425 6904866 SM 7-07 (Full Permission)

Service Manual
425 Compact Excavator

Modestas Vasiliauskas
Kestučio g. 6
Kursenai
Siauliu rajonas
LT81182
Lithuania
Email address:
S/N A1HW11001 & Above
Dealer Copy -- Not for Resale

[email protected]
6904866 (7-07) Printed in U.S.A. © Bobcat Company 2007
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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-2003-0903
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
B-10731A B-19964 B-19959

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

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 rear door closed except for and get immediate medical
Never fill fuel tank with engine service. Close and latch door 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.
MSW28-0805
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ALPHABETICAL INDEX
AIR CLEANER ........................................................ 60-01 HEATER COIL .........................................................70-01

AIR CLEANER SERVICE ....................................... 10-01 HEATER SYSTEM...................................................70-01
ALTERNATOR ....................................................... 50-01 HEATER UNIT .........................................................70-01
ALTERNATOR BELT............................................... 10-01 HEATER VALVE ......................................................70-01
ARM ........................................................................ 40-01 HORN .....................................................................40-01
ARM CYLINDER .................................................... 20-01 HYDRAULIC CONTROL VALVE .............................20-01
HYDRAULIC CONNECTION SPECS ............... SPEC-01
BATTERY................................................................ 50-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
BLADE ................................................................... 30-01 HYDRAULIC FILTER...............................................20-01
BLADE CONTROL.................................................. 40-01 HYDRAULIC PUMP ................................................20-01
BLADE CYLINDER ................................................. 20-01 HYDRAULIC RESERVOIR......................................20-01
BLOWER FAN ........................................................ 70-01 HYDRAULIC SYSTEM ............................................10-01
BOOM ..................................................................... 40-01 HYDRAULIC SYSTEM INFORMATION .................20-01
BOOM CYLINDER .................................................. 20-01 HYDRAULIC X-CHANGE VALVE............................20-01
BOOM SWING CYLINDER..................................... 20-01
BOOM SWING PEDAL ........................................... 40-01 LEFT CONTROL LEVER (JOYSTICK) ...................20-01
BUCKET ................................................................. 40-01 LEFT CONSOLE .....................................................40-01
BUCKET CYLINDER .............................................. 20-01 LEFT SIDE COVER.................................................40-01
LIFTING AND BLOCKING THE EXCAVATOR ........10-01
CAB......................................................................... 40-01 LIFTING THE EXCAVATOR ....................................10-01
CAMSHAFT AND TIMING GEARS......................... 60-01 LIGHTS....................................................................50-01
CANOPY ................................................................. 40-01 LUBRICATION SYSTEM .........................................60-01

CASE DRAIN FILTER ............................................ 20-01 LUBRICATING THE EXCAVATOR ..........................10-01
CONVERSIONS ...............................................SPEC-01
CONTROL PATTERN SELECTOR VALVE ............20-01 MAGNETIC LOCKOUT SENSOR ...........................50-01
COUNTERWEIGHT ............................................... 40-01 MAIN RELIEF VALVE ..............................................20-01
CRANKSHAFT AND PISTONS .............................. 60-01 MANIFOLD ASSEMBLY / ACCUMULATOR ...........20-01
CROSSPORT RELIEF VALVES ............................ 20-01
CYLINDER HEAD ................................................... 60-01 NON-PRESSURIZED ACCUMULATOR .................20-01
DIAGNOSTICS SERVICE CODES......................... 50-01 OIL COOLER...........................................................20-01

DIRECT TO TANK VALVE ...................................... 20-01 OPERATOR CAB (ROPS/TOPS) ............................10-01
ELECTRICAL SYSTEM INFORMATION ................ 50-01 PIVOT PINS ............................................................10-01

ENGINE COOLING SYSTEM ...................... 10-01, 60-01 PORT RELIEF VALVES...........................................20-01
ENGINE INFORMATION ........................................ 60-01 PRESSURE REDUCING VALVE.............................20-01
ENGINE LUBRICATION SYSTEM.......................... 10-01
ENGINE SPEED CONTROL .................................. 60-01 REGULAR MAINTENANCE ...................................70-01
EXCAVATOR SPECIFICATIONS .......................SPEC-01 RIGHT CONTROL LEVER (JOYSTICK) .................20-01
EXCAVATOR STORAGE AND RETURN TO RIGHT CONSOLE ...................................................40-01
SERVICE .............................................................. 10-01 RIGHT SIDE COVER ..................................10-01, 40-01
FLOOR MAT AND FLOOR PANELS ...................... 40-01

FLYWHEEL AND HOUSING................................... 60-01
FUEL LEVEL SENDER........................................... 50-01
FUEL SYSTEM ............................................ 10-01, 60-01
FUEL TANK............................................................. 40-01
Continued On Next Page
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ALPHABETICAL INDEX (CONT’D)
SEAT AND SEAT MOUNT...................................40-01

SEAT BELT .............................................................10-01
SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR MUFFLER ...................10-01, 60-01
STARTER ............................................................... 50-01
STOPPING THE ENGINE AND LEAVING
THE EXCAVATOR .................................................10-01
SWING CIRCLE GEAR ...........................................30-01
SWING FRAME .......................................................40-01
SWING MOTOR .....................................................20-01
SWING MOTOR DRIVE CARRIER..........................20-01
SWIVEL JOINT .......................................................20-01
TAILGATE .....................................................10-01, 40-01

TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TRACK FRAME COMPONENTS ............................30-01
TRANSPORTING THE EXCAVATOR
ON A TRAILER......................................................10-01
TRAVEL LEVER / PEDALS .....................................40-01
TRAVEL MOTOR......................................... 10-01, 20-01
TROUBLESHOOTING.............................................70-01

UPPERSTRUCTURE ..............................................40-01
UPPERSTRUCTURE SLEW LOCK .............10-01, 40-01
X-CHANGE..............................................................40-01
X-CHANGE (HYDRAULIC)......................................40-01
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CONTENTS SAFETY AND
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
UNDERCARRIAGE
EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 UPPERSTRUCTURE

& SWING
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 SECTION
UNDERCARRIAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
ELECTRICAL
SYSTEM AND
UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01 ANALYSIS
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01

ENGINE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 SERVICE
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER
SPECIFICATIONS
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II
425 Service Manual
FOREWORD
This manual is for the Bobcat Hydraulic Excavator mechanic. It provides necessary servicing and adjustment procedures
for the hydraulic 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 hydraulic 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 (Optional on
tightened and is Bobcat some models.
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.

4. Inspect for loose or broken 12. Inspect for fuel, oil or
parts or connections. hydraulic fluid leaks.
5. Machine signs must be 13. Lubricate the excavator.

legible and in the correct
location.
6. Steering levers, control levers 14. Check the condition of the

and foot pedals must return to battery and cables.
neutral. Check that foot
pedals lock and control lever
locks are in working order.
7. Inspect the air cleaner for Recommend to the owner that all
damage or leaks. Check the necessary corrections be made
condition of the element. before the machine is returned to
service.
8. Check the electrical charging

system.
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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 instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the

W-2003-0903 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.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Compact Excavator Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Bobcat Excavator. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• 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.
• The Bobcat Compact Excavator Safety Video is

available from your Bobcat dealer or at
www.training.bobcat.com or www.bobcat.com.
SI EXC-0206 SM
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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.

Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI EXC-0206 SM
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SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the

emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
• Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,

explosive dust or gases.
• The operator cab, engine compartment, and engine

• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the 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 a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI EXC-0206 SM
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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 1
1
P-70501A
The engine serial number (Item 1) is located on the

engine in the location shown [Figure 2].
1

P-69863
The excavator serial number plate (Item 1) is located on

the frame of the machine in the location shown [Figure
1].
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.
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DELIVERY REPORT
Figure 3
B-16315
The delivery report must be filled out 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. Make sure it is filled out

completely [Figure 3].
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EXCAVATOR IDENTIFICATION
ARM CYLINDER OPERATOR

AUXILIARY HANDBOOK
QUICK
COUPLERS LIFT POINT OPERATOR SEAT
With SEAT BELT
BUCKET CONTROL
CYLINDER LEVERS
(JOYSTICKS)
BOOM
ARM
BUCKET
LINK
BOOM
CYLINDER
X-CHANGE®

TIE DOWN /
LIFT POINTS BLADE
CYLINDER
†BUCKET
●CANOPY/CAB
(ROPS/TOPS)
RIGHT SIDE
COVER
REAR
DOOR
COUNTERWEIGHTS BLADE
TRACK FRAME
TIE DOWN
UPPERSTRUCTURE
TRACK B-23467
B-23469
† BUCKET - Several different buckets and other attachments are available from the Bobcat Excavator.
● ROPS, TOPS - (Roll Over Protective Structure / Tip Over Protective Structure) as standard equipment. The ROPS/
TOPS meets SAE J1040, ISO 3471 and ISO 12117.
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SAFETY AND MAINTENANCE SAFETY AND
MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . 10-70-3
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . 10-90-1
Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing Oil Filter . . . . . . . . . . . . . . . . . . 10-90-2
EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . 10-170-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-4
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . 10-80-4
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Hydraulic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing And Replacing The Case Drain Filter . . . . . . . 10-100-2
Removing And Replacing The Hydraulic Filter . . . . . . . . 10-100-2
Removing And Replacing The Hydraulic Fluid . . . . . . . . 10-100-3
LIFTING AND BLOCKING THE EXCAVATOR . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1
LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . 10-110-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
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SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB (ROPS / TOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Front Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
Heating, Ventilation, and Air Conditioning Duct . . . . . . . . . . . . . . . 10-20-5
Right Side Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
Window Washer Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1

Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . 10-180-1

Emergency Exits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TRANSPORTING THE EXCAVATOR ON A TRAILER . . . . . . . . . . . . 10-30-1

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-1

20 of 726
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
Always park the machine on a level surface.
Figure 10-10-1
P-69958A

Raise one side of the machine (approximately 4 in.) using
the boom and arm as shown in [Figure 10-10-1].
Raise the blade fully and install jackstands under the

blade and the track frame. Lower the boom until all
machine weight is on the jackstands.
Stop the engine.
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
or fall and result in injury or death.
W-2218-1195
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903
10-10-1 425 Service Manual

21 of 726

22 of 726
UPPERSTRUCTURE SLEW LOCK
Operation
Figure 10-11-1
P-69867
Push down on the front (Item 1) [Figure 10-11-1] of the

foot pedal to engage the upperstructure swing lock.

Push down on the rear (Item 2) [Figure 10-11-1] to
disengage the upperstructure slew lock.
NOTE: Upperstructure must be in the straight

forward or straight rearward position for
upperstructure to lock.

23 of 726

24 of 726
LIFTING THE EXCAVATOR Figure 10-12-2
Procedure
Figure 10-12-1
2
2 1
P-69913A
Fasten chains to the ends of the blade (Item 1) [Figure

P-69906 10-12-1] and [Figure 10-12-2] and up to a lifting fixture
above the canopy/cab. The lifting fixture must extend
over the sides of the canopy/cab to prevent the chains
Fully extend the cylinders of the bucket, arm, and boom from hitting the ROPS/TOPS.
so that the excavator is in the position as shown [Figure

10-12-1]. Install a one inch (25 mm) bolt and nut (Grade 5 or 8)
through the holes at the boom (Item 2) [Figure 10-12-1]
Raise the blade all the way. and [Figure 10-12-2]. Fasten a chain from the bolt to the
lift fixture.
Put all the control levers in neutral.
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.
• Do not swing boom or upperstructure. Engage
the swing locking lever.
• Never lift with operator on machine.
W-2202-0595

25 of 726

26 of 726
OPERATOR CAB (ROPS / TOPS) Figure 10-20-2
Description
The excavator has an optional operator cab (ROPS/

TOPS) (Roll Over Protective Structure/Tip Over
Protective Structure). The ROPS/TOPS meets SAE
J1040, ISO 3471 and ISO 12117.
An enclosed cab (ROPS/TOPS) is an Option or can be 2

installed as a Field Accessory.
1
Both the cab and canopy provide operator protection if
the excavator is tipped over. The seat belt must be worn
for ROPS /TOPS protection.
P-68193
When the door is in the open position, push down on the

WARNING latch (Item 1) [Figure 10-20-2] and close the door.
Never modify operator cab by welding, grinding, From inside the cab, open the door using handle (Item 2)
drilling holes or adding attachments unless [Figure 10-20-2].
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
Cab Door
Figure 10-20-1
P-68192
The cab door can be locked (Item 1) [Figure 10-20-1]

with the same key as the starter switch.
Push the door all the way open (Item 2) [Figure 10-20-1]
until the latch engages to hold the door in the open
position.

27 of 726
OPERATOR CAB (ROPS / TOPS) (CONT’D) Figure 10-20-5
Front Window
Opening The Front Window
Figure 10-20-3
P-69886
Use both window grab handles to pull the top of the

window in [Figure 10-20-5].
Continue moving the window in and up over the

P-49097
operator’s head until the window is fully raised.
Figure 10-20-6

Retract the two top window latch pins (Item 1) [Figure
10-20-3].
Figure 10-20-4
2 1
P-66518A
1
When the window is fully raised, the latch (Item 1) will
close on the bracket. Turn the two top latches (Item 2)
P-49098
[Figure 10-20-6] to the locked position.
Turn the two top latches (Item 1) [Figure 10-20-4] to the Closing The Front Window
unlocked position.
Support the window while releasing both window latch
pins and placing the pins in the unlocked position [Figure
10-20-6].
Support the window using the left grab handle and pull
down on the latch (Item 1) [Figure 10-20-5] to release
the window.
Use both window grab handles to pull the window down

[Figure 10-20-5].
Rotate the top latches (Item 1) [Figure 10-20-4] to the

locked position (Item 1) [Figure 10-20-3].

28 of 726
OPERATOR CAB (ROPS / TOPS) (CONT’D) Window Washer Reservoir
Front Wiper Figure 10-20-8
Figure 10-20-7
P-69870
P-49095
The window washer reservoir (Item 1) [Figure 10-20-8]
is located under the right side cover.
The front window is equipped with a wiper (Item 1)
[Figure 10-20-7] and washer.

29 of 726
OPERATOR CAB (ROPS / TOPS) (CONT’D) Opening The Right Front Window
Right Side Window Figure 10-20-11
Opening The Right Rear Window
Figure 10-20-9
1
1
P-49119
Pull back on the latch / handle (Item 1) [Figure 10-20-

P-49176 11].
Figure 10-20-12

Pull forward on the latch / handle (Item 1) [Figure 10-20-
9].
Figure 10-20-10
1 P-49120
Pull the latch / handle (Item 1) [Figure 10-20-12] back to

P-49177 open the window.
Closing The Right Front Window

Pull the latch / handle (Item 1) [Figure 10-20-10] forward
to open the window. Push the handle forward to close the window.
Closing The Right Rear Window
Push the handle back to close the window.

30 of 726
OPERATOR CAB (ROPS / TOPS) (CONT’D) Figure 10-20-14
Heating, Ventilation, and Air Conditioning Duct

1
NOTE: The air conditioner duct can be ordered and
used on heater models.
There are two HVAC ducts that the operator can choose 2
to install.
3
Figure 10-20-13
P-42588
Place the air conditioning duct (Item 1) on the housing

and over the locking stud (Item 2) [Figure 10-20-14].
Reinstall the screw (Item 3) [Figure 10-20-14].
Figure 10-20-15

P-69871
The small duct (Item 1) [Figure 10-20-13] is standard for

heater use.
The large duct (Item 1) [Figure 10-20-14] is standard for

models that have air conditioner available.
NOTE: This duct (Item 1) [Figure 10-20-14] can be

removed for improved operator visibility.
1
Installation
P-42590
Remove the screw and pull straight up to remove the
duct (Item 1) [Figure 10-20-13].
Fully seat the duct and rotate the lock (Item 1) [Figure
10-20-15].

31 of 726

32 of 726
TRANSPORTING THE EXCAVATOR ON A TRAILER Fastening
Loading And Unloading
Figure 10-30-2
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

1
transport vehicle.
Align the ramps with the center of the transport vehicle.

Secure the ramps to the truck bed and be sure ramp
angle does not exceed 15 degrees.
1
Use metal loading ramps with a slip resistant surface.
Use ramps that are the correct length and width and can
P-69899A
support the weight of the machine.
The rear of the trailer must be blocked or supported when Figure 10-30-3
loading or unloading the excavator to prevent the front of
the transport vehicle from raising.
Determine the direction of the track movement before

moving the machine (blade forward).
Engage the slew lock.
Figure 10-30-1
1
P-69894
Fasten chains to the front corners of the blade (Item 1)

[Figure 10-30-2] and to the tie down loop at the rear of
the track frame (Item 1) [Figure 10-30-3] to prevent it
from moving when going up or down slopes or during
sudden stops.
P-69892 Use chain binders to tighten the chains and then safely
tie the chain binder levers to prevent loosening.
Move the machine forward onto the transport vehicle
[Figure 10-30-1].
Do not change direction of the machine while it is on the

ramps.
WARNING
Adequately designed ramps of sufficient strength are
Lower the boom, arm, bucket, and blade to the transport needed to support the weight of the machine when
vehicle. loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
Stop the engine and remove the key (if equipped). W-2058-0494
Put blocks at the front and rear of the tracks.

33 of 726

34 of 726
TAILGATE Figure 10-40-2
Opening And Closing
WARNING
AVOID INJURY OR DEATH 1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
P-73464
WARNING Hold the tailgate up and pull outward on the latch (Item 1)
Keep the rear door closed when operating the [Figure 10-40-2]. Slowly lower the tailgate until the latch
machine. Failure to do so could seriously injure a is locked and holds the tailgate open.
bystander.
W-2020-1285 Closing

Lift up slightly on the tailgate and push inward on the
Figure 10-40-1
latch (Item 1) [Figure 10-40-2]. Slowly lower the tailgate
until the tailgate is fully closed.
P-69922A
Opening
Pull outward on the latch (Item 1) [Figure 10-40-1] and

lift the tailgate up.
NOTE: The tailgate can be locked using the start key.

35 of 726

36 of 726
RIGHT SIDE COVER Hold the side cover up and pull outward on the latch
(Item 1) [Figure 10-41-2]. Slowly lower the side cover
Opening And Closing until the latch is locked and holds the side cover open.
Closing
WARNING Lift up slightly on the side cover and push inward on the
latch (Item 1) [Figure 10-41-2]. Slowly lower the side
cover until the side cover is fully closed.
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 10-41-1
1
1

P-69925A
Opening
Pull outward on the latch (Item 1) [Figure 10-41-1] and

lift the side cover up.
NOTE: The side cover can be locked using the start

key.
Figure 10-41-2
P-73479

37 of 726

38 of 726
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals.
WARNING
Failure to do so will result in excessive wear and early
failures. The service schedule is a guide for correct Instructions are necessary before operating or
maintenance of the Bobcat excavator. 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
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
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 and
Tubelines, Reservoir Breather Cap 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 Canopy/Cab Check condition. Check mounting hardware.
Seat Belt Check condition. Check mounting hardware.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Pivot Points Grease all machinery pivot points.
Cab Heater Air Filter Clean the filter as needed.
Console Lockout Check console lockout for proper operation.
X-Change Lubricate and inspect for damage or loose parts.
Swing Circle and Pinion Grease two fittings.
Fuel Tank & Filter Drain water and sediment from fuel tank and fuel filter.
Battery Check battery, cables, connections and electrolyte level. Add distilled water
as needed.
Spark Arrestor Muffler Clean the spark chamber.
Fuel Filters Replace fuel filter.
Inline Fuel Filter Replace inline fuel filter.
Engine Oil and Filter Replace oil and filter use CD or better grade oil and Bobcat filter. ▼
Alternator Belt Check condition of belt and adjust as needed. ●
Radiator, Oil Cooler Clean debris from the radiator fins.
Primary Hydraulic Filter Replace the primary hydraulic filter. ^
Case Drain Filter Replace the case drain filter. ^
Alternator & Starter Check the alternator and starter connections. ^
Engine Valves Check and adjust the engine valve clearance.
Engine Cooling System Drain and flush the cooling system. Replace the coolant.
Hydraulic System Replace the hydraulic fluid and filters. Clean the reservoir.
Travel Motor Replace the lubricant in both travel motors. ^
* If Equipped
● Check after the first 50 hours, then 100 hour intervals thereafter.
▼ First oil and filter change must occur at 50 hours; then 500 hour intervals thereafter.
^ Check after the first 100 hours, then 500 hour intervals thereafter.
■ Or every 6 months.

39 of 726

40 of 726
AIR CLEANER SERVICE Figure 10-60-2
See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-50-1.)
Daily Check
The air cleaner is located in the engine compartment.

Open the tailgate to access the air cleaner for service.
(See TAILGATE on Page 10-40-1.)
Figure 10-60-1
1
1
2
P73187
Pull the outer filter (Item 1) [Figure 10-60-2] from the air
cleaner housing.
Check the housing for damage.
3 Clean the housing and the seal surface. DO NOT use

2 compressed air.
P-73186 Install a new filter.
Figure 10-60-3
Check the condition indicator (Item 1) [Figure 10-60-1]. If
the red ring shows in the condition indicator, the filter
needs to be replaced.
3
Replace the inner filter every third time the outer filter is
replaced or as indicated.
2
Replacing Filter Elements
Outer Filter
Release the two fasteners (Item 2) [Figure 10-60-1].

2
Remove and clean the dust cup (Item 3) [Figure 10-60-
1]. 1
P-73186A
Install the dust cup (Item 1) and engage the fasteners

(Item 2) [Figure 10-60-3].
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
After the outer filter has been replaced, press the button
(Item 3) [Figure 10-60-3] on the end of the condition
indicator and start the engine. Run at full RPM, then
reduce engine speed and stop the engine. If the red ring
shows in the condition indicator, replace the inner filter.

41 of 726
AIR CLEANER SERVICE (CONT’D)
Replacing Filter Elements (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, press the

button (Item 3) [Figure 10-60-3] on the top of the
condition indicator and start the engine. Run at full
RPM, then reduce engine speed and stop the engine.
If the red ring shows in the condition indicator, replace
the inner filter.
Figure 10-60-4

1
P-73188
Remove the dust cup, outer filter and inner filter (Item 1)
[Figure 10-60-4].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install the new inner filter.
Install the outer filter and the dust cup.
Press the button on the condition indicator to remove the

red ring.

42 of 726
ENGINE COOLING SYSTEM Figure 10-70-2
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
Cleaning
NOTE: Allow the cooling system and engine to cool 2

before servicing or cleaning the cooling
system.
Open the tailgate.

1
Figure 10-70-1
2 P-69942
1 Clean both sides of the oil cooler (Item 1) and the radiator
1 (Item 2) [Figure 10-70-2]
Use air pressure or water pressure to clean the radiator

1 and oil cooler. Be careful not to damage fins when
cleaning.

Reinstall the cover (Item 2) with the four bolts (Item 1)
[Figure 10-70-1].
1
P-69941
Remove the four bolts (Item 1) and remove the cover

(Item 2) [Figure 10-70-1].

43 of 726
ENGINE COOLING SYSTEM (CONT’D)
Checking Level
IMPORTANT
AVOID ENGINE DAMAGE
WARNING Always use the correct ratio of water to antifreeze.
AVOID BURNS Too much antifreeze reduces cooling system

Do not remove radiator cap when the engine is hot. efficiency and may cause serious premature engine
You can be seriously burned. damage.
W-2070-1203
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
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-2019-1285
Open the tailgate.
Figure 10-70-3
P-73193
Check the coolant level in the coolant recovery tank (Item

1) [Figure 10-70-3].
The coolant level must be between the MIN and MAX

marks on the coolant recovery tank when the engine is
cold.
NOTE: The cooling system is factory filled with

propylene glycol (purple color). DO NOT mix
propylene glycol with ethylene glycol.

44 of 726
ENGINE COOLING SYSTEM (CONT’D) Figure 10-70-5
Removing And Replacing Coolant
See the SERVICE SCHEDULE for correct service

intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
Stop the engine. Open the tailgate
WARNING
AVOID BURNS 1
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203 P-69944
Figure 10-70-4 Put a hose on the drain valve at the bottom of the
radiator. Open the drain valve (Item 1) [Figure 10-70-5]
1 and drain the coolant into a container.
After all the coolant is removed, close the drain valve.

2 Recycle or dispose of the used coolant in an
environmentally safe manner.
Mix the coolant in a separate container for correct

capacity. (See Capacities on Page SPEC-10-7.)
NOTE: The cooling system is factory filled with

propylene glycol (purple color). DO NOT mix
propylene glycol with ethylene glycol.
P-73193
Add premixed coolant; 47% water and 53% propylene
glycol to the radiator and recovery tank.
When the engine is cool, remove the coolant from the
recovery tank (Item 1) [Figure 10-70-4]. One gallon and one pint of propylene glycol mixed with
one gallon of water is the correct mixture of coolant to
When the engine is cool, loosen and remove the radiator provide a -34°F (-37°C) freeze protection.
cap (Item 2) [Figure 10-70-4].
Use a refractometer to check the condition of propylene
glycol in your cooling system. Install the radiator cap. Be
sure the radiator cap is tight.
Run the engine until it is at operating temperature. Stop

the engine.
Add coolant to the recovery tank as needed.
Close the tailgate.

45 of 726

46 of 726
FUEL SYSTEM Filling The Fuel Tank
Fuel Specifications Figure 10-80-1
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
1
The following is a suggested blending guideline which
should prevent fuel gelling problems during freezing
temperature
Temp. F° (C°) No. 2 No. 1

Above +15° (-9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
Contact your fuel supplier for local recommendations. P-73004
Open the right side cover.

WARNING Remove the fuel fill cap (Item 1) [Figure 10-80-1].
Stop and cool the engine before adding fuel. NO

Use a clean, approved safety container to add fuel. Add
SMOKING! Failure to obey warnings can cause an fuel only in an area that has a free movement of air and
explosion or fire. no flames or sparks. NO SMOKING!
W-2063-0887
Install and tighten the fuel fill cap.
Clean up any spilled fuel.

WARNING See the SERVICE SCHEDULE for the service interval
when to remove water from or replace the fuel filter. (See
Always clean up spilled fuel or oil. Keep heat, flames,
SERVICE SCHEDULE on Page 10-50-1.)
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
NOTE: The fuel cap can be locked using the start key.
explosion or fire which can result in injury or death.
W-2103-1285

47 of 726
FUEL SYSTEM (CONT’D) Replacing Elements
Fuel Filters The floor mat and floor panel will need to be removed for
access to both fuel filters.
Removing Water
See the SERVICE SCHEDULE for the service interval
Figure 10-80-2 when to replace elements. (See SERVICE SCHEDULE
on Page 10-50-1.)
Figure 10-80-4
1
1
P-69932
1

Turn the upperstructure so the boom is centered between
P-73050
the rear tracks for easier access to the fuel filter (Item 1)
[Figure 10-80-2] that is located in the upperstructure
behind the boom. Remove the two bolts (Item 1) and plate (Item 2) [Figure
10-80-4].
Figure 10-80-3
Figure 10-80-5
P-69933
1 P-73051
Loosen the drain (Item 1) [Figure 10-80-3] at the bottom

of the filter to drain water from the filter. Remove the floor mat (Item 1) [Figure 10-80-5] and
insulation.

48 of 726
FUEL SYSTEM (CONT’D) Figure 10-80-8
Fuel Filters (Cont’d)
Replacing Elements (Cont’d)

1
Figure 10-80-6
1 1 1
P-69933
2 Remove the filter (Item 1) [Figure 10-80-8].

1
1 Clean the area around the filter housing. Put clean oil on
P-73053
the seal of the new filter. Install the fuel filter and hand
tighten. Clean up any spilled fuel.

Remove the seven bolts (Item 1) and the floor panel Remove the air from the fuel system. (See Removing Air
(Item 2) [Figure 10-80-6]. From The Fuel System on Page 10-80-4.)
Figure 10-80-7
P-73021
NOTE: Fuel will flow from the fuel inlet hose when it
is removed from the inline filter. Clamp off the
inlet hose before removing it from the filter or
plug the hose when it is removed.
Remove the filter (Item 1) [Figure 10-80-7] from the

retaining clamp.
Remove the two hose clamps (Item 2). Remove and

replace the filter (Item 1) [Figure 10-80-7].

49 of 726
FUEL SYSTEM (CONT’D) Reuse, recycle or dispose of fuel in an environmentally
safe manner.
Draining The Fuel Tank

Figure 10-80-9
WARNING
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
1
from a physician familiar with this injury.
W-2072-0496
Removing Air From The Fuel System
The excavator fuel system is a self bleed system and is

purged of air every time the start key is turned to the run
P-69933 position or keyless switch is pressed.

NOTE: For correct procedure for accessing fuel filter
and fuel hose shown below (See Fuel Filters
on Page 10-80-2.)
Loosen the drain (Item 1) [Figure 10-80-9] at the bottom

of the filter to drain water from the filter. (See Fuel Filters
on Page 10-80-2.)
Figure 10-80-10
P-73021
Remove the inlet hose (Item 1) [Figure 10-80-10] from

the fuel filter.
Turn the start key to the ON position.

Drain the fuel into a container.
Turn the start key to the OFF position.

50 of 726
ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2
Check the engine oil after every 8-10 hours of operation

and before starting the engine.
Figure 10-90-1
P-73189

Open the tailgate and remove the dipstick (Item 1)
[Figure 10-90-1]. B-16320
Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets the correct API
Use a good quality motor oil that meets the correct API Service Classification [Figure 10-90-2].
Service Classification.
Install the dipstick and close the tailgate.

51 of 726
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-5
Removing And Replacing Oil Filter
See the SERVICE SCHEDULE for the service interval for

replacing the engine oil and filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
Run the engine until it is at operating temperature. Stop

the engine.
Figure 10-90-3
1
P-73191
Remove the oil filter (Item 1) [Figure 10-90-5] and clean

the filter housing surface.
Recycle or dispose of used oil in an environmentally safe

manner.
1
Use a genuine Bobcat replacement filter.

Put clean oil on the filter gasket. Install the filter and hand
tighten.
P-73190
Install and tighten the oil plug.
Position the upperstructure (Item 1) [Figure 10-90-3] so Figure 10-90-6

the tailgate is centered between the rear tracks.
Open the tailgate. 1
Figure 10-90-4
P-73192
1
Remove the fill cap (Item 1) [Figure 10-90-6].
Put oil in the engine. (See Engine Oil Chart on Page 10-
P-69937 90-1.) (See Capacities on Page SPEC-10-6.)
Install the fill cap.
Remove the plug (Item 1) [Figure 10-90-4] from the Start the engine and let it run for several minutes.
bottom of the engine oil pan. Drain the oil into a
container. Stop the engine. Check for leaks at the oil filter. Check
the oil level.
Recycle or dispose of used oil in an environmentally safe
Add oil as needed if it is not at the top mark on the
manner.
dipstick.

52 of 726
HYDRAULIC SYSTEM Figure 10-100-2
Checking And Adding Fluid
Put the machine on a flat level surface.
Retract the arm and bucket cylinders, put the bucket on

the ground and raise the blade fully. Stop the engine.

1
Figure 10-100-1
P-73003
Check the condition of the fill strainer screen (Item 1)

[Figure 10-100-2]. Clean or replace as necessary.
1
Be sure the screen is installed before adding fluid.
Add the correct fluid to the reservoir until it is visible in the

sight gauge.
P-73002 Check the cap and clean as necessary. Replace the cap
if damaged.
Check the hydraulic fluid level, it must be visible in the Install the cap. Close the tailgate.
sight gauge (Item 1) [Figure 10-100-1].
Hydraulic Fluid Chart
Clean the surface around the reservoir (breather) cap
and remove the cap (Item 2) [Figure 10-100-1] from the Figure 10-100-3
reservoir.
WARNING
W-2103-1285
P-64023A
Use the correct hydraulic fluid shown in chart [Figure 10-

100-3].
Add hydraulic fluid as needed to bring the level to the

center of sight gauge (Item 1) [Figure 10-100-3].
Install the oil fill cap.

53 of 726
HYDRAULIC SYSTEM (CONT’D) Removing And Replacing The Case Drain Filter
Removing And Replacing The Hydraulic Filter NOTE: The hydraulic tank must be drained before
removing the case drain filter. (See Removing
And Replacing The Hydraulic Fluid on Page
10-100-3.)
WARNING Open the right side cover.
Drain the hydraulic tank. (See Removing And Replacing
The Hydraulic Fluid on Page 10-100-3.)
W-2103-1285
Figure 10-100-5

Open the tailgate.
Figure 10-100-4
2

1
P-73001
1
Remove the hose (Item 1). Remove the filter (Item 2)

[Figure 10-100-5] from the bottom of the hydraulic tank.
Remove the elbow from the old filter and install it on the
new filter but do not tighten the jam nut. The elbow will
P-73195 need to be orientated correctly after the filter is installed.
Remove the straight adapter from the old filter and install
Remove the hydraulic filter (Item 1) [Figure 10-100-4]. it on the new filter. Tighten the adapter.
Clean the housing where the filter gasket makes contact. NOTE: The straight adapter may remain installed in
the hydraulic tank when the filter is removed.
Put clean hydraulic fluid on the gasket. Install the new
filter and hand tighten only. Install a new filter and tighten. Orientate the elbow and
tighten the jam nut. Reinstall the hose and tighten.

54 of 726
HYDRAULIC SYSTEM (CONT’D) Figure 10-100-7
Removing And Replacing The Hydraulic Fluid

2
WARNING
1
Use a piece of cardboard or wood to find leaks. Do P-69998
from a physician familiar with this injury. Remove the drain hose (Item 1) [Figure 10-100-7] from
W-2072-0496 the clamp and route it out the side of the uppersturucture.
Remove the drain hose cap (Item 2) [Figure 10-100-7].

Retract the arm and bucket cylinders, lower the bucket to
the ground. Lower the blade to the ground. Stop the
Drain the fluid into a container.
engine.

Recycle or dispose of the fluid in an environmentally safe
manner.
Figure 10-100-6
Install the drain hose cap (Item 2) [Figure 10-100-7].
Reposition the hose back into the upperstructure and

secure it to the clamp.
Always replace the filters when changing the hydraulic

oil.
Install new Bobcat hydraulic fluid. (See Capacities on

Page SPEC-10-7.) (See Hydraulic Fluid Chart on Page
10-100-1.)
1
NOTE: If the pump has been removed from the
excavator for repair, see the Service Manual
for the correct procedure for removing air
P-69997
from the hydraulic pump and from the
hydraulic system.
A hydraulic reservoir drain hose (Item 1) [Figure 10-100-
6] is located below the reservoir and secured to the
upperstructure with a clamp.

55 of 726

56 of 726
LUBRICATING THE EXCAVATOR Figure 10-110-2
Lubrication Locations
Lubricate the excavator as specified in the SERVICE

SCHEDULE for the best performance of the machine.
(See SERVICE SCHEDULE on Page 10-50-1.) 5
Record the operating hours each time you lubricate the 4

excavator.
Always use a good quality lithium based multipurpose

grease when lubricating the machine. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the excavator 6 P-69970

EVERY 8-10 HOURS:
Figure 10-110-1 4. Boom Swing Cylinder Rod End (1) [Figure 10-110-2]
5. Boom Cylinder Base End (1) [Figure 10-110-2]

1
6. Boom Swing Bottom Pin (1) [Figure 10-110-2]

3 Figure 10-110-3
3
9
2
P-69969 8
Ref Description (# of Fittings)
1. Blade Cylinder Rod End (1) [Figure 10-110-1] 8

P-69994
2. Blade Cylinder Base End (1) [Figure 10-110-1]
3. Blade Pivots (2) [Figure 10-110-1] 7. Boom Swing Top Pin (1) [Figure 10-110-3]
8. Boom Swing Pivot (3) [Figure 10-110-3]
9. Boom Pivot (1) [Figure 10-110-3]

57 of 726
LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-110-6
Lubrication Locations (Cont’d)

16
Figure 10-110-4
11
15
16
P-73038
10
15. Bucket / Arm Pin (1) [Figure 10-110-6]
P-69971
16. Bucket Link Pin (2) [Figure 10-110-6]
10. Boom Cylinder Rod End (1) [Figure 10-110-4] Figure 10-110-7

11. Arm Cylinder Base End (1) [Figure 10-110-4]
Figure 10-110-5
12
13 18
14 18 17
P-73039
17. Bucket Cylinder Rod End (1) [Figure 10-110-7]

P-69990
18. Bucket Link (2) [Figure 10-110-7]
12. Arm Cylinder Rod End (1) [Figure 10-110-5]
13. Arm Pivot (1) [Figure 10-110-5]
14. Bucket Cylinder Base End (1) [Figure 10-110-5]

58 of 726
LUBRICATING THE EXCAVATOR (CONT’D)
Lubrication Locations (Cont’d)
Figure 10-110-8
21 20
19
P-69993
19. Boom Swing Cylinder Base End (1) [Figure 10-110-8]

Lubricate the following locations on the hydraulic
excavator EVERY 50 HOURS:
20. Slew Circle (1) [Figure 10-110-8]
21. Slew Pinion (1) [Figure 10-110-8]. (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.)

59 of 726

60 of 726
TRAVEL MOTOR Removing And Replacing Oil
Checking And Adding Oil See the SERVICE SCHEDULE for the correct service
Figure 10-120-1
Park the excavator on a level surface with plugs (Items 1
& 2) [Figure 10-120-1] in the position shown. Remove
both plugs and drain the lubricant into a container.
1 WARNING
2 sparks or lighted tobacco away from fuel and oil.
W-2103-1285
P-69996
Install the bottom plug (Item 2) [Figure 10-120-1]. Add
lubricant through the top plug hole until the lube level is at
Park the excavator on a level surface with the plugs the bottom edge of the hole. (See Capacities on Page
(Items 1 & 2) [Figure 10-120-1] in the position as shown. SPEC-10-6.)

Remove the plug (Item 1) [Figure 10-120-1]. The lube Install the plug (Item 1) [Figure 10-120-1].
level must be at the bottom edge of the hole.
Add lubricant through the hole if the lube level is low.

(See Capacities on Page SPEC-10-6.)
10-120-1 425 Service Manuall

61 of 726

62 of 726
SPARK ARRESTOR MUFFLER Figure 10-130-1
Cleaning Procedure

WARNING
1
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 P-69996
gases which can kill without warning.
W-2050-1285
Remove the plug (Item 1) [Figure 10-130-1] from the
bottom of the muffler.
Start the engine and run for about 10 seconds while a
WARNING second person, wearing safety glasses, holds a piece of

wood over the outlet of the muffler. The carbon deposits

will be forced out of the muffler plug hole (Item 1) [Figure
Stop engine and allow the muffler to cool before 10-130-1].
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury. Stop the engine. Install and tighten the plug.
W-2011-1285
Close the tailgate.
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.

63 of 726

64 of 726
ALTERNATOR BELT Belt Replacement
Belt Adjustment Figure 10-140-2
Open the tailgate.

1
Figure 10-140-1
2
1
P-73197
Remove the two bolts (Item 1) and remove the shield

P-73196 assembly (Item 2) [Figure 10-140-2].
Figure 10-140-3

Using a belt tension gauge, measure the belt tension
midway between the crankshaft pulley and alternator
1
pulley [Figure 10-140-1].
Belt tension is as follows:

New belt 70 - 80 ft. lb. (311 - 356 N)
Used belt 56 - 66 ft. lb. (249 - 294 N)
WARNING 2

• Do Not Operate with damaged or missing P-73199
screens, shields or rubber deflectors.
• Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can Loosen the bolts (Items 1 & 2) [Figure 10-140-3] until the
cause injury or death. alternator can be moved toward the engine. Remove the
W-2528-0406 old belt and install a new belt.
Adjust the alternator outward until the belt tension is

correct. Tighten the two bolts (Items 1 & 2) [Figure 10-
140-3].
Repleace the alternator belt shield assembly.
65 of 726 10-140-1 425 Service Manual


66 of 726
SEAT BELT Figure 10-150-1
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,

or damage to the buckle, latch plate, retractor (if
equipped), or hardware.
B-22283
The items below are referenced in [Figure 10-150-1].
1. Check the seat belt 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 proper function. Make

sure latch plate is not excessively worn, deformed or
buckle is not damaged.
3. Check the retractor web storage device (if equipped)

by extending the seat belt webbing to determine if it
extends 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 weakened.
See your Bobcat dealer for approved seat belt system

replacement parts for your machine.

67 of 726

68 of 726
PIVOT PINS
Inspection And Maintenance
Figure 10-160-1
P-69995
The boom, arm and cylinders pivots (Item 1) have a large

pin held in position with a snap ring (Item 2) [Figure 10-

160-1].
Check that the snap rings are securely inserted into the
grooves on the pins and that the snap rings are not
damaged. See your Bobcat dealer for replacement parts.

69 of 726

70 of 726
EXCAVATOR STORAGE AND RETURN TO SERVICE Return to Service
Storage After the Bobcat Excavator has been in storage, it is

necessary to follow a list of items to return the excavator
Sometimes it may be necessary to store your Bobcat to service.
Excavator for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the excavator including the engine
• Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the excavator.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in place.
• Drive the excavator onto planks in a dry protected
shelter. • Lubricate the excavator.
• Lower the boom fully with the bucket flat on the • Remove cover from exhaust pipe opening.
ground. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put grease on any exposed cylinder rods. correct operation.
• Put fuel stabilizer in the fuel tank and run the engine • Drive the excavator off of the planks.
a few minutes to circulate the stabilizer to the pump
• Operate machine, check for correct function.
and fuel injectors.
• Drain and flush the cooling system. Refill with • Stop the engine and check for leaks. Repair as

premixed coolant. needed.
• Replace all fluids and filters (engine, hydraulic).
• Replace all filters (i.e.: air cleaner, heater, etc.).
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is
correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage
condition.

71 of 726

72 of 726
STOPPING THE ENGINE AND LEAVING THE Figure 10-180-3
EXCAVATOR
Procedure
Figure 10-180-1
STOP ON
START
6808261
Figure 10-180-4
P-69888A
Stop the machine on level ground. Lower the work

equipment and the blade to the ground [Figure 10-180-

1].
Figure 10-180-2
1
P16616
1
Turn the key switch to STOP [Figure 10-180-3] or press
the STOP Button (Item 1) [Figure 10-180-4].
Disconnect the seat belt. Remove the key from the switch
to prevent operation of machine by unauthorized
personnel. Raise the control console and exit the
P-69884 machine.
Move the engine speed control (Item 1) [Figure 10-180-

2] to low idle.
Let the engine run at idle speed for 5 minutes before

stopping the engine.

73 of 726
STOPPING THE ENGINE AND LEAVING THE
EXCAVATOR (CONT’D)
Emergency Exits
The right side rear window and the front window provide
exits.
Right Side Rear Window
Figure 10-180-5

P-69885
Exit through the window [Figure 10-180-5].
Front Window
Figure 10-180-6
P-69886
Raise the front window and exit through the window

[Figure 10-180-6].
NOTE: If the excavator has a Special Applications Kit

installed, the front window is NOT an
emergency exit.

74 of 726
HYDRAULIC SYSTEM
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6 HYDRAULIC
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5 SYSTEM
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
BUCKET CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1

75 of 726
HYDRAULIC SYSTEM (CONT’D)
CONTROL PATTERN SELECTOR VALVE . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
CROSSPORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . 20-32-1

Testing And Adjusting The Crossport Relief Valves . . . . . . 20-32-1
DIRECT TO TANK VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Desciption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-150-3
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Arm Valve Section Disassembly And Assembly . . . . . . . 20-40-40
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-60
Auxiliary Valve Section Disassembly And Assembly . . . . 20-40-30

Blade Valve Section Disassembly And Assembly . . . . . . 20-40-16
Boom Swing Valve Section Disassembly And Assembly. 20-40-50
Boom Valve Section Disassembly And Assembly . . . . . . 20-40-45
Bucket Valve Section Disassembly And Assembly . . . . . 20-40-35
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Inlet Section Disassembly And Assembly . . . . . . . . . . . . 20-40-55
Left Travel Valve Section Disassembly And Assembly . . 20-40-12
Right Travel Valve Section Disassembly And Assembly . . 20-40-8
Slew Valve Section Disassembly And Assembly . . . . . . . 20-40-25
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . 20-120-1

76 of 726
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-22
Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . 20-50-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Parts Identification (Piston Pump) . . . . . . . . . . . . . . . . . . . 20-50-8
Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-16
Piston Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Testing Auxiliary Hydraulic Flow . . . . . . . . . . . . . . . . . . . . 20-50-4
Testing The Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . 20-10-1
Troubleshooting The Cylinder Circuit. . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Swing (Upperstructure Slew) Circuit 20-10-7
Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . . 20-10-8
HYDRAULIC X-CHANGE VALVE . . . . . . . . . . . . . . . . . . . . . 20-170-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-4
LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . .20-111-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-8
Handle Removal And Installation. . . . . . . . . . . . . . . . . . . .20-111-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Testing And Adjusting The Main Relief Valve . . . . . . . . . . 20-30-1

77 of 726
MANIFOLD ASSEMBLY / ACCUMULATOR . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
NON-PRESSURIZED ACCUMULATOR . . . . . . . . . . . . . . . . 20-160-1

Desciption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Testing And Adjusting Port Relief Valve Pressure . . . . . . . 20-31-1
PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . 20-33-1

Testing And Adjusting The Pressure Reducing Valve . . . . 20-33-1

RIGHT CONTROL LEVER (JOYSTICK). . . . . . . . . . . . . . . . 20-110-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-10
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . 20-110-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
SWING MOTOR DRIVE CARRIER. . . . . . . . . . . . . . . . . . . . . 20-91-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-3

78 of 726
SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-4
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3

79 of 726

80 of 726
425 HYDRAULIC SCHEMATIC
S/N A1HW11001 AND ABOVE
(PRINTED JULY 2007)
V-0855legend
Printable Version Click Here
LEGEND
1 HYDRAULIC RESERVOIR: Pressurized 9 LOAD SENSE BLEED VALVE 20 RESTRICTOR - 0.108 inch (2,7 mm) 34 ORIFICE – 2 Speed Shifting
with Fill Strainer
Capacity (to center of sight glass): 10 FLUSHING VALVE: . . . 218 PSI (15 Bar) 21 RESTRICTOR - 0.083 inch (2,1 mm) 35 TEST PORT - "P1" PORT - System Pressure
2.4 Gal. (9.1 L) When tested at diagnostic port P1 35
at Low Engine Idle
Hyd. System (W/Reservoir) Capacity: 22 PRESSURE REDUCING VALVE 36 RESTRICTOR – One Way
5.5 Gal. (20.7 L) 435 PSI (30 Bar)
11 ACCUMULATOR – Non Pressurized 37 CHECK VALVE
23 SOLENOID ACTIVATED DIRECTIONAL
2 PRESSURIZED BREATHER/FILL CAP 12 COMPENSATOR CONTROL VALVE - Joystick Lockout
with FILTER: 38 SOLENOID ACTIVATED DIRECTIONAL
5 PSI (3.4 Bar) - Outlet 13 LOAD CHECK (2 per Section, 14 Total) 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
0.435 PSI (0.3 Bar) - Inlet Only 7 Shown CONTROL VALVE - Two Speed
39 CHECK VALVE 80 PSI (5,5 bar)
3 HYDRAULIC FILTER ELEMENT 14 RELIEF VALVE - PORT (4): 25 SOLENOID ACTIVATED DIRECTIONAL
40 CHECK VALVE – Load Sense
15 Micron 3335 PSI (230 Bar)
CONTROL VALVE - Male Coupler
4 FILTER BY-PASS 50 PSI (3.44 Bar) 15 RELIEF VALVE - PORT (2): 41 ORIFICE - 0.025 inch (0,64 mm)
3045 PSI (210 Bar) 26 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - Female Coupler 42 FILTER – Hydraulic X-Change Valve
5 CASE DRAIN FILTER 16 RELIEF VALVE - PORT (2):
2610 PSI (180 Bar) Dealer Copy --27Not ACCUMULATOR
for Resale
6 HYDRAULIC PUMP . . . . . . Two Section - 17 RELIEF VALVE - PORT (1): 28 TEST PORT - "G" PORT - Pressure
Variable Displacement Piston Pump 3915 PSI (270 Bar) Reducing Valve
Section P1 & P2:
15.4 GPM (58,3 L/min.) at High Engine Idle 18 SWING MOTOR CROSS PORT RELIEF 29 TEST PORT - "B1" PORT - Joystick Pilot
VALVES (2): Pressure
7 LOAD SENSE RELIEF VALVE (Main Relief):
With Standard Arm: 2030 PSI (140 Bar) 30 ORIFICE - Straight Travel
With Standard Arm: 2610 PSI (180 Bar) When tested at diagnostic port P1 35
When tested at diagnostic port P1 35 at High Engine Idle 31 TRAVEL MOTOR SPOOL
at High Engine Idle
With Long Arm: 2175 PSI (150 Bar) 32 VALVE - 2 -Speed (2)
With Long Arm: 2900 PSI (200 Bar) When tested at diagnostic port P1 35
When tested at diagnostic port P1 35 at High Engine Idle 33 CROSSPORT RELIEF VALVE:
at High Engine Idle
3480 PSI (240 Bar)
19 ORIFICE
8 SHUTTLE ORIFICE - 0.022 inch (0,56 mm)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-0855legend (6-28-07)
81 of 726
CENTER
425 HYDRAULIC SCHEMATIC SWIVEL
JOINT
S/N A1HW11001 AND ABOVE 3
BLADE
(PRINTED JULY 2007) G G
2 CYLINDER
V-0855 PRESSURIZED BREATHER
P T3 F F
H H
Printable Version Click Here 12 OIL COOLER
E E
MAIN FILTER
A 4 WITH BY-PASS B B
B
a 1 D D
RESERVOIR R.H. TRAVEL MOTOR
C C
30 TRVL RH b
A Q2 Q1
12 A
CASE DRAIN 5
FILTER
A T1
B 34
a
SLEW MOTOR
A TRVL LH b PS 33
13
12 32
18 A
TRAVEL JOYSTICK
B 3
4 6
BLADE HYDRAULIC PUMP
B 17
13 P 31
12
18
19 A T
P2 P1
DIRECT TO B 1
TANK VALVE
a
(EXCLUDED FOR
U.S. OPTION) 2
SLEW b L.H. TRAVEL MOTOR
13
MALE 12 Q2
LH JOYSTICK Q1
(RETURN)
1
A
a 16
B T2
2
34
FEMALE
BUCKET CYLINDER P
(PRESSURE) AUX. b
13 PILOT PS 33
12 T MANIFOLD
3 P P1 35
A 32
14
B 4
T1 22
BUCKET
1
a
2
T 37
b
ARM CYLINDER
13 P
23 31
12
B
J-STK
A T B1
15 P2 P1
B 3 29 24
ARM 4
A
a
BOOM CYLINDER b RH JOYSTICK 2-SPD G 28
13
12 25
A C AUX ROD
14
B 27
ACC
D AUX BASE
OFFSET CYLINDER LOCKING BOOM a
VALVE b 26
13
20 12
L3
A IS
O
L3
B
L1
L1
IS
ST
O
R
IS
D
1
FRONT
21
IS
ISO/STD
1
OFFSET
R
O
BACK
CONVERTER
(ISO SHOWN)
3
R
R
3
IS
O
HYDRAULIC X-CHANGE ENCLOSURE

36 (OPTIONAL)
PUMP SUPPLY
39
WORKING CIRCUITS
M
PILOT PRESSURE
LS
38
SYSTEM RETURN LINES
7 40 DIRECT TANK RETURN

LS2 LS3
P T T1 LOAD SENSE
P1
10 9 8 T INTERSECTION OF HYDRAULIC LINES
INDICATED BY JUNCTION DOT
P
11 41
42
V-0855 (6-28-07)
82 of 726
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS
WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed

Solid Line - Working (Main) Line, Restriction - Affected by Viscosity
Return Line (line conducting fluid (property of resistance to flowing
from working devices to the reservoir) fluid).
and Feed line (main line conductor).
VARIABLE ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
PILOT PRESSURE - Dashed Line -
Pilot Line (Line which conducts TEMPERATURE CONTROL -
control fluid). (Indication of temperature).
DRAIN CIRCUITS - Dotted Line -

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.

FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies

Connected). electric signal with pressure.
DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.
PRESSURE SWITCH - Switch

activates when pressure reaches
specified level.
MUFFLER (silencer) - Reduces

noise.

83 of 726
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

linear energy and in which the fluid pressure operates
alternately in both directions (forward and backward CONTROL VALVE WITH DETENT
strokes). (Holds Valve in Position) - device for
maintaining a given position
DOUBLE ACTING HYDRAULIC (mechanical).
CYLINDER, UNEQUAL
DISPLACEMENT - With single piston CONTROL VALVE ACTIVATED BY A
rod. PULL BUTTON (manual).
DOUBLE ACTING HYDRAULIC

CYLINDER, UNEQUAL CONTROL VALVE ACTIVATED BY A
DISPLACEMENT and CUSHION ON PUSH-PULL BUTTON (manual).
ONE END - With single piston rod.
CONTROL VALVE ACTIVATED BY A

LEVER (manual).
PUMP: To convert mechanical energy into hydraulic

energy.
CONTROL VALVE ACTIVATED BY A
PEDAL (manual).
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
CONTROL VALVE WITH SPRING
RETURN (mechanical).
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).
MOTOR: To convert hydraulic energy into rotary CONTROL VALVE ACTIVATED BY A

mechanical energy. PROPORTIONAL ELECTRICAL
SOLENOID (electrical).
FIXED CAPACITY DISPLACEMENT CONTROL VALVE ACTIVATED BY

BIDIRECTIONAL HYDRAULIC DUAL ELECTRICAL SOLENOID
MOTOR - With two directions of flow (electrical).
(bidirectional.
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).

84 of 726

NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for
allows free flow in one direction only. the opening (fully or restricted) or the closing of one or
more flow paths (represented by several squares).
NON-RETURN VALVE (Check Valve) TWO PORTS and CLOSED FLOW

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-

RETURN VALVE- It is possible to MANUALLY ACTIVATED
open the valve by pilot pressure. DIRECTION CONTROL VALVE
T
OUT IN
(Variable Position) Joystick
P
Controlled, variable pressure to shift
the pilot activated directional control
SHUTTLE VALVE - The Inlet port
valve spool.
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.

85 of 726

PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT
force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.
LOCK VALVE - hydraulic pressure is

applied to open the valve to allow the
hydraulic cylinder to move.
FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.
ONE WAY RESTRICTOR VALVE

(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
direction.
TOW VALVE - Normally in closed

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

86 of 726
Troubleshooting The Hydraulic Circuit
TROUBLESHOOTING THE HYDRAULIC CIRCUIT

PROBLEM CAUSE CORRECTION
No hydraulic operation at one or Hydraulic oil level low Refill with correct oil
more circuits Hydraulic pump drive coupling damaged Replace
Hydraulic pump defective Repair or replace
Main relief valve defective Readjust or replace
Hydraulic power insufficient to one Main relief valve pressure setting incorrect Readjust or replace
or more circuits
All hydraulic speed too slow Hydraulic oil level or viscosity incorrect Fill to correct level
Use correct viscosity oil
Engine RPM reduced Readjust or replace
Control valve linkage defective Check, repair or replace
Hydraulic pump volume low Check, repair or replace
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
Relief valve excessively activated Use proper operating
procedures

One or more relief valves not set correctly Readjust or replace
Extreme operating conditions. High ambient
temperature (i.e.: Enclosed structure)
Engine accessory drive belt loose Tighten Belt

87 of 726
HYDRAULIC SYSTEM TROUBLESHOOTING (CONT’D)
Troubleshooting The Cylinder Circuit
TROUBLESHOOTING THE CYLINDER CIRCUIT

Cylinder inoperable 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
Lever linkage incorrectly adjusted Readjust
Control console lockout switch Readjust or replace
Cylinder internal leakage excessive Repair or replace
Joystick manifold pressure reducing valve Repair or replace
defective
Joystick internal leakage excessive Repair or replace
Cylinder for insufficient Lever linkage incorrectly adjusted Readjust
Main relief valve pressure to low Readjust or replace
Cylinder speed too slow Cylinder internal leakage excessive Repair or replace
Joystick manifold solenoid valve defective Repair or replace
defective

Control valve internal leakage excessive Repair or replace
Low tie rod torque on 3 spool & 6 spool control Tighten tie rods to correct
valves torque
Low or dirty fluid Add or replace the hydraulic
fluid
Main relief valve malfunctioning Readjust or replace

88 of 726
Troubleshooting The Swing (Upperstructure Slew) Circuit
TROUBLESHOOTING THE SWING (UPPERSTRUCTURE SLEW) CIRCUIT

Slew not operating Control console raised Lower control console.
Control console lock out switch incorrectly adjusted Readjust or replace
or defective
Slew lock pin engaged Disengage lock pin
defective
Slew motor gear defective Repair or replace
Slew motor defective Repair or replace
Slew force Main relief valve set too low Readjust or replace
Slew motor relief valve pressure too low Readjust or replace
Slew speed too low Pump flow low Check, repair or replace
Blocked or restricted line to slew motor Replace
Slew motor internal leakage excessive Repair or replace
Slew over run excessive Control valve spool sticking Repair or replace

Joystick spool sticking Repair or replace
Slew motor relief valve set too low Repair or replace
Slew motor internal leakage excessive Repair or replace
Slew motor seal leakage Case drain line plugged Replace

89 of 726
Troubleshooting The Travel Circuit
TROUBLESHOOTING THE TRAVEL CIRCUIT

Travel system inoperable Lever linkage incorrectly adjusted Readjust
Track tension too tight Readjust
Defective pump Check, repair or replace
Travel motor counter balance spool sticking Repair or replace
Travel motor internal leakage excessive Repair or replace
Travel motor defective Repair or replace
Travel motor gears defective Repair or replace
Swivel joint defective Repair or replace
Main relief valve pressure too low Readjust or replace
Travel power Track tension too tight Readjust
Main relief valve pressure too low Readjust or replace
Swivel joint leaking Repair or replace
Travel motor counterbalance spool sticking Repair or replace
Speed too slow Swivel joint internal leakage excessive Repair or replace
Low pump pressure Check, repair or replace

Travel motor internal leakage excessive Repair or replace
Travel motor seal leakage Return line filter plugged Inspect, clean or replace
Machine not running straight Lever linkage incorrectly adjusted Readjust
Track tension not equal Readjust
Pump output not equal Repair or replace
Travel motor internal leakage not equal Repair or replace
Travel motor counterbalance spool sticking Repair or replace
Main relief valve pressure set too low Repair or replace
Swivel joint internal leakage excessive Repair or replace
Control valve internal leakage not equal Repair or replace
Machine will not hold on slope or Travel motor counterbalance valve leakage Repair or replace
while digging excessive
Hose damage Replace
Blade drops while machine is Lever linkage unaligned Readjust
moving Cylinder internal leakage excessive Repair or replace
Swivel joint internal leakage from travel motor Repair or replace
pressure circuit into blade cylinder circuit
High/low shift inoperative (2- Control valve defective Replace
speed) Low pressure to 2-speed valve Readjust

90 of 726
BOOM CYLINDER 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.
Figure 20-20-1 1
1
P-73044
Figure 20-20-4

P-73040
Support the boom with a chain hoist (Item 1) [Figure 20-

20-1].
1
Figure 20-20-2
P-73046
3
Slide the shield down until the keyhole (Item 1) [Figure
20-20-3] in the shield lines up with the mounting stud
2 (Item 1) [Figure 20-20-4] on the cylinder.
Remove the shield.
P-73041
Remove the boom shield bolt (Item 1), washer (Item 2)

and spacer (Item 3) [Figure 20-20-2].

91 of 726
BOOM CYLINDER (CONT’D) Figure 20-20-7
Testing (Cont’d)
Figure 20-20-5 1
P-53168
Lower the cylinder (Item 1) [Figure 20-20-7] until it rests

P-53167 on the blade.
Start the engine and fully retract the cylinder rod (Item 2)
Remove the snap ring (Item 1) [Figure 20-20-5] and [Figure 20-20-7].
washer.

Stop the engine. Relieve hydraulic pressure.
Figure 20-20-6
1
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-50699
Remove the rod end pin (Item 1) [Figure 20-20-6].

92 of 726
BOOM CYLINDER (CONT’D)
Testing (Cont’d)
Figure 20-20-8
P-22223
Remove the hose from the base end of the cylinder. Cap
the hose (Item 1) [Figure 20-20-8].

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

93 of 726
Removal And Installation
pressure.
Figure 20-20-9 1
1
P-73044
Figure 20-20-12

P-73040

20-9].
1
Figure 20-20-10
P-73046
3
Slide the shield down until the keyhole (Item 1) [Figure
20-20-11] in the shield lines up with the mounting stud
2 (Item 1) [Figure 20-20-12] on the cylinder.
Remove the shield.
P-73041
Remove the boom shield bolt (Item 1), washer (Item 2)

and spacer (Item 3) [Figure 20-20-10].

94 of 726
Removal And Installation (Cont’d)
Figure 20-20-13 2
1
1
2
P-53168
Lower the cylinder (Item 1) [Figure 20-20-15] until it rests

P-53167 on the blade.
Mark and remove the hoses (Item 2) [Figure 20-20-15].

Remove the snap ring (Item 1) [Figure 20-20-13] and
washer.

Figure 20-20-14
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-50699

95 of 726
Figure 20-20-16
1
2
P-53169
Loosen the hose clamp (Item 1). Remove the snap ring
(Item 2) [Figure 20-20-16] and washer.

Remove the pin (Item 3) [Figure 20-20-16].
Figure 20-20-17
P-53170
Remove the shims (Item 1) [Figure 20-20-17] from both

sides of the cylinder.
Remove the cylinder.

96 of 726
Parts Identification
1. Grease
Fitting
2. Bushing
3. Plug
4. O-Ring
5. Housing
6. Nut
7. Seal
8. Piston
9. Backup Ring
10. Rod Seal 1
11. Head
12. Wiper Seal
5 3
13. Rod
2
4

3 6
4
7
8
4
9
10
4
11
12
1
13
PE2416S

97 of 726
Disassembly
Clean the outside of the boom cylinder before 3

2
disassembly.
1
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder. N-22354
Put the base end of the cylinder in a vise.

Remove the head and the rod assembly from the cylinder
Figure 20-20-18 [Figure 20-20-19]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-20-19].

Figure 20-20-20
1
3
1 1
N-22352
Insert the adjustable gland nut wrench into the holes

(Item 1) [Figure 20-20-18] to loosen the head.
N-22355
Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-20-20].

98 of 726
Disassembly (Cont’d)
Figure 20-20-21
3
2 2
1
1
N-22364
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-20-

N-22356 23].
Figure 20-20-24
Remove the O-ring (Item 1) and the back-up ring (Item 2)
[Figure 20-20-21].

Remove the O-ring (Item 3) [Figure 20-20-21].
1
Figure 20-20-22
2
1
P-53171
Remove the bushing (Item 1) [Figure 20-20-24] from the

cylinder base end.
N-22357
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-20-22].

99 of 726
Assembly
3
Clean all parts in solvent and dry with compressed air.
Inspect the cylinder parts for wear or damage. Replace 1

any worn or damaged parts. 2
Always install new O-rings and seals.
Lubricate all O-rings and seals with hydraulic oil during

installation.
Use the following tools to assemble the cylinder:

N-22355
MEL1396 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor Install the O-ring (Item 1) and seal (Item 2) on the piston
MEL1075 - Adjustable Gland Nut Wrench (Item 3) [Figure 20-20-26].
Figure 20-20-27
Figure 20-20-25

N-22358
P-7424
Use a ring compressor to compress the seal to the

Install the new seal on the tool and slowly stretch it until it correct size. Leave the piston in the compressor for
fits the piston [Figure 20-20-25]. approximately three minutes [Figure 20-20-27].
Allow the seal to stretch for 30 seconds before installing it

on the piston.

100 of 726
Assembly (Cont’d)
Figure 20-20-28
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 20-
P-7427 20-30] toward the outside of the head.
Figure 20-20-31
Install the rod seal on the rod seal tool [Figure 20-20-28].

NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20- 1

2
20-28]. 3
Figure 20-20-29
N-22356
Install the O-ring (Item 1) [Figure 20-20-31].
Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-20-31].
P-7425
Install the rod seal in the head [Figure 20-20-29].

101 of 726
BOOM CYLINDER (CONT’D) Tighten the plug to 8 ft.-lb. (11 N•m) torque.
Assembly (Cont’d) Put the base end of the cylinder in a vise.
Figure 20-20-32 Figure 20-20-34
2 1
3
N-22354 N-22352
Install the head (Item 1) and the piston (Item 2) [Figure Insert the adjustable gland nut wrench into the holes
20-20-32]. (Item 1) [Figure 20-20-34] to tighten the head. Tighten

the head until it is flush with the end of the housing.
Grease the piston where the nut contacts the piston. Do
not get grease on the threads. Figure 20-20-35
Provide an adequate support for the cylinder before

tightening.
NOTE: Clean and dry the rod threads. Install a NEW

1
NUT with pre-applied Loctite®.
Install the nut (Item 3) [Figure 20-20-32].
Tighten the nut to 850 ft.-lb. (1153 N•m) torque.
Figure 20-20-33
P-53171
Install the bushing and seal (Item 1) [Figure 20-20-35]

on both sides of the cylinder base end.
N-22364
Install O-ring (Item 1) and plug (Item 2) [Figure 20-20-

33].

102 of 726
ARM CYLINDER Figure 20-21-3
Testing
1
pressure.
2
Figure 20-21-1
1
P-56033

washer.
Figure 20-21-4

P-73040

21-1].
Figure 20-21-2
1
P-56034
Start the engine and fully retract the cylinder rod (Item 1)
[Figure 20-21-4].
P-56032
Support the arm cylinder (Item 1) [Figure 20-21-2].

103 of 726
ARM CYLINDER (CONT’D) Figure 20-21-6
Testing (Cont’d)
WARNING
sufficient force to enter a person’s body by 1
immediately.
W-2145-0290 P-56036
Figure 20-21-5 Install a plug (Item 1) [Figure 20-21-6] on the hose.
Start the engine and retract the cylinder.
If there is any leakage from the base end fitting, remove

the cylinder for repair or replacement.

1
P-56035
Remove the hose (Item 1) [Figure 20-21-5] from the

base end of the cylinder.

104 of 726
Lower the boom/bucket and blade to the ground. 1
pressure.
2
Figure 20-21-7
P-56033

washer.

P-73040
IMPORTANT
21-7]. When repairing hydrostatic and hydraulic systems,
Figure 20-21-8 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
1
Figure 20-21-10
P-56032
1
Support the arm cylinder (Item 1) [Figure 20-21-8].
P-56265
Remove the hose (Item 1) and hose clamp (Item 2)

[Figure 20-21-10].

105 of 726
ARM CYLINDER (CONT’D)
Figure 20-21-11
P-56035
Remove the hose (Item 1) [Figure 20-21-11].

Figure 20-21-12
P-56037
Remove the snap ring (Item 1), washer and base end pin
(Item 2) [Figure 20-21-12].

106 of 726
ARM CYLINDER (CONT’D)
1. Grease Fitting
2. Plug
3. O-Ring
4. Housing
5. Nut 1
6. Seal
7. Piston
8. Backup Ring
9. Spacer 4
10. Rod Seal
11. Head
12. Wiper Seal
3
13. Rod
14. Bushing 2 3 2
6
7

5
3
3
8
9
10
3
11
12 1
13
14
PE2415S

107 of 726
Disassembly
3
Clean the outside of the arm cylinder before disassembly. 2 4
1

MEL1075-2 - Special Offset Pins

cylinder.
N-22423
Figure 20-21-13 Remove the head and the rod assembly from the cylinder
[Figure 20-21-14]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-21-14].

1 Figure 20-21-15
2
1 1
N-22421
Insert the adjustable gland nut wrench into the two holes
N-22418


108 of 726
Figure 20-21-16
3
2
2
1
1
N-22364
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20-

N-22356 21-18].
Figure 20-21-19
[Figure 20-21-16].

Figure 20-21-17
2
1
1
P16562
Remove the bushing (Item 1) [Figure 20-21-19].
N-22357


109 of 726
Assembly 3

1
Inspect all parts for wear or damage. Replace any worn
or damaged parts. 2
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

MEL1033 - Rod Seal Installation Tool N-22418
Piston Ring Compressor
MEL1075-2 - Special Offset Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-21-21].
Figure 20-21-20
Figure 20-21-22

P-7424
N-22358
Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-21-20]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it three minutes [Figure 20-21-22].
on the piston.

110 of 726
Assembly (Cont’d)
Figure 20-21-23
N-22359
Figure 20-21-26

1
Rotate the handles to collapse the rod seal [Figure 20-
21-23]. 2
3
Figure 20-21-24
N-22356

[Figure 20-21-26].
P-7425

111 of 726
Assembly (Cont’d)
Figure 20-21-27
1
2
4 3 1
N-22421
N-22423 (Item 1) [Figure 20-21-29] to tighten the head. Head to
be torqued until flush with the end of the housing.
Install the head (Item 1), spacer (Item 2) and the piston
Figure 20-21-30
(Item 3) [Figure 20-21-27] on the rod as shown.

not get grease on the threads.

tightening.

Figure 20-21-28 1
P16562
Install the bushing (Item 1) [Figure 20-21-30]. The

bushing must be aligned with the grease channel in the
rod end of the cylinder.
N-22364
Install O-ring (Item 1) and plug (Item 2) [Figure 20-21-

28].
Tighten the plug to 8 ft.-lb. (11 N•m) torque.
Put the base end of the hydraulic cylinder in a vise.

112 of 726
BOOM SWING CYLINDER Figure 20-22-2
Testing
pressure.
Figure 20-22-1
P-55567
Support the rod end of cylinder [Figure 20-22-2].

P-55559

washer.
Remove the pivot pin (Item 2) [Figure 20-22-1].
Lower the control console and fasten the seat belt. Start
the engine and retract the boom swing cylinder.
Stop the engine. With the key in the ON position, move

the hydraulic controls to release the hydraulic pressure.
Raise the control console.

113 of 726
BOOM SWING CYLINDER (CONT’D) Figure 20-22-4
Testing (Cont’d)
WARNING
sufficient force to enter a person’s body by 2
physician familiar with this injury is not received P-73049
immediately.
W-2145-0290
Install a cap (Item 1) [Figure 20-22-4] on the fitting and
tighten.
Figure 20-22-3
Lower the control console and fasten seat belt. Start the
engine and retract the boom swing cylinder.

If there is any leakage from the base end hose (Item 2)
[Figure 20-22-4] on the cylinder, remove the cylinder for
repair or replacement.
1
P-73048
Remove the boom swing cylinder base end hose (Item 1)

[Figure 20-22-3] at the hydraulic control valve.

114 of 726
BOOM SWING CYLINDER (CONT'D) Figure 20-22-6
Lower the boom/bucket and blade to the ground. 1
With the engine off, turn the key to the ON position and 1
pressure.
IMPORTANT
When repairing hydrostatic and hydraulic systems, P-73022

Remove the rod end and base end hoses (Item 1)
[Figure 20-22-6] from the lock valve on the cylinder.
damage the system.
I-2003-0888
Figure 20-22-7
Remove the floor mat and floor panel. (See Removal And

Installation on Page 40-90-1.)
Figure 20-22-5 1
2
P-73023
1 Remove the bolt (Item 1) and pin retainer (Item 2)

[Figure 20-22-7].
P-55559
Remove the pivot pin (Item 3) [Figure 20-22-7].
Remove the snap ring (Item 1) [Figure 20-22-5] and Move the cylinder forward. Remove the grease hose
washer. from the base end of the cylinder.
Remove the pivot pin (Item 2) [Figure 20-22-5]. Remove the cylinder.

115 of 726
BOOM SWING CYLINDER (CONT'D)
1. Housing
2. Plug
3. O-Ring
4. Nut
5. Seal 2
6. Piston 3
7. Backup Ring
8. Rod Seal
9. Head
10. Wiper Seal
11. Rod 1 2
12. Bushing 3
13. Grease Fitting
4
3
5

6
3
7
8
3
9
10
11
12
13
PE2418S

116 of 726
BOOM SWING CYLINDER (CONT'D) Figure 20-22-10
Disassembly
3
Clean the outside of the boom swing cylinder before 2
disassembly. 1


cylinder.
N-22365
Figure 20-22-8 Remove the head and rod assembly from the cylinder
3) [Figure 20-22-10].

Figure 20-22-11
1
3
2
1
P-73502
Remove the cylinder lock valve (Item 1) [Figure 20-22-

8].
Figure 20-22-9 N-22367

1
N-22350

117 of 726
Figure 20-22-12
1
2
2
1
1
N-22364
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-22-

N-22356 14].
Figure 20-22-15
Remove the O-rings (Item 1) and the back-up ring (Item
2) from the head (Item 3) [Figure 20-22-12].

Figure 20-22-13
2
1
P-16562

N-22357


118 of 726
Assembly
3
Inspect all parts for wear or damage. Replace any worn 1

or damaged parts. 2


MEL1075-1 - Standard Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-22-17].
Figure 20-22-16
Figure 20-22-18

P-7424
N-22358
on the piston.

119 of 726
Assembly (Cont’d)
Figure 20-22-19
N-22359
Figure 20-22-22

4
Rotate the handles to collapse the rod seal [Figure 20- 1

22-19]. 2
3
Figure 20-22-20
N-22356
Install the back-up ring (Item 2) and O-ring (Item 3) on

the head (Item 4) [Figure 20-22-22].
P-7425

120 of 726
BOOM SWING CYLINDER (CONT’D) Tighten the plug to 8 ft.-lb. (11 N•m) torque.
Assembly (Cont’d) Put the base end of the cylinder in a vise.
Figure 20-22-23 Figure 20-22-25
2 1
1
N-22365 N-22350
Install the head (Item 1) and the piston (Item 2) [Figure Insert the adjustable gland nut wrench into the two holes
20-22-23] on the rod as shown. (Item 1) [Figure 20-22-25] to tighten the head. Head to

not get grease on the threads. Figure 20-22-26

tightening.

Figure 20-22-24
1
P-16562

N-22364
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

22-24].

121 of 726

122 of 726
BUCKET CYLINDER Figure 20-23-3
Testing
pressure.
Figure 20-23-1
1
P-22306
Remove the link (Item 1) [Figure 20-23-3].
Figure 20-23-4

P-73040
Support the boom using a chain hoist [Figure 20-23-1].
Figure 20-23-2
1
P-22307
1
the engine and retract the bucket cylinder [Figure 20-23-
4].
2
P-22305
Remove the retaining rings (Item 1), washers and plate

(Item 2) [Figure 20-23-2].

123 of 726
BUCKET CYLINDER (CONT’D) Figure 20-23-6
Testing (Cont’d)
WARNING 1
immediately.
W-2145-0290 P-22309
Figure 20-23-5 Install a plug (Item 1) [Figure 20-23-6] on the hose fitting
and tighten.
the engine and retract the bucket cylinder.

If there is any leakage from the base end fitting on the
1 bucket cylinder, remove the cylinder for repair or
replacement.
P-22308
Disconnect the bucket cylinder base end hose (Item 1)

[Figure 20-23-5].

124 of 726
Lower the boom/bucket and blade to the ground. Stop

the engine.
pressure.
IMPORTANT
P-22306

Figure 20-23-9
damage the system.
I-2003-0888

Install a chain hoist to the boom lift point.
Figure 20-23-7
1 3
1
2
1
P-6321
2
Disconnect the two hoses (Item 1) [Figure 20-23-9] from
the bucket cylinder.
P-22305 Remove the snap ring (Item 2) and washer (Item 3)

[Figure 20-23-9] from the cylinder base end pin.
Remove the snap rings (Item 1), washers and plate (Item Remove the cylinder base end pin.
2) [Figure 20-23-7].

125 of 726
BUCKET CYLINDER (CONT’D)
1. Housing 2
2. Plug
3. O-Ring 3
4. Housing 1
5. Nut
6. Seal
7. Piston
8. Backup Ring
9. Rod Seal 4
10. Head
11. Rod Seal
12. Rod
13. Bushing
5
3
6

7
3
2
3
8
9
10
1
11
12
13
PE2417S

126 of 726
Disassembly
3
Clean the outside of the bucket cylinder before 2
disassembly. 1


cylinder. N-22436
Figure 20-23-10
3) [Figure 20-23-11].
1

Figure 20-23-12
1
2
1
N-22434
N-22414


127 of 726
Figure 20-23-13
3
2
2
1
1
N-22364

N-22356 23-15].
Figure 20-23-16
[Figure 20-23-13].

Figure 20-23-14
1
P16562
N-22357


128 of 726
Assembly
3

or damaged parts. 2


MEL1075-2 - Special Offset Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-23-18].
Figure 20-23-17
Figure 20-23-19

P-7424
N-22358
on the piston.

129 of 726
Assembly (Cont’d)
Figure 20-23-20
N-22359
Figure 20-23-23

1
23-20]. 2
3
Figure 20-23-21
N-22356

[Figure 20-23-23].
P-7425

130 of 726
Assembly (Cont’d)
Figure 20-23-24
1 1
2
3
N-22434
Install the head (Item 1) and the piston (Item 2) [Figure
Figure 20-23-27
20-23-24] on the rod as shown.


tightening.

Figure 20-23-25
1
P16562

N-22364

23-25].

131 of 726

132 of 726
BLADE CYLINDER Figure 20-24-3
Testing
move the blade control lever to relieve hydraulic
pressure.
Figure 20-24-1
1
3
P-22249
Support the cylinder and remove the pin (Item 1) [Figure

20-24-3].
2
Figure 20-24-4
1

3
P-22247
Remove the two nuts (Item 1) [Figure 20-24-1] from the

studs.
Remove the two bolts and nuts (Item 2) [Figure 20-24-1]

from the cylinder shields.
Remove the shields (Item 3) [Figure 20-24-1].
Figure 20-24-2 P-22250
the engine and retract the blade cylinder [Figure 20-24-
4].

1
P-22248

washer from the cylinder rod end.

133 of 726
BLADE CYLINDER (CONT’D) Figure 20-24-6
Testing (Cont’d)
WARNING
and possible death if proper medical treatment by a 1
immediately.
W-2145-0290 P-22251
Figure 20-24-5 Install a plug (Item 1) [Figure 20-24-6] on the hose fitting
and tighten.
Lower control console and fasten seat belt. Start the

engine and retract the blade cylinder.

If there is any leakage from the base end fitting on the
cylinder, remove the cylinder for repair or replacement.
P-22252
Remove the base end hose (Item 1) [Figure 20-24-5].

134 of 726
move the blade control lever to relieve hydraulic
pressure.
Figure 20-24-7
1
3
P-22249
Support the cylinder and remove the pin (Item 1) [Figure

20-24-9].
2
1
3
IMPORTANT

P-22247

Remove the nuts (Item 1) [Figure 20-24-7] from the clean the work area before disassembly and keep all
studs. parts clean. Always use caps and plugs on hoses,
Remove the bolts and nuts (Item 2) [Figure 20-24-7] damage the system.
I-2003-0888
from the cylinder shields.
Remove the shields (Item 3) [Figure 20-24-7]. Figure 20-24-10
Figure 20-24-8
1
3
P-22250
P-22248
Remove the hoses (Item 1) [Figure 20-24-10].
Remove the snap ring (Item 1) [Figure 20-24-8] and Remove the base end snap ring and washer (Item 2)
washer from the cylinder rod end. [Figure 20-24-10].
Remove the base end pin (Item 3) [Figure 20-24-10].


135 of 726
BLADE CYLINDER (CONT’D)
1. Grease Fitting
2. Plug
3. O-Ring 1
4. Housing
5. Nut
6. Seal 4 2
7. Piston 3
8. Backup Ring
9. Rod Seal
10. Head
11. Wiper Seal 5
12. Rod 3
3 6
2
7

3
8
9
10 1
11
12
PE2419S

136 of 726
Disassembly
Clean the outside of the blade cylinder before

3
disassembly.
2
Use the following tools to disassemble the cylinder: 1


cylinder. N-22413

Figure 20-24-11 [Figure 20-24-12]. Put the rod end in a vise.
3) [Figure 20-24-12].

Figure 20-24-13
1
3
2
1
1
N-22442
N-22414


137 of 726
Figure 20-24-14
3
2
1 2
N-22364

N-22356 24-16].

[Figure 20-24-14].

Figure 20-24-15
N-22357


138 of 726
Assembly
3

or damaged parts. 2


MEL1075-1 - Standard Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-24-18].
Figure 20-24-17
Figure 20-24-19

P-7424
N-22358
on the piston.

139 of 726
Assembly (Cont’d)
Figure 20-24-20
N-22359
Figure 20-24-23

1
24-20]. 2
3
Figure 20-24-21
N-22356

[Figure 20-24-23].
P-7425

140 of 726
Assembly (Cont’d)
Figure 20-24-24
1
1
2
3
1
N-22442
Install the head (Item 1) and piston (Item 2) [Figure 20-
24-24] on the rod as shown.


tightening.

Figure 20-24-25
N-22364

24-25].

141 of 726

142 of 726
MAIN RELIEF VALVE The following tools will be needed for the testing at the
diagnostic coupler:
Testing And Adjusting The Main Relief Valve
MEL1355 - Test Kit includes the following:
All testing is done with the hydraulic oil at operating MEL1355-3 - 5000 PSI Gauge
temperature and the engine at high speed setting of max MEL1355-12 - Coupler
2520 RPM. MEL1355-9 - Thermometer
Figure 20-30-1 System Pressures At Gauge Port Specifications
TEST CONDITIONS
3 2 1. Engine High Idle Speed
2. Warm oil over relief function to minimum 150° F (66°

C). Cycle all functions during warm up procedure.
1
Warm oil until the pressure build-up valve stabilizes
near its target pressure.
3. Activate function until cylinder movement stops. Hold

over relief for 5 to 10 seconds.
Record pressure.
P-73251

There is one diagnostic coupler (Item 1) that is used to
check the main relief valve. The second coupler (Item 2)
is used to check joystick pressure. The third coupler
(Item 3) [Figure 20-30-1] is used to check the pressure
reducing valve.
425 with Standard Arm
TEST TARGET
SYSTEM CHECK FUNCTION TO ENGAGE CIRCUIT PRESSURIZED PORT (PSI) ACCEPTABLE RANGE (PSI)
JOYSTICK PILOT PRESSURE ANY JOYSTICK FUNCTION JOYSTICK PILOT G 435 406 - 450
SYSTEM BACK PRESSURE NONE - CONSOLE DOWN THROUGH NEUTRAL P1 340 290 - 420
MAIN RELIEF ANY FUNCTION P1 P1 2610 2523 - 2668
EXCEPTSLEW
SWING MOTOR - CROSS PORT RELIEF SWING RIGHT P1 P1 2030 1885 - 2175
SWING MOTOR - CROSS PORT RELIEF SWING LEFT P1 P1 2030 1885 - 2175
425 with Long Arm
TEST TARGET
EXCEPTSLEW

143 of 726
MAIN RELIEF VALVE (CONT’D) Figure 20-30-3
Testing And Adjusting The Main Relief Valve (Cont’d)
Figure 20-30-2
1
P-73257
Connect the test gauge coupler and 5000 PSI (345 bar)
gauge to the diagnostic coupler (Item 1) [Figure 20-30-
3].
P-73257
Engage the blade raise circuit over relief and record the
pressure.

gauge from the test kit to the P1 diagnostic coupler (Item Figure 20-30-4
1) [Figure 20-30-2].
Lower the control console and fasten the seat belt.
Start the engine and run at full RPM until hydraulic fluid is 1
at operating temperature 150° F (66° C).
With the console lowered, and the engine at full RPM

there is pressure buildup valve pressure of 600 PSI
(41,38 bar).
Remove the gauge.
P-73259
The main relief valve (Item 1) [Figure 20-30-4] pressure

should be as follows:
A target pressure of 2610 PSI (180 bar) with an

acceptable range of 2523-2668 PSI (174-184 bar)
Stop the engine.

144 of 726
MAIN RELIEF VALVE (CONT’D)
Testing And Adjusting The Main Relief Valve (Cont’d)
Figure 20-30-5
P-73260
If adjustment is needed, remove the cap and loosen the

nut (Item 1) [Figure 20-30-5].

Turn the adjustment screw (Item 2) [Figure 20-30-5]
clockwise to increase the pressure or counterclockwise
to decrease the pressure.
NOTE: 1/2 turn is approximately 400 PSI (28 bar).
Tighten the nut (Item 1) [Figure 20-30-5].
Retest the main relief valve after adjustment.

145 of 726

146 of 726
PORT RELIEF VALVES Arm Port Relief set at:
Rod End (Item 3) [Figure 20-31-1] & [Figure 20-31-
Testing And Adjusting Port Relief Valve Pressure 2] 3045 PSI (210 bar).
Base End (Item 4) [Figure 20-31-1] & [Figure 20-31-
Figure 20-31-1 2] 3045 PSI (210 bar).
7 5 Bucket Port Relief set at:

9 3 1 Rod End (Item 5) [Figure 20-31-1] & [Figure 20-31-
2] 3335 PSI (230 bar).
Base End (Item 6) [Figure 20-31-1] & [Figure 20-31-
2] 3335 PSI (230 bar).
Auxiliary Port Relief set at:

Male Quick Coupler (Item 7) [Figure 20-31-1] &
[Figure 20-31-2] 2610 PSI (180 bar).
Female Quick Coupler (Item 8) [Figure 20-31-1] &
6 2 [Figure 20-31-2] 2610 PSI (180 bar).
10 8 4
Blade Port Relief set at:
P-73261 Rod End (Item 9) [Figure 20-31-1] & [Figure 20-31-
2] 3915 PSI (270 bar).
Base End (Item 10) [Figure 20-31-1] & [Figure 20-
Figure 20-31-2 31-2] 3915 PSI (270 bar).

7 3 When testing the port relief valves with a hydraulic hand
9 1 pump, slowly pressurize the valve. If the hand pump is
5
pumped fast, the pressure will be altered by as much as
50 PSI (3,5 bar).
When testing port relief valves with a hydraulic hand

pump, valve crack pressure should be observed.
For 3045 PSI (210 bar) relief valves, crack pressure is

xxxx ± 50 PSI (xxx ± 3,5 bar).
6 2
10
4 For 3915 PSI (270 bar) relief valves, crack pressure is
8
xxxx ± 50 PSI (xxx ± 3,5 bar).
P-73103
For 3335 PSI (230 bar) relief valves, crack pressure is

Boom Port Relief set at: 3220 ± 50 PSI (222 ± 3,5 bar).
Rod End (Item 1) [Figure 20-31-1] & [Figure 20-31-
2] 3335 PSI (230 bar). When testing port reliefs valves with a hydraulic hand
Base End (Item 2) [Figure 20-31-1] & [Figure 20-31- pump, valve crack pressure should be observed.
2] 3335 PSI (230 bar).
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
Bobcat hydraulic fluid.

147 of 726
PORT RELIEF VALVES (CONT’D)
Testing And Adjusting Port Relief Valve Pressure

(Cont’d)
Figure 20-31-3
P-73267
Install the hand pump hose and a pressure gauge

(minimum of 5000 PSI [345 bar]) into the valve section
work port in which the port relief valve is located [Figure
20-31-3]. Slowly pressurize this section with the hand
pump until the port relief valve opens and make a note of
the pressure reading.
Relief valves are non-adjustable. When testing the relief

valves and pressure is not per the above pressure
settings, remove and replace the relief valve.
WARNING
Wear safety glasses to prevent eye injury when any
W-2019-1285

148 of 726
CROSSPORT RELIEF VALVES The following tools will be needed for the testing at the
diagnostic coupler:
Testing And Adjusting The Crossport Relief Valves
MEL1355 - Test Kit includes the following:
All testing is done with the hydraulic oil at operating MEL1355-3 - 5000 PSI Gauge
temperature and the engine high speed setting of max MEL1355-12 - Coupler
2520 RPM. MEL1355-9 - Thermometer
Figure 20-32-1 System Pressures At Gauge Port Specifications
TEST CONDITIONS
3 2 1. Engine High Idle Speed
2. Warm oil over relief function to minimum 150° F (66°

C). Cycle all functions during warm up procedure.
1
Warm oil until the pressure build-up valve stabilizes
near its target pressure.
3. Activate function until cylinder movement stops. Hold

over relief for 5-10 seconds.
Record pressure.
P-73251

There is one diagnostic coupler (Item 1) that is used to
check the main relief valve. The second coupler (Item 2)
is used in to check joystick pressure. The third coupler
(Item 3) [Figure 20-32-1] is used to check the pressure
reducing valve.
425 with Standard Arm
TEST TARGET
EXCEPTSLEW
425 with Long Arm
TEST TARGET
EXCEPTSLEW

149 of 726
CROSSPORT RELIEF VALVES (CONT’D) 425 with Long Arm
Testing And Adjusting The Crossport Relief Valves A target pressure of 2175 PSI (150 bar) with an
(Cont’d) acceptable range of 2030-2320 PSI (140-160 bar).
Open the right side cover. Stop the engine.
Figure 20-32-2 If the relief valves need adjustment, remove the floor mat
and floor panel. (See FLOOR MAT AND FLOOR PANEL
on Page 40-90-1.)
Figure 20-32-3
P-73257

1
gauge from the test kit to the P1 diagnostic coupler (Item
P-73262
1) [Figure 20-32-2].
Lower control console and fasten the seat belt. Locate the crossport reliefs (Item 1) [Figure 20-32-3]
under the right console frame.
Start the engine and run at full RPM until the hydraulic
fluid is at a minimum operating temperature of 150° F Figure 20-32-4
(66° C).
With the console lowered, and the engine at full RPM

there is pressure buildup valve pressure of 600 PSI (42 2
bar). 1
The crossport relief valves are preset to 2125 PSI (147

bar). Adding the pressure buildup valve pressure raises
the gauge readings.
Engage the slew lock lever (See UPPERSTRUCTURE

SLEW LOCK on Page 10-11-1) to prevent the
upperstructure from turning.
Engage the slew circuit to the right, over the relief and P-73263
record the pressure.
Repeat the procedure to the left and record the pressure. The front relief valve (Item 1) [Figure 20-32-4] is slew
left.
The crossport relief valve pressure should be as follows:
The rear relief valve (Item 2) [Figure 20-32-4] is slew
425 with Standard Arm right.
A target pressure of 2030 PSI (140 bar) with an NOTE: Left and right as viewed from the operators
acceptable range of 1885-2175 PSI (130-150 bar). seat.

150 of 726
CROSSPORT RELIEF VALVES (CONT’D)
Testing And Adjusting The Crossport Relief Valves

(Cont’d)
Figure 20-32-5
P-73264
Figure 20-32-6

1
2
P-73265
Loosen the nut (Item 1) [Figure 20-32-5] and [Figure 20-

32-6].
Turn the adjustment screw (Item 2) [Figure 20-32-5] and

[Figure 20-32-6] clockwise to increase the pressure or
counter clockwise to decrease pressure.
NOTE: 1/4 turn is 100 PSI (6,9 bar)
Tighten the nut (Item 1) [Figure 20-32-5], reinstall the

right floor panel and retest the crossport relief valves.

151 of 726

152 of 726
PRESSURE REDUCING VALVE A target pressure of 435 PSI (30 bar) with an acceptable
range of 406-450 PSI (28-31 bar).
Testing And Adjusting The Pressure Reducing Valve
Move the engine speed control to low idle speed.
The pressure reducing valve supplies lower hydraulic
pressure to joysticks. Stop the engine.
The following tools will be needed for testing the pressure With the engine off, and the key in the run position, lower
reducing valve: the left console and move both joysticks to relieve
hydraulic pressure.
MEL 1355 - Test Kit includes the following
MEL 1355-2 - 1000 PSI Gauge Figure 20-33-2
MEL 1355-9 - Thermometer
Figure 20-33-1
2

P-73266
P-73702 Loosen the nut (Item 1) [Figure 20-33-2].
Turn the adjustment screw (Item 2) [Figure 20-33-2]

The G diagnostic port (Item 1) [Figure 20-33-1] located clockwise to increase the pressure or counterclockwise
on the end of the manifold block will be used to check the to decrease the pressure.
pressure reducing valve.
NOTE: 1/2 turn is approximately 30 PSI (2,1 bar).
With the engine off and the key in the run position, lower
the left console and move both joysticks to relieve Tighten the nut (Item 1) [Figure 20-33-2].
hydraulic pressure.
Retest the pressure reducing valve after adjustment.
If the pressure is still incorrect, relieve hydraulic pressure
Install a 1000 PSI (69 bar) gauge on the P1 diagnostic and remove the pressure reducing valve from the
port [Figure 20-33-1]. manifold assembly for inspection or repair.
Lower the control console and fasten the seat belt. If the amount of oil pressure is at or over the service
limits, it is an indication of worn O-rings and back-up
Start the engine and warm the hydraulic fluid to a rings on the pressure reducing valve or a stuck pressure
minimum operating temperature of 150° F (66° C). reducing valve.
With the hydraulic fluid at operating temperature, run the Inspect the port of the pressure reducing valve (Item 1)
engine at full RPM. [Figure 20-33-2] on the manifold assembly to verify no
damage. If damaged replace the manifold assembly.
Engage the bucket curl circuit and fully curl the bucket.
The pressure reducing valve pressure should be as

follows:

153 of 726
PRESSURE REDUCING VALVE (CONT’D)
Testing And Adjusting The Pressure Reducing Valve

(Cont’d)
Figure 20-33-3
P-35527
Inspect the O-rings and back-up rings on the pressure

reducing valve [Figure 20-33-3]. If O-rings and back-up
rings are worn or damaged, replace O-rings and back-up
rings.

Re-install the pressure reducing valve in the manifold
assembly.
Repeat the pressure reducing valve test.
If the O-rings and back-rings were not worn or damaged

and the correct pressure could not be achieved, replace
the pressure reducing valve.

154 of 726
HYDRAULIC CONTROL VALVE
Description
The hydraulic control valve is a 11 section closed center

system and has one main relief valve. The main relief
valve operates at 2610 PSI (180 bar) on the 425 with
Standard Arm and 2900 PSI (200 bar) on the 425 with
Long Arm.
The blade section has 3915 PSI (270 bar) work port
reliefs. The boom and bucket section have 3335 PSI
(230 bar) work port reliefs. The arm section has 3045
PSI (210 bar) work port reliefs. The auxiliary section has
2610 PSI (180 bar) work port reliefs.

155 of 726
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-2

1
Stop the engine. 1 1
With the engine off, turn the start key to the ON position
and move both hydraulic control levers to relieve
hydraulic pressure.
1
IMPORTANT P-73105

Remove and cap the ten hoses (Item 1) [Figure 20-40-
2].
Figure 20-40-3
damage the system.
I-2003-0888

Drain the hydraulic reservoir.(See Checking And Adding
Fluid on Page 10-100-1.) 1 1
Mark all tubelines and hoses for proper installation.
Figure 20-40-1
1 1
1
1 1
P-73106
Remove and cap the eleven hoses (Item 1) [Figure 20-

40-3].
P-73104
Remove and cap the seven hoses (Item 1) [Figure 20-

40-1].

156 of 726
Figure 20-40-4
1
1
1
P-73109
1
1
Remove the screws (Item 1) [Figure 20-40-6] and move
P-73107 the fuel fill out of the way.
Figure 20-40-7
Remove and cap the eight hoses (Item 1) [Figure 20-40-
4].

Figure 20-40-5
1
1 1 2
2
P-73110
3
3 Remove and cap the hose (Item 1) [Figure 20-40-7].
P-73108
Remove the cotter pin (Item 1), clevis pin (Item 2) and
linkage (Item 3) [Figure 20-40-5].

157 of 726
Figure 20-40-8
1 1
P-73112
Remove the nut, flat washer and rubber washer (Item 1)

P-73114 [Figure 20-40-10] from the control valve.
Figure 20-40-11
Install a sling (Item 1) [Figure 20-40-8] around the
control valve and connect to a chain hoist.

Figure 20-40-9
1
1
1
P-73113
1
Remove the nut, flat washer and rubber washer (Item 1)
P-73111 [Figure 20-40-11] from the control valve.
Raise the hoist and remove the control valve from the
Remove the nut, flat washer and rubber washer (Item 1) excavator.
[Figure 20-40-9] from the control valve.

158 of 726
HYDRAULIC CONTROL VALVE (CONT’D)
1. Outlet Section
2. Right Travel Section
3. Left Travel Section
4. Blade Section
5. Slew Section
6. Auxiliary Section
7. Bucket Section
8. Arm Section
9. Boom Section
10. Boom Swing Section
11. Inlet Section
12. Port Relief 3915 PSI (270 bar)
13. Port Relief 3625 PSI (250 bar)
14. Direct LS Pressure Relief Valve
Port Relief 2610 (180 bar)

14
12 13 12
6
1 2 3 4 5 7 8 9 10 11
13 14 13 14
12
P-69838

159 of 726
Disassembly
Clean the outside of the control valve before

disassembly.
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly P-73116
damage the system.

I-2003-0888
Remove the fittings and hose [Figure 20-40-13].
Figure 20-40-12 Figure 20-40-14

1
1
1
2
1
P-73103 P-73139
Remove the three bolts (Item 1) from the mount plate Remove the nuts (Item 1) [Figure 20-40-14].
(Item 2) [Figure 20-40-12].
Remove the mount plate from the control valve.
Mark all of the sections of the control valve for proper

installation.

160 of 726
Figure 20-40-15
1
P-73140
Remove the end cap (Item 1) [Figure 20-40-15] from the

control valve.

161 of 726
Right Travel Valve Section Disassembly And

Assembly
Figure 20-40-16
2
2
1
1 P-61256
Remove the screws (Item 1) from both end caps (Item 2)

[Figure 20-40-18].
P-73141
Installation: Tighten the screws to 27 in.-lb. (3 N•m)
torque.
Remove the gasket (Item 1) [Figure 20-40-16] from the

valve section. Remove the end caps from the valve section.
Figure 20-40-17 Figure 20-40-19
1
1
P-73142 P-61257
Remove the right travel valve section (Item 1) [Figure Remove the O-ring (Item 1) [Figure 20-40-19] from the
20-40-17] from the control valve. end caps.

162 of 726

Assembly (Cont’d)
Figure 20-40-20
1
P-61260
Record the orientation of the spool (Item 1) [Figure 20-

40-22]. Remove the spool from the valve section.
P-61258
NOTE: The spool is not symmetrical. Incorrect spool
installation will cause poor hydraulic valve
Remove the centering springs (Item 1) [Figure 20-40-20] performance.

from the spring guides.
Figure 20-40-23
Figure 20-40-21
Cut
2.0”
0.50” Dia
1 1.500”
0.750”
B-14674
P-61259
To remove the plugs from the spool, a holding fixture will

Remove the spring guides (Item 1) [Figure 20-40-21] have to be made from a 0.750 inch thick x 1.500 inch
from both ends of the valve spool. wide x 2.0 inch long (19 mm thick x 38 mm wide x 50 mm
long) piece of hardwood. Drill a 0.50 inch (13 mm) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-23].
NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.

163 of 726

Assembly (Cont’d)
Figure 20-40-24
1
3 P-61503
2
Remove the O-ring (Item 1) [Figure 20-40-26] from the
plugs.
P-61504
Figure 20-40-27
Using the wood blocks (Item 1) clamp the spool

assembly (Item 2) in a vise and loosen the plugs (Item 3)
[Figure 20-40-24].
Installation: Apply thread lock adhesive (Loctite® 262)

or equivalent to the threads. Tighten the plugs to 44 in.-
lb. (5 N•m) torque.
1
Figure 20-40-25
2
P-61262
1
valve section.
Installation: Tighten the plug to 22 ft.-lb. (30 N•m)

torque.
P-61508
Remove the plugs (Item 1) from the spool (Item 2)

[Figure 20-40-25].

164 of 726

Assembly (Cont’d)
Figure 20-40-28
2
1
P-61305
Check the orifice (Item 1) [Figure 20-40-30] in the

compensator to be sure it is not plugged.
P-61263
Check the crossport hole (Item 2) [Figure 20-40-30] to
be sure it is not plugged.

plug.
Figure 20-40-29
P-61264
Remove the compensator (Item 1) [Figure 20-40-29]

from the valve section.

165 of 726
Left Travel Valve Section Disassembly And Assembly
Figure 20-40-31
2
1
1
2
1
P-61268

P-73143 [Figure 20-40-33].

Remove the gasket (Item 1) [Figure 20-40-31] from the torque.
valve section.

Remove the end caps from the valve section.
Figure 20-40-32
Figure 20-40-34
1
1
P-73144
P-61257
Remove the left travel valve section (Item 1) [Figure 20-

40-32] from the control valve. Remove the O-ring (Item 1) [Figure 20-40-34] from the
end caps.

166 of 726

(Cont’d)
Figure 20-40-35
1 P-61271
1 Record the orientation of the spool (Item 1) [Figure 20-

P-61269
Remove the centering springs (Item 1) [Figure 20-40-35] performance.

Figure 20-40-38
Figure 20-40-36
Cut
2.0”
0.50” Dia
1 1.500”
0.750”
B-14674
P-61270

Remove the spring guides (Item 1) [Figure 20-40-36] have to be made from a 0.750 inch thick x 1.500 inch
from both ends of the valve spool. wide x 2.0 inch long (19 mm thick x 38 mm wide x 50 mm

damaged.

167 of 726

(Cont’d)
Figure 20-40-39
1
3 P-61503
2
plugs.
P-61504
Figure 20-40-42

assembly (Item 2) in a vise and loosen the plugs (Item 3)
[Figure 20-40-39].

Figure 20-40-40
1
1
2
P-61272
1
valve section.

torque.
P-61508
Remove the plugs (Item 1) from the spool (Item 2)

[Figure 20-40-40].

168 of 726

(Cont’d)
Figure 20-40-43
2
1
P-61305

P-61263

plug.
Figure 20-40-44
P-61273


169 of 726
Blade Valve Section Disassembly And Assembly
Figure 20-40-46 1
1
P-61278
Remove the plug (Item 1) [Figure 20-40-48].

P-73145
Installation: Tighten the plug to 22-26 ft.-lb. (30-35 N•m)
Remove the gasket (Item 1) [Figure 20-40-46] from the Figure 20-40-49
valve section.

Figure 20-40-47
1
2
1
1
P-61279
P-73146 Remove the O-rings (Item 1) and backup ring (Item 2)

[Figure 20-40-49] from the plug.
Remove blade valve section (Item 1) [Figure 20-40-47]

from the control valve.

170 of 726

(Cont’d)
Figure 20-40-50
1
1
2
P-61282
Remove the spring (Item 1) and valve assembly (Item 2)

[Figure 20-40-52].
P-61280
Figure 20-40-53

port relief valve.

torque. 1
Figure 20-40-51
2
1
P-61283
1 Remove the screws (Item 1) from the valve spool retainer

(Item 2) [Figure 20-40-53].

torque.
P-61281
Remove the retainer.
Remove the O-ring (Item 1) from the plug [Figure 20-40-

51].

171 of 726

(Cont’d)
1
Figure 20-40-54
P-61289
Assembly: Install the seal on the spool with the flange

(Item 1) [Figure 20-40-56] toward the outside of the
P-61284 valve section.
Figure 20-40-57
Remove the seal carrier (Item 1) [Figure 20-40-54].

Figure 20-40-55
P-61286
P-61285 Remove the O-ring (Item 1) [Figure 20-40-57].
Remove the seal (Item 1) [Figure 20-40-55] from the

seal carrier.

172 of 726

(Cont’d) IMPORTANT
Figure 20-40-58
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-60
1
P-61287
Remove the O-ring (Item 1) [Figure 20-40-58] from the 2

valve section.
Figure 20-40-59 P-61292
Figure 20-40-61
2 1
1
P-61288
Remove the screws (Item 1) from the end cap (Item 2) P-61291
[Figure 20-40-59].
Installation: Tighten the screws to 27 in.-lb. (3 N•m) Using a brass drift (Item 1) [Figure 20-40-60] press in on
torque. the center ball (Item 1) [Figure 20-40-61].
Remove the end cap. Continue to press in on the ball and remove the detent
sleeve (Item 2) [Figure 20-40-60].

173 of 726

(Cont’d)
Figure 20-40-62
2
2
P-61295
1
Remove the retainer (Item 2) [Figure 20-40-64].
P-61293 Figure 20-40-65
Remove the center ball (Item 1) and three detent balls

(Item 2) [Figure 20-40-62].
Figure 20-40-63
1
1 P-61296
Remove the spool assembly (Item 1) [Figure 20-40-65].
P-61294
Remove the spring (Item 1) [Figure 20-40-63].

174 of 726

(Cont’d)
Figure 20-40-66 1
2
3
1 P-61289

Figure 20-40-69
Using a screwdriver (Item 1) to hold the spool (Item 2)

loosen the detent ball retainer (Item 3) [Figure 20-40-
66].
Installation: Apply thread lock adhesive (Loctite® 242) 1

or equivalent to the threads. Tighten the detent ball
retainer to 44 in.-lb. (5 N•m) torque.
Figure 20-40-67
9
8
6 4
P-61300
2
1
detent ball retainer.
7
5
3
P-61297
Remove the detent ball retainer (Item 1), spring retainer

(Item 2), spring (Item 3), housing (Item 4), spring retainer
(Item 5), retainer (Item 6), seal (Item 7) and O-ring (Item
8) from the spool (Item 9) [Figure 20-40-67].

175 of 726

(Cont’d)
Figure 20-40-70
1
3
3
2 2
1
P-61505

assembly (Item 2) in a vise and loosen the linkage end
P-61351 (Item 3) [Figure 20-40-72].

Remove the spring (Item 1) and poppet (Item 2) [Figure or equivalent to the threads. Tighten the linkage end to

20-40-70] from the spool. 44 in.-lb. (5 N•m) torque.
Figure 20-40-71 Figure 20-40-73

Cut
3
2.0”
0.50” Dia 2
1
1.500”
0.750”
B-14674 P-61506
To remove the linkage end from the spool, a holding Remove the linkage end (Item 1), spring (Item 2), and
fixture will have to be made from a 0.750 inch thick x 1.50 poppet (Item 3) from the spool (Item 4) [Figure 20-40-
inch wide x 2.0 inch long (19 mm thick x 38 mm wide x 50 73].
mm long) piece of hardwood. Drill a 0.50 inch (13 mm)
hole in the center of the hardwood block. Cut the block

damaged.

176 of 726

(Cont’d)
Figure 20-40-74 1
P-61263

plug.
P-61507
Remove the O-ring (Item 1) [Figure 20-40-74] from the Figure 20-40-77

linkage end.
Figure 20-40-75
P-61304
P-61303 Remove the compensator (Item 1) [Figure 20-40-77]


valve section.

torque.

177 of 726

(Cont’d)
Figure 20-40-78
P-61305



178 of 726
Slew Valve Section Disassembly And Assembly
Figure 20-40-79
1
P-61308
Install a hex wrench (Item 1) [Figure 20-40-81] to hold

P-73147 the spool limiter.
Remove the nut (Item 2) [Figure 20-40-81].

valve section. Repeat the procedure on the opposite end of the valve

section.
Figure 20-40-80
Installation: Tighten the nut to 22 ft.-lb. (30 N•m) torque.
Figure 20-40-82
P-73148
Remove the slew valve section (Item 1) [Figure 20-40-

P-53851
80] from the control valve.

nuts.

179 of 726

(Cont’d)
Figure 20-40-83
P-61257
1 1

end caps.
P-61309
Figure 20-40-86
Measure and record the length of the spool limiter (Item

1) [Figure 20-40-83] on both ends of the valve section.
1
Remove the spool limiters.
1
Figure 20-40-84
1 P-61311
2
Remove the centering springs (Item 1) [Figure 20-40-86]

1
P-61310

[Figure 20-40-84].
Assembly: Tighten the screws to 27 in.-lb. (3 N•m)

torque.
Remove the end caps from the valve section.

180 of 726
Slew Valve Section Disassembly And Assembly Cut

(Cont’d)
Figure 20-40-87
2.0”
0.50” Dia
1
1.500”
0.750”
B-14674

have to be made from a 0.750 inch thick x 1.500 inch
P-61312 wide x 2.0 inch long (19 mm thick x 38 mm wide x 50 mm
long) piece of hardwood. Drill a 0.50 inch (13 mm) hole in
the center of the hardwood block. Cut the block
Remove the spring guides (Item 1) [Figure 20-40-87] lengthwise [Figure 20-40-89].

from both ends of the valve spool.
Figure 20-40-88 blocks to grip the spool, or the spool will be
damaged.
Figure 20-40-90
1 3
P-61313
2

P-61504
NOTE: The spool is not symmetrical. Incorrect spool Using the wood blocks (Item 1) clamp the spool
installation will cause poor hydraulic valve assembly (Item 2) in a vise and loosen the plugs (Item 3)
performance. [Figure 20-40-90]. (Both ends)


181 of 726

(Cont’d)
Figure 20-40-91
1
4
3
1 2
2 1
3
P-61315

valve section.
P-61502
torque.
Remove the plugs (Item 1), springs (Item 2), and poppet

(Item 3) from the spool (Item 4) [Figure 20-40-91].
Figure 20-40-92 Figure 20-40-94
1
1
P-61503 P-61263
Remove the O-ring (Item 1) [Figure 20-40-92] from the Remove the O-ring (Item 1) [Figure 20-40-94] from the
plugs. plug.

182 of 726

(Cont’d)
Figure 20-40-95
P-61316

Figure 20-40-96
P-61305
Check the orifice (Item 1) [Figure 20-40-96] to be sure it

is not plugged.
Check the crossport hole (Item 2) [Figure 20-40-96] in

the compensator, to be sure it is not plugged.

183 of 726
Auxiliary Valve Section Disassembly And Assembly
Figure 20-40-97 4
3
2
1
1 P-73165
Remove the port relief valve (Item 1) [Figure 20-40-99]

P-73149 from the valve section.
Remove the plug (Item 2), spring (Item 3) and port relief
Remove the gasket (Item 1) [Figure 20-40-97] from the valve (Item 4) [Figure 20-40-99] from the valve section.
valve section.

Figure 20-40-98 torque.
Figure 20-40-100
P-73150
P-73166
Remove the second auxiliary valve section (Item 1)
[Figure 20-40-98] from the control valve.
plug.

184 of 726

(Cont’d)
Figure 20-40-101
1
2
P-73169
1 Remove the O-ring (Item 1) [Figure 20-40-103] from

both end caps.
P-73167
Figure 20-40-104
Remove the O-rings (Item 1) and backup ring (Item 2)

[Figure 20-40-101] from the load check valve body. 1
Figure 20-40-102
1
2
1 2
P-73170
1
Remove the centering springs (Item 1) [Figure 20-40-

104] from both ends of the valve spool.
P-73168
Remove the screws (Item 1) [Figure 20-40-102] from

both end caps.

torque.
Remove the end cap (Item 2) [Figure 20-40-102] from

both ends of the valve section.

185 of 726

(Cont’d)
Figure 20-40-105
1
P-73174
Assembly: The spool (Item 1) is symmetrical, and can

be installed in the valve section with the two spool
P-73171 grooves (Item 2) [Figure 20-40-107] either toward the
top, or the bottom of the valve section.
Remove the spring guides (Item 1) [Figure 20-40-105] Figure 20-40-108

Figure 20-40-106
P-73176
P-73172 Remove the plug (Item 1) [Figure 20-40-108] from the

valve section.
Record the orientation of the spool (Item 1) [Figure 20- Installation: Tighten the plug to 22 ft.-lb. (30 N•m)
40-106]. Remove the spool from the valve section. torque.

performance.

186 of 726

(Cont’d)
Figure 20-40-109
P-73179
Check the plug (Item 1) [Figure 20-40-111] from the

bottom of the valve.
P-73177
Figure 20-40-112

check valve.
Figure 20-40-110
1
1
1
P-73180

plug.
P-73178
Remove the piston (Item 1) and spring (Item 2) [Figure

20-40-110] from the check valve.

187 of 726

(Cont’d)
Figure 20-40-113
1
P-73184

Figure 20-40-114
P-73183



188 of 726
Bucket Valve Section Disassembly And Assembly

1
Figure 20-40-115
1
1
P-61328
Remove the plugs (Item 1) [Figure 20-40-117] from the

P-73151 port relief valves.
Installation: Tighten the plugs to 22-26 ft.-lb. (30-35

Remove the gasket (Item 1) [Figure 20-40-115] from the N•m) torque.
valve section.

Figure 20-40-118
Figure 20-40-116
P-61281
P-73152

Remove the bucket valve section (Item 1) [Figure 20-40- plugs.

189 of 726

(Cont’d)
Figure 20-40-119
2
1
P-61257
2
1 Remove the O-ring (Item 1) [Figure 20-40-121] from the
end cap.
P-61329
Figure 20-40-122
Remove the springs (Item 1) and valves (Item 2) [Figure

20-40-119].
1
Figure 20-40-120
1
2 P-61331
1
1
Remove the centering springs (Item 1) [Figure 20-40-
122] from both ends of the valve spool.
P-61330

[Figure 20-40-120].
Remove the end caps.
Installation: Tighten the screws to 27 in-.lb. (3 N•m)

torque.

190 of 726
Bucket Valve Section Disassembly And Assembly Cut

(Cont’d)
Figure 20-40-123
2.0”
0.50” Dia
1.500”
1 0.750”
B-14674
1

damaged.
Figure 20-40-126
3
P-61333
2

P-61504
performance. [Figure 20-40-126]. (Both ends).


191 of 726

(Cont’d)
Figure 20-40-127
3
1 2
1
2 1
3
P-61335

top of the valve section.
P-61502
torque.
Remove the plugs (Item 1), springs (Item 2) and poppets

(Item 3) from the spool (Item 4) [Figure 20-40-127]. Figure 20-40-130
Figure 20-40-128
P-61263
P-61503
plug.
plugs.

192 of 726

(Cont’d)
Figure 20-40-131
P-61336

Figure 20-40-132
P-61305



193 of 726
Arm Valve Section Disassembly And Assembly

1
Figure 20-40-133
1
1
P-61328


valve section.

Figure 20-40-136
Figure 20-40-134
P-61281
P-73154

Remove the arm valve section (Item 1) [Figure 20-40- plugs.

194 of 726

(Cont’d)
Figure 20-40-137
2
1
P-61257
2
end caps.
P-61329
Figure 20-40-140

20-40-137].
1
Figure 20-40-138
1
2 1 P-61331
1
Remove the centering spring (Item 1) [Figure 20-40-140]
P-61330
Remove the screws (Item 1) from both valve section end

caps (Item 2) [Figure 20-40-138].
Installation: Tighten the screws to 27 in.-lbs (3 N•m)

torque.

195 of 726
Arm Valve Section Disassembly And Assembly Cut

(Cont’d)
Figure 20-40-141
2.0”
0.50” Dia
1.500”
0.750”
1
B-14674
1

damaged.
Figure 20-40-144
3
P-61333
2

P-61504
installation will cause poor hydraulic valve assembly (Item 2) in a vise and loosen the plug (Item 3)


196 of 726

(Cont’d)
Figure 20-40-145
3
1 2
1
2 1
3
P-61335

P-61502
torque.

Figure 20-40-146
P-61263
P-61503
plug.
plugs.

197 of 726

(Cont’d)
Figure 20-40-149
P-61336

Figure 20-40-150
P-61305



198 of 726
Boom Valve Section Disassembly And Assembly

1
Figure 20-40-151 1
P-61328


valve section.

Figure 20-40-154
Figure 20-40-152
P-61281
P-73156
Remove the O-ring [Figure 20-40-154] from the plugs.

Remove the boom valve section (Item 1) [Figure 20-40-

199 of 726

(Cont’d)
Figure 20-40-155
2
1
P-61257
2
end caps.
P-61329
Figure 20-40-158

20-40-155].
1
Figure 20-40-156
1
2 1 P-61331
1
Remove the centering spring (Item 1) [Figure 20-40-158]
P-61330

[Figure 20-40-156].

torque.

200 of 726
Boom Valve Section Disassembly And Assembly Cut

(Cont’d)
Figure 20-40-159
2.0”
0.50” Dia
1.500”
0.750”
1
B-14674
1 To remove the plugs from the spool, a holding fixture will


damaged.
Figure 20-40-162
3
P-61333
2

P-61504


201 of 726

(Cont’d)
Figure 20-40-163
3
2
1 1
2 1
3
P-61335

P-61502
torque.

Figure 20-40-164
P-61263
P-61503
plug.
plugs.

202 of 726

(Cont’d)
Figure 20-40-167
P-61336

Figure 20-40-168
P-61305



203 of 726
Boom Swing Valve Section Disassembly And

Assembly
Figure 20-40-169
2 1
1 1
P-61344
Remove the screws (Item 1) from the valve spool retainer

(Item 2) [Figure 20-40-171].
P-73158
torque.

valve section. Remove the retainer.
Figure 20-40-170 Figure 20-40-172
1
1
P-73159 P-61345
Remove the boom swing valve section (Item 1) [Figure Remove the seal (Item 1) [Figure 20-40-172] from the
20-40-170] from the control valve. spool.

204 of 726

Assembly (Cont’d)
Figure 20-40-173
1
1
2
P-61347
Remove the screws (Item 1) from the end cap (Item 2)

[Figure 20-40-175].
P-61289
torque.

(Item 1) [Figure 20-40-173] toward the outside of the Remove the end cap.
valve section.
Figure 20-40-176
Figure 20-40-174
1
1
P-61348
P-61346
Remove the spool assembly (Item 1) [Figure 20-40-176].

valve spool.
NOTE: The valve spool (Item 2) [Figure 20-40-174] can

only be removed from the valve section from
the spring end of the valve section.

205 of 726

Assembly (Cont’d)
Figure 20-40-177 1
P-61289
1
Figure 20-40-180
Loosen the bolt (Item 1) [Figure 20-40-177].

NOTE: To remove the bolt, the spool must be held on
the linkage end (Item 2) [Figure 20-40-177], to
keep the spool from rotating.
3
Figure 20-40-178
2
5 1
3
1
P-61351
4 Remove the spring (Item 1) and poppet (Item 2) from the

2 spool (Item 3) [Figure 20-40-180].
P-61350
Remove the spring assembly (Item 1), retainer (Item 2),

seal (Item 3) and O-ring (Item 4) from the spool (Item 5)
[Figure 20-40-178].

206 of 726

Assembly (Cont’d)
4
Figure 20-40-181
Cut 3
2
1
2.0”
0.50” Dia
P-61506
1.500” Remove the linkage end (Item 1), spring (Item 2), and
0.750” poppet (Item 3) from the spool (Item 4) [Figure 20-40-
B-14674 183].
Figure 20-40-184
To remove the linkage end from the spool, a holding

fixture will have to be made from a 0.750 inch thick x 1.50
inch wide x 2.0 inch long (19 mm thick x 38 mm wide x 50
mm long) piece of hardwood. Drill a 0.50 inch (13 mm)
hole in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-181]. 1
damaged.
Figure 20-40-182
P-61507

linkage end.
P-61505

assembly (Item 2) in a vise and loosen the linkage end
(Item 3) [Figure 20-40-182].

or equivalent to the threads. Tighten the linkage end to
44 in.-lb. (5 N•m) torque.

207 of 726

Assembly (Cont’d)
Figure 20-40-185
P-61354
1
P-61353
Figure 20-40-188

valve section.
Installation: Tighten the plug to 22 ft.-lb. (30 N•m) 2

torque.
Figure 20-40-186
1
1
P-61305


P-61263

plug.

208 of 726
Inlet Section Disassembly And Assembly
Figure 20-40-189
1
P-61396

P-73138 plug.
Figure 20-40-192
Remove the gasket (Item 1) [Figure 20-40-189].

Figure 20-40-190
P-61368
P-61367 Remove the spring (Item 1) [Figure 20-40-192].

open center valve.

torque.

209 of 726
Inlet Section Disassembly And Assembly (Cont’d)
Figure 20-40-193
1
P-61371

P-61369 plug.
Figure 20-40-196
Remove the spool (Item 1) [Figure 20-40-193].

Figure 20-40-194
1
1
P-61372
P-61370 Remove the protective cover (Item 1) from the main relief
valve (Item 2) [Figure 20-40-196].
Remove the plug (Item 1) [Figure 20-40-194]. Remove the main relief valve from the inlet section.
Installation: Tighten the plug to 15 ft.-lb. (20 N•m) Installation: Tighten the main relief valve to 33 ft.-lb. (45
torque. N•m) torque.

210 of 726
Figure 20-40-197
1
2
2
P-53933
1
Check the port (Item 1) [Figure 20-40-199] in the load
P-53937 sense bleed valve to be sure it is not plugged.
Remove the filter (Item 2) [Figure 20-40-199] from the

Remove the O-rings (Item 1) and back-up ring (Item 2) end of the load sense bleed valve.
[Figure 20-40-197] from the relief valve.

Figure 20-40-200
Figure 20-40-198
1
4
3
2
1
P-53936
P-61373
Remove the plug (Item 1), shims (Item 2), spring (Item 3)
Remove the load sense bleed valve (Item 1) [Figure 20- and spool (Item 4) [Figure 20-40-200] from the load
40-198] from the inlet section. sense bleed valve.
Installation: Tighten the load sense bleed valve to 15 ft.- Installation: Tighten the plug to 15 ft.-lb. (20 N•m)
lb. (20 N•m) torque. torque.

211 of 726
Figure 20-40-201
1 3
1
4
2
P-61509
Remove the plug (Item 1), spring (Item 2) and poppet

P-53860 (Item 3) from the port (Item 4) [Figure 20-40-203].
Figure 20-40-204
plug.

Figure 20-40-202
1
P-61374
1
P-53935
torque.
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-202].

212 of 726
Figure 20-40-205
P-61281

plug.

Figure 20-40-206
P-61375
Remove the tie rods (Item 1) [Figure 20-40-206] from the

inlet section.
Installation: Tighten the tie rods to 11 ft.-lb. (15 N•m)

torque.

213 of 726
Assembly
IMPORTANT
1
damage the system.
I-2003-0888
P-73159
Inspect all parts for wear or damage. Replace any worn Install the boom swing valve section (Item 1) [Figure 20-
or damaged parts. 40-208] on the tie rods.
Always install new seals and O-rings. Lubricate all seals Figure 20-40-209

Figure 20-40-207
P-73158
Install the gasket (Item 1) [Figure 20-40-209] on the

P-73138
boom swing valve section.
Install the gasket (Item 1) [Figure 20-40-207] on the inlet

section.

214 of 726
Assembly (Cont’d)
Figure 20-40-210
P-73154
Install the arm valve section (Item 1) [Figure 20-40-212]

P-73156 on the tie rods.
Figure 20-40-213
Install the boom valve section (Item 1) [Figure 20-40-
210] on the tie rods.

Figure 20-40-211
P-73153
Install the gasket (Item 1) [Figure 20-40-213] on the arm


boom valve section.

215 of 726
Assembly (Cont’d)
Figure 20-40-214
P-73150
Install the auxiliary valve section (Item 1) [Figure 20-40-

P-73152 216] on the tie rods.
Figure 20-40-217
Install the bucket valve section (Item 1) [Figure 20-40-

Figure 20-40-215
1
P-73149

P-73151 auxiliary valve section.

bucket valve section.

216 of 726
Assembly (Cont’d)
Figure 20-40-218
1
P-73146
Install the blade valve section (Item 1) [Figure 20-40-

P-73148 220] on the tie rods.
Figure 20-40-221
Install the slew valve section (Item 1) [Figure 20-40-218]
on the tie rods.

Figure 20-40-219
1
P-73145

P-73147 blade valve section.
Install the gasket (Item 1) [Figure 20-40-219] on the slew

valve section.

217 of 726
Assembly (Cont’d)
Figure 20-40-222
1
P-73142
Install the right travel valve section (Item 1) [Figure 20-

P-73144 40-224] on the tie rods.
Figure 20-40-225
Install the left travel valve section (Item 1) [Figure 20-40-

Figure 20-40-223
1
P-73141
Install the gasket (Item 1) [Figure 20-40-225] on the right

P-73143 travel valve section.
Install the gasket (Item 1) [Figure 20-40-223] on the left

travel valve section.

218 of 726
HYDRAULIC CONTROL VALVE (CONT’D) The spools must not stick, if the spools stick, loosen the
tie rod nuts and tighten per above information.
Assembly (Cont’d)
Recheck the control valve assembly for level settings.
Figure 20-40-226
Figure 20-40-228
P-73140
P-73116
Install the end cap (Item 1) [Figure 20-40-226] on the tie

rods. Install the fittings and hose [Figure 20-40-228].

Figure 20-40-227 Figure 20-40-229
1 1
2
P-73139 P-73103
Install the nuts (Item 1) [Figure 20-40-227] on the tie Install the mount plate (Item 1) with three bolts and nuts
rods and finger tight. (Item 2) [Figure 20-40-229].
Be sure the valve assembly does not rock on a flat

surface.
Initially tighten the tie rod nuts (Item 1) to 5 ft.-lb. (7 N•m)

torque in a crisscross manner. Final tighten the tie rod
nuts (Item 1) [Figure 20-40-227] to 11 ft.-lb. (15 N•m)
torque.
The valve assembly must not have any spacing between

the valve sections and the spools must be free when
pushed in and released.

219 of 726

220 of 726
HYDRAULIC PUMP Figure 20-50-2
Description
1
IMPORTANT
damage the system. 2
I-2003-0888
P-69546A
Figure 20-50-1
Pump outlet 1 (Item 1) [Figure 20-50-1] & [Figure 20-50-

2] provides hydraulic fluid to the right hand travel, boom
swing and boom valve sections.
Pump outlet 2 (Item 2) [Figure 20-50-1] & [Figure 20-50-

2] provides hydraulic fluid flow to the left hand travel, arm

and bucket valve sections.
1
Hydraulic flow from pump outlet 2 (Item 2) [Figure 20-50-
1] & [Figure 20-50-2].
2
P-73127

221 of 726
HYDRAULIC PUMP (CONT’D) Engage the following hydraulic functions, and continue to
engage the functions.
Torque Adjustment
Engage the auxiliary hydraulics.
Prior to making any torque adjustment, all piston and Extend the bucket cylinder.
gear pump tests must be completed and are to rated Extend the arm cylinder.
specifications. (See the following pages for pump tests.) Extend the boom cylinder.
Extend the boom swing cylinder.
Prior to making any torque adjustment, make sure the no Engage the upperstructure slew.
load engine RPM is correct.
With all the above hydraulic functions engaged, the
Figure 20-50-3 engine speed must maintain 1950 to 2050 RPM.
Loosen the nut (Item 2) [Figure 20-50-3] and turn the

adjustment screw clockwise to increase pump torque.
counterclockwise to decrease pump torque.
Tighten the nut and retest the pump.
Increase or decrease pump torque until correct engine

1 RPM is maintained.
2

P-73128
The adjustment screw (Item 1) [Figure 20-50-3] is used

to match the maximum hydraulic horsepower of the
pump to the maximum rated engine horsepower.
Remove any auxiliary hydraulic attachments from the

excavator.
Engage the slew lock.
Start the engine and move the speed control to the high
idle position.

222 of 726
HYDRAULIC PUMP (CONT’D) Figure 20-50-6
Testing The Piston Pump
All pump testing is done with the hydraulic oil at operating 2

temperature and with the engine high speed setting of
2350 to 2420 RPM.
3
The following tool will be needed for the hydraulic pump
test:
1
MEL10003 - Hydraulic Tester
Stop the engine.
Open the tailgate. P-73130
Figure 20-50-4
Connect the inlet side (Item 1) of the tester to the pump
to the outlet side of the hydraulic pump (Item 2) [Figure
20-50-6].
Connect the outlet side of the tester to the hose (Item 3)

1 [Figure 20-50-6] that was removed from the pump.

Figure 20-50-7
P-73129
Figure 20-50-5
1
1
P-22253
NOTE: Open the flow control knob (Item 1) [Figure 20-

50-7] fully to prevent pump damage. This is a
direct pump test. There is no relief valve in the
system.
Start the engine and run at low RPM. Make sure the
tester is connected correctly. If no flow is indicated at the
P-69546A tester, the hoses are connected wrong.
Increase the engine speed to full RPM. Warm the

Remove the outlet hose (Item 1) [Figure 20-50-4] & hydraulic fluid to 150° F (66° C) by turning the restrictor
[Figure 20-50-5] from the hydraulic pump being tested. valve until the gauge reads about 1000 PSI (69 bar). Do
not exceed system pressure.

223 of 726
HYDRAULIC PUMP (CONT’D) Testing Auxiliary Hydraulic Flow
Testing The Piston Pump (Cont’d) The auxiliary hydraulic flow for the 425 excavator is the
combined flow of two pump outlets.
After the temperature is correct, open the restrictor valve
fully. All testing is done with the hydraulic oil at operating
temperature and the engine high speed setting of 2350 to
Record the pump free flow GPM (L/min.). 2420 RPM.
Pump flow on a new piston pump is 5.23 GPM (19,8 L/ The following tool will be needed for the auxiliary
min.). hydraulic flow test:
Figure 20-50-8 MEL10003-Hydraulic Tester.
Stop the engine.
Figure 20-50-9
2

1 1
P-22253
Close the flow control knob (Item 1) [Figure 20-50-8]

slowly to 100 PSI (6,9 bar) below the relief valve setting
P-73131
(2610 PSI [180 bar]).
Record the pump high pressure flow GPM (L/min.). Connect the inlet side of the tester to the female coupler
(Item 1). Connect the outlet side of the tester to the male
NOTE: The high pressure flow must be at least 80% of coupler (Item 2) [Figure 20-50-9].
free flow.
HIGH PRESSURE FLOW (GPM)
%= x100
FREE FLOW (GPM)
If the high pressure flow is less than 80% of free flow,

remove the hydraulic pump for repair or replacement.
Repeat the procedure for pump outlet 2.
The pump free flow and pump pressure flow must be

equal between outlet 1 and 2.

224 of 726
HYDRAULIC PUMP (CONT’D) Removal
Testing Auxiliary Hydraulic Flow (Cont’d) Drain the hydraulic reservoir. (See Removing And
Replacing The Hydraulic Fluid on Page 10-100-3.)
Figure 20-50-10
Remove the counterweight. (See COUNTERWEIGHT on
Page 40-210-1.)
Remove the spark arrestor muffler. (See SPARK

ARRESTOR MUFFLER on Page 60-30-1.)
Figure 20-50-11
P-22253
2 1
NOTE: Open the flow control knob (Item 1) [Figure 20-
50-10] fully.

Start the engine, and run at low RPM. Engage the
auxiliary hydraulic circuit.
P-73160
NOTE: When engaging the auxiliary hydraulic circuit,

make sure the female coupler is pressure and Mark and remove the hoses (Item 1 & 2) [Figure 20-50-
the male coupler is return. 11].
Make sure the tester is connected correctly. If no flow is Figure 20-50-12

indicated at the tester, the hoses are connected wrong.
Increase the engine speed to full RPM. Warm the

hydraulic fluid to 150° F (66° C) by turning the restrictor
valve until the gauge reads about 1000 PSI (69 bar). Do
not exceed system pressure.
After the temperature is correct, open the restrictor valve

fully.
Record the auxiliary hydraulic free flow GPM (L/min.). 1
1
2
P-73161
Remove the two bolts (Item 1) and the pump (Item 2)

[Figure 20-50-12].

225 of 726
Installation 1
NOTE: When the hydraulic pump has been drained,

the hydraulic pump must be purged of air 2
2
during refill of the hydraulic fluid. The pump
must be filled before installing the pump inlet
fitting.
Figure 20-50-13
P-73134
Install the pump inlet fitting (Item 1) and the two bolts
1 (Item 2) [Figure 20-50-15].
Apply Loctite® 242 on bolts and tighten the bolts (Item 2)

[Figure 20-50-15] to 22-26 ft.-lb. (30-35 N•m) torque.
2 1

Figure 20-50-16
P-73137
Install the two bolts (Item 1) and the hoses (Item 2)

[Figure 20-50-13].
Tighten the bolts to 55 - 60 ft.-lb. (75 - 85 N•m) torque.
Figure 20-50-14
1
1 P-73160
Install the hoses (Item 1) [Figure 20-50-16].
Fill the hydraulic reservoir. (See Removing And

P-73133
Fill the top of the hydraulic pump (Item 1) [Figure 20-50-

14] with new or filtered Bobcat hydraulic oil.

226 of 726
HYDRAULIC PUMP (CONT’D)
Coupler Removal And Installation
Figure 20-50-17
1.863 - 1.877 in.

(47,3 - 47,7 mm)
P--69553A
Remove the bolt (Item 1) [Figure 20-50-17] from the

coupler.

Slide the coupler off of the pump shaft.
When installing the coupler, maintain a distance of 1.863-

1.877 in. (47,3-47,7 mm) from the pump mount flange to
the coupler edge.
Tighten the coupler bolt (Item 1) [Figure 20-50-17] to 36-

40 ft.-lb. (49-54 N•m) torque.

227 of 726
HYDRAULIC PUMP (CONT’D)
Parts Identification (Piston Pump)
1. O-ring
2. O-ring
3. Piston
4. Spring 1 2
5. Shim 3
6. Sleeve 4
7. Pin 5 5 5
8. Housing 55
9. Seal 6
10. Ring 7
11. Swash Plate
12. Bearing 11
13. Plug
14. Plug 8
15. Ring
16. Rotary Group 5
17. Shaft 15 12
18. Ring
9
19. Shim 13 10

20. End Plate
14
21. Screw 16
22. O-ring
23. Screw
24. Screw
25. Port Plate
26. Pin
27. Bearing 20
28. Control plate
22
29. Gasket 21 17
30. Group Assy 24
18
19
25
26
28
23
27
30
29
MS2288S

228 of 726
Disassembly
1
Clean the outside of the hydraulic pump before
disassembly.
Figure 20-50-18
3
2
1
P-69553A
2
Remove the bolt (Item 1), coupler (Item 2), and two
fittings (Item 3) [Figure 20-50-20].
1 P-73135

Remove the two bolts (Item 1) and fitting (Item 2) [Figure
20-50-18].
Figure 20-50-19
P-73136

fitting.

229 of 726
Piston Pump Disassembly

1
Clean the outside of the pump before disassembly. 1
Figure 20-50-21
1
1
2 1
2
1
P-69803
Mark and remove the 4 bolts (Item 1) and port plate (Item
2) [Figure 20-50-23].
P-69802 NOTE: Mark the length and location of each bolt for
correct assembly.

Remove the two bolts (Item 1) and end plate (Item 2) Figure 20-50-24
[Figure 20-50-21] from the pump.
Figure 20-50-22
2
1
1
P-69822
P-69810 Remove the piston (Item 1) and bearing (Item 2) [Figure

20-50-24] from the port plate.

230 of 726
Piston Pump Disassembly (Cont’d)
Figure 20-50-25
1
1 2
2
P-69804
Remove the spring guide (Item 1) and spring seat (Item

P-58907 2) [Figure 20-50-27].
Figure 20-50-28
Remove the O-ring (Item 1) and two shims (Item 2)
[Figure 20-50-25] from the piston.

Figure 20-50-26
3
1
2
2
1
P-69805
Remove the washer (Item 1) and snap ring (Item 2)

P-69823 [Figure 20-50-28].
Remove the gasket (Item 1), control plate (Item 2), and
spring (Item 3) [Figure 20-50-26].

231 of 726
Figure 20-50-29
P-58928
Remove the retainer (Item 1) [Figure 20-50-31].

P-69806
Figure 20-50-32
Lay the pump on its side and remove the rotating group
(Item 1) [Figure 20-50-29]. 1

NOTE: The following procedure shown is to
disassemble the rotating group for inspection
only. The rotating group parts cannot be
ordered separately and must be ordered as an
assembly. 1
1
NOTE: Check for scratches or damage on the sliding
surfaces.
Figure 20-50-30
P-58920
Remove and inspect the pins (Item 1) [Figure 20-50-32]

for wear or damage.
1
P-58919
Remove the retainer plate (Item 1) and pistons (Item 2)

[Figure 20-50-30] from the cylinder block.

232 of 726
Figure 20-50-33
P-69818
Remove the swash plate (Item 1) [Figure 20-50-35].

P-69807
Figure 20-50-36
Remove the shaft (Item 1) [Figure 20-50-33] from the

pump housing.

2
Figure 20-50-34
P-69809
Remove the brass guide seat (Item 1) and steel guide

seat (Item 2) [Figure 20-50-36] from the swash plate.
P-69817
NOTE: Mark the location of each guide for correct
assembly.
Remove the snap ring (Item 1) [Figure 20-50-34] from
the shaft.
NOTE: Inspect the shaft for damage or wear. Replace

shaft if damaged or worn.

233 of 726
Figure 20-50-37
3 1
1
P-69816
Figure 20-50-40
P-69811
Remove the steel (black) guide (Item 1), chromed guide

5
(Item 2), and shim (Item 3) [Figure 20-50-37] from the

pump housing. 4
2
NOTE: Mark the location of each guide for correct
assembly.
6
Figure 20-50-38
3
1
P-69814
3 Remove the piston (Item 1) [Figure 20-50-39] & [Figure

20-50-40], five coned disc springs (Item 2), spacer (Item
3), shims (Item 4), sleeve (Item 5), and pin (Item 6)
[Figure 20-50-40].
2
1
P-69812
Remove the snap ring (Item 1), seal (Item 2), and bearing
(Item 3) [Figure 20-50-38].

234 of 726
Figure 20-50-41 5
2
6
1 3
1 P-69825
1
Remove the piston (Item 1) [Figure 20-50-42] & [Figure

P-69813 20-50-43], five coned disc springs (Item 2), spacer (Item
3), shims (Item 4), sleeve (Item 5), and pin (Item 6)
[Figure 20-50-43].
Remove the two O-rings (Item 1) [Figure 20-50-41] from
the piston. Figure 20-50-44

Figure 20-50-42
P-69813
P-69824
Remove the two O-rings (Item 1) [Figure 20-50-44] from
the piston.

235 of 726
Piston Pump Assembly
Clean all parts in solvent and dry with compressed air. Do 2

not use compressed air to dry the bearings.
3
5
or damaged parts.
1
4
Apply a thin coat of hydraulic fluid to all components
before assembly.
6 P-69825
Figure 20-50-45
Install the pin (Item 1), sleeve (Item 2), shims (Item 3),
spacer (Item 4), five coned disc springs (Item 5), and
NOTE: When installing the pin (Item 1) [Figure 20-50-

46] insert the beveled side of the pin towards

1 the swash plate (Item 1) [Figure 20-50-35].
Figure 20-50-47
1
P-69813
Install the two O-rings (Item 1) [Figure 20-50-45] on the

piston.
2
MS2049A
The five coned disc springs (Item 1) must face the piston
(Item 2) [Figure 20-50-47] as shown.

236 of 726
Piston Pump Assembly (Cont’d)

1
Figure 20-50-48
2
MS2049A
1
The five coned disc springs (Item 1) must face the piston
P-69813 (Item 2) [Figure 20-50-50] as shown.
Figure 20-50-51
Install the two O-rings (Item 1) [Figure 20-50-48] on the
piston.

Figure 20-50-49
1
2
3
5
2
3
1
P-69812
4
Install the bearing (Item 1), seal (Item 2), and snap ring
6 (Item 3) [Figure 20-50-51].
P-69814
Install the pin (Item 1), sleeve (Item 2), shims (Item 3),
spacer (Item 4), five coned disc springs (Item 5), and
NOTE: When installing the pin (Item 1) [Figure 20-50-

49] insert the beveled side of the pin towards
the swash plate (Item 1) [Figure 20-50-35].

237 of 726
Figure 20-50-52
1
P-69818
Install the swash plate (Item 1) [Figure 20-50-54] into the

P-69811 pump housing.
Figure 20-50-55
Install the steel (black) guide (Item 1), chromed guide
(Item 2), and shim (Item 3) [Figure 20-50-52].

NOTE: Apply assembly lube to the shim for ease of
assembly. 1
Figure 20-50-53
P-69817
Install the snap ring (Item 1) [Figure 20-50-55] on the

shaft.
1
P-69808
Install the brass guide seat (Item 1) and steel guide seat
(Item 2) [Figure 20-50-53] in the swash plate.
NOTE: Apply assembly lube to the guide seats for

ease of assembly.

238 of 726
Figure 20-50-56
P-58928
Install the retainer (Item 1) [Figure 20-50-58] on the pins.

P-69807
Figure 20-50-59
Install the shaft (Item 1) [Figure 20-50-56] into the pump

housing.

Figure 20-50-57
1
1
2
1
1
P-58919
Install the retainer and piston assembly (Item 1) in the

cylinder block (Item 2) [Figure 20-50-59].
P-58920
Install the pins (Item 1) [Figure 20-50-57].

239 of 726
Figure 20-50-60
2 1
P-69804
Install the spring seat (Item 1) and spring guide (Item 2)

P-69806 [Figure 20-50-62].
Figure 20-50-63
Lay the pump on its side and install the rotating group
(Item 1) [Figure 20-50-60].

2
Figure 20-50-61 1
2
1
P-69820
Install the gasket (Item 1) and spring (Item 2) [Figure 20-

P-69805 50-63].
Install the snap ring (Item 1) and the washer (Item 2)

[Figure 20-50-61].

240 of 726

2
Figure 20-50-64 2
2 2
1
2
P-69803
Install the port plate (Item 1) and four bolts (Item 2)

P-58907 [Figure 20-50-66] and tighten the bolts to xx-xx ft.-lb. (xx-
xx N•m) torque.
Install the O-ring (Item 1) and two shims (Item 2) [Figure Figure 20-50-67
20-50-64] on the piston.

Figure 20-50-65
3 1
P-69810
P-69815 Install the O-ring (Item 1) [Figure 20-50-67] on the end

plate.
Install the piston (Item 1) and bearing (Item 2) [Figure

20-50-65].
Apply assembly grease on the control plate (Item 3)

[Figure 20-50-65] and align on pin.

241 of 726
HYDRAULIC PUMP (CONT’D) Assembly
Piston Pump Assembly (Cont’d) Figure 20-50-69
Figure 20-50-68
1.863 - 1.877 in.
2
(47,3 - 47,7 mm)
2
1 2
P-69553A
P-69802
Install the coupler (Item 1) [Figure 20-50-69] on the
pump.
Install the end plate (Item 1) and two bolts (Item 2)
[Figure 20-50-68] on the pump. Tighten the coupler bolt (Item 2) [Figure 20-50-69] to 36-

Tighten the bolts to xx - xx ft.-lb. (xx - xx N•m) torque.
Install the two fittings (Item 3) [Figure 20-50-69] on the
pump.
NOTE: Do not install the pump inlet fitting until the

pump is installed and filled with clean
hydraulic oil.

242 of 726
MANIFOLD ASSEMBLY / ACCUMULATOR Figure 20-60-1
Description
The manifold body contains a joystick solenoid, two

speed solenoid valve, a pressure reducing valve and two 1
solenoids for auxiliary.
The body is connected to the accumulator.
The manifold supplies target pressure of 435 PSI (30 bar)

with an acceptable range of 406-450 PSI (28-31 bar) to
the joysticks to activate the control valve spools.
The accumulator provides short term reserve pressure

1
for joystick function with the engine off and the key in the P-73308
ON position.
Removal And Installation Disconnect the four electrical connectors (Item 1)

[Figure 20-60-1].
move both control levers to relieve hydraulic pressure. Figure 20-60-2
Drain the hydraulic reservoir. (See Removing And

Remove the right side cover. (See Removal And

IMPORTANT 1

P-73311
damage the system. Remove and cap the hoses (Item 1) [Figure 20-60-2].
I-2003-0888
Mark the hoses for correct installation.
WARNING
immediately.
W-2145-0290

243 of 726
MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-5
Figure 20-60-3
1
2
P-73317
Remove and cap the hose (Item 1) [Figure 20-60-5].

P-73314
Remove the manifold assembly (Item 2) [Figure 20-60-5]
from the excavator.
Remove and cap the hoses (Item 1) [Figure 20-60-3].

Figure 20-60-4
P-73309
Remove the two nuts (Item 1) [Figure 20-60-4] from the

manifold bracket.

244 of 726
MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D)
10
1. Accumulator
2. Valve Body 3
3. O-Ring
4. Pressure Reducing Valve 10
5. Aux. Base Spool
6. Aux. Rod Spool 9 3
7. Two Speed Spool
8. Pilot Supply Spool 3
10
9. Coil
10. Nut 9 3
11. Plug 3 10
12. Backup Ring
13. Spring 8
9
14. Ball 3
15. Seat
3 7 3
9
12
3 3 6 3
12

12
12 3 5
3 12
12 3
12 4
3 12
12 3
12 3
12 3
12 3
3 12
12 12
3
12
3 3
12
12
1
3
11
2 3
3
15
14
13
3
11
MS1401B

245 of 726
Disassembly And Assembly
Clean the outside of the manifold assembly before

disassembly.
Figure 20-60-6
1
2
P-73337

1 accumulator.
Figure 20-60-9
P-73307

1
Remove the bolts (Item 1) and mount plate (Item 2)
[Figure 20-60-6] from the manifold.
Figure 20-60-7
P-73338
Remove the nut (Item 1) [Figure 20-60-9] from the

green tie strap solenoid.
1
Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.
P-73336
Remove the accumulator (Item 1) [Figure 20-60-7].
Installation: Tighten the accumulator to 33 ft.-lb. (45

N•m) torque.

246 of 726
Disassembly And Assembly (Cont’d)
Figure 20-60-10
1
1
P-73340

P-73345 solenoid stem.
Figure 20-60-13
solenoid.

Figure 20-60-11
P-73341
Remove the solenoid stem (Item 1) [Figure 20-60-13].

P-73339
Installation: Tighten the solenoid stem to 22 ft.-lb. (30
N•m) torque.
Remove the coil with the green tie strap (Item 1) [Figure
20-60-11] from the solenoid stem.

247 of 726
Figure 20-60-14 1
1
2
2
P-73344
1
P-73342 solenoid.
Figure 20-60-17
Remove the O-rings (Item 1) and backup rings (Item 2)
[Figure 20-60-14] from the solenoid stem.

Figure 20-60-15
1
P-73346
Remove the coil with the yellow tie strap (Item 1) [Figure
P-73343 20-60-17] from the solenoid stem.
Remove the nut (Item 1) [Figure 20-60-15] from the

yellow tie strap solenoid.

248 of 726
Figure 20-60-18 1
2
2
1
1
P-73349

P-73347 [Figure 20-60-20] from the solenoid stem.
Figure 20-60-21
solenoid stem.

Figure 20-60-19
P-73350
Remove the nut (Item 1) [Figure 20-60-21] from the red

P-73348 tie strap solenoid.


N•m) torque.

249 of 726
Figure 20-60-22
P-73353
Installation: Install the solenoid with the metal base

P-73351 (Item 1) [Figure 20-60-24] down toward the base of the
spool.
Remove the O-ring (Item 1) [Figure 20-60-22] from the Figure 20-60-25
solenoid.

Figure 20-60-23
1
1
P-73354
P-73352 Remove the solenoid stem (Item 1) [Figure 20-60-25].

Remove the coil with the red tie strap (Item 1) [Figure N•m) torque.
20-60-23] from the solenoid stem.

250 of 726
Figure 20-60-26 1
1
1
1
P-73357
2
P-73355 solenoid.
Figure 20-60-29
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-60-26].

Figure 20-60-27
1
P-73358
Remove the coil with the blue tie strap (Item 1) [Figure
P-73356 20-60-29] from the solenoid stem.
Remove the nut (Item 1) [Figure 20-60-27] from the blue

tie strap solenoid.

251 of 726
Figure 20-60-30 1
1
1
2
2
P-73360
1
Remove the O-rings (Item 1) and back-up rings (Item 2)
P-73353 [Figure 20-60-32].
Figure 20-60-33
Installation: Install the solenoid with the metal base
(Item 1) [Figure 20-60-30] down toward the base of the

spool.
Figure 20-60-31 1
P-73372
Remove the pressure reducing valve (Item 1) [Figure 20-

60-33].
P-73359
Installation: Tighten the pressure reducing valve to 22
ft.-lb. (30 N•m) torque.

N•m) torque.

252 of 726
Figure 20-60-34
1
1
1
1
P-73364
2
2
Remove the O-rings (Item 1) [Figure 20-60-36] from the
P-73362 load check.
Figure 20-60-37
[Figure 20-60-34] from the pressure reducing valve.

Figure 20-60-35
1 1
P-73365
Remove the two plugs (Item 1) [Figure 20-60-37].

P-73363
Installation: Tighten the two plugs to 17 ft.-lb. (23 N•m)
torque.
Remove the load check (Item 1) [Figure 20-60-35].
Installation: Tighten the load check to 29.5 ft.-lb. (40

N•m) torque.

253 of 726
MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D)
Figure 20-60-38
P-73366

plugs.

254 of 726
TRAVEL MOTOR Figure 20-70-2
Description
1
The travel motor is a hydraulic motor which receives
hydraulic fluid from the hydraulic pump through the
1
hydraulic control valve. The speed that the travel motor
rotates is related to the amount of hydraulic fluid it
receives. This travel motor is equipped with 2 speed.
Lift and block the side of the track frame where the travel
motor will be removed. 1
Release the track tension and remove the track. (See P-55412
Rubber Track Removal And Installation on Page 30-20-
5.)
Remove the hoses (Item 1) [Figure 20-70-2] from the
Figure 20-70-1 travel motor.
Figure 20-70-3

1
N-16281
1
P-55413
Remove the bolts (Item 1) [Figure 20-70-1] from the
track frame cover.
Installation: Tighten the bolts to 20-25 ft.-lb. (27-34 N•m) travel motor.
torque.
Installation: Apply thread lock (LOCTITE® #242) to the
Remove the cover. bolts and tighten to 78-85 ft.-lb. (105-115 N•m) torque.
Remove the travel motor from the track frame.
IMPORTANT
damage the system.
I-2003-0888
Mark the hoses for correct installation.

255 of 726
TRAVEL MOTOR (CONT’D)
1. Snap Ring
2. Plug 14
3. O-Ring 13
4. Cover
5. Bushing 22 12 11
6. Drive Shaft 10
7. Snap Ring 8
21
8. Planetary Carrier
9. Sun Gear
20 7
10. Snap Ring
11. Anti-Rotation Washer
6 4
12. Bearing 19 5
13. Planetary Gear
14. Thrust Washer 3
15. Planetary Gear 18
16. Ring Gear 1
17. Snap Ring
18. Shim(s) 17
19. Bearings 2
20. Spacer 33 16
34

21. Snap Ring 32
22. O-Ring 31
23. Seal Ring
24. Snap Ring 30
25. Snap Ring 10
29
26. Bearing 22
27. Drive Shaft
28. Hub
29. Seal 54 28
30. Swash Plate
53 15
31. Rotating Block
32. Motor Plate 10
52
33. AligN•ment Pin 51 9
27
34. Bearing
35. O-Ring 26
36. AligN•ment Pin 24 23
37. Motor Cover
44
38. Spool 19
39. Washer 49 45 42
50 40 41 25
40. Spring 46 40
41. O-Ring 48
42. Plug 38
43. Bolt 43 37
44. Plug 39
45. O-Ring 48
47 35
46. Spool 51
47. Fitting
48. O-Ring 42
49. Relief Valve 39
40
50. Bolt 41
51. Washer
52. Spring 36
53. Piston
54. Ball
D-2373A

256 of 726
TRAVEL MOTOR (CONT’D) Figure 20-70-5
Disassembly
IMPORTANT
damage the system.
I-2003-0888
B-14729
The following tool will need to be ordered from OTC Tool

to reassemble the travel motor: Remove the internal snap ring from the travel motor case
[Figure 20-70-5].
MEL1519 for torque ring and seal ring assembly.
Figure 20-70-6
Figure 20-70-4

1
B-14730
B-14497
To remove the cover, install two threaded pins in the

Remove the drain plugs (Item 1) [Figure 20-70-4] from drain holes and lift the cover off [Figure 20-70-6].
the end cover.
Air pressure may also be used to remove the cover.
Drain the oil into a container.

257 of 726
Figure 20-70-7
B-14732
Remove the planetary carrier [Figure 20-70-9].

B-14731
Figure 20-70-10
Screw the adapter in a drain hole and apply 8-11 PSI

[Figure 20-70-7].

1
NOTE: Do not use excess pressure or seal damage
2
may result.
4
Figure 20-70-8
3
B-14733
Remove the snap rings (Item 1), the anti-rotation

washers (Item 2), the gears (Item 3), the bearings (Item
4) and the bottom thrust washers (Item 5) [Figure 20-70-
10] from the planetary carrier assembly.
B-14772A

cover.

258 of 726
Figure 20-70-11
1
2
B-14736
Remove the snap rings (Item 1) and the gears/bearings

B-14734 (Item 2) [Figure 20-70-13].
Figure 20-70-14
Remove the sun gear (Item 1) [Figure 20-70-11] from the
carrier.

Figure 20-70-12 1
2 2
1 B-14737
Remove the external snap ring (Item 1) and the shim(s)

B-14735 (Item 2) [Figure 20-70-14].
Before the ring gear can be pulled from the hub, a plate
Remove the sun gear (Item 1) from the planetary carrier, must be placed on the three pins of the planetary carrier.
by removing the snap ring (Item 2) and pushing the sun
gear (Item 1) [Figure 20-70-12] out of the carrier. The plate will provide support for the three jaw puller.

259 of 726
Figure 20-70-15
0.250 inch
(6,35 mm)
5.500 inch
(140 mm)
B-14739
Remove the ball bearing from the ring gear [Figure 20-
B-14725 70-17].
NOTE: Do not damage the top surface of the bearing

Fabricate or obtain the plate [Figure 20-70-15] locally. as it is lapped (polished) to mate with the front
seal ring.

The dimensions of the plate are as follows:
Figure 20-70-18
Diameter 5.500 inches (140 mm)
Thickness 0.250 inch (6.35 mm)
Figure 20-70-16
1
B-14740

B-14738 ring gear.
Using a three jaw puller, separate the hub and the ring
gear assembly [Figure 20-70-16].

260 of 726
Figure 20-70-19
B-14839
Remove the front seal ring from the motor hub [Figure
B-14741 20-70-21].
Figure 20-70-22
Remove the internal snap ring (Item 1) and spacer (Item
2) [Figure 20-70-19].

1
Figure 20-70-20
2
B-14812
Remove the four bolts (Item 1) from the relief valve block
B-14742 (Item 2) [Figure 20-70-22].
Remove the two O-rings (Item 3) [Figure 20-70-22].

Remove the second bearing from the ring gear [Figