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D)

Left Travel, Right Travel And Blade Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-40-63

P-87168

Inspect the orifice (Item 1) [Figure 20-40-63] for damage

Dealer Copy -- Not for Resale


and plugging.

251 of 879 20-40-19 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-66

Auxiliary And Slew Valve Section Disassembly And


Assembly 1

Figure 20-40-64

P-87161

Remove the plug (Item 1) [Figure 20-40-66].

P-87159 Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-


lb) torque.

Remove the plugs (Item 1) [Figure 20-40-64]. Figure 20-40-67

Dealer Copy -- Not for Resale


Installation: Tighten the plug to 70 N•m (52 ft-lb) torque.

Figure 20-40-65 1

2 1

1 P-35253

Remove the O-ring (Item 1) [Figure 20-40-67].


P-87160

Remove the O-rings (Item 1) and back-up ring (Item 2)


[Figure 20-40-65].

252 of 879 20-40-20 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-70

Auxiliary And Slew Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-40-68 2
1

P-35281

Hold the spool stroke limitation adjustment screw (Item 1)


to remove the fitting (Item 2) [Figure 20-40-70].
P-87157
Figure 20-40-71

Remove the compensator (Item 1) [Figure 20-40-68].

Dealer Copy -- Not for Resale


Figure 20-40-69 1

1 1

P-35283

Remove the O-ring (Item 1) [Figure 20-40-71].


P-87162

Remove the fittings (Item 1) [Figure 20-40-69] from both


ends of the valve section.

253 of 879 20-40-21 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-74

Auxiliary And Slew Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-40-72

P-35279

Remove the O-ring (Item 1) [Figure 20-40-74].

P-35280 Figure 20-40-75

Record the distance of the spool stroke limitation

Dealer Copy -- Not for Resale


adjustment screw (Item 1) [Figure 20-40-72] for correct
installation.

Figure 20-40-73 1

2
2

P-35266
1

1 Remove the centering spring (Item 1) [Figure 20-40-75].

Remove the spring seat (Item 2) [Figure 20-40-75] from


1 both ends.
2
P-87144

Remove the four screws (Item 1) [Figure 20-40-73] from


both ends of the value.

Installation: Tighten the screws to 25 N•m (18 ft-lb)


torque.

Remove both covers (Item 2) [Figure 20-40-73]

254 of 879 20-40-22 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-78

Auxiliary And Slew Valve Section Disassembly And


Assembly (Cont’d)
3
Figure 20-40-76 1 2

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the


plug. Remove the O-ring (Item 3) [Figure 20-40-78] from
P-35267 the plug.

Remove the spool (Item 1) [Figure 20-40-76].

Dealer Copy -- Not for Resale


Figure 20-40-77

1
P-35268

Remove the check valves (Item 1) [Figure 20-40-77].

Tighten the check valves to 27 - 33 N•m (20 - 24 ft-lb)


torque.

255 of 879 20-40-23 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-81

Boom Swing Valve Section Disassembly And


Assembly

Figure 20-40-79 1 2
4 3
1

1 1

P-87171

Remove the O-rings (Item 1) and back-up ring (Item 2)


from the plug and the body. Remove the poppet (Item 3)
P-87169 and spring (Item 4) [Figure 20-40-81].

Figure 20-40-82
Remove the valves (Item 1) [Figure 20-40-79].

Dealer Copy -- Not for Resale


1
Installation: Tighten the valves to 70 N•m (52 ft-lb)
torque.

Figure 20-40-80

P-87156

Remove the plug (Item 1) [Figure 20-40-82].

Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-


P-87170 lb) torque.

Remove the plug (Item 1) [Figure 20-40-80] from the


body.

256 of 879 20-40-24 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-85

Boom Swing Valve Section Disassembly And 2


Assembly (Cont’d)

Figure 20-40-83

1
1
1

2 P-87166

Remove the four screws (Item 1) [Figure 20-40-85] from


both ends of the valve.
P-35253
Installation: Tighten the screws to 25 N•m (18 ft-lb)
torque.
Remove the O-ring (Item 1) [Figure 20-40-83].

Dealer Copy -- Not for Resale


Remove both covers (Item 2) [Figure 20-40-85].
Figure 20-40-84
Figure 20-40-86

P-87157
P-35279

Remove the compensator (Item 1) [Figure 20-40-84].


Remove the O-ring (Item 1) [Figure 20-40-86].

257 of 879 20-40-25 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-89

Boom Swing Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-40-87

1
2 P-35268

Remove the check valves (Item 1) [Figure 20-40-89].

P-35266 Installation: Tighten the check valves to 27 - 33 N•m (20


- 24 ft-lb) torque.

Remove the centering spring (Item 1) [Figure 20-40-87] Figure 20-40-90

Dealer Copy -- Not for Resale


from both ends.

Remove the spring seat (Item 2) [Figure 20-40-87] from


both ends.

Figure 20-40-88

1 2
1 3

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the


plug. Remove the O-ring (Item 3) [Figure 20-40-90] from
the plug.
P-35267

Remove the spool (Item 1) [Figure 20-40-88].

258 of 879 20-40-26 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-93

Articulated Boom Valve Section Disassembly And


Assembly 1

Figure 20-40-91

P-87161

Remove the plug (Item 1) [Figure 20-40-93].

S37680 Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-


lb) torque.

Remove the relief valves (Item 1) [Figure 20-40-91]. Figure 20-40-94

Dealer Copy -- Not for Resale


Installation: Tighten the valves to 70 N•m (52 ft-lb)
torque.
1
Figure 20-40-92

1
1

P-35253

2 Remove the O-ring (Item 1) [Figure 20-40-94].

P-35260

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-40-92].

259 of 879 20-40-27 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-97

Articulated Boom Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-40-95 2
1

P-35281

Hold the spool stroke limitation adjustment screw (Item 1)


to remove the fitting (Item 2) [Figure 20-40-97].
P-87157
Figure 20-40-98

Remove the compensator (Item 1) [Figure 20-40-95].

Dealer Copy -- Not for Resale


Figure 20-40-96 1

1 1

P-35283

Remove the O-ring (Item 1) [Figure 20-40-98].


P-87162

Remove the fittings (Item 1) [Figure 20-40-96] from both


ends of the valve section.

260 of 879 20-40-28 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-101

Articulated Boom Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-40-99

P-35279

Remove the O-ring (Item 1) [Figure 20-40-101].

P-35280 Figure 20-40-102

Record the distance of the spool stroke limitation

Dealer Copy -- Not for Resale


adjustment screw (Item 1) [Figure 20-40-99] for correct
installation.

Figure 20-40-100 1

2
2

P-35266
1

1 Remove the centering spring (Item 1) [Figure 20-40-


102].

1 Remove the spring seat (Item 2) [Figure 20-40-102] from


2
P-87144 both ends.

Remove the four screws (Item 1) [Figure 20-40-100]


from both ends of the valve.

Installation: Tighten the screws to 25 N•m (18 ft-lb)


torque.

Remove both covers (Item 2) [Figure 20-40-100]

261 of 879 20-40-29 E80 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-105

Articulated Boom Valve Section Disassembly And


Assembly (Cont’d)
3
Figure 20-40-103 1 2

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the


plug. Remove the O-ring (Item 3) [Figure 20-40-105]
P-35267 from the plug.

Remove the spool (Item 1) [Figure 20-40-103].

Dealer Copy -- Not for Resale


Figure 20-40-104

1
P-35268

Remove the check valves (Item 1) [Figure 20-40-104].

Tighten the check valves to 27 - 33 N•m (20 - 24 ft-lb)


torque.

262 of 879 20-40-30 E80 Service Manual


PUMP (HYDRAULIC PISTON)

Hydraulic Pump Work Sheet

Please review pump procedure as illustrated in Pump Testing on Page 20-50-6.

If any of the following adjustments are not obtainable, pump repair is required.

The outline listed below, gives the five adjustments for setting the hydraulic pump. The adjustments are listed in the order
in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page
location within the Service Manual for the complete adjustment procedure.

I. Torque Limiter Supply Pressure Adjustment on Page 20-50-6.

1. Bottom out pump margin spool (Approximately six turns in).

2. Remove the plug and install fitting and hose from the torque limit supply spool to a drain pan.

3. Install a 5000 kPa (50 bar) (725 psi) pressure gauge on the test port on the hydraulic control valve.

4. Warm hydraulic fluid to 50 - 60°C (122 - 144°F).

5. Run engine at high idle

Dealer Copy -- Not for Resale


6. Adjust as necessary to get 2000 ± 138 kPa (20 ± 1,38 bar) (290 ± 20 psi).

7. Record pressure

__________ TLS PRESSURE

8. Remove the hose and fitting from the torque limiter supply spool and plug the port

9. Reset pump margin spool (Approximately six turns out.)

II. Pump Margin Pressure Adjustment on Page 20-50-7.

10. Run engine at high idle

11. Adjust as necessary to get 1800 ± 138 kPa (18 ± 1,38 bar) (260 ± 20 psi).

12. Record pressure

__________ PM PRESSURE

13. Remove 5000 kPa (50 bar) (725 psi) pressure gauge.

III. Back-up Relief Valve Adjustment on Page 20-50-7.

14. Install 69000 kPa (690 bar) (10000 psi) gauge on the test port on the hydraulic control valve.

15. Turn the load sense relief valve in 1 turn.

16. Run engine at high idle and raise the blade until the blade cylinders are fully retracted and the relief valve opens.

17. Adjust back-up relief valve as necessary to get 34000 ± 345 kPa (340 ± 3,45 bar) (4931 ± 50 psi).

263 of 879 20-50-1 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Hydraulic Pump Work Sheet (Cont’d)

18. Record pressure

19. Reset load sense relief valve (one turn out)

__________ PRESSURE

IV. Load Sense Relief Valve Adjustment on Page 20-50-9.

20. Install 69000 kPa (690 bar) (10000 psi) gauge on the test port on the hydraulic control valve.

21. Run engine at high idle and raise the blade until the blade cylinders are fully retracted and the relief valve opens.

22. Adjust load sense relief valve as necessary to get 28000 ± 345 kPa (280 ± 3,45 bar) (4060 ± 50 psi).

23. Record pressure

__________ PRESSURE

24. Remove the 69000 kPa (690 bar) (10000 psi) gauge, from the diagnostic coupler at the hydraulic control valve.

Dealer Copy -- Not for Resale


V. Torque Limiter Adjustment on Page 20-50-10.

25. Remove the outlet hose from the pump, install a cap on the hose and install the inlet hose from the hydraulic tester,
to the outlet of the pump.

26. Route the outlet hose of the hydraulic tester to the tee fitting installed on the hydraulic reservoir adapter.

27. Bottom out the pump margin spool (approximately six turns in)

28. Run engine at high idle.

29. Free flow on the hydraulic tester is 144 L/min (38 U.S. gpm)

30. Adjust the hydraulic tester to 10300 kPa (103 bar) (1500 psi)

31. Adjust torque limiter to 144 L/min (38 U.S. gpm).

32. Record flow and engine rpm.

__________ FLOW

33. Adjust the hydraulic tester to 24100 kPa (241 bar) (3500 psi).

34. Adjust the torque limiter to obtain 64 L/min (17 U.S. gpm)

35. Record flow and engine rpm.

__________ FLOW

264 of 879 20-50-2 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Hydraulic Pump Work Sheet (Cont’d)

36. Remove the hydraulic tester

37. Install the pump outlet hose on the hydraulic control valve.

38. Reset pump margin spool to 1800 ± 138 kPa (18 ± 1,38 bar) (260 ± 20 psi).

ALL PUMP ADJUSTMENTS ARE NOW COMPLETED

Dealer Copy -- Not for Resale

265 of 879 20-50-3 E80 Service Manual


HYDRAULIC PISTON PUMP (CONT’D) Figure 20-50-1

Testing Information

The testing of the piston pump must be done in the


following order:

Torque limiter supply pressure


Pump margin pressure
Back-up Relief Valve
Load sense relief valve
Torque Limiter
2
All testing is done with the hydraulic oil at 50 - 60°C (122 1 3 4
- 140°F). 5
P103672
Check and adjust the engine high idle as needed before
any hydraulic testing.
The following parts are included in MEL 1713:
The hydraulic hoses, tubelines and fittings on the E80
Excavator are BSPP fittings. Item 1 [Figure 20-50-1]: MEL 1713-1 Male-8 BSPP to
Male-8 NPTF.
To test the piston pump, order the test kit:
Item 2 [Figure 20-50-1]: MEL 1713-2 Female-8 BSPP to

Dealer Copy -- Not for Resale


MEL 1713 - Hydraulic Test Kit Male-8 NPTF.

Use the gauge and hose assembly from test kit MEL Item 3 [Figure 20-50-1]: MEL 1713-3 Male-12 BSPP to
1173A. Male-8 NPTF.

Item 4 [Figure 20-50-1]: MEL 1713-4 Female-12 BSPP


to Male-8 NPTF.

Item 5 [Figure 20-50-1]: MEL1713-5 Female-12 ORFS


to Male-8 NPTF.

266 of 879 20-50-4 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-3

Testing Information (Cont’d)

Remove the left upperstructure cover. (See Removal And


Installation on Page 40-20-1.)

Figure 20-50-2

1 P-86559

Install the test coupler (Item 1) [Figure 20-50-3]

P-86558

Dealer Copy -- Not for Resale


Remove the plug (Item 1) [Figure 20-50-2] from the
hydraulic control valve.

267 of 879 20-50-5 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-6

Pump Testing

Torque Limiter Supply Pressure Adjustment 4


5

Figure 20-50-4 1
3

2
1

P-86562

Install a fitting and drain hose (Item 1) [Figure 20-50-6].


Place the other end of the hose in a drain pan.

P-86560 NOTE: To adjust the Torque Limiter Supply Pressure,


the Pump Margin Spool must be temporarily
bottomed out.

Dealer Copy -- Not for Resale


Install a 50000 kPa (500 bar) (725 psi) pressure gauge
on the test coupler (Item 1) [Figure 20-50-4]. Loosen the nut (Item 2) [Figure 20-50-6].

Figure 20-50-5 Turn the pump margin spool (bottom spool) (Item 3)
[Figure 20-50-6] all the way in (approximately six turns).

Start the engine and run it at high idle.

Loosen the nut (Item 4) and adjust the torque limiter


supply pressure spool (Item 5) [Figure 20-50-6] until the
1
pressure gauge reads 2000 kPa (20 bar) (290 psi).

Turn the adjustment screw clockwise to increase


pressure and counterclockwise to decrease pressure.

NOTE: 1/4 turn is approximately 241 kPa (2,41 bar)


(35 psi).

P-86561
Tighten the nut (Item 4) [Figure 20-50-6].

Stop the engine.


Remove the plug (Item 1) [Figure 20-50-5].
Repeat the procedure listed above until the pressure
is set.

Turn the pump margin spool (bottom spool) (Item 3)


[Figure 20-50-6] back to its original position
(approximately six turns).

Tighten the nut (Item 2) [Figure 20-50-6].

Remove the hose (Item 1) [Figure 20-50-6] and fitting.


Install the plug.

268 of 879 20-50-6 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Back-up Relief Valve Adjustment

Pump Testing (Cont’d) Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

Pump Margin Pressure Adjustment Figure 20-50-8

Start the engine and run at high idle.

Figure 20-50-7

P-86566

1
Remove the plastic cap (Item 1) [Figure 20-50-8].
P-86561

Dealer Copy -- Not for Resale


Figure 20-50-9

Loosen the nut (Item 1) and adjust the pump margin


pressure adjustment spool (Item 2) [Figure 20-50-7] until
the pressure gauge reads 1800 kPa (18 bar) (260 psi). 1

Turn the adjustment screw clockwise to increase


pressure and counterclockwise to decrease pressure.

NOTE: 1/4 turn is 345 kPa (3,45 bar) (50 psi).

Tighten the nut (Item 1) [Figure 20-50-7].

Stop the engine.

Remove the gauge from the test coupler.


P-86567

Loosen the locknut and turn the load sense relief valve
WARNING adjustment screw (Item 1) [Figure 20-50-9] in 1.5 turn,
increasing the relief pressure approximately 8274 kPa
(83 bar) (1200 psi) to 36266 kPa (363 bar) (5260 psi).
AVOID INJURY OR DEATH The load sense relief is now set to a higher pressure.
Never work under the excavator cab without
installing an approved cab support device. Lower the cab.
W-2435-0502

269 of 879 20-50-7 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-11

Pump Testing (Cont’d)

Back-up Relief Valve Adjustment (Cont’d)

Figure 20-50-10

1
2

P-86564

Remove the plastic cap (Item 1) [Figure 20-50-11].

Figure 20-50-12
P-86560

Dealer Copy -- Not for Resale


Install a 69000 kPa (690 bar) (10000 psi) pressure gauge
on the test coupler (Item 1) [Figure 20-50-10].

Start the excavator and warm up the hydraulic oil to


operating temperature.
1
Move the engine speed control to the high speed
position.
2
Raise the blade until the blade cylinders are fully
retracted and the relief valve opens.
P-86565
Record the pressure.

The pressure at the gauge (Item 2) [Figure 20-50-10] Loosen the lock nut (Item 1) [Figure 20-50-12].
should be 34000 kPa (340 bar) (4931 psi).
Turn the adjustment screw (Item 2) [Figure 20-50-12]
Stop the engine. inwards to increase pressure and outwards to decrease
pressure.

NOTE: One quarter turn is approximately 1380 kPa


(13,8 bar) (200 psi).

Tighten the nut and retest the back-up relief valve.

Tilt the cab and turn the load sense relief valve
adjustment screw (Item 1) [Figure 20-50-9 on Page 7]
one turn outwards to the original setting.

Lower the cab.

270 of 879 20-50-8 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-14

Pump Testing (Cont’d)

Load Sense Relief Valve Adjustment 2

Figure 20-50-13

P-86567

Loosen the lock nut (Item 1) [Figure 20-50-14].

Turn the adjustment screw (Item 2) [Figure 20-50-14]


P-86560 inwards to increase pressure and outwards to decrease
pressure.

Dealer Copy -- Not for Resale


Install a 69000 kPa (690 bar) (10000 psi) pressure gauge NOTE: One quarter turn is approximately 1380 kPa
on the test coupler (Item 1) [Figure 20-50-13]. (13,8 bar) (200 psi).

Move the engine speed control to the high idle position. Tighten the lock nut and lower the cab.

Raise the blade until the blade cylinders are fully


retracted and the relief valve opens.

Record the pressure. WARNING


The pressure at the gauge (Item 2) [Figure 20-50-13]
AVOID INJURY OR DEATH
should be 28000 (280 bar) (4060 psi).
Never work under the excavator cab without
installing an approved cab support device.
Stop the engine. W-2435-0502

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)


Retest the load sense relief valve.

271 of 879 20-50-9 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-17

Pump Testing (Cont’d)

Torque Limiter Adjustment

Figure 20-50-15
1

P-86571

Install the female O-ring face seal (Item 1) [Figure 20-50-


17]and adapter to male fitting on the pump outlet.

P-86569 Figure 20-50-18

Dealer Copy -- Not for Resale


Remove the outlet hose (Item 1) [Figure 20-50-15] from
the pump.

Figure 20-50-16 1

P-86572
2

Connect the inlet hose (Item 1) [Figure 20-50-18] from


the tester to the adapter.

P-86570

Install the adapter (Item 1) and cap (Item 2) [Figure 20-


50-16] on the hose.

272 of 879 20-50-10 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-21

Pump Testing (Cont’d)

Torque Limiter Adjustment (Cont’d) 1

Figure 20-50-19

1 P-86575

Install the tee fitting (Item 1) on the reservoir adapter.


Install the 457 mm (18 in) adapter hose (Item 2) [Figure
20-50-21] on the return line adapter and tee fitting.
P-86573
Figure 20-50-22

Dealer Copy -- Not for Resale


Remove the return hose (Item 1) [Figure 20-50-19].

Figure 20-50-20

1 P-86576

Connect the OUTLET side of the hydraulic tester (Item 1)


P-86574 [Figure 20-50-22] to the tee fitting.

Install the male BSPP to male JIC adapter (Item 1) on the


return hose. Install the female BSPP to male JIC adapter
(Item 2) [Figure 20-50-20] on the reservoir.

273 of 879 20-50-11 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-25

Pump Testing (Cont’d)

Torque Limiter Adjustment (Cont’d) 1

Figure 20-50-23

P-22253

The flow should be 144 L/m (38 U.S. gpm) on the flow
1
tester (Item 1) [Figure 20-50-25].

P-22253 Turn the hydraulic tester flow control (Item 2) clockwise


until the gauge (Item 3) [Figure 20-50-25] shows 10300
kPa (103 bar) (1500 psi).

Dealer Copy -- Not for Resale


Fully open the hydraulic tester flow control (Item 1)
[Figure 20-50-23]. The gauge (Item 1) [Figure 20-50-25] should show 144
L/min (38 U.S. gpm) which is flow at low pressure.
Figure 20-50-24
Figure 20-50-26

1
P-86577
P-86578

Loosen the nut (Item 1) and turn the pump margin


adjustment screw (Item 2) [Figure 20-50-24] all the way Remove the dust cover (Item 1) [Figure 20-50-26].
in (approximately six turns).

Start the engine and run it at high idle.

274 of 879 20-50-12 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) NOTE: If adjustments were made to flow at high
pressure verify the flow at low pressure.
Pump Testing (Cont’d)
Install the protective cap on the hydraulic pump torque
Torque Limiter Adjustment (Cont’d) limiter.

Figure 20-50-27 Remove the hydraulic tester, fittings and adapter hose.

Install the outlet hose on the pump.

Install the return line on the reservoir.

Figure 20-50-28
1
2

P-86579
1

Dealer Copy -- Not for Resale


Check that the 13 mm nut (Item 1) [Figure 20-50-27] is
locked in place.

Adjust the flow at the hydraulic pump torque limiter.


P-86563
Loosen the 27 mm nut (Item 2) [Figure 20-50-27] and
adjust the flow at low pressure with an Allen wrench.
Adjust the pump margin spool (Item 1) [Figure 20-50-28]
When the proper flow is obtained, 144 L/min (38 U.S. back to the original position (approximately six turns
gpm) at 10300 kPa (103 bar) (1500 psi), lock the 27 mm outwards).
nut (Item 2) [Figure 20-50-27].
Retest and adjust the pump margin spool as needed.
NOTE: Changing the flow at low pressure (27 mm (See Pump Margin Pressure Adjustment on Page 20-50-
nut) will affect the flow at high pressure (13 7.)
mm nut).
ALL PUMP ADJUSTMENTS ARE NOW COMPLETED.
Turn the hydraulic tester flow control (Item 2) clockwise
until the gauge (Item 3) [Figure 20-50-25] reads 24100 Remove the test fitting from the valve. Install the left
kPa (241 bar) (3500 psi). upperstructure cover. (See Removal And Installation on
Page 40-20-1.)
NOTE: Do not exceed 33998 kPa (340 bar) (4931 psi)
with the hydraulic tester or the pump will be
damaged.

The gauge should show 64 L/min (17 U.S. gpm) which is


flow at high pressure.

Adjust the flow at the hydraulic pump torque limiter.


Loosen the 13 mm nut (Item 1) [Figure 20-50-27] and
adjust the flow at high pressure with an Allen wrench.

When the proper flow is obtained, 64 L/min (17 U.S.


gpm) at 24100 kPa (241 bar) (3500 psi), lock the 13 mm
nut (Item 1) [Figure 20-50-27].

275 of 879 20-50-13 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-31

Removal And Installation

Drain the hydraulic reservoir. (See Removing And


Replacing Hydraulic Fluid on Page 10-140-6.)

Remove the air cleaner. (See Housing Removal And


Installation on Page 60-40-1.)

Remove the gear pump. (See Removal And Installation 1


on Page 20-51-3.)

Figure 20-50-29

P-87478
1
1
Remove the top inlet flange bolts (Item 1) [Figure 20-50-
31].

1 Figure 20-50-32
1

Dealer Copy -- Not for Resale


2

3
P-87476

Remove the four bolts (Item 1) and remove the cover


(Item 2) [Figure 20-50-29]. 1 2

Figure 20-50-30

2
P-87479

Remove the load sense line (Item 1), high pressure lines
(Item 2) and case drain line (Item 3) [Figure 20-50-32].

P-87477

Remove the bottom inlet flange bolts (Item 1) [Figure 20-


50-30].

276 of 879 20-50-14 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-35

Removal And Installation (Cont’d)

Figure 20-50-33

P-87482

Slide the pump away from the engine and remove the
P-87480 pump [Figure 20-50-35].

Install a sling (Item 1) [Figure 20-50-33] and hoist on the


pump.

Dealer Copy -- Not for Resale


Figure 20-50-34

P-87481

Remove the bolts (Item 1) [Figure 20-50-34] and


washers.

277 of 879 20-50-15 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Parts Identification

1. Plug
2. O-ring
3. Spring 7
4. Spring Seat
5. Spool Assembly
6. Spool
7. Bolt
8. O-ring 19
9. Spring Seat
10. Spring
11. Spring
12. O-ring
6
13. Body
14. Locknut
5
15. Washer
16. Screw 3 4
17. Nut 1 2
18. Cap
19. Housing

Dealer Copy -- Not for Resale


8

18

17
16
14 15

13
12

11
10
9

MS-2790S

278 of 879 20-50-16 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Removal And Installation

Clean the outside of the pump with clean solvent and dry
it with compressed air before removing any components
from the pump.

Figure 20-50-36

P-87516

Dealer Copy -- Not for Resale


Remove the tubeline (Item 1) [Figure 20-50-36] from the
pump control and torque limiter valve.

NOTE: Mark the tubeline for correct installation.

Loosen and remove the two mounting bolts (Item 2)


[Figure 20-50-36] from the torque limiter valve.

Installation: Tighten the mounting bolts to 9,5 - 10,5 N•m


(7.0 - 7.5 ft-lb) torque.

Figure 20-50-37

P-35330

Remove the torque limiter (Item 1) [Figure 20-50-37]


from the pump.

279 of 879 20-50-17 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-40

Torque Limiter Valve Disassembly

Figure 20-50-38

1 1

2
N-23329

Remove the spring (Item 1) and spring seat (Item 2)


N-23327 [Figure 20-50-40].

Figure 20-50-41
Remove the O-ring (Item 1) [Figure 20-50-38] from the
torque limiter valve.

Dealer Copy -- Not for Resale


NOTE: Do not scratch or damage the mounting
surface on the valve body.

Remove the plug (Item 2) [Figure 20-50-38].

NOTE: The plug (Item 2) [Figure 20-50-38] is under


spring pressure.

Figure 20-50-39 1

P-35320

Remove the control spool assembly (Item 1) [Figure 20-


1 50-41].

NOTE: Do not scratch or damage the spool.


Scratches in the spool can cause internal
leakage.

N-23328

Remove the O-ring (Item 1) [Figure 20-50-39].

280 of 879 20-50-18 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-44

Torque Limiter Valve Disassembly (Cont’d)

Figure 20-50-42
2

N-23333
1
2
Remove the two springs (Items 1 and 2) [Figure 20-50-
P-35321 44].

Figure 20-50-45
Remove the metering spool (Item 1) from the control
spool (Item 2) [Figure 20-50-42].

Dealer Copy -- Not for Resale


Figure 20-50-43

P-35322

Remove the plug (Item 1) [Figure 20-50-45].


N-23332

Remove the spring retainer (Item 1) [Figure 20-50-43]


from the torque limiter valve.

281 of 879 20-50-19 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-48

Torque Limiter Valve Disassembly (Cont’d)

Figure 20-50-46

2
P-35325

1
Loosen the large nut (Item 1) [Figure 20-50-48].
P-35323
Turn the small nut (Item 2) [Figure 20-50-48] to remove
the adjustment body.
Remove the O-ring (Item 1) [Figure 20-50-46].
Figure 20-50-49

Dealer Copy -- Not for Resale


The following procedures are only used if the adjustment
assembly is removed.

NOTE: If the adjustment assembly is removed and/or


disassembled, the torque limiter must be
tested and adjusted after the pump assembly
1
is installed in the machine. (See Initial Torque
Limiter Valve Setting on Page 20-50-26.)

Figure 20-50-47

P-35326

Hold the adjustment bolt (Item 1) with an Allen wrench


and loosen the nut (Item 2) [Figure 20-50-49].

P-35324

Remove the dust cap (Item 1) [Figure 20-50-47].

282 of 879 20-50-20 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Disassembly (Cont’d)

Figure 20-50-50

1
4

P-35327

Remove the adjustment screw (Item 1), O-ring washer


(Item 2) and large nut (Item 3) from the adjustment body

Dealer Copy -- Not for Resale


(Item 4) [Figure 20-50-50].

Figure 20-50-51

P-35328

Remove the O-ring (Item 1) [Figure 20-50-51].

283 of 879 20-50-21 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-53

Torque Limiter Valve Assembly


3
Clean all the parts in solvent and dry with compressed
4
air.

Inspect seats and spools for wear. 1


2
Apply clean oil to new O-rings and spools.

The following procedures are only used if the adjustment


assembly is removed.

Figure 20-50-52
P-35327

1
Install the O-ring washer (Item 1) on the adjustment
screw (Item 2) [Figure 20-50-53].

Install the adjustment screw (Item 2) in the adjustment


body (Item 3) [Figure 20-50-53].

Dealer Copy -- Not for Resale


Install the nut (Item 4) [Figure 20-50-53] on the
adjustment body.

Figure 20-50-54

P-35328

Install the O-ring (Item 1) [Figure 20-50-52].

P-35325

Install the adjustment screw / adjustment body (Item 1)


[Figure 20-50-54] assembly into the valve body.

284 of 879 20-50-22 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-57

Torque Limiter Valve Assembly (Cont’d)

Figure 20-50-55

N-23332

1
Install the spring seat (Item 1) [Figure 20-50-57] in the
P-35324 valve body with the ball side facing the control spool.

Figure 20-50-58
Install the dust cap (Item 1) [Figure 20-50-55].

Dealer Copy -- Not for Resale


NOTE: After the pump assembly is installed in the
machine, the torque limiter must be tested
and adjusted. (See Initial Torque Limiter Valve
Setting on Page 20-50-26.)

Figure 20-50-56

2 1
2
1
P-35321

Put oil on the metering spool (Item 1) and install it in the


control spool (Item 2) [Figure 20-50-58].

NOTE: The end of the metering spool with the three


rings should enter the control spool first.
N-23333

Install the two springs (Items 1 and 2) [Figure 20-50-56]


in the valve body.

NOTE: Install the big spring first.

285 of 879 20-50-23 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-61

Torque Limiter Valve Assembly (Cont’d)

Figure 20-50-59

N-23328
1

Install the O-ring (Item 1) on the plug. Install the plug


P-35320 (Item 2) [Figure 20-50-61].

Figure 20-50-62
Install the control spool assembly (Item 1) [Figure 20-50-
59] in the valve body.

Dealer Copy -- Not for Resale


NOTE: Do not scratch or damage the spool (Item 1) 1
[Figure 20-50-59]. Scratches in the spool can
cause internal leakage.

Figure 20-50-60

N-23327
2

Install the O-ring (Item 1) [Figure 20-50-62].

1
N-23329

Install the spring seat (Item 1) [Figure 20-50-60] in the


valve body, with the smaller side facing the spring.

Install the spring (Item 2) [Figure 20-50-60] in the valve


body.

286 of 879 20-50-24 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Assembly (Cont’d)

Figure 20-50-63

1
P-35323

Install the O-ring (Item 1) [Figure 20-50-63] on the plug.

Dealer Copy -- Not for Resale


Figure 20-50-64

P-35322

Install the plug (Item 1) [Figure 20-50-64].

287 of 879 20-50-25 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-67

Initial Torque Limiter Valve Setting

The following procedures are only used if the adjustment


assembly is removed.

Figure 20-50-65

107 mm
(4.21 in)

P-40592

1
Measure from the plug to the top of the small adjusting
screw [Figure 20-50-67]. Set the small adjustment screw
to 106 mm (4.15 in).

N-23336 Figure 20-50-68

Dealer Copy -- Not for Resale


Remove the dust cap (Item 1) [Figure 20-50-65].

Figure 20-50-66

2 1

P-35330
96 mm
(3.78 in)
Align the linkage pin (Item 1) on the hydraulic piston
pump into the hole (Item 1) [Figure 20-50-68] in the
P-40592 torque limiter valve.

Turn the valve slightly to align the dowel pin (Item 2) on


Measure from the plug to the top of the large adjustment the hydraulic piston pump into the hole (Item 2) [Figure
screw. Set the large adjustment screw to 96 mm (3.78 in) 20-50-68] in the torque limiter valve.
[Figure 20-50-66].
NOTE: Before tightening the bolts, make sure the
dowel pin is aligned with the housing.

288 of 879 20-50-26 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Initial Torque Limiter Valve Setting (Cont’d)

Figure 20-50-69

P-87516

Tighten the bolts (Item 1) [Figure 20-50-69] to 9,5 - 10,5


N•m (7.0 - 7.5 ft-lb) torque.

Dealer Copy -- Not for Resale


Install the tubeline (Item 2) [Figure 20-50-69].

289 of 879 20-50-27 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Pump Control Parts Identification

1. Cap (If Equipped)


2. O-ring
3. Nut 1
4. Adjusting Screw
5. Adjustment Screw Body 1
6. Spring Seat 2
7. Spring
8. Spring 2
3
9. Spring Seat
10. Spool 3
11. Plug 2
12. Valve Body
2
13. Bolt
14. Fitting 4
15. Elbow
4

Dealer Copy -- Not for Resale


2

6
2

7 6

8
7
9 8

10 9

10
2 11
11
2

2 2

2
12
2
14
13

15 2
14 2
2

11 11

MS1540

290 of 879 20-50-28 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Pump Control Removal And Installation

Clean the outside of the pump with clean solvent and dry
it with compressed air before removing any components
from the pump.

Figure 20-50-70

P-87516

Dealer Copy -- Not for Resale


Mark the tubeline (Item 1) [Figure 20-50-70] for correct
assembly.

Remove the tubeline (Item 1) [Figure 20-50-70] from the


pump control and torque limiter valve.

Figure 20-50-71

1 1

P-87517

Remove the four bolts (Item 1) and remove the pump


control (Item 2) [Figure 20-50-71] from the hydraulic
piston pump.

Installation: Tighten the bolts to 13 N•m (10 ft-lb) torque.

291 of 879 20-50-29 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-74

Pump Control Disassembly And Assembly

Figure 20-50-72
4

3
1 2

1
P-35335

Remove the adjustment screw (Item 1), nut (Item 2), and
P-35332 O-ring washer (Item 3) from the adjustment assembly
(Item 4) [Figure 20-50-74].

Remove the three O-rings (Item 1) [Figure 20-50-72] Remove the adjustment assembly (Item 4) [Figure 20-
from the valve. 50-74].

Dealer Copy -- Not for Resale


Pump Margin Control Figure 20-50-75

Figure 20-50-73

3
2 3 1 4
1
P-35344

P-35333
Remove the adjustment seat (Item 1), large spring (Item
2), and the small spring (Item 3) [Figure 20-50-75] from
Before disassembling the pump margin control, remove the adjustment assembly.
the cap (Item 1) and O-ring washer (Item 2) [Figure 20-
50-73] from the adjustment assembly (If equipped.) Remove the O-ring (Item 4) [Figure 20-50-75].

Measure the adjustment screw (Item 3) [Figure 20-50-


73] thread length for the correct initial adjustment.

292 of 879 20-50-30 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-78

Pump Control Disassembly And Assembly (Cont’d)

Pump Margin Control (Cont’d)

Figure 20-50-76

N-23380

Check the spool for scratches and make sure the orifice
1 (Item 1) [Figure 20-50-78] is not plugged.

P-35336 Figure 20-50-79

Dealer Copy -- Not for Resale


Remove the spring seat (Item 1) [Figure 20-50-76].

Figure 20-50-77

P-35338

Remove the plug (Item 1) [Figure 20-50-79].

P-35337

Remove the spool (Item 1) [Figure 20-50-77].

293 of 879 20-50-31 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Torque Limiter Supply Control

Pump Control Disassembly And Assembly (Cont’d) Figure 20-50-81

Pump Margin Control (Cont’d)

Figure 20-50-80

1
3
2

P-35341

Before disassembling the pump torque limiter supply


P-35339 control, remove the cap (Item 1) and O-ring washer (Item
2) [Figure 20-50-81] from the adjustment assembly (If
equipped).

Dealer Copy -- Not for Resale


Remove the O-ring washer (Item 1) [Figure 20-50-80].
Measure the adjustment screw (Item 3) [Figure 20-50-
81] thread length for the correct initial adjustment.

Figure 20-50-82

P-35342

Loosen the nut (Item 1) [Figure 20-50-82].

294 of 879 20-50-32 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-85

Pump Control Disassembly And Assembly (Cont’d)

Torque Limiter Supply Control (Cont’d)

Figure 20-50-83 1

3
1

P-35345

4
Remove the spring seat (Item 1) [Figure 20-50-85].
2
Figure 20-50-86
P-35343

Dealer Copy -- Not for Resale


Remove the adjustment screw (Item 1), nut (Item 2), and
O-ring washer (Item 3) from the adjustment assembly
(Item 4) [Figure 20-50-83].
1
Remove the adjustment assembly (Item 4) [Figure 20-
50-83].

Figure 20-50-84

P-35346
4
3
Remove the spool (Item 1) [Figure 20-50-86].

1
2

P-35344

Remove the adjustment seat (Item 1), large spring (Item


2) [Figure 20-50-84], and small spring (Item 3) from the
adjustment assembly.

Remove the O-ring (Item 4) [Figure 20-50-84].

295 of 879 20-50-33 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-89

Pump Control Disassembly And Assembly (Cont’d)

Torque Limiter Supply Control (Cont’d)

Figure 20-50-87

P-35348

Remove the O-ring washer (Item 1) [Figure 20-50-89].

N-23379

Dealer Copy -- Not for Resale


Check the spool for scratches and make sure the orifices
(Items 1 and 2) [Figure 20-50-87] are not plugged.

Figure 20-50-88

P-35347

Remove the plug (Item 1) [Figure 20-50-88].

296 of 879 20-50-34 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D)

Parts Identification

1. Snap Ring
2. Seal
3. Housing
4. Plug
5. O-ring 7
6. Bearing
5 6
7. Shaft
8. Shim 3
9. Swash Plate
10. Rotating Group
11. Piston Assembly
12. Retaining Plate
13. Ball Guide
14. Cylinder Block 2
15. Pin 1
16. Thrust Washer 19
17. Spring
18. Snap Ring 18
19. Valve Plate 17
14 16
20. Piston

Dealer Copy -- Not for Resale


4 15
21. Piston Guide 10
22. Dowel Pin 12
13
23. Destroking Piston
24. Destroking Piston Guide 11
25. End Cap
26. Bolt 9
27. Coupler
28. Lock Washer 8
29. Gear Pump 26
28

25 5
27
21
17
20

8 6
29

22
5

24 26
23
B-23974

297 of 879 20-50-35 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-91

Disassembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

N-23355
Clean the outside of the hydraulic piston pump with
solvent and dry with compressed air.
Remove the pin assembly (Item 1) [Figure 20-50-91].
Remove the torque limiter valve. (See Torque Limiter
Valve Removal And Installation on Page 20-50-17.) Figure 20-50-92

Remove the pump control assembly. (See Pump Control


Removal And Installation on Page 20-50-29.)

Dealer Copy -- Not for Resale


Figure 20-50-90

1
P-61054

Remove the plug (Item 1) [Figure 20-50-92] from the


pump housing and drain the oil.
N-23354

Remove the screw (Item 1) [Figure 20-50-90] from the


pin assembly.

298 of 879 20-50-36 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-95

Disassembly (Cont’d)
1
3
Figure 20-50-93

P-61070

Remove the O-ring (Item 1) [Figure 20-50-95].


P-35349
Remove the destroking piston (Item 2) [Figure 20-50-
95].
Remove the O-ring (Item 1) [Figure 20-50-93] from the
plug. Remove the stroking piston / spring assembly (Item 3)

Dealer Copy -- Not for Resale


[Figure 20-50-95].
Mark the pump housing for proper installation.
Figure 20-50-96
Figure 20-50-94

2
1

1 1

N-23387
P-61055

Inspect the destroking piston (Item 1) [Figure 20-50-96]


Remove the four bolts (Item 1) [Figure 20-50-94]. for scratches and replace it if needed.

Remove the end cap (Item 2) [Figure 20-50-94] from the


pump.

299 of 879 20-50-37 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-99

Disassembly (Cont‘d)

Figure 20-50-97

2
1

P-61072

Remove the shim(s) (Item 1) [Figure 20-50-99] from the


N-23388 pump shaft.

Figure 20-50-100
Remove the spring (Item 1) from the stroking piston (Item
2) [Figure 20-50-97].

Dealer Copy -- Not for Resale


Figure 20-50-98

1
1

P-61073

Lay the pump assembly on its side and remove the rotary
P61071 group, swash plate, and shaft (Item 1) [Figure 20-50-
100] from the housing.

Remove the bearing (Item 1) [Figure 20-50-98].

300 of 879 20-50-38 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-103

Disassembly (Cont’d)
1
Figure 20-50-101

3
P-35354

Remove the retaining ball (Item 1) [Figure 20-50-103].


P-61074
Figure 20-50-104

Slide the rotary group (Item 1) and swash plate (Item 2)


from the shaft assembly (Item 3) [Figure 20-50-101]. 1

Dealer Copy -- Not for Resale


NOTE: It is NOT important that the pistons are
installed in their original positions.

NOTE: Check that there are no scratches or metal


deposits on the sliding surface. (Pistons must 1
be replaced in sets.) 1

Figure 20-50-102

1 P-35355

Inspect the three pins (Item 1) [Figure 20-50-104] for


wear and/or damage.

NOTE: The following procedure is only to


disassemble the rotating group for
inspection. The rotating group parts can not
be ordered separately and must be ordered as
an assembly.

P-35361

Remove the retainer plate and pistons (Item 1) [Figure


20-50-102].

301 of 879 20-50-39 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-107

Disassembly (Cont’d)
1
Figure 20-50-105
2

4 4

3 2 3
1 2 3
4

N-15289

Install the second trimmed washer (Item 1) over the


N-15299 threaded rod (Item 2) and install the nut (Item 3) [Figure
20-50-107].

To remove the spring from inside the cylinder block, use NOTE: The modified washer (Item 1) must fit between
a threaded rod (or bolt) (Item 1), two trimmed washers the three pins (Item 4) [Figure 20-50-107].

Dealer Copy -- Not for Resale


(Item 2), and two nuts (Item 3) [Figure 20-50-105].
Figure 20-50-108
Figure 20-50-106

4
1
2

1
2

3
N-15290
N-15288

Tighten the nut (Item 1) until the spring is compressed


Install the threaded rod and nut (Item 1) through the enough to remove the snap ring (Item 2) [Figure 20-50-
trimmed washer (Item 2) and through the block assembly 108].
(Item 3) [Figure 20-50-106].
Loosen the nut to release the tension on the spring and
NOTE: The modified washer (Item 2) must fit over the remove the bolts and washers.
spring, but must also fit inside the snap ring
(Item 4) [Figure 20-50-106].

302 of 879 20-50-40 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-111

Disassembly (Cont’d)

Figure 20-50-109

1
2 3
1 3
3 2

N-23395

Remove the bolt (Item 1) and remove the torque limiter


N-15291 plate (Item 2) [Figure 20-50-111].

NOTE: The caps (Item 3) [Figure 20-50-111] cannot be


Remove the spring (Item 1), washer (Item 2) and the replaced, order a new swash plate if
three pins (Item 3) [Figure 20-50-109] from the cylinder necessary.

Dealer Copy -- Not for Resale


block.
Figure 20-50-112
Figure 20-50-110

N-15284
P-61075

Press the bearing (Item 1) [Figure 20-50-112] off the


Remove the swash plate (Item 1) from the shaft (Item 2) shaft.
[Figure 20-50-110].

303 of 879 20-50-41 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-115

Disassembly (Cont’d)

Figure 20-50-113
1

N-15277

Remove the two brass bearings (Item 1) [Figure 20-50-


P-35356 115] from the housing.

Figure 20-50-116
Remove the snap ring (Item 1 [Figure 20-50-113] from
the housing.

Dealer Copy -- Not for Resale


Figure 20-50-114

1
1

N-15280

Remove the race (Item 1) [Figure 20-50-116] from the


P-35357 housing.

Remove the seal (Item 1) [Figure 20-50-114] from the


housing.

NOTE: The shaft seal can be removed without


disassembling the pump.

304 of 879 20-50-42 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-119

Disassembly (Cont’d)

Figure 20-50-117

1 1

1
1

P-61078

1
Remove the bearing race from the port block assembly
P-61076 with a bearing puller (Item 1) [Figure 20-50-119].

Figure 20-50-120
Remove the O-rings (Item 1) [Figure 20-50-117].

Dealer Copy -- Not for Resale


Figure 20-50-118
2

N-23418

P-61077 Remove the stroking piston (Item 1) [Figure 20-50-120].


(Spring Side)

Remove the valve plate (Item 1) [Figure 20-50-118]. Remove the destroking piston (Item 2) [Figure 20-50-
120].

305 of 879 20-50-43 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-122

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-61080
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and damage. Install the bearing race (Item 1) [Figure 20-50-122] in the
port block assembly.
Replace any worn or damaged parts.

Figure 20-50-121

Dealer Copy -- Not for Resale


3
1

P-61079

Apply Loctite® 241 or equivalent on the threads and


install the destroking piston (Item 1) in the hole next to
the alignment pin (Item 2) [Figure 20-50-121].

Apply Loctite® 241 or equivalent on the threads and


install the stroking piston (Item 3) [Figure 20-50-121].

306 of 879 20-50-44 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-125

Assembly (Cont’d)

Figure 20-50-123

P-35356

Install the snap ring (Item 1) [Figure 20-50-125].


N-15296
Figure 20-50-126

Press the race into the housing [Figure 20-50-123].

Dealer Copy -- Not for Resale


Figure 20-50-124
2

1
1

N-15285

Press the bearing (Item 1) on the shaft (Item 2) [Figure


P-35357 20-50-126].

Install the shaft seal (Item 1) [Figure 20-50-124].

307 of 879 20-50-45 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-129

Assembly (Cont’d)
1
Figure 20-50-127 2

P-61083

Install the port block (Item 1) [Figure 20-50-129].


P-61081
Install the four bolts (Item 2) [Figure 20-50-129] and
tighten them to 119 N•m (88 ft-lb) torque.
To find the correct shim washer thickness for bearing end
play, the shaft / bearing assembly (Item 1) [Figure 20-50- Figure 20-50-130

Dealer Copy -- Not for Resale


127] must be installed in the housing.

Figure 20-50-128

P-35360

P-61082 Turn over the pump assembly [Figure 20-50-130].

Install the bearing (Item 1) [Figure 20-50-128] on the


shaft.

308 of 879 20-50-46 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-132

Assembly (Cont’d)

Figure 20-50-131

N-15277

Install the two brass bearings (Item 1) [Figure 20-50-


P-35359 132].

Figure 20-50-133
Install a dial indicator on the housing as shown [Figure
20-50-131] and set it to zero.

Dealer Copy -- Not for Resale


Pull the shaft up as far as it will go and record the reading
on the dial indicator. Repeat the procedure several times. 3
The reading must be the same each time.

Add the nominal pre-load of 0,025 mm (0.001 in) to the


reading found on the dial indicator [Figure 20-50-131].
The actual pre-load is 0,000 mm (0.000 in) to 0,050 mm
(0.002 in)
2 1
Example: (In Inches)

0.150 Measured movement of the shaft N-15283

0.001 Nominal Pre-load


Apply Loctite® 241 or equivalent and install the torque
= 0.151 ± thickness of the shim needed. (See Assembly limiter plate (Item 1) and bolt (Item 2) on the swash plate
on Page 20-50-44.) (Item 3) [Figure 20-50-133].

When the proper thickness of the shim washer is


determined, remove the dial indicator from the pump
housing.

Remove the two mounting bolts.

Remove the port block.

Remove the bearing and shaft from the pump housing.

309 of 879 20-50-47 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-136

Assembly (Cont’d)

Figure 20-50-134
3 2
1 2 3

1
2

N-15299

To compress the spring inside the cylinder block, use a


P-61075 threaded rod (or bolt) (Item 1), two trimmed washers
(Item 2), and two nuts (Item 3) [Figure 20-50-136].

Install the swash plate (Item 1) on the shaft (Item 2) Figure 20-50-137
[Figure 20-50-134].

Dealer Copy -- Not for Resale


Figure 20-50-135
2
1

3 3
2 1

N-15289

N-15291 Install the threaded rod and nut (Item 1) through the
modified washer (Item 2) and the block assembly (Item 3)
[Figure 20-50-137].
Apply clean grease to the three pins (Item 1) [Figure 20-
50-135] and install them in the appropriate groove.

Install the washer (Item 2) and the spring (Item 3)


[Figure 20-50-135].

NOTE: If the rotating group is damaged, the parts can


not be ordered separately and must be
ordered as an assembly.

310 of 879 20-50-48 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-140

Assembly (Cont’d)
1
Figure 20-50-138

2
1

3
P-35354

Install the retaining ball (Item 1) [Figure 20-50-140] on


N-15288 the three pins.

Figure 20-50-141
NOTE: The modified washer (Item 1) must fit over the
spring (Item 2), but must also fit inside the
1

Dealer Copy -- Not for Resale


snap ring (Item 3) [Figure 20-50-138].

Figure 20-50-139

2
1 P-35361

Install the retainer and piston assembly (Item 1) in the


cylinder block (Item 2) [Figure 20-50-141].
N-15290
NOTE: It is NOT important that the pistons are
installed in their original positions.
Tighten the nut (Item 1) until the spring is compressed
enough to install the snap ring (Item 2) [Figure 20-50-
139].

Remove the threaded rod / washer assembly.

311 of 879 20-50-49 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Set the pump housing in the up-right position.

Assembly (Cont’d) Figure 20-50-144

Figure 20-50-142

2
1
1

P-61072

P-61074
Install the shim (Item 1) [Figure 20-50-144].

Slide the rotary group assembly (Item 1) on the shaft Figure 20-50-145
(Item 2) [Figure 20-50-142].

Dealer Copy -- Not for Resale


Figure 20-50-143

2
1

P-61086

P-61073 Install the bearing (Item 1) [Figure 20-50-145] on the


shaft.

Lay the pump housing on its side and install the rotary Install the O-ring (Item 2) [Figure 20-50-145].
group assembly, swash plate and shaft in the housing
[Figure 20-50-143].

312 of 879 20-50-50 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-148

Assembly (Cont’d)
1
Figure 20-50-146

P-61089
1
3
Install the stroking piston assembly (Item 1) [Figure 20-
N-23399 50-148].

Figure 20-50-149
Install the valve plate (Item 1) on the port block assembly.
The valve plate can only be installed by aligning the

Dealer Copy -- Not for Resale


groove (Item 2) with the pin (Item 3) [Figure 20-50-146]. 1

Figure 20-50-147

3
1 2
2
3

1
1 P-61090

1
Install the end cap (Item 1) [Figure 20-50-149].

P-61087 NOTE: Align the stroking piston assembly (Item 2)


with the shaft (Item 3) [Figure 20-50-149].

Install the O-rings [Figure 20-50-147].

Grease the inside of the control piston (Item 2) [Figure


20-50-147].

Install the control piston (Item 2) on the control piston


shaft (Item 3) [Figure 20-50-147].

313 of 879 20-50-51 E80 Service Manual


PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-152

Assembly (Cont’d)

Figure 20-50-150

1
1 N-23354

Apply Loctite® 241 or equivalent on the bolt (Item 1)


P-61055 [Figure 20-50-152]. Tighten the bolt to 13 N•m (10 ft-lb)
torque.

Install the four bolts (Item 1) [Figure 20-50-150] and Install the torque limiter valve. (See Torque Limiter Valve
tighten to 119 N•m (88 ft-lb) torque. Removal And Installation on Page 20-50-17.)

Dealer Copy -- Not for Resale


Figure 20-50-151 Install the pump control assembly. (See Pump Control
Removal And Installation on Page 20-50-29.)

2
N-23355

Install the pin assembly (Item 1) [Figure 20-50-151].

The dowel pin (Item 2) must be fully seated in the hole


(Item 3) [Figure 20-50-151] on the swash plate.

314 of 879 20-50-52 E80 Service Manual


PUMP (GEAR) Pump Testing

Testing Information Figure 20-51-2

All testing is done with the hydraulic oil at 50 - 60°C (122


- 140°F).

Check and adjust the engine high idle as needed before


any hydraulic testing.

The hydraulic hoses, tubelines and fittings on the E80


Excavator are BSPP fittings.

Figure 20-51-1
1

P-86580

Remove the hose (Item 1) [Figure 20-51-2] from the


2 gear pump.
1
Figure 20-51-3

Dealer Copy -- Not for Resale


2
P103673

To test the gear pump, use the following fittings from MEL
1713 Hydraulic Test Kit: 1

Item 1 [Figure 20-51-1]: MEL 1713-1 Male-8 BSPP to


Male 8 NPTF.

Item 2 [Figure 20-51-1]: MEL 1713-2 Female-8 to Male-


8 NPTF. P-86581

Connect the hydraulic tester inlet side (Item 1) [Figure


20-51-3] and adapter fitting to the gear pump.

Connect the hydraulic tester outlet side (Item 2) [Figure


20-51-3] and adapter fitting to the hose removed from the
gear pump.

315 of 879 20-51-1 E80 Service Manual


PUMP (GEAR) (CONT'D) NOTE: The high pressure flow must be at least 80%
of the free flow.
Pump Testing (Cont’d) HIGH PRESSURE FLOW (L/min [U.S. gpm])
%= X 100
Figure 20-51-4 FREE FLOW (L/min [U.S. gpm])

If the high pressure flow is less than 80% of the free flow,
remove the hydraulic pump for repair or replacement.

P-22253

Turn the hydraulic tester flow control (Item 1) [Figure 20-


51-4] counterclockwise until all restriction is removed.

Dealer Copy -- Not for Resale


NOTE: This is a direct pump test. There is no relief
valve in the system.

Start and run the engine at a low rpm. Make sure the
tester is connected correctly. If no flow is indicated at the
tester, the hoses are connected wrong.

Increase the engine speed to full rpm. Warm up the


hydraulic fluid to a temperature of 50 - 60°C (122 -
140°F) by turning the restrictor valve until the gauge
reads about 6900 kPa (69 bar) (1000 psi).

Fully open the restrictor valve when the temperature is


correct.

Record the pump free flow L/min (U.S. gpm).

Pump flow on a new pump is 21,9 L/min (5.8 U.S. gpm)


at 2200 engine rpm.

Slowly close the flow control knob (Item 1) [Figure 20-


51-4] to 13400 kPa (134 bar) (1950 psi).

Record the pump high pressure flow L/min (U.S. gpm).

316 of 879 20-51-2 E80 Service Manual


PUMP (GEAR) (CONT'D) Figure 20-51-6

Removal And Installation

Drain the hydraulic reservoir. (See Removing And


Replacing Hydraulic Fluid on Page 10-140-6.)

Mark the pump for correct installation. 1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P-87372
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Installation: Install the O-ring (Item 1) [Figure 20-51-6]
I-2003-0888 in the O-ring groove of the flange.

Figure 20-51-5 Figure 20-51-7

Dealer Copy -- Not for Resale


1

P-87371 P-87373

Remove the four bolts (Item 1) [Figure 20-51-5], flange Remove the four bolts, flange (Item 1) [Figure 20-51-7]
and hose from the high pressure side of the pump. and hose from the suction side of the pump.

317 of 879 20-51-3 E80 Service Manual


PUMP (GEAR) (CONT'D) Figure 20-51-10

Removal And Installation (Cont’d)

Figure 20-51-8

2
1

P-87376

Remove the O-ring (Item 1) and coupler (Item 2) [Figure


P-87374 20-51-10].

Installation: Install the O-ring (Item 1) [Figure 20-51-8]


in the O-ring groove of the flange.

Dealer Copy -- Not for Resale


Figure 20-51-9

P-87375

Remove the bolts (Item 1) [Figure 20-51-9] and the


pump.

318 of 879 20-51-4 E80 Service Manual


PUMP (GEAR) (CONT'D) Figure 20-51-13

Disassembly And Assembly

Figure 20-51-11
1

P-87379

Remove the end cap (Item 1) [Figure 20-51-13].


P-87377
Figure 20-51-14

Mark the pump (Item 1) [Figure 20-51-11] for correct


assembly.

Dealer Copy -- Not for Resale


1
Figure 20-51-12

1 1

1
1 P-87380

Remove the gear housing (Item 1) [Figure 20-51-14].

P-87378

Remove the four bolts (Item 1) [Figure 20-51-12].

Installation: Tighten the bolts to 61 N•m (45 ft-lb) torque.

319 of 879 20-51-5 E80 Service Manual


PUMP (GEAR) (CONT'D) Figure 20-51-17

Disassembly And Assembly (Cont’d)

Figure 20-51-15

P-87383

Remove the bearings (Item 1) [Figure 20-51-17].


P-87381
Figure 20-51-18

Remove the square cut seal (Item 1) [Figure 20-51-15]


from both sides of the gear housing.

Dealer Copy -- Not for Resale


1
Figure 20-51-16

P-87384

Separate the bearings and remove the dowel pin (Item 1)


[Figure 20-51-18].
P-87382

Remove the seal and back-up ring (Item 1) [Figure 20-


51-16].

320 of 879 20-51-6 E80 Service Manual


PUMP (GEAR) (CONT'D) Figure 20-51-21

Disassembly And Assembly (Cont’d)


1
Figure 20-51-19

P-87387

2 Remove the seal and back-up ring (Item 1) [Figure 20-


P-87385 51-21].

Figure 20-51-22
Remove the drive gear (Item 1). Remove the idler gear
(Item 2) [Figure 20-51-19].

Dealer Copy -- Not for Resale


Figure 20-51-20
1

P-87384

Separate the bearings and remove the dowel pin (Item 1)


P-87386 [Figure 20-51-22].

Remove the bearings (Item 1) [Figure 20-51-20].

321 of 879 20-51-7 E80 Service Manual


PUMP (GEAR) (CONT'D) Figure 20-51-25

Disassembly And Assembly (Cont’d)

Figure 20-51-23
1
1

P-87390

1 Remove the seal (Item 1) [Figure 20-51-25].


P-87388

Remove the dowel pins (Item 1) [Figure 20-51-23].

Dealer Copy -- Not for Resale


Figure 20-51-24

P-87138

Remove the snap ring (Item 1) [Figure 20-51-24].

322 of 879 20-51-8 E80 Service Manual


MANIFOLD ASSEMBLY / ACCUMULATOR Figure 20-60-2

Description

The accumulator provides short term reserve pressure


for joystick function with the engine off and the key in the
run position.
1
Removal And Installation

With the engine off and the key in the run position, move
the control levers to relieve hydraulic pressure.

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

Figure 20-60-1 P-87105

Mark and disconnect the wire harness (Item 1) [Figure


20-60-2].

Figure 20-60-3

Dealer Copy -- Not for Resale


1

1
1 P-87104
1

Mark and remove the hoses (Item 1) [Figure 20-60-1].


1

P-87106

IMPORTANT
Remove the bolts (Item 1) [Figure 20-60-3] and remove
When repairing hydrostatic and hydraulic systems, the manifold.
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

323 of 879 20-60-1 E80 Service Manual


MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-6

Disassembly And Assembly

Figure 20-60-4 1

2 2 2

P-87109

Remove the back-up rings (Item 1) and O-rings (Item 2)


P-87107 [Figure 20-60-6].

Figure 20-60-7
Remove the nuts (Item 1) [Figure 20-60-4] and remove
the coils.

Dealer Copy -- Not for Resale


Figure 20-60-5
1
1

P-87110

Remove the pressure reducing valve (Item 1) [Figure 20-


P-87108 60-7].

Remove the spools (Item 1) [Figure 20-60-5].

324 of 879 20-60-2 E80 Service Manual


MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-10

Disassembly And Assembly (Cont’d)


2 2
Figure 20-60-8

2 2

1 1

P-87113
1 1

Remove the back-up rings (Item 1) and O-rings (Item 2)


P-87111 [Figure 20-60-10].

Figure 20-60-11
Remove the back-up rings (Item 1) and O-rings (Item 2)
[Figure 20-60-8].

Dealer Copy -- Not for Resale


Figure 20-60-9

1
P-87114

Remove the accumulator (Item 1) [Figure 20-60-11].


P-87112

Remove the build up valve (Item 1) [Figure 20-60-9].

325 of 879 20-60-3 E80 Service Manual


MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-60-12

P-87115

Remove the O-ring (Item 1) [Figure 20-60-12].

Dealer Copy -- Not for Resale

326 of 879 20-60-4 E80 Service Manual


TRAVEL MOTOR Figure 20-70-3

Removal And Installation

Remove the track. (See Track Removal And Installation


on Page 30-20-4.) or (See Track Removal And
Installation on Page 30-20-4.)

Remove the drive sprocket. (See Sprocket Removal And 2


Installation on Page 30-20-36.)

Figure 20-70-1 1

P-87914

Attach a lifting hook (Item 1) and chain (Item 2) [Figure


1
1 20-70-3] to the travel motor.
1
Remove the travel motor.

Dealer Copy -- Not for Resale


P-87909

Remove the bolts (Item 1) [Figure 20-70-1].

Remove the cover (Item 2) [Figure 20-70-1].

Figure 20-70-2

1 2
2
1 2

2
2
P-87910

Remove the hoses (Item 1) and bolts (Item 2) [Figure


20-70-2].

Installation: Apply thread lock adhesive (Loctite® 242 or


equivalent) to the bolt threads. Tighten the bolts to 265
N•m (195 ft-lb) torque.

327 of 879 20-70-1 E80 Service Manual


TRAVEL MOTOR (CONT'D)

Parts Identification

1 Spring
2 Piston Assembly
3 Shoe 2 1
3
4 Pin
5 4
5 Pivot 6
6 Seal
7
7 Bearing
8 Shaft 8
9 Swash Plate 9
10 Piston
11 Retainer Plate 10
12 Thrust Ball
13 Washer 11
14 Pin
15 Cylinder 12
16 Snap Ring
17 Mating Plate
18 Friction Plate
13

Dealer Copy -- Not for Resale


19 O-ring
20 Timing Plate 14
21 Plug 15
22 Rear Flange 13 17
23 Retainer Spring 1 18
13
24 Filter 16 19
25 Ball 10
26 Valve 19
27 Spool 1
28 Bolt 21 21
19 20
29 Back-Up Ring 1
30 Sleeve 22
23 19 7
31 Collar 21 19
32 Shim 1 26
33 Poppet
4
1 24
21 25
19 19 21
21 1 31 21 27
19 23
32 21
19 1 19
30 16 21
28 26 1
19
29 10 19
29 21
33 19
26
33 19
19
29 30
10 31 1
29 19
21
32

B-23945

328 of 879 20-70-2 E80 Service Manual


TRAVEL MOTOR (CONT'D)

Parts Identification Gear Reduction Hub

1 Bolt
2 Thrust Washer
3 Planetary Gear
4 Roller Bearing
5 Inner Ring
6 Collar
7 Nut
8 Ball Bearing
9 Hub
2 1
10 Seal 3
11 Spindle 4
12 Pin
5
13 O-ring 2
14 Plug
15 Snap Ring 7
16 Cover 8 6
17 Steel Ball
9
18 Sun Gear
19 Carrier

Dealer Copy -- Not for Resale


8
10
11

14
15 13
16
12 13
13
3 2 1 17

4
5
19
18

15

18

B-23946

329 of 879 20-70-3 E80 Service Manual


TRAVEL MOTOR (CONT'D) Recycle or dispose of used fluid in an environmentally
safe manner.
Disassembly
Figure 20-70-6
Clean the outside of the travel motor before disassembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

Figure 20-70-4
P-89338

Remove the snap ring (Item 1) [Figure 20-70-6].

Figure 20-70-7

Dealer Copy -- Not for Resale


1

P-89004

1
Remove the plugs (Item 1) [Figure 20-70-4].

Remove and discard the O-rings from the plugs.


P-89085
Figure 20-70-5

Remove the cover (Item 1) [Figure 20-70-7].

Remove and discard the O-ring from the cover.

P-89005

Drain the fluid from the travel motor [Figure 20-70-5].

330 of 879 20-70-4 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-10

Disassembly (Cont’d)
1
Figure 20-70-8

2
1

P-89010

Remove the bolts, thrust washers, and planetary gears


P-89008 (Item 1) [Figure 20-70-10].

Remove the roller bearing and inner ring from the carrier.
Remove the sun gear (Item 1) [Figure 20-70-8].
NOTE: Do not reuse the bolts holding the planetary

Dealer Copy -- Not for Resale


Remove the steel ball (Item 2) [Figure 20-70-8] from the gears to the carrier.
sun gear.
Figure 20-70-11
Figure 20-70-9

1
2

P-89011
P-89009

Remove the snap ring (Item 1) and sun gear (Item 2)


Remove the carrier assembly (Item 1) [Figure 20-70-9] [Figure 20-70-11] from the carrier.
from the hub.

331 of 879 20-70-5 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-14

Disassembly (Cont’d)

Figure 20-70-12

1
1

2 P-89339

Remove the sleeve (Item 1) [Figure 20-70-14].


P-89012
Figure 20-70-15

Remove the bolts (Item 1) and thrust washers (Item 2)


[Figure 20-70-12].

Dealer Copy -- Not for Resale


Figure 20-70-13

2
P-89014

Remove the plug (Item 1) [Figure 20-70-15].

P-89013

Remove the planetary gears (Item 1), roller bearings and


inner rings (Item 2) [Figure 20-70-13].

Remove the thrust washers and thrust collars from the


spindle.

332 of 879 20-70-6 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-18

Disassembly (Cont’d)

Figure 20-70-16

P-89017

Remove the bolts from the rear flange [Figure 20-70-18].


P-89015
Figure 20-70-19

Remove the plug (Item 1) [Figure 20-70-16].

Dealer Copy -- Not for Resale


Figure 20-70-17

1
1

P-89018

Remove the rear flange (Item 1) [Figure 20-70-19].


P-89016

Remove the plug (Item 1) [Figure 20-70-17].

333 of 879 20-70-7 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-22

Disassembly (Cont’d)

Figure 20-70-20

P-89021

Remove the timing plate (Item 1) [Figure 20-70-22].


P-89019
Figure 20-70-23

Remove the pins (Item 1) [Figure 20-70-20].

Dealer Copy -- Not for Resale


Figure 20-70-21

P-89022

Remove the pin (Item 1) [Figure 20-70-23] from the rear


P-89020
flange.

Remove and discard the two O-rings (Item 1) [Figure 20-


70-21].

Remove the ten springs from the rear flange.

334 of 879 20-70-8 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-26

Disassembly (Cont’d)

Figure 20-70-24

1
1 2

P-89025

Remove the O-ring (Item 1) and back-up rings (Item 2)


P-89023 [Figure 20-70-26] from the valve seat.

Discard the O-ring and back-up rings.


Remove the bearing (Item 1) [Figure 20-70-24].
Figure 20-70-27

Dealer Copy -- Not for Resale


Figure 20-70-25

P-89026
P-89024

Remove the O-ring (Item 1) [Figure 20-70-27] from the


Remove the sleeve (Item 1) [Figure 20-70-25]. sleeve.

Discard the O-ring.

335 of 879 20-70-9 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-30

Disassembly (Cont’d)

Figure 20-70-28

P-89029

1
Remove the O-ring (Item 1) [Figure 20-70-30] from the
P-89027 plug.

Figure 20-70-31
Remove the plug (Item 1) [Figure 20-70-28] from the
rear flange. (Both sides)

Dealer Copy -- Not for Resale


Remove the spring retainer and spring. (Both sides)

Figure 20-70-29

P-89030

Remove the plug (Item 1) [Figure 20-70-31].


1
P-89028

Remove the spool (Item 1) [Figure 20-70-29].

336 of 879 20-70-10 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-34

Disassembly (Cont’d)

Figure 20-70-32

1 P-89033

Remove the plug (Item 1) [Figure 20-70-34].


P-89031
Remove and discard the O-ring from the plug.

Remove the spring and valve (Item 1) [Figure 20-70-32]. Figure 20-70-35

Dealer Copy -- Not for Resale


Figure 20-70-33

P-89075
1
P-89032
Remove the spool (Item 1) [Figure 20-70-35] and spring.

Remove the O-ring (Item 1) [Figure 20-70-33] from the


plug.

Discard the O-ring.

337 of 879 20-70-11 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-38

Disassembly (Cont’d)

Figure 20-70-36

P-89037

Remove the cylinder block assembly (Item 1) [Figure 20-


P-89035 70-38].

Figure 20-70-39
Remove the piston by injecting low air pressure into the
access hole in the spindle [Figure 20-70-36].

Dealer Copy -- Not for Resale


Remove the O-ring from the piston.

Discard the O-ring.

Turn the motor on its side and drain the hydraulic fluid
into an approved container.

Figure 20-70-37
1 2

P-89038
1

Remove the piston assembly (Item 1) from the cylinder


block (Item 2) [Figure 20-70-39].

P-89036

Remove the mating plates and friction plates (Item 1)


[Figure 20-70-37].

338 of 879 20-70-12 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-42

Disassembly (Cont’d)

Figure 20-70-40
1

2
1
2 1

P-89041

1 Remove the washer and pins (Item 1) from the cylinder


P-89039 block (Item 2) [Figure 20-70-42].

Remove the pistons (Item 1) from the retainer plate (Item


2) [Figure 20-70-40].

Dealer Copy -- Not for Resale


Figure 20-70-41

P-89040

Remove the thrust ball (Item 1) from the cylinder block


(Item 2) [Figure 20-70-41].

339 of 879 20-70-13 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-45

Disassembly (Cont’d)

Figure 20-70-43
1

P-89045

Remove the swash plate (Item 1) [Figure 20-70-45].


P-89043
Figure 20-70-46

Place the cylinder block in a press [Figure 20-70-43].

Dealer Copy -- Not for Resale


Figure 20-70-44

3
P-89046

Remove the shaft (Item 1) [Figure 20-70-46].


P-89044

Remove the snap ring (Item 1), washer (Item 2), and
spring (Item 3) [Figure 20-70-43] and [Figure 20-70-44].

340 of 879 20-70-14 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-49

Disassembly (Cont’d)

Figure 20-70-47

1
2

P-89049

Remove the set screws (Item 1) [Figure 20-70-49].


P-89336
Figure 20-70-50

Place the shaft (Item 1) in a press and remove the


bearing (Item 2) [Figure 20-70-47].

Dealer Copy -- Not for Resale


Do not reuse the bearing.

Figure 20-70-48
1

P-89052

Remove the nut (Item 1) [Figure 20-70-50].

Do not reuse the nut.

P-89047

Remove the pivots and parallel pins (Item 1) [Figure 20-


70-48].

Remove the 2-speed pistons and springs by applying low


air pressure to the oil passages.

341 of 879 20-70-15 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-53

Disassembly (Cont’d)

Figure 20-70-51

1 1

P-89055

2
Remove the bearing (Item 1) [Figure 20-70-53] from
P-89053 both sides of the hub.

Figure 20-70-54
Separate the spindle (Item 1) from the hub (Item 2)
[Figure 20-70-51].

Dealer Copy -- Not for Resale


Figure 20-70-52

P-89056

2
Remove the seal ring assembly (Item 1) [Figure 20-70-
P-89054 54] from the spindle.

Remove the seal ring assembly (Item 1) from the hub


(Item 2) [Figure 20-70-52].

NOTE: Do not reuse the seal.

342 of 879 20-70-16 E80 Service Manual


TRAVEL MOTOR (CONT'D)

Disassembly (Cont’d)

Figure 20-70-55

P-89057

Remove the oil seal (Item 1) from the spindle (Item 2)


[Figure 20-70-55].

Dealer Copy -- Not for Resale

343 of 879 20-70-17 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-57

Assembly
1
Clean all parts in solvent and dry with compressed air.
Inspect all parts and replace those that are damaged. If
any of the planetary gears are damaged, replace all the
planetary gears and the sun gear from that planetary.
2
One damaged gear can cause a microscopic fatigue
crack in the mating teeth and cause premature failure
after servicing.

Apply oil to all O-rings (as noted) and light grease to the
ball and roller bearings before installation.
P-46426
Position the hub in a press.

Figure 20-70-56 Install the O-ring (Item 1) on both seal rings (Item 2)
[Figure 20-70-57].

NOTE: Inspect the seal ring for burrs before installing


the O-ring. Make sure the O-ring is not twisted
when installing it. To remove any twists,

Dealer Copy -- Not for Resale


gently pull a section of the O-ring and let it
snap back.

Figure 20-70-58

P-89061

Install the bearing (Item 1) [Figure 20-70-56].

Use the same procedure to install the bearing on the


opposite side of the hub.

Apply a light film of grease onto the O-ring of the seal ring
assemblies. P-61811

Install the seal ring assembly (Item 1) [Figure 20-70-58].

Use firm even pressure to pop the O-ring into the


housing.

Apply a light film of oil to the metal seal ring.

344 of 879 20-70-18 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-61

Assembly (Cont’d)

Figure 20-70-59

P-87899

The seal assembly stand off height must be equal and


P-61812 the O-ring must not be twisted [Figure 20-70-61].

Figure 20-70-62
The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 20-70-59].

Dealer Copy -- Not for Resale


Figure 20-70-60

P-89053

Install the spindle onto the hub [Figure 20-70-62].


P-87900
Apply Loctite® 270 (or equivalent) to a new ring nut.

Install the seal ring assembly (Item 1) [Figure 20-70-60]. Install the ring nut with the chamfer towards the bearing.

Use firm even pressure to pop the O-ring into the


housing.

Apply a light film of oil to the metal seal ring.

345 of 879 20-70-19 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-65

Assembly (Cont’d)

Figure 20-70-63

P-89067

Install the oil seal (Item 1) [Figure 20-70-65] into the


P-89050 spindle.

Install the parallel pin / pivot assemblies.


Use a spanner wrench and tighten the nut to 533 - 644
N•m (393 - 475 ft-lb) torque [Figure 20-70-63]. Install the spring into the piston.

Dealer Copy -- Not for Resale


Figure 20-70-64 Figure 20-70-66

P-89049 P-89068

Install the set screws (Item 1) [Figure 20-70-64]. Install the piston assembly (Item 1) [Figure 20-70-66]
into the spindle.
Tighten the set screws to 8 - 11 N•m (6 - 8 ft-lb).

346 of 879 20-70-20 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-69

Assembly (Cont’d)

Figure 20-70-67 1

P-89045

Install the swash plate (Item 1) [Figure 20-70-69].


P-89069
NOTE: Make sure the pivots mounted on the spindle
enter the pivot holes of the swash plate.
Heat the bearing (Item 1) to 72 - 128°C (162 - 262°F) and
install the shaft (Item 2) [Figure 20-70-67]. Figure 20-70-70

Dealer Copy -- Not for Resale


Figure 20-70-68

2
5

3
1

P-89043

P-89070
Install the washer (Item 1), spring (Item 2), washer (Item
3) and snap ring (Item 4) into the cylinder block (Item 5)
Install the shaft (Item 1) [Figure 20-70-68] into the [Figure 20-70-70].
spindle.

347 of 879 20-70-21 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-73

Assembly (Cont’d)

Figure 20-70-71

1
1
1
2

1
P-89039

Install the pistons (Item 1) into the retainer plate (Item 2)


P-89041 [Figure 20-70-73].

Figure 20-70-74
Install the pins (Item 1) [Figure 20-70-71] into the
cylinder block.

Dealer Copy -- Not for Resale


1
Figure 20-70-72

P-61778

Install the piston assembly (Item 1) [Figure 20-70-74]


P-89040 into the cylinder block.

Install the washer and thrust ball (Item 1) [Figure 20-70-


72] onto the cylinder block.

348 of 879 20-70-22 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-77

Assembly (Cont’d)

Figure 20-70-75

1
1

P-89073

Install the friction plate (Item 1) [Figure 20-70-77]. Install


P-89036 the remaining mating plates and friction plates
alternately.

Install the cylinder block assembly (Item 1) [Figure 20- NOTE: Immerse the friction plates in hydraulic fluid
70-75] onto the shaft. prior to installation.

Dealer Copy -- Not for Resale


Figure 20-70-76 Figure 20-70-78

1
1

P-89072 P-89035

Install the mating plate (Item 1) [Figure 20-70-76]. Install the O-ring onto the piston. Install the piston (Item
1) [Figure 20-70-78] into the spindle.

349 of 879 20-70-23 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-81

Assembly (Cont’d)

Figure 20-70-79

1
P-89028

1 Install the spool (Item 1) [Figure 20-70-81].


P-89032
Figure 20-70-82

Install the O-ring (Item 1) [Figure 20-70-79] onto the


plug.

Dealer Copy -- Not for Resale


Install the valve and spring into the plug. 1

Figure 20-70-80

P-89029

Install the O-ring (Item 1) [Figure 20-70-82] onto the


1
plug.

P-89031

Install the plug assembly (Item 1) into the rear flange


(Item 2) [Figure 20-70-80].

Do not tighten it yet.

350 of 879 20-70-24 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-85

Assembly (Cont’d)

Figure 20-70-83

P-89025

Install the O-ring and back-up ring (Item 1) [Figure 20-


P-89027 70-85].

Figure 20-70-86
Install the spring retainer, spring and plug (both ends of
the spool) [Figure 20-70-83].

Dealer Copy -- Not for Resale


Figure 20-70-84

P-89074

1
Install the valve (Item 1) [Figure 20-70-86].
P-89026

Install the O-ring (Item 1) [Figure 20-70-84] onto the


valve.

351 of 879 20-70-25 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-89

Assembly (Cont’d)

Figure 20-70-87

1
1

P-89021

Install the timing plate (Item 1) [Figure 20-70-89].


P-89075
Figure 20-70-90

Install the spring (Item 1) and spool (Item 2) [Figure 20-


70-87].

Dealer Copy -- Not for Resale


Install the O-ring on the plug and install the plug.

Do not tighten it yet.

Figure 20-70-88
1

P-89340

1
Install the springs (Item 1) [Figure 20-70-90].

P-89023

Install the bearing (Item 1) [Figure 20-70-88].

Install the parallel pins.

352 of 879 20-70-26 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-93

Assembly (Cont’d)

Figure 20-70-91
1

1
P-89018

Install the rear flange (Item 1) onto the spindle (Item 2)


P-89020 [Figure 20-70-93]. Make sure the pins on the spindle
align with the holes in the rear flange.

Install the O-rings (Item 1) [Figure 20-70-91] into the Tighten the bolts to 85 - 118 N•m (63 - 87 ft-lb) torque.
groove of the spindle.

Dealer Copy -- Not for Resale


Figure 20-70-94
Figure 20-70-92

P-89015
P-89019

Tighten the plug (Item 1) [Figure 20-70-94] to 78 - 117


Install the parallel pins (Item 1) [Figure 20-70-92]. N•m (58 - 86 ft-lb) torque.

Add 1,2 L (1.3 qt) of hydraulic fluid to the spindle.

353 of 879 20-70-27 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-97

Assembly (Cont’d)

Figure 20-70-95 1

P-89016
1

Tighten the plug (Item 1) [Figure 20-70-97] to 74 - 117


P-89339 N•m (58 - 86 ft-lb) torque.

Figure 20-70-98
Tighten the valve (Item 1) [Figure 20-70-95] to 122 - 152
N•m (90 - 112 ft-lb) torque.

Dealer Copy -- Not for Resale


Figure 20-70-96

2 1

1 P-89011

Insert the sun gear (Item 1) into the carrier and install the
P-89014 snap ring (Item 2) [Figure 20-70-98].

Tighten the plug (Item 1) [Figure 20-70-96] to 313 - 392


N•m (231 - 289 ft-lb) torque.

354 of 879 20-70-28 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-101

Assembly (Cont’d)

Figure 20-70-99

P-89079

Install the thrust collar (Item 1) [Figure 20-70-101].


P-89010
Figure 20-70-102

Install the inner race, bearing and planetary gears (Item


1) [Figure 20-70-99] onto the carrier.

Dealer Copy -- Not for Resale


2
Figure 20-70-100

P-89080

Install the thrust washer (Item 1) onto the spindle shaft


(Item 2) [Figure 20-70-102].
P-89078

Install thrust washers and new bolts (Item 1) [Figure 20-


70-100].

Tighten the bolts to 28 - 39 N•m (21 - 29 ft-lb) torque

355 of 879 20-70-29 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-105

Assembly (Cont’d)

Figure 20-70-103
1

P-89083

Install the carrier assembly (Item 1) [Figure 20-70-105].


P-89013
Figure 20-70-106

Install the inner race, bearing and planetary gear (Item 1)


[Figure 20-70-103].

Dealer Copy -- Not for Resale


1
Figure 20-70-104

P-89084

Install the steel ball (Item 1) onto the sun gear (Item 2)
[Figure 20-70-106].
P-89082
Install the sun gear.

Install the thrust washers and new bolts (Item 1) [Figure Install the O-ring into the groove in the hub
20-70-104].

Tighten the bolts to 49 - 68 N•m (36 - 50 ft-lb) torque

356 of 879 20-70-30 E80 Service Manual


TRAVEL MOTOR (CONT'D) Figure 20-70-109

Assembly (Cont’d)

Figure 20-70-107

1
P-89087

Install the plugs (Item 1) [Figure 20-70-109].


P-89085
Tighten the plugs to 49 - 68 N•m (36 - 50 ft-lb) torque.

Install the hub cover (Item 1) [Figure 20-70-107].

Dealer Copy -- Not for Resale


Figure 20-70-108

P-89338

Install the snap ring (Item 1) [Figure 20-70-108].

Install O-rings on the plugs.

357 of 879 20-70-31 E80 Service Manual


Dealer Copy -- Not for Resale

358 of 879 20-70-32 E80 Service Manual


SWIVEL JOINT Figure 20-80-2

Removal And Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-89335
Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

Remove the center cover. (See Removal And Installation Attach a sling (Item 1) [Figure 20-80-2].
on Page 40-70-1.)
Figure 20-80-3
Mark the hoses.
2
Figure 20-80-1

Dealer Copy -- Not for Resale


1 1
1
1
1

1
1

1
P-89311
1
1
Remove the bolts (Item 1) and bottom access plate (Item
P-89310
2) [Figure 20-80-3].

Remove the hoses (Item 1) [Figure 20-80-1] from the top Mark the hoses for ease of installation.
of the swivel joint.

359 of 879 20-80-1 E80 Service Manual


SWIVEL JOINT (CONT'D) Figure 20-80-6

Removal And Installation (Cont’d)


1
Figure 20-80-4

P-89314

Remove the hoses (Item 1) [Figure 20-80-6].


P-89312
Figure 20-80-7

Remove the hoses (Item 1) [Figure 20-80-4].


1

Dealer Copy -- Not for Resale


Figure 20-80-5
1

P-89315

Remove the hoses (Item 1) [Figure 20-80-7].


P-89313

Remove the hoses (Item 1) [Figure 20-80-5].

360 of 879 20-80-2 E80 Service Manual


SWIVEL JOINT (CONT'D) Figure 20-80-9

Removal And Installation (Cont’d)

Figure 20-80-8 1

P-89317

Remove the bolts (Item 1) [Figure 20-80-9].


P-89316

Remove the bolts (Item 1) [Figure 20-80-8].

Dealer Copy -- Not for Resale

361 of 879 20-80-3 E80 Service Manual


SWIVEL JOINT (CONT'D)

Parts Identification

1. Plug
2. Rotor
3. Dust Seal 1
4. O-ring
5. Seal 2
6. Housing
7. Shim 6
8. Spacer
9. Retainer
10. Cover
11. Washer
12. Bolt

Dealer Copy -- Not for Resale


3
8

4 9

5 10

11

12

MS2788

362 of 879 20-80-4 E80 Service Manual


SWIVEL JOINT (CONT'D) Figure 20-80-12

Disassembly 2
3
Figure 20-80-10 1

1 1
1

1 1 NA1242

2
Remove the seals (Item 1), O-ring (Item 2) and dust seal
NA1240 (Item 3) [Figure 20-80-12] from the housing.

Figure 20-80-13
Remove the bolts (Item 1) and cover (Item 2) [Figure 20-
80-10].

Dealer Copy -- Not for Resale


Remove the shim and O-ring from the cover.
1
Remove the snap ring, spacer and shim from the bottom
of the rotor. 1

Figure 20-80-11

1 1
1 NA1244

Remove the plugs (Item 1) [Figure 20-80-13].

NA1241

Remove the rotor (Item 1) from the housing (Item 2)


[Figure 20-80-11].

363 of 879 20-80-5 E80 Service Manual


SWIVEL JOINT (CONT'D) Figure 20-80-15

Assembly 2
3
Clean all components in solvent and dry with 1
compressed air.
1
NOTE: Be careful not to scratch the rotor surface as
damage to the finished surface could cause
1
internal leakage.

Check the components for wear and damage. 1

Always use new seals and O-rings.

Apply clean hydraulic oil to the components during NA1242


installation.

Wrap the plugs with teflon tape. Install the seals (Item 1), O-ring (Item 2) and dust seal
(Item 3) [Figure 20-80-15] in the housing.
Figure 20-80-14
Figure 20-80-16

Dealer Copy -- Not for Resale


2

1
1

1 NA1243

Install the plugs (Item 1) [Figure 20-80-14]. Tighten the 2


plugs to 58 - 69 N•m (43 - 51 ft-lb) torque.

Install the plugs (Item 2) [Figure 20-80-14]. Tighten the


plugs to 30 - 39 N•m (22 - 29 ft-lb) torque.

NA1245

Install the housing (Item 1) on the rotor (Item 2) [Figure


20-80-16].

364 of 879 20-80-6 E80 Service Manual


SWIVEL JOINT (CONT'D) Figure 20-80-18

Assembly (Cont’d)

Figure 20-80-17
1 1
4 5
2

1 1

3 6
NA1240
1

Install the bolts (Item 1) [Figure 20-80-18]. Tighten the


NA1246 bolts to 49 - 59 N•m (36 - 44 ft-lb) torque.

Install the shim (Item 1), spacer (Item 2) and snap ring
(Item 3) [Figure 20-80-17].

Dealer Copy -- Not for Resale


Install the O-ring (Item 4), shim (Item 5) and cover (Item
6) [Figure 20-80-17].

365 of 879 20-80-7 E80 Service Manual


Dealer Copy -- Not for Resale

366 of 879 20-80-8 E80 Service Manual


SWING MOTOR Figure 20-90-2

Removal And Installation

Remove the center cover. (See Removal And Installation


on Page 40-70-1.)

Drain the hydraulic reservoir. (See Removing And


Replacing Hydraulic Fluid on Page 10-140-6.)

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

Figure 20-90-1 1

P-87572

Remove the hoses (Item 1) [Figure 20-90-2] from the PG


and SH ports.
1 Figure 20-90-3

Dealer Copy -- Not for Resale


P-87254
1

Remove the plug (Item 1) [Figure 20-90-1] and drain the


swing motor drive carrier.

IMPORTANT P-87573

When repairing hydrostatic and hydraulic systems,


clean the work area before disassembly and keep all Remove the hoses (Item 1) [Figure 20-90-3] from the A
parts clean. Always use caps and plugs on hoses, and B ports.
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

NOTE: Mark all hoses before removal for ease of


installation.

367 of 879 20-90-1 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-6

Removal And Installation (Cont’d)

Figure 20-90-4

1 1
1 1

P-87575

Remove the bolts (Item 1) [Figure 20-90-6].


P-87574
Installation: Tighten the bolts to 101,7 ± 16 N•m (75 ± 12
ft-lb) torque.
Remove the hoses (Item 1) [Figure 20-90-4].
Figure 20-90-7

Dealer Copy -- Not for Resale


Figure 20-90-5

1
1
1

P-87577
P-87575

Install two bolts (Item 1) [Figure 20-90-7] (removed in


Mark the swing motor (Item 1) and swing motor drive previous step) in the threaded holes in the swing motor.
carrier (Item 2) [Figure 20-90-5] for proper installation. Tighten the bolts evenly to separate the swing motor from
the swing motor drive carrier.

Remove the swing motor.

368 of 879 20-90-2 E80 Service Manual


SWING MOTOR (CONT’D)

Parts Identification

1. Relief Valve
2. Bolt
3. Plug
4. O-ring
5. Spring 3
1
6. Anticavitation Valve
7. End Cap
8. Bearing 2
9. Valve Plate
10. Spring 6
11. Brake Piston 7 5
12. Separation Plate
13. Friction Plate 3
8
14. Snap Ring
15. Washer 4
9
16. Cylinder Block
17. Ball Guide 10
18. Piston Assembly 11
19. Piston Retainer
4
20. Thrust Plate 4

Dealer Copy -- Not for Resale


21. Pipe Plug 14
22. Dipstick Assembly 12
23. Brake Valve 15
13 10
15
16

15
17

18

19
2 20
21
23
22
8

14

NA-1044

369 of 879 20-90-3 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-10

Disassembly And Assembly

Figure 20-90-8

2
2

1 1

P-87586

Remove the springs (Item 1) and spools (Item 2) [Figure


P-87584 20-90-10].

Figure 20-90-11
Remove the three bolts and remove the brake valve
(Item 1) [Figure 20-90-8].

Dealer Copy -- Not for Resale


Figure 20-90-9

1
1 1

P-87587

Remove the plug (Item 1) [Figure 20-90-11] from both


P-87585 sides of the end cap.

Installation: Tighten the plugs to 79 - 98 N•m (58 - 72 ft-


Remove the O-rings (Item 1) [Figure 20-90-9]. lb) torque.

370 of 879 20-90-4 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-14

Disassembly And Assembly (Cont’d)

Figure 20-90-12

1
1

P-87590

Remove the spool (Item 1) [Figure 20-90-14] from both


P-87588 sides of the end cap.

Figure 20-90-15
Remove the O-ring (Item 1) [Figure 20-90-12] from both
plugs.

Dealer Copy -- Not for Resale


Figure 20-90-13

1
1

P-87591

Remove the relief valves (Item 1) [Figure 20-90-15].


P-87589
Installation: Tighten the relief valves to 148 - 167 N•m
(109 - 123 ft-lb) torque.
Remove the spring (Item 1) [Figure 20-90-13] from both
sides of the end cap.

371 of 879 20-90-5 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-18

Disassembly And Assembly (Cont’d)

Figure 20-90-16
1

P-87594

Remove the valve plate (Item 1) [Figure 20-90-18] from


P-87592 the end cap.

Figure 20-90-19
Remove the O-ring (Item 1) [Figure 20-90-16] from both
relief valves.

Dealer Copy -- Not for Resale


Figure 20-90-17
1

1
1

P-87596
1

Installation: The hole (Item 1) in the valve plate must


P-87593 engage the pin (Item 2) [Figure 20-90-19] on the end
cap.

Remove the four bolts (Item 1) [Figure 20-90-17] and


remove the end cap.

Installation: Tighten the bolts to 85 - 118 N•m (63 - 87 ft-


lb) torque.

372 of 879 20-90-6 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-22

Disassembly And Assembly (Cont’d)

Figure 20-90-20
1

P-87598

Installation: Do not install springs in the spring bores


P-87595 with threaded holes (Item 1) [Figure 20-90-22].

Figure 20-90-23
Remove the bearing (Item 1) [Figure 20-90-20].

Dealer Copy -- Not for Resale


Figure 20-90-21

P-87599

P-87597 Install two screws (Item 1) [Figure 20-90-23] in the


threaded holes of the brake piston. Pull up on the screws
and remove the brake piston.
Remove the O-ring (Item 1). Remove the sixteen springs
(Item 2) [Figure 20-90-21].

373 of 879 20-90-7 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-26

Disassembly And Assembly (Cont’d)


1
Figure 20-90-24

P-87602

Remove the second friction plate (Item 1) [Figure 20-90-


P-87600 26].

Figure 20-90-27
Remove the friction plate (Item 1) [Figure 20-90-24].

Dealer Copy -- Not for Resale


Figure 20-90-25
1

1
1

P-86577

P-87601 Remove the O-rings (Item 1) [Figure 20-90-27].

Remove the separation plate (Item 1) [Figure 20-90-25].

374 of 879 20-90-8 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-30

Disassembly And Assembly (Cont’d)

Figure 20-90-28 1

1
P-87605

Remove the piston assemblies (Item 1) [Figure 20-90-


P-87603 30] from the retainer.

Figure 20-90-31
Tip the housing and remove the rotating group (Item 1)
[Figure 20-90-28].

Dealer Copy -- Not for Resale


1
Figure 20-90-29

P-87606

Remove the ball guide (Item 1) [Figure 20-90-31].


P-87604

Remove the piston assemblies / retainer (Item 1) [Figure


20-90-29] from the cylinder block.

NOTE: It is not important that the pistons are installed


in the original bores.

375 of 879 20-90-9 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-34

Disassembly And Assembly (Cont’d)

Figure 20-90-32

2
1

P-87615

Using a press and an appropriately sized spacer (Item 1),


P-87607 compress the spring in the cylinder block (Item 2) [Figure
20-90-34].

Remove the washer (Item 1) [Figure 20-90-32]. Figure 20-90-35

Dealer Copy -- Not for Resale


Figure 20-90-33

1
1
1

P-87616

P-87608
Remove the snap ring (Item 1) [Figure 20-90-35].
Remove the cylinder block from the press.
Remove the three pins (Item 1) [Figure 20-90-33].

376 of 879 20-90-10 E80 Service Manual


SWING MOTOR (CONT’D) Figure 20-90-38

Disassembly And Assembly (Cont’d)

Figure 20-90-36

1
3 2
1

P-87611

Remove the snap ring (Item 1) [Figure 20-90-38] from


P-87617 the shaft.

Figure 20-90-39
Remove the top washer (Item 1), spring (Item 2) and
bottom washer (Item 3) [Figure 20-90-36].

Dealer Copy -- Not for Resale


Figure 20-90-37
1

P-87612

Remove the shaft (Item 1) [Figure 20-90-39].


P-87609

Remove the thrust plate (Item 1) [Figure 20-90-37].

377 of 879 20-90-11 E80 Service Manual


SWING MOTOR (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-90-40

P-87613

Remove the bearing (Item 1) [Figure 20-90-40].

Dealer Copy -- Not for Resale


Figure 20-90-41

P-87614

Remove the seal (Item 1) [Figure 20-90-41].

Prior to assembly perform the following steps:

Clean all parts in solvent and dry with compressed air.

Check the components for wear and damage.

Always use new O-rings and seals.

Apply clean hydraulic oil to the components during


installation.

378 of 879 20-90-12 E80 Service Manual


SWING MOTOR (DRIVE CARRIER) Figure 20-91-3

Removal And Installation

Remove the swing motor. (See Removal And Installation


on Page 20-90-1.)

Figure 20-91-1

P-87581

Install two bolts (Item 1) [Figure 20-91-3] (removed in


1
2 previous step) in the threaded holes in the swing motor
drive carrier. Tighten the bolts evenly to separate the
swing motor drive carrier from the frame.
P-87579
Figure 20-91-4

Dealer Copy -- Not for Resale


Remove the grease hose (Item 1) and the drain hose
(Item 2) [Figure 20-91-1]. 1

NOTE: Mark the swing motor drive carrier and frame


for proper installation.

Figure 20-91-2

P-87581

1 Install a sling (Item 1) [Figure 20-91-4] and hoisting


device to the swing motor drive carrier.
1 Remove the swing motor drive carrier.
1
P-87580

Remove the bolts (Item 1) [Figure 20-91-2].

379 of 879 20-91-1 E80 Service Manual


SWING MOTOR (DRIVE CARRIER) (CONT’D)

Parts Identification

1. Snap Ring
2. Thrust Washer
3. Bearing Race
1
4. Needle Bearing 2
5. Planetary Gear
6. Sun Gear 3
7. Carrier 4
8. Screw 5
9. Thrust Plate 6
2
10. Collar 2
11. O-ring
12. Bearing 7
13. Seal
14. Housing
15. Plug
16. Dust Seal 6 2
17. Pinion Shaft
8
3
9 4

Dealer Copy -- Not for Resale


5
7
2

10

12

11
13

14

15
12

16

17

NA-1043

380 of 879 20-91-2 E80 Service Manual


SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-7

Disassembly And Assembly


1
Figure 20-91-5 2
3

1 4
5
7 6

NA-1114

Remove the snap ring (Item 1), thrust washer (Item 2),
NA-1110 planetary gear (Item 3), bearing (Item 4) bearing race
(Item 5) and thrust washer (Item 6) [Figure 20-91-7].

Remove the sun gear (Item 1) [Figure 20-91-5]. Remove the sun gear thrust washer (Item 7) [Figure 20-
91-7].

Dealer Copy -- Not for Resale


Figure 20-91-6
Figure 20-91-8

1
1

NA-1111
NA-1112

Remove the carrier assembly (Item 1) [Figure 20-91-6].


Remove the sun gear (Item 1) [Figure 20-91-8].

381 of 879 20-91-3 E80 Service Manual


SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-11

Disassembly And Assembly (Cont’d) 1

Figure 20-91-9 2

1 4
3

NA-1116

Remove the thrust washer (Item 1), planetary gear (Item


NA-1113 2), bearing (Item 3), bearing race (Item 4) and thrust
washer (Item 5) [Figure 20-91-11].

Remove the carrier assembly (Item 1) [Figure 20-91-9]. Figure 20-91-12

Dealer Copy -- Not for Resale


Figure 20-91-10
1
1
1

NA-1117

NA-1115
Remove both halves of the collar (Item 1) [Figure 20-91-
12].
Heat the screws (Item 1) [Figure 20-91-10] to melt the
thread adhesive.

Remove the screws (Item 1) and remove the thrust plate


(Item 2) [Figure 20-91-10].

382 of 879 20-91-4 E80 Service Manual


SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-15

Disassembly And Assembly (Cont’d)


1
Figure 20-91-13

1 NA-1119

Remove the bearing (Item 1) [Figure 20-91-15].


NA-1118
Figure 20-91-16

Remove the pinion shaft (Item 1) [Figure 20-91-13].


1

Dealer Copy -- Not for Resale


Figure 20-91-14

NA-1120

Remove the seal (Item 1) [Figure 20-91-16].


NA-1130

Remove the bearing (Item 1) and dust seal (Item 2)


[Figure 20-91-14] from the pinion shaft.

383 of 879 20-91-5 E80 Service Manual


Dealer Copy -- Not for Resale

384 of 879 20-91-6 E80 Service Manual


CONTROL PATTERN SELECTOR VALVE Figure 20-100-1

Removal And Installation

Remove the left upperstructure cover. (See Removal And


Installation on Page 40-20-1.)

Mark all hoses for proper installation.


1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P-86429
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Remove the two bolts (Item 1) [Figure 20-100-1], lock
I-2003-0888 washers and flat washers.

Figure 10-141-1 Figure 20-100-2

Dealer Copy -- Not for Resale


1 1

P-86428 P-86430

Remove the eight hoses from the control pattern selector Lay the valve down and remove the spacer (Item 1)
valve (Item 1) [Figure 10-141-1]. [Figure 20-100-2].

Remove the valve from the excavator.

385 of 879 20-100-1 E80 Service Manual


CONTROL PATTERN SELECTOR VALVE (CONT'D)

Parts Identification

1. Set Screw
2. Spring
3. Ball
4. Screw
7
5. Washer
6. Spool
7. U Seal
8. Valve Block

Dealer Copy -- Not for Resale


7

3
2
1
MS-2811S

386 of 879 20-100-2 E80 Service Manual


CONTROL PATTERN SELECTOR VALVE (CONT'D) Figure 20-100-5

Disassembly

Figure 20-100-3

P-86431
1

Remove the screw (Item 1) [Figure 20-100-5] and


P-86433 washer.

Figure 20-100-6
Remove the set screw (Item 1) [Figure 20-100-3].

Dealer Copy -- Not for Resale


Figure 20-100-4

1
2
1
P-86434

P-86432 Remove the spool (Item 1) [Figure 20-100-6] from the


valve body.

Remove the spring (Item 1) and ball (Item 2) [Figure 20-


100-4].

387 of 879 20-100-3 E80 Service Manual


CONTROL PATTERN SELECTOR VALVE (CONT'D)

Disassembly (Cont’d)

Figure 20-100-7

1 1

P-86435

Remove the U seal (Item 1) [Figure 20-100-7] from both


ends of the spool.

Dealer Copy -- Not for Resale

388 of 879 20-100-4 E80 Service Manual


CONTROL PATTERN SELECTOR VALVE (CONT'D) Figure 20-100-10

Assembly

Clean all parts in solvent and dry with compressed air.


Inspect all parts for wear and damage. Replace any worn
or damaged part.

Always install new seals and O-rings. Lubricate all seals


and O-rings with clean hydraulic fluid before installation.

Figure 20-100-8

P-86431

Install the washer and screw (Item 1) [Figure 20-100-


10].

NOTE: The washer must engage the slot (Item 2)


[Figure 20-100-9] in the spool.
1 1

Dealer Copy -- Not for Resale


Figure 20-100-11

P-86435

Install the U seal (Item 1) [Figure 20-100-8] on both ends


of the spool.

Figure 20-100-9

P-86432

Apply a light coat of grease to and install the ball (Item 1).
1 Install the spring (Item 2) [Figure 20-100-11].

2
P-86434

Apply oil to and install the spool (Item 1) [Figure 20-100-


9] in the valve body.

389 of 879 20-100-5 E80 Service Manual


CONTROL PATTERN SELECTOR VALVE (CONT'D)

Assembly (Cont’d)

Figure 20-100-12

P-86433

Install the set screw (Item 1) [Figure 20-100-12].

Dealer Copy -- Not for Resale

390 of 879 20-100-6 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) Figure 20-110-3

Testing

Remove the left upperstructure cover. (See Removal And


Installation on Page 40-20-1.) 1

Figure 20-110-1

P-86421

Install a 6900 kPa (69 bar) (1000 psi) gauge (Item 1)


[Figure 20-110-3] on the pilot line. Start the excavator
and warm up the hydraulic oil to operating temperature.
1

P-86419 Engage the circuit to be tested. Record the operating


pressure.

Dealer Copy -- Not for Resale


Cut and remove the cable ties (Item 1) [Figure 20-110- The operating pressure should be approximately 2800
1]. kPa (28 bar) (415 psi).

Find the pilot line of the control lever that is to be checked If the operating pressure is correct, check the valve
at the control valve assembly. section spool for proper operation. If the operating
pressure is incorrect, test the pressure reducing valve.
Figure 20-110-2 (See Testing And Adjusting The Pressure Reducing
Valve on Page 20-32-1.)

If the pressure reducing valve is incorrect, adjust the


pressure reducing valve. (See Testing And Adjusting The
Pressure Reducing Valve on Page 20-32-1.) Retest the
right control lever.

P-86420

Disconnect the hydraulic hose (Item 1) [Figure 20-110-2]


from the control valve.

391 of 879 20-110-1 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-6

Handle Removal And Installation

Remove the right console cover. (See Console Cover


Removal And Installation on Page 40-50-1.) 1
Figure 20-110-4

P-86683

Use a small flat blade screwdriver to depress the wire


terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-110-6].
1
P-86681 Installation: Use a small flat blade screwdriver to bend
the wire terminal tabs on each wire before installing the

Dealer Copy -- Not for Resale


individual wires in the connector bodies.
Disconnect the wire harness (Item 1) [Figure 20-110-4].
Figure 20-110-7
Figure 20-110-5

P-86684
P-86682

Pull the harness (Item 1) [Figure 20-110-7] out of the


Remove the lock (Item 1) [Figure 20-110-5] from the housing.
connector body.

Mark the wires to the connector bodies.

392 of 879 20-110-2 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Joystick Assembly Removal And Installation

Handle Removal And Installation (Cont’d) Remove the right console cover. (See Console Cover
Removal And Installation on Page 40-50-1.)
Figure 20-110-8
Figure 20-110-10

P-86685 1
P-86681

Loosen the nut (Item 1) [Figure 20-110-8] and unthread


the handle. Disconnect the wire harness (Item 1) [Figure 20-110-10].

Dealer Copy -- Not for Resale


Figure 20-110-9 Figure 20-110-11

190,5 mm
(7.50”)
1

P-86686 P-86663

Installation: Install the cable tie (Item 1) [Figure 20-110- Remove the bolts (Item 1) [Figure 20-110-11] and
9] at 190,5 mm (7.5 in) from the base of the handle. This washers from the blade control valve.
provides the correct amount of slack in the handle wire
harness. Reposition the blade control valve towards the rear of the
cab.

393 of 879 20-110-3 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-14

Joystick Assembly Removal And Installation (Cont’d)

Figure 20-110-12

2 1

1
P-86689
1

Tilt the joystick (Item 1) towards the rear of the cab. Mark
P-86687 and remove the hoses (Item 2) [Figure 20-110-14].

Remove the joystick.


Remove the bolts (Item 1) [Figure 20-110-12], flat
washers and lock washers from the front of the joystick.

Dealer Copy -- Not for Resale


Figure 20-110-13
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

P-86688

Remove the bolts (Item 1) [Figure 20-110-13], flat


washers and lock washers from the rear of the joystick.

394 of 879 20-110-4 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

Parts Identification

1. Handle Assembly
2. Dust Boot
3. Connector Lock
4. Connector
5. Nut
6. Seal
7. Plug
8. O-ring
9. Push Rod
10. Spring Retainer
16
11. Spring Seat
12. Spring
13. Washer 6
14. Spool 6 17
7
15. Spring 7 8
16. Nut 8
17. Control Plate 9
18. Dust Boot 9 18
3 10
19. U-Joint 4 10

Dealer Copy -- Not for Resale


20. Plate 11
11
21. Grommet
22. Body 19 12
12
23. Pipe Plug 13
24. Plug 1 13
20
14
14

15
15
2

21 22

5
23
8

24

MS-2789S

395 of 879 20-110-5 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-17

Disassembly And Assembly

Figure 20-110-15 2

3 P-86692

Loosen the nut (Item 1) and remove the handle (Item 2)


P-86690 and boot (Item 3) [Figure 20-110-17].

Figure 20-110-18
Remove the lock (Item 1) [Figure 20-110-15] from the
connector body.

Dealer Copy -- Not for Resale


Mark the wires to the connector body. 1
Figure 20-110-16

1 190,5 mm
(7.50”)

P-86686

Installation: Install the cable tie (Item 1) [Figure 20-110-


18] at 190,5 mm (7.5 in) from the base of the handle.
This provides the correct amount of slack in the handle
P-86691 wire harness.

Use a small flat blade screwdriver to depress the wire


terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-110-16].

Installation: Use a small flat blade screwdriver to bend


the wire terminal tabs on each wire before installing the
individual wires in the connector bodies.

396 of 879 20-110-6 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-21

Disassembly And Assembly (Cont’d)

Figure 20-110-19 1

P-86695

Remove the control plate (Item 1) [Figure 20-110-21].


P-86693
Figure 20-110-22

Remove the dust boot (Item 1) [Figure 20-110-19].

Dealer Copy -- Not for Resale


Figure 20-110-20
1

P-86696

Remove the U-joint (Item 1) [Figure 20-110-22].


P-86694

Remove the nut (Item 1) [Figure 20-110-20].

397 of 879 20-110-7 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-25

Disassembly And Assembly (Cont’d)

Figure 20-110-23

P-86699

Remove the pushrod (Item 1) [Figure 20-110-25].


P-50872
Figure 20-110-26

Mark the plate (Item 1) [Figure 20-110-23] for correct


installation.

Dealer Copy -- Not for Resale


Remove the plate.

Figure 20-110-24

2 1

P-86701

1 Remove the O-ring (Item 1) from the O.D. of the plug.


Remove the seal (Item 2) [Figure 20-110-26] from the
I.D. of the plug.

P-21730

Remove the plug assemblies (Item 1) [Figure 20-110-


24].

398 of 879 20-110-8 E80 Service Manual


RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-29

Disassembly And Assembly (Cont’d)

Figure 20-110-27
2

3 1

1 P-86704

Remove the spring seat (Item 1), spring (Item 2), and
P-86702 washer (Item 3) [Figure 20-110-29] from the spool.

Figure 20-110-30
Remove the spool assemblies (Item 1) [Figure 20-110-
27].

Dealer Copy -- Not for Resale


Figure 20-110-28 1

1 1

P-86705

Remove the springs (Item 1) [Figure 20-110-30].


P-86703

Compress the spring and remove the spring retainers


(Item 1) [Figure 20-110-28].

399 of 879 20-110-9 E80 Service Manual


Dealer Copy -- Not for Resale

400 of 879 20-110-10 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) Figure 20-120-3

Testing

Remove the left upperstructure cover. (See Removal And


Installation on Page 40-20-1.) 1

Figure 20-120-1

P-86421

Install a 6900 kPa (69 bar) (1000 psi) gauge (Item 1)


[Figure 20-120-3] on the pilot line. Start the excavator
and warm up the hydraulic oil to operating temperature.
1

P-86419 Engage the circuit to be tested. Record the operating


pressure.

Dealer Copy -- Not for Resale


Cut and remove the cable ties (Item 1) [Figure 20-120- The operating pressure should be approximately 2800
1]. kPa (28 bar) (415 psi).

Find the pilot line of the control lever that is to be checked If the operating pressure is correct, check the valve
at the control valve assembly. section spool for proper operation. If the operating
pressure is incorrect, test the pressure reducing valve.
Figure 20-120-2 (See Testing And Adjusting The Pressure Reducing
Valve on Page 20-32-1.)

If the pressure reducing valve is incorrect, adjust the


pressure reducing valve. (See Testing And Adjusting The
Pressure Reducing Valve on Page 20-32-1.) Retest the
right control lever.

P-86420

Disconnect the hydraulic hose (Item 1) [Figure 20-120-2]


from the control valve.

401 of 879 20-120-1 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-6

Handle Removal And Installation

Remove the upper left console cover. (See Upper 1


Console Cover Removal And Installation on Page 40-60-
2.)

Figure 20-120-4

P-86769

Use a small flat blade screwdriver to depress the wire


terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-120-6].

Installation: Use a small flat blade screwdriver to bend


P-86762 the wire terminal tabs on each wire before installing the

Dealer Copy -- Not for Resale


individual wires in the connector body.

Disconnect the wire harness (Item 1) [Figure 20-120-4]. Figure 20-120-7

Figure 20-120-5

P-86771

P-86768
Pull the harness (Item 1) [Figure 20-120-7] out of the
housing.
Remove the lock (Item 1) [Figure 20-120-5] from the
connector body.

Mark the wires to the connector bodies.

402 of 879 20-120-2 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Joystick Assembly Removal And Installation

Handle Removal And Installation (Cont’d) Remove the upper left console cover. (See Upper
Console Cover Removal And Installation on Page 40-60-
Figure 20-120-8 2.)

Figure 20-120-10

1 1

P-86685

P-86762
Loosen the nut (Item 1) [Figure 20-120-8] and unthread
the handle.

Dealer Copy -- Not for Resale


Disconnect the wire harness (Item 1) [Figure 20-120-10].
Figure 20-120-9

190,5 mm
(7.50”)

P-86686

Installation: Install the cable tie (Item 1) [Figure 20-120-


9] at 190,5 mm (7.5 in) from the base of the handle. This
provides the correct amount of slack in the handle wire
harness.

403 of 879 20-120-3 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT'D)

Joystick Assembly Removal And Installation (Cont’d)

Figure 20-120-11

P-86771

Remove the four bolts (Item 1) [Figure 20-120-11], flat


washers and lock washers from the joystick.

Dealer Copy -- Not for Resale


Figure 20-120-12

2 1

P-86772

Tilt the joystick (Item 1) towards the rear of the cab. Mark
and remove the hoses (Item 2) [Figure 20-120-12].

Remove the joystick.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

404 of 879 20-120-4 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT’D)

Parts Identification

1. Handle Assembly
2. Dust Boot
3. Connector Lock
4. Connector
5. Nut
6. Seal
7. Plug
8. O-ring
9. Push Rod
10. Spring Retainer
16
11. Spring Seat
12. Spring
13. Washer 6
14. Spool 6 17
7
15. Spring 7 8
16. Nut 8
17. Control Plate 9
18. Dust Boot 9 18
3 10
19. U-Joint 4 10
20. Plate 11
11

Dealer Copy -- Not for Resale


21. Grommet
22. Body 19 12
12
23. Pipe Plug 13
24. Plug 1 13
20
14
14

15
15
2

21 22

5
23
8

24

MS-2789S

405 of 879 20-120-5 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-15

Disassembly And Assembly

Figure 20-120-13

P-86692

Loosen the nut (Item 1) and remove the handle (Item 2)


P-86690 and boot (Item 3) [Figure 20-120-15].

Figure 20-120-16
Remove the lock (Item 1) [Figure 20-120-13] from the
connector body.

Dealer Copy -- Not for Resale


Mark the wires to the connector bodies. 1
Figure 20-120-14

1 190,5 mm
(7.50”)

P-86686

Installation: Install the cable tie (Item 1) [Figure 20-120-


16] at 190,5 mm (5.5 in) from the base of the handle.
This provides the correct amount of slack in the handle
P-86691 wire harness.

Use a small flat blade screwdriver to depress the wire


terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-120-14].

Installation: Use a small flat blade screwdriver to bend


the wire terminal tabs on each wire before installing the
individual wires in the connector bodies.

406 of 879 20-120-6 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-19

Disassembly And Assembly (Cont’d)

Figure 20-120-17 1

P-86695

Remove the control plate (Item 1) [Figure 20-120-19].


P-86693
Figure 20-120-20

Remove the dust boot (Item 1) [Figure 20-120-17].

Dealer Copy -- Not for Resale


Figure 20-120-18
1

P-86696

Remove the U-joint (Item 1) [Figure 20-120-20].


P-86694

Remove the nut (Item 1) [Figure 20-120-18].

407 of 879 20-120-7 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-23

Disassembly And Assembly (Cont’d)

Figure 20-120-21

P-86699

Remove the pushrod (Item 1) [Figure 20-120-23].


P-50872
Figure 20-120-24

Mark the plate (Item 1) [Figure 20-120-21] for correct


installation.

Dealer Copy -- Not for Resale


Remove the plate.

Figure 20-120-22

2 1

P-86701

1 Remove the O-ring (Item 1) from the O.D. of the plug.


Remove the seal (Item 2) [Figure 20-120-24] from the
I.D. of the plug.

P-21730

Remove the plug assemblies (Item 1) [Figure 20-120-


22].

408 of 879 20-120-8 E80 Service Manual


LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-27

Disassembly And Assembly (Cont’d)

Figure 20-120-25
2

3 1

1 P-86704

Remove the spring seat (Item 1), spring (Item 2), and
P-86702 washer (Item 3) [Figure 20-120-27] from the spool.

Figure 20-120-28
Remove the spool assemblies (Item 1) [Figure 20-120-
25].

Dealer Copy -- Not for Resale


Figure 20-120-26 1

1 1

P-86705

Remove the springs (Item 1) [Figure 20-120-28].


P-86703

Compress the spring and remove the spring retainers


(Item 1) [Figure 20-120-26].

409 of 879 20-120-9 E80 Service Manual


Dealer Copy -- Not for Resale

410 of 879 20-120-10 E80 Service Manual


BLADE CONTROL VALVE

Removal And Installation


IMPORTANT
Remove the right console cover. (See Console Cover
Removal And Installation on Page 40-50-1.) When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-130-1 parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1 1

P-86663

Dealer Copy -- Not for Resale


Remove the bolts (Item 1) [Figure 20-130-1] and
washers.

Figure 20-130-2

2
2
P-86664

Tilt the valve (Item 1) towards the rear of the cab. Mark
and remove the four hoses (Item 2) [Figure 20-130-2].

Remove the valve.

411 of 879 20-130-1 E80 Service Manual


BLADE CONTROL VALVE (CONT’D)

Parts Identification

1. Lever
2. Guide
3. Cover
4. Pushrod
5. Seal
6. Spring Keeper
7. Spring Seat
8. Spring
9. Washer 12
10. Spool
11. O-ring
12. Bushing 1
13. Dust Boot
14 Pin 13
15. Nut
16. Bolt
17. Bolt 2
14
18. Pin
19. Plug

Dealer Copy -- Not for Resale


20. O-ring
21. Spring 3 15
22. Plug
23. Body

4 16

17
5

18
6
19
7

20
8

9 21

10 22

11
23

MS-2796

412 of 879 20-130-2 E80 Service Manual


BLADE CONTROL VALVE (CONT’D) Figure 20-130-5

Disassembly And Assembly

Figure 20-130-3

1
1

P-86667

Remove the snap ring (Item 1) and pin (Item 2) [Figure


P-86665 20-130-5].

Figure 20-130-6
Remove the knob (Item 1) [Figure 20-130-3].

Dealer Copy -- Not for Resale


Figure 20-130-4
1

P-86668

P-86666 Remove the lever (Item 1) [Figure 20-130-6].

Pull up on and remove the dust boot (Item 1) [Figure 20-


130-4].

413 of 879 20-130-3 E80 Service Manual


BLADE CONTROL VALVE (CONT’D) Figure 20-130-9

Disassembly And Assembly (Cont’d)

Figure 20-130-7

1
1

P-86671
2

Remove the plunger (Item 1) [Figure 20-130-9] from the


P-86658 plug.

Figure 20-130-10
Remove the two bolts (Item 1) and cover (Item 2) [Figure
20-130-7].

Dealer Copy -- Not for Resale


Figure 20-130-8

2 1

P-86673

Remove the O-ring (Item 1) from the O.D. of the plug.


P-86670 Remove the seal (Item 2) [Figure 20-130-10] from the
I.D. of the plug.

Remove the plunger assemblies (Item 1) [Figure 20-130-


8].

414 of 879 20-130-4 E80 Service Manual


BLADE CONTROL VALVE (CONT’D) Figure 20-130-13

Disassembly And Assembly (Cont’d)

Figure 20-130-11

4 3 2 1

P-86674

Remove the spring seat (Item 1), spring (Item 2), and
P-86673 washer (Item 3) from the spool (Item 4) [Figure 20-130-
13].

Remove the spool assemblies (Item 1) [Figure 20-130- Figure 20-130-14


11].

Dealer Copy -- Not for Resale


Figure 20-130-12

1
1

P-86675

P-86703 Remove the springs (Item 1) [Figure 20-130-14].

Compress the spring and remove the spring keepers


(Item 1) [Figure 20-130-12].

415 of 879 20-130-5 E80 Service Manual


BLADE CONTROL VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-130-15

P-86676

Use a 10 mm hex wrench (Item 1) [Figure 20-130-15] to


remove the plugs.

Dealer Copy -- Not for Resale


Figure 20-130-16

P-86677

Remove the O-ring (Item 1) [Figure 20-130-16] from the


plug.

416 of 879 20-130-6 E80 Service Manual


HYDRAULIC RESERVOIR Figure 20-140-3

Removal And Installation


2
Remove the fuel tank. (See Removal And Installation on
Page 40-110-1.) 1

Drain the hydraulic fluid. (See Removing And Replacing


Hydraulic Fluid on Page 10-140-6.) 3

Remove the suction filter. (See Removing And Replacing


Hydraulic Filters on Page 10-140-2.)

Figure 20-140-1

P-87212

Remove the fuel transfer line (Item 1) from the hose


restraint (Item 2) [Figure 20-140-3].
1
Remove the hoses (Item 3) [Figure 20-140-3].
2
Figure 20-140-4

Dealer Copy -- Not for Resale


1

P-87209 1

Remove the bolts (Item 1), washers and suction tube


(Item 2) [Figure 20-140-1].

Figure 20-140-2

1
1
P-87247
1

Remove the bolt (Item 1) [Figure 20-140-4].

P-87211

Remove the hydraulic return lines (Item 1) [Figure 20-


140-2] from the front of the tank.

NOTE: Mark the hydraulic hoses for ease of


installation.

417 of 879 20-140-1 E80 Service Manual


HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-7

Removal And Installation (Cont’d)

Figure 20-140-5

1
2

1 P-87216

Remove the bolt (Item 1) [Figure 20-140-7].


P-87246
Figure 20-140-8

Remove the bolts (Item 1) and shield (Item 2) [Figure 20-


140-5]. 2

Dealer Copy -- Not for Resale


Figure 20-140-6

1
1

P-87218

Remove the bolt (Item 1) and shield (Item 2) [Figure 20-


140-8].
P-87248

Remove the hydraulic hose (Item 1) [Figure 20-140-6].

418 of 879 20-140-2 E80 Service Manual


HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-11

Removal And Installation (Cont’d)

Figure 20-140-9

2 P-87251

Remove the bolt (Item 1) [Figure 20-140-11].


P-87249
Figure 20-140-12

Remove the bolt (Item 1) and shield (Item 2) [Figure 20-


140-9].

Dealer Copy -- Not for Resale


Figure 20-140-10

P-87237

Remove the bolt (Item 1) [Figure 20-140-12].

P-87217

Remove the P-clamp bolt (Item 1) [Figure 20-140-10]


and reposition the hose so that it will not interfere with the
removal of the tank.

419 of 879 20-140-3 E80 Service Manual


HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-15

Removal And Installation (Cont’d)


2
Figure 20-140-13
1

1
1
P-87238

Attach a chain (Item 1) and lifting device (Item 2) [Figure


P-87219 20-140-15].

Remove the bolts (Item 1) [Figure 20-140-13] from the


reservoir lifting points.

Dealer Copy -- Not for Resale


Figure 20-140-14

P-87252

Install lifting rings (Item 1) [Figure 20-140-14].

420 of 879 20-140-4 E80 Service Manual


HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-18

Removal And Installation (Cont’d)

Figure 20-140-16

1
1

P-86677

Inspect the mounting plate for shims (Item 1) [Figure 20-


P-86676 140-18]. Record the number and the locations of the
shims for ease of installation.

Remove the bolts (Item 1) [Figure 20-140-16] and


washers.

Dealer Copy -- Not for Resale


Figure 20-140-17

P-87583

Remove the bolts (Item 1) [Figure 20-140-17] and


washers.

Remove the hydraulic reservoir.

421 of 879 20-140-5 E80 Service Manual


Dealer Copy -- Not for Resale

422 of 879 20-140-6 E80 Service Manual


OIL COOLER

Removal And Installation

The oil cooler and radiator are removed from the


excavator as a unit. (See Radiator Removal And
Installation on Page 60-50-1.)

Dealer Copy -- Not for Resale

423 of 879 20-150-1 E80 Service Manual


Dealer Copy -- Not for Resale

424 of 879 20-150-2 E80 Service Manual


DIRECT TO TANK VALVE

Removal And Installation


IMPORTANT
Open the center cover.
When repairing hydrostatic and hydraulic systems,
Figure 20-160-1 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

Figure 20-160-3

P-86805

Dealer Copy -- Not for Resale


Pull up on and remove the washer bottle (Item 1) [Figure
20-160-1] from the mount. Reposition the bottle to gain
access to the valve.
P-86807
Figure 20-160-2

Remove the bolts (Item 1) [Figure 20-160-3] and


washers. Remove the valve from the machine.

P-86806

Mark and remove the three hoses (Item 1) [Figure 20-


160-2].

425 of 879 20-160-1 E80 Service Manual


DIRECT TO TANK VALVE (CONT’D) Figure 20-160-6

Disassembly And Assembly

Figure 20-160-4 1

P-86811

Remove the O-rings (Item 1) [Figure 20-160-6] from the


P-86809 spool.

Figure 20-160-7
Remove the snap ring (Item 1) [Figure 20-160-4].

Dealer Copy -- Not for Resale


Figure 20-160-5

P-86812

P-86810 Remove the O-rings (Item 1) [Figure 20-160-7] from the


inside bore of the valve.

Remove the spool (Item 1) [Figure 20-160-5].

426 of 879 20-160-2 E80 Service Manual


AUXILIARY BREAKER VALVE Figure 20-170-2

Description

The one way auxiliary flow valve provides auxiliary


hydraulic flow in one direction only when the auxiliary
flow switch on the right joystick is activated.
1
Removal And Installation

Remove the left upperstructure cover. (See Removal And


Installation on Page 40-20-1.)

Mark all hoses for proper installation.

P-86437

IMPORTANT Remove the nut from both fittings (Item 1) [Figure 20-
170-2] and remove the valve.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly

Dealer Copy -- Not for Resale


damage the system.
I-2003-0888

Figure 20-170-1

1 1

1 P-86436

Remove the five hoses (Item 1) [Figure 20-170-1].

427 of 879 20-170-1 E80 Service Manual


AUXILIARY BREAKER VALVE (CONT'D)

Parts Identification

1. Plug
2. O-ring
3. Back-up Ring
4. Ball
5. Valve Block

Dealer Copy -- Not for Resale


4
2
3
2

MS-2810S

428 of 879 20-170-2 E80 Service Manual


AUXILIARY BREAKER VALVE (CONT'D) Figure 20-170-5

Disassembly And Assembly


2
Figure 20-170-3

1
1

1 P-86440

Remove the O-rings (Item 1) and back-up ring (Item 2)


P-86438 [Figure 20-170-5] from the plug.

Remove the plug (Item 1) [Figure 20-170-3].

Dealer Copy -- Not for Resale


Figure 20-170-4

P-86439

Remove the ball (Item 1) [Figure 20-170-4].

429 of 879 20-170-3 E80 Service Manual


Dealer Copy -- Not for Resale

430 of 879 20-170-4 E80 Service Manual


BOOM SWING VALVE Figure 20-180-2

Removal And Installation

Remove the floor mat. (See Removal And Installation on


1
Page 40-100-1.)

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

1
WARNING
AVOID INJURY OR DEATH 2
Never work under the excavator cab without P-86471
installing an approved cab support device.
W-2435-0502
Remove the two fittings (Item 1) [Figure 20-180-2].

Loosen the bottom fitting (Item 2) [Figure 20-180-2].

IMPORTANT Figure 20-180-3

Dealer Copy -- Not for Resale


When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 1

Figure 20-180-1

1
2
2
P-86472

Disengage the pedal lock (Item 1) and remove the two


bolts (Item 2) [Figure 20-180-3].

1 Remove the valve.

1
P-86470

Mark and remove the four hoses (Item 1) [Figure 20-


180-1].

431 of 879 20-180-1 E80 Service Manual


BOOM SWING VALVE (CONT'D)

Parts Identification

1. Bolt
2. Pin
3. Dust Boot
4. Bolt
5. Cover
6. Spring Retainer
7. Spring Seat
8. Spring
9. Spring
10. Washer
11. Spool
12. Body 1
13. O-ring
14. Plug 20
15. Plug 2
16. O-ring
17. Seal 19
3
18. Pushrod
19. Screw

Dealer Copy -- Not for Resale


20. Cam 4
5 18

17

6 16
7
15

8
14
9

10

13

11
12

B-23950

432 of 879 20-180-2 E80 Service Manual


BOOM SWING VALVE (CONT'D) Figure 20-180-6

Disassembly And Assembly

Figure 20-180-4

1 1

P-86480

Loosen the screw (Item 1) [Figure 20-180-6].


P-86473
Figure 20-180-7

Remove the two bolts (Item 1) [Figure 20-180-4] and


washers. 2
1

Dealer Copy -- Not for Resale


Remove the pedal.

Figure 20-180-5

P-86481

Loosen the screw (Item 1) until the spring tension is


released from the cam (Item 2) [Figure 20-180-7].

Installation: Tighten the screw (Item 1) [Figure 20-180-


P-86474 7] until all free play is removed from the cam.

Remove the dust boot (Item 1) [Figure 20-180-5].

433 of 879 20-180-3 E80 Service Manual


BOOM SWING VALVE (CONT'D) Figure 20-180-10

Disassembly And Assembly (Cont’d)

Figure 20-180-8
1

3 1

P-86476
2

Remove the push rod / plug assemblies (Item 1) [Figure


P-86482 20-180-10].

Figure 20-180-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-180-8].

Dealer Copy -- Not for Resale


Figure 20-180-9

1
1
3
1
2

2 P-86477

Remove the pushrod (Item 1) and O-ring (Item 2) [Figure


P-86475 20-180-11] from the plug.

Remove the seal (Item 3) [Figure 20-180-11] from the


Loosen and remove the bolts (Item 1) evenly as the inside diameter of the plug.
cover (Item 2) [Figure 20-180-9] is under spring tension.

Remove the cover.

434 of 879 20-180-4 E80 Service Manual


BOOM SWING VALVE (CONT'D) Figure 20-180-14

Disassembly And Assembly (Cont’d)

Figure 20-180-12 2
4 3

P-86486

Remove the spring seat (Item 2), spring (Item 3), and
P-86478 washer (Item 4) [Figure 20-180-14] from the spool.

Figure 20-180-15
Remove the spool assemblies (Item 1) [Figure 20-180-
12].

Dealer Copy -- Not for Resale


Figure 20-180-13

1 P-86479

Remove the spring (Item 1) [Figure 20-180-15] from the


P-86485 bores.

Compress the spring (Item 1) [Figure 20-180-13] and


remove the spring keepers (Item 1) [Figure 20-180-14].

435 of 879 20-180-5 E80 Service Manual


BOOM SWING VALVE (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-180-16

P-86487

Use a 10 mm hex wrench (Item 1) [Figure 20-180-16] to


remove the plug.

Dealer Copy -- Not for Resale


Figure 20-180-17

P-86488

Remove the O-ring (Item 1) [Figure 20-180-17] from the


plug.

436 of 879 20-180-6 E80 Service Manual


AUXILIARY HYDRAULIC VALVE Figure 20-190-2

Removal And Installation

Remove the floor mat. (See Removal And Installation on


Page 40-100-1.)

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

WARNING
AVOID INJURY OR DEATH 2
Never work under the excavator cab without P-86484
installing an approved cab support device.
W-2435-0502
Remove the fittings (Item 1) [Figure 20-190-2].

Loosen the bottom fitting (Item 2) [Figure 20-190-2].

IMPORTANT Figure 20-190-3

Dealer Copy -- Not for Resale


When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-190-1
2

2
P-86522

1
Disengage the pedal lock (Item 1) and remove the two
1 bolts (Item 2) [Figure 20-190-3].

Remove the valve.


1

1
P-86483

Mark and remove the four hoses (Item 1) [Figure 20-


190-1].

437 of 879 20-190-1 E80 Service Manual


AUXILIARY HYDRAULIC VALVE (CONT'D)

Parts Identification

1. Bolt
2. Pin
3. Dust Boot
4. Bolt
5. Cover
6. Spring Retainer
7. Spring Seat
8. Spring
9. Spring
10. Washer 1
11. Spool
12. Body 20
13. O-ring 2
14. Plug
15. Plug 19
3
16. O-ring
17. Seal
18. Pushrod 4
19. Screw

Dealer Copy -- Not for Resale


5 18
20. Cam
17

6 16
7
15

8
14
9

10

13

11
12

B-23950

438 of 879 20-190-2 E80 Service Manual


AUXILIARY HYDRAULIC VALVE (CONT'D) Figure 20-190-6

Disassembly And Assembly

Figure 20-190-4

1 1

P-86480

Loosen the screw (Item 1) [Figure 20-190-6].


P-86473
Figure 20-190-7

Remove the two bolts (Item 1) [Figure 20-190-4] and


washers. 2
1

Dealer Copy -- Not for Resale


Remove the pedal.

Figure 20-190-5

P-86481

Loosen the screw (Item 1) until the spring tension is


released from the cam (Item 2) [Figure 20-190-7].

Installation: Tighten the screw (Item 1) [Figure 20-190-


P-86474 7] until all free play is removed from the cam.

Remove the dust boot (Item 1) [Figure 20-190-5].

439 of 879 20-190-3 E80 Service Manual


AUXILIARY HYDRAULIC VALVE (CONT'D) Figure 20-190-10

Disassembly And Assembly (Cont’d)

Figure 20-190-8
1

3 1

P-86476
2

Remove the push rod / plug assemblies (Item 1) [Figure


P-86482 20-190-10].

Figure 20-190-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-190-8].

Dealer Copy -- Not for Resale


Figure 20-190-9

1
1
3
1
2

2 P-86477

Remove the pushrod (Item 1) and O-ring (Item 2) [Figure


P-86475 20-190-11] from the plug.

Remove the seal (Item 3) [Figure 20-190-11] from the


Loosen and remove the bolts (Item 1) evenly as the inside diameter of the plug.
cover (Item 2) [Figure 20-190-9] is under spring tension.

Remove the cover.

440 of 879 20-190-4 E80 Service Manual


AUXILIARY HYDRAULIC VALVE (CONT'D) Figure 20-190-14

Disassembly And Assembly (Cont’d)

Figure 20-190-12 2
4 3

P-86486

Remove the spring seat (Item 2), spring (Item 3), and
P-86478 washer (Item 4) [Figure 20-190-14] from the spool.

Figure 20-190-15
Remove the spool assemblies (Item 1) [Figure 20-190-
12].

Dealer Copy -- Not for Resale


Figure 20-190-13

1 P-86479

Remove the spring (Item 1) [Figure 20-190-15] from the


P-86485 bores.

Compress the spring (Item 1) [Figure 20-190-13] and


remove the spring keepers (Item 1) [Figure 20-190-14].

441 of 879 20-190-5 E80 Service Manual


AUXILIARY HYDRAULIC VALVE (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-190-16

P-86487

Use a 10 mm hex wrench (Item 1) [Figure 20-190-16] to


remove the plug.

Dealer Copy -- Not for Resale


Figure 20-190-17

P-86488

Remove the O-ring (Item 1) [Figure 20-190-17] from the


plug.

442 of 879 20-190-6 E80 Service Manual


ARTICULATED BOOM VALVE (OPTIONAL) Figure 20-200-2

Removal And Installation

Remove the floor mat. (See Removal And Installation on


Page 40-100-1.)
1
Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

WARNING
AVOID INJURY OR DEATH 2
Never work under the excavator cab without S37671
installing an approved cab support device.
W-2435-0502
Remove the two fittings (Item 1) [Figure 20-200-2].

Loosen the bottom fitting (Item 2) [Figure 20-200-2].

IMPORTANT Figure 20-200-3

Dealer Copy -- Not for Resale


When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

Figure 20-200-1
2
2

S37672

1
Disengage the pedal lock (Item 1) and remove the two
bolts (Item 2) [Figure 20-200-3].
1
Remove the valve.
1

S37670

Mark and remove the four hoses (Item 1) [Figure 20-


200-1].

443 of 879 20-200-1 E80 Service Manual


ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D)

Parts Identification

1. Bolt
2. Pin
3. Dust Boot
4. Bolt
5. Cover
6. Spring Retainer
7. Spring Seat
8. Spring
9. Spring
10. Washer
1
11. Spool
12. Body 20
13. O-ring
2
14. Plug
15. Plug 19
16. O-ring 3
17. Seal
18. Pushrod 4
19. Screw

Dealer Copy -- Not for Resale


5 18
20. Cam
17

6 16
7
15

8
14
9

10

13

11
12

B-23950

444 of 879 20-200-2 E80 Service Manual


ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D) Figure 20-200-6

Disassembly And Assembly

Figure 20-200-4

1 1

P-86480

Loosen the screw (Item 1) [Figure 20-200-6].


P-86473
Figure 20-200-7

Remove the two bolts (Item 1) [Figure 20-200-4] and


washers. 2
1

Dealer Copy -- Not for Resale


Remove the pedal.

Figure 20-200-5

P-86481

Loosen the screw (Item 1) until the spring tension is


released from the cam (Item 2) [Figure 20-200-7].

Installation: Tighten the screw (Item 1) [Figure 20-200-


P-86474 7] until all free play is removed from the cam.

Remove the dust boot (Item 1) [Figure 20-200-5].

445 of 879 20-200-3 E80 Service Manual


ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D) Figure 20-200-10

Disassembly And Assembly (Cont’d)

Figure 20-200-8
1

3 1

P-86476
2

Remove the push rod / plug assemblies (Item 1) [Figure


P-86482 20-200-10].

Figure 20-200-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-200-8].

Dealer Copy -- Not for Resale


Figure 20-200-9

1
1
3
1
2

2 P-86477

Remove the pushrod (Item 1) and O-ring (Item 2) [Figure


P-86475 20-200-11] from the plug.

Remove the seal (Item 3) [Figure 20-200-11] from the


Loosen and remove the bolts (Item 1) evenly as the inside diameter of the plug.
cover (Item 2) [Figure 20-200-9] is under spring tension.

Remove the cover.

446 of 879 20-200-4 E80 Service Manual


ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D) Figure 20-200-14

Disassembly And Assembly (Cont’d)

Figure 20-200-12 2
4 3

P-86486

Remove the spring seat (Item 2), spring (Item 3) and


P-86478 washer (Item 4) [Figure 20-200-14] from the spool.

Figure 20-200-15
Remove the spool assemblies (Item 1) [Figure 20-200-
12].

Dealer Copy -- Not for Resale


Figure 20-200-13

1 P-86479

Remove the spring (Item 1) [Figure 20-200-15] from the


P-86485 bores.

Compress the spring (Item 1) [Figure 20-200-13] and


remove the spring keepers (Item 1) [Figure 20-200-14].

447 of 879 20-200-5 E80 Service Manual


ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-200-16

P-86487

Use a 10 mm hex wrench (Item 1) [Figure 20-200-16] to


remove the plug.

Dealer Copy -- Not for Resale


Figure 20-200-17

P-86488

Remove the O-ring (Item 1) [Figure 20-200-17] from the


plug.

448 of 879 20-200-6 E80 Service Manual


TRAVEL CONTROL VALVE Figure 20-210-2

Removal And Installation

Remove the floor mat. (See Removal And Installation on


Page 40-100-1.)

Tilt the cab. (See Tilting The Cab on Page 10-210-1.) 1

WARNING 2

AVOID INJURY OR DEATH


1
Never work under the excavator cab without P-86444
installing an approved cab support device.
W-2435-0502
Remove the three hoses (Item 1) from the side of the
valve. Remove the fittings (Item 2) [Figure 20-210-2].

Figure 20-210-3

IMPORTANT

Dealer Copy -- Not for Resale


When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Figure 20-210-1

P-86445

Remove the bolts (Item 1) [Figure 20-210-3] and


washers from the rear of the valve.

1 1

P-86443

Mark and remove the four hoses (Item 1) [Figure 20-


210-1] from the bottom of the valve.

449 of 879 20-210-1 E80 Service Manual


TRAVEL CONTROL VALVE (CONT'D)

Removal And Installation (Cont’d)

Figure 20-210-4

P-86446

Remove the bolts (Item 1) [Figure 20-210-4] from the


front of the valve.

Dealer Copy -- Not for Resale


Remove the valve / lever assembly from the cab.

450 of 879 20-210-2 E80 Service Manual


TRAVEL CONTROL VALVE (CONT'D)

Parts Identification

1. Ball 11. Housing (Bottom) 21. Dust Seal


2. Cover 12 Spool 22. Grease Cap
3. Plug 13. Washer 23. Dust Boot
4. Piston 14. O-ring 24. Cam
5. Spring 15. Plug 25. Screw
6. Cover 16. Washer 26. Pin
7. Bolt 17. Spring 27. Bushing
8. Push Rod 18. Spring 28. O-ring
9. O-ring 19. Spring Seat
10. Plug 20. Piston

Dealer Copy -- Not for Resale


27 26 25 24 23
1 22

2
21

3 20

5
19 28

6
18

7 17

8 16

15
9 10 11 12 13 14

B-23944

451 of 879 20-210-3 E80 Service Manual


TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-7

Disassembly And Assembly

Figure 20-210-5 1
1
2

P-86450

Remove the dust boots (Item 1) [Figure 20-210-7].


P-86447
Figure 20-210-8

Remove the two bolts (Item 1) and washers. Remove the


left travel control lever / foot pedal (Item 2) [Figure 20-

Dealer Copy -- Not for Resale


210-5].

Figure 20-210-6
1

P-86451

Loosen and remove the bolts (Item 1) [Figure 20-210-8]


evenly, as the cover is under spring pressure.
2
P-86449

Remove the two bolts (Item 1) and washers. Remove the


right travel control lever / foot pedal (Item 2) [Figure 20-
210-6].

452 of 879 20-210-4 E80 Service Manual


TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-11

Disassembly And Assembly (Cont’d)

Figure 20-210-9

P-86454

Remove the cover / cam assembly (Item 1) [Figure 20-


P-86452 210-11].

Figure 20-210-12
Remove the cover / cam assembly (Item 1) [Figure 20-
210-9].

Dealer Copy -- Not for Resale


Figure 20-210-10
1

P-86455

Loosen the screw (Item 1) [Figure 20-210-12] on both


P-86453 cam assemblies.

NOTE: Heat the screw to melt the thread adhesive.


Loosen and remove the bolts (Item 1) [Figure 20-210-
10] evenly, as the cover is under spring pressure. Installation: Apply Loctite® 242 or equivalent to the
screw.

453 of 879 20-210-5 E80 Service Manual


TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-15

Disassembly And Assembly (Cont’d)

Figure 20-210-13

P-86458

1
Using a blunt tool, push the pushrod (Item 1) [Figure 20-
P-86456 210-15] out of the plug.

Figure 20-210-16
Remove the pin (Item 1) from both cover / cam
assemblies. Remove the cam (Item 2) [Figure 20-210-

Dealer Copy -- Not for Resale


13] from the cover.
1
Figure 20-210-14

P-86459

Remove the plug (Item 1) [Figure 20-210-16] from the


bores.
P-86457

Remove the cover (Item 1) [Figure 20-210-14].

454 of 879 20-210-6 E80 Service Manual


TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-19

Disassembly And Assembly (Cont’d)

Figure 20-210-17

2
P-86462

Remove the dust seal (Item 1) [Figure 20-210-19] from


P-86460 the inside diameter of the plug.

Repeat the procedure for the three remaining plugs.


Remove the piston (Item 1) and spring (Item 2) [Figure
20-210-17]. Figure 20-210-20

Dealer Copy -- Not for Resale


Figure 20-210-18

2
1
P-86463

P-86461
Remove the O-rings (Item 1) [Figure 20-210-20].

Remove the O-ring (Item 1) and grease cap (Item 2)


[Figure 20-210-18] from the plug.

455 of 879 20-210-7 E80 Service Manual


TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-23

Disassembly And Assembly (Cont’d)

Figure 20-210-21

P-86467
1

Compress the springs (Item 1) and remove the spring


P-86464 seat (Item 2) [Figure 20-210-23].

Figure 20-210-24
Remove the spool / spring assemblies (Item 1) [Figure
20-210-21].

Dealer Copy -- Not for Resale


Figure 20-210-22

1 3 2 1

P-86469

1
Remove the spring (Item 1) and washer (Item 2) from the
P-86465 spool (Item 3) [Figure 20-210-24].

Remove the springs (Item 1) [Figure 20-210-22].

456 of 879 20-210-8 E80 Service Manual


AUTO IDLE VALVE Figure 20-220-3

Testing And Adjusting

Remove the auto idle pressure switch. (See Removal


And Installation on Page 50-160-1.)

Figure 20-220-1 1

P-91763

If adjustment is needed, loosen the nut (Item 1) [Figure


20-220-3].

Turn the adjustment screw (Item 2) clockwise to increase


P-91761 pressure and counterclockwise to decrease pressure.
Tighten the nut (Item 1) [Figure 20-220-3].

Dealer Copy -- Not for Resale


Install the test fitting and 6900 kPa (69 bar) (1000 psi)
gauge (Item 1) [Figure 20-220-1] into the auto idle
pressure switch port.

Figure 20-220-2

P-86211B

Move the auto idle switch (Item 1) [Figure 20-220-2] to


the OFF position.

Start the engine and run at high idle.

With work functions inactive, the pressure gauge should


read 2000 kPa (20 bar) (290 psi).

Activate the blade raise function. The pressure gauge


should read 2500 kPa (25 bar) (360 psi).

457 of 879 20-220-1 E80 Service Manual


AUTO IDLE VALVE (CONT'D) Figure 20-220-6

Removal And Installation

Figure 20-220-4
1

1 P-91765

Remove the bolts (Item 1) [Figure 20-220-6].


P-91759
Remove the valve.

Disconnect the wire harness (Item 1) [Figure 20-220-4]. Figure 20-220-7

Dealer Copy -- Not for Resale


IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 1

Figure 20-220-5
P-91766

Remove the sending unit (Item 1) [Figure 20-220-7].

P-91764

Mark and remove the hoses (Item 1) [Figure 20-220-5].

458 of 879 20-220-2 E80 Service Manual


AUTO IDLE VALVE (CONT'D) Figure 20-220-10

Removal And Installation (Cont'd)

Figure 20-220-8
1

P-91768
1

Remove the O-rings (Item 1) and back-up rings (Item 2)


P-91760 [Figure 20-220-10].

Remove the O-ring (Item 1) [Figure 20-220-8].

Dealer Copy -- Not for Resale


Figure 20-220-9

P-91767

Remove the valve (Item 1) [Figure 20-220-9].

459 of 879 20-220-3 E80 Service Manual


Dealer Copy -- Not for Resale

460 of 879 20-220-4 E80 Service Manual


UNDERCARRIAGE

BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) . . . . . . . . . . . . . . . . 30-20-1


Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-11
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-16
Track Tensioner Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-17
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-18
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-20
Lower Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-22
Lower Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-23
Lower Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-26

Dealer Copy -- Not for Resale


Upper Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-32
Upper Roller Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-33
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-36

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) . . . . . . . . . . . . . . . . . . 30-21-1


Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-3
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-6
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-7
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-10
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-15
Track Tensioner Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-16
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-17
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-19
Guide Plate Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-21
Lower Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-22
Lower Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-23
Lower Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-26
Upper Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-32
Upper Roller Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-33
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-36

TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1


Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

461 of 879 30-01 E80 Service Manual


SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2

Dealer Copy -- Not for Resale

462 of 879 30-02 E80 Service Manual


BLADE Figure 30-10-3

Removal And Installation


1
Lower the blade the ground.

Remove the blade cylinders. (See Removal And


Installation on Page 20-24-2.)

Figure 30-10-1

2 P-87813

Install a chain hoist (Item 1) [Figure 30-10-3] in the


1 center of the blade crossmember.

Dealer Copy -- Not for Resale


P-87814

Figure 30-10-2

P-87810

Remove the right and left pivot pin retaining nuts (Item 1)
and bolt (Item 2) [Figure 30-10-1] and [Figure 30-10-2].

463 of 879 30-10-1 E80 Service Manual


BLADE (CONT’D)

Removal And Installation (Cont’d)

Figure 30-10-4

P-87811

Figure 30-10-5

Dealer Copy -- Not for Resale


1

P-87812

Remove the right and left pivot pin (Item 1) [Figure 30-
10-4] and [Figure 30-10-5] and shims.

Lift and remove the blade.

464 of 879 30-10-2 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK)

Track Lug Height

Rubber Track

The lug height of a new rubber track is 29,2 mm (1.15 in).

Figure 30-20-1

Straight Edge

Dealer Copy -- Not for Resale


B-14489

To find the percentage of wear on a excavator track,


measure the height of the lug by placing a straight edge
across the top of three lugs and measuring the distance
from the base of the track to the bottom of the straight
edge [Figure 30-20-1].

Divide this measurement by the new track height and


multiply by 100. This will give the percentage of track lug
left.

Example: lug height 23,4 mm (0.92 in)


0.92
1.15 x 100 = 80

80% of the track lug is remaining, with 20% wear on the


track lugs.

465 of 879 30-20-1 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Checking Tension WARNING


NOTE: The wear of the pins and bushings on the
undercarriage varies with the working AVOID INJURY
conditions and the types of soil. It is Keep fingers and hands out of pinch points when
necessary to inspect track tension to maintain checking the track tension.
W-2142-0903
the correct tension. See Service Schedule for
the correct service interval. (See Chart on
Page 10-80-1.) Figure 30-20-4

Figure 30-20-2

10-15 mm
(0.39-0.59 in)

Dealer Copy -- Not for Resale


P-86332

P-49234
Figure 30-20-5

Raise the side of the machine (approximately 102 mm [4


in]) using the boom and arm [Figure 30-20-2]. Track Frame

Figure 30-20-3

10-15 mm
(0.39-0.59 in)

Track
Roller

Track
B-14067

1
1 Measure the clearance at the middle track roller. Do not
put your fingers into the pinch points between the track
and the track roller. Use a bolt or a dowel of the
P-86328A
appropriate size to check the gap between the contact
edge of the roller and the top edge of the track guide
Fully raise the blade and install jackstands (Item 1) [Figure 30-20-4] and [Figure 30-20-5].
[Figure 30-20-3] under the blade and track frame. Raise
the boom until all machine weight is on the jackstands. Track Clearance 10 - 15 mm
(0.39 - 0.59 in)
Stop the engine.

466 of 879 30-20-2 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Adjusting Tension

Figure 30-20-6

1 2

1
P-86333A

NOTE: The track tension grease fitting (Item 1) is


installed into the end of the bleed fitting (Item

Dealer Copy -- Not for Resale


2). DO NOT loosen the grease fitting (Item 1),
loosen the bleed fitting (Item 2) [Figure 30-20-
6] ONLY (maximum of 1-1/2 turns) when
releasing track pressure.

Add grease to the fitting (Item 1) [Figure 30-20-6] until


the track tension is correct.

To release track pressure, loosen the bleed fitting (Item


2) [Figure 30-20-6] to release tension from the track.

NOTE: Do not loosen the grease fitting (Item 1)


[Figure 30-20-6].

Repeat the procedure for the other side.

WARNING
AVOID INJURY OR DEATH
• Do not loosen bleed fitting more than 1-1/2 turns.
• Do not loosen parts other than bleed fitting.
Grease is under high pressure.
W-2474-0104

467 of 879 30-20-3 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Removal And Installation WARNING


Lift and block both sides of the machine as follows:
Put jackstands under the blade and rear corners of
Fully raise the blade. the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
Figure 30-20-7 or fall and result in injury or death.
W-2218-1195

Stop the engine.

Release track tension. (See Adjusting Tension on Page


30-20-3.)

1 WARNING
AVOID INJURY OR DEATH
• Do not loosen bleed fitting more than 1-1/2 turns.

Dealer Copy -- Not for Resale


P-87901 • Do not loosen parts other than bleed fitting.
Grease is under high pressure.
W-2474-0104
Use the boom and arm to lift up the blade end of the
machine, and install jackstands (Item 1) [Figure 30-20-7]
under the blade. Start the engine.

Raise the boom. Slowly turn the track in the forward direction.

Figure 30-20-9
Figure 30-20-8

1
P-40669
P-40662

Insert a steel rod or pipe (Item 1) [Figure 30-20-9]


Swing the upperstructure 180° and use the boom and (Approximately 44,5 mm [1.750 in] diameter) between
arm to slowly lift the opposite end of the undercarriage, the track and the idler wheel.
and install jackstands (Item 1) [Figure 30-20-8] under the
undercarriage.

Raise the boom until the weight of the machine is


supported by the jackstands.

468 of 879 30-20-4 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-11
TRACK) (CONT’D)

Track Removal And Installation (Cont’d)

Figure 30-20-10

1
1

P-40888

Insert a pry bar (Item 1) [Figure 30-20-11] between the


track and the idler wheel, and pry out on the track until
P-40670 the track slides off the idler wheel.

Insert a second steel rod or pipe (Item 1) [Figure 30-20- Remove the track.
10], at a distance of two lugs, between the track and the

Dealer Copy -- Not for Resale


idler wheel. Continue to turn the track until the first pipe To install the rubber track:
contacts the track frame.
Put the track over the rear drive sprocket lugs.
Stop the engine.
Put the front of the track onto the front idler wheel.

See Adjustment for adding grease to the grease spring


and for checking track tension. (See Adjusting Tension
on Page 30-20-3.)

469 of 879 30-20-5 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Idler Removal And Installation

Figure 30-20-12

P-87929

Remove the track. (See Track Removal And Installation


on Page 30-20-4.)

Dealer Copy -- Not for Resale


Install a chain (Item 1) [Figure 30-20-12] and hoist to the
idler and slide the idler towards the front of the track
frame.

Figure 30-20-13

P-87930

Remove the four bolts (Item 1) and washers. Remove the


idler (Item 2) [Figure 30-20-13].

NOTE: The bolts may need to be heated to melt the


thread adhesive.

Installation: Apply thread adhesive (Loctite® 262 or


equivalent) to the bolt threads. Tight the bolts to 255 -
285 N•m (188 - 210 ft-lb) torque.

470 of 879 30-20-6 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Idler Parts Identification

1. Idler
2. Support 6
3. Shaft
4. Bushing
5. Floating Seal
6. Pin
7. O-ring 2
8. Plug 7
5
8 1
4

Dealer Copy -- Not for Resale


3

4
5

6
7

E80-2120S
MS-

471 of 879 30-20-7 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-16
TRACK) (CONT’D)

Idler Disassembly

Figure 30-20-14

P-89261

Figure 30-20-17

P-89259

Remove the roll pin (Item 1) [Figure 30-20-14].

Dealer Copy -- Not for Resale


Figure 30-20-15 1

P-89263

Remove the floating seal (Item 1) [Figure 30-20-16] and


[Figure 30-20-17] from the support and idler.

P-89260

Pull up on and remove the support (Item 1) [Figure 30-


20-15].

472 of 879 30-20-8 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-20
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-20-18

P-89267

Figure 30-20-21

P-89264

Remove the O-ring (Item 1) [Figure 30-20-18] from the 1


shaft.

Dealer Copy -- Not for Resale


Figure 30-20-19

P-89268

Remove the floating seal (Item 1) [Figure 30-20-20] and


[Figure 30-20-21] from the support and idler.

P-89266

Tip the idler over and remove the support / shaft


assembly (Item 1) [Figure 30-20-19].

473 of 879 30-20-9 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-24
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-20-22 1

P-89270

Remove the O-ring (Item 1) [Figure 30-20-24].

P-89262 Figure 30-20-25

Remove the O-ring (Item 1) [Figure 30-20-22] from all


four of the steel seals.

Dealer Copy -- Not for Resale


1
Figure 30-20-23

P-89271

Remove the bushings (Item 1) [Figure 30-20-25] from


2 both sides of the idler.

P-89269

Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-20-23] from the support.

474 of 879 30-20-10 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER NOTE: Inspect the seal ring for burrs before
TRACK) (CONT’D) installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
Idler Assembly any twists, gently pull a section of the O-ring
and let it snap back.
Clean all parts in solvent and dry with compressed air.
Figure 30-20-28
The seal assemblies are a matched set and must be
replaced in pairs.
1
Figure 30-20-26

P-40754

Dealer Copy -- Not for Resale


Place the seal assembly in the installation tool (Item 1)
P-89271 [Figure 30-20-28].

The O-ring and seal ring assembly have to be lubricated


Install the bushings (Item 1) [Figure 30-20-26] on both with alcohol, so that the O-ring will slip past the housing
sides of the idler. retaining ring and seal uniformly in the housing radius.

Figure 30-20-27 Dip the seal assembly in a pan of alcohol.

Figure 30-20-29

1
1

P-89262

P-89276
Install the O-ring (Item 1) [Figure 30-20-27] on the seal
ring. Repeat this procedure on all four seal assemblies.
Shake off the excess alcohol and install the seal
The O-ring and seal ring must be clean and free of any assembly (Item 1) [Figure 30-20-29] in the idler.
dust, oil film and foreign matter.
Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Remove the installation tool.

475 of 879 30-20-11 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-32
TRACK) (CONT’D)

Idler Assembly (Cont’d) 1

Figure 30-20-30 2

P-89269

Install the shaft (Item 1) in the support. Install the roll pin
(Item 2) [Figure 30-20-32] through the shaft and support
P-89277 assembly.

Figure 30-20-33
The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-20-30].

Dealer Copy -- Not for Resale


1
Figure 30-20-31

1
P-40754

Place the seal assembly (Item 1) [Figure 30-20-33] in


P-89270 the installation tool.

The O-ring and seal ring assembly have to be lubricated


Install the O-ring (Item 1) [Figure 30-20-31] onto the with alcohol, so that the O-ring will slip past the housing
shaft. retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

476 of 879 30-20-12 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-36
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-34 1

P-89264

Install the idler (Item 1) [Figure 30-20-36] on the shaft /


support assembly.
P-89274
Figure 30-20-37

Shake off the excess alcohol and install the seal


assembly (Item 1) [Figure 30-20-34] in the support. 1

Dealer Copy -- Not for Resale


Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Figure 30-20-35

P-40754

Place the seal assembly (Item 1) [Figure 30-20-37] in


the installation tool.

The O-ring and seal ring assembly have to be lubricated


with alcohol, so that the O-ring will slip past the housing
P-89275 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.


The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-20-35].

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

477 of 879 30-20-13 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-40
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-38
1

P-89280

Install the O-ring (Item 1) [Figure 30-20-40] on the shaft.

P-89278 Figure 30-20-41

Shake off the excess alcohol and install the seal 1


assembly (Item 1) [Figure 30-20-38] in the idler.

Dealer Copy -- Not for Resale


Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Remove the installation tool.

Figure 30-20-39

P-40754

Place the seal assembly (Item 1) [Figure 30-20-41] in


the installation tool.

The O-ring and seal ring assembly have to be lubricated


with alcohol, so that the O-ring will slip past the housing
1 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.


P-89279

The seal assembly stand off height must be equal and


the O-ring (Item 1) [Figure 30-20-39] must not be
twisted.

478 of 879 30-20-14 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-44
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-42 1

P-89283

Install the support (Item 1) on the shaft. Press down on


the support and install the roll pin (Item 2) [Figure 30-20-
P-89281 44].

Figure 30-20-45
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-20-42] in the idler.

Dealer Copy -- Not for Resale


Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Remove the installation tool.


1
Figure 30-20-43

89324

Remove the plug (Item 1) [Figure 30-20-45].

Add 0,101 - 0,139 L (3.4 - 4.7 U.S. fl oz) 30W oil to the
1
idler. Install the plug (Item 1) [Figure 30-20-45].

P-89282

The seal stand off height must be equal and the O-ring
(Item 1) [Figure 30-20-43] must not be twisted.

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

479 of 879 30-20-15 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Tensioner Removal And Installation WARNING


Figure 30-20-46

P-62574

AVOID INJURY OR DEATH


• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly.
W-2617-1004
P-89261

Install a sling (Item 1) [Figure 30-20-46] and hoist on the


grease cylinder.

Dealer Copy -- Not for Resale


Figure 30-20-47

P-87932

Guide the grease cylinder (Item 1) [Figure 30-20-47] out


of the track frame.

DO NOT DISASSEMBLE OR REPAIR THE COIL


SPRING ASSEMBLY (Item 1) [Figure 30-20-47].

480 of 879 30-20-16 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Tensioner Parts Identification

1. Piston Rod
2. Piston 6
3. Piston Ring 5
4. Back-up Ring 4
5. Packing
6. Snap Ring 3
7. Dust Seal
8. Cylinder 2
9. Spring Assembly
10. Grease Fitting

Dealer Copy -- Not for Resale


8

10

EM7807

481 of 879 30-20-17 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly WARNING


Figure 30-20-48

P-62574

AVOID INJURY OR DEATH


• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly.
W-2617-1004
P-87927

Figure 30-20-50
Remove the grease fitting and adapter (Item 1) [Figure
30-20-48].

Dealer Copy -- Not for Resale


Figure 30-20-49

2
1

P-87933

2 1
Use a 12 mm x 1,75 x 203 mm long bolt to thread the bolt
(Item 1) into the piston (Item 2) [Figure 30-20-50]. Pull
P-87928
the piston out of the cylinder.

Remove the piston rod (Item 1) [Figure 30-20-49] from


the cylinder.

DO NOT DISASSEMBLE OR REPAIR THE COIL


SPRING ASSEMBLY (Item 2) [Figure 30-20-49]

482 of 879 30-20-18 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-53
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly


1
(Cont’d)

Figure 30-20-51

P-87935
2

Remove the two piston rings (Item 1) [Figure 30-20-53].

Figure 30-20-54
P-87937

Remove the snap ring (Item 1) and packing (Item 2)

Dealer Copy -- Not for Resale


[Figure 30-20-51].

Figure 30-20-52

1
1

P-87934

Remove the dust seal (Item 1) [Figure 30-20-54].

P-87936

Remove the back-up ring (Item 1) [Figure 30-20-52].

483 of 879 30-20-19 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-57
TRACK) (CONT’D)
2
Roller Removal And Installation

NOTE: The track does not have to be removed to 3


remove the top roller.

Figure 30-20-55

P-89268

Installation: Install the flat spot of the shaft (Item 1) to


1 the top of the mount. Tighten the bolt (Item 2) to 105 - 115
N•m (78 - 85 ft-lb) torque. Tighten the nut (Item 3)
1 [Figure 30-20-57] against the mount.

P-87911 Figure 30-20-58

Dealer Copy -- Not for Resale


Install blocks (Item 1) [Figure 30-20-55] between the
track frame and track. Loosen the track. (See Adjusting
Tension on Page 30-20-3.)
1
Figure 30-20-56

1
2 2

P-89285

NOTE: Remove the track to remove the bottom roller.

Place a jack under the bottom roller (Item 1). Remove the
four bolts (Item 2) [Figure 30-20-58].
P-87912
Installation: Apply thread adhesive (Loctite® 242 or
equivalent) to the bolt threads. Tighten the bolts to 160 -
Loosen the nut (Item 1) [Figure 30-20-56] and bolt. 180 N•m (118 - 113 ft-lb) torque.
Remove the top roller.

484 of 879 30-20-20 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Roller Removal And Installation (Cont’d)

Figure 30-20-59

P-89286

Lower the jack and remove the roller (Item 1) [Figure 30-
20-59].

Dealer Copy -- Not for Resale

485 of 879 30-20-21 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Lower Roller Parts Identification

1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug

4
5
6

2
5

Dealer Copy -- Not for Resale


2
8 7

E80-2150S

486 of 879 30-20-22 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-62
TRACK) (CONT’D)

Lower Roller Disassembly


1
Figure 30-20-60

P-89289

Remove the seal assembly [Figure 30-20-62].

P-89287 Figure 30-20-63

Drive the pin (Item 1) towards the top of the collar (Item
2) [Figure 30-20-60].

Dealer Copy -- Not for Resale


NOTE: The pin bore in the collar is stepped.

Figure 30-20-61

1
1

P-89290

Remove the seal assembly (Item 1). Remove the O-ring


(Item 2) [Figure 30-20-63].

P-89288

Remove the collar (Item 1) [Figure 30-20-61].

487 of 879 30-20-23 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-66
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

Figure 30-20-64

P-89293

1
Remove the seal assembly (Item 1) [Figure 30-20-66]
from the collar.
P-89291
Figure 30-20-67

Remove the shaft assembly (Item 1) [Figure 30-20-64]


from the roller.

Dealer Copy -- Not for Resale


Figure 30-20-65 1

P-89262

Remove the O-ring (Item 1) [Figure 30-20-67] from all


four seal rings.
P-89292

Remove the seal assembly (Item 1) [Figure 30-20-65]


from the roller.

488 of 879 30-20-24 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-70
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)


1
Figure 30-20-68

P-89296

1
Remove the O-ring (Item 1) [Figure 30-20-70].

P-87924 Figure 30-20-71

Remove the pin (Item 1) [Figure 30-20-68].

Dealer Copy -- Not for Resale


Figure 30-20-69
1

1
P-89297

Remove the bushing (Item 1) [Figure 30-20-71] from


both sides of the roller.
P-87925

Remove the shaft (Item 1) [Figure 30-20-69].

489 of 879 30-20-25 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-74
TRACK) (CONT’D)

Lower Roller Assembly


1
Clean all parts in solvent and dry with compressed air.

The seal assemblies are a matched set and must be


replaced in pairs.

Figure 30-20-72

1
P-89295

Install the shaft (Item 1) [Figure 30-20-74] in the collar.

Figure 30-20-75

Dealer Copy -- Not for Resale


P-89297

Install the bushing (Item 1) [Figure 30-20-72] on both


sides of the roller.

Figure 30-20-73

P-89294

Install the pin (Item 1) [Figure 30-20-75] in the collar and


through the shaft.

P-89296

Install the O-ring (Item 1) [Figure 30-20-73] on the shaft.

490 of 879 30-20-26 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Dip the seal assembly in a pan of alcohol.
TRACK) (CONT’D)
Figure 30-20-78
Lower Roller Assembly (Cont’d)

Figure 30-20-76

1
P-89298

P-89262 Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-20-78] in the collar.

Install the O-ring (Item 1) [Figure 30-20-76] on the seal Use firm, even pressure on the installation tool to pop the
ring. Repeat this procedure on all four seal assemblies.

Dealer Copy -- Not for Resale


O-ring in to the collar.

The O-ring and seal ring must be clean and free of any Remove the installation tool.
dust, oil film and foreign matter.
Figure 30-20-79
NOTE: Inspect the seal ring for burrs before
installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.

Figure 30-20-77

P-89299

The seal assembly stand off height must be equal and


the O-ring must not be twisted [Figure 30-20-79].

P-40754

Place the seal assembly in the installation tool (Item 1)


[Figure 30-20-77].

The O-ring and seal ring assembly have to be lubricated


with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.

491 of 879 30-20-27 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-82
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-80

P-89301

The seal assembly stand off height must be equal and


the O-ring must not be twisted [Figure 30-20-82].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly (Item 1) [Figure 30-20-80] in NOTE: Do not get any oil on the rubber O-rings.
the installation tool.

Dealer Copy -- Not for Resale


Figure 30-20-83
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1
Dip the O-ring and seal assembly in a pan of alcohol.

Figure 30-20-81

P-89302

Install the roller (Item 1) [Figure 30-20-83] on the shaft.

P-89300

Shake off the excess alcohol and install the seal


assembly (Item 1) [Figure 30-20-81] in the roller.

Use firm, even pressure on the installation tool to pop the


O-ring in to the collar.

Remove the installation tool.

492 of 879 30-20-28 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-86
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-84

P-89304

The seal assembly stand off height must be equal and


the O-ring must not be twisted [Figure 30-20-86].
P-40754
Figure 30-20-87

Place the seal assembly in the installation tool (Item 1)


[Figure 30-20-84].

Dealer Copy -- Not for Resale


The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
1
retaining ring and seal uniformly in the housing radius.

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-20-85

P-89305

Install the O-ring (Item 1) [Figure 30-20-87].

P-89303

Shake off the excess alcohol and install the seal


assembly (Item 1) [Figure 30-20-85] in the roller.

Use firm, even pressure on the installation tool to pop the


O-ring in to the collar.

Remove the installation tool.

493 of 879 30-20-29 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-90
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-88

P-89307

The seal assembly stand off height must be equal and


the O-ring must not be twisted [Figure 30-20-90].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.
[Figure 30-20-88].

Dealer Copy -- Not for Resale


Figure 30-20-91
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius. 1

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-20-89

P-89308

Install the collar (Item 1) on the shaft. Install the pin (Item
1 2) [Figure 30-20-91] in the collar.

P-89306

Shake off the excess alcohol and install the seal


assembly (Item 1) [Figure 30-20-89] in the roller.

Use firm, even pressure on the installation tool to pop the


O-ring in to the collar.

Remove the installation tool.

494 of 879 30-20-30 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-92

P-89309

Push down on the collar until the pin bore of the collar is
aligned with the pin bore of the shaft. Fully seat the pin

Dealer Copy -- Not for Resale


(Item 1) [Figure 30-20-92].

Remove the plug (Item 2) [Figure 30-20-92]. Add 0,121 -


0,160 L (4.1 - 5.4 U.S. fl oz) of 30W oil to the roller.

Install the plug.

495 of 879 30-20-31 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Upper Roller Parts Identification

1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal 6
8. Shaft
9. Bolt
10. Nut
11. Mount
5

1
4

Dealer Copy -- Not for Resale


1 2

10

8
11

7
1

E80-2140S

496 of 879 30-20-32 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-95
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly

Figure 30-20-93
1

P-87918

Install a 50,8 mm (2.0 in) long 3,175 mm (1/8 in) NPT


pipe (Item 1) into the cover. Pull up on the pipe to remove
P-87915 the cover (Item 2) [Figure 30-20-95].

Figure 30-20-96
Remove the snap ring (Item 1) [Figure 30-20-93].

Dealer Copy -- Not for Resale


Figure 30-20-94

1
1

P-87919

P-87916 Remove the O-ring (Item 1) [Figure 30-20-96].

Remove the pipe plug (Item 1) [Figure 30-20-94].

497 of 879 30-20-33 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-99
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)


1
Figure 30-20-97

1 P-87922

Remove the seal (Item 1) [Figure 30-20-99] from the


shaft.
P-87920
Figure 30-20-100

Remove the snap ring (Item 1) [Figure 30-20-97].

Dealer Copy -- Not for Resale


Turn the roller over and drain the oil.
1
Assembly: Add 0,133 - 0,169 L (4.5 - 5.7 U.S. fl oz) of
30W oil to the roller before installing the cover.

Figure 30-20-98

P-87923

1
Remove the seal (Item 1) [Figure 30-20-100] from the
roller.

P-87921

Remove the shaft (Item 1) [Figure 30-20-98] from the


roller.

498 of 879 30-20-34 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

Figure 30-20-101

P-87924

Remove the snap ring (Item 1) [Figure 30-20-101].

Dealer Copy -- Not for Resale


Figure 30-20-102

P-87925

Remove the bearings (Item 1) [Figure 30-20-102] from


both ends of the roller.

499 of 879 30-20-35 E80 Service Manual


TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Sprocket Removal And Installation

Figure 30-20-103

P-87908

Remove the drive sprocket bolts (Item 1) [Figure 30-20-


103].

Dealer Copy -- Not for Resale


Installation: Apply thread adhesive (Loctite® 242 or
equivalent) to the bolt threads. Tighten the bolts to 160 -
180 N•m (118 - 133 ft-lb) torque.

Remove the drive sprocket from the travel motor.

500 of 879 30-20-36 E80 Service Manual


TRACK MAINTENANCE Causes of the damage:

Track Damage Identification When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
The following pages show photos and illustrations of of the embedded steel cords causes steel cords to be
track damage and their probable cause. These pages are cut:
intended to be used for identifying the reason for track
damage and how to avoid future track damage. Figure 30-30-3

Cutting Of Steel Cords

Figure 30-30-1

PI-13035

Dealer Copy -- Not for Resale


When the rubber track is detracting, the idler or sprocket
P-3864 rides on the projections of the embedded metal [Figure
30-30-3].

Figure 30-30-2 When the rubber track is detracted, projections of rubber


tracks get stuck between the frame of the undercarriage.

The rubber track is clogged with stones or foreign


obstacles.

When moisture invades through a cut on the lug side


rubber surface, the embedded steel cords will corrode.
The deterioration of the design strength may lead to the
breaking off of the steel cords.

Prevention:
Steel Cords
The following preventions should be taken to minimize
the risk of this damage:
PI-13034
Periodical checking of the recommended track
tension. (See Checking Tension on Page 30-20-2.)
Damage:
Avoiding quick turns on bumpy and rocky fields.
Embedded steel cords are cut off [Figure 30-30-1] and
[Figure 30-30-2]. Drive carefully to prevent stones and other articles
from clogging the rubber tracks.
Replacement:
Driving over sharp objects should be avoided. If this is
Replacement is required. impossible, do not make turns while driving over
sharp objects.

501 of 879 30-30-1 E80 Service Manual


TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d) Causes of the damage:

Abrasion Of Embedded Metals When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Figure 30-30-4 inevitable. The following cases sometimes accelerate
their abrasion:

Rubber tracks are driven with an extraordinary heavy


load on them.

Rubber tracks are used on sandy fields.

Prevention:

As long as rubber tracks are used under normal


operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generates
a heavy load for rubber tracks, and when they are
P-3865 operated under a sandy field condition for a long time.

Dealer Copy -- Not for Resale


Damage:

In proportion to the service time, embedded metals will


gradually wear away by friction [Figure 30-30-4].

Figure 30-30-5

Abrasion

D D1 = 0.67D
PI-13037

Replacement:

Replacement is required when the width of the


embedded metals (D1) becomes 67% of the original
width (D) [Figure 30-30-5].

502 of 879 30-30-2 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Embedded metals are adhered between the steel cords
and the rubber body. The following cases generate
Separation Of Embedded Metals external forces greater than the adhesion strength,
causing separation of the embedded metals:
Figure 30-30-6
Figure 30-30-7

Idler

Rubber
Track

P-4379

PI-13039

Dealer Copy -- Not for Resale


Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded metals embedded metals, the embedded metals will eventually
cause their separation from the rubber track's body peel off [Figure 30-30-7].
[Figure 30-30-6].
Figure 30-30-8
Replacement:

Even a partial separation of embedded metals requires


replacement of the track.
Guide

PI-13040

When a rubber track is detracted, it becomes stuck


between the guide or the undercarriage frame, causing
the separation of embedded metals [Figure 30-30-8].

503 of 879 30-30-3 E80 Service Manual


TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Separation Of Embedded Metals (Cont’d)

Figure 30-30-9

Abrasion

PI-13041

Dealer Copy -- Not for Resale


Abnormally worn sprockets will pull embedded metals out
[Figure 30-30-9].

Prevention:

Similar to the prevention against the cutting of the steel


cords:

Track tension should be periodically checked. (See


Checking Tension on Page 30-20-2.)

Quick turns on bumpy and rocky fields should be


avoided.

If abnormal wear of sprockets is observed, they


should be replaced immediately.

504 of 879 30-30-4 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-11

Separation Of Embedded Metals Due To Corrosion Embedded metal Good

Figure 30-30-10

Separation of
bonded
rubber cover

PI-13043

Embedded metals are bonded to the rubber body. The


P-4378 following operating conditions cause embedded metals
to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals

Dealer Copy -- Not for Resale


Damage: from the rubber body [Figure 30-30-11]:

Due to corrosion of embedded metals, the adhesion to Excessively salty fields, like the sea shore
the rubber body deteriorates, resulting in complete
separation [Figure 30-30-10]. Strong acidic or alkali soil conditions

Replacement: Compost spread grounds.

Even a partial separation of embedded metals requires a On tracks that are out of adjustment, the track rollers,
rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at the side of the track roller, causing exposure of
the embedded metals. Consequently the embedded
metals will corrode resulting in their separation from the
rubber body.

Prevention:

If rubber tracks are used under such field conditions as


described under (Causes of the damage). The tracks
should be washed with plenty of water. After being
completely dried, they should be stored correctly.

When the bonded rubber cover is separated from the


embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacing the
rubber track.

505 of 879 30-30-5 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-13

Cuts On The Lug Side Rubber

Figure 30-30-12 Cuts

PI-13045

When rubber tracks drive over projections or sharp


P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface

Dealer Copy -- Not for Resale


Damage: will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
Cuts on the lug side rubber are one of the most occurring steel cords' breakage due to their corrosion. It is highly
types of track damage [Figure 30-30-12]. recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 30-30-13].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately repaired Machine operators are requested to drive with great
with cold vulcanization rubber. attention to the ground's surface especially in terrains of
the following type:

Construction sites

Demolition sites

Paths covered with rocks and wood

Concrete ridges

Stumpy fields.

When operating on terrains as mentioned above, high


speed, quick turns and overloading should be avoided.

506 of 879 30-30-6 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue causes cracks, especially on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 30-30-14 even small external cracks. When operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.

Prevention:

Rubber tracks are designed with special rubber


compounds to prevent cracks due to fatigue. External
injuries on the lug side rubber sometimes cause more
chance of cracking. Machine operators should observe
soil conditions when driving, so as not to cause external
injuries to the lug side rubber. In order to minimize the
occurrence of ozone cracks, attention should be paid to
the following instructions for maintenance:

P-4382 Avoid exposing stored tracks to direct sun light.

Avoid exposing stored tracks to direct rain and snow

Dealer Copy -- Not for Resale


Figure 30-30-15 fall.

Store tracks in well ventilated warehouses.

Use the tracks at least once a month.

P-4380

Damage:

Small cracks around the root of the lug caused by


operation fatigue [Figure 30-30-14] and [Figure 30-30-
15].

Replacement:

When the cracks reach so deep that they expose the


steel cords, track replacement is required.

507 of 879 30-30-7 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Lug abrasion is inevitable. Even if lug abrasion is
proceeding, the rubber track can still be used. As the
Lug Abrasion traction performance deteriorates accordingly, it is highly
recommended to replace the abraded tracks with new
Figure 30-30-16 ones when the lug height becomes less than 5 mm
(0.197 in).

Prevention:

In order to prevent the rubber track from abnormal or


premature abrasion, following operating conditions
should be avoided:

Making quick and repeated turns on concrete and


asphalt roads.

Driving up and down hilly paths with slippage.

Making frequent turns on paths covered with rocks


P-4381 and wood.

Dealer Copy -- Not for Resale


Figure 30-30-17

Lug abrasion

PI-13049

Damage:

As its service time proceeds, the lug side inevitably


undergoes abrasion [Figure 30-30-16] and [Figure 30-
30-17].

Replacement:

No replacement is required.

508 of 879 30-30-8 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Figure 30-30-19

Track Damage Identification (Cont’d)

Cracks And Cuts On The Lug Side Rubber


Crack at the edge of Cut on lug side
Figure 30-30-18
embedded metal rubber

PI-13051

Causes of the damage:

When rubber tracks drive over sharp projections,


PI-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals

Dealer Copy -- Not for Resale


Damage: [Figure 30-30-19].

Sometimes cracks and cuts on the lug side rubber at the Prevention:
edges of the embedded metals can be observed [Figure
30-30-18]. To avoid extensive stress applied to the lug root
where metals are embedded, machine operators are
Replacement: requested to avoid driving over stumps and ridges.

No replacement is required unless the cuts on the lug


side rubber are discovered all around the edges of the
embedded metals, as this will result in a complete cut off.

509 of 879 30-30-9 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Figure 30-30-21

Track Damage Identification (Cont’d)

Abrasion Of The Track Roller Side Track


Figure 30-30-20 Abrasion

PI-13053

Causes of the damage:

The abrasion of the track roller side rubber surface


P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against

Dealer Copy -- Not for Resale


Damage: the side of the rubber track causing the abrasion [Figure
30-30-21].
The rubber surface on which track rollers run is gradually
abraded. It will end in the exposure of the embedded The level of abrasion is highly dependent on terrain
metals [Figure 30-30-20]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers, increase the abrasion level.
It is recommended to replace the rubber track when more After an extended period of abrasion, it will be more likely
than half of the embedded metals are completely for exposed embedded metals to catch moisture through
exposed. the inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.

Prevention:

After operation in wet fields containing many small


stones, wash off the mud that is stuck on the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

510 of 879 30-30-10 E80 Service Manual


TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) This damage is caused by objects on the field or by
interference with the machine frame.
Cuts On The Edges Of Track Roller Side
Figure 30-30-24
Figure 30-30-22

PI-13056
P-4384

In case of damage by objects on the operating ground:

Dealer Copy -- Not for Resale


Figure 30-30-23
The edges of rubber track are often deformed, mainly
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. When a machine drives over
Edge Edge concrete ridges, this type of damage easily occurs
[Figure 30-30-24].

PI-13055

Damage:

Both edges of the rubber track have no special


reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 30-30-22] and
[Figure 30-30-23].

Replacement:

In such case, the rubber track does not have to be


replaced.

511 of 879 30-30-11 E80 Service Manual


TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Cuts On The Edges Of Track Roller Side (Cont’d)

Figure 30-30-25

Cut

Tear

PI-13057

Dealer Copy -- Not for Resale


In case of damage by interference with the machine
frame:

If a machine continues operating with rubber tracks


being detracted, the rubber tracks may get caught up
in the machine frame or undercarriage parts, resulting
in damage. When a machine travels along side
slopes, the rubber tracks are deformed so much that
they come into contact with the machine frame and
undercarriage parts, which causes cutting, gouging
and rubbing of rubber tracks in the end [Figure 30-30-
25].

Prevention:

When traveling, a machine operator should be careful not


to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracking.

512 of 879 30-30-12 E80 Service Manual


SWING CIRCLE GEAR

Swing Bearing Removal

Remove the upperstructure. (See Removal on Page 40-


10-1.)

Figure 30-40-1

P11599

Dealer Copy -- Not for Resale


Install a C-clamp (Item 1) [Figure 30-40-1] to prevent the
swing bearing from turning while being removed.

Figure 30-40-2

P-89381

Remove the twenty-four bolts and nuts that hold the


swing bearing on the track frame (Item 1) [Figure 30-40-
2].

Remove the swing bearing.

513 of 879 30-40-1 E80 Service Manual


SWING CIRCLE GEAR (CONT’D) Figure 30-40-5

Swing Bearing Installation

Figure 30-40-3

1
1

OUTER RACE
Soft zone is at
INNER RACE the Ball Bearing
Soft zone is filler plug
identified by a
letter “S”
stamped on ring
P-23504

Install the swing bearing bolts (Item 1) [Figure 30-40-5]


PI-13677 and lock nuts.

Tighten the bolts to 392 N•m (289 ft-lb) torque.


Figure 30-40-4
Put lubriplate grease or an equivalent on the swing

Dealer Copy -- Not for Resale


bearing gear.

P-89382

If reusing the existing swing bearing, use top, side and


edge aligning marks to put the swing bearing in the
correct location. If installing a new swing bearing find the
soft zone area (Item 1) [Figure 30-40-3] and [Figure 30-
40-4].

Install the swing bearing so the inside soft zone (Item 1)


[Figure 30-40-3] and [Figure 30-40-4] is at the right
hand side of the excavator.

NOTE: Do not put the soft zone to the front or rear of


the excavator.

514 of 879 30-40-2 E80 Service Manual


LOWER TRACK ROLLER

Parts Identification

1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug

4
5
6

2
5

Dealer Copy -- Not for Resale


2
8 7

E802150S

515 of 879 30-50-1


LOWER TRACK ROLLER (CONT’D) Figure 30-50-3

Disassembly

NOTE: The procedure is shown on a steel track roller. 1


The procedure is the same for the rubber
track roller.

Figure 30-50-1

P-89289
2

Remove the seal assembly [Figure 30-50-3].

Figure 30-50-4

P-89287

Dealer Copy -- Not for Resale


Drive the pin (Item 1) towards the top of the collar (Item
2) [Figure 30-50-1].

NOTE: The pin bore in the collar is stepped.


2
Figure 30-50-2
1

P-89290
1

Remove the seal assembly (Item 1). Remove the O-ring


(Item 2) [Figure 30-50-4].

P-89288

Remove the collar (Item 1) [Figure 30-50-2].

516 of 879 30-50-2


LOWER TRACK ROLLER (CONT’D) Figure 30-50-7

Disassembly (Cont’d)

Figure 30-50-5

P-89293
1

Remove the seal assembly (Item 1) [Figure 30-50-7]


P-89291 from the collar.

Figure 30-50-8
Remove the shaft assembly (Item 1) [Figure 30-50-5]
from the roller.

Dealer Copy -- Not for Resale


Figure 30-50-6
1

P-89262

Remove the O-ring (Item 1) [Figure 30-50-8] from all four


P-89292 seal rings.

Remove the seal assembly (Item 1) [Figure 30-50-6]


from the roller.

517 of 879 30-50-3


LOWER TRACK ROLLER (CONT’D) Figure 30-50-11

Disassembly (Cont’d)
1
Figure 30-50-9

P-89296
1

Remove the O-ring (Item 1) [Figure 30-50-11].


P-87924
Figure 30-50-12

Remove the pin (Item 1) [Figure 30-50-9].

Dealer Copy -- Not for Resale


Figure 30-50-10
1

1
P-89297

Remove the bushing (Item 1) [Figure 30-50-12] from


P-87925 both sides of the roller.

Remove the shaft (Item 1) [Figure 30-50-10].

518 of 879 30-50-4


LOWER TRACK ROLLER (CONT’D) Figure 30-50-15

Assembly

Clean all parts in solvent and dry them with compressed 1


air.

The seal assemblies are a matched set and must be


replaced in pairs.

Figure 30-50-13

1
P-89295

Install the shaft (Item 1) [Figure 30-50-15] in the collar.

Figure 30-50-16

Dealer Copy -- Not for Resale


P-89297

Install the bushing (Item 1) [Figure 30-50-13] on both


sides of the roller.

Figure 30-50-14

P-89294

Install the pin (Item 1) [Figure 30-50-16] in the collar and


through the shaft.

P-89296

Install the O-ring (Item 1) [Figure 30-50-14] on the shaft.

519 of 879 30-50-5


LOWER TRACK ROLLER (CONT’D) Dip the seal assembly in a pan of alcohol.

Assembly (Cont’d) Figure 30-50-19

Figure 30-50-17

1
P-89298

P-89262
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-50-19] in the collar.
Install the O-ring (Item 1) [Figure 30-50-17] on the seal
ring. Repeat this procedure on all four seal assemblies. Use firm, even pressure on the installation tool to pop the

Dealer Copy -- Not for Resale


O-ring in to the collar.
The O-ring and seal ring must be clean and free of any
dust, oil film and foreign matter. Remove the installation tool.

NOTE: Inspect the seal ring for burrs before Figure 30-50-20
installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.

Figure 30-50-18

P-89299

The seal assembly stand off height must be equal and


the O-ring must not be twisted [Figure 30-50-20].

P-40754

Place the seal assembly in the installation tool (Item 1)


[Figure 30-50-18].

The O-ring and seal ring assembly have to be lubricated


with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.

520 of 879 30-50-6


LOWER TRACK ROLLER (CONT’D) Figure 30-50-23

Assembly (Cont’d)

Figure 30-50-21

P-89301

The seal assembly stand off height must be equal and


P-40754 the O-ring must not be twisted [Figure 30-50-23].

Apply a light film of oil to both metal seal rings.


Place the seal assembly (Item 1) [Figure 30-50-21] in
the installation tool. NOTE: Do not get any oil on the rubber O-rings.

Dealer Copy -- Not for Resale


The O-ring and seal ring assembly have to be lubricated Figure 30-50-24
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1
Dip the O-ring and seal assembly in a pan of alcohol.

Figure 30-50-22

P-89302

Install the roller (Item 1) [Figure 30-50-24] on the shaft.

P-89300

Shake off the excess alcohol and install the seal


assembly (Item 1) [Figure 30-50-22] in the roller.

Use firm, even pressure on the installation tool to pop the


O-ring in to the collar.

Remove the installation tool.

521 of 879 30-50-7


LOWER TRACK ROLLER (CONT’D) Figure 30-50-27

Assembly (Cont’d)

Figure 30-50-25

P-89304

The seal assembly stand off height must be equal and


P-40754 the O-ring must not be twisted [Figure 30-50-27].

Figure 30-50-28
Place the seal assembly in the installation tool (Item 1)
[Figure 30-50-25].

Dealer Copy -- Not for Resale


The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius. 1

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-50-26

P-89305

Install the O-ring (Item 1) [Figure 30-50-28].

P-89303

Shake off the excess alcohol and install the seal


assembly (Item 1) [Figure 30-50-26] in the roller.

Use firm, even pressure on the installation tool to pop the


O-ring in to the collar.

Remove the installation tool.

522 of 879 30-50-8


LOWER TRACK ROLLER (CONT’D) Figure 30-50-31

Assembly (Cont’d)

Figure 30-50-29

P-89307

The seal assembly stand off height must be equal and


P-40754 the O-ring must not be twisted [Figure 30-50-31].

Apply a light film of oil to both metal seal rings.


Place the seal assembly in the installation tool (Item 1)
[Figure 30-50-29]. NOTE: Do not get any oil on the rubber O-rings.

Dealer Copy -- Not for Resale


The O-ring and seal ring assembly have to be lubricated Figure 30-50-32
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1
Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-50-30

P-89308

Install the collar (Item 1) on the shaft. Install the pin (Item
1
2) [Figure 30-50-32] in the collar.

P-89306

Shake off the excess alcohol and install the seal


assembly (Item 1) [Figure 30-50-30] in the roller.

Use firm, even pressure on the installation tool to pop the


O-ring in to the collar.

Remove the installation tool.

523 of 879 30-50-9


LOWER TRACK ROLLER (CONT’D)

Assembly (Cont’d)

Figure 30-50-33

P-89309

Push down on the collar until the pin bore of the collar is
aligned with the pin bore of the shaft. Fully seat the pin

Dealer Copy -- Not for Resale


(Item 1) [Figure 30-50-33].

Remove the plug (Item 2) [Figure 30-50-33]. Add 120 -


160 cc (4.1 - 5.4 oz.) of 30W oil to the roller.

Install the plug.

524 of 879 30-50-10


UPPER TRACK ROLLER

Parts Identification

1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal 6
8. Shaft
9. Bolt
10. Nut
11. Mount
5

1
4

1 2

Dealer Copy -- Not for Resale


10

8
11

7
1

525 of 879 30-60-1


UPPER TRACK ROLLER (CONT’D) Figure 30-60-3

Disassembly And Assembly

Figure 30-60-1

P-87918

Install a 50,8 mm (2.0 in) long 3,175 mm (1/8 in) NPT


P-87915 pipe (Item 1) into the cover. Pull up on the pipe to remove
the cover (Item 2) [Figure 30-60-3].

Remove the snap ring (Item 1) [Figure 30-60-1]. Figure 30-60-4

Dealer Copy -- Not for Resale


Figure 30-60-2

1 1

P-87919

P-87916
Remove the O-ring (Item 1) [Figure 30-60-4].

Remove the pipe plug (Item 1) [Figure 30-60-2].

526 of 879 30-60-2


UPPER TRACK ROLLER (CONT’D) Figure 30-60-7

Disassembly And Assembly (Cont’d)

Figure 30-60-5 1

1
P-87922

Remove the seal (Item 1) [Figure 30-60-7] from the


P-87920 shaft.

Figure 30-60-8
Remove the snap ring (Item 1) [Figure 30-60-5].

Dealer Copy -- Not for Resale


Turn the roller over and drain the oil.
1
Assembly: Add 130 - 170 cc (4.5 - 5.7 oz) of 30W oil to
the roller before installing the cover.

Figure 30-60-6

P-87923

1
Remove the seal (Item 1) [Figure 30-60-8] from the
roller.

P-87921

Remove the shaft (Item 1) [Figure 30-60-6] from the


roller.

527 of 879 30-60-3


UPPER TRACK ROLLER (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 30-60-9

P-87924

Remove the snap ring (Item 1) [Figure 30-60-9].

Dealer Copy -- Not for Resale


Figure 30-60-10

P-87925

Remove the bearings (Item 1) [Figure 30-60-10] from


both ends of the roller.

528 of 879 30-60-4


SWING CIRCLE GEAR

Swing Bearing Removal

Remove the upperstructure. (See Removal on Page 40-


10-1.)

Figure 30-70-1

P11599

Dealer Copy -- Not for Resale


Install a C-clamp (Item 1) [Figure 30-70-1] to prevent the
swing bearing from turning while being removed.

Figure 30-70-2

P-89381

Remove the 24 bolts and nuts that hold the swing bearing
on the track frame (Item 1) [Figure 30-70-2].

Remove the swing bearing.

529 of 879 30-70-1


SWING CIRCLE GEAR (CONT’D) Figure 30-70-5

Swing Bearing Installation

Figure 30-70-3

1
1

OUTER RACE
Soft zone is at
INNER RACE the Ball Bearing
Soft zone is filler plug
identified by a
letter “S”
stamped on ring
P-23504

Install the swing bearing bolts (Item 1) [Figure 30-70-5]


PI-13677 and lock nuts.

Tighten the bolts to 392 N•m (289 ft-lb) torque.


Figure 30-70-4
Put lubriplate grease or an equivalent on the swing

Dealer Copy -- Not for Resale


bearing gear.

P-89382

If reusing the existing swing bearing, use top, side and


edge aligning marks to put the swing bearing in the
correct location. If installing a new swing bearing find the
soft zone area (Item 1) [Figure 30-70-3] and [Figure 30-
70-4].

Install the swing bearing so the inside soft zone (Item 1)


[Figure 30-70-3] and [Figure 30-70-4] is at the right
hand side of the excavator.

NOTE: Do not put the soft zone to the front or rear of


the excavator.

530 of 879 30-70-2


UPPERSTRUCTURE & SWING SECTION

UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3

UPPERSTRUCTURE SIDE COVER (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

UPPERSTRUCTURE SIDE COVER (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-15
Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-16
Lower Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-17
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-18
Front Window Strut Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-23
Front Window Slide Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-24
Cab Tilt Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-25

Dealer Copy -- Not for Resale


Cab Tilt Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-26
Cab Tilt Assembly Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-27
Headliner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-28

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2

RIGHT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1


Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1


Lower Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Upper Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-2
Gas Strut Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-3
Lock Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-4
Lock Lever Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5
Console Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-6

CENTER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

CENTER ACCESS COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

531 of 879 40-01 E80 Service Manual


FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-110-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-110-1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-5
Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-6

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-2

BOOM (ARTICULATED) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-141-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-141-1

Dealer Copy -- Not for Resale


ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-2
Bucket And Link Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-150-3

QUICK COUPLER (KLAC SYSTEM™). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1


Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-7

QUICK COUPLER (LEHNHOFF SYSTEM®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-1


Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-1
Removal (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-2
Installation (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-3
Parts Identification (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-4
Disassembly And Assembly (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-5
Parts Identification (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-6
Disassembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-7
Assembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-161-11

BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Side Cutting Edge Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 40-170-2

532 of 879 40-02 E80 Service Manual


RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-3

REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1

Dealer Copy -- Not for Resale

533 of 879 40-03 E80 Service Manual


Dealer Copy -- Not for Resale

534 of 879 40-04 E80 Service Manual


UPPERSTRUCTURE Figure 40-10-2

Removal

Drain the hydraulic reservoir. (See Removing And 3


Replacing Hydraulic Fluid on Page 10-140-6.)

Drain the fuel tank. (See Draining The Fuel Tank on Page
10-120-4.)
2
Remove the swing motor drive carrier. (See Removal
And Installation on Page 20-91-1.) 1

Remove the swivel joint. (See Removal And Installation


on Page 20-80-1.) 2
P-89379
Remove the boom. (See Removal And Installation on
Page 40-110-1.)
Install the boom pivot pin (Item 1), spacers (Item 2) and
Remove the cab. (See Removal And Installation on Page strap (Item 3) [Figure 40-10-2] on the pivot pin.
40-30-1.)
NOTE: The spacers are needed to prevent the strap
Remove the engine. (See Engine Removal And from sliding on the pivot pin causing the
Installation on Page 60-10-9.) upperstructure to tip side to side.

Dealer Copy -- Not for Resale


Remove the counterweight. (See Removal And
Installation on Page 40-90-1.)

Remove the hydraulic reservoir. (See Removal And


Installation on Page 20-140-1.)

Remove the fuel tank. (See Removal And Installation on


Page 40-110-1.)

Figure 40-10-1

P-89376

Mark the track frame to swing bearing (Item 1) [Figure


40-10-1].

535 of 879 40-10-1 E80 Service Manual


UPPERSTRUCTURE (CONT’D) Figure 40-10-5

Removal (Cont’d)

Figure 40-10-3 1
1
1 1

P-89376

Remove the bolts (Item 1) [Figure 40-10-5].


P-89377
Rotate the upperstructure by hand and continue
removing the bolts.
Figure 40-10-4
NOTE: The upperstructure is mounted to the track

Dealer Copy -- Not for Resale


frame with twenty-four bolts.
1
Figure 40-10-6

P-89378

Install the rear lifting brackets (Item 1) [Figure 40-10-3]


and [Figure 40-10-4].
P-89379

Install chains and a hoist to the lifting brackets.


Raise the upperstructure. Make sure the upperstructure
NOTE: The chain hoist the lifting chains are attached is level as it is being raised [Figure 40-10-6].
to must have a swivel hook to allow the
upperstructure to be turned. Lower the upperstructure and adjust the lifting chains as
needed, to pull the upperstructure squarely off the track
Apply a small amount of lifting pressure to the frame.
upperstructure with the chain hoist.
Remove the upperstructure and position it on suitable
support stands or blocks.

536 of 879 40-10-2 E80 Service Manual


UPPERSTRUCTURE (CONT’D) Figure 40-10-9

Installation

Figure 40-10-7

FRONT OF MACHINE

INNER RACE OUTER RACE


Soft zone is Soft zone is 1
identified by a at the
letter “S” ball bearing
stamped on filler plug
N-15781
ring

Use a 18 mm tap in the holes (Item 1) [Figure 40-10-9]


PI-13677 of the upperstructure to remove any dried thread lock
adhesive.

Figure 40-10-8 Figure 40-10-10

Dealer Copy -- Not for Resale


1

P-89380 B-13678

Rotate the swing bearing so the outside soft zone (Item Make three alignment pins by using M18 X 110 mm long
1) [Figure 40-10-7] and [Figure 40-10-8] is to the right bolts. Cut the head off these bolts at 90 mm (3.50 in),
hand side of the excavator. then taper the end of the bolts [Figure 40-10-10].

NOTE: The upperstructure can only be installed on


the swing bearing in one position. Match the
mount holes in the swing bearing to the
mount holes in the upperstructure.

537 of 879 40-10-3 E80 Service Manual


UPPERSTRUCTURE (CONT’D) Figure 40-10-13

Installation (Cont’d)

Figure 40-10-11
1

1
1
N-15787

1 Remove the three, 90 mm (3.50 in) alignment pins (Item


N-15784 1) [Figure 40-10-13] from the upperstructure.

These headless pins can be removed from the bottom.


Install the pins (Item 1) [Figure 40-10-11] into the
upperstructure at approximately 120° apart. These will Apply thread adhesive (Loctite® 242 or equivalent) to the

Dealer Copy -- Not for Resale


act as alignment pins while lowering the upperstructure threads of the bolts. Install the bolts into all holes (except
onto the swing bearing. the three with the alignment bolts installed). Tighten
these bolts to 392 N•m (289 ft-lb) torque.
Install the upperstructure onto the swing bearing using
the alignment marks and the alignment pins. Remove the chains and lifting brackets.

Figure 40-10-12 Install the swing motor drive carrier. (See Removal And
Installation on Page 20-91-1.)

Check the backlash between the gears by moving the


frame back and forth at several points throughout 360° of
frame rotation. There must be some backlash present.

Install the swing motor. (See Removal And Installation on


Page 20-90-1.)

B-13693

Make sure the swivel joint is centered into the


upperstructure access hole [Figure 40-10-12].

538 of 879 40-10-4 E80 Service Manual


UPPERSTRUCTURE SIDE COVER (LEFT)

Removal And Installation

Figure 40-20-1

1
1

P-86415

Remove the four rubber plugs (Item 1) [Figure 40-20-1].

Dealer Copy -- Not for Resale


Figure 40-20-2

2
2 2

1
1
1 P-86416

Remove the three bottom bolts (Item 1), flat washers and
lock washers. Remove the four top bolts (Item 2) [Figure
40-20-2], flat washers and lock washers.

Remove the cover.

Note the number and position of the shims located


between the cover and upperstructure. Place the shims
in the correct position for installation.

539 of 879 40-20-1 E80 Service Manual


Dealer Copy -- Not for Resale

540 of 879 40-20-2 E80 Service Manual


UPPERSTRUCTURE SIDE COVER (RIGHT)

Removal And Installation

Figure 40-21-1

1 1

P-86824

Remove the three rubber plugs (Item 1) [Figure 40-21-


1].

Dealer Copy -- Not for Resale


Figure 40-21-2

2 2

1
1

P-86827

Remove the three bottom bolts (Item 1), flat washers and
lock washers. Remove the three top bolts (Item 2)
[Figure 40-21-2], flat washers and lock washers.

Remove the cover.

Note the number and position of the shims located


between the cover and upperstructure. Place the shims
in the correct position for installation.

541 of 879 40-21-1 E80 Service Manual


Dealer Copy -- Not for Resale

542 of 879 40-21-2 E80 Service Manual


CAB Figure 40-30-3

Removal And Installation

Remove the door. (See Door Removal And Installation 1


on Page 40-30-15.) 1

Remove the seat. (See Seat Removal And Installation on


Page 40-40-1.)

Remove the floor mat. (See Removal And Installation on


Page 40-100-1.)

Remove the instrument panel. (See Removal And


2
Installation on Page 50-100-1.)
P-87717
Remove the right console switch cover. (See Removal
And Installation on Page 50-120-1.)
Remove the screws (Item 1) and the right pocket cover
Figure 40-30-1 (Item 2) [Figure 40-30-3].

Figure 40-30-4

Dealer Copy -- Not for Resale


1 1

P-87715

P-87728
Figure 40-30-2

Remove the cover (Item 1) [Figure 40-30-4].

P-87716

Remove the bolts (Item 1) [Figure 40-30-1] and [Figure


40-30-2] from the base of the right console. Reposition
the right console to create access to the side covers.

543 of 879 40-30-1 E80 Service Manual


CAB (CONT'D) Figure 40-30-7

Removal And Installation (Cont’d)

Figure 40-30-5

P-87721

Remove the screw (Item 1) [Figure 40-30-7].


P-87729
Figure 40-30-8

Remove the screw (Item 1) [Figure 40-30-5].

Dealer Copy -- Not for Resale


Figure 40-30-6
1

1 P-87730

Remove the screw (Item 1) [Figure 40-30-8].


P-87720

Remove the screw (Item 1) [Figure 40-30-6].

544 of 879 40-30-2 E80 Service Manual


CAB (CONT'D) Figure 40-30-11

Removal And Installation (Cont’d)

Figure 40-30-9

1
1

1 P-87734

Figure 40-30-12
P-87731

Tilt the cover inwards and remove the wires (Item 1)


[Figure 40-30-9] from the hour meter.

Dealer Copy -- Not for Resale


Remove the side cover. 1

Figure 40-30-10

1 P-87735

1 Remove the screws (Item 1) [Figure 40-30-11] and


2 [Figure 40-30-12] and air duct (Item 2) [Figure 40-30-
12].

P-87733

Remove the screws (Item 1) and right side cover (Item 2)


[Figure 40-30-10].

545 of 879 40-30-3 E80 Service Manual


CAB (CONT'D) Figure 40-30-15

Removal And Installation (Cont’d)

Figure 40-30-13

1
2

P-87738

1
Disconnect the wire harness (Item 1) from the upper duct
P-87736 controller and remove the controller (Item 2) [Figure 40-
30-15].

Figure 40-30-14 Figure 40-30-16

Dealer Copy -- Not for Resale


2

1 1

P-87737 P-87739

Remove the screws (Item 1) [Figure 40-30-13] and Remove the screw (Item 1) and duct (Item 2) [Figure 40-
[Figure 40-30-14]. 30-16].

546 of 879 40-30-4 E80 Service Manual


CAB (CONT'D) Figure 40-30-19

Removal And Installation (Cont’d)

Figure 40-30-17

P-87743
1

Disconnect the harness (Item 1) from the duct controller


P-87740 and remove the controller (Item 2) [Figure 40-30-19].

Figure 40-30-20
Figure 40-30-18

Dealer Copy -- Not for Resale


1

P-87744
P-87741

Figure 40-30-21
Remove the screws (Item 1) [Figure 40-30-17] and
[Figure 40-30-18].
1

P-87745

Remove the screw (Item 1) [Figure 40-30-45] and


[Figure 40-30-21] and duct (Item 2) [Figure 40-30-21].

547 of 879 40-30-5 E80 Service Manual


CAB (CONT'D) Figure 40-30-24

Removal And Installation (Cont’d)

Figure 40-30-22
1 1

1 1
1 1

P-87749
2

Remove the screws (Item 1) and column cover (Item 2)


P-87747 [Figure 40-30-24].

Figure 40-30-25
Remove the bolts (Item 1) and relay cover (Item 2)
[Figure 40-30-22].

Dealer Copy -- Not for Resale


Figure 40-30-23
1

1 P-87749
1

Figure 40-30-26
2 P-87748

Remove the screws (Item 1) and rear cover (Item 2)


[Figure 40-30-23]. 1

P-87751

Remove the bolt (Item 1) [Figure 40-30-25] and [Figure


40-30-26] and column duct (Item 2) [Figure 40-30-26].

548 of 879 40-30-6 E80 Service Manual


CAB (CONT'D) Figure 40-30-29

Removal And Installation (Cont’d)

Figure 40-30-27

2 1

2
1

1
P-87756

Figure 40-30-30
P-87752

Remove the bolts (Item 1) and ducts (Item 2) [Figure 40- 1 2


30-27].

Dealer Copy -- Not for Resale


Figure 40-30-28
1

P-87748

Remove the bolts (Item 1) [Figure 40-30-29] and [Figure


1 40-30-30] and rear duct control (Item 2) [Figure 40-30-
30].

P-87758

Disconnect the connector (Item 1) [Figure 40-30-28]


from the rear duct control.

549 of 879 40-30-7 E80 Service Manual


CAB (CONT'D) Figure 40-30-33

Removal And Installation (Cont’d)

Figure 40-30-31
1

1 2
1 1 1 1

P-87761

Remove the bolts (Item 1) from the P-clamps (Item 2)


P-87759 [Figure 40-30-33]. Place the relay block on the seat
mount.

Remove the relays (Item 1) [Figure 40-30-31]. Figure 40-30-34

Dealer Copy -- Not for Resale


Figure 40-30-32

1 1 1 1 1

P-87748

P-87760
Disconnect the wires (Item 1) [Figure 40-30-34] from the
beeper.
Remove the screws (Item 1) [Figure 40-30-32].

Install the relays.

550 of 879 40-30-8 E80 Service Manual


CAB (CONT'D) Figure 40-30-37

Removal And Installation (Cont’d)

Figure 40-30-35
1

1 1

2 P-87766

Remove the bolt (Item 1) [Figure 40-30-37] from the


P-87763 ground wire.

Figure 40-30-38
Remove the screws (Item 1) and controller (Item 2)
[Figure 40-30-35].

Dealer Copy -- Not for Resale


Figure 40-30-36

1 1
1
2

P-87748

1 Remove the bolts (Item 1) [Figure 40-30-38] from the P-


2 clamps.
P-87764

Remove the bolts (Item 1) from the P-clamps (Item 2)


[Figure 40-30-36].

551 of 879 40-30-9 E80 Service Manual


CAB (CONT'D) Figure 40-30-41

Removal And Installation (Cont’d) 1


Figure 40-30-39

1
1

P-87768

Remove the harness from the tie downs (Item 1) [Figure


P-87767 40-30-41].

Figure 40-30-42
Disconnect the radio harness (Item 1) [Figure 40-30-39].

Dealer Copy -- Not for Resale


Figure 40-30-40

2
2 1
1 1

P-87770

P-87768 Remove the cover (Item 1) [Figure 40-30-42] from the


wiper motor.

Remove the bolts (Item 1) from the P-clamps (Item 2)


[Figure 40-30-40].

552 of 879 40-30-10 E80 Service Manual


CAB (CONT'D) Figure 40-30-45

Removal And Installation (Cont’d)


1
Figure 40-30-43

1 1

1
P-87773

Remove the harness (Item 1) [Figure 40-30-45] from the


P-87771 hold downs.

Figure 40-30-46
Disconnect the wire harness (Item 1) [Figure 40-30-43].

Dealer Copy -- Not for Resale


Figure 40-30-44

1 1

P-87774

P-87772 Remove the bolts (Item 1) [Figure 40-30-46] from the


front of the cab.

Disconnect the washer bottle hose (Item 1) [Figure 40-


30-44].

553 of 879 40-30-11 E80 Service Manual


CAB (CONT'D) Figure 40-30-49

Removal And Installation (Cont’d)

Figure 40-30-47

1
1
1
1

P-87747

Install lifting hooks (Item 1) [Figure 40-30-49].


P-87776
Figure 40-30-50

Install the lifting hooks (Item 1) [Figure 40-30-47].


1

Dealer Copy -- Not for Resale


Figure 40-30-48

1
1

NA-1129

Attach lifting straps (Item 1) [Figure 40-30-50] to the


P-87775 lifting hooks.

Attach a lifting device to the straps.


Remove the bolts (Item 1) [Figure 40-30-48].
NOTE: The cab weighs approximately 480 kg (1058 lb)

554 of 879 40-30-12 E80 Service Manual


CAB (CONT'D) Figure 40-30-53

Removal And Installation (Cont’d)

Figure 40-30-51

1
1
2

1 P-87792

Remove the right front bolts (Item 1) [Figure 40-30-53].


P-87790
Figure 40-30-54

Remove the rear corner nuts (Item 1) and bolts (Item 2)


[Figure 40-30-51] (Both sides). 1

Dealer Copy -- Not for Resale


Figure 40-30-52

P-87793

Remove the front center nuts (Item 1) [Figure 40-30-54].

P-87791

Remove the right side bolt (Item 1) [Figure 40-30-52].

555 of 879 40-30-13 E80 Service Manual


CAB (CONT'D) Figure 40-30-56

Removal And Installation (Cont’d)

Figure 40-30-55

1 1

P-87795

Figure 40-30-57
P-87794

Remove the left front bolts (Item 1) [Figure 40-30-55].

Dealer Copy -- Not for Resale


1

P-87796

Remove the left side bolts (Item 1) [Figure 40-30-56] and


[Figure 40-30-57].

Remove the cab.

556 of 879 40-30-14 E80 Service Manual


CAB (CONT'D)

Door Removal And Installation

Figure 40-30-58

Dealer Copy -- Not for Resale


1

P-87666

Remove the hinge bolts (Item 1) [Figure 40-30-58].

Remove the door.

557 of 879 40-30-15 E80 Service Manual


CAB (CONT'D) Figure 40-30-61

Front Window Removal And Installation


1
Open the front window to the fully open and locked
position.

Figure 40-30-59
1

P-87668

With the help of a second person supporting the window,


release the window latches [Figure 40-30-61] and
partially lower the window.

P-87808 Figure 40-30-62

Dealer Copy -- Not for Resale


Figure 40-30-60

1
1

P-87669

P-87747 Tilt the front window and remove the roller (Item 1)
[Figure 40-30-62] (Both sides).

Remove the window slide bar bolts (Item 1) [Figure 40- Remove the window.
30-59] and [Figure 40-30-60].

558 of 879 40-30-16 E80 Service Manual


CAB (CONT'D)

Lower Front Window Removal And Installation

Open the front window.

Figure 40-30-63

P-87745

Dealer Copy -- Not for Resale


Grasp the lower window and pull it upwards until the
window is out of the channel [Figure 40-30-63].

Remove the window.

559 of 879 40-30-17 E80 Service Manual


CAB (CONT’D) Figure 40-30-65

Glass Installation

Top, Right Side, Left Side And Rear Glass.

NOTE: See your Bobcat dealer for the correct


urethane adhesive, combo primer, glass
cleaner and bumpers for correctly installing
the new glass.

Remove the majority of the old urethane adhesive from


the perimeter of the cab.
2
NOTE: Leave a thin film (0,79 mm (0.03 in) thick) of
the old urethane on the cab frame. Fresh 1
urethane will bond to the remaining film. NA1157

Prime and paint any bare metal or scratches.


Install the damper (Item 1) on the frame (Item 2) [Figure
Clean the metal surfaces with general purposes adhesive 40-30-65].
cleaner. Clean the glass surface with glass cleaner.

Figure 40-30-64 Shake the combo primer for one minute.

Apply one coat of the combo primer to the perimeter of

Dealer Copy -- Not for Resale


1 2 the cab and damper (Item 1) [Figure 40-30-65].
2
Shake the combo primer for one minute.

Allow the combo primer to dry for at least 15 minutes.


Excess primer can be removed from the glass using a
razor blade.

Cut the tip of the adhesive tube to the desired shape and
size to provide a bead with sufficient height to give good
1
contact with the glass around the entire perimeter.
2
1
2 1 Figure 40-30-66
NA1156

Install the damper (Item 1) on the glass (Item 2) [Figure 1


40-30-64].

MS1993

Apply a 6,4 X 9,5 mm (0.25 X 0.375 in) triangle shaped


bead of urethane adhesive (Item 1) [Figure 40-30-66] to
the perimeter of the cab.

560 of 879 40-30-18 E80 Service Manual


CAB (CONT’D) Door And Front Window Glass

Glass Installation (Cont’d) NOTE: The door and front windows are supplied as
kits that include the glass, urethane adhesive,
Top, Right Side, Left Side And Rear Glass (Cont’d)
combo primer, glass cleaner and damper for
Figure 40-30-67 correctly installing the new glass.

Remove the front window or door that is to be repaired


1 from the excavator.

Figure 40-30-68

MS1994

1
Install the glass and damper assembly (Item 1) [Figure
40-30-67]. Press the glass into the cab to make complete
contact with the adhesive. Tape the glass in place.

Dealer Copy -- Not for Resale


Allow the adhesive to cure for a minimum of twelve hours P-61216
at 70° F and 20% relative humidity.

Remove the tape after the adhesive is cured. Remove the broken glass (Item 1) [Figure 40-30-68].

Figure 40-30-69

1
2

P-61218

Cut and remove the old urethane adhesive (Item 1)


leaving less than a 0,79 mm (0.03 in) thick layer (Item 2)
[Figure 40-30-69] for the new adhesive to bond to.

NOTE: Be careful not to scratch the paint on the


frame.

561 of 879 40-30-19 E80 Service Manual


CAB (CONT’D) Figure 40-30-72

Glass Installation (Cont’d)


1
Door And Front Window Glass (Cont’d)

Figure 40-30-70

P-89351

Figure 40-30-73

P-61219

Place the glass on a flat surface with the painted side of

Dealer Copy -- Not for Resale


the glass (Item 1) [Figure 40-30-70] facing up. 1

Thoroughly clean the entire glass with glass cleaner.

Figure 40-30-71

P-89353

1
Install the dampers on the front window frame (Item 1)
[Figure 40-30-72] or on the door frame (Item 1) [Figure
40-30-73]. (The dampers are used to space the glass
away from the metal so there is no glass to metal
contact.)

P-61220

Apply one coat of combo primer (Item 1) [Figure 40-30-


71] on the painted edge of the glass.

Apply the combo primer to any scratches on the door/


front window frame in the area where the glass is
installed.

Allow the primer to dry for a minimum of 15 minutes.

Excess primer may be removed from the glass using a


razor blade.

562 of 879 40-30-20 E80 Service Manual


CAB (CONT’D)

Glass Installation (Cont’d)


Door And Front Window Glass (Cont’d) IMPORTANT
Figure 40-30-74 If the glass has direct contact with the metal frame,
the glass may break due to machine vibration.
I-2236-0105

P-61224

Apply a 6,4 X 9,5 mm (0.25 X 0.375 in) triangle shaped

Dealer Copy -- Not for Resale


bead of urethane adhesive (Item 1) [Figure 40-30-74]
around the front window/door frame.

Apply the adhesive directly on top of the old adhesive.

Figure 40-30-75

P-89350

Place the frame (Item 1) [Figure 40-30-75] on the glass.


The frame must be centered on the glass, and the glass
must not have direct contact with the front window/door
frame.

563 of 879 40-30-21 E80 Service Manual


CAB (CONT’D)

Glass Installation (Cont’d)


Door And Front Window Glass (Cont’d) IMPORTANT
Figure 40-30-76 If the glass has direct contact with the metal frame,
the glass may break due to machine vibration.
I-2236-0105

P-89352

Figure 40-30-77

Dealer Copy -- Not for Resale


P-89355

Clamp the frame and glass together [Figure 40-30-76]


and [Figure 40-30-77].

Place the clamps over the rubber bumpers on the frame.

Allow the adhesive to cure for a minimum of twelve hours


at 70° F and 20% relative humidity before removing the
clamps.

Install the front window/door on the excavator. (See the


correct Service Manual for installation procedure)

Install the wiper assembly on the front window. (See the


correct Service Manual for installation procedure)

564 of 879 40-30-22 E80 Service Manual


CAB (CONT’D)

Front Window Strut Removal And Installation

Remove the front window. (See Front Window Removal


And Installation on Page 40-30-16.)

Figure 40-30-78

P-87671

Dealer Copy -- Not for Resale


Remove the nut (Item 1) [Figure 40-30-78] from the
bottom of the strut.

Figure 40-30-79

P-87672

Remove the nut (Item 1) [Figure 40-30-79] from the top


of the strut.

Remove the strut.

565 of 879 40-30-23 E80 Service Manual


CAB (CONT’D) Figure 40-30-82

Front Window Slide Bar Removal And Installation

Remove the front window. (See Front Window Removal


And Installation on Page 40-30-16.) 1

Remove the front window strut. (See Front Window Strut


Removal And Installation on Page 40-30-23.)

Figure 40-30-80

1
P-87745

Remove the bushing (Item 1) [Figure 40-30-82] from the


side bar.

Dealer Copy -- Not for Resale


P-87673

Remove the C-clip (Item 1) [Figure 40-30-80].

Figure 40-30-81

P-87674

Remove the slide bar (Item 1) [Figure 40-30-81].

566 of 879 40-30-24 E80 Service Manual


CAB (CONT’D) Figure 40-30-85

Cab Tilt Assembly Removal And Installation


1
Remove the floor mat. (See Removal And Installation on
Page 40-100-1.)

Remove the left upperstructure side cover. (See Removal


And Installation on Page 40-20-1.)

Figure 40-30-83

1 P-89320

Remove the tilt assembly (Item 1) [Figure 40-30-85].


1

Dealer Copy -- Not for Resale


P-89319

Remove the bolts (Item 1) [Figure 40-30-83].

Figure 40-30-84

1 1 1

P-89320

Support the assembly and remove the bolts (Item 1)


[Figure 40-30-84].

Support the tilt assembly when removing the last bolt.

567 of 879 40-30-25 E80 Service Manual


CAB (CONT’D)

Cab Tilt Parts Identification

1. Clip
2. Washer
3. Shim
4. Link
5. Plate
6. Pin
7. Bracket
8. Bolt
9. Grease Fitting

Dealer Copy -- Not for Resale


1
2
3
4

5
1
2 4
3 3
2

8
7 6
2
3
2
9

568 of 879 40-30-26 E80 Service Manual


CAB (CONT’D)

Cab Tilt Assembly Disassembly And Assembly

Figure 40-30-86

1 1

P-89322

Remove the clips (Item 1) [Figure 40-30-86] and


washers.

Dealer Copy -- Not for Resale


Figure 40-30-87

1
1 2

P-89320

Remove the pins (Item 1) [Figure 40-30-87] and


washers.

Remove the links (Item 2) [Figure 40-30-87].

569 of 879 40-30-27 E80 Service Manual


CAB (CONT’D) Figure 40-30-90

Headliner Removal And Installation

Figure 40-30-88

1
1
1

P-92416

2
Slide the radio out of the opening and disconnect the
P-92413 radio harness (Item 1) and antenna cable (Item 2)
[Figure 40-30-90].

Remove the screws (Item 1) and faceplate (Item 2) Figure 40-30-91


[Figure 40-30-88].

Dealer Copy -- Not for Resale


Figure 40-30-89 1

1
1

P-92763

P-92414 Remove the screws (Item 1) [Figure 40-30-91].

Remove the screws (Item 1) [Figure 40-30-89].

570 of 879 40-30-28 E80 Service Manual


CAB (CONT’D) Figure 40-30-94

Headliner Removal And Installation (Cont’d)

Figure 40-30-92

1
1

P-92768

Remove the speaker from the headliner and disconnect


P-92764 the wires (Item 1) [Figure 40-30-94].

Figure 40-30-95
Remove the speaker from the headliner and disconnect
the wires (Item 1) [Figure 40-30-92].

Dealer Copy -- Not for Resale


Figure 40-30-93

1 1

1 P-92770

Remove the front window bumpers (Item 1) [Figure 40-


P-92765 30-95].

Remove the screws (Item 1) [Figure 40-30-93].

571 of 879 40-30-29 E80 Service Manual


CAB (CONT’D) Figure 40-30-98

Headliner Removal And Installation (Cont’d)

Figure 40-30-96

1
1
1

1 1 1
1

P-92771

Remove the remaining screws (Item 1) [Figure 40-30-


P-92766 98].

Figure 40-30-99
Remove the screws (Item 1) [Figure 40-30-96].

Dealer Copy -- Not for Resale


Figure 40-30-97

1
1
1
1
P-92772

P-92767 Remove the dome light lens (Item 1) [Figure 40-30-99].

Remove the screws (Item 1) [Figure 40-30-97].

572 of 879 40-30-30 E80 Service Manual


CAB (CONT’D) Figure 40-30-102

Headliner Removal And Installation (Cont’d)

Figure 40-30-100

P-92774

1
Remove the headliner (Item 1) [Figure 40-30-102].
P-92775

Remove the screws (Item 1) [Figure 40-30-100].

Dealer Copy -- Not for Resale


Figure 40-30-101

P-92773

Remove the dome light and disconnect the electrical


connector (Item 1) [Figure 40-30-101].

573 of 879 40-30-31 E80 Service Manual


Dealer Copy -- Not for Resale

574 of 879 40-30-32 E80 Service Manual


SEAT Figure 40-40-2

Seat Removal And Installation

Open the upper front window. (See Front Window on


Page 10-30-2.)

Remove the lower front window. (See Lower Front


Window Removal And Installation on Page 40-30-17.)

Figure 40-40-1
1
2
1
2
P-87665

1 Figure 40-40-3

Dealer Copy -- Not for Resale


P-87713

Remove the bolts (Item 1) and travel control levers (Item 1


2) [Figure 40-40-1]. 1

P-87664

Remove the bolts (Item 1) [Figure 40-40-2] and [Figure


40-40-3].

Remove the seat through the front of the cab.

575 of 879 40-40-1 E80 Service Manual


SEAT (CONT’D) Figure 40-40-6

Seat Mount Removal And Installation

Remove the seat. (See Seat Removal And Installation on


Page 40-40-1.)

Figure 40-40-4

P-87815

1
Remove the C-clip (Item 1) [Figure 40-40-6] from the left
console.

Figure 40-40-7
P-87715

Dealer Copy -- Not for Resale


Figure 40-40-5

1
P-87816

Remove the bolts (Item 1) [Figure 40-40-7].


P-87716

Remove the bolts [Figure 40-40-4] and [Figure 40-40-5]


from the right console.

Lay the console off to the side.

576 of 879 40-40-2 E80 Service Manual


SEAT (CONT’D) Figure 40-40-9

Seat Mount Removal And Installation (Cont’d)

Figure 40-40-8

P-87820

Figure 40-40-10
P-87717

Remove the nut (Item 1) and pin (Item 2) [Figure 40-40-


8].

Dealer Copy -- Not for Resale


1

P-87716

Slide the seat mount to the rear and remove the bolts
(Item 1) [Figure 40-40-9] and [Figure 40-40-10].

577 of 879 40-40-3 E80 Service Manual


SEAT (CONT’D)

Seat Mount Removal And Installation (Cont’d)

Figure 40-40-11

P-87819

Figure 40-40-12

Dealer Copy -- Not for Resale


1

P-87818

Slide the seat mount forward and remove the bolts (Item
1) [Figure 40-40-11] and [Figure 40-40-12].

Remove the seat mount.

578 of 879 40-40-4 E80 Service Manual


RIGHT CONSOLE Figure 40-50-3

Console Cover Removal And Installation

Figure 40-50-1

P-86658

Remove the screw (Item 1) [Figure 40-50-3] from the


P-86659 rear of the cover.

Figure 40-50-4
Pull the dust boot (Item 1) [Figure 40-50-1] towards the
rear of the cab.

Dealer Copy -- Not for Resale


Figure 40-50-2 2
3

P-86661

Lift the cover (Item 1) up until the cover is free of the


P-86660 joystick dust boot (Item 2) and blade lever dust boot (Item
3) [Figure 40-50-4].

Remove the screws (Item 1) [Figure 40-50-2].

579 of 879 40-50-1 E80 Service Manual


RIGHT CONSOLE (CONT’D)

Console Cover Removal And Installation (Cont’d)

Figure 40-50-5

P-86662

Tilt the cover towards the rear of the cab and disconnect
the key switch wire harness (Item 1) [Figure 40-50-5].

Dealer Copy -- Not for Resale


Remove the cover.

580 of 879 40-50-2 E80 Service Manual


LEFT CONSOLE Figure 40-60-3

Lower Console Cover Removal And Installation

Remove the upper console cover. (See Upper Console


Cover Removal And Installation on Page 40-60-2.) 1

Figure 40-60-1

P-86765

Raise the console and remove the two screws (Item 1)


[Figure 40-60-3] from the bottom of the cover.

Figure 40-60-4
P-86764

Dealer Copy -- Not for Resale


Remove the two screws (Item 1) [Figure 40-60-1] from
1
the front of the cover.

Figure 40-60-2

1 P-86766

Lower the console and remove the cover (Item 1) [Figure


40-60-4].

P-866763

Remove the two screws (Item 1) [Figure 40-60-2] from


the rear of the cover.

581 of 879 40-60-1 E80 Service Manual


LEFT CONSOLE (CONT’D) Figure 40-60-7

Upper Console Cover Removal And Installation

Figure 40-60-5

P-86758

Tilt the cover towards the rear of the cab and disconnect
P-86757 the wire harness (Item 1) [Figure 40-60-7].

Remove the cover.


Pull the dust boot towards the rear of the cab and remove
the two screws (Item 1) [Figure 40-60-5].

Dealer Copy -- Not for Resale


Figure 40-60-6

P-86756

Remove the two screws (Item 1) [Figure 40-60-6] from


the rear of the cover.

582 of 879 40-60-2 E80 Service Manual


LEFT CONSOLE (CONT’D) Figure 40-60-10

Gas Strut Removal And Installation


3
Remove the upper console cover. (See Upper Console
Cover Removal And Installation on Page 40-60-2.)

Remove the lower console cover. (See Lower Console


Cover Removal And Installation on Page 40-60-1.)
2
Figure 40-60-8
1

1 P-86780

Remove the two bolts (Item 1), mount (Item 2) and


bushing (Item 3) [Figure 40-60-10].

NOTE: Loosen and remove the bolts evenly until the


gas strut is fully extended.

Dealer Copy -- Not for Resale


Figure 40-60-11
P-86779

Remove the nut (Item 1) [Figure 40-60-8].


1
Figure 40-60-9

1
P-86782
2

Support the console and remove the gas strut (Item 1)


[Figure 40-60-11].

P-86778

Remove the snap ring (Item 1) and washer. Remove the


nut (Item 2) [Figure 40-60-9].

583 of 879 40-60-3 E80 Service Manual


LEFT CONSOLE (CONT’D)

Lock Lever Removal And Installation

Remove the gas strut (See Gas Strut Removal And


Installation on Page 40-60-3.)

Figure 40-60-12

1 1

P-86785

Dealer Copy -- Not for Resale


Remove the bolts (Item 1) and lever (Item 2) [Figure 40-
60-12].

584 of 879 40-60-4 E80 Service Manual


LEFT CONSOLE (CONT’D) Figure 40-60-15

Lock Lever Disassembly And Assembly

Figure 40-60-13

1
1

P-86788

Remove the shims (Item 1) [Figure 40-60-15] from both


P-86786 sides of the lever.

Figure 40-60-16
Remove the snap ring (Item 1) [Figure 40-60-13].

Dealer Copy -- Not for Resale


Figure 40-60-14
1

P-86789

P-86787 Remove the bushing (Item 1) [Figure 40-60-16] from the


lever.

Remove the pin (Item 1) [Figure 40-60-14].

585 of 879 40-60-5 E80 Service Manual


LEFT CONSOLE (CONT’D)

Console Removal And Installation

Remove the left joystick. (See Joystick Assembly


Removal And Installation on Page 20-120-3.)

Remove the gas strut. (See Gas Strut Removal And


Installation on Page 40-60-3.)

Figure 40-60-17

Dealer Copy -- Not for Resale


P-86783

Remove the snap ring (Item 1) [Figure 40-60-17] and


washer.

Figure 40-60-18

P-86784

Remove the pin (Item 1) [Figure 40-60-18] and remove


the console.

586 of 879 40-60-6 E80 Service Manual


CENTER COVER

Removal And Installation

Figure 40-70-1

P-86417

Remove the four bolts (Item 1) and the cover (Item 2)


[Figure 40-70-1].

Dealer Copy -- Not for Resale

587 of 879 40-70-1 E80 Service Manual


Dealer Copy -- Not for Resale

588 of 879 40-70-2 E80 Service Manual


CENTER ACCESS COVER

Removal And Installation

Open the cover.

Figure 40-80-1

2
2

P-86813

Dealer Copy -- Not for Resale


Loosen and remove the prop rod (Item 1) from the cover.
Remove the four bolts (Item 2) [Figure 40-80-1] and the
cover.

589 of 879 40-80-1 E80 Service Manual


Dealer Copy -- Not for Resale

590 of 879 40-80-2 E80 Service Manual


COUNTERWEIGHT Figure 40-90-3

Removal And Installation

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

Remove the rear cover. (See Removal And Installation


on Page 40-190-1.)

Figure 40-90-1

P-89559

Disconnect the harness (Item 1) [Figure 40-90-3] from


the motion alarm.
1

Dealer Copy -- Not for Resale


P-89560

Figure 40-90-2

P-89561

Remove the two plugs (Item 1) [Figure 40-90-1] and


[Figure 40-90-2].

591 of 879 40-90-1 E80 Service Manual


COUNTERWEIGHT (CONT’D) Figure 40-90-6

Removal And Installation (Cont’d)

Figure 40-90-4

P-93486

1
Install a lifting device to the lifting chains [Figure 40-90-
P-93537 6].

NOTE: The counterweight weighs 1274 kg (2806 lb).


Figure 40-90-5 Use a lifting device of sufficient capacity.
Raise the hoist until the weight of the

Dealer Copy -- Not for Resale


counterweight is supported by the hoist.
2

1
WARNING
AVOID INJURY OR DEATH
• Use a lifting fixture with sufficient capacity for
the weight of the excavator plus any added
attachments.
• Maintain center of gravity and balance when
lifting.
P-93538
• Do not swing boom or upperstructure. Engage
the upperstructure slew lock.
Install lifting rings (Item 1) and chains (Item 2) [Figure • Never lift with operator on machine.
W-2202-0607
40-90-4] and [Figure 40-90-5].

592 of 879 40-90-2 E80 Service Manual


COUNTERWEIGHT (CONT’D) Figure 40-90-9

Removal And Installation (Cont’d)

Figure 40-90-7

P-89557
1

Remove the bolts (Item 1) [Figure 40-90-7], [Figure 40-


P-89556 90-8] and [Figure 40-90-9].

Installation: Tighten the bolts to 1372 N•m (1010 ft-lb)


Figure 40-90-8 torque.

Dealer Copy -- Not for Resale


Remove the counterweight.

P-89558

593 of 879 40-90-3 E80 Service Manual


Dealer Copy -- Not for Resale

594 of 879 40-90-4 E80 Service Manual


FLOOR MAT

Removal And Installation

Figure 40-100-1

P-86442

Pull up on and remove the floor mat (Item 1) [Figure 40-


100-1].

Dealer Copy -- Not for Resale


For E80 model with articulated boom option:

Figure 40-100-2
Articulated Boom

S37673

Pull up on and remove the floor mat (Item 1) [Figure 40-


100-2].

595 of 879 40-100-1 E80 Service Manual


Dealer Copy -- Not for Resale

596 of 879 40-100-2 E80 Service Manual


FUEL TANK Figure 40-110-3

Removal And Installation

Remove the rear cover. (See Removal And Installation


on Page 40-190-1.)
1
1
Drain the fuel tank.

Open the right side cover.

Figure 40-110-1

1 P-87223

Remove the bolts (Item 1) [Figure 40-110-3] and


reposition the wire harness.

Figure 40-110-4

Dealer Copy -- Not for Resale


P-87221 1

Disconnect the fuel sending unit wire harness (Item 1)


[Figure 40-110-1].

Figure 40-110-2

P-87224

Loosen the hose clamps (Item 1) and remove the hose


(Item 2) [Figure 40-110-4] from the top of the fuel tank.

P-87222

Remove the two bolts (Item 1) [Figure 40-110-2].

597 of 879 40-110-1 E80 Service Manual


FUEL TANK (CONT’D) Figure 40-110-7

Removal And Installation (Cont’d)


2
Figure 40-110-5

P-87229
2

Loosen the hose clamp (Item 1) and remove the fuel


P-87234 supply line (Item 2) [Figure 40-110-7].

Figure 40-110-8
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 40-110-5].

Dealer Copy -- Not for Resale


Figure 40-110-6

1 P-87225

Remove the bolts (Item 1) [Figure 40-110-8] from the


P-87235 tank lifting points.

Remove the bolt (Item 1) [Figure 40-110-6].

598 of 879 40-110-2 E80 Service Manual


FUEL TANK (CONT’D) Figure 40-110-11

Removal And Installation (Cont’d)

Figure 40-110-9

1 1

1 P-87242
1

Figure 40-110-12
P-87226

Install lifting hooks (Item 1) [Figure 40-110-9].


1

Dealer Copy -- Not for Resale


Figure 40-110-10 1

1
1

P-87241

Remove the tank mounting bolts (Item 1) [Figure 40-110-


11] and [Figure 40-110-12].

P-87243

Attach a chain (Item 1) and lifting device (Item 2) [Figure


40-110-10] to the lifting hooks.

599 of 879 40-110-3 E80 Service Manual


FUEL TANK (CONT’D)

Removal And Installation (Cont’d)

Figure 40-110-13

P-87226

Lift the tank high enough to access the bolt (Item 1)


[Figure 40-110-13] on the left side of the fuel tank.

Dealer Copy -- Not for Resale


Remove the bolt.

Remove the fuel tank.

Figure 40-110-14

P-87243

Record the number and location of the shims (Item 1)


[Figure 40-110-14].

600 of 879 40-110-4 E80 Service Manual


HORN

Removal And Installation

Remove the left upperstructure side cover. (See Removal


And Installation on Page 40-20-1.)

Figure 40-120-1

P-86441

Dealer Copy -- Not for Resale


Disconnect the wire harness (Item 1). Remove the bolt
(Item 2) [Figure 40-120-1] and washer.

Remove the horn.

601 of 879 40-120-1 E80 Service Manual


Dealer Copy -- Not for Resale

602 of 879 40-120-2 E80 Service Manual


SWING FRAME Figure 40-130-3

Removal And Installation

Rotate the upperstructure so that the blade is to the rear


of the excavator. 1
2
Remove the boom. (See Removal And Installation on
Page 40-140-1.)

Figure 40-130-1

P-87409

Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-


130-3].

Figure 40-130-4

Dealer Copy -- Not for Resale


1
P-87650

Measure the length of the hoses from the top of the


clamp to the end of each hose [Figure 40-130-1].

Figure 40-130-2

P-87410

Remove the pivot pin (Item 1) [Figure 40-130-4] from the


rod end of the swing cylinder.

1 2 1 1

P-87649

Remove the bolts (Item 1) and the clamp (Item 2) [Figure


40-130-2].

603 of 879 40-130-1 E80 Service Manual


SWING FRAME (CONT'D) Figure 40-130-7

Removal And Installation (Cont’d)

Figure 40-130-5

1
1

P-87655
2

Support the bottom pin [Figure 40-130-7].


P-87653
Figure 40-130-8

Remove the bolts (Item 1) and plate (Item 2) [Figure 40-


130-5].

Dealer Copy -- Not for Resale


Figure 40-130-6

1
2
P-87807
2
Install a porta-power between the top and bottom pins,
and press the top pin out [Figure 40-130-8].
P-87654

Install the boom pin (Item 1) using spacers (Item 2) to


position a lifting strap (Item 3) [Figure 40-130-6] on the
center of the boom pin.

NOTE: The spacers will prevent the strap from


sliding on the boom pin, causing the swing
frame to tip from side to side.

604 of 879 40-130-2 E80 Service Manual


SWING FRAME (CONT'D) Figure 40-130-11

Removal And Installation (Cont’d)

Figure 40-130-9

2 1

1
1 P-87657

Use a large punch (Item 1) [Figure 40-130-11] and drive


P-87374 the bottom swing frame pin out.

Figure 40-130-12
Remove the bolts (Item 1) and plate (Item 2) [Figure 40-
130-9].

Dealer Copy -- Not for Resale


Figure 40-130-10

1
1

P-87659

Remove the top spacer (Item 1) [Figure 40-130-12] from


P-87663 the swing frame.

Install a spacer tube (Item 1) [Figure 40-130-10] and


jack under the swing frame. The spacer tube must be
large enough to allow the pin to be driven into the center
of the spacer for pin removal.

605 of 879 40-130-3 E80 Service Manual


SWING FRAME (CONT'D)

Removal And Installation (Cont’d)

Figure 40-130-13

P-87660

Remove the bottom spacer (Item 1) [Figure 40-130-13]


from the swing frame.

Dealer Copy -- Not for Resale


Remove the swing frame.

606 of 879 40-130-4 E80 Service Manual


SWING FRAME (CONT’D) Figure 40-130-14

Bushing Removal 4
2

1
IMPORTANT
Do Not point (hammer) on the boom swing bracket.
Excess pressure can cause the casting to crack.
I-2095-1195 3

The following parts will be needed for removal and 5


installation of the swing frame bushings:
P-23570

1. Bolt - 19 x 153 mm or (3/4 x 6 in).


Install the spacer (Item 1) and washer (Item 2) [Figure
2. Nut - 19 mm or (3/4 in). 40-130-14] over the flanged end of the bushing.
3. Washer - 22 mm I.D. x 102 mm O.D. x 10 mm thick or The spacer (Item 1) [Figure 40-130-14] must be
(7/8 I.D. x 4-1/64 O.D. x 3/8 in thick). centered over the bushing to avoid contact between the
bushing and the spacer during removal.
4. Washer - 22 mm I.D. x 119 mm O.D. x 10 mm thick or

Dealer Copy -- Not for Resale


(7/8 I.D. x 4-11/16 O.D. x 3/8 in thick). Install the washer (Item 3) [Figure 40-130-14] onto the
opposite end of the bushing. This washer must be
5. Washer - 22 mm I.D. 146 mm O.D. x 13 mm thick or centered on the bushing and must not contact the
(7/8 I.D. x 5-3/4 O.D. x 1/2 in thick). casting.
6. Spacer - 119 mm I.D. x 140 mm O.D. x 38 mm thick Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
or (4-11/16 I.D. x 5-1/2 O.D. x 2 in thick). 130-14] through the washers and the spacer.

Tighten the bolt and nut to remove the bushing from the
casting.

607 of 879 40-130-5 E80 Service Manual


SWING FRAME (CONT’D) Figure 40-130-16

Bushing Installation

Apply a film of grease to the outer diameter of the


bushing and to the inner diameter of the casting.

Center the bushing on the casting hole.

NOTE: Make sure that the bushing is centered into


the casting hole and that it starts in the hole
evenly and square.

Figure 40-130-15

P-23573

Figure 40-130-17
4
1

Dealer Copy -- Not for Resale


2
3

5 P-23571

Put the washer (Item 1) [Figure 40-130-15] over the


flanged end of the bushing.
P-23572
Put the spacer (Item 2) and the washer (Item 3) [Figure
40-130-15] over the bushing hole casting. Center the
spacer and the washer over the bushing hole. The same procedure is used to remove and install the
bushings in the frame castings [Figure 40-130-16] and
Install the bolt (Item 4) through the washers, the spacer [Figure 40-130-17].
and the bushing. Install the nut (Item 5) [Figure 40-130-
15].

Tighten the bolt and nut until the bushing is seated in the
casting.

608 of 879 40-130-6 E80 Service Manual


BOOM

Removal And Installation

Remove the arm. (See Removal And Installation on Page


IMPORTANT
40-150-1.)
When repairing hydrostatic and hydraulic systems,
Remove the boom cylinder. (See Removal And clean the work area before disassembly and keep all
Installation on Page 20-20-4.) parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Remove the articulated boom. (See Removal And damage the system.
I-2003-0888
Installation on Page 40-141-1.) (Optional)

Figure 40-140-1 Figure 40-140-3

1
1

Dealer Copy -- Not for Resale


P-87003 P-87004

Figure 40-140-2 Figure 40-140-4


Articulated Boom Articulated Boom
1
1 1
1

1 1

S37676 S37677

Disconnect the wire harness (Item 1) [Figure 40-140-1] Mark and remove the hoses (Item 1) [Figure 40-140-3]
or [Figure 40-140-2]. or [Figure 40-140-4].

609 of 879 40-140-1 E80 Service Manual


BOOM (CONT’D) Bushing Removal And Installation

Removal And Installation (Cont’d) Figure 40-140-7

Figure 40-140-5

4
1 2 1

P-87084

P-87005
Remove the seals (Item 1) [Figure 40-140-7] from both
sides of the boom.
Remove the hose (Item 1) [Figure 40-140-5] (Both
sides). Remove the bushings from both sides of the boom.

Dealer Copy -- Not for Resale


Remove the nuts (Item 2), bolt (Item 3), and pivot pin Install new bushings in the boom.
(Item 4) [Figure 40-140-5].
Figure 40-140-8
Figure 40-140-6

1 5 mm (0.197 in)
TS-1614A
P-87006

Install the bushings until they are seated 5 mm (0.197 in)


Remove the boom [Figure 40-140-6]. in the pin boss [Figure 40-140-8].

Install new seals on both sides of the boom.

610 of 879 40-140-2 E80 Service Manual


BOOM (ARTICULATED) (OPTIONAL) Figure 40-141-3

Removal And Installation


3
Remove the arm. (See Removal And Installation on Page
40-150-1.)

Figure 40-141-1 1

2
2 1 4

S37808

Mark and remove the hoses (Item 1) [Figure 40-141-3]


(Both sides).

Remove the nuts (Item 2) and bolt (Item 3) [Figure 40-


S37686 141-3] (Both sides).

Dealer Copy -- Not for Resale


Remove the pivot pin (Item 4) [Figure 40-141-3].
Support the articulated boom with a chain hoist (Item 1)
in the articulated boom lifting point, and with a hoist at the Remove the articulated boom.
front of the articulated boom (Item 2) [Figure 40-141-1].

Remove the articulated boom cylinders. (See Removal


And Installation on Page 20-25-3.)

Figure 40-141-2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-87005

Disconnect the wire harness (Item 1) [Figure 40-141-2]


from the boom light (Both sides).

611 of 879 40-141-1 E80 Service Manual


BOOM (ARTICULATED) (OPTIONAL) (CONT’D) Figure 40-141-5

Removal And Installation (Cont’d)

Figure 40-141-4

5 mm (0.197 in)

TS-1614A

1
Install the bushings until they are seated 5 mm (0.197 in)
P-87084 in the pin boss [Figure 40-141-5].

Install new seals on both sides of the articulated boom.


Remove the seals (Item 1) [Figure 40-141-4] from both
sides of the articulated boom.

Dealer Copy -- Not for Resale


Remove the bushings from both sides of the articulated
boom.

Install new bushings in the articulated boom.

612 of 879 40-141-2 E80 Service Manual


ARM Figure 40-150-3

Removal And Installation

Remove the bucket or attachment.

Remove the bucket cylinder. (See Removal And


Installation on Page 20-23-1.)

Remove the arm cylinder. (See Removal And Installation 2


on Page 20-21-3.)
1
Lower the boom / arm and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic P-87025
pressure.

Figure 40-150-1 Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-
150-3].
Articulated Boom
Figure 40-150-4

Dealer Copy -- Not for Resale


1 1

P-87019 S37686

Support the boom with a chain hoist (Item 1) [Figure 40- P-87024
150-1].

Figure 40-150-2 Remove the hydraulic lines (Item 1) [Figure 40-150-4]


(Both sides).

S37809

Support the arm with a chain hoist (Item 1) [Figure 40-


150-2].

613 of 879 40-150-1 E80 Service Manual


ARM (CONT’D) Arm To Boom Bushing Removal And Installation

Removal And Installation (Cont’d) Figure 40-150-7

Figure 40-150-5

2
1

P-87079

P-86891
Remove the seal (Item 1) and bushing (Item 2) [Figure
40-150-7] from both sides of the arm.
Remove the pivot pin (Item 1) [Figure 40-150-5].
Install the new bushings in the arm.

Dealer Copy -- Not for Resale


Figure 40-150-6
Figure 40-150-8

P-86893 5 mm (0.197 in)


TS-1614A

Remove the arm (Item 1) and shims (Item 2) [Figure 40-


150-6]. Install the bushings until they are seated 5 mm (0.197 in)
in the pin boss [Figure 40-150-8] (Both sides).

Install new seals on both sides of the arm.

614 of 879 40-150-2 E80 Service Manual


ARM (CONT’D) Figure 40-150-11

Bucket And Link Bushing Removal And Installation

Figure 40-150-9

5 mm (0.197 in)
TS-1614A

2
Install the bushings until they are seated 5 mm (0.197 in)
P-87081 in the pin boss [Figure 40-150-11] (Both sides).

Figure 40-150-10

Dealer Copy -- Not for Resale


1

P-87080

Remove the seals (Item 1) and bushings (Item 2) [Figure


40-150-9] and [Figure 40-150-10] from both sides of the
arm.

Install the new bushings in the arm.

615 of 879 40-150-3 E80 Service Manual


Dealer Copy -- Not for Resale

616 of 879 40-150-4 E80 Service Manual


QUICK COUPLER (KLAC SYSTEM™)

Troubleshooting

PROBLEM CAUSE CORRECTION


Coupler does not seat properly on the Mud, dirt, stones or debris are lodged Remove mud, dirt, stones and debris
attachment mounting frame. between the coupler and the from between the coupler and the
attachment mounting frame. attachment mounting frame.
Worn locking mechanism. Repair or replace worn pins and
locking mechanisms.
Attachment mounting frame damaged. Repair or replace the attachment
mounting frame.

Daily Inspection

Figure 40-160-1

Dealer Copy -- Not for Resale


1

P-72274

Inspect the quick coupler for wear or damage. Inspect the


quick locking shaft (Item 1) and the hooks (Item 2)
[Figure 40-160-1] (on the attachment) for wear or
damage.

Repair or replace damaged parts.

617 of 879 40-160-1 E80 Service Manual


QUICK COUPLER (KLAC SYSTEM™) (CONT’D) Figure 40-160-3

Removal And Installation

Figure 40-160-2
Unlatched Position Latched Position

P-72283

Install the tool (Item 1) [Figure 40-160-3] in the quick


P-72272 P-72272 coupler as shown. Push down on the tool until the latch
snaps closed.

Remove the attachment.

Dealer Copy -- Not for Resale


The quick coupler must be in the latched position (Item 1)
[Figure 40-160-2] for disassembly.

Inspect the quick coupler to make sure the latch is in the


latched position.

If the latch is in the unlatched position, see [Figure 40-


160-3] for additional information.

If the latch is in the latched position, proceed to [Figure


40-160-4].

WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
latching and unlatching the attachment quick
coupler.
W-2541-1106

618 of 879 40-160-2 E80 Service Manual


QUICK COUPLER (KLAC SYSTEM™) (CONT’D) Figure 40-160-5

Removal And Installation (Cont’d)

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist: 1
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-72269
W-2019-0907

Remove pins (Item 1) [Figure 40-160-5].


Figure 40-160-4
Figure 40-160-6

Dealer Copy -- Not for Resale


P-72270 1
P-72265

Remove the bolts (Item 1) [Figure 40-160-4] and nuts.


Raise the arm and bucket link until the coupler is free
Installation: Align the holes of the connecting pins with [Figure 40-160-6].
the holes in the coupler. Install the two bolts (Item 1)
[Figure 40-160-4] and nuts. Tighten the nuts securely Installation: Align the arm and bucket link with the
against the couple. coupler [Figure 40-160-6]. Lower the arm and bucket
link into the coupler.

NOTE: Place the coupler on the ground with the


mounting pin (Item 1) [Figure 40-160-6] facing
towards the excavator.

619 of 879 40-160-3 E80 Service Manual


QUICK COUPLER (KLAC SYSTEM™) (CONT'D)

Parts Identification

1. Coupler Body
2. Spring
3. Locking Plate
4. Tool

4
2

Dealer Copy -- Not for Resale

P-88398

620 of 879 40-160-4 E80 Service Manual


QUICK COUPLER (KLAC SYSTEM™) (CONT’D) Figure 40-160-8

Disassembly
1

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present.
• Engine is running. 1
• Tools are being used. P-72284
W-2505-0604

Remove the spring end hook (Item 1) [Figure 40-160-8]


Figure 40-160-7
from the quick coupler.
2 1 3
Figure 40-160-9

Dealer Copy -- Not for Resale


2
3 1

1
P-72285

The two springs (Item 1) [Figure 40-160-7] have different P-72294


style of end hooks.
Remove the opposite end of the two springs (Item 1)
The spring hook (Item 2) [Figure 40-160-7] are full circle
[Figure 40-160-9].
hooks.

The spring hook (Item 3) [Figure 40-160-7] are partial


circle hooks.

The spring ends must be positioned as shown when


assembled.

621 of 879 40-160-5 E80 Service Manual


QUICK COUPLER (KLAC SYSTEM™) (CONT’D)

Disassembly (Cont’d)

Figure 40-160-10

1 1

P-72295

Remove the two roll pins (Item 1) [Figure 40-160-10].


Drive the roll pins inwards to remove.

Dealer Copy -- Not for Resale


Figure 40-160-11

P-72296

Remove the latch (Item 1) [Figure 40-160-11].

622 of 879 40-160-6 E80 Service Manual


QUICK COUPLER (KLAC SYSTEM™) (CONT’D) Figure 40-160-14

Assembly

Figure 40-160-12

P-72294
1

Install the partial circle hook end of the spring [Figure 40-
P-72296 160-14].

Figure 40-160-15
Install the latch (Item 1) [Figure 40-160-12].

Dealer Copy -- Not for Resale


Figure 40-160-13 1

2 1
1
P-72284

P-72295 Install the full circle end of the spring hook (Item 1)
[Figure 40-160-15] on the quick coupler.

Install the two roll pins (Item 1) [Figure 40-160-13]. Drive Do not lubricate the quick coupler. Lubrication will cause
the roll pins inwards until the roll pins are flush with the dirt to collect and interfere with proper movement of the
outside edge of the quick coupler. quick coupler.

623 of 879 40-160-7 E80 Service Manual


Dealer Copy -- Not for Resale

624 of 879 40-160-8 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®)

Troubleshooting

PROBLEM CAUSE CORRECTION


Coupler does not seat properly on the Mud, dirt, stones or debris are lodged Remove mud, dirt, stones and debris
attachment mounting frame. between the coupler and the from between the coupler and the
attachment mounting frame. attachment mounting frame.
Worn locking mechanism. Repair or replace worn pins and
locking mechanisms.
Attachment mounting frame damaged. Repair or replace the attachment
mounting frame.

Daily Inspection

Figure 40-161-1

(MS03 & MS08)

Dealer Copy -- Not for Resale


2

P-88183

Inspect the quick coupler for wear or damage. Inspect the


the hooks (Item 1) and coupler locking shaft (Item 2)
[Figure 40-161-1] (on the attachment) for wear or
damage.

Repair or replace damaged parts.

625 of 879 40-161-1 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) Figure 40-161-4

Removal (MS03 And MS08)

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-88000
W-2019-0907

Raise the arm and bucket link until the quick coupler is
Figure 40-161-2 free [Figure 40-161-4].

2
2

Dealer Copy -- Not for Resale


1

1
1

P-88003

Remove the four nuts (Items 1). Remove the two bolts
(Item 2) [Figure 40-161-2].

Figure 40-161-3

1
P-88001

Remove the two connecting pins (Item 1) and O-rings


(Item 2) [Figure 40-161-3].

626 of 879 40-161-2 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) Figure 40-161-7

Installation (MS03 And MS08)


1
Figure 40-161-5 1

2
2

P-88003

1 Install the two bolts (Item 1) [Figure 40-161-7].


P-88000
Install nuts (Item 2) [Figure 40-161-7] just until contact is
made with the coupler.
Place the coupler on the ground with the hooks (Item 1)
[Figure 40-161-5] facing towards the excavator. NOTE: Do Not tighten nuts (Item 2) [Figure 40-161-7]
against the coupler. The retaining bolt must

Dealer Copy -- Not for Resale


Align the arm and bucket link with the coupler [Figure rotate freely.
40-161-5].
Install and tighten nuts (Item 3) securely against the two
Figure 40-161-6 nuts (Item 2) [Figure 40-161-7]. The retaining bolts must
rotate freely.
2

3
P-88001

Install the O-rings (Item 1) [Figure 40-161-6] between


the coupler pivot point and the arm and bucket link when
lowering into position.

NOTE: The O-rings will prevent dirt and debris from


entering the pivot points of the coupler.

Align the holes of the connecting pins with the holes


(Item 2) [Figure 40-161-6] in the coupler.

Install the two pins (Item 3) [Figure 40-161-6] through


the coupler, arm and bucket link.

627 of 879 40-161-3 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT'D)

Parts Identification (MS03)

1. Bolt
2. Lock Washer
3. Coupler Housing
4. Pressure Spring
5. Locking Mechanism 1

Dealer Copy -- Not for Resale


4

P-88114

628 of 879 40-161-4 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D)

Disassembly And Assembly (MS03)

Figure 40-161-8

P-88004

Remove the two bolts (Item 1) [Figure 40-161-8] and


lock washers.

Dealer Copy -- Not for Resale


Figure 40-161-9

P-88005

Turn the threaded spindle (Item 1) counterclockwise until


the locking mechanism (Item 2) [Figure 40-161-9] is free
from the housing.

629 of 879 40-161-5 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT'D)

Parts Identification (MS08)

1. Housing
2. Bushing
3. Bushing
4. O-ring
5. Cover
6. O-ring
7. O-ring 1
8. Reversing Lever
9. Threaded Pin
10. Pressure Spring 2
11. Pin
12. Pivoting Journal
13. Spring Washer
14. Bolt
15. Bearing Block 26 3
16. Locking Pin
4
17. Pressure Spring
18. Thrust Journal 3
19. Pin 25
20. O-ring 24
21. Driving Fork

Dealer Copy -- Not for Resale


22. Control Shaft
23. Bolt
24. Snap Ring 5
25. Bushing
6
26. Bushing
7
23
22
8
9

21 10 11
20
19
12
20 17
19 18

16
15 13

14

P-88115

630 of 879 40-161-6 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) NOTE: Do not scratch the mounting surface while
removing sealant.
Disassembly (MS08)
Figure 40-161-12

WARNING 1

AVOID INJURY OR DEATH


Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

P-88010
Figure 40-161-10

Remove the two bolts (Item 1) [Figure 40-161-12].


2
Figure 40-161-13

Dealer Copy -- Not for Resale


1

P-88009

2
Remove the eight bolts (Item 1) and cover (Item 2)
[Figure 40-161-10].
P-88011

Figure 40-161-11
Tilt the bearing block and pivoting journal (Item 1) up and
1 remove from the spring guide (Item 2) [Figure 40-161-
13].

P-88122

Remove all sealant (Item 1) [Figure 40-161-11] from the


housing and cover.

631 of 879 40-161-7 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) Figure 40-161-16

Disassembly (MS08) (Cont’d)

Figure 40-161-14

1
P-88013

Remove the snap ring (Item 1) [Figure 40-161-16].


P-88012
Figure 40-161-17

Remove the pivoting journal (Item 1) [Figure 40-161-14]


from the bearing block.

Dealer Copy -- Not for Resale


Figure 40-161-15

2
1

P-88014

NOTE: Before removing the control shaft, note the


position of each of the components so that
when the coupler is reassembled all
P-88017
components are positioned correctly on the
control shaft [Figure 40-161-17].
Remove the pressure spring (Item 1) from the spring
guide (Item 2) [Figure 40-161-15].

632 of 879 40-161-8 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) Figure 40-161-20

Disassembly (MS08) (Cont’d)


4
Figure 40-161-18
1

1
3
2

P-88018

Remove the snap ring (Item 1) and pin (Item 2). Remove
the spring guide (Item 3) from the driving fork (Item 4)
P-88015
[Figure 40-161-20].

Remove the control shaft (Item 1) [Figure 40-161-18]. Figure 40-161-21

Figure 40-161-19

Dealer Copy -- Not for Resale


1

P-88019

P-88016
Remove the locking pin assemblies [Figure 40-161-21].

Remove O-rings (Item 1) [Figure 40-161-19].

633 of 879 40-161-9 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D)

Disassembly (MS08) (Cont’d)

Figure 40-161-22

3
4 6

5
2 1

P-88021

Remove the snap ring (Item 1) and pin (Item 2). Remove
the driving fork (Item 3) [Figure 40-161-22].

Dealer Copy -- Not for Resale


Remove the snap ring (Item 4) and pin (Item 5). Remove
the reversing lever (Item 6) [Figure 40-161-22].

Repeat the procedure for the other locking pin.

Figure 40-161-23

2 3

P-88022

Remove the bushing (Item 1), O-ring (Item 2) and


bushing (Item 3) [Figure 40-161-23] from both locking
pin bores.

634 of 879 40-161-10 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) Figure 40-161-26

Assembly (MS08)

Figure 40-161-24

2 1

P-88019

3
Install the locking pin assemblies [Figure 40-161-26].
P-88022
NOTE: Position the locking levers with the flat side
down and away from the cover.
Install bushing (Item 1), O-ring (Item 2) and bushing (Item
3) [Figure 40-161-24] in both locking pin bores. Figure 40-161-27

Dealer Copy -- Not for Resale


Figure 40-161-25
1

4 3

3 1

4
2
2
5 6 P-88018

P-88021
Install the driving fork (Item 1), pin (Item 2) and snap ring
(Item 3) on the spring guide (Item 4) [Figure 40-161-27].
Install reversing lever (Item 1), pin (Item 2) and snap ring
(Item 3) [Figure 40-161-25] on the locking pin.

Install the driving fork (Item 4), pin (Item 5) and snap ring
(Item 6) [Figure 40-161-25] on the reversing lever.
Repeat the procedure for the other locking pin.

635 of 879 40-161-11 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) Figure 40-161-30

Assembly (MS08) (Cont’d)

Figure 40-161-28

P-88023

Install the control shaft through the first locking lever


P-88016 driving fork (Item 1) [Figure 40-161-30].

Figure 40-161-31
Install the O-rings (Item 1) [Figure 40-161-28].

Figure 40-161-29

Dealer Copy -- Not for Resale


1

P-88024

P-88015 Install the control shaft through the spring guide driving
fork (Item 1) [Figure 40-161-31].

Install the control shaft (Item 1) [Figure 40-161-29].

636 of 879 40-161-12 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D) Figure 40-161-34

Assembly (MS08) (Cont’d)

Figure 40-161-32

1 P-88011

Install pressure spring (Item 1) on the spring guide. Tilt


P-88025 the bearing block and pivoting journal (Item 2) [Figure
40-161-34] down and install on the spring guide.

Install the control shaft through the second locking lever Figure 40-161-35
driving fork (Item 1) [Figure 40-161-32].

Dealer Copy -- Not for Resale


NOTE: Check proper alignment of all three driving
forks on the control shaft. If not aligned 1
properly, repeat the procedure.

Figure 40-161-33

P-88010

1
Install the two bolts (Item 1) [Figure 40-161-35].

P-88013

Install the snap ring (Item 1) [Figure 40-161-33].

637 of 879 40-161-13 E80 Service Manual


QUICK COUPLER (LEHNHOFF SYSTEM®) (CONT’D)

Assembly (MS08) (Cont’d)

Figure 40-161-36

P-88026

Apply a bead of sealant around the cover mounting


surface (Item1) [Figure 40-161-36].

Dealer Copy -- Not for Resale


Figure 40-161-37

P-88009

Install the cover (Item 1) [Figure 40-161-37].

Apply Loctite® 242 on the eight bolts.

Install the eight bolts (Item 2) [Figure 40-161-37].

638 of 879 40-161-14 E80 Service Manual


BUCKET Figure 40-170-2

Bucket Teeth Removal And Installation

WARNING 1

Wear safety glasses to prevent eye injury when any


of the following conditions exist:
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-87320
W-2505-0604

Use a punch and a hammer and drive the retainer pin


Position the bucket at a 30° angle up from the ground so
(Item 1) down and out the bottom of the tooth (Item 2)
that the bucket teeth are easily accessible. Install a block
[Figure 40-170-2]. Remove the tooth from the shank.
under the bucket.
Figure 40-170-3
Lower the boom until the bucket is fully on the ground
and resting on the block.

Dealer Copy -- Not for Resale


Stop the engine and exit the excavator. 2

Figure 40-170-1 1

1
P-87316

Remove the rubber retainer (Item 1) from the shank (Item


2) [Figure 40-170-3].
3
P-87315 Installation: Install the rubber retainer (Item 1) into the
tooth shank (Item 2) [Figure 40-170-3].
The bucket tooth (Item 1) has a unique retaining pin (Item
Position the new tooth point (Item 2) [Figure 40-170-2]
2) and rubber retainer (Item 3). The retaining pin (Item 2)
on the shank (Item 2) [Figure 40-170-3].
must be installed as shown, with the notch towards the
rubber retainer (Item 3). The rubber retainer (Item 3)
Install the retainer pin (Item 1) [Figure 40-170-3] until it is
[Figure 40-170-1] will be installed into the shank before
flush with the top of the tooth.
the tooth is installed on the shank.

639 of 879 40-170-1 E80 Service Manual


BUCKET (CONT’D)

Bucket Side Cutting Edge Removal And Installation

Figure 40-170-4

P-87323

Remove the three nuts (Item 1) and bolts. Remove the


cutting edge (Item 2) [Figure 40-170-4].

Dealer Copy -- Not for Resale

640 of 879 40-170-2 E80 Service Manual


RIGHT SIDE COVER Figure 40-180-3

Removal And Installation

Remove the center access cover. (See Removal And


Installation on Page 40-80-1.)
2
Remove the center cover. (See Removal And Installation
on Page 40-70-1.)

Open the right side cover. (See Opening And Closing on


Page 10-50-1.)
1
Figure 40-180-1

P-87198

1 Figure 40-180-4

Dealer Copy -- Not for Resale


P-87197
1
Figure 40-180-2

P-87196

Remove the clip (Item 1) and washers (Item 2) [Figure


40-180-3] and [Figure 40-180-4] from the bottom of the
1 gas strut.

2 Support the cover and remove the gas strut.

Close the right side cover.

P-87021

Remove the clip (Item 1) and washer (Item 2) [Figure 40-


180-1] and [Figure 40-180-2] from the top of the gas
strut.

641 of 879 40-180-1 E80 Service Manual


RIGHT SIDE COVER (CONT’D) Figure 40-180-7

Removal And Installation (Cont’d)

Figure 40-180-5

1
2

P-87203
1

Figure 40-180-8
P-87200

Figure 40-180-6

Dealer Copy -- Not for Resale


1

2
P-87202

1
Remove the front and rear hinge pins (Item 1) [Figure
P-87201 40-180-7] and [Figure 40-180-8].

Remove the cotter pin (Item 1) and washer (Item 2)


[Figure 40-180-5] and [Figure 40-180-6] from the front
and rear hinge pins.

642 of 879 40-180-2 E80 Service Manual


RIGHT SIDE COVER (CONT’D) Latch Adjustment

Removal And Installation (Cont’d) Figure 40-180-10

Figure 40-180-9

1
1
2

1
P-86943

P-87204
Loosen the nut (Item 1) and adjust the latch (Item 2)
[Figure 40-180-10]. Tighten the nut after the adjustment
Remove the spacers (Item 1) [Figure 40-180-9]. is made.

Close the right side cover before operating the excavator.

Dealer Copy -- Not for Resale


Remove the cover.

643 of 879 40-180-3 E80 Service Manual


Dealer Copy -- Not for Resale

644 of 879 40-180-4 E80 Service Manual


REAR COVER Figure 40-190-3

Removal And Installation

Remove the center access cover. (See Removal And


1
Installation on Page 40-80-1.)

Remove the center cover. (See Removal And Installation


on Page 40-70-1.)

Tilt the cab. (See Tilting The Cab on Page 10-210-1.)

Figure 40-190-1

P-87207

Remove the bolt (Item 1) [Figure 40-190-3] from the


upper right side of the rear cover.

Figure 40-190-4

Dealer Copy -- Not for Resale


P-87205

Remove the bolt (Item 1) [Figure 40-190-1] from the


lower left side of the rear cover.
1
Figure 40-190-2

P-92769

Remove the bolt (Item 1) [Figure 40-190-4].


1
Remove the rear cover.

P-87206

Remove the bolt (Item 1) [Figure 40-190-2] from the


lower right side of the rear cover.

645 of 879 40-190-1 E80 Service Manual


Dealer Copy -- Not for Resale

646 of 879 40-190-2 E80 Service Manual


ELECTRICAL SYSTEM & ANALYSIS

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1


Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5
Alternator Regulator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-7

Dealer Copy -- Not for Resale


Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-9

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

CONSOLE LOCKOUT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1


Testing / Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2

FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

DIAGNOSTIC SERVICE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1


Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Flashing Patterns Of Engine Check Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-4

DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1


Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Code Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-6

647 of 879 50-01 E80 Service Manual


INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1

RIGHT CONSOLE SWITCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Rocker Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-2
Speed Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-3
Engine Emergency Stop Switch Removal And Installation . . . . . . . . . . . . . . . . . . . 50-120-3
Auxiliary Power Outlet Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-4

WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

MOTION ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2

Dealer Copy -- Not for Resale


FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

AUTO IDLE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

648 of 879 50-02 E80 Service Manual


RED ADDITIONAL WORKING LIGHT (OPTION)
1 RED/BLU

WIRING SCHEMATIC W/T GAUGE +


W -
U 2 YEL/BLU WATER TEMP SENDER
WORKING LIGHTS
(R) BLK

ADD. WORKING
RED
E80 (S/N AETB11001 AND ABOVE) FUEL GAUGE +
U 3 YEL/RED BLK
FUEL SENDER (L) BLK 87a
LIGHT RELAY LIGHT RELAY
87a
F - YEL
BLU/BLK YEL 30
(S/N AET311001 AND ABOVE) BACK LIGHTS 4 WHT/RED RED RED 87
30
87 RED/GRN
BLK/YEL E/G OIL PRESS SWITCH (R)
L17 L18 BLK BLK
5 0.85B BLK 85 86 LGN LGN 86 85 BLK
(PRINTED FEBRUARY 2011) PILOT BUZZER
BLK HEAD LIGHTS
WATER SEPARATOR RED
V-1316 WATER SEPARATOR 11
(L)
0
L16 BLK WHT/RED 2 RNG SPEAKER
6 6 I
AIR CLEANER BLK/WHT BLK INDICATOR -
Printable Version Click Here FUEL EMPTY
L3
7
+ 3 II
ANTENNA
(LH) (RH)
L5 BLK 10 9 WHT/RED
RED/BLU
9 + - + -
ENG OIL PRESS BLK/YEL 4 27 RED/BLU WHT/RED
BLK = BLACK L2 LIGHT SWITCH WHT/RED 3 8 GRY/RED
WATER TEMP. 10 BLU/BLK 5 1 GRN/YEL RADIO
BLU = BLUE
L6 GRN/YEL 18
BRN = BROWN BLK/YEL
CONTROL UNIT 2 RED/WHT
DBL = DARK BLUE CAR STEREO 1 GRY/BLU
8 RED/BLK RADIO SWITCH
DGN = DARK GREEN CHARGE 3
L1 (OPTION) 9 BLK/WHT
GRN = GREEN OVER LOAD 13 GRY/RED 9 10 0 7
GRY = GRAY L15 GRY 5
NOT USED 14 LGN 11 22 YEL/RED I 1 BLU/WHT 4 CD PLAYER
LBL = LIGHT BLUE L13
LGN = LIGHT GREEN PREHEAT 15 BLU/WHT 9 10 BLK (OPTION)
PNK = PINK L4 14 BLK
HIGH SPEED 16 YEL/RED 20
PUR = PURPLE L7 11
RED = RED ENGINE WARNING 20 BLK/WHT 6 BRN KET 18P
L12 + WHT/BLU 5
RNG = ORANGE WORKING LIGHT 18 RED 7 BRN/WHT CN4
TAN = TAN L11 AMP 040 28P SIG
21 BLK/RED 14 8 BLK/WHT
WHT = WHITE LCD TACH CN1 -
CAB LIGHT

WHT/RED
RED/GRN
YEL = YELLOW

BLU/WHT
BLU/RED

RED/BLU
PRESSURE SENSOR (OWD) HEATED SEAT (OPTION)
28 WHT/BLU B 10W E BLK
GAUGE PANEL

GRN
BLU
YEL
BRN

BLU/RED + BLK
7 0
5 1 2 3 4 5 6 7 8
BLK 28
OVER LOAD BLK 1 I 10A 10A 10A 10A 10A 10A 10A 10A
SEAT HEATER
10 9 WHT/RED
WARNING 15 16 17 WHT
WINDOW WASHER 0
1 BLU (OWD) OVER LOAD WARNING RED/WHT FUEL FEED PUMP BRN BRN
BLU/BLK BLU/BLK 5 I (OWD)SWITCH STARTER RELAY
FUSE BLOCK RED/BLU - +

DIODE 1
10 9 WHT/RED BLK BLU/RED
+
BLK
RED/BLU P 85 87 YEL
DIODE 6

P 17 BLU/WHT L WHT
WASHER SWITCH 86 30
18 S WHT BLK/YEL BLK/YEL WHT
- YEL
BLK BLK + 18 19 20 WHT/RED

ORN/WHT

BLU/WHT
BLK/WHT
WIPER SWITCH

BLU/BLK
STOP M 15A 15A 20A 20A 20A 30A
0
BLK D PP BLU BLK
15 BLU/RED 6 I 2 BLU B RUN -
9 10 11 12 13 14 STARTER
16 BLU/YEL 3 II SWITCH
ACC
C C B WHT WHT
10 9WHT/RED DIODE 5 AIR HEATER

WHT/RED

WHT/BLU
WIPER MOTOR E

RED/BLU
45A

BLU/BLK
ENG CONTROL DIAL BLK
22

12

23
BLK
2
WHT/RED R2
PREHEAT RELAY

WHT
FUSIBLE LINK 2

BLU
1 GRN/RED 38 B
LOW CW +5V
FUEL PUMP BRN
2 GRN 35 BLU
SIG BR
3 GRN/BLK WHT/RED WHT/BLU + - BLK R1
HIGH
06 LGN/YEL
P STARTER C

105D ECU
RNG/BLU 16 AUTO IDLE PRESSURE SWITCH BLK/GRN
(Electronic B
GRN/BLK Control Unit) LGN/WHT BLK GRN/ BLK/WHT RED
17 7 0
5 YEL
WATER TEMP. SENSOR BLK 1 I
30bar
30 10 9 WHT/RED
CAN
FUEL INJECTION PUMP 120ohm CAN-L 39 BLK 03 CHECKER RED/BLU 1 3 RED/WHT RED/WHT
CAN-H 40 WHT 02 04 AUTO IDLE SELECT SWITCH BLK 2 A
BLK
2 BLU/RED 19 01 POWER PLUG
ENGINE
HOUR METER
SPEED 1 BLU/GRN 18 WHT/RED 12V 2.3KW
SENSOR GND-RPM BLK
BLK/YEL BLK
08
COLD START DEVICE COIL (STARTING) - RED/BLU RED
YEL/BLK 41 44 BLK/GRN WHT/RED
(PRE-HEAT)
(ACC)
07 BLU/RED Dealer Copy -- Not for Resale + HORN RELAY
27A
FUSIBLE LINK 1
CN5-1 YEL/RED 20 BRN WHT HORN
(STARTER RELAY) 87a
34 GRN/BLK YEL/RED BLU/WHT 30
YEL/GRN BLU/RED 87 RED/BLK

DIODE 8
CN5-2 42 24
(Neutral)
0 7 TWO SPEED BLK
CN5-5 RED/BLU 43 5 BLU/WHT GRN 86 85 BLK
RACK RELAY WHT/RED SOLENOID
CN5-4 PNK/GRN 36 I 1 YEL/RED
VALVE CIRCUIT BREAKER BATTERY RELAY
87a WHT/RED 9 10 BLK HORN SWITCH
CN5-6 GRN/BLK 28 RED/ MAIN RELAY
GND-A BLK (ON L.H. JOYSTICK) B A
30 WHT WHT
RACK ACTUATOR 87 87a ONE WAY FLOW RELAY
RNG/ TWO SPEED SWITCH 87a
WHT/ 30 RNG BLK
BLK 85 86 RED BRN/WHT BR
33 87 BLU/WHT 30 ONE WAY FLOW
87 RED/BLU
NC SOLENOID VALVE BLK E
85 86 CONSOLE LOCKOUT
CN6-2 RED/BLK 48 1 YEL C BLU/WHT 86 85 BLK
SOLENOID VALVE BRN/WHT RED
RED/GRN YEL/GRN
A BLU/GRN 3 BLK NO (Pilot Cut Off)
CN6-1 YEL/GRN 01 13
ONE WAY FLOW SWITCH 0.85B
B CN6-4 YEL/BLU 11 9 BLK CONSOLE LOCKOUT (ON R.H. JOYSTICK)
EMERGENCY OFF SWITCH

DIODE 9
A CN6-3 YEL/RED 21 FCI 48P 47 BLK
STOP SWITCH (Pilot Cut Off) BLK
B CN6-6 RED 31 CN3 45 BLK BLK
CN6-5 RED/BLK
ROTATING SW
YEL/RED (ON JOYSTICK L.H)
QUICK CLAMP (Not Available Option) - +
EGR VALVE RED/BLK RED/BLK BLU/WHT 43E YEL/RED 12V 100AH
(R.H)
(Exhaust Gas
0.85LB (R.H)
Recirculation) 7 0 BATTERY
5 31B
0.85LR
11 WHT/RED 57B 0.85LB 57A 1 I
(L.H) 0.85B WHT
13 9 60L 0.85WR
LED GRN/YEL 10 BLU/WHT 43F YEL/BLU (L.H)
22 WHT/BLU 0.85B
RED/WHT
BLU 0.85B
REAR ACTUATOR QUICK CLAMP SWITCH
0.85B WHT
OPEN 2 GRY/GRN 18 10
SECOND AUXILIARY HYDRAULIC
CLOSE 3 GRY/YEL 19
M COMPRESSOR IG L P B(BATT)
MOTION ALARM (OPTION)
RELAY
RECEIVER DRIER
87a ROTATING BEACON (OPTION)
FACE ACTUATOR LOW PRESS HIGH PRESS
30 MOTION ALARM SWITCH
RNG/RED CUT OFF CUT OFF
OPEN 2 RNG 20 87 BLK/WHT PRESS SWITCH
7 0 5 0 7
BEACON BLU/RED BLU/RED 5
CLOSE 3 RNG/YEL 21 RED 1 I I 1 LGN/RED LGN/BLK LGN/BLK + IG
M RED/BLK 86 85
BLU/WHT 9 9
A/C CONTROL PANEL BLK BLK 10 WHT/RED WHT/RED 10 BLK -

DIODE 4
9 YEL/GRN COMPRESSOR
BUZZER L
AIRCON UNIT BEACON SWITCH
FOOT ACTUATOR F
6 E
FOOT 2 GRN/WHT 6 THERMOSTAT
DIODE 7

DEF. 3 GRN 7
M
RED/BLU 5 ALTERNATOR E
BLK
BLOWER RESISTOR
STARTER SWITCH CONNECTION 12V 60A
BLK 4
+ - HRS NO.GT7A-26PD-DS 26P AMP 040 28P
M BLK TML B BR R1 R2 C ACC
PST
22 21 20 19 18 17 8 7 6 5 4 3 2 1
OFF
13 12 11 2 1
RED RNG YEL 10 9 8 7 6 5 4 3
ON
WARM 4 LGN/WHT 14 26 25
28 27 26 25 24 23 16 15 14 13 12 11 10 9
2 1 3 24 23 22 21 20 19 18 17 16 15 14
START
COOL 6 LGN/BLK 15 BLU BLU
M (CN2) (CN1)
3 YEL/RED 2
1 YEL/WHT 16 86 87 87a 86 87 87a 86 87 87a
2 BLK 1

BLOWER RELAY
8 7 6 5 4 3 2 1 47 48
31 32 33 34 35 36 37 38 39 40
WATER VALVE ASS'Y 18 17 16 15 14 13 12 11 10 9
85 30 85 30 85 30 21 22 23 24 25 26 27 28 29 30
45 46

43 44
(CN4) 11 12 13 14 15 16 17 18 19 20
3 BLU/BLK (HI)
26 41 42
BLK HRS 26P 5 BLU/YEL (MID) 1 2 3 4 5 6 7 8 9 10

CN2 8 BLU/WHT (LOW)


BLU BLU BLU
649
Printed of 879
in Europe V-1316 (2-27-11)
(CN3)
ELECTRICAL SYSTEM INFORMATION

Troubleshooting Chart

The following troubleshooting chart is provided for


WARNING
assistance in locating and correcting the most common
AVOID INJURY OR DEATH
problems.
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807

PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9

Dealer Copy -- Not for Resale


KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

650 of 879 50-10-1 E80 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Location / Identification

Description A decal is on the cover to show location and amp ratings.

Figure 50-10-1 Remove the cover to check or replace the fuses.

Figure 50-10-2

1 1 2 3 4 5 6 7 8

9 10 11 12 13 14

P-86276

B-23955
The excavator has a 12 volt, negative ground electrical
system. The electrical system is protected by fuses

Dealer Copy -- Not for Resale


located below the operator’s seat (Item 1) [Figure 50-10- The fuse locations and sizes are shown below and in
1]. [Figure 50-10-2].

The fuses will protect the electrical system when there is REF DESCRIPTION AMP
an electrical overload. The reason for the overload must 1 Warning Light, Motion Alarm 10
be found before starting the engine again. 2 Two Speed, Console Lock, Cab Light 10
3 Wiper, Washer 10
The battery cables must be clean and tight. Check the 4 Stereo, ECU, Air Conditioning Control Panel 10
electrolyte level in the battery. Add distilled water as 5 Instrument Panel 10
needed. Remove acid or corrosion from the battery and 6 Horn, Breaker Switch, Beacon / Strobe Light 10
cables with a sodium bicarbonate and water solution. 7 EGR Valve 10
8 Starter 10
Put Battery Saver P/N 6664458 or grease on the battery 9 Can Checker 15
terminals and cable ends to prevent corrosion. 10 Power Plug 15
11 Condenser Fan, Compressor Clutch 20
12 Air Conditioner / Heater 20
13 Fuel Pump, Hour Meter 20

WARNING 14 Work Light, Boom Light 30

AVOID INJURY OR DEATH


Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.


In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities


of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

651 of 879 50-10-2 E80 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 50-10-4

Fuse And Relay Location / Identification (Cont’d)

Figure 50-10-3
1 2 3 4 5 6 7 8 9 10

11 12

2 P-86246

3 The relays are shown in [Figure 50-10-3] and [Figure


P-86907 50-10-4] and in the below chart. The relays are located
behind the access panel that is located behind the
operator’s seat.
A 60 amp circuit breaker (Item 1) and two fusible links
(Item 2) 27 amp and (Item 3) 45 amp [Figure 50-10-3] REF DESCRIPTION

Dealer Copy -- Not for Resale


are located under the front center cover. 1 Breaker Switch
2 Horn
The 27 amp fusible link (Item 2) is for the start circuit and 3 Lights (Boom)
the 45 amp fusible link (Item 3) [Figure 50-10-3] is for the 4 Blower (3) (High)
pre-heat circuit. 5 Blower (2) (Med)
6 Blower (1) (Lo)
7 Compressor
8 Additional Lights (Cab Work Lights)
9 Rack (Speed Control)
10 Main
11 Pre-Heat
12 Starter

NOTE: Relays (Item 11 and 12) [Figure 50-10-3] are


located under the center cover.

652 of 879 50-10-3 E80 Service Manual


Dealer Copy -- Not for Resale

653 of 879 50-10-4 E80 Service Manual


BATTERY Figure 50-20-2

Servicing

Open the right side cover. (See Opening And Closing on


Page 10-50-1.)

Figure 50-20-1

P9589 P9590

1 1 The battery cables must be clean and tight. Remove acid


2
or corrosion from the battery and cables using a sodium
bicarbonate and water solution. Cover the battery
terminals and cable ends with battery saver grease to
P-92919 prevent corrosion [Figure 50-20-2].

Dealer Copy -- Not for Resale


Check for broken or loose connections.
The battery is located in the right front corner of the
machine. If the battery cables are removed for any reason,
disconnect the negative (-) cable first. When installing the
Remove the two bolts and washers (Item 1), the retaining battery cables, connect the negative (-) cable to the
plate (Item 2) [Figure 50-20-1]. battery last.

The original equipment battery is maintenance free. If a


replacement battery is installed, check the electrolyte
level in the battery.

If the electrolyte level is lower than 13 mm (0.50 in)


above the plates, add distilled water only.

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.


In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities


of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

654 of 879 50-20-1 E80 Service Manual


BATTERY (CONT’D) Figure 50-20-4

Removal And Installation


1
2
Open the right side cover. (See Opening And Closing on 1
Page 10-50-1.)

Figure 50-20-3

1 5
4
1 3
1 5
6

P-92918

2 Remove the two bolts and washers (Item 1), the retaining
2 plate (Item 2) [Figure 50-20-4] and the plastic cover.
2 Disconnect the negative (-) cable (Item 3) [Figure 50-20-
3
P-86287 4] first.

Dealer Copy -- Not for Resale


Disconnect the positive (+) cable (Item 4) [Figure 50-20-
Remove the three plugs (Item 1) [Figure 50-20-3] and 4].
the bolts and washers.
Remove the two nuts (Item 5) and remove the hold down
Loosen the three bolts (Item 2) and remove the cover clamp (Item 6) [Figure 50-20-4].
(Item 3) [Figure 50-20-3].
Remove the battery.
NOTE: There may be washers used as shims
between the bolts (Item 2), the upperstructure Always clean the terminals and the cable ends, even
and the cover (Item 3) [Figure 50-20-3]. when installing a new battery.

Install the battery. Install the hold down clamp and tighten
the bolts.

Connect the battery cables. Connect the negative (-)


cable (Item 3) [Figure 50-20-4] last to prevent sparks.

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.


In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities


of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

655 of 879 50-20-2 E80 Service Manual


BATTERY (CONT’D) Start the engine. After the engine has started, remove the
ground (-) cable first (Item 1) [Figure 50-20-6].
Using A Booster Battery (Jump Starting)
Disconnect the cable from the battery (Item 1) [Figure
If it is necessary to use a booster battery to start the 50-20-5].
engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and NOTE: See Cold Temperature Starting in the
disconnect the battery cables. Operators Manual.
Make sure the key switch is OFF. The booster battery
must be 12 volt.

Open the right side cover.


Figure 50-20-5 IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2222-0903

Dealer Copy -- Not for Resale


1

P-86284
WARNING
AVOID INJURY OR DEATH
Figure 50-20-6 Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.


In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities


of water or milk! DO NOT induce vomiting. Get
1 prompt medical attention.
W-2065-0807

P-86285

Connect one end of the first cable to the positive (+)


terminal of the booster battery. Connect the other end of
the same cable to the positive (+) terminal (Item 1)
[Figure 50-20-5] of the excavator battery.

Connect one end of the second cable to the negative (-)


terminal of the booster battery. Connect the other end of
the same cable to a bolt (Item 1) [Figure 50-20-6] that
connects the flywheel cover to the engine.

656 of 879 50-20-3 E80 Service Manual


Dealer Copy -- Not for Resale

657 of 879 50-20-4 E80 Service Manual


ALTERNATOR Belt Replacement

Belt Adjustment Figure 50-30-3

See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)

Open the right side cover. (See Opening And Closing on


Page 10-50-1.)

Figure 50-30-1 1

P-86293
1

Loosen the alternator mounting bolt (located below the


alternator). Loosen the bolt (Item 1) [Figure 50-30-3].
Remove the old belt and install a new belt.

Dealer Copy -- Not for Resale


When belt tension is correct, tighten the alternator bolts.
P-86293

Loosen the alternator mounting bolt (located below the


alternator). Loosen the bolt (Item 1) [Figure 50-30-1]. WARNING
Figure 50-30-2 AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
screens, shields or rubber deflectors.
• Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
W-2528-0406

P-86292

Press down on the belt midway between the fan pulley


and the alternator pulley. The correct tension should
allow the belt to deflect 10 mm (0.375 in) [Figure 50-30-
2].

When the belt tension is correct, tighten the alternator


bolts.

658 of 879 50-30-1 E80 Service Manual


ALTERNATOR (CONT’D) Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
Charging System Inspection corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive

WARNING terminal.

AVOID INJURY OR DEATH


Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
WARNING
AVOID INJURY OR DEATH
Do not jump start or charge a frozen or damaged Batteries contain acid which burns eyes and skin on
battery. Warm battery to 60°F (16°C) before contact. Wear goggles, protective clothing and
connecting to a charger. Unplug charger before rubber gloves to keep acid off body.
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging. In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
Battery gas can explode and cause serious injury. and wash eye with clean, cool water for at least 15
W-2066-0705
minutes.

If electrolyte is taken internally drink large quantities

Dealer Copy -- Not for Resale


of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
IMPORTANT W-2065-0807

Damage to the alternator can occur if: Figure 50-30-4


• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.) 1
• Extra battery cables (booster cables) are
connected wrong.
I-2222-0903

If the charging system malfunctions, check the following:

Check the condition and tension of the alternator belt. If


the belt is worn or deteriorated, replace the belt. (See
Belt Replacement on Page 50-30-1.)
P-86955A

Inspect the alternator wiring harness and connectors at


alternator. Harness and connectors must be clean and With the key in the run position and the engine off, the
tight. icon (Item 1) [Figure 50-30-4] must be illuminated.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
batteries.)

Verify the charge of the battery. Make sure battery is fully


charged.

659 of 879 50-30-2 E80 Service Manual


ALTERNATOR (CONT’D) Figure 50-30-7

Charging System Inspection (Cont’d)

Figure 50-30-5

P-87391

Start the engine. At low idle, the icon must be off. If the
P-87392 icon is on, inspect the alternator belt (Item 1) [Figure 50-
30-7] for correct tension.

If the icon does not illuminate, disconnect the harness If the icon flashes, inspect the diode positive (+) side.
(Item 1) [Figure 50-30-5] from the alternator.

Dealer Copy -- Not for Resale


Figure 50-30-8
Figure 50-30-6

P-86211B
P-87395

Increase engine speed to approximately 1500 rpm. Turn


Ground the “L” terminal (Item 1) [Figure 50-30-6]. the boom work light (Item 1) [Figure 50-30-8] to the on
position.
NOTE: The “L” terminal has a red / white wire.

If the icon still does not illuminate, replace the indicator.

If the icon is illuminated, inspect the rotor assembly and


brushes for wear or damage.

660 of 879 50-30-3 E80 Service Manual


ALTERNATOR (CONT’D) Alternator Voltage Testing

Charging System Inspection (Cont’d) Figure 50-30-10

Figure 50-30-9

2 1

1
P-86282

P-86282
Run the engine at rated speed. Check to make sure that
all accessories are turned OFF. Connect the positive lead
If the icon is illuminated, measure the voltage at the of the voltmeter to the positive terminal (Item 1) of the
battery (Item 1) [Figure 50-30-9]. battery. Connect the negative lead of the volt meter to the

Dealer Copy -- Not for Resale


negative terminal (Item 2) [Figure 50-30-10]. If the
Battery voltage should be between 13 and 15 volts. reading on the voltmeter is under 13 volts or more than
15.5 volts, disassemble the alternator and check the
If the voltage is over 15.5 volts, replace the regulator. components.

If the voltage is less than 13 volts, inspect the auxiliary


diode.

661 of 879 50-30-4 E80 Service Manual


ALTERNATOR (CONT’D) High Voltage Testing

Low Voltage Testing Figure 50-30-13

Figure 50-30-11

P-87392

P-87392
With the key in the OFF position, remove the L & IG
terminal connector (Item 1) [Figure 50-30-13] from the
Turn the engine OFF and remove the L & IG terminal alternator.
connector (Item 1) [Figure 50-30-11] from the alternator.

Dealer Copy -- Not for Resale


Turn the key to the ON position.

Figure 50-30-12

P-87394

Check the voltage across the “L” terminal (Item 1)


[Figure 50-30-12]. The voltage should be what the
battery voltage is. If not, check the wire harness. If the
wire harness is ok, remove the alternator for replacement
or repair.

662 of 879 50-30-5 E80 Service Manual


ALTERNATOR (CONT’D) Alternator Regulator Testing

High Voltage Testing (Cont’d) Figure 50-30-16

Figure 50-30-14
2

1
P-87403

P-87393
Touch the IG terminal (Item 1) with a probe and the
ground (Item 2) [Figure 50-30-16] with another probe.
Figure 50-30-15
Figure 50-30-17

Dealer Copy -- Not for Resale


1

P-86282

P-87404

Check the voltage between the IG terminal (Item 1)


[Figure 50-30-14] and the positive (+) terminal on the Reverse the probes to check in the other direction
battery (Item 1) [Figure 50-30-15]. [Figure 50-30-17].

The voltage should be what the battery voltage is. If not, There should be continuity in one only direction. Meter
check the wire harness and relay. If the wire harness and readings should be different when probes are reversed. If
relay are ok, remove the alternator for replacement or there is no continuity or continuity in both directions,
repair. replace the regulator.

663 of 879 50-30-6 E80 Service Manual


ALTERNATOR (CONT’D) Figure 50-30-20

Removal And Installation

Open the right side cover. (See Opening And Closing on


Page 10-50-1.)

Figure 50-30-18

1
1

P-87397

Disconnect the wire harness (Item 1) [Figure 50-30-20].

2 Figure 50-30-21

P-87392

Dealer Copy -- Not for Resale


Disconnect the wire harness (Item 1). Remove the nut
and washer. Remove the wire (Item 2) [Figure 50-30- 3
18]. 1

Figure 50-30-19 2

1
P-87398

Remove the bolt (Item 1) from the alternator. Loosen the


bracket bolt (Item 2). Remove the belt (Item 3) [Figure
50-30-21].

P-87396

Loosen the top bolt (Item 1) [Figure 50-30-19]. Loosen


the bottom bolt and nut.

664 of 879 50-30-7 E80 Service Manual


ALTERNATOR (CONT’D) Figure 50-30-24

Removal And Installation (Cont’d)

Figure 50-30-22
2
1
2
1

P-87402

Turn the alternator over and remove the screw (Item 1).
P-87399 Remove the ground wire (Item 2) [Figure 50-30-24].

Remove the alternator from the machine.


Rotate the alternator (Item 1) away from the engine.
Rotate the bracket (Item 2) [Figure 50-30-22] away from

Dealer Copy -- Not for Resale


the alternator.

Figure 50-30-23

P-87401

Remove the bolt (Item 1) [Figure 50-30-23], washer,


spacer and nut from the bottom alternator mount.

665 of 879 50-30-8 E80 Service Manual


ALTERNATOR (CONT’D)

Parts Identification

1. Nut
2. Pulley
3. Case Half
4. Rotor
5. Stator
6. Case Half
7. Nut
8. Bolt

Dealer Copy -- Not for Resale


6

2 3
1

B-23973

666 of 879 50-30-9 E80 Service Manual


Dealer Copy -- Not for Resale

667 of 879 50-30-10 E80 Service Manual


STARTER Figure 50-40-2

Testing

Figure 50-40-1 Bat


S
M

Bat
S
M Cranking
Motor

Cranking
Motor
A-1991

Connect a jumper wire (of at least 4 gauge in size)


A-1992 between the M terminal and the BAT terminal [Figure 50-
40-2].

The key switch must be in the OFF position. If the starter turns, the defect is in the solenoid.

Dealer Copy -- Not for Resale


The battery must be at full charge. If the starter does not turn, the starter is defective.

The cable connections on the battery must be clean and


tight.

Connect a jumper wire between S terminal and BAT


terminal [Figure 50-40-1].

If the starter turns but does not turn the engine, the
starter drive has a defect.

668 of 879 50-40-1 E80 Service Manual


STARTER (CONT'D) Figure 50-40-5

Removal And Installation

Open the right side cover. (See Opening And Closing on


Page 10-50-1.)

Disconnect the negative cable from the battery. (See


Removal And Installation on Page 50-20-2.)

Remove the air cleaner. (See Housing Removal And


Installation on Page 60-40-1.)

Figure 50-40-3 1 2

P-87463

Remove the nut (Item 1), washers and wire (Item 2)


[Figure 50-40-5].
1
Figure 50-40-6

Dealer Copy -- Not for Resale


2

P-87461

Loosen the clamp (Item 1) and remove the hose (Item 2)


[Figure 50-40-3].
1
Figure 50-40-4

P-87464

Slide the protective boot (Item 1) [Figure 50-40-6] of the


bolt.

P-87462

Slide the protective boot (Item 1) [Figure 50-40-4] off the


nut.

669 of 879 50-40-2 E80 Service Manual


STARTER (CONT'D) Figure 50-40-8

Removal And Installation (Cont’d)

Figure 50-40-7
1

1 P-87466

Figure 50-40-9
P-87465

Remove the bolt (Item 1) and wire (Item 2) [Figure 50-


40-7].

Dealer Copy -- Not for Resale


1

P-87519

Remove the starter mount bolts (Item 1) [Figure 50-40-8]


and [Figure 50-40-9].

NOTE: The bottom mount bolt is also used to attach


the frame to the engine ground strap.

Remove the starter.

670 of 879 50-40-3 E80 Service Manual


STARTER (CONT'D)

Parts Identification

1. Rubber cover
2. Solenoid
3. Shims
4. Plunger
5. Torsion Spring 1
6. Shift Lever 2
7. Gear Housing
8. Bolt 3
9. Retaining Ring
10. Pinion Stop 5
11. Spring 6
12. Clutch Assembly
13. Bearing Retainer
14. Pinion Shaft 7
15. Rear Cover 4
16. O-ring
17. Brush Holder
18. Field Coil Assembly 10
19. Armature Assembly 11
12

Dealer Copy -- Not for Resale


13
8
18 9
14 18
15 18

16

17

18

19

E80025S

671 of 879 50-40-4 E80 Service Manual


LIGHTS Boom Light Bulb Replacement

Boom Light Removal And Installation Figure 50-50-3

Figure 50-50-1
4
2
3

1 1

1
P-86654

P-86653
Remove the screws (Item 1) and bezel (Item 2). Pull the
lens (Item 3) [Figure 50-50-3] out of the housing.
Disconnect the wire harness (Item 1) [Figure 50-50-1].
NOTE: The lens must be installed with the word

Dealer Copy -- Not for Resale


Figure 50-50-2 “Top” (Item 4) [Figure 50-50-3] to the top of the
housing.

Figure 50-50-4
2

1
P-86654

1
Remove the nut (Item 1) and washers. Remove the light
P-86656
(Item 2) [Figure 50-50-2] from the boom.

Support the lens (Item 1) and remove the screw (Item 2)


[Figure 50-50-4], washer and ground wire.

Remove the bulb from the lens.

672 of 879 50-50-1 E80 Service Manual


LIGHTS (CONT’D)

Boom Light Bulb Replacement (Cont’d)

Figure 50-50-5

P-86655

Disconnect the wire harness (Item 1) [Figure 50-50-5]


and remove the harness / bulb assembly.

Dealer Copy -- Not for Resale


NOTE: Do not touch the glass of the halogen bulb
with your fingers or allow the bulb to come in
contact with oils. If contaminated, the bulb
must be cleaned with mild alcohol and a clean
cloth [Figure 50-50-5].

673 of 879 50-50-2 E80 Service Manual


CONSOLE LOCKOUT SWITCH Figure 50-60-3

Testing / Adjustment

Remove the upper left console cover. (See Upper


Console Cover Removal And Installation on Page 40-60-
2.)

Figure 50-60-1

P-86775
1

There must be continuity when the console is in the down


and locked position [Figure 50-60-3].

Figure 50-60-4

P-86773

Dealer Copy -- Not for Resale


Disconnect the wire harness (Item 1) [Figure 50-60-1].
2
Connect a multimeter to the switch wire harness.

Figure 50-60-2
1

P-86776

Loosen the nut (Item 1) and turn the stop (Item 2) [Figure
50-60-4] out to raise the stop, or in to lower the stop.

Tighten the nut (Item 1) [Figure 50-60-4] after adjusting


the stop height.

P-86654

There must be no continuity when the console is in the


raised position [Figure 50-60-2].

674 of 879 50-60-1 E80 Service Manual


CONSOLE LOCKOUT SWITCH (CONT’D)

Removal And Installation

Remove the upper console cover. (See Upper Console


Cover Removal And Installation on Page 40-60-2.)

Remove the lower console cover. (See Lower Console


Cover Removal And Installation on Page 40-60-1.)

Figure 50-60-5

Dealer Copy -- Not for Resale


P-86773

Disconnect the wire harness (Item 1) [Figure 50-60-5].

Figure 50-60-6

P-86777

Loosen the nut (Item 1) [Figure 50-60-6] and remove the


switch.

675 of 879 50-60-2 E80 Service Manual


FUEL LEVEL SENDER Figure 50-70-3

Removal And Installation


1
Disconnect the negative battery cable. (See Removal
And Installation on Page 50-20-2.)

Remove the rear cover. (See Removal And Installation


on Page 40-190-1.)

Figure 50-70-1

P-89565

Remove the sender (Item 1) [Figure 50-70-3].

Figure 50-70-4

Dealer Copy -- Not for Resale


P-89563
1

Disconnect the harness (Item 1) [Figure 50-70-1].

Figure 50-70-2

1
P-89570

Installation: Install the sender with the arrow (Item 1)


[Figure 50-70-4] pointing up.

1
1

P-89564

Remove the screws (Item 1) [Figure 50-70-2].

676 of 879 50-70-1 E80 Service Manual


Dealer Copy -- Not for Resale

677 of 879 50-70-2 E80 Service Manual


DIAGNOSTIC SERVICE CODE

Service Codes List

Figure 50-80-1 The error codes will be displayed on the instrument panel
as flashing light sequences on icon (Item 1) [Figure 50-
80-1].
2
See the following chart for the codes, the conditions and
the flashing sequence.

Flash Examples: (4) four long flashes, (4-1) four long


flashes followed by one short flash, (4-4) four long
flashes followed by four short flash.

1 See [Figure 50-80-2 on Page 50-80-4] for additional


information on following the flashing code sequence.

P-86955A

Dealer Copy -- Not for Resale


FLASHES ITEM CONDITIONS OPERATION WHEN FAILURE OCCURS ACTION
4 Coolant Sensor voltage is 4.8V or more, Engine runs with a coolant temperature of Correct
temperature or 0.2V or less. 30°C failure.
sensor failure
5 Accelerator Sensor voltage is 4.6V or more, [Without optional back-up accelerator sensor] Correct
sensor failure or 0.2V or less. Engine runs at 1500 rpm. (Option can change) failure.
[With optional back-up accelerator sensor]
Select back-up accelerator sensor: No
limitation
Back-up accelerator sensor failure: Engine
runs at 1500 rpm. (Option can change)
6 Speed sensor Engine start signal (E8) is on, but [With optional back-up speed sensor] Turn key
failure the engine speed is zero. Back-up speed sensor becomes active; speed OFF.
Engine speed decreases by 480 is limited to 1800 rpm.(Option can change)
rpm or more in 40 ms Back-up speed sensor failed: Engine stops.
[Without optional back-up speed sensor]
Engine stops.
7 Rack position Correlation between rack Engine runs with limited output and speed. Turn key
sensor failure actuator output and rack position (Rack position control is inactive and speed OFF.
exceeds threshold upper limit by control is active).
0.32 seconds or more.
Correlation between rack
actuator output and rack position
exceeds threshold upper limit by
0.16 seconds or more.

678 of 879 50-80-1 E80 Service Manual


FLASHES ITEM CONDITIONS OPERATION WHEN FAILURE OCCURS ACTION
8 Rack actuator Rack actuator current is too high. Engine stops. Turn key
failure Rack actuator current is too low. OFF.

Engine accelerates with


minimum rack actuator output
Engine stalls while rack position
sensor is failed.
9 Over speed Idling engine speed exceeds Engine stops. Turn key
high idling speed plus 600 rpm. OFF.
1-1 Back-up speed Engine start signal (E8) is on, but Engine continues to run while main speed Turn key
sensor failure the engine speed is zero. sensor is used. OFF.
Engine speed decreases by 480 Back-up speed sensor failed: Engine stops.
rpm or more in 40ms.
1-2 CAN CAN communication packets Last value is retained. Back-up sensor Correct
communication cannot be received. becomes active. failure.
failure
1-3 EGR valve Low status is detected even Engine runs with limited output (92%) and Turn key
failure though port is off. speed (1800 rpm) OFF.
High status is detected even
though port is on.

Dealer Copy -- Not for Resale


1-4 CSD solenoid High status is detected even Engine continues to run with port being off. Turn key
valve failure though port is off. OFF.
Low status is detected even
though port is on.
1-5 Air heater relay High status is detected even Engine runs with air heater relay being off. Turn key
failure though port is off. OFF.
Low status is detected even
though port is on.
1-6 Main relay Power is not shut off even Engine runs normally. Correct
failure though main relay is off. failure.
Or turn
key OFF.
1-7 Rack actuator Low status is detected even Engine stops. Turn key
relay failure though port is off. OFF.
High status is detected even
though port is on.
1-8 Back-up Sensor voltage is 4.6V or more, Engine continues to run while main Correct
accelerator or 0.2V or less. accelerator sensor is used. failure.
sensor failure Main accelerator sensor failure: Engine runs
at 1500 rpm. (Option can change)
1-9 Atmospheric Sensor voltage is 4.6V or more, Atmospheric pressure compensation is Turn key
pressure sensor or 0.2V or less. canceled. OFF.
failure
2-1 Oil pressure Oil pressure switch fails to turn Engine runs normally. (Option can change) Turn key
switch failure on when engine is off. OFF.
2-2 Charge switch Charge switch fails to turn on Engine runs normally. Turn key
failure when engine is off. OFF.
2-3 Power supply E-ECU supply voltage exceeds Engine runs normally. Correct
voltage 10.0V. failure.
abnormal E-ECU supply voltage exceeds
16.0V.

679 of 879 50-80-2 E80 Service Manual


FLASHES ITEM CONDITIONS OPERATION WHEN FAILURE OCCURS ACTION
2-4 Sensor 5V Monitoring voltage is approx. 0 V. Engine runs normally. Turn key
failure Monitoring voltage is 4.5 V or OFF.
less.
Monitoring voltage is 5.5 V or
more.
2-5 E-ECU overheat E-ECU temperature exceeds Engine runs normally. (Option can change) Correct
alarm 105°C. failure.
Alarm is canceled when E-ECU
temperature decreases to
100°C. (option can change)
3-1 Oil pressure low Oil pressure switch fails to turn Engine runs normally. (Option can change) Correct
off when engine is running. failure.
3-2 Charge failure Charge switch fails to turn off Engine runs normally. Turn key
when engine is running. OFF.
3-3 Coolant Coolant temperature switch turns Engine runs normally. (Option can change) Turn key
temperature on. OFF.
abnormal
3-4 Air cleaner Air cleaner switch turns on. Engine runs normally. (Option can change) Turn key
blockage alarm OFF.
3-5 Oily water Oily water separator switch turns Engine runs normally. (Option can change) Turn key

Dealer Copy -- Not for Resale


separator alarm on. OFF.
3-6 Coolant Coolant temperature is 115°C or Engine runs normally. Correct
temperature higher. failure.
high alarm alarm is canceled when Coolant
temperature decreases to 110°C.
(Option can change)
4-1 E-ECU failure Flash ROM suffers checksum Engine stops. Turn key
[ROM error] error. OFF.
4-1 E-ECU failure Reading /Writing fails. Engine runs normally. Turn key
[EEPROM error] EEPROM suffers checksum OFF.
error.
4-1 E-ECU failure E-ECU fails to communicate with Engine runs normally. Turn key
[EEPROM sub CPU. OFF.
failure]
4-1 E-ECU failure Map format is invalid. Engine stops. Turn key
[Mapping error] OFF.
4-1 E-ECU failure Sensor voltage is 4.6V or more, Engine runs normally. Correct
[E-ECU or 1.0V or less. failure.
temperature
sensor failure]

680 of 879 50-80-3 E80 Service Manual


DIAGNOSTIC SERVICE CODE (CONT’D)

Flashing Patterns Of Engine Check Lamp

When detecting these failures, the E-ECU (Engine control unit) flashes the engine check lamp to alert the operator to the
occurrence of failure conditions. The engine check lamp will illuminate for two sec. when the E-ECU is power on. This
allows checking if the E-ECU is supplied with power normally.

Flashing patterns of the engine check lamp are shown in [Figure 50-80-2]. When accelerator sensor failure (flashing five
times) and EGR valve failure (flashing 1-3 times) occur, the engine check lamp flashes as shown in [Figure 50-80-2].
When two or more failures have occurred simultaneously, the engine check lamp scrolls through all the failure modes,
then repeats.

Figure 50-80-2

Dealer Copy -- Not for Resale


P-86919

681 of 879 50-80-4 E80 Service Manual


DIAGNOSTIC TOOL Figure 50-90-2

Software Installation

Follow the procedure below to install the software on the


service laptop to run the diagnostic tool program.

NOTE: The service laptop must have one of the


following operating systems:

Windows 2000 Professional SP1


1
Windows XP Professional 1

Windows XP Home
P-95356
Windows XP Tablet PC Edition

Windows Vista When the Yanmar Diagnostic Tool screen pops up, click
once on the next icon (Item 1) [Figure 50-90-2].
Figure 50-90-1
Figure 50-90-3

Dealer Copy -- Not for Resale


1
P-95491
P-95357

Record the serial number and license key numbers from


CD label (Item 1) [Figure 50-90-1]. Enter your name and organization where shown. Enter
the serial number from the CD label in the serial number
Load the compact disc into the Service P.C. box (Item 1) [Figure 50-90-3].

Click once on the next icon.

682 of 879 50-90-1 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-6

Software Installation (Cont'd)

Figure 50-90-4

1
1

2 P-95360

When the installation complete screen appears, click on


P-95358 the close icon (Item 1) [Figure 50-90-6].

The software is now installed on the Service PC.


Select everyone (Item 1) [Figure 50-90-4] if using a
shared Service PC. NOTE: The program will automatically open after the

Dealer Copy -- Not for Resale


software has been installed. The program can
Choose a folder to install the program and click once on be left open while connecting the service PC
the next icon (Item 2) [Figure 50-90-4]. to the excavator or closed if it is not being
used at this time.
NOTE: It is recommended to use the default
directory. If another directory is used, record
the location of the directory for driver
installation.

Figure 50-90-5

P-95359

When the confirm installation screen appears, click on


the next icon (Item 1) [Figure 50-90-5]. The installation
will start.

683 of 879 50-90-2 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-9

Installation

Figure 50-90-7
1

1 1

P-95322

Connect the diagnostic cable P/N 7009359 (Item 1)


P-95320 [Figure 50-90-9] to the CAN checker connector.

Figure 50-90-10
Tilt the seat back forward and remove the four screws
(Item 1). Remove the cover (Item 2) [Figure 50-90-7].

Dealer Copy -- Not for Resale


Figure 50-90-8

1
1

P-95323

Connect the opposite end of the cable to the diagnosis


P-95321 interface box P/N 7009358 [Figure 50-90-10].

Locate the CAN checker connector (Item 1) [Figure 50-


90-8].

684 of 879 50-90-3 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-13

Installation (Cont’d)

Figure 50-90-11

1
P-95308

When the Service PC is connected to the system for the


P-95324 first time after the software has been installed, the
welcome to the found new hardware wizard screen will
open and ask to connect to windows update to search for
Connect the USB cable (Item 1) [Figure 50-90-11] to the software. Select the no, not this time option (Item 1) and
diagnosis interface box. Connect the opposite end of the click once on the next icon (Item 2) [Figure 50-90-13].

Dealer Copy -- Not for Resale


cable to the Service PC.
Figure 50-90-14
Turn the Service PC on.

Figure 50-90-12

1
P-95369

P-95325 Select the install from a list or specific location


(advanced) option (Item 1) and click once on the next
icon (Item 2) [Figure 50-90-14].
With the engine off, turn the key (Item 1) [Figure 50-90-
12] to the run position.

685 of 879 50-90-4 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-17

Installation (Cont’d)

Figure 50-90-15

P-95367
1 2

Click once on the finish icon (Item 1) [Figure 50-90-17]


P-95371 to complete the hardware installation.

The driver is now installed.


Choose the setup driver folder (Item 1) under the folder
where the software was installed. Click once on the next Figure 50-90-18

Dealer Copy -- Not for Resale


icon (Item 2) [Figure 50-90-15].
1
Figure 50-90-16

3
4

5
6

1
P-95361

P-95372 A user ID and password will need to be set up the first


time the Service PC is used.

If the Service PC is running windows XP, or a newer Enter a user ID (Item 1) and password (Item 2). Reenter
program, click once on the continue anyway icon (Item 1) the password (Item 3) [Figure 50-90-18].
[Figure 50-90-16] to continue the driver installation.
Select the expert authority level (Item 4). Enter the
license key (Item 5) [Figure 50-90-18] that is printed on
the CD label.

Click once on the OK icon (Item 6) [Figure 50-90-18].

686 of 879 50-90-5 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-21

Code Retrieval

NOTE: For code descriptions and troubleshooting


procedures, refer to BATS.
1
With the engine off, turn the key to the run position.

Figure 50-90-19

2
1

P-95344

When the next screen appears, click once on the


industrial icon (Item 1). The engine icon will show up on
the drop down menu. Click once on the engine icon (Item
2) [Figure 50-90-21].

Figure 50-90-22

Dealer Copy -- Not for Resale


P-95347

With the service PC turned on and connected to the


excavator, double click on the diagnostic tool icon (Item
1) [Figure 50-90-19].
1
Figure 50-90-20

P-95343

When the login screen appears, type in the user ID (Item


1) and password (Item 2). Click once on the login icon
(Item 3) [Figure 50-90-22].

P-95346

The diagnostic tool screen will flash on the Service PC.


[Figure 50-90-20].

687 of 879 50-90-6 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-25

Code Retrieval (Cont’d)

Figure 50-90-23

2
1

P-95349

If the key switch is not in the run position or if there is no


P-95345 communication between the excavator and Service PC
the error code (Item 1) [Figure 50-90-25] will be
displayed.
Set the data rate to 500K (Item 1) and click once on the
start (expert mode) icon (Item 2) [Figure 50-90-23]. Click once on the close icon (Item 2) [Figure 50-90-25]

Dealer Copy -- Not for Resale


after the error has been corrected.
Figure 50-90-24
Figure 50-90-26

1
1

P-95348
P-95350

The initialization menu will open and automatically run a


self diagnostic test and close if there are no errors Click once on the diagnostic code icon (Item 1) [Figure
[Figure 50-90-24]. 50-90-26].

688 of 879 50-90-7 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-28

Code Retrieval (Cont’d) 1


Figure 50-90-27

2 3 4 5 6 7

1 2 3 4

P-95353

Click once on the logged DTC icon (Item 1) [Figure 50-


P-95352 90-28].

The logged DTC screen shows if the code is active (Item


The active code DTC screen will open and display any 2), code number (Item 3), description (Item 4), how many
currently active code numbers (Item 1), description (Item times the code has occurred (OC) (Item 5), the time

Dealer Copy -- Not for Resale


2) and probable cause (Item 3) [Figure 50-90-27]. when the code was first registered (Item 6) and the latest
time the code was registered (Item 7) [Figure 50-90-28].
Click once on the code and the probable cause and a
corrective action will be displayed in the bottom box (Item Click on the code and the probable cause and a
4) [Figure 50-90-27]. corrective action will be displayed in the bottom box (Item
8) [Figure 50-90-28].

689 of 879 50-90-8 E80 Service Manual


DIAGNOSTIC TOOL (CONT'D) Figure 50-90-31

Code Retrieval (Cont’d)

Figure 50-90-29

1
1

P-95350

2 3 Click once on the connect icon (Item 1) [Figure 50-90-


P-95351 31]. Check for active codes.

Click once on the DTC information list (Item 1) [Figure


50-90-29].

Dealer Copy -- Not for Resale


The DTC information list shows all the codes (Item 2) and
descriptions (Item 3) [Figure 50-90-29].

Click on the code and the probable cause and a


corrective action will be displayed in the bottom box (Item
4) [Figure 50-90-29].

After the corrective action has been taken, click once on


the disconnect icon (Item 5) [Figure 50-90-29].

NOTE: The disconnect and connect icons may be


used on the active code DTC, logged DTC and
DTC information list screens.

Figure 50-90-30

P-95325

Cycle the key switch (Item 1) OFF and ON [Figure 50-


90-30].

690 of 879 50-90-9 E80 Service Manual


Dealer Copy -- Not for Resale

691 of 879 50-90-10 E80 Service Manual


INSTRUMENT PANEL Figure 50-100-3

Removal And Installation

Figure 50-100-1 1

P-87727

1
Disconnect the two wire harness connectors (Item 1)
P-87725 [Figure 50-100-3].

Remove the cover (Item 1) [Figure 50-100-1].

Dealer Copy -- Not for Resale


Figure 50-100-2

P-87726

Remove the four screws (Item 1) [Figure 50-100-2].

692 of 879 50-100-1 E80 Service Manual


INSTRUMENT PANEL (CONT’D) Figure 50-100-6

Disassembly And Assembly

Figure 50-100-4
1

1
P-87680

2 Turn the panel over and remove the bezel (Item 1)


P-87678 [Figure 50-100-6] and lens.

Figure 50-100-7
Remove the four screws (Item 1) and bracket (Item 2)
[Figure 50-100-4].

Dealer Copy -- Not for Resale


Figure 50-100-5 1

1 P-87681

1 Remove the panel divider (Item 1) [Figure 50-100-7].


P-87679

Remove the four screws (Item 1) [Figure 50-100-5].

693 of 879 50-100-2 E80 Service Manual


INSTRUMENT PANEL (CONT’D) Figure 50-100-10

Disassembly And Assembly (Cont’d)

Figure 50-100-8 1

1 1

P-87684
1

Turn the gauge assembly over. Remove the light holders


1 P-87682 (Item 1) [Figure 50-100-10].

Figure 50-100-11
Remove the six screws (Item 1) [Figure 50-100-8].

Dealer Copy -- Not for Resale


Figure 50-100-9

P-887685

P-87683 Remove the bulb (Item 1) [Figure 50-100-11] from the


holder.

Remove the gauge assembly (Item 1) [Figure 50-100-9].

694 of 879 50-100-3 E80 Service Manual


INSTRUMENT PANEL (CONT’D) Figure 50-100-14

Disassembly And Assembly (Cont’d)

Figure 50-100-12 1

2
1 1

P-87687

Remove the plastic guards (Item 1) [Figure 50-100-14]


P-87689 from the gauges.

Figure 50-100-15
Pull up on and remove the gauge indicators (Item 1 and
2) [Figure 50-100-12].
1

Dealer Copy -- Not for Resale


NOTE: Mark the location of the fuel indicator (Item 1) 2
[Figure 50-100-12] and install the indicator in
the same position. If the fuel gauge is being
replaced, fill the fuel tank completely and 1
install the indicator at the “F” mark.

Figure 50-100-13
2
1
1
P-87686

Turn the assembly over and remove the three screws


(Item 1) from the temperature gauge. Remove the three
screws (Item 2) [Figure 50-100-15] from the fuel gauge.
1 Remove the gauges from the assembly.
1

P-87688

Remove the four screws (Item 1) [Figure 50-100-13] and


remove the faceplate.

695 of 879 50-100-4 E80 Service Manual


KEY SWITCH Figure 50-110-3

Removal And Installation

Remove the right console cover. (See Console Cover


Removal And Installation on Page 40-50-1.)

Figure 50-110-1

1
P-86680

Remove the switch assembly (Item 1) [Figure 50-110-3]


1 from the back of the console cover.

P-86678

Dealer Copy -- Not for Resale


Remove the nut (Item 1) [Figure 50-110-1].

Figure 50-110-2

P-86679

Remove the flat washer (Item 1) and wave washer (Item


2) [Figure 50-110-2].

696 of 879 50-110-1 E80 Service Manual


Dealer Copy -- Not for Resale

697 of 879 50-110-2 E80 Service Manual


RIGHT CONSOLE SWITCH COVER Figure 50-120-3

Removal And Installation

Figure 50-120-1
1

P-87693

Remove the screw (Item 1) [Figure 50-120-3].


P-87691
Figure 50-120-4

Remove the screw (Item 1) [Figure 50-120-1].

Dealer Copy -- Not for Resale


Figure 50-120-2
1

P-87694

Lift up on and remove the cover (Item 1) [Figure 50-120-


P-87692 4].

Remove the cover (Item 1) [Figure 50-120-2].

698 of 879 50-120-1 E80 Service Manual


RIGHT CONSOLE SWITCH COVER (CONT’D) Rocker Switch Removal And Installation

Removal And Installation (Cont’d) NOTE: The removal of the two speed switch is
shown, all rocker switch removal is the same.
Figure 50-120-5
Figure 50-120-6

P-87695

P-87696

Remove the two screws (Item 1) [Figure 50-120-5].


Disconnect the wire harness (Item 1) [Figure 50-120-6]

Dealer Copy -- Not for Resale


Tilt the cover toward the operator seat. from the switch.

Figure 50-120-7

P-87697

Depress the tabs on both sides of the switch and remove


the switch (Item 1) [Figure 50-120-7] from the cover.

699 of 879 50-120-2 E80 Service Manual


RIGHT CONSOLE SWITCH COVER (CONT’D) Engine Emergency Stop Switch Removal And
Installation
Speed Control Removal And Installation
Figure 50-120-10
Figure 50-120-8

1
1

P-87701
P-87698

Disconnect the wire harness (Item 1) [Figure 50-120-10].


Disconnect the wire harness (Item 1) [Figure 50-120-8].
Figure 50-120-11

Dealer Copy -- Not for Resale


Figure 50-120-9

P-87700
P-87699

Remove the nut (Item 1) [Figure 50-120-11] and remove


Remove the two screws (Item 1) [Figure 50-120-9] and the switch.
the speed control.

700 of 879 50-120-3 E80 Service Manual


RIGHT CONSOLE SWITCH COVER (CONT’D) Figure 50-120-14

Auxiliary Power Outlet Removal And Installation

Figure 50-120-12 1

P-87704

Remove the collar (Item 1) and slide the housing (Item 2)


P-87702 [Figure 50-120-14] out of the cover.

Disconnect the wire harness (Item 1) [Figure 50-120-12].

Dealer Copy -- Not for Resale


Figure 50-120-13

P-87703

Remove the nut (Item 1) [Figure 50-120-13].

701 of 879 50-120-4 E80 Service Manual


WIPER MOTOR Figure 50-130-3

Removal And Installation


2
Figure 50-130-1

1
P-87706

Remove the nut (Item 1) and remove the upper arm (Item
P-87705 2) [Figure 50-130-3].

Figure 50-130-4
Disconnect the washer hose (Item 1) [Figure 50-130-1]
inside the cab.

Dealer Copy -- Not for Resale


Figure 50-130-2
1

P-87708

Remove the wiper motor cover (Item 1) [Figure 50-130-


P-87707 4].

Tilt the cover (Item 1) [Figure 50-130-2] on the wiper arm


to the open position.

702 of 879 50-130-1 E80 Service Manual


WIPER MOTOR (CONT’D) Figure 50-130-7

Removal And Installation (Cont’d)

Figure 50-130-5

1
1

1
P-87711

Remove the top and bottom nut (Item 1) [Figure 50-130-


P-87709 7] and remove the wiper motor.

Disconnect the wire harness connectors (Item 1) [Figure


50-130-5].

Dealer Copy -- Not for Resale


Figure 50-130-6

P-87710

Remove the plastic nut (Item 1) and castle nut (Item 2)


[Figure 50-130-6].

703 of 879 50-130-2 E80 Service Manual


MOTION ALARM SYSTEM (IF EQUIPPED) Figure 50-140-2
Description
This excavator may be equipped with a motion alarm
system. The motion alarm (when the motion alarm switch
is in the ON position) will sound when the operator
moves the travel control levers in the either the forward
or reverse direction. Slight movement of the steering
levers in either the forward or reverse direction is
required with hydraulic components before the back-up
alarm will sound. 1

Inspecting

Figure 50-140-1
P-86211C

Make sure the motion alarm switch (Item 1) [Figure 50-


140-2] is in the ON position.

Move the travel control levers (one lever at a time) in the


1 forward direction. The motion alarm must sound. Move
the travel control levers (one lever at a time) in the

Dealer Copy -- Not for Resale


reverse direction. The motion alarm must sound.

Return both levers to neutral and turn excavator key to


P-86951A
OFF position. Exit the excavator. (See the Operation &
Maintenance Manual for the correct procedure.)

Inspect for damaged or missing motion alarm decal (Item


1) [Figure 50-140-1]. Replace if required.

NOTE: The excavator will need to be moved slightly


in both the forward and reverse direction to
test the motion alarm. Keep all bystanders
away from machine during test.

Make sure there are no bystanders in the area.

WARNING
AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807

Sit in the operator’s seat and fasten the seat belt. Start
the engine. (See the Operation & Maintenance Manual
for the correct procedure.)

704 of 879 50-140-1 E80 Service Manual


MOTION ALARM SYSTEM (IF EQUIPPED) (CONT’D) Adjusting Switch Position

Inspecting (Cont’d) Stop the engine. Raise the operator cab. (See Tilting The
Cab on Page 10-210-1.)
The motion alarm is located inside the lower part of the
engine compartment. Figure 50-140-4

Figure 50-140-3

2 1
1

P-86915 P-86551

Inspect the motion alarm electrical connector (Item 1) The motion alarm switch (Item 1) [Figure 50-140-4] is
and wire harness (Item 2) [Figure 50-140-3] for damage. hydraulic pressure activated and located under the

Dealer Copy -- Not for Resale


Repair or replace any damaged components. operator cab in the motion alarm valve.

The switch (Item 1) [Figure 50-140-4] is non-adjustable.


It must be fully installed into the valve housing and
tightened.

Inspect the motion alarm system for proper function if


switch is replaced.

WARNING
This machine is equipped with a motion alarm.
ALARM MUST SOUND!
when operating forward or backward.

Failure to maintain a clear view in the direction of


travel could result in serious injury or death.

The operator is responsible for the safe operation of


this machine.
W-2786-0309

705 of 879 50-140-2 E80 Service Manual


FUEL TRANSFER PUMP Figure 50-150-3

Removal And Installation

Figure 50-150-1 2

1 2 1

P-92652

Loosen the clamps (Item 1) and remove the hoses (Item


P-92644 2) [Figure 50-150-3].

Figure 50-150-4
Remove the tie strap (Item 1) [Figure 50-150-1].

Dealer Copy -- Not for Resale


Figure 50-150-2

1 1

P-92642

P-92643 Remove the upper bolts (Item 1) [Figure 50-150-4] and


lower bolts.

Disconnect the wires (Item 1) [Figure 50-150-2]. Remove the pump.

706 of 879 50-150-1 E80 Service Manual


FUEL TRANSFER PUMP (CONT’D)

Removal And Installation (Cont’d)

Figure 50-150-5

P-92639

Remove the fittings (Item 1) [Figure 50-150-5].

Dealer Copy -- Not for Resale

707 of 879 50-150-2 E80 Service Manual


AUTO IDLE PRESSURE SWITCH

Removal And Installation

Remove the center cover. (See Removal And Installation


on Page 40-70-1.)

Figure 50-160-1

P-91759

Dealer Copy -- Not for Resale


Disconnect the wire harness (Item 1). Remove the switch
(Item 2) [Figure 50-160-1].

Figure 50-160-2

P-91760

Remove the wire harness (Item 1) [Figure 50-160-2]


from the switch.

Installation: Install the green / red wire on the C terminal


and the green / white wire on the ON terminal.

708 of 879 50-160-1 E80 Service Manual


Dealer Copy -- Not for Resale

709 of 879 50-160-2 E80 Service Manual


ENGINE SERVICE

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Compression - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-16

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1


Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1


Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1


Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Radiator Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8

Dealer Copy -- Not for Resale


Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Fuel Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-11
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Water Pump Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
Thermostat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Temperature Switch - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Temperature Sensor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15
Thermostat - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1


Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-4
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-6

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1


Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-6
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-10
Fuel Injector Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-12
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-12

710 of 879 60-01 E80 Service Manual


CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-3
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-4
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-5
Valve Guide - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Intake And Exhaust Valve - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Valve Stem Bend - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Valve Face And Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-8
Valve Spring - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-8
Push Rod - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9
Rocker Arm - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9
Valve Bridge - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-10

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1


Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Cylinder Bore - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-5
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-6

Dealer Copy -- Not for Resale


CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Timing Gear Case Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Timing Gear Backlash - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-5

COLD START DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1

EXHAUST GAS RECIRCULATION VALVE (EGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2

MANIFOLD AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1


Hydraulic Pump Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Flywheel Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2

711 of 879 60-02 E80 Service Manual


ENGINE INFORMATION Figure 60-10-1
Description

The E80W Excavator has a Yanmar direct injected


4TNV98-ESDB8 diesel engine with a displacement of 3,3
L (202.5 in³). The engine is rated at an SAE Gross 42,5
Kw (57 hp) and has a closed crankcase ventilation
system [Figure 60-10-1].

The engine has 4 cylinders and the rotation is counter-


clockwise (viewed from the flywheel side). It is equipped
with an air heater, installed in the intake manifold, for
assisting in cold starts.

The engine serial number is stamped on the engine and


S9055
the model number is located on top of the valve cover.
Use these numbers to obtain the correct service parts.

The engine is liquid cooled with a ethylene glycol/water


mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by the engine. The
speed of the fan is determined by the engine rpm.

Dealer Copy -- Not for Resale

712 of 879 60-10-1 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Specifications

All dimensions are given in millimeters. Respective Imperial dimensions are given in inches enclosed by
parentheses.

Fuel Injection Nozzles

Opening Pressure 21600 - 22600 kPa (216 - 226 Bar) (3133 - 3278 psi)
Fuel Tightness Nozzle Seat Dry Nozzle just below opening psi for 5 seconds.

Fuel Injection Pump

High Idle 1050 rpm


Low Idle 2150 rpm

Cylinder Head

Cylinder Head Surface Distortion 0,05 mm (0.0020 in) or less


Cylinder Had Surface Distortion Allowable Limit 0,15 mm (0.0059 in)
Compression 3330 - 3540 kPa (33,3 - 35,4 Bar) (483 - 513 psi)

Dealer Copy -- Not for Resale


Compression Allowable Limit 2650 - 2860 kPa (26,5 - 28,6 Bar) (384 - 414 psi)
Allowable Difference Between Cylinders 200 - 290 kPa (2,0 - 2,9 Bar) (29 - 43 psi)

Valves

Valve Seat Width


Intake Valve Stem O.D 6,945 - 6,960 mm (0.2734 - 0.2740 in)
Intake Valve Stem O.D. Allowable Limit 6,9 mm (0.2717 in)
Intake Valve Guide I.D. 7,0 - 7,015 mm (0.2756 - 0.2762 in)
Intake Valve Guide I.D. Allowable Limit 7,08 mm (0.2787 in)
Intake Valve Stem Bend 0,04 - 0,07 mm (0.0016 - 0.0028 in)
Intake Valve Stem Bend Allowable Limit 0,17 mm (0.0067 in)
Exhaust Valve Stem O.D. 6,940 - 6,955 mm (0.2732 - 0.2738 in)
Exhaust Valve Stem O.D. Allowable Limit 6,90 mm (0.2717 in)
Exhaust Valve Guide I.D. 7,0 - 7,015 mm (0.2756 - 0.2762 in)
Exhaust Valve Guide I.D. Allowable Limit 7,08 mm (0.2787 in)
Exhaust Valve Stem Bend 0,045 - 0,075 mm (0.0018 - 0.0030 in)
Exhaust Valve Stem Bend Allowable Limit 0,17 mm (0.0067 in)
Valve Guide Projection From Cylinder Head 11,7 - 12,01 mm (0.460 0.472 in)
Intake Valve Recession 0,36 - 0,56 mm (0.0142 - 0.0220 in)
Intake Valve Recession Allowable Limit 0,8 mm (0.0318 in)
Exhaust Valve Recession 0,35 - 0,55 mm (0.0138 - 0.0217 in)
Exhaust Valve Recession Allowable Limit 0,8 mm (0.0315 in)
Valve Clearance 0,15 - 0,25 mm (0.006 - 0.010 in)
Valve Seat Angle (Int.) 120° degrees
Valve Seat Angle (Exh.) 90° degrees

713 of 879 60-10-2 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Valve Springs

Free Length 39,7 mm (1.5630 in)


Allowable Limit 39,2 mm (1.5433 in)
Inclination Allowable Limit 1,4 mm (0.0551 in)

Rocker Arm And Shaft

O.D. Of Rocker Arm Shaft 18,470 - 18,490 mm (0.7272 - 0.7280 in)


O.D. Of Rocker Arm Shaft Allowable Limit 18,44 mm (0.7260 in)
I.D. Of Rocker Arm 18,5 - 18,52 mm (0.7283 - 0.7291 in)
I.D. of Rocker Arm Allowable Limit 18,57 mm (0.7311 in)
Clearance Between Rocker Arm And Shaft 0,01 - 0,05 mm (0.0004 - 0.0020 in)
Clearance Between Rocker Arm & Shaft Allowable Limit 0,13 mm (0.0051 in)

Camshaft

Dealer Copy -- Not for Resale


Endplay 0,05 - 0,20 mm (0.0020 - 0.0079 in)
Endplay Allowable Limit 0,030 mm (0.0118 in)
Alignment (1/2 dial gauge reading) 0,0 - 0,02 mm (0.0 - 0.0008 in)
Alignment Allowable Limit 0,05 mm (0.0020 in)
Cam Lobe Height 43,4 - 43,6 mm (1.7087 - 1.7165 in)
Cam Lob Height Allowable Limit 50,65 mm (1.6988 in)
Gear End Bushing I.D. 49,99 - 50,055 mm (1.9681 - 1.9707 in)
Gear End Bushing I.D. Allowable Limit 50,13 mm (1.9736 in)
Gear End Camshaft O.D. 49,925 - 49,950 mm (1.9655 - 1.9665 in)
Gear End Camshaft O.D. Allowable Limit 49,890 mm (1.9642 in)
Gear End Oil Clearance 0,04 - 0,130 mm (0.0016 - 0.0051 in)
Gear End Oil Clearance Allowable Limit 0,240 mm (0.0094 in)
Intermediate Bore I.D. 50,0 - 50,025 mm (1.9685 - 1.9695 in)
Intermediate Bore I.D. Allowable Limit 50,1 mm (1.9724 in)
Intermediate Camshaft O.D. 49,91 - 49,935 mm (1.9650 - 1.9659 in)
Intermediate Camshaft O.D. Allowable Limit 49,875 mm (1.9636 in)
Intermediate Camshaft Oil Clearance 0,065 - 0,115 mm (0.0026 - 0.0045 in)
Flywheel End Inside Bore 50,0 - 50,025 mm (1.9685 - 1.9695 in)
Flywheel End Inside Bore Allowable Limit 50,1 mm (1.9724 in)
Flywheel End Camshaft O.D. 49,925 - 49,950 mm (1.9655 - 1.9665 in)
Flywheel End Camshaft O.D. Allowable Limit 49,890 mm (1.9642 in)
Flywheel End Oil Clearance 0,050 - 0,10 mm (0.0020 - 0.0039 in)
Flywheel End Oil Clearance Allowable Limit 0,210 mm (0.0083 in)

714 of 879 60-10-3 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Tappet

Tappet Bore I.D. 12,0 - 12,018 mm (0.4724 - 0.4731 in)


Tappet Bore I.D. Allowable Limit 12,038 mm (0.4739 in)
Tappet Stem O.D. 11,975 - 11,990 mm (0.4715 - 0.4720 in)
Tappet Stem O.D. Allowable Limit 11,955 mm (0.4707 in)
Oil Clearance 0,010 - 0,043 mm (0.004 - 0.0017 in)
Oil Clearance Allowable Limit 0,083 mm (0.0033 in)

Push Rod

Push Rod Bend Allowable Limit 0,03 mm (0.0012 in)

Cylinders

Cylinder Bore I.D. 98,000 - 98,030 mm (3.8538 - 3.8594 in)


Allowable limit 98,130 mm (3.8634 in)

Dealer Copy -- Not for Resale


Roundness 87,25 - 87,27 mm (3.435 - 3.436 in)
Taper +0,15 mm (+0.006 in)

Piston Rings

Top Ring End Gap 0,250 - 0,450 mm (0.0098 - 0.0177 in)


Top Ring End Gap Allowable Limit 0,540 mm (0.0213 in)
Top Ring Side Clearance 0,080 - 0,120 mm (0.0031 - 0.0047 in)
Top Ring Width 1,940 - 1,960 mm (0.0764 - 0.0772 in)
Top Ring Width Allowable Limit 1,920 mm (0.0756 in)
2nd Ring End Gap 0,450 - 0,650 mm (0.017 - 0.0256 in)
2nd Ring End Gap Allowable Limit 0,730 mm (0.0287 in)
2nd Ring Side Clearance 0,90 - 0,125 mm (0.0035 - 0.0049 in)
2nd Ring Side Clearance Allowable Limit 0,245 mm (0.0096 in)
2nd Ring Width 1,970 1,990 mm (0.0776 - 0.0783 in)
2nd Ring Width Allowable Limit 1,950 mm (0.0768 in)
Oil Ring End Gap 0,250 - 0,450 mm (0.0098 - 0.0177 in)
Oil Ring End Gap Allowable Limit 0,550 mm (0.0217 in)
Oil Ring Side Clearance 0,025 - 0,060 mm (0.0010 - 0.0024 in)
Oil Ring Side Clearance Allowable Limit 0,180 mm (0.0071 in)
Oil Ring Width 2,970 - 2,990 mm (0.1169 - 0.1177 in)
Oil Ring Width Allowable Limit 2,950 mm (0.1161 in)

715 of 879 60-10-4 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Pistons

*Piston O.D. @ 90 to Piston Pin 97,930 - 97,960 mm (3.8555 - 3.8567 in)


*Piston O.D. @ 90 To Piston Pin Allowable Limit 97,895 mm (3.8541 in)
Piston Pin Bore 30,0 - 30,009 mm (1.1811 - 1.815 in)
Piston Pin Bore Allowable Limit 30,039 mm (1.1826 in)
Piston Pin O.D. 29,989 - 30,0 mm (1.1807 - 1.1811 in)
Piston Pin O.D. Allowable Limit 29,959 mm (1.1795 in)
Oil Clearance 0,000 - 0,020 mm (0.0000 - 0.0008 in)
Oil Clearance Allowable Limit 0,080 mm (0.0031 in)
*Piston O.D is measured @ 22,0 mm (0.8661 in) from the bottom of the piston skirt.

Connecting Rods

Piston Pin Bushing I.D. 30,025 - 30,038 mm (1.1821 - 1.1826 in)


Piston Pin Bushing I.D. Allowable Limit 30,068 mm (1.1838 in)

Dealer Copy -- Not for Resale


Piston Pin O.D. 29,987 - 30,000 mm (1.1806 - 1.1811 in)
Piston Pin O.D. Allowable Limit 29,959 mm (1.1795 in)
Oil Clearance 0,025 - 0,051 mm (0.0010 - 0.0020 in)
Oil Clearance Allowable Limit 0,109 mm (0.0043 in)
Side Clearance 0,20 - 0,40 mm (0.0079 - 0.0157 in)

Oil Pump

Oil Pressure @ Rated rpm 290 - 309 kPa (2,9 - 3,9 Bar) (42 - 57 psi)
Idle Speed Allowable Limit 60 kPa (0,6 Bar) (9 psi)
Outer Rotor Outside Clearance 0,100 - 0,155 mm (0.0039 - 0.0061 in)
Outer Rotor Outside Clearance Limit 0,25 mm (0.0098 in)
Outer Rotor Side Clearance 0,05 - 0,10 mm (0.0020 - 0.0039 in)
Outer Rotor Side Clearance Limit 0,15 mm (0.0059 in)
Outer Rotor To Inner Rotor Tip Clearance 0,16 mm (0.0063 in)
Gear Boss Diameter 53,05 - 53,15 mm (2.0886 - 2.0925 in)
Rotor Diameter 53,45 - 53,55 mm (2.1043 - 2.1083 in)
Gearboss / Rotor Clearance 0,3 - 0,5 mm (0.012 - 0.020 in)
Gear Boss / Rotor Clearance Allowable Limit 0,6 mm (0.024 in)
Width Across Flat Of Gear Boss 49,45 - 49,75 mm (1.9468 - 1.9587 in)
Width Across Flat Of Rotor 49,95 - 50,05 mm (1.9665 - 1.9705 in)
Width Clearance Across Flat Of Gear Boss / Flat Of rotor 0,2 - 0,5 mm (0.008 - 0.020 in)
Width Clearance Across Flat Of Gear Boss / Flat Of 0,7 mm (0.028 in)
Rotor Allowable Limit

716 of 879 60-10-5 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Crankshaft

Crankshaft Alignment Allowable Limit (1/2 Dial Gauge 0,02 mm (0.0008 in)
Reading)
Connecting Rod Journal O.D. 57,952 - 57,962 mm (2.2816 - 2.2820 in)
Connecting Rod Journal O.D. Allowable Limit 57,902 mm (2.2796 in)
Connecting Rod Bearing I.D. 58,0 - 58,026 mm (2.2835 - 2.2845 in)
Connecting Rod Bearing Thickness 1,492 - 1,5 mm (0.0587 - 0.0591 in)
Oil Clearance Between Connecting Rod Journal And 0,038 - 0,074 mm (0.0015 - 0.0029 in)
Bearing
Oil Clearance Between Connecting Rod Journal And 0,150 mm (0.0059 in)
Bearing Allowable Limit
Main Bearing Journal O.D. 64,952 - 64,962 mm (2.5572 - 2.5576 in)
Main Bearing Journal O.D. Allowable Limit 64,902 mm (2.5552 in)
Main Bearing I.D. 65,0 - 65,020 mm (2.5590 - 2.5598 in)
Main Bearing Thickness 1,995 - 2,010 mm (0.0785 - 0.0791 in)

Dealer Copy -- Not for Resale


Oil Clearance Between Main Bearing Journal And 0,038 - 0,068 mm (0.0015 - 0.0027 in)
Bearing
Oil Clearance Between Main Bearing Journal And 0,150 mm (0.0059 in)
Bearing Allowable Limit

Thrust Bearing

Crankshaft End Play 0,13 - 0,23 mm (0.0051 - 0.0091 in)


Crankshaft End Play Allowable Limit 0,28 mm (0.0110 in)

Timing Gear Backlash

Crank Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)


Crank Gear Allowable Limit 0,16 mm (0.0063 in)
Cam Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
Cam Gear Allowable Limit 0,16 mm (0.0063 in)
Idler Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
Idler Gear Allowable Limit 0,16 mm (0.0063 in)
Fuel Injection Pump Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
Fuel Injection Pump Gear Allowable Limit 0,16 mm (0.0063 in)
PTO Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
PTO Gear Allowable Limit 0,16 mm (0.0063 in)
Lubricating Oil Pump Gear 0,09 - 0,15 mm (0.0035 - 0.0059 in)
Lubricating Oil Pump Gear Allowable Limit 0,17 mm (0.0067 in)
Balancer Drive Gear 0,12 - 0,18 mm (0.0047 - 0.0071 in)
Balancer Drive Gear Allowable Limit 0,20 mm (0.0079 in)

717 of 879 60-10-6 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Idler Gear Shaft And Bushing

Shaft O.D. 45,950 - 45,975 mm (1.8091 - 1.8100 in)


Shaft O.D. Allowable Limit 45,900 mm (1.8071 in)
Bushing I.D. 46,0 - 46,025 mm (1.8110 - 1.8120 in)
Busing I.D. Allowable Limit 46,075 mm (1.8140 in)
Oil Clearance 0,025 - 0,075 mm (0.0010 - 0.0030 in)
Oil Clearance Allowable Limit 0,175 mm (0.0069 in)

Torque Values

N•m ft-lb
*Cylinder Head Bolt 101,1 - 112,9 76 - 83
*Connecting rod Bolt 53,9 - 58,8 40 - 43
*Flywheel Bolt 186,2 - 205,8 137 - 152
*Main Bearing Cap Bolt 108,1 - 117,9 80 - 87

Dealer Copy -- Not for Resale


*Crankshaft Pulley Bolt 107,9 - 127,5 80 - 94
Fuel Injector Bolt 22,6 - 28,4 17 - 21
Fuel Pump Drive Gear Nut 113 - 123 83 - 90
High Pressure Fuel Lines Bolt 19,6 - 24,5 14 - 18

* Lightly Oiled Threads

718 of 879 60-10-7 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common.

PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53

Dealer Copy -- Not for Resale


Start and stop 9, 10, 11

KEY TO CORRECT THE CAUSE


1. Battery capacity low 28. Worn valves and seat
2. Bad electrical connections 29. Broken or worn piston rings
3. Faulty starter motor 30. Worn valve stems or guides
4. Incorrect grade of oil 31. Worn or damaged bearings
5. Low cranking speed 32. Not enough oil in the oil pan
6. Fuel tank empty 33. Switch is defective
7. Faulty stop control operation 34. Oil pump worn
8. Plugged fuel line 35. Relief valve is stuck open
9. Plugged fuel filter 36. Relief valve is stuck closed
10. Restriction in the air cleaner 37. Broken relief valve spring
11. Air in the fuel system 38. Faulty suction pipe
12. Faulty fuel injection pump 39. Plugged oil filter
13. Faulty fuel injectors 40. Piston seizure
14. Broken injection pump drive 41. Incorrect piston height
15. Incorrect injection pump timing 42. Faulty engine mounting
16. Incorrect valve timing 43. Incorrect alignment of flywheel
17. Poor compression 44. Faulty thermostat
18. Plugged fuel tank vent 45. Restriction in water jacket
19. Incorrect grade of fuel 46. Loose alternator belt
20. Exhaust pipe restriction 47. Plugged radiator
21. Cylinder head gasket leaking 48. Plugged breather pipe
22. Over heating 49. Plugged breather pipe
23. Cold running 50. Damaged valve stem oil deflectors
24. Incorrect tappet adjustment 51. Coolant level too low
25. Sticking valves 52. Plugged oil pump pipe strainer
26. Incorrect high pressure fuel lines 53. Broken valve spring
27. Worn cylinder bores

719 of 879 60-10-8 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-3

Engine Removal And Installation 1

Disconnect the negative (-) cable on the battery. (See


Removal And Installation on Page 50-20-2.) 2

Remove the right side upperstructure cover. (See


Removal And Installation on Page 40-21-1.)

Remove the right side cover. (See Removal And


Installation on Page 40-180-1.)
1
Remove the hydraulic piston pump. (See Removal And
Installation on Page 20-50-14.)
P-87532
Drain the radiator. (See Removing And Replacing
Coolant on Page 10-110-2.)
Loosen the clamps (Item 1) and remove the lower
Remove the muffler. (See Removal And Installation on radiator hose (Item 2) [Figure 60-10-3].
Page 60-30-1.)
Figure 60-10-4
Remove the fan. (See Fan Removal And Installation on
Page 60-50-10.). 3

Dealer Copy -- Not for Resale


Remove the air cleaner. (See Housing Removal And 2
Installation on Page 60-40-1.) 1

Figure 60-10-2
4

2
2

1 P-87533

1 Loosen the hose clamps (Item 1) and remove the heater


hoses (Item 2). Cut and remove the cable tie (Item 3).
Remove the bolt (Item 4) [Figure 60-10-4] from the
clamp. Reposition the hoses.
P-87531

Loosen the clamps (Item 1) and remove the upper


radiator hose (Item 2) [Figure 60-10-2].

720 of 879 60-10-9 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-7

Engine Removal And Installation (Cont’d)


2
Figure 60-10-5

3
2 3
1

P-87536
2
3 Loosen the nut (Item 1). Loosen the adjustment bolt (Item
P-87534 2) and remove the belt (Item 3) [Figure 60-10-7] from the
A/C compressor pulley.

Cut and remove the cable ties (Item 1). Loosen the hose Figure 60-10-8
clamps (Item 2) and remove the fuel lines (Item 3)

Dealer Copy -- Not for Resale


[Figure 60-10-5].
3
Figure 60-10-6

2
1 2

P-87577

Remove the three screws (Item 1) and remove the dust


P-87535 shield (Item 2). Remove the three bolts (Item 3) [Figure
60-10-8].

Remove the two bolts (Item 1) and washers. Remove the


belt shield (Item 2) [Figure 60-10-6].

721 of 879 60-10-10 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-11

Engine Removal And Installation (Cont’d)

Figure 60-10-9

1 1

1 P-87463

Remove the nuts (Item 1) [Figure 60-10-11] and


P-86872 disconnect the wire harness from the starter.

Figure 60-10-12
Remove the bolt (Item 1) [Figure 60-10-9] and lower the
compressor to the excavator frame.

Dealer Copy -- Not for Resale


1
Figure 60-10-10

3 2 2

P-87519

1 Remove the bolt (Item 1) and ground strap. Remove the


P-87539 nut (Item 2) [Figure 60-10-12] and clamp from the stud.

Disconnect the wire harness (Item 1) from the


compressor. Remove the four bolts (Item 2) and
compressor bracket (Item 3) [Figure 60-10-10].

722 of 879 60-10-11 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-15

Engine Removal And Installation (Cont’d)

Figure 60-10-13
4
3
2
1

P-87542

1
Reinstall the bolt (Item 1) in the engine lifting bracket.
P-87540 Remove the bolt (Item 2) and clamp. Loosen the hose
clamp and remove the fuel line (Item 3). Remove the nut
and disconnect the manifold heater cable (Item 4)
Cut and remove the cable tie (Item 1). Remove the bolts [Figure 60-10-15].
(Item 2) [Figure 60-10-13] and clamps.

Dealer Copy -- Not for Resale


Figure 60-10-16
Figure 60-10-14

2
1
1 1

P-87543
P-87541

Disconnect the two wire harness connectors (Item 1).


Remove the two bolts (Item 1) [Figure 60-10-14] from Disconnect the oil pressure sender wire harness (Item 2)
the rear of the engine. [Figure 60-10-16].

723 of 879 60-10-12 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-19

Engine Removal And Installation (Cont’d)

Figure 60-10-17

1 1

1
P-87546

2
Remove the three bolts (Item 1) [Figure 60-10-19] and
P-87544 clamps.

Figure 60-10-20
Remove the bolt (Item 1) and reposition the fuel filter
(Item 2) [Figure 60-10-17].

Dealer Copy -- Not for Resale


Figure 60-10-18

1
1

P-87547

Disconnect the temperature valve wire harness (Item 1)


P-87545 [Figure 60-10-20].

Remove the two bolts (Item 1) and remove the fuel pump
bracket (Item 2) [Figure 60-10-18].

724 of 879 60-10-13 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-23

Engine Removal And Installation (Cont’d)


1
Figure 60-10-21

1
P-87520

1
Install a lifting hoist (Item 1) [Figure 60-10-23] and chain
P-87548 on the engine lifting points.

Figure 60-10-24
Disconnect the wire harness connectors (Item 1).
Remove the bolt (Item 2) [Figure 60-10-21].

Dealer Copy -- Not for Resale


Figure 60-10-22
1
1

1
2

P-87522

Remove the two rear engine mounting bolts (Item 1)


P-87549 [Figure 60-10-24], washers and top half of the mount.

Disconnect the wire harness from the EGR valve (Item 1)


and temperature sender (Item 2) [Figure 60-10-22].

725 of 879 60-10-14 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-27

Engine Removal And Installation (Cont’d)

Figure 60-10-25

P-87602

Raise the hoist and remove the engine [Figure 60-10-


P-87523 27].

Figure 60-10-26

Dealer Copy -- Not for Resale


1

P-87521

Remove the front two engine mounting bolts (Item 1)


[Figure 60-10-25] and [Figure 60-10-26], washers and
top half of the mount.

726 of 879 60-10-15 E80 Service Manual


ENGINE INFORMATION (CONT’D) Figure 60-10-29

Compression - Testing
1
The tools listed will be needed to do the following
procedure:

MEL10630 - Engine Compression Kit


- Compression Adapter

Run the engine until it reaches operating temperature.

Stop the engine.

Figure 60-10-28
P-91032

Figure 60-10-30

Dealer Copy -- Not for Resale


1 1
2

P-91031

Turn the fuel supply valve (Item 1) to the off position.


Disconnect the E/G speed sensor (Item 2) [Figure 60- P-91033
10-28].

Remove the high pressure fuel lines (Item 1) [Figure 60-


10-29] and [Figure 60-10-30] from the injection pump
and injectors.

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

Installation: Tighten the high pressure fuel line nuts to


29 - 34 N•m (22 - 25 ft-lb) torque.

727 of 879 60-10-16 E80 Service Manual


ENGINE INFORMATION (CONT’D)

Compression - Testing (Cont’d)

Remove the fuel injector. (See Fuel Injector Removal


And Installation on Page 60-70-10.)

Figure 60-10-31

NA1387

Dealer Copy -- Not for Resale


Install the compression gauge and adapter test assembly
(Item 1) [Figure 60-10-31] on the to be tested cylinder.

Crank the engine with the starter at 200 - 300 rpm.

Compression pressure at 3330 - 3540 kPa


250 rpm (33,3 - 35,4 bar)
(483 - 513 psi)
Allowable Limit 2650 - 2860 kPa
(26,5 - 28,6 bar)
(384 - 414 psi)
Variance among cylinders 200 - 300 kPa
(2 - 3 bar)
(29 - 43 psi)

728 of 879 60-10-17 E80 Service Manual


Dealer Copy -- Not for Resale

729 of 879 60-10-18 E80 Service Manual


ENGINE SPEED CONTROL

Adjustment

Figure 60-20-1

1 Engine Control
Dial
2 ECU (Engine
Control Unit)

2 1

EM7804

Dealer Copy -- Not for Resale


When the engine control dial is moved, the output voltage
changes according to the dial position [Figure 60-20-1].

730 of 879 60-20-1 E80 Service Manual


ENGINE SPEED CONTROL (CONT’D)

Adjustment (Cont’d)

Figure 60-20-2

Dealer Copy -- Not for Resale


3

S9597

The engine control dial has a built-in potentiometer (Item


1). When the control knob (Item 2) is moved, the output
voltage (through 2 and 3 terminals) will vary from the 5V
supplied from the engine throttle controller, as shown in
the graph (Item 3) [Figure 60-20-2].

731 of 879 60-20-2 E80 Service Manual


MUFFLER Figure 60-30-3

Removal And Installation

Remove the alternator. (See Removal And Installation on


Page 50-30-7.)

Figure 60-30-1 1

P-87527

Remove the gasket (Item 1) [Figure 60-30-3] from the


1 manifold.

P-87525

Dealer Copy -- Not for Resale


Remove the two nuts (Item 1) [Figure 60-30-1] from the
tail pipe end of the muffler.

Figure 60-30-2

P-87296

Remove the four nuts (Item 1) [Figure 60-30-2] located


under the muffler.

Remove the muffler.

732 of 879 60-30-1 E80 Service Manual


Dealer Copy -- Not for Resale

733 of 879 60-30-2 E80 Service Manual


AIR CLEANER

Housing Removal And Installation

Open the right side cover.

Figure 60-40-1

3
1

2 1

P-87295

Dealer Copy -- Not for Resale


Loosen the hose clamps (Item 1) and remove the hoses
(Item 2) from the air cleaner housing. Disconnect the wire
harness (Item 3) [Figure 60-40-1].

Figure 60-40-2

P-87296

Remove the two bolts (Item 1) [Figure 60-40-2] and


washers.

Remove the air cleaner housing.

NOTE: Plug the intake to keep contamination out of


the engine.

734 of 879 60-40-1 E80 Service Manual


Dealer Copy -- Not for Resale

735 of 879 60-40-2 E80 Service Manual


ENGINE COOLING SYSTEM Figure 60-50-2

Radiator Removal And Installation

Drain the hydraulic reservoir. (See Removing And


Replacing Hydraulic Fluid on Page 10-140-6.) 1

Drain the radiator. (See Removing And Replacing


Coolant on Page 10-110-2.)
2
Remove the right side cover. (See Removal And
Installation on Page 40-180-1.)
1
Remove the right upperstructure side cover. (See
Removal And Installation on Page 40-21-1.)
P-89474
Remove the air conditioning belt. (See Belt Replacement
on Page 70-20-2.)
Remove the bolts (Item 1) and guard (Item 2) [Figure 60-
Figure 60-50-1 50-2].

Figure 60-50-3
1

Dealer Copy -- Not for Resale


1
2

1 2

P-89409

P-89410
Remove the clamps (Item 1) and top radiator hose (Item
2) [Figure 60-50-1].
Remove the clamps (Item 1) and lower radiator hose
(Item 2) [Figure 60-50-3].

736 of 879 60-50-1 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-6

Radiator Removal And Installation (Cont’d)

Figure 60-50-4

2
1

P-89413

P-89411 Remove the bolt (Item 1) [Figure 60-50-6].

Figure 60-50-7
Remove the bolts (Item 1) and fan shield (Item 2) [Figure
60-50-4].

Dealer Copy -- Not for Resale


Figure 60-50-5

2
1
P-89414

P-89412 Lift and remove the coolant reservoir (Item 1) [Figure 60-
50-7].

Remove the clamp (Item 1) and hose (Item 2) [Figure


60-50-5].

737 of 879 60-50-2 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-10

Radiator Removal And Installation (Cont’d)

Figure 60-50-8

P-89417

Remove the hose (Item 1) [Figure 60-50-10].


P-89415
Figure 60-50-11

Remove the hose (Item 1) [Figure 60-50-8].

Dealer Copy -- Not for Resale


Figure 60-50-9 1
1

1
1

P-89418

Remove the bolts (Item 1) [Figure 60-50-11].


P-89416

Remove the bolts (Item 1) [Figure 60-50-9].

738 of 879 60-50-3 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-14

Radiator Removal And Installation (Cont’d) 2

Figure 60-50-12

1 1

P-89432

Remove the fitting (Item 1) and bolt (Item 2) [Figure 60-


P-89419 50-14].

Figure 60-50-15
Remove the bolt (Item 1) [Figure 60-50-12].

Dealer Copy -- Not for Resale


Figure 60-50-13

1
1

P-89433

P-89431 Loosen the bolt (Item 1) [Figure 60-50-15] on the hose


clamp.

Remove the bolts (Item 1) and plate (Item 2) [Figure 60-


50-13].

739 of 879 60-50-4 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-18

Radiator Removal And Installation (Cont’d)

Figure 60-50-16

1
2
P-89425

Remove the bolt (Item 1) [Figure 60-50-18].


P-89481
Figure 60-50-19

Loosen the hose clamp (Item 1) and remove the lower 2


radiator hose (Item 2) [Figure 60-50-16].

Dealer Copy -- Not for Resale


Figure 60-50-17

1 1
2

P-89421

Remove the bolt (Item 1) and position the brace (Item 2)


[Figure 60-50-19] to allow access to cooling lines.
P-89425
Remove the condenser. (See Removal And Installation
on Page 70-60-1.)
Loosen the clamp (Item 1) and remove the drain hose
(Item 2) [Figure 60-50-17]. Remove the battery. (See Removal And Installation on
Page 50-20-2.)

740 of 879 60-50-5 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-22

Radiator Removal And Installation (Cont’d)


2
Figure 60-50-20

1
1
1

2
P-89422

1 Install lifting brackets (Item 1) and a chain (Item 2)


P-89426 [Figure 60-50-22].

Remove the bolts (Item 1) and seal strip (Item 2) [Figure


60-50-20].

Dealer Copy -- Not for Resale


Figure 60-50-21

1
1

P-89427

Remove the bolts (Item 1) and brace (Item 2) [Figure 60-


50-21].

741 of 879 60-50-6 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D)

Radiator Removal And Installation (Cont’d)

Figure 60-50-23

1
1

P-89424

Figure 60-50-24

Dealer Copy -- Not for Resale


1
1

P-89423

Remove the bolts (Item 1) [Figure 60-50-23] and [Figure


60-50-24].

Remove the radiator / oil cooler.

742 of 879 60-50-7 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-27

Radiator Disassembly And Assembly

Figure 60-50-25

1 1
2

P-89475
1

Remove the bolts (Item 1) [Figure 60-50-27].


P-89479
Lift the radiator from the frame.

Figure 60-50-26 Figure 60-50-28

Dealer Copy -- Not for Resale


1

2
1 1

1
P-89480 P-89477

Remove the bolts (Item 1) and fan shroud (Item 2) Remove the bolts (Item 1) [Figure 60-50-28].
[Figure 60-50-25] and [Figure 60-50-26].

743 of 879 60-50-8 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D)

Radiator Disassembly And Assembly (Cont’d)

Figure 60-50-29

1 1

P-89476

Remove the bolts (Item 1) [Figure 60-50-29].

Dealer Copy -- Not for Resale


Figure 60-50-30

1 1

P-89478

Remove the bolts (Item 1) [Figure 60-50-30] and lift the


oil cooler from the frame.

744 of 879 60-50-9 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-33

Fan Removal And Installation

Figure 60-50-31

1
1

P-87530

Slide the fan towards the radiator and remove the spacer
P-87528 (Item 1) [Figure 60-50-33].

Remove the fan.


Remove the two bolts (Item 1) and remove the fan guard
(Item 2) [Figure 60-50-31].

Dealer Copy -- Not for Resale


Figure 60-50-32

P-87259

Remove the four bolts (Item 1) [Figure 60-50-32] from


the fan.

745 of 879 60-50-10 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D)

Fuel Cooler Removal And Installation

Figure 60-50-34

1 1

P-86884

Loosen the hose clamps (Item 1) [Figure 60-50-34] and


remove the hoses.

Dealer Copy -- Not for Resale


Figure 60-50-35

1 1

P-86885

Remove the bolts (Item 1) and remove the cooler (Item 2)


[Figure 60-50-35].

746 of 879 60-50-11 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D)

Water Pump Removal And Installation

NOTE: Replace the engine coolant pump as an


assembly only. Do not attempt to repair the
engine coolant pump or replace individual
components.

Remove the alternator belt. (See Belt Replacement on


Page 50-30-1.)

Figure 60-50-36

1
2

Dealer Copy -- Not for Resale


3

S9605

Remove the fan (Item 1), spacer (Item 2) and pulley (Item
3) [Figure 60-50-36].

Disconnect the coolant hoses and the temperature switch


lead wire from the engine coolant pump.

Remove the engine coolant pump (Item 4) [Figure 60-


50-36].

Installation: Install a new O-ring between the engine


coolant pump and the joint.

NOTE: The correct O-ring must be used. The O-ring


dimensions are the same as a commercially
available O-ring, the material is different.

747 of 879 60-50-12 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D)

Water Pump Parts Identification

1. Thermostat Cover
2. Gasket
3. Thermostat
4. O-ring
5. O-ring
6. Water Pump
7. Temperature Switch
8. Gasket
9. Gasket
10. Belt
11. Pulley
12. Spacer 14
13. Fan
14. Bolt 1
2
3

5 4

Dealer Copy -- Not for Resale


8
7
6

9 1

11

12

10

14

13

S9600

748 of 879 60-50-13 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Temperature Switch - Testing

Thermostat Removal And Installation Figure 60-50-38

Figure 60-50-37 3

1
1

3 2
2

6 4

5
S9607

Connect a continuity light or ohmmeter to the


temperature switch. Connect one lead to the terminal of
the switch (Item 1) and the other lead to the metal portion
of the switch (Item 2) [Figure 60-50-38].

Dealer Copy -- Not for Resale


Install the temperature switch and an accurate
thermometer (Item 3) [Figure 60-50-38] in engine
coolant.

S9606 Slowly increase the temperature of the fluid.

The temperature switch is working properly if the


Remove the thermostat cover (Item 1) and the thermostat
continuity light or ohmmeter indicates continuity when the
(Item 2) [Figure 60-50-37].
fluid reaches 107 - 113°C (225 - 235°F).
Installation: Use a new gasket (Item 3) and O-ring (Item
4) [Figure 60-50-37].

Remove the temperature switch (Item 5) [Figure 60-50-


37].

Installation: Use a new gasket (Item 6) [Figure 60-50-


37].

749 of 879 60-50-14 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D) Thermostat - Testing

Temperature Sensor - Testing Figure 60-50-40

Figure 60-50-39
2

2
1
1

S9609

S9608
Install the thermostat (Item 1) and an accurate
thermometer (Item 2) [Figure 60-50-40] in hot water.
Connect an electric resistor to the coupler of the water
temperature sensor (Item 1) [Figure 60-50-39]. Slowly increase the temperature of the fluid.

Dealer Copy -- Not for Resale


Install the temperature switch and an accurate The thermostat is operating properly if it starts to open at
thermometer (Item 2) [Figure 60-50-39] in engine the temperature value stamped on the flange of the
coolant. thermostat, and fully opens as the temperature of the
water is increased.
Slowly increase the temperature of the fluid and measure
the electric resistance value.

If the resistance value at each of the following


temperatures is within the permissible range specified,
the water temperature sensor is operating properly.

RESISTANCE
WATER TEMPERATURE
(K OHM)
20°C (68°F) 2.45 (+/- 0.13)
80°C (176°F) 0.318 (+/- 0.008)
0.008°C (32°F) (0.1836)

750 of 879 60-50-15 E80 Service Manual


ENGINE COOLING SYSTEM (CONT’D)

Thermostat Testing (Cont’d)

Figure 60-50-41

S9610

Install the radiator cap (Item 1) [Figure 60-50-41] on a


cooling system tester.

Dealer Copy -- Not for Resale


Apply 75 - 105 kPa (0,75 - 1,05 bar) (10,8 - 14,8 psi) to
the radiator cap. The radiator cap relief valve must open
within the specified range.

751 of 879 60-50-16 E80 Service Manual


LUBRICATION SYSTEM

Oil Pan Removal And Installation

Figure 60-60-1

1
2

NA1084

Dealer Copy -- Not for Resale


Remove the bolts (Item 1) and remove the oil pan (Item
2) [Figure 60-60-1].

Figure 60-60-2

3
2

NA1090

Remove the bolts (Item 1), oil pickup tube (Item 2) and O-
ring (Item 3) [Figure 60-60-2].

752 of 879 60-60-1 E80 Service Manual


LUBRICATION SYSTEM (CONT’D) Figure 60-60-4

Oil Pump Removal And Installation

NOTE: If the oil pump must be replaced, replace it as


an assembly only. Do not replace individual
components.
2 1
The oil pump is located in the front gear case and is
driven by the same gear train that drives the camshaft
and fuel injection pump. Remove the front gear case 4
cover to gain access to the oil pump.
3
Figure 60-60-3

S9386

1
Remove the engine cooling fan guard, engine cooling fan
(Item 1), spacer (Item 2), pulley (Item 3) and belt (Item 4)
2
[Figure 60-60-4].

5 Remove the crankshaft pulley and the gear case cover.

Dealer Copy -- Not for Resale


Figure 60-60-5

4
S9385

Gear Case Housing (Item 1)


Outer Rotor (Item 2)
Inner Rotor (Item 3)
Cover Plate (Item 4)
Drive Gear (Item 5) [Figure 60-60-3] 1

2 S9387

Remove the oil pump assembly bolts. Remove the oil


pump assembly (Item 1) from the gear case housing
(Item 2) [Figure 60-60-5].

753 of 879 60-60-2 E80 Service Manual


LUBRICATION SYSTEM (CONT’D)

Oil Pump Removal And Installation (Cont’d)

Figure 60-60-6

2 S9393

Remove the outer rotor (Item 1) [Figure 60-60-6] from


the gear case housing.

Dealer Copy -- Not for Resale


Installation: Lubricate the outer rotor and pump bore in
the gear case with clean engine oil. The punch mark
(Item 2) [Figure 60-60-6] on the end of the outer rotor
must face away from the gear case housing

754 of 879 60-60-3 E80 Service Manual


LUBRICATION SYSTEM (CONT’D) Figure 60-60-8

Oil Pump Inspection

Wash the oil pump, oil pressure regulator and oil pump
cavity with clean solvent. Inspect for wear or damage. 1
Replace if necessary. 2

NOTE: If any oil pump component clearance exceeds


its limit, the oil pump must be replaced as an
assembly.

Figure 60-60-7

1
S9389
2

Measure the clearance between the lobes of the inner


rotor (Item 1) and outer rotor (Item 2) [Figure 60-60-8].

Allowable Limit 0,16 mm (0.0063 in)

Figure 60-60-9

Dealer Copy -- Not for Resale


S9388

Measure the clearance between the outer rotor (Item 1)


and pump body (Item 2) [Figure 60-60-7].

0,1 - 1,155 mm
Clearance 1
(0.0039 - 0.0061 in)
Allowable Limit 0,25 mm (0.0098 in) 2

S9390

Determine the side clearance of the outer rotor (Item 1)


across the pump cavity (Item 2) [Figure 60-60-9].
Measure the side clearance using a depth micrometer.

0,05 - 0,10 mm
Side Clearance
(0.002 - 0.0039 in)
Allowable Limit 0,15 mm (0.0059 in)

755 of 879 60-60-4 E80 Service Manual


LUBRICATION SYSTEM (CONT’D)

Oil Pump Inspection (Cont’d)

Figure 60-60-10

S9391

Determine the rotor shaft clearance. Measure the outside


diameter of the rotor shaft (Item 1) and the bore diameter

Dealer Copy -- Not for Resale


in the gear case housing (Item 2) [Figure 60-60-10].

Calculate the difference between the two measurements


to determine the clearance.

12,980 - 13,020 mm
Gear Case Bearing I.D.
(0.5110 - 0.5126 in)
Allowable Limit 13,050 mm (0.5138 in)
12,955 - 13,020 mm
Rotor Shaft O.D.
(0.5100 - 0.5104 in)
Allowable Limit 12,945 mm (0.5096 in)
0,015 - 0,065 mm
Rotor Clearance
(0.0006 - 0.0026 in)
Allowable Limit 0,105 mm (0.0041 in)

If the clearance exceeds the allowable limit, replace the


oil pump.

756 of 879 60-60-5 E80 Service Manual


LUBRICATION SYSTEM (CONT’D)

Engine Oil Pressure - Testing

Perform an engine oil pressure check if there is any


indication of low oil pressure such as the oil pressure
indicator is on or the oil pressure gauge indicates low oil
pressure.

Figure 60-60-11

Dealer Copy -- Not for Resale


S9392

Disconnect the wire harness from the oil pressure switch


(Item 1) [Figure 60-60-11].

Remove the oil pressure switch.

Install a mechanical oil pressure gauge in the oil pressure


switch port.

Start the engine:

At Idle Speed Allowable 60 kPa (0,6 bar) (8,7 psi) or


Limit more

290 - 390 kPa


At Rated Speed (2,90 - 3,90 bar
(42,1 - 56,6 psi)

• If the mechanical oil pressure test gauge indicates


good oil pressure, replace the faulty oil pressure
switch or sending unit, or faulty machine oil pressure
gauge in instrument panel.

• If the mechanical oil pressure test gauge indicates low


oil pressure, troubleshoot the lubrication system to
locate the cause of the low oil pressure.

757 of 879 60-60-6 E80 Service Manual


FUEL SYSTEM Figure 60-70-2

Fuel Injection Pump Removal And Installation

Remove the fan. (See Fan Removal And Installation on 1


Page 60-50-10.)
2

WARNING
AVOID INJURY OR DEATH 1
1
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible. P-91048
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention Disconnect the three wire harness connectors (Item 1).
from a physician familiar with this injury. Remove the three rear bolts (Item 2) [Figure 60-70-2].
W-2072-0807

Figure 60-70-1

Dealer Copy -- Not for Resale


1

P-91047

Remove the two bolts (Item 1) and belt guard (Item 2)


[Figure 60-70-1].

758 of 879 60-70-1 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-5

Fuel Injection Pump Removal And Installation


(Cont’d)

Figure 60-70-3 3

1 1

1 2 NA1359

Remove the oil line (Item 1) and clamp (Item 2). Locate
the mark (Item 3) [Figure 60-70-5] on the boss of the
P-91032 injection pump and make a corresponding mark on the
gear case.

Figure 60-70-4 Figure 60-70-6

Dealer Copy -- Not for Resale


1

1
1

P-91033 NA1360

Remove the high pressure fuel lines (Item 1) [Figure 60- Remove the seven front cover bolts and cover (Item 1)
70-3] and [Figure 60-70-4] from the injection pump and [Figure 60-70-6].
injectors.

Installation: Tighten the high pressure fuel line nuts to


29 - 34 N•m (22 - 25 ft-lb) torque.

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

759 of 879 60-70-2 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-9

Fuel Injection Pump Removal And Installation


(Cont’d)

Figure 60-70-7

NA1363

Use a puller (Item 1) [Figure 60-70-9] to remove the


drive gear / hub assembly.
NA1361
Remove the four flange nuts and remove the fuel
injection pump.
Scribe a reference mark (Item 1) [Figure 60-70-7] across

Dealer Copy -- Not for Resale


the injection pump gear and idler gear. Installation: Tighten the nuts to 23 - 28 N•m (17 - 21 ft-
lb) torque.
Figure 60-70-8
Figure 60-70-10

3
1

2
NA1362
NA1359

Remove the nut (Item 1) and washer (Item 2) [Figure 60-


70-8]. If installing the original fuel injection pump, align the
reference marks (Item 1) [Figure 60-70-10] made earlier
Do not loosen or remove the four bolts (Item 3) [Figure and install the pump.
60-70-8] from the pump gear drive hub.

NOTE: If the hub is removed from the gear, correct


fuel injection timing will be difficult or
impossible to obtain.

Installation: Tighten the nut to 113 - 123 N•m (83 - 91 ft-


lb) torque.

760 of 879 60-70-3 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-12

Fuel Injection Pump Removal And Installation


(Cont’d)

Figure 60-70-11

1
2

NA1365

Locate the timing index number (Item 1) [Figure 60-70-


12] located on the engine side of the fuel injection pump.

Calculate the difference between the pump timing index


numbers from the new fuel injection pump and the
2 original fuel injection pump.

Dealer Copy -- Not for Resale


1 NOTE: The number is stamped as a two digit number.
Treat the number as if it has a decimal point
between the two digits. (Example 68 = 6.8)

Figure 60-70-13

NA1366

If installing a new fuel injection pump, clean the timing


case cover and install the timing grid sticker (provided
with the new fuel injection pump), aligning the standard 1
mark (Item 1) with the reference mark (Item 2) [Figure
60-70-11] made earlier.

NA1363

Example: The replacement injection pump is 7.3 (Item 1)


[Figure 60-70-13] and the original injection pump is 6.8.
The difference is +0.5.

761 of 879 60-70-4 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-15

Fuel Injection Pump Removal And Installation


(Cont’d)

Figure 60-70-14

Dealer Copy -- Not for Resale


NA1366

1
Rotate the top of the fuel injection pump away from the
engine until the +0.5° mark (Item 1) aligns with the pump
NA1366 mark (Item 2) [Figure 60-70-15].

If the difference is a positive number, the injection pump


mounting position must be advanced (rotate pump away
from the engine) to the calculated positive mark [Figure
60-70-14].

If the difference is a negative number, the injection pump


mounting position must be retarded (rotate pump toward
the engine) to the calculated negative mark (Item 2)
[Figure 60-70-14].

NOTE: Each mark on the sticker is a 0.5° timing


change.

The calculated difference shown in this example


indicates that the new fuel injection pump must be
installed at +0.5° (advanced) from the mark made during
the removal of the original fuel injection pump.

762 of 879 60-70-5 E80 Service Manual


FUEL SYSTEM (CONT’D) Use the following calculation to determine the correct fuel
injection timing. (Timing index number x 2)+FIR number
Fuel Injection Pump - Timing = Fuel injection timing in degrees.

Example: (6.8 x 2) + 4 = 13.6 + 4 = 17.6° Fuel Injection


Timing.

IMPORTANT Record the results of the calculation.

Do not attempt to maintain or adjust unless you are Figure 60-70-18


trained and have the correct equipment.
I-2028-0289

Figure 60-70-16

Dealer Copy -- Not for Resale


P-91031

Turn the shut off valve (Item 1) [Figure 60-70-18] to the


NA1365 closed position.

Figure 60-70-19
Locate the timing index number (Item 1) [Figure 60-70-
16] located on the engine side of the fuel injection pump.

NOTE: The number is stamped as a two digit number.


Treat the number as if it has a decimal point
between the two digits (Example 68 = 6.8).
1
Figure 60-70-17

1
P-91042

Clamp the fuel injector pump return fuel line (Item 1)


[Figure 60-70-19].

P-91051

The engine model number (Item 1) [Figure 60-70-17] is


4TNV98-XXXXX. The FIR number (first number in the
model code) for this engine is 4.

763 of 879 60-70-6 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-22

Fuel Injection Pump - Timing (Cont’d)


1
Figure 60-70-20

NA1374

Install a dial indicator (Item 1) [Figure 60-70-22] in the


NA1372 plunger bore.

Figure 60-70-23
Figure 60-70-21

Dealer Copy -- Not for Resale


1

P-91050
P-91052

Remove the plug (Item 1) [Figure 60-70-23] from the


Remove the forward plug (Item 1) [Figure 60-70-20] and flywheel inspection port.
[Figure 60-70-21] from the pump plunger bore.

764 of 879 60-70-7 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-26

Fuel Injection Pump - Timing (Cont’d)

Figure 60-70-24
1
2

NA1379

Rotate the crankshaft until the timing mark (Item 1)


NA1377 (calculated earlier) is aligned with the reference mark
(Item 2) [Figure 60-70-26]. Highlight the mark on the
flywheel.
Figure 60-70-25
Rotate the crank shaft counter clockwise until the dial

Dealer Copy -- Not for Resale


indicator (Item 1) [Figure 60-70-22 on Page 60-70-7]
shows the injection pump plunger is at the bottom of its
stroke.
4
Slightly rock the crankshaft back and forth to confirm the
3 5
plunger is at the bottom of the stroke. Zero the dial
indicator.
2

NA1376

Using a wrench on the crankshaft pulley bolt, rotate the


crankshaft in a clockwise position (as viewed from the fan
end of the engine.) Rotate the crankshaft until the mark
(Item 1) [Figure 60-70-24] and [Figure 60-70-25] shows
in the inspection window.

The mark shown is TDC, the number 4 designates a four


cylinder engine.

The marks on the flywheel are as follows:

(Item 1) Top dead center


(Item 2) 10 BTDC
(Item 3) 15 BTDC
(Item 4) 20 BTDC
(Item 5) Direction of rotation [Figure 60-70-25].

765 of 879 60-70-8 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-29

Fuel Injection Pump - Timing (Cont’d)

Figure 60-70-27

1
2

P-91048

Loosen the nuts (Item 1) and bolts (Item 2) [Figure 60-


NA1380 70-29].

Figure 60-70-30
Slowly rotate the crankshaft clockwise until the dial
indicator (Item 1) [Figure 60-70-27] shows a plunger lift

Dealer Copy -- Not for Resale


of 2,5 mm (0.098 in).
2
Figure 60-70-28

NA1371
2

To advance the injection timing rotate the top of the fuel


injection pump away from the engine (Item 1) [Figure 60-
NA1379 70-30].

To retard the injection timing rotate the top of the fuel


If the highlighted timing mark (Item 1) is aligned with the injection pump towards the engine (Item 2) [Figure 60-
reference mark (Item 2) [Figure 60-70-28] the fuel 70-30].
injection timing is correct.
Rotate the fuel injection pump in the correct direction until
If the timing is incorrect, rotate the flywheel until the the dial indicator reads 2,5 mm (0.098 in). Tighten the
highlighted timing mark is aligned with the reference nuts (Item 1) and bolts (Item 2) [Figure 60-70-29].
mark.
NOTE: The highlighted flywheel timing mark must be
Note the reading on the dial indicator. If the reading is aligned with the reference mark.
less than 2,5 mm (0.098 in) the fuel injection timing is
advanced. Remove the dial indicator, reinstall the fuel injection plug,
turn on the fuel and remove the clamp from the return
fuel line. Operate the engine and check for leaks.

766 of 879 60-70-9 E80 Service Manual


FUEL SYSTEM (CONT’D) Figure 60-70-33

Fuel Injector Removal And Installation


4
Figure 60-70-31 2
3

1 6

P-91032

Figure 60-70-32

Dealer Copy -- Not for Resale


NA1360

1
1 Use a flat blade screw driver to pry the fuel injector
grommet (Item 1) out of the valve cover. Remove the
valve cover nuts (Item 2) and O-rings (Item 3). Remove
the valve cover (Item 4) and gasket (Item 5). Remove the
return fuel line (Item 6) [Figure 60-70-33].

P-91033

Remove the high pressure fuel lines [Figure 60-70-31]


and [Figure 60-70-32] from the injection pump and
injectors.

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

Installation: Tighten the high pressure fuel line nuts to


29 - 34 N•m (22 - 25 ft-lb) torque.

767 of 879 60-70-10 E80 Service Manual


FUEL SYSTEM (CONT’D)

Fuel Injector Removal And Installation (Cont’d)

Figure 60-70-34

5
4

NA1386

Remove the fuel injector clamp bolts (Item 1). Remove


the clamps (Item 2). Lift up on and remove the fuel

Dealer Copy -- Not for Resale


injector (Item 3) [Figure 60-70-34] from the cylinder
head.

Remove the nozzle protectors (Item 4) and seats (Item 5)


[Figure 60-70-34].

NOTE: Do not reuse the nozzle protectors and seats.

768 of 879 60-70-11 E80 Service Manual


FUEL SYSTEM (CONT’D) Nozzle Spray Condition

Fuel Injector Pressure - Testing Figure 60-70-36

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807 NA1382

Thoroughly clean the fuel injector nozzle using clean


Check that the spray pattern is correct [Figure 60-70-
diesel fuel and a brass wire brush.
36].
Figure 60-70-35
Operate the hand lever slowly to a pressure just below

Dealer Copy -- Not for Resale


opening pressure and hold that pressure for 5 seconds.
There must be no leaking or dripping from the injector
nozzle.

NA1360

Connect the nozzle to the tester, with the nozzle aimed to


the ground [Figure 60-70-35].

Operate the hand lever at a slow rate and record the


opening pressure. If the pressure is not correct, replace
the adjusting spacer.

Fuel Injection Pressure 21600 - 22600 kPa


(216 - 226 bar)
(3133 - 3278 psi)

769 of 879 60-70-12 E80 Service Manual


FUEL SYSTEM (CONT’D)

Nozzle Spray Condition (Cont’d)

Figure 60-70-37

6
5
4
3

Dealer Copy -- Not for Resale


2

NA1385

Remove the nut (Item 1) [Figure 60-70-37].

Installation: Tighten the nut to 40 - 45 N•m (30 - 33 ft-lb)


torque.

Remove the nozzle body (Item 2), nozzle valve (Item 3),
spacer (Item 4), spring seat (Item 5), spring (Item 6), and
shims (Item 7) from the body (Item 8) [Figure 60-70-37].

Add or remove shims (Item 7) [Figure 60-70-37] as


needed.

NOTE: Each shim added will increase pressure by


approximately 1900 kPa (19 bar) (275 psi).

770 of 879 60-70-13 E80 Service Manual


Dealer Copy -- Not for Resale

771 of 879 60-70-14 E80 Service Manual


CYLINDER HEAD

Valve Clearance Adjustment

Figure 60-80-1

5 The four valve cylinder head operates two valves with a


single rocker arm by using a valve bridge (Item 1)
4
between the two valves (Item 2). Clearance (Item 3)
between the valve bridge and valves must be adjusted
1
before adjusting the clearance (Item 4) between the
rocker arm (Item 5) [Figure 60-80-1] and valve bridge.
3
With the number 1 cylinder (flywheel end) at TDC, adjust
the following valves.
2 2

NA1072

Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

Dealer Copy -- Not for Resale


No. 1 Cylinder at X X X X
TDC Compression

Rotate the crankshaft until the number 4 cylinder (radiator end) is at TDC. Adjust the following valves.

Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No. 4 Cylinder at X X X X
TDC Compression

772 of 879 60-80-1 E80 Service Manual


CYLINDER HEAD (CONT’D) Figure 60-80-4

Valve Clearance Adjustment (Cont’d)

Figure 60-80-2

1
2

1
NA1077

Use a feeler gauge (Item 1) [Figure 60-80-4] to measure


NA1074 the clearance between the rocker arm and valve bridge.

Figure 60-80-5
Loosen the valve bridge adjustment screw (Item 1) until
there is visible clearance (Item 2) [Figure 60-80-2]
3

Dealer Copy -- Not for Resale


between the adjusting screw and front valve.
1
2
Figure 60-80-3

NA1078

Loosen the locknut (Item 1) and adjust the valve


clearance (Item 2) by turning the adjustment screw (Item
NA1076 3) [Figure 60-80-5] until there is a slight drag felt on the
feeler gauge.

Apply light downward pressure on the valve bridge and Tighten the lock nut (Item 1) [Figure 60-80-5].
adjust the valve bridge adjusting screw until there is zero
clearance between the screw and front valve. Tighten the Check and adjust the rest of the valves.
back nut and verify that there is still no clearance (Item 1)
[Figure 60-80-3].

773 of 879 60-80-2 E80 Service Manual


CYLINDER HEAD (CONT’D) Figure 60-80-8

Cylinder Head Removal And Installation


1
Figure 60-80-6 1
4
2 4

3 3

1 5

2
NA1046

Remove the bolts (Item 1). Remove the rocker arm and
NA1045 shaft assembly from the head. Remove the push rods
(Item 2). Remove the valve bridge assemblies (Item 3)
and seats (Item 4) [Figure 60-80-8].
Remove the high pressure fuel lines. Use a flat bladed
screwdriver to remove the fuel injection line grommets NOTE: Mark the push rods and rocker arms so the

Dealer Copy -- Not for Resale


(Item 1) [Figure 60-80-6]. parts are installed in the original position.

NOTE: There is a notch at the 3 O’clock position in Figure 60-80-9


the valve cover opening to insert the
screwdriver.
6
Remove the valve cover nuts (Item 2) and O-rings (Item
3). Remove the valve cover (Item 4) and valve cover 3 1
gasket (Item 5) [Figure 60-80-6]. 5

Figure 60-80-7
2
2
4
3 1
4 2
3
N-1047
4
5 6
Remove the studs (Item 1) from the supports (Item 2).
Slide the supports, washers (Item 3), rocker arms (Item
4) and fuel injector retainers (Item 5) off the shaft (Item 6)
[Figure 60-80-9].

NA1386

Remove the return line (Item 1). Remove injector clamp


bolts (Item 2) and remove the clamps (Item 3). Pull up on
and remove the fuel injector (Item 4). Remove and
discard the nozzle protector (Item 5) and seat (Item 6)
[Figure 60-80-7].

774 of 879 60-80-3 E80 Service Manual


CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly

Cylinder Head Removal And Installation (Cont’d) Figure 60-80-12

Figure 60-80-10
1

7 16 14 6
1 9 18 12 4
A
3 11 17 10 2
5 13 15 8

NA1050

NA1048
Use a valve spring compressor tool (Item 1) [Figure 60-
80-12] to compress the valve spring.
Loosen the cylinder head bolts in the sequence shown
[Figure 60-80-10]. Figure 60-80-13

Dealer Copy -- Not for Resale


NOTE: A is the flywheel side. 1
2
Installation: Apply oil to the bolt threads. Tighten the 3
bolts in the correct sequence in order of #18 - #1 to 103 -
113 N•m (76 - 83 ft-lb) torque. 5

Figure 60-80-11

4
2
NA1051

Remove the valve keepers (Item 1). Slowly release the


tension on the valve spring. Remove the spring retainer
(Item 2) and valve spring (Item 3). Remove the valves
(Item 4) and remove the valve stem seals (Item 5)
3 [Figure 60-80-13].
NA1049

Remove the bolts (Item 1). Remove the cylinder head


(Item 2) and remove and discard the gasket (Item 3)
[Figure 60-80-11].

775 of 879 60-80-4 E80 Service Manual


CYLINDER HEAD (CONT’D) Cylinder Head - Servicing

Cylinder Head Disassembly And Assembly (Cont’d) Clean the surface of the cylinder head.

Figure 60-80-14 Figure 60-80-15

1
1

NA1052 NA1057

Use a drift and hammer to drive the valve guides (Item 1) Put a straight edge (Item 1) [Figure 60-80-15] on the
[Figure 60-80-14] out of the head. cylinder head.

Dealer Copy -- Not for Resale


NOTE: Do not remove the valve guides until the NOTE: Do not put the straight edge across
inspection and measurement procedures combustion chambers.
have been performed.
Put a feeler gauge (Item 2) [Figure 60-80-15] between
the straight edge and the surface of the cylinder head.

Figure 60-80-16

PI-9988

Put the straight edge on the cylinder head’s four sides


and on the two diagonals as shown [Figure 60-80-16].

The maximum distortion of the head surface is ± 0,15


mm (± 0.0059 in). If the measurement exceeds the
specification, replace the cylinder head.

776 of 879 60-80-5 E80 Service Manual


CYLINDER HEAD (CONT’D) Figure 60-80-19

Valve Guide - Inspection

Clean the valve seat and combustion chamber.

Figure 60-80-17

NA1056

Measure the valve guide I.D. at three different depths


and 90° apart [Figure 60-80-19].

P-87490 NOTE: Measure the valve guides while they are still
installed in the cylinder head.

Dealer Copy -- Not for Resale


Install the valve into the guide. Measure the valve Valve Guide 7,0 - 7,015 mm
recessing with a depth gauge [Figure 60-80-17]. (0.2756 - 0.2762 in)

Figure 60-80-18 Allowable Limit 7,08 mm


(0.2787 in)
2 Valve Guide Projection 11,7 - 12,0 mm
From Cylinder Head (0.460 - 0.472 in)

1. Cylinder Head Surface


2. Recessing

PI-9990

If the measurement exceeds the allowable limit, replace


the valve or cylinder head [Figure 60-80-18].

Recessing (Intake) 0,36 - 0,56 mm


(0.0142 - 0.0220 in)
Recessing (Exhaust) 0,35 - 0,55 mm
(0.0138 - 0.0217 in)
Allowable Limit 0,8 mm
(Intake, Exhaust) (0.0315 in)

777 of 879 60-80-6 E80 Service Manual


CYLINDER HEAD (CONT’D) Valve Stem Bend - Inspection

Intake And Exhaust Valve - Inspection Figure 60-80-21

Figure 60-80-20
1

1 1

1 1

NA-1059

NA1058
Place the valve stem on an inspection block. Use a feeler
gauge (Item 1) [Figure 60-80-21] to measure the gap.
Measure the valve stem diameter (Item 1) [Figure 60-80-
20] where shown. Intake Valve Stem Bend 0,040 - 0,070 mm

Dealer Copy -- Not for Resale


(0.0016 - 0.0028 in)
Intake Valve Stem O.D. 6,945 - 6,960 mm
Exhaust Valve Stem Bend 0,045 - 0,075 mm
(0.2734 - 0.2740 in)
(0.0018 - 0.0030 in)
Allowable Limit 6,90 mm
Allowable Limit 0,17 mm
(Intake, Exhaust) (0.2717 in)
(0.0067 in)

Exhaust Valve Stem O.D. 6,940 - 6,955 mm


(0.2732 - 0.2738 in)
Allowable Limit 6,90 mm
(Intake, Exhaust) (0.2717 in)

778 of 879 60-80-7 E80 Service Manual


CYLINDER HEAD (CONT’D) Valve Spring - Inspection

Valve Face And Seat Figure 60-80-24

Figure 60-80-22

NA1065

NA1062
Measure the valve spring free length [Figure 60-80-24].

Inspect the valve. The contact pattern should be Free Length 39,7 mm
approximately centered on the valve face (Item 1) (1.563 in)

Dealer Copy -- Not for Resale


[Figure 60-80-22].
Allowable Limit 39,2 mm
Figure 60-80-23 (1.5433 in)

Figure 60-80-25

150°
1
40°

NA1063

NA1064
The valve seat diameter (Item 1) [Figure 60-80-23] can
be adjusted by top grinding with a 150° stone to make the
seat diameter smaller, and bottom grinding using a 40° Use a flat surface and square to check the springs for
stone to make the seat diameter larger. squareness [Figure 60-80-25].

Seat Angle Intake 120° Squareness Allowable 1,4 mm


Limit (0.0551 in)
Exhaust 90°

779 of 879 60-80-8 E80 Service Manual


CYLINDER HEAD (CONT’D) Figure 60-80-28

Push Rod - Inspection

Figure 60-80-26 2

1 1

2
NA1055

Measure the rocker arm shaft at two points 90° apart


NA1053 (Item 1) and (Item 2) [Figure 60-80-28].

Calculate the difference of the shaft and rocker arm bore


Place the push rod on an inspection block. Use a feeler I.D.
gauge (Item 1) [Figure 60-80-26] to measure the gap.

Dealer Copy -- Not for Resale


Arm Hole Diameter 18,5 - 18,52 mm
Push Rod Bend Less than 0,03 mm (0.7283 - 0.7291 in)
(0.0012 in)
Allowable Limit 18,57 mm
Allowable Limit 0,03 mm (0.7311 in)
(0.0012 in)
Shaft O.D. 18,47 - 18,49 mm
(0.7272 - 0.7280 in)
Rocker Arm - Inspection
Allowable Limit 18,44 mm
Figure 60-80-27 (0.7260 in)
Oil Clearance 0,010 - 0,050 mm
(0.004 - 0.0020 in)
Allowable Limit 0,13 mm
(0.0051 in)

NA1054

Measure the ID of the rocker arm bore [Figure 60-80-


27].

780 of 879 60-80-9 E80 Service Manual


CYLINDER HEAD (CONT’D)

Valve Bridge - Inspection

Figure 60-80-29

1
1

NA1066

Visually inspect the contact surface (Item 1) at both ends


of the valve bridge for wear and mushrooming. Remove

Dealer Copy -- Not for Resale


and inspect the seat (Item 2) [Figure 60-80-29].

781 of 879 60-80-10 E80 Service Manual


CRANKSHAFT AND PISTONS Figure 60-90-2

Piston And Connecting Rod Removal And


Installation 2

Figure 60-90-1
3
4

7
6

NA1091

NA1094
Measure the connecting rod side clearance [Figure 60-

Dealer Copy -- Not for Resale


90-1].
Remove the bearings (Item 1), compression rings (Item
Connecting Rod Side 0,20 - 0,40 mm 2), oil ring (Item 3), circlips (Item 4) and wrist pin (Item 5)
Clearance (0.0079 - 0.0157 in) [Figure 60-90-2] from the piston.

Remove the connecting rod (Item 6) and bearing (Item 7)


[Figure 60-90-2].

782 of 879 60-90-1 E80 Service Manual


CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-4

Piston And Connecting Rod - Servicing

Figure 60-90-3

22 mm
(0.8661 in)
NA1085

Measure 22 mm (0.8661 in) upwards from the bottom of


P47273 the piston skirt at 90° from the wrist pin bore [Figure 60-
90-4].

Measure the connecting rod wrist pin bore and wrist pin Piston OD 97,93 - 97,96 mm
diameter [Figure 60-90-3]. (3.8555 - 3.8567 in)

Dealer Copy -- Not for Resale


Allowable Limit 97,895 mm
Wrist Pin Bushing ID 30,025 - 30,038 mm
(3.8541 in)
(1.1821 - 1.1826 in)
Allowable Limit 30,068 mm Figure 60-90-5
(1.1838 in)
Wrist Pin OD 29,987 - 30,0 mm
(1.1806 - 1.1811 in)
Allowable Limit 29,959 mm
(1.1795 in)
Oil Clearance 0,025 - 0,51 mm
(0.0010 - 0.0020 in)
Allowable Limit 0,109 mm
(0.0043 in)

P-47272

Measure the wrist pin bore ID [Figure 60-90-5].

Wrist Pin Bore ID 30,0 - 30,009 mm


(1.1811 - 1.1815 in)
Allowable Limit 30,039 mm
(1.1826 in)

783 of 879 60-90-2 E80 Service Manual


CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-7

Piston And Connecting Rod - Servicing (Cont’d)

Figure 60-90-6

B3622

Install a piston ring into the lower part of the cylinder


PI-10017 bore. Measure the ring gap with a feeler gauge [Figure
60-90-7].

Remove the carbon from the ring grooves. Measure the If the gap exceeds the allowable limit, replace the ring.
clearance between the ring and groove with a feeler

Dealer Copy -- Not for Resale


gauge [Figure 60-90-6]. Top Ring End Gap 0,250 - 0,450 mm
(0.0098 - 0.0177 in)
If the clearance exceeds the allowable limit, replace the
ring. If the clearance still exceeds the allowable limit, Allowable Limit 0,540 mm
replace the piston. (0.0213 in)
Second Ring End Gap 0,450 - 0,650 mm
Top Ring Side Clearance 0,08 - 0,12 mm (0.017 - 0.0256 in)
(0.0031 - 0.0047 in) Allowable Limit 0,730 mm
Second Ring Side 0,09 - 0,125 mm (0.0287 in)
Clearance (0.0035 - 0.0049 in) Oil Ring End Gap 0,250 - 0,450 mm
Oil Ring Side Clearance 0,025 - 0,060 mm (0.0098 - 0.0177 in)
(0.0010 - 0.0024 in) Allowable Limit 0,550 mm
(0.0217 in)

784 of 879 60-90-3 E80 Service Manual


CRANKSHAFT AND PISTONS (CONT’D) Crankshaft End Play

Cylinder Bore - Inspection Figure 60-90-10

Figure 60-90-8

NA1096

B-4066
Install a dial indicator on the cylinder block [Figure 60-
90-10]. Move the crankshaft back and forth to measure
Use a gauge to measure the inside of the cylinder bore end play.
[Figure 60-90-8].

Dealer Copy -- Not for Resale


Crankshaft End Play 0,13 - 0,23 mm
Figure 60-90-9 (0.0051 - 0.0091 in)
Allowable Limit 0,28 mm
(0.0110 in)

A-2717

To find the maximum wear, check the inside diameter in


six different locations [Figure 60-90-9].

If the cylinder bore is not within specifications, bore and


hone the cylinder for an oversize piston.

Cylinder ID 98,0 - 98,03 mm


(3.8583 - 3.8594 in)
Allowable Limit 98,13 mm
(3.8634 in)
Cylinder Bore 0,01 mm
Taper/Roundness (0.0004 in)
Allowable Limit 0,03 mm
(0.0012 in)

785 of 879 60-90-4 E80 Service Manual


CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-13

Crankshaft And Bearings Removal And Installation


3
Figure 60-90-11
2
1 2
3 1
4
5

NA1099

Do not remove the crankshaft gear (Item 1), key (Item 2)


NA1095 and parallel pin (Item 3) [Figure 60-90-13] unless worn
or damaged.

Remove the bolts (Item 1) and flywheel (Item 2) [Figure


60-90-11].

Dealer Copy -- Not for Resale


Installation: Tighten the bolts to 186 - 206 N•m (137 -
152 ft-lb) torque.

Remove the oil seal retainer bolts (Item 3), oil seal
retainer (Item 4) and seal (Item 5) [Figure 60-90-11].

Figure 60-90-12

NA1098

Mark for reassembly and remove the rod bearing caps,


rod bearings, bearing caps and main bearings [Figure
60-90-12].

NOTE: The arrows on the main bearing caps point to


the flywheel side of the engine.

Remove the crankshaft from the block.

786 of 879 60-90-5 E80 Service Manual


CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-15

Crankshaft And Bearings - Servicing

Figure 60-90-14

A2716

Measure the main bearing journal and connecting rod


A2763 journal [Figure 60-90-15].

Connecting Journal OD 57,952 - 57,962 mm


Put the crankshaft on V-blocks. Install a dial indicator on Rod Journal (2.2816 - 2.2827 in)
the center journal [Figure 60-90-14].
Allowable Limit 57,902 mm

Dealer Copy -- Not for Resale


Turn the crankshaft at a slow rate to obtain the (2.2796 in)
misalignment (one half of the alignment measurement). Bearing ID 58,0 - 58,026 mm
(2.2835 - 2.2845 in)
If the misalignment exceeds the allowable limit, replace Bearing Insert 1,492 - 1,50 mm
the crankshaft. Thickness (0.0587 - 0.0591 in)
Oil Clearance 0,038 - 0,074 mm
Alignment 0,02 mm
(0.0015 - 0.0029 in)
(0.0008 in)
Allowable Limit 0,150 mm
(0.0059 in)
Main Bearing Journal OD 64,952 - 64,962 mm
Journal (2.5572 - 2.5576 in)
Allowable Limit 64,902 mm
(2.5552 in)
Bearing ID 65,0 - 65,020 mm
(2.559 - 2.5598 in)
Bearing Insert 1,995 - 2,010 mm
Thickness (0.0785 - 0.0791in)
Oil Clearance 0,038 - 0,068 mm
(0.0015 - 0.0027 in)
Allowable Limit 0,150 mm
(0.0059 in)

787 of 879 60-90-6 E80 Service Manual


CAMSHAFT AND TIMING GEARS

Timing Gear Case Cover Removal And Installation

Remove the bolt and washer from the crankshaft pulley.

Remove the pulley.

Installation: Tighten the crankshaft pulley bolt to 108 -


128 N•m (80 - 94 ft-lb) torque.

Figure 60-100-1

Dealer Copy -- Not for Resale


3
2 NA1089

Remove the bolts (Item 1). Remove the timing gear case
(Item 2). Clean all of the old sealant off the cylinder block
and timing gear case. Remove the O-rings (Item 3)
[Figure 60-100-1].

788 of 879 60-100-1 E80 Service Manual


CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-3

Timing Gear Backlash - Inspection

Figure 60-100-2

1
3
2
4

NA1081

5
6 Install a dial indicator and rotate the idler gear back and
NA1080 forth to check the idler gear to crankshaft backlash
[Figure 60-100-3]. Check the remainder of the gears
using the above procedure.
Before removing the timing gears, measure the backlash
to determine wear.

Dealer Copy -- Not for Resale


(Item 1) Fuel injection pump drive gear
(Item 2) Idler gear
(Item 3) Camshaft drive gear
(Item 4) Auxiliary drive gear (optional)
(Item 5) Crankshaft drive gear
(Item 6) [Figure 60-100-2] oil pump drive gear.

Fuel Injection Pump Gear 0,08 - 0,14 mm


(0.0031 - 0.0055 in)
Idler Gear 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Camshaft Gear 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Auxiliary Drive Gear 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Crank Shaft Gear 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Allowable Limit 0,16 mm
(0.0063 in)
Oil Pump Gear 0,09 - 0,15 mm
(0.0035 - 0.0059 in)
Allowable Limit 0,17 mm
(0.0067 in)

789 of 879 60-100-2 E80 Service Manual


CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-5

Idler Gear And Camshaft Removal And Installation

Figure 60-100-4

1 NA1086

4
Install a dial indicator on the cylinder block. Move the
2 camshaft back and forth to measure end play [Figure 60-
NA1082
100-5].

Remove the bolts (Item 1) from the idler gear shaft (Item Camshaft End Play 0,05 - 0,20 mm
2) and bushing (Item 3). Remove the idler gear (Item 4) (0.0020 - 0.0079 in)

Dealer Copy -- Not for Resale


[Figure 60-100-4].
Allowable Limit 0,030 mm
Measure the OD of the idler gear shaft (Item 2) and the (0.0118 in)
ID of the bushing (Item 3) [Figure 60-100-4] and
calculate the oil clearance. Figure 60-100-6

Shaft OD 45,95 - 45,975 mm


(1.8091 - 1.8100 in)
Allowable Limit 45,9 mm 3
(1.8071 in)
Bushing ID 46,0 - 46,025 mm 2
(1.8110 - 1.8120 in)
Allowable Limit 46,075 mm
(1.8140 in)
Oil Clearance 0,025 - 0,075 mm
(0.001 - 0.003 in)
1
Allowable Limit 0,175 mm
(0.0069 in) P-87490

Do not remove the crankshaft gear unless it requires


replacement. If it must be removed, remove it using a Remove the two bolts (Item 1) from the retaining plate
gear puller. (Item 2) [Figure 60-100-6]. Rotate the crankshaft to push
the tappets away from the camshaft and remove the
To remove the camshaft gear, the camshaft must be camshaft assembly.
removed from the engine.
NOTE: Be careful to not damage the front camshaft
bearing.

Mark and remove the tappets (Item 3) [Figure 60-100-6].

790 of 879 60-100-3 E80 Service Manual


CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-8

Camshaft - Servicing

Figure 60-100-7

B-5001

Measure the cam lobes at their highest point [Figure 60-


A-2760 100-8].

If the measurement is less than the allowable limit,


Put the camshaft in V-blocks. Install a dial indicator replace the camshaft.
[Figure 60-100-7].

Dealer Copy -- Not for Resale


Cam Lobe Height 43,4 - 43,6 mm
Turn the camshaft at a slow rate. If the misalignment (1.7087 - 1.7165 in)
exceeds the allowable limit, replace the camshaft.
Allowable Limit 43,15 mm
(1.6988 in)
Camshaft Alignment 0,02 mm
Allowable Limit (0.0008 in)

791 of 879 60-100-4 E80 Service Manual


CAMSHAFT AND TIMING GEARS (CONT’D) Flywheel And Bore ID 50,0 - 50,025 mm
Journal (1.9685 - 1.9695 in)
Camshaft - Servicing (Cont’d)
Allowable Limit 50,1 mm
Figure 60-100-9 (1.9724 in)
Camshaft OD 49,925 - 49,95 mm
(1.9655 - 1.9665 in)
Allowable Limit 49,89 mm
(1.7673 in)
Oil Clearance 0,05 - 0,1 mm
(0.0020 - 0.0039 in)
Allowable Limit 0,210 mm
(0.0083 in)

Idler Gear And Shaft - Servicing

Figure 60-100-10
A-2761

Measure the camshaft journal [Figure 60-100-9].

Dealer Copy -- Not for Resale


Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the camshaft. 1 2

Gear End Bushing ID 49,99 - 50,06 mm


Journal (1.9681 - 1.9707 in)
Allowable Limit 50,130 mm
(1.9736 in)
Camshaft OD 49,925 - 49,950 mm
(1.9655 - 1.9665 in) S9893

Allowable Limit 49,89 mm


(1.9642 in) Measure the outside diameter (Item 1) [Figure 60-100-
Oil Clearance 0,04 - 0,13 mm 10] of the idler gear shaft.
(0.0016 - 0.0051 in)
Allowable Limit 0,240 mm Measure the inside diameter (Item 2) [Figure 60-100-10]
(0.0094 in) of the idler gear bushing.

Intermediate Bore ID 50,0 - 50,025 mm


45,950 - 45,975 mm
Journal (1.9685 - 1.9695 in) Shaft outside diameter
(1.8091 - 1.8100 in)
Allowable Limit 50,1 mm
45,900 mm
(1.9724 in) Allowable Limit
(1.8071 in)
Camshaft OD 49,91 - 49,935 mm 46,000 - 46,025 mm
(1.9650 - 1.9659 in) Bushing inside diameter
(1.8110 - 1.8120 in)
Allowable Limit 49,875 mm 46,075 mm
(1.9636 in) Allowable Limit
(1.8140 in)
Oil Clearance 0,065 - 0,115 mm 0,0254 - 0,0762 mm
(0.0026 - 0.0045 in) Oil clearance
(0.0010 - 0.0030 in)
Allowable Limit 0,225 mm 0,175 mm
(0.0089 in) Allowable Limit
(0.0069 in)

If the oil clearance exceeds the allowable limit, replace


the bushing.

792 of 879 60-100-5 E80 Service Manual


Dealer Copy -- Not for Resale

793 of 879 60-100-6 E80 Service Manual


COLD START DEVICE Figure 60-110-3

Description

Figure 60-110-1

P-91040

Use an ohmmeter to check the cold start device [Figure


P-91037 60-110-3].

Connect one probe to the solenoid stud and the other


The cold start device (CSD) (Item 1) [Figure 60-110-1] is probe to a good ground. The reading should be
located in the top front of the fuel injection pump and is approximately 8.5 - 9 ohm. If the resistance is infinite or

Dealer Copy -- Not for Resale


connected to the engine’s cooling system. With the zero, the solenoid is defective and must be replaced.
engine coolant temperature below 5°C (41°F) the cold
start device advances the fuel injection timing and slightly Removal And Installation
increases fuel injection volume.
Figure 60-110-4
When the engine coolant temperature rises above 10°C
(50°F) the cold start device shuts off.

NOTE: The low idle speed will be slightly higher than


normal when the cold start device is
operating.
1
Testing

Figure 60-110-2

P-91041
1

Remove the solenoid (Item 1) [Figure 60-110-4] from the


fuel injection pump.

P-91039

Pull the boot back and disconnect the wire harness (Item
1) [Figure 60-110-2].

794 of 879 60-110-1 E80 Service Manual


Dealer Copy -- Not for Resale

795 of 879 60-110-2 E80 Service Manual


EXHAUST GAS RECIRCULATION VALVE (EGR) Figure 60-120-3

Description

Figure 60-120-1

NA1360

Figure 60-120-4
P-91042

The EGR valve (Item 1) [Figure 60-120-1] has four built


in coils. The power to each of the coils is either on or off.

Dealer Copy -- Not for Resale


Depending on which coil is on and which coil is off, the
step motor rotates to determine the valve lift.

The power to each coil is turned on and off by the ECU


based on engine speed and fuel injection rate.

Testing

Figure 60-120-2
NA1358

Test between pins 1 & 2 and 2 & 3 [Figure 60-120-3] and


[Figure 60-120-4].

Test between pins 4 & 5 and 5 & 6 [Figure 60-120-3] and


[Figure 60-120-4].

1 The reading should be 13 - 17 ohm at 20°C (68°F).

P-91043

Disconnect the wire harness (Item 1) [Figure 60-120-2].

Use a multimeter to check the EGR valve.

796 of 879 60-120-1 E80 Service Manual


EXHAUST GAS RECIRCULATION VALVE (EGR) Removal And Installation
(CONT’D)
Drain the radiator. (See Removing And Replacing
Testing (Cont’d) Coolant on Page 10-110-2.)

Figure 60-120-5 Figure 60-120-6

1 4
3

2 1

P-91046
P-91043

Remove the two nuts (Item 1), bolts (Item 2) and pipe Disconnect the wire harness (Item 1) [Figure 60-120-6].
(Item 3) [Figure 60-120-5]. Remove the gaskets.

Dealer Copy -- Not for Resale


Figure 60-120-7
NOTE: Always use new gaskets when installing the
EGR pipe.

Turn the key to the run position and observe the valve
functions through the exhaust gas inlet (Item 4) [Figure
60-120-5]. 1
3 4
NOTE: When the key is first turned to the run
position, the ECU checks valve operation by
opening and shutting the valve. 5
2

If the EGR valve does not operate smoothly,


replace the valve.
5
P-91046

Remove the two nuts (Item 1), bolts (Item 2) and pipe
(Item 3). Remove the coolant lines (Item 4). Remove the
two bolts (Item 5) [Figure 60-120-7] and remove the
valve assembly.

NOTE: Always use new gaskets when installing the


EGR pipe.

797 of 879 60-120-2 E80 Service Manual


MANIFOLD AIR HEATER Removal And Installation

Description Figure 60-130-3

The manifold air heater will be energized for up to twenty- 2


three seconds to preheat the intake air. The duration of
the air heater run time depends on the engine coolant
temperature.
1
Testing 1

Figure 60-130-1
1
1

P-91036

Remove the four bolts (Item 1) and the heater (Item 2)


[Figure 60-130-3].

Dealer Copy -- Not for Resale


P-91035

Disconnect the wire harness (Item 1) [Figure 60-130-1].

Figure 60-130-2

P-91034

Use an ohmmeter to check the air heater [Figure 60-


130-2].

Connect one probe to the wire harness stud and the


other probe to a good ground.

The reading should be approximately 0.3 - 0.5 ohm. If the


resistance is infinite or zero, the heater is defective and
must be replaced.

798 of 879 60-130-1 E80 Service Manual


Dealer Copy -- Not for Resale

799 of 879 60-130-2 E80 Service Manual


ENGINE FLYWHEEL Figure 60-140-3

Hydraulic Pump Coupler Removal And Installation

Remove the hydraulic piston pump. (See Removal And


Installation on Page 20-50-14.)

Figure 60-140-1

1
1
P-87488

Remove the snap ring (Item 1) [Figure 60-140-3].

Figure 60-140-4
2
P-87483

Dealer Copy -- Not for Resale


Remove the twelve bolts (Item 1) and plate (Item 2)
[Figure 60-140-1].

Installation: Apply thread adhesive (Loctite® 242) to the


bolt threads before installation.

Tighten the bolts to 61 N•m (45 ft-lb) torque.

Figure 60-140-2

1 P-87489

2 Turn the coupler over and remove the center of the


coupler [Figure 60-140-4].

P-87487

Remove the bolts (Item 1) and coupler (Item 2) [Figure


60-140-2].

NOTE: The bolts may need to be heated to melt the


thread adhesive before removal.

Installation: Apply thread adhesive (Loctite® 271) to the


bolt threads before assembly.

800 of 879 60-140-1 E80 Service Manual


ENGINE FLYWHEEL (CONT’D) Flywheel Ring Gear Removal And Installation

Flywheel Removal And Installation

Figure 60-140-5
WARNING
AVOID INJURY OR DEATH
1 Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
1
• Engine is running.
• Tools are being used.
W-2019-0907

1
The ring gear on the flywheel is an interference fit. Heat
the ring gear enough to expand it and hit it with a
P-87490
hammer evenly to remove it.

Clean the outer surface of the flywheel to give a smooth


Remove the six bolts (Item 1) [Figure 60-140-5] from the fit.
flywheel.

Dealer Copy -- Not for Resale


Clean the new ring gear and heat it to a temperature of
Installation: Tighten the bolts 186 - 206 N•m (137 - 152 232 - 260°C (450 - 500°F)
ft-lb) torque.
Fit the ring gear over the flywheel. Make sure the gear is
Remove the flywheel. seated correctly.

801 of 879 60-140-2 E80 Service Manual


HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1


Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 70-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 70-30-1
The Compressor Operates Improperly Or Not At All . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Dealer Copy -- Not for Resale


Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-2
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-4
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-5
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-6

SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1


Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 70-40-1
Charging With A Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-4

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4

CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1


Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

802 of 879 70-01 E80 Service Manual


BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

HVAC CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Dealer Copy -- Not for Resale

803 of 879 70-02 E80 Service Manual


AIR CONDITIONING SYSTEM FLOW

Description

In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.

The compressor (Item 1) (See Chart on Page 70-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 70-10-2.).

Ambient air passing through the condenser removes the heat from the refrigerant, resulting in a physical state change in
the refrigerant from a gas to a liquid.

The liquid refrigerant moves on to the receiver/drier (Item 3) (See Chart on Page 70-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) Page (See Chart on Page 70-10-2.).

The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 70-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) (See Chart on Page 70-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and

Dealer Copy -- Not for Resale


drips into the drain pan, which directs the water out of the cab.

The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

804 of 879 70-10-1 E80 Service Manual


AIR CONDITIONING SYSTEM FLOW (CONT'D)

Chart

Thermostat
Cold Air
Evaporator

5
Evaporator
4 Expansion Valve

Blower 6

Dealer Copy -- Not for Resale


1 Compressor

2 Condenser
Pressure
Switch
Sight
Glass

Fan
Desiccant

3 Receiver Drier

High Pressure Gas Low Pressure Liquid


High Pressure Liquid
Low Pressure Gas

805 of 879 70-10-2 E80 Service Manual


AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-3

Components

Figure 70-10-1

1
P-86814

1 Condenser: The condenser (Item 1) [Figure 70-10-3] is


P-86815 the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
Compressor: The compressor (Item 1) [Figure 70-10-1]
is the pump that circulates the refrigerant through the Figure 70-10-4

Dealer Copy -- Not for Resale


system. It raises the pressure of the refrigerant for heat
transfer through the condenser and evaporator.

NOTE: The A/C system (Compressor) is 2


recommended to be turned on for at least five
minutes weekly through the year to lubricate
the internal components. 1

Figure 70-10-2

P-86814

Receiver / Drier: The receiver / drier (Item 1) [Figure 70-


10-4] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
1 from the system. It also serves as a storage tank for the
extra liquid refrigerant until it is needed by the evaporator.

P-86889 Pressure Switch: The pressure switch (Item 2) [Figure


70-10-4] will disengage the compressor clutch at high
pressure readings on the high side, or at very low
Compressor Diode: The compressor diode is located pressure on the high side, which indicates loss of
under the compressor [Figure 70-10-2]. refrigerant.

806 of 879 70-10-3 E80 Service Manual


AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-7

Components (Cont’d) 3 2

Figure 70-10-5

P-87074
1

Thermostat: The thermostat (Item 1) [Figure 70-10-7]


P-87055 controls the temperature of the evaporator coil.

Heater Coil: The heater coil (Item 2) [Figure 70-10-7]


Evaporator / Heater Unit: The evaporator / heater unit supplies the warm air into the cab by passing air through
(Item 1) [Figure 70-10-5] is located under the operator the coil.

Dealer Copy -- Not for Resale


seat in the excavator cab. The unit delivers cold air for
the A/C and warm air for heat into the cab. The unit Evaporator Coil: The evaporator coil (Item 3) [Figure 70-
contains the blower, heater coil, evaporator coil, 10-7] cools and dehumidifies the air before it enters the
thermostat, and expansion valve. cab.

Figure 70-10-6 Figure 70-10-8

1 1

P-87067 P-87068

Expansion Valve: The expansion valve (Item 1) [Figure Heater / Evaporator Blower: The blower (Item 1) [Figure
70-10-6] controls the amount of refrigerant entering the 70-10-8] pushes air through the heater and evaporator
evaporator coil. coils and into the cab.

807 of 879 70-10-4 E80 Service Manual


AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-10

Components (Cont’d)

Figure 70-10-9

6 3 5 5
1

P-86818
2
4
Heater Valve: The heater valve (Item 1) [Figure 70-10-
P-86817 10] is used to control the amount of engine coolant that
flows to the heater coil.

Control Panel: The panel (Item 1) [Figure 70-10-9] has


three separate components.

Dealer Copy -- Not for Resale


Fan Switch: This is a three position switch (Item 2)
[Figure 70-10-9]. When the fan switch is in the off
position the A/C will not engage.

A/C Switch: The switch (Item 3) [Figure 70-10-9] will be


illuminated when the A/C is engaged.

Temperature Control: The temperature control (Item 4)


[Figure 70-10-9] controls the cooling / heating air
temperature.

Directional Switches: The switches (Item 5) [Figure 70-


10-9] control the direction of the air flow.

Off Switch: The off switch (Item 6) [Figure 70-10-9] shuts


the HVAC system off.

808 of 879 70-10-5 E80 Service Manual


AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-12

Safety Equipment

In servicing A/C and heater systems you will be exposed


to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.

Figure 70-10-11

P-16399

R-134a inside a canister or in an A/C system is a liquid


under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8°C (21.6°F)
“INSTANTLY”.

If it spills on your skin or in your eyes you should flood the

Dealer Copy -- Not for Resale


P-16398 area with cool water and SEEK MEDICAL ATTENTION
FAST! It is a good idea to wear gloves to prevent frost
bite if you should get refrigerant on your hands [Figure
In addition to exercising caution in your work, DO WEAR 70-10-12].
SAFETY GLASSES OR A FACE SHIELD when you are
using R-134a or a leak detector, adjusting service valves
or the manifold gage set connectors. Safety glasses or a
transparent face shield are practical safety items and one
or the other is absolutely required [Figure 70-10-11]. WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
WARNING if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
In the event of a leak, wear safety goggles. Escaping when it contacts open flame or very hot
refrigerant can cause severe injuries to eyes. In substances.
contact with a flame, R134a refrigerant gives a toxic • NEVER SMOKE when there is the possibility of
gas. even small amounts of 134A in the air.
W-2371-0500 Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500

809 of 879 70-10-6 E80 Service Manual


REGULAR MAINTENANCE Figure 70-20-3

Filters

Remove the Heat / AC filter. (See Cleaning And


Maintenance on Page 10-100-1.)
2
Clean the filter by shaking it or using low air pressure.

Belt Adjustment 1

See the Chart for the correct service interval. (See


SERVICE SCHEDULE on Page 10-80-1.)

Open the right side cover. (See Opening And Closing on


Page 10-50-1.)
P-86920
Figure 70-20-1

Press down on the belt midway between the crankshaft


2 pulley and the compressor pulley. The correct tension
should allow the belt to deflect 10 mm (0.375 in) [Figure
70-20-3].

Loosen the lock nut (Item 1) and adjust the bolt (Item 2)

Dealer Copy -- Not for Resale


[Figure 70-20-3] until the belt tension is correct.
1
When the belt tension is correct, tighten the lock nut
(Item 1) [Figure 70-20-3].

Tighten the belt idler mounting bolt (Item 1) [Figure 70-


20-2].
P-86922

Reinstall the shield (Item 2) and the two bolts and


The air conditioning belt will be adjusted by using the bolt washers (Item 1) [Figure 70-20-1].
(Item 1) [Figure 70-20-1].

Figure 70-20-2

WARNING
AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
1 screens, shields or rubber deflectors.
• Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
W-2528-0406

P-86921

NOTE: The belt shield is removed for photo clarity in


the following two photos.

Loosen the belt idler mounting bolt (Item 1) [Figure 70-


20-2].

810 of 879 70-20-1 E80 Service Manual


REGULAR MAINTENANCE (CONT’D) Figure 70-20-6

Belt Replacement

Figure 70-20-4
2
1
1

P-86920

Loosen the lock nut (Item 1) and the bolt (Item 2) [Figure
P-86922 70-20-6] until the belt can be removed.

Install a new belt.


Remove the two bolts and washers (Item 1) and remove
the shield (Item 2) [Figure 70-20-4]. Adjust the bolt (Item 2) until the belt tension is correct.

Dealer Copy -- Not for Resale


Tighten the lock nut (Item 1) [Figure 70-20-6].
Figure 70-20-5
Tighten the belt idler mounting bolt (Item 1) [Figure 70-
20-5].

Reinstall the shield (Item 2) and the two bolts and


washers (Item 1) [Figure 70-20-4].
1

WARNING
AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
screens, shields or rubber deflectors.
P-86921 • Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
Loosen the belt idler mounting bolt (Item 1) [Figure 70- W-2528-0406
20-5].

811 of 879 70-20-2 E80 Service Manual


REGULAR MAINTENANCE (CONT’D)

Condenser

Open the right side cover.

Figure 70-20-7

1
P-86814

Check the condenser (Item 1) [Figure 70-20-7] for mud

Dealer Copy -- Not for Resale


or dirt.

The condenser can be cleaned with low water or air


pressure.

812 of 879 70-20-3 E80 Service Manual


REGULAR MAINTENANCE (CONT’D)

Air Conditioning Service Chart

Service Company Name / Phone Number:


Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:

Pre Service Conditions 15 Minutes 30 Minutes Notes


Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure:
Low Side Pressure:
Ambient Humidity:
Observations:

Dealer Copy -- Not for Resale


Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes


Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure:
Low Side Pressure:
Ambient Humidity:
Observations:

813 of 879 70-20-4 E80 Service Manual


REGULAR MAINTENANCE (CONT’D) Figure 70-20-10

Evaporator / Heater Coil 1

NOTE: The following procedure is shown for


cleaning the evaporator / heater coil. The unit
is not serviceable separately.

Remove the evaporator / heater unit. (See Removal And


Installation on Page 70-80-1.)

Remove the blower fan. (See Removal And Installation


on Page 70-110-1.)

Figure 70-20-8
P-87074

1 Clean and inspect the evaporator / heater coil (Item 1)


[Figure 70-20-10].

Dealer Copy -- Not for Resale


1
1
P-87072

Remove the five screws (Item 1) [Figure 70-20-8].

Figure 70-20-9

P-87073

Remove the cover (Item 1) [Figure 70-20-9].

814 of 879 70-20-5 E80 Service Manual


Dealer Copy -- Not for Resale

815 of 879 70-20-6 E80 Service Manual


TROUBLESHOOTING

Blower Motor Does Not Operate

POSSIBLE CAUSE INSPECTION SOLUTION


1. Blown Fuse Inspect the fuse/wiring Replace fuse/repair wiring
2. Broken wiring or bad
Check the fan motor ground and connectors Repair the wiring or connector
connection
Check the lead wires from the motor with a circuit
3. Fan Motor Malfunction Replace motor
tester
4. Resistor Malfunction Check resistor using a circuit tester Replace resistor
5. Fan motor switch
Check power into and out of the fan switch Replace fan switch
malfunction

Blower Motor Operates Normally, But Air Flow Is Insufficient

POSSIBLE CAUSE INSPECTION SOLUTION


1. Evaporator inlet Remove the obstruction and clean
Check evaporator for plugging
obstruction evaporator fins with air or water
Check to make sure air hoses are properly hooked
2. Air leak Repair or adjust
to Louvers and air ducts
3. Defective thermo switch
Check thermostat using a circuit tester Replace thermostat
(frozen evaporator)

Dealer Copy -- Not for Resale


Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

POSSIBLE CAUSE INSPECTION SOLUTION


The high side pressure will be low and bubbles Repair any leaks and recharge the
1. System low on refrigerant
may be present in sight glass on receiver/drier refrigerant to the correct level
Use refrigerant recovery equipment
to capture excess refrigerant.
2. Excessive Refrigerant The high pressure side will be high Charge to the correct refrigerant
level

The Compressor Operates Improperly Or Not At All

POSSIBLE CAUSE INSPECTION SOLUTION


1. Loose drive belt The belt is vibrating or oscillating Adjust tension
2. Internal compressor
The compressor is locked up and the belt slips Replace compressor
malfunction
MAGNETIC CLUTCH RELATED
3. Low battery voltage Clutch slips Recharge the battery
4. Faulty coil Clutch slips Replace the magnetic clutch
5. Oil on the clutch surface Clutch slips Replace or clean the clutch surface
Clutch does not engage and there is not reading
6. Open oil when a circuit tester is connected between the coil Replace clutch
and terminals
7. Broken wiring or poor Clutch will not engage. Inspect the ground and
Repair
ground connections.
8. Wiring harness Test the conductance of the pressure switch,
Check operation
components thermostat, relay, etc.

816 of 879 70-30-1 E80 Service Manual


TROUBLESHOOTING (CONT'D)

Gauge Pressure Related Troubleshooting

Figure 70-30-1 Install the gauge set on the low pressure port (Item 1)
and the high pressure port (Item 2) [Figure 70-30-1].

Open all windows and doors.

Start the engine and run at 1800 - 2000 rpm.


2
Check the high / low pressure of refrigerant.

1
P-86825

High Pressure 790 - 980 kPa (7,9 - 9,8 bar) (114 - 142 psi)
Low Pressure 90 kPa (0,9 bar) (14 psi)

Dealer Copy -- Not for Resale


POSSIBLE CAUSE INSPECTION SOLUTION
Inspect connections for traces of refrigerant oil Reassemble fittings
Low refrigerant level Use leak detection device to check for leakage at Repair / replace leaking
all major components and connections component

High Pressure Over 2260 kPa (22,6 bar) (327 psi)


Low Pressure Approximately 240 -290 kPa (2,4 - 2,9 bar) (35 - 42 psi)

POSSIBLE CAUSE INSPECTION SOLUTION


Recover refrigerant and
Overcharge, frost on condenser High system pressure
recharge to correct pressure
Condenser tube and / or fin Inspect condenser for damaged tubes or cooling
Repair / replace condenser
damage fins.

High Pressure 1970 - 2450 kPa (19,7 - 24,5 bar) (285 - 355 psi)
Low Pressure 240 - 340 kPa (2,4 - 3,4 bar) (35 - 50 psi)

POSSIBLE CAUSE SOLUTION


Recover refrigerant, replace receiver / dryer and
Air in system
recharge system

817 of 879 70-30-2 E80 Service Manual


TROUBLESHOOTING (CONT'D)

Gauge Pressure Related Troubleshooting (Cont’d)

High Pressure Over 590 kPa (5,9 bar) (85 psi)


Low Pressure Approximately 760 mm Hg (29.9 In HG) (Negative Pressure)

Turn on air conditioning, set blower switch to high, turn air conditioner OFF and wait 10 minutes. Re-check High / Low
pressure readings.
High Pressure 1280 - 1860 kPa (12,8 - 18,6 bar) (185 - 270 psi)
Low Pressure 140 - 320 kPa (1,4 - 3,2 bar) (21 - 47 psi)

POSSIBLE CAUSE SOLUTION


Moisture in system Recover refrigerant and replace receiver dryer
Recover refrigerant and replace evaporator core
Contaminated system
assembly

High Pressure 590 - 1770 kPa (5,9 - 17,7 bar) (85 - 256 psi)
Low Pressure 500 mm Hg (19.7 in Hg) (Negative Pressure)

POSSIBLE CAUSE SOLUTION


Recover refrigerant, replace receiver / dryer, vacuum
Moisture in the system has iced up the expansion valve
and recharge the system

Dealer Copy -- Not for Resale


High Pressure Over 2120 - 2260 kPa (21,2 - 22,6 bar) (313 - 327 psi)
Low Pressure 250 kPa (2,5 bar) (36 psi)

POSSIBLE CAUSE INSPECTION SOLUTION


Refrigerant pressure problem due Install temperature sensor
Inspect whether the temperature sensor is installed
to defective expansion valve or correctly, replace expansion
correctly
temperature sensor valve.

High Pressure over 690 - 1080 kPa (6,9 - 10,8 bar) (100 - 156 psi)
Low Pressure 390 - 590 kPa (3,9 - 5,9 bar) (57 - 85 psi)

POSSIBLE CAUSE SOLUTION


Low pressure due to poor compressor performance Inspect and replace compressor if necessary

818 of 879 70-30-3 E80 Service Manual


TROUBLESHOOTING (CONT'D)

Temperature / Pressure Chart

NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE


TEMP C (F) kPag (barg) (psig) TEMP C (F) kPag (barg) (psig)
-9 (16) 108 (1,08) (15.69) 34 (93) 760 (7,60) (110.20)
-8 (18) 118 (1,18) (17.04) 34 (94) 773 (7,73) (112.10)
-7 (20) 127 (1,27) (18.43) 35 (95) 787 (7,87) (114.10)
-6 (22) 137 (1,37) (19.87) 38 (100) 857 (8,57) (124.30)
-4 (24) 147 (1,47) (21.35) 39 (102) 886 (8,86) (128.50)
-3 (26) 158 (1,58) (22.88) 40 (104) 916 (9,16) (132.90)
-2 (28) 169 (1,69) (24.47) 41 (106) 947 (9,47) (137.30)
-1 (30) 179 (1,79) (26.10) 42 (108) 978 (9,78) (141.90)
0 (32) 192 (1,92) (27.79) 43 (110) 1010 (10,10) (146.50)
1 (34) 204 (2,04) (29.52) 44 (112) 1043 (10,43) (151.30)
2 (36) 216 (2,16) (31.32) 46 (114) 1076 (10,76) (156.10)
3 (38) 229 (2,29) (33.17) 47 (116) 1111 (11,11) (161.10)
4 (40) 242 (2,42) (35.07) 48 (118) 1145 (11,45) (166.10)
6 (42) 255 (2,55) (37.03) 49 (120) 1181 (11,81) (171.30)
7 (44) 269 (2,69) (39.05) 50 (122) 1218 (12,18) (176.60)
7 (45) 276 (2,76) (40.09) 51 (124) 1255 (12,55) (182.00)
10 (50) 314 (3,14) (45.48) 52 (126) 1293 (12,93) (187.50)
13 (55) 353 (3,53) (51.27) 53 (128) 1331 (13,31) (193.10)

Dealer Copy -- Not for Resale


16 (60) 396 (3,96) (57.47) 54 (130) 1371 (13,71) (198.90)
18 (65) 442 (4,42) (64.10) 57 (135) 1473 (14,73) (213.70)
21 (70) 491 (4,91) (71.19) 60 (140) 1582 (15,82) (229.40)
24 (75) 543 (5,43) (78.75) 63 (145) 1695 (16,95) (245.80)
27 (80) 598 (5,98) (86.80) 66 (150) 1813 (18,13) (263.00)
29 (85) 658 (6,58) (95.40) 68 (155) 1938 (19,38) (281.10)
32 (90) 720 (7,20) (104.40) 71 (160) 2069 (20,69) (300.10)
33 (91) 733 (7,33) (106.30) 74 (165) 2207 (22,07) (320.10)
33 (92) 746 (7,46) (108.20) 77 (170) 2350 (23,50) (340.80)

Evaporator

Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add -12.5 ± -0.5°C (9 ± 1°F) to the temperature on the chart.

Condenser

Temperatures are not ambient temperatures but condensing temperatures. Add 4°C (40°F) to the ambient temperature to
get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.

Example: Ambient Temperature = 32°C (90°F)

32°C (90°F)
+ 4°C (40°F)
54°C (130°F) condenser temperature = 1379 kPa (14 bar) (200 psig)

Conditions and pressures will vary from system to system.

819 of 879 70-30-4 E80 Service Manual


TROUBLESHOOTING (CONT'D) Figure 70-30-4

Poor A/C Performance


1
Start the excavator. Engage the A/C system with the
blower fan on high. Run the excavator at full rpm for
approximately 15 minutes, with the cab door closed.

Figure 70-30-2 1

1
P-86951

Figure 70-30-5

P-86229

Dealer Copy -- Not for Resale


Figure 70-30-3

N-22411

Check the temperature at the louvers (Item 1) [Figure


70-30-2], [Figure 70-30-3] and [Figure 70-30-4] with a
thermometer [Figure 70-30-5].

The louver temperature should be between 2,2 - 11,6°C


1 (36 - 53°F) depending on the amount of humidity in the
air.

If louver temperature is too high see the System


P-86230 Troubleshooting Chart. (See Gauge Pressure Related
Troubleshooting on Page 70-30-2.)

Check the fan for proper operation or noise, and replace


if necessary. (See Removal And Installation on Page 70-
110-1.)

Check the air conditioning belt tension. (See Belt


Adjustment on Page 70-20-1.)

Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Evaporator / Heater Coil on Page 70-20-
5.)

Inspect the sight glass located on the receiver/drier for air


bubbles. (See Insufficient Cooling Although Air Flow And
Compressor Operation Are Normal on Page 70-30-1.)

820 of 879 70-30-5 E80 Service Manual


TROUBLESHOOTING (CONT'D)

HVAC Repair And Leaks

Figure 70-30-6

P-86816

Whenever the A/C system is opened to the atmosphere


or there has been a leak in the system, the receiver/drier
(Item 1) [Figure 70-30-6] must be changed.

Dealer Copy -- Not for Resale


Never leave hose fittings, compressor fittings or
components uncapped while working on the A/C system.

821 of 879 70-30-6 E80 Service Manual


SYSTEM CHARGING AND RECLAMATION Figure 70-40-2

Reclamation And Charging With Recovery / Charging


Unit 1

Figure 70-40-1

N-23024

NOTE: Before reclaiming a refrigeration system, it is


1
recommended to identify the type of
P-86815 refrigerant that is in the A/C system and
wether it is pure enough to use or not. The
tool MEL1592, Refrigerant Identifier (Item 1)
Open the right side cover and locate the low pressure [Figure 70-40-2] will determine the kind of

Dealer Copy -- Not for Resale


port (Item 1) and high pressure port (Item 2) [Figure 70- refrigerant and any possible harmful or
40-1]. dangerous substances that may be present in
the system. Thus preventing mixing of
dangerous material with your reclaimed R-
134a in your reclaimer, and further

WARNING contamination to other A/C systems that are


reclaimed and charged from your MEL 1581
Recovery/Recycling/Recharging Machine.
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

NOTE: This procedure is run with the excavator


engine OFF, and the A/C switch in the OFF
position.

822 of 879 70-40-1 E80 Service Manual


SYSTEM CHARGING AND RECLAMATION (CONT'D)

Reclamation And Charging With Recovery / Charging


Unit (Cont’d) WARNING
Figure 70-40-3 HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
1 knowledge, and experience to service refrigeration
equipment.
W-2373-0500
P-86819

Figure 70-40-4
Remove the protective cap and connect the Refrigerant

Dealer Copy -- Not for Resale


Identifier to the low pressure hose (Item 1) [Figure 70-
40-3].

Connect the refrigerant identifier to a power source.

Follow the steps displayed on the refrigerant identifier


screen.

Allow two minutes for the refrigerant identifier to display


the type of refrigerant and air content. If potentially
flammable hydrocarbons are present an alarm will sound
and the visual display will indicate it.

Disconnect the refrigerant identifier from the excavator A/ N-22291


C.
Use an approved recover/charging unit [Figure 70-40-4]
If the refrigerant is dangerous or flammable, it must be
to evacuate the system.
evacuated from the A/C system into a separate container
and properly and safely disposed of.
Connect the reclaimer to the excavator A/C charge ports.
If R134a is found, evacuate the system.

823 of 879 70-40-2 E80 Service Manual


SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-7

Reclamation And Charging With Recovery / Charging


Unit (Cont’d)

Figure 70-40-5

N-22381

NOTE: The reclaimer unit has a complete step by


step set of instructions [Figure 70-40-7] to
2 follow for reclamation and recharging of the
P-86825
A/C system. A trained technician should
follow these instructions as they may very
Connect the Red hose (Item 1) [Figure 70-40-5] to the slightly depend on the model and brand of

Dealer Copy -- Not for Resale


high pressure port and open the valve. reclaimer used.

Connect the Blue hose (Item 2) [Figure 70-40-5] to the


low pressure port and open the valve.

Figure 70-40-6

N-22292

Turn the reclaimer unit to the ON position and follow the


on screen instructions [Figure 70-40-6].

824 of 879 70-40-3 E80 Service Manual


SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-9

Charging With A Manifold Gauge Set

Open the right side cover.

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500 P-52658

Figure 70-40-8
Connect the Yellow hose (Item 1) [Figure 70-40-9] to the
vacuum pump.

Dealer Copy -- Not for Resale


1

2
1

3
P-87052

Check to see that the hand valves (Item 1) [Figure 70-


40-8] are closed on the manifold gauge set.

If there is any refrigerant in the A/C system, it must be


recovered by an approved A/C reclamation procedure.
(See Reclamation And Charging With Recovery /
Charging Unit on Page -1.)

Connect the gauges to the excavator A/C charge ports.

Connect the Red hose (Item 2) [Figure 70-40-8] to the


high pressure port and open the valve.

Connect the Blue hose (Item 3) [Figure 70-40-8] to the


low pressure port and open the valve.

825 of 879 70-40-4 E80 Service Manual


SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-12

Charging With A Manifold Gauge Set (Cont’d)

Figure 70-40-10

P-87051

A thermistor vacuum gauge (Item 1) [Figure 70-40-12]


1 can be used to determine the critical vacuum level during
P-87050
evacuation. It is a solid state instrument that constantly
monitors and visually indicates the vacuum level.
Start the vacuum pump and open the ISO-valve (Item 1)
[Figure 70-40-10] on the vacuum pump. The thermistor vacuum gauge is used with the vacuum

Dealer Copy -- Not for Resale


pump [Figure 70-40-12].
Run the vacuum pump for at least 5 - 10 minutes to make
sure that a vacuum has been pulled on the system. Start the vacuum pump and open the ISO-valve on the
vacuum pump.
Close the ISO-valve (Item 1) [Figure 70-40-10] (which
isolates the vacuum pump from the A/C system) and turn Make sure that both hand valves, and both charge port
OFF the vacuum pump. valves are open.

Figure 70-40-11 Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.

Stop the vacuum pump and close the ISO-valve on the


1 vacuum pump.

Close both hand valves on the manifold gauge set and


remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.

Remove the vacuum pump and thermistor vacuum


gauge.

P-87052

Note the vacuum pressure indicated on the low pressure


(Blue) gauge (Item 1) [Figure 70-40-11]. Let stand for 5-
10 minutes and recheck the pressure for changes.

If the pressure drops, this may be an indication of a leak


in the A/C system.

Determine the problem with the A/C system and repair it.

826 of 879 70-40-5 E80 Service Manual


SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-15

Charging With A Manifold Gauge Set (Cont’d)

Figure 70-40-13 1

3
1 2 3

P-86817

Press the A/C (Item 1) [Figure 70-40-15] switch to ON


2 position.
P-87053

Press the fan switch (Item 2) [Figure 70-40-15] to HIGH


Place a refrigerant container with R134a (Item 1) on a position.
charging scale (Item 2) [Figure 70-40-13] and zero out

Dealer Copy -- Not for Resale


the scale. Press the cool switch (Item 3) until all the indicator lights
(Item 4) [Figure 70-40-15] are green.
Connect the yellow hose (Item 3) [Figure 70-40-13] from
the manifold gauge set to the valve on the refrigerant Start the engine, with the left console in the raised
tank. position, and run at medium speed.

Figure 70-40-14 Watch the scale and run the system until the
predetermined amount of refrigerant is added to the A/C
system.

The A/C system holds 0,63 - 0,67 kg (1.38 - 1.48 lb) of


refrigerant.

Turn OFF the valve on the refrigerant container, and the


1 hand valves on the manifold gauge set.
2
Turn OFF the engine, and remove the A/C charging
equipment from the excavator.

P-87054

Open the valve on the refrigerant container (Item 1) and


open the low pressure hand valve (Blue) (Item 2) [Figure
70-40-14] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.

827 of 879 70-40-6 E80 Service Manual


COMPRESSOR Figure 70-50-3

Removal And Installation

Open the right side cover.

Remove the right upperstructure side cover. (See


Removal And Installation on Page 40-21-1.)
1
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 70-40-1.)

Figure 70-50-1

P-86823

1 Remove the belt (Item 1) [Figure 70-50-3].

Figure 70-50-4
2 1

Dealer Copy -- Not for Resale


P-86820

Remove the two bolts (Item 1) and washers. Remove the


belt shield (Item 2) [Figure 70-50-1].
1
Figure 70-50-2

P-86877
2
Remove the bolt (Item 1) [Figure 70-50-4] and the hoses
1 from the compressor.

P-86822

Loosen the nut (Item 1) on the pulley. Loosen the


adjustment bolt (Item 2) [Figure 70-50-2].

828 of 879 70-50-1 E80 Service Manual


COMPRESSOR (CONT'D) Figure 70-50-7

Removal And Installation (Cont'd)

Figure 70-50-5

1
1

2
P-86873

1
Remove the three screws (Item 1) and remove the dust
P-86871 cover (Item 2) [Figure 70-50-7].

Figure 70-50-8
Remove the seal washers (Item 1) [Figure 70-50-5] from
the tubelines.

Dealer Copy -- Not for Resale


Figure 70-50-6

1 P-86875

Disconnect the wire harness (Item 1) [Figure 70-50-8].


P-86872

Remove the rear bolt (Item 1) [Figure 70-50-6] and


washer.

829 of 879 70-50-2 E80 Service Manual


COMPRESSOR (CONT'D) Oil

Removal And Installation (Cont'd) Figure 70-50-11

Figure 70-50-9
1

P-86877

1 P-86874
The compressor (Item 1) [Figure 70-50-11] is factory
filled with 0,266 L (9.0 U.S. fl oz) of PAG oil (Polyalkelene
Remove the three bolts (Item 1) [Figure 70-50-9] and the Glycol).
compressor from the excavator.

Dealer Copy -- Not for Resale


It is necessary to check, replenish or replace the
Figure 70-50-10 compressor oil in the following cases:

1. When the evaporator, condenser or receiver-drier is


replaced.

2 2. When refrigerant has leaked from the system.

1 3. When refrigerant is suddenly released from the


cooling cycle.

4. When any oil related problems occur in the cooling


1 cycle.

When one of the components (the evaporator, condenser


or receiver-drier) is replaced, 0,029 L (1.0 U.S. fl oz) of
P-86876
PAG oil should be added for each component replaced.

If the A/C compressor is changed, no oil should be added


Remove the two bolts (Item 1) and washers. Remove the
to the system, the compressor comes factory filled with
bracket (Item 2) [Figure 70-50-10].
oil.

NOTE: Only PAG oil should be used. Never mix R-12


and R-134a Oils.

830 of 879 70-50-3 E80 Service Manual


COMPRESSOR (CONT'D) Figure 70-50-12

Oil Check

The compressor oil should be checked as follows when


1
oil is being added to an in service excavator.

There is a close affinity between oil and refrigerant.


During normal operation, part of the oil circulates with the
refrigerant in the system. When checking the amount of
oil in the system or replacing any system component, the
compressor must be run in advance to insure return of oil
to the compressor.

If the amount of refrigerant in the system has decreased,


charge the system. (See SYSTEM CHARGING AND P-86878
RECLAMATION on Page 70-40-1.)

Open the cab door and windows. Figure 70-50-13

Run the blower at maximum speed.

Run the compressor for at least 20 minutes at 800 - 1200


rpm.

Dealer Copy -- Not for Resale


Remove the compressor from the excavator. (See
Removal And Installation on Page 70-50-1.)

P-16534A

Remove the oil drain plug (Item 1) [Figure 70-50-12] and


drain the oil through the connectors and the oil drain hole
[Figure 70-50-13].

Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4


- 10.8 ft-lb) torque.

831 of 879 70-50-4 E80 Service Manual


COMPRESSOR (CONT'D) Figure 70-50-15

Oil Check (Cont'd)

Figure 70-50-14

P-86878

1
Add new compressor oil through the suction side
N-22246 connector (Item 1) [Figure 70-50-15].

Installation: Add 0,266 L (9.0 U.S. fl oz) of PAG oil.


NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil NOTE: The suction port on the compressor is marked

Dealer Copy -- Not for Resale


through the discharge-side connector by with an S and is the larger port on the
rotating the drive pulley (Item 1) [Figure 70-50- compressor.
14] several times by hand.

Measure the drained oil in a measuring cylinder.

Check the oil for contamination, dirt, metal shavings, or


varnish color. Discard the oil if contaminated.

NOTE: If metal shavings are found in the compressor


oil, replace the complete compressor
assembly.

832 of 879 70-50-5 E80 Service Manual


Dealer Copy -- Not for Resale

833 of 879 70-50-6 E80 Service Manual


CONDENSER Figure 70-60-2

Removal And Installation

Evacuate the A/C system. (See SYSTEM CHARGING


AND RECLAMATION on Page 70-40-1.)

Figure 70-60-1

2 1

P-86822
3

Figure 70-60-3

1
P-86879

Dealer Copy -- Not for Resale


1
Loosen the bottom bolt (Item 1). Remove the top bolt
(Item 2) and washer. Reposition the brace (Item 3)
[Figure 70-60-1] to gain access to the A/C hoses.

Mark the A/C hoses for proper installation.

P-86823

Remove the hoses (Item 1) [Figure 70-60-2] and [Figure


70-60-3] from the condenser.

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

834 of 879 70-60-1 E80 Service Manual


CONDENSER (CONT'D) Figure 70-60-5

Removal And Installation (Cont'd)

Figure 70-60-4

1
1

1
1 P-86883

1 Remove the condenser (Item 1) [Figure 70-60-5] from


P-86882 the excavator.

Remove the four bolts (Item 1) [Figure 70-60-4].

Dealer Copy -- Not for Resale


Installation: Do not over tighten the bolts (Item 1)
[Figure 70-60-4] and damage the condenser.

835 of 879 70-60-2 E80 Service Manual


RECEIVER / DRIER Figure 70-70-2

Receiver / Drier Removal And Installation

Evacuate the A/C system. (See SYSTEM CHARGING


AND RECLAMATION on Page 70-40-1.) 1

Open the center cover. (See Opening And Closing on


Page 10-70-1.)
2
Figure 70-70-1

1 P-86887

1 Disconnect the wire harness (Item 1) [Figure 70-70-2].

Remove the two bolts (Item 2) [Figure 70-70-2] and


remove the receiver / drier from the excavator.

NOTE: When replacing a receiver / drier, 0,029 L (1.0

Dealer Copy -- Not for Resale


U.S. fl oz) of PAG oil must be added to the
P-86886 system when recharging.

Mark the hoses (Item 1) [Figure 70-70-1] for proper


installation.

Note the flow direction on the drier for proper installation.

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

Remove the A/C hoses (Item 1) [Figure 70-70-1] from


the receiver / drier.

Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.

836 of 879 70-70-1 E80 Service Manual


RECEIVER / DRIER (CONT’D)

Pressure Switch Removal And Installation

Open the center cover.


WARNING
In the event of a leak, wear safety goggles. Escaping
Figure 70-70-3 refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
1 W-2371-0500

P-86888

Dealer Copy -- Not for Resale


Figure 70-70-4

P-86886

The pressure switch (Item 1) [Figure 70-70-3] and


[Figure 70-70-4] is located on the receiver / drier.

Disconnect the wire harness (Item 2) [Figure 70-70-4]


from the pressure switch wire harness.

NOTE: The pressure switch can be changed without


evacuating the A/C system.

Remove the pressure switch from the receiver / drier.

837 of 879 70-70-2 E80 Service Manual


EVAPORATOR / HEATER UNIT Figure 70-80-2

Removal And Installation


1
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 70-40-1.)

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas. P-87059
W-2371-0500

Remove the two bolts (Item 1) [Figure 70-80-2] and


Tilt the cab. (See Tilting The Cab on Page 10-210-1.)
washers.
Drain the radiator. (See Removing And Replacing
Figure 70-80-3
Coolant on Page 10-110-2.)

Figure 70-80-1 2

Dealer Copy -- Not for Resale


2

P-87060
1

P-87058 Remove the wire harness (Item 1) from the mount.


Support the housing and remove the two bolts (Item 2)
[Figure 70-80-3] and washers.
Disconnect the A/C lines (Item 1). Loosen the hose
clamps and remove the heater hoses (Item 2) [Figure
Lower the housing.
70-80-1].

NOTE: Mark the hoses before removal for correct


installation.

838 of 879 70-80-1 E80 Service Manual


EVAPORATOR / HEATER UNIT (CONT’D)

Removal And Installation (Cont’d)

Figure 70-80-4

P-87061

Disconnect the wire harness [Figure 70-80-4].

Dealer Copy -- Not for Resale


Remove the unit from the machine.

839 of 879 70-80-2 E80 Service Manual


THERMOSTAT Figure 70-90-3

Inspection
2
NOTE: The thermostat is not serviceable separately.
The procedure shown is for inspection
purposes.

Remove the blower fan. (See Removal And Installation


on Page 70-110-1.)

Figure 70-90-1
1

1
P-87074

1 Inspect the thermostat (Item 1) for damage. Inspect the


1 thermostat probe (Item 2) [Figure 70-90-3] for correct
placement.

Dealer Copy -- Not for Resale


P-87072

Remove the five screws (Item 1) [Figure 70-90-1].

Figure 70-90-2

P-87073

Remove the cover (Item 1) [Figure 70-90-2].

840 of 879 70-90-1 E80 Service Manual


Dealer Copy -- Not for Resale

841 of 879 70-90-2 E80 Service Manual


EXPANSION VALVE Figure 70-100-3

Removal And Installation

NOTE: The expansion valve is not serviceable 1


separately. The procedure shown is for
inspection purposes.

Remove the evaporator / heater unit. (See Removal And


Installation on Page 70-80-1.)

Figure 70-100-1

P-87064
2

1 Remove the bottom cover (Item 1) [Figure 70-100-3].

Figure 70-100-4

Dealer Copy -- Not for Resale


P-87062

Loosen the clamps (Item 1) and remove the fittings (Item


2) [Figure 70-100-1].

Figure 70-100-2
1

P-87065
1

Remove the bolts (Item 1) [Figure 70-100-4] and


1 washers from both sides.

P-87063

Remove the two bolts (Item 1) [Figure 70-100-2] and


washers from both sides.

842 of 879 70-100-1 E80 Service Manual


EXPANSION VALVE (CONT’D) Figure 70-100-7

Removal And Installation (Cont’d)

Figure 70-100-5 1 2

1 2

P-87075

Remove the tubelines (Item 1). Loosen the tubeline nuts


P-87066 (Item 2) and remove the expansion valve (Item 3)
[Figure 70-100-7].

Remove the heater core / evaporator (Item 1) [Figure 70-


100-5] from the top cover.

Dealer Copy -- Not for Resale


Figure 70-100-6

1
P-87070

Remove the tape [Figure 70-100-6].

843 of 879 70-100-2 E80 Service Manual


BLOWER FAN Figure 70-110-3

Removal And Installation


1
Remove the evaporator / heater unit. (See Removal And
Installation on Page 70-80-1.)

Figure 70-110-1

P-87064
1

Remove the bottom cover (Item 1) [Figure 70-110-3].

Figure 70-110-4

P-87062

Dealer Copy -- Not for Resale


Loosen the clamps (Item 1) and remove the fittings (Item
2) [Figure 70-110-1].

Figure 70-110-2

1
1

1 P-87065

Remove the two bolts (Item 1) [Figure 70-110-4] and


washers from both sides.

P-87063

Remove the two bolts (Item 1) [Figure 70-110-2] and


washers from both sides.

844 of 879 70-110-1 E80 Service Manual


BLOWER FAN (CONT’D) Figure 70-110-7

Removal And Installation (Cont’d)

Figure 70-110-5
1
1

P-87071

Remove the motor / fan assembly (Item 1) [Figure 70-


P-87066 110-7].

Figure 70-110-8
Remove the heater core / evaporator (Item 1) [Figure 70-
110-5] from the top cover.

Dealer Copy -- Not for Resale


Figure 70-110-6
1 1 1 1 2

3
2

1 1

P-87068

Disconnect the wire harness (Item 1) [Figure 70-110-8].


P-87068
Remove the two screws (Item 2) [Figure 70-110-8].

Remove the eight screws (Item 1) [Figure 70-110-6]. Remove the resistor block (Item 3) [Figure 70-110-8].

845 of 879 70-110-2 E80 Service Manual


HEATER VALVE Figure 70-120-3

Removal And Installation

Drain the radiator. (See Removing And Replacing


Coolant on Page 10-110-2.)

Figure 70-120-1
1

P-87407

Remove the bolts (Item 1) [Figure 70-120-3] and


washers. Remove the valve assembly from the machine.

1 1 Figure 70-120-4
P-87405

Dealer Copy -- Not for Resale


Loosen the clamps (Item 1) [Figure 70-120-1] and 1
remove the hoses from the valve.
2
Figure 70-120-2

P-87408

Remove the bolts (Item 1). Remove the bracket (Item 2)


[Figure 70-120-4] from the valve.

1
P-87406

Disconnect the wire harness (Item 1) [Figure 70-120-2].

846 of 879 70-120-1 E80 Service Manual


Dealer Copy -- Not for Resale

847 of 879 70-120-2 E80 Service Manual


HVAC CONTROLLER Figure 70-130-3

Removal And Installation

Remove the upper left console cover. (See Upper


Console Cover Removal And Installation on Page 40-60-
2.)
1
Figure 70-130-1

P-86761

Remove the controller (Item 1) [Figure 70-130-3] from


1 the upper console cover.

P-86759

Dealer Copy -- Not for Resale


Remove the screws (Item 1) [Figure 70-130-1].

Figure 70-130-2

P-86760

Remove the screws (Item 1) [Figure 70-130-2].

848 of 879 70-130-1 E80 Service Manual


Dealer Copy -- Not for Resale

849 of 879 70-130-2 E80 Service Manual


SPECIFICATIONS

E80 EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1


Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Machine Dimensions (Articulated Boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Machine Dimensions (Standard Arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Machine Dimensions (Long Arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Slew System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9

Dealer Copy -- Not for Resale


TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1


O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-3

HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

850 of 879 SPEC-01 E80 Service Manual


Dealer Copy -- Not for Resale

851 of 879 SPEC-02 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS

Machine Dimensions

• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

70°

55°

Dealer Copy -- Not for Resale


2266mm 6167 mm
(89.2 in) (242.8 in)
1370 mm 4797 mm
1030 mm
(54.0 in) (188.8 in)
(40.5 in)
923 mm 1298 mm
(36.3 in) (51.1 in)

737 mm
2638 mm (29.0 in) 2085 mm
(103.9 in) (82.1 in)

446 mm
648 mm 410 mm (17.3 in)
450 mm (17.6 in)
(17.7 in) (25.5 in)
362 mm 1912 mm
1850 mm (75.3 in)
(72.8 in) (14.3 in) 2200 mm
(86.6 in)
2300 mm
2823 mm
(90.6 in)
(111.1 in)
3282 mm
(129.2 in)
MS2791

852 of 879 SPEC-10-1 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Machine Dimensions (Articulated Boom)


• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

70°

55°

Dealer Copy -- Not for Resale


2266mm 5660 mm
(89.2 in) (222.8 in)
1030 mm 1370 mm 4290 mm
(40.5 in) (54.0 in) (168.9 in)
923 mm 1298 mm
(36.3 in) (51.1 in)

2580 mm
737 mm (101.6 in)
2605 mm
(29.0 in)
(102.6 in)

450 mm 648 mm 304 mm 446 mm


(17.7 in) (25.5 in) (12.0 in) (17.3 in)
1850 mm 364 mm 1912 mm
(72.8 in) (14.3 in) (75.3 in)
2200 mm
2300 mm
(86.6 in)
(90.6 in)
2850 mm
(112.2 in)
3282 mm
(129.2 in) EM6971

853 of 879 SPEC-10-2 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Machine Dimensions (Articulated Boom) (Cont’d)

• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

2480 mm
(97.6 in)

7375 mm
(290.4 in)

Dealer Copy -- Not for Resale


5360 mm
(211.0 in)

4105 mm
(161.6 in)

7180 mm
(282.7 in)

EM6972

854 of 879 SPEC-10-3 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Machine Dimensions (Standard Arm)

• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

2700 mm
(106.3 in)

7070 mm
(278.3 in)

Dealer Copy -- Not for Resale


5085 mm
(200.2 in)

3730 mm
(146.9 in)

4675 mm
(184.0 in)

7480 mm
(294.5 in)

MS2792A

855 of 879 SPEC-10-4 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Machine Dimensions (Long Arm)

• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

2700 mm
(106.3 in)

7070 mm
(278.3 in)

Dealer Copy -- Not for Resale


5085 mm
(200.2 in)

3730 mm
(146.9 in)

4675 mm
(184.0 in)

7480 mm
(294.5 in)

MS2792A

856 of 879 SPEC-10-5 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Performance

Operating weight w/ cab, steel tracks and 610 mm 8380 kg(18475 lb)
(24 in) bucket
If equipped with long arm, add: 60 kg (133 lb)
If equipped with articulated boom option, add: 920 kg (2028 lb)
Travel Speed Low Range 2,9 km/h (1.8 mph)
High Range 4,6 km/h (2.9 mph)
Digging Force (per ISO 6015)
Arm (Standard) 40855 N (9185 lbf)
Arm (Long Arm Option) 34068 N (7659 lbf)
Arm (Articulated Boom Option) 40855 N (9185 lbf)
Bucket 54623 N (12280 lbf)
Boom Swing (Offset) Left 70° Right 55°

Controls

Steering Two hand levers or foot pedals.


Hydraulics Two hand operated levers (joysticks) control boom, bucket, arm and

Dealer Copy -- Not for Resale


upperstructure slew. Left pedal controls articulated boom (option).
Auxiliary Hydraulics Electric switch in right joystick, right pedal and electric switches in
left joystick (if equipped)
Auxiliary Pressure Release Right pedal and electric switches in left joystick (if equipped)
Engine Engine speed control dial, key type start switch
Starting Aid Air Intake Heater - activated by key switch
Brakes
Travel
Service And Parking Hydraulic lock in motor circuit
Swing
Service Automatically applied slew brake integrated in slew motor
Holding Automatically applied slew brake integrated in slew motor

Engine

Make / Model Yanmar 4TNV98-ESDB8


Fuel / Cooling Diesel / Liquid (Antifreeze mixture)
Horsepower (SAE Gross) 40.7 Kw (54.6 hp)
Torque 223 - 243 N•m (164.5 - 179.1 ft-lb) @ 1300 rpm
Number Of Cylinders 4
Displacement 3.319 L (202.5 in3)
Bore / Stroke 98 x 110 mm (3.85 x 4.33 in)
Lubrication Pressure System with Filter
Crankcase Ventilation Closed Breather
Air Cleaner Dual dry replaceable paper cartridges
Ignition Diesel Compression
Low Idle 1050 rpm
High Idle 2150 rpm
Engine Coolant Ethylene Glycol / water mixture (50% EG / 50% water)

857 of 879 SPEC-10-6 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic System

Pump Type Engine driven, variable displacement dual piston pump with pressure
compensating, load sensing and torque limiter controls.
Two gear pumps.
Piston Pump Capacity 2 @ 70 L/min (18.5 U.S. gpm)
Gear Pump Capacity 70 L/min (18.5 U.S. gpm)
Gear Pump Capacity 9,9 L/min (2.6 U.S. gpm)
Auxiliary Flow 120 L/min (31.7 U.S. gpm)
Control Valve 12 spool closed centre
System Relief Pressure
Travel Circuits 30000 kPa (300 bar) (4278 psi)
Slew Circuit, Boom Swing, Blade,
Travel Straight, Secondary
Auxiliaries (If equipped) 30000 kPa (300 bar) (4278 psi)
Boom, Arm, Bucket,
Primary Auxiliary Hydraulics 30000 kPa (300 bar) (4278 psi)
Joystick Control Pressure 2940 kPa (29,4 bar) (427 psi)

Dealer Copy -- Not for Resale


Arm Port Relief, Base And Rod End 31000 kPa (310 bar) (4496 psi)
Boom Port Relief, Base End 31000 kPa (310 bar) (4496 psi)
And Rod End
Articulated Boom Port Relief, Base End 31000 kPa (310 bar) (4496 psi)
And Rod End (Option)
Bucket Port Relief, Base End 31000 kPa (310 bar) (4496 psi)
Rod End
Swing Motor Cross Port Relief Valves 25000 kPa (250 bar) (3626 psi)
Hydraulic Filter Bypass 150 kPa (1,5 bar) (21 psi)

Hydraulic Cylinders

Cylinder Bore Rod Stroke


Boom (cushion up) 115 mm (4.52 in) 75 mm (2.95 in) 775 mm (30.51 in)
Articulated Boom (cushion 100 mm (3.94 in) 55 mm (2.17 in) 370 mm (14.57 in)
extend / retract) (Option)
Arm 100 mm (3.94 in) 65 mm (2.56 in) 866 mm (34.88 in)
Bucket (cushion extend / 85 mm (3.35 in) 55 mm (2.17 in) 690 mm (27.17 in)
retract)
Boom Swing (cushion left/ 110 mm (4.33 in) 60 mm (2.36 in) 738 mm (29.05 in)
right)
Blade 100 mm (3.94 in) 60 mm (2.36 in) 149 mm (5.87 in)

858 of 879 SPEC-10-7 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic Cycle Times

Boom Raise 3.2 seconds Lower 3.0 seconds


Articulated Boom (Option) Raise 5.3 seconds Lower 4.6 seconds
Arm Retract 3.8 seconds Extend 2.9 seconds
Bucket Curl 3.3 seconds Dump 2.1 seconds
Blade Raise 2.4 seconds Lower 2.9 seconds
Boom Swing Left 6.9 seconds Right 8.6 seconds

Electrical

Starting Aid Air Intake Heater


Alternator 12 volts, 60 Amp open frame w/ internal regulator
Battery 12 volts - 750 CCA @ -18°C (0°F)
Starter 12 volts gear reduction 3.0 Kw (4.0 hp)
Instrumentation Fuel gauge, audible alarm, visual warning for engine functions and hourmeter

Drive System

Dealer Copy -- Not for Resale


Final Drive Each track is independently driven by an Axial Piston Motor
Type of Reduction Two-stage planetary gear reduction

Slew System

Slew Motor Axial Piston Motor


Slew Circle Single row shear type ball bearing with internal gear
Slew Speed 9.6 rpm

Undercarriage

Crawler Track Design Sealed track rollers with boxed section track, Roller frame, Grease type track
adjuster

Capacities

Fuel Tank 78 L (20.6 U.S. gal)


Hydraulic Reservoir Only (Center of 87 L (23.0 U.S. gal)
Sight Glass)
Hydraulic System (with Reservoir) 127 L (35.5 U.S. gal)
Cooling System 10,0 L (10.6 qt)
Engine Oil and Filter 11,6 L (12.25 qt)
Final Drive (each) 1,4 L (1.5 qt)

859 of 879 SPEC-10-8 E80 Service Manual


E80 EXCAVATOR SPECIFICATIONS (CONT’D)

Tracks

Type Rubber Steel


Width 450 mm (17.7 in) 450 mm (17.7 in)
Number Of Shoes Single Assembly 39
Number of Track Rollers (per side) 5 5

Ground Pressure

Ground Pressure 39 kPa (0,39 bar) (5.66 psi)

Dealer Copy -- Not for Resale

860 of 879 SPEC-10-9 E80 Service Manual


Dealer Copy -- Not for Resale

861 of 879 SPEC-10-10 E80 Service Manual


TORQUE SPECIFICATIONS FOR BOLTS

Torque For General SAE Bolts

The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.

THREAD SIZE SAE GRADE 5 SAE GRADE 8


0.250 9,0 - 10,2 12,4 - 13,6
N•m (80 - 90) (110 - 120)
(ft-lb) 0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
0.375 34 - 38 47 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
N•m 0.750 300 - 330 410 - 450
(ft-lb) (220 - 245) (300 - 330)

Dealer Copy -- Not for Resale


0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 5830 - 6500
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

862 of 879 SPEC-20-1 E80 Service Manual


TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric Bolts

THREAD SIZE MATERIAL


(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 f.-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb. (69 - 87 ft-lb)
M 14 x 1.25 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

Dealer Copy -- Not for Resale

863 of 879 SPEC-20-2 E80 Service Manual


HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-2
O-ring Face Seal Tightening Torque
O-ring Face Seal Connection
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 9/16” - 18 18 (13)
IMPORTANT 3/8” 11/16” - 16 30 (22)
1/2” 13/16” - 16 54 (40)
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 5/8” 1” - 14 81 (60)
parts clean. Always use caps and plugs on hoses, 3/4” 1-3/16” - 12 114 (84)
tubelines and ports to keep dirt out. Dirt can quickly 7/8” 1-3/16” - 12 133 (98)
damage the system.
I-2003-0888 1” 1-7/16” - 12 160 (118)
1-1/4” 1-11/16” - 12 209 (154)
Figure SPEC-30-1 1-1/2” 2” - 12 221 (163)

Dealer Copy -- Not for Resale


B-7575

When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-30-1].

864 of 879 SPEC-30-1 E80 Service Manual


HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONT’D)
Figure SPEC-30-4
Straight Thread O-ring Fitting

Figure SPEC-30-3
1

Nut Nut

Washer
Washer
O-ring

O-ring
TS-1619A

A-1852 Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until

Dealer Copy -- Not for Resale


of the connection (Item 1) [Figure SPEC-30-4].
the washer is tight against the surface [Figure SPEC-30-
3]. Figure SPEC-30-5

Tubelines And Hoses Flare Fitting Tightening Torque


Tubeline x TORQUE
Replace any tubelines that are bent or flattened. They will Outside x N•m
restrict flow, which will slow hydraulic action and cause Diameter Thread Size (ft-lb)
heat. 1/4” 7/16” - 20 18 (13)
Replace hoses which show signs of wear, damage or 5/16” 1/2” - 20 23 (17)
weather cracked rubber. 3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
Always use two wrenches when loosening and tightening
hose or tubeline fittings. 5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)
Use the chart [Figure SPEC-30-5] to find the correct
tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.

865 of 879 SPEC-30-2 E80 Service Manual


HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-7
(CONT’D)
Port Seal and O-ring Boss
Port Seal Fitting Tightening Torque
x TORQUE
Figure SPEC-30-6 x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
Nut Seals 1-3/16” - 12 133 (98)
To Fitting 1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
Nut Seals 1-5/8” - 12 221 (163)
To Port Use the chart [Figure SPEC-30-7] to tighten the port seal
fitting.

Port seal and nut, washer and O-ring (O-ring Boss)


fittings use the same tightening torque valve chart.

Dealer Copy -- Not for Resale


Secondary O-ring Seal P-13008

The nut is the primary seal, the O-ring is the secondary


seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-30-6].

The hex portion of the nut does not contact the surface of
the component when the nut is tight.

866 of 879 SPEC-30-3 E80 Service Manual


Dealer Copy -- Not for Resale

867 of 879 SPEC-30-4 E80 Service Manual


HYDRAULIC FLUID SPECIFICATIONS

Specifications

Use only Bobcat hydraulic fluid.


WARNING
During cold weather (0°C [32°F] and below), do not
DO NOT use automatic transmission fluids in the
operate machine until the engine has run for at least
excavator or permanent damage to the hydraulic system
five minutes at less than half throttle. This warm-up
will result.
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
Bobcat hydraulic fluid is available in:
period.
• 9.5 L (2.5 U.S. gal) qty 2 (P/N 6903117)
When temperatures are below -30°C (-20°F), the
hydrostatic oil must be heated or kept warm. The
• 18.9 L (5 U.S. gal) (P/N 6903118
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
• 208 L (55 U.S. gal) (P/N 6903119)
temperature will be above -18°C (0°F) if possible.
W-2027-0910

WARNING
AVOID INJURY OR DEATH

Dealer Copy -- Not for Resale


Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

When temperatures below -18°C (0°F) are common, the


excavator must be kept in a warm building. Extra warm-
up time must be used each time the excavator is started
during cold temperature conditions. Cold fluid will not
flow easily and it makes action of the hydraulic function
slower. Loss of fluid flow to the hydraulic system
(Indicated by hydraulic temp/pressure lights on) can
cause system damage in less than 60 seconds.

868 of 879 SPEC-40-1 E80 Service Manual


Dealer Copy -- Not for Resale

869 of 879 SPEC-40-2 E80 Service Manual


CONVERSIONS

Decimal And Millimeter Equivalent Chart

Dealer Copy -- Not for Resale


U.S. To Metric Conversion Chart

870 of 879 SPEC-50-1 E80 Service Manual


Dealer Copy -- Not for Resale

871 of 879 SPEC-50-2 E80 Service Manual


ALPHABETICAL INDEX

AIR CLEANER SERVICE . . . . . . . . . . . 10-90-1 CYLINDER (BOOM) . . . . . . . . . . . . . . .20-20-1


AIR CLEANER . . . . . . . . . . . . . . . . . . . 60-40-1 CYLINDER (BUCKET) . . . . . . . . . . . . .20-23-1
AIR CONDITIONING SYSTEM FLOW . 70-10-1 CYLINDER HEAD . . . . . . . . . . . . . . . .60-80-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 50-30-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-15
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 DIAGNOSTIC SERVICE CODE . . . . . .50-80-1
ARTICULATED BOOM VALVE (OPTIONAL) DIAGNOSTIC TOOL . . . . . . . . . . . . . . .50-90-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1 DIRECT TO TANK VALVE . . . . . . . . .20-160-1
AUTO IDLE PRESSURE SWITCH . . 50-160-1 E80 EXCAVATOR SPECIFICATIONS
AUTO IDLE VALVE . . . . . . . . . . . . . . 20-220-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
AUXILIARY BREAKER VALVE . . . . . 20-170-1 ELECTRICAL SYSTEM INFORMATION
AUXILIARY HYDRAULIC VALVE . . . . 20-190-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 EMERGENCY EXIT . . . . . . . . . . . . . .10-190-1
BLADE CONTROL VALVE . . . . . . . . . 20-130-1 ENGINE COOLING SYSTEM . . . . . .10-110-1
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 ENGINE COOLING SYSTEM . . . . . . .60-50-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 70-110-1 ENGINE FLYWHEEL . . . . . . . . . . . . .60-140-1
BOBCAT EXCAVATOR IDENTIFICATION 1-16 ENGINE INFORMATION . . . . . . . . . . .60-10-1
BOOM (ARTICULATED) (OPTIONAL) ENGINE LUBRICATION SYSTEM . . .10-130-1

Dealer Copy -- Not for Resale


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-141-1 ENGINE SPEED CONTROL . . . . . . . .60-20-1
BOOM SWING VALVE . . . . . . . . . . . . 20-180-1 EVAPORATOR / HEATER UNIT . . . . . .70-80-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1 EXHAUST GAS RECIRCULATION VALVE
BUCKET . . . . . . . . . . . . . . . . . . . . . . . 40-170-1 (EGR) . . . . . . . . . . . . . . . . . . . . . . . . .60-120-1
CAB FILTER . . . . . . . . . . . . . . . . . . . . 10-100-1 EXPANSION VALVE . . . . . . . . . . . . . .70-100-1
CAB TILT PROCEDURE . . . . . . . . . . 10-210-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-12
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 FLOOR MAT . . . . . . . . . . . . . . . . . . . .40-100-1
CAMSHAFT AND TIMING GEARS . . 60-100-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CENTER ACCESS COVER . . . . . . . . . 40-80-1 FUEL LEVEL SENDER . . . . . . . . . . . .50-70-1
CENTER COVER . . . . . . . . . . . . . . . . . 10-70-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-120-1
CENTER COVER . . . . . . . . . . . . . . . . . 40-70-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .60-70-1
COLD START DEVICE . . . . . . . . . . . 60-110-1 FUEL TANK . . . . . . . . . . . . . . . . . . . .40-110-1
COMPRESSOR . . . . . . . . . . . . . . . . . . 70-50-1 FUEL TRANSFER PUMP . . . . . . . . . .50-150-1
CONDENSER . . . . . . . . . . . . . . . . . . . 70-60-1 HEATER VALVE . . . . . . . . . . . . . . . . .70-120-1
CONSOLE LOCKOUT SWITCH . . . . . 50-60-1 HORN . . . . . . . . . . . . . . . . . . . . . . . . .40-120-1
CONTROL CONSOLE LOCKOUTS . 10-220-1 HVAC CONTROLLER . . . . . . . . . . . .70-130-1
CONTROL PATTERN SELECTOR VALVE HYDRAULIC CONNECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-30-1
CONVERSIONS . . . . . . . . . . . . . . . SPEC-50-1 HYDRAULIC CONTROL VALVE . . . . .20-40-1
COUNTERWEIGHT . . . . . . . . . . . . . . . 40-90-1 HYDRAULIC FLUID SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
CRANKSHAFT AND PISTONS . . . . . . 60-90-1
HYDRAULIC RESERVOIR . . . . . . . . .20-140-1
CYLINDER (ARM) . . . . . . . . . . . . . . . . 20-21-1
HYDRAULIC SYSTEM INFORMATION
CYLINDER (ARTICULATED BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 20-25-1
HYDRAULIC SYSTEM . . . . . . . . . . . .10-140-1
CYLINDER (BLADE) . . . . . . . . . . . . . . 20-24-1
INSTRUMENT PANEL . . . . . . . . . . . .50-100-1
CYLINDER (BOOM SWING) . . . . . . . . 20-22-1

872 of 879 INDEX-01 S100 Service Manual


KEY SWITCH . . . . . . . . . . . . . . . . . . . 50-110-1 SWING CIRCLE GEAR . . . . . . . . . . . 30-70-1
LEFT CONSOLE . . . . . . . . . . . . . . . . .40-60-1 SWING FRAME . . . . . . . . . . . . . . . . 40-130-1
LEFT CONTROL LEVER (JOYSTICK) SWING MOTOR (DRIVE CARRIER) . 20-91-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-1 SWING MOTOR . . . . . . . . . . . . . . . . . 20-90-1
LIFTING AND BLOCKING THE EXCAVATOR SWIVEL JOINT . . . . . . . . . . . . . . . . . . 20-80-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1
SYSTEM CHARGING AND RECLAMATION
LIFTING THE EXCAVATOR . . . . . . . . .10-20-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .50-50-1 THERMOSTAT . . . . . . . . . . . . . . . . . . 70-90-1
LOWER TRACK ROLLER . . . . . . . . . .30-50-1 TORQUE SPECIFICATIONS FOR BOLTS
LUBRICATING THE EXCAVATOR . . .10-150-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
LUBRICATION SYSTEM . . . . . . . . . . .60-60-1 TOWING THE EXCAVATOR . . . . . . 10-230-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 TRACK MAINTENANCE . . . . . . . . . . 30-30-1
MANIFOLD AIR HEATER . . . . . . . . .60-130-1 TRACK UNDERCARRIAGE COMPONENTS
MANIFOLD ASSEMBLY / ACCUMULATOR (RUBBER TRACK) . . . . . . . . . . . . . . . 30-20-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1 TRANSPORTING THE EXCAVATOR ON A
MOTION ALARM SYSTEM (IF EQUIPPED) TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-140-1 TRAVEL CONTROL VALVE . . . . . . . 20-210-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . .60-30-1 TRAVEL MOTOR . . . . . . . . . . . . . . . 10-170-1
OIL COOLER . . . . . . . . . . . . . . . . . . .20-150-1 TRAVEL MOTOR . . . . . . . . . . . . . . . . 20-70-1

Dealer Copy -- Not for Resale


OPERATOR CAB . . . . . . . . . . . . . . . . .10-30-1 TROUBLESHOOTING . . . . . . . . . . . . 70-30-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . .10-160-1 UPPER TRACK ROLLER . . . . . . . . . . 30-60-1
PUMP (GEAR) . . . . . . . . . . . . . . . . . . .20-51-1 UPPERSTRUCTURE SIDE COVER (LEFT)
PUMP (HYDRAULIC PISTON) . . . . . . .20-50-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
QUICK COUPLER (KLAC SYSTEM) .40-160-1 UPPERSTRUCTURE SIDE COVER (RIGHT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
QUICK COUPLER (LEHNHOFF SYSTEM)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-161-1 UPPERSTRUCTURE . . . . . . . . . . . . . 40-10-1
REAR COVER . . . . . . . . . . . . . . . . . . .10-60-1 VALVE (PILOT PRESSURE RELIEF) 20-32-1
REAR COVER . . . . . . . . . . . . . . . . . .40-190-1 VALVES (PORT RELIEF) . . . . . . . . . . 20-31-1
RECEIVER / DRIER . . . . . . . . . . . . . . .70-70-1 VALVES (RELIEF) . . . . . . . . . . . . . . . 20-30-1
REGULAR MAINTENANCE . . . . . . . . .70-20-1 WIPER MOTOR . . . . . . . . . . . . . . . . 50-130-1
RIGHT CONSOLE SWITCH COVER .50-120-1
RIGHT CONSOLE . . . . . . . . . . . . . . . .40-50-1
RIGHT CONTROL LEVER (JOYSTICK)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
RIGHT SIDE COVER . . . . . . . . . . . . . .10-50-1
RIGHT SIDE COVER . . . . . . . . . . . . .40-180-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . 1-10
SEAT BELT . . . . . . . . . . . . . . . . . . . . .10-200-1
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-1
SERIAL NUMBER LOCATIONS . . . . . . . 1-14
SERVICE MANUAL REVISION . . . . . . SMR-1
SERVICE SCHEDULE . . . . . . . . . . . . .10-80-1
SPARK ARRESTER MUFFLER . . . . .10-180-1
STARTER . . . . . . . . . . . . . . . . . . . . . . .50-40-1
SWING CIRCLE GEAR . . . . . . . . . . . .30-40-1

873 of 879 INDEX-02 S100 Service Manual


ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: E80 - 1


Date: 9 Jun 2009
Product: Bobcat Excavator
Model: E80
Manual No: 6987194 (6-09)

Dealer Copy -- Not for Resale


The following Sections are a revision to the above Service Manual.

COVER
ALPHABETICAL INDEX
FOREWORD

20-01
20-190 Added

40-01
40-30
40-160
40-170

50-01
50-130 Added
50-140 Added

874 of 879 SMR-1 E80 Service Manual


Dealer Copy -- Not for Resale

875 of 879 SMR-2 E80 Service Manual


ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: E80 - 2


Date: 15 November 2009
Product: Bobcat Excavator
Model: E80
Manual No: 6987194 (11-09)

Dealer Copy -- Not for Resale


The following Sections are a revision to the above Service Manual.

COVER 50-01
MAINTENANCE SAFETY 50-81 Added
ALPHABETICAL INDEX 50-130 Added
50-140 Added
10-01
10-30 SPEC-10
10-50

20-30
20-40
20-50
20-51
20-70
20-190 Added

40-01
40-130
40-131 Added

876 of 879 SMR-3 E80 Service Manual


Dealer Copy -- Not for Resale

877 of 879 SMR-4 E80 Service Manual


ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: E80 - 3


Date: 15 February 2011
Product: Bobcat Excavator
Model: E80
Manual No: 6987194 (02-11)

Dealer Copy -- Not for Resale


E80 Service Manual (P/N 6987194) Dated 02-11 contains updated service information which replaces the previous
E80 Service Manaul (P/N 6987194) Dated 11-09.

878 of 879 SMR-5 E80 Service Manual


Dealer Copy -- Not for Resale

879 of 879 SMR-6 E80 Service Manual

You might also like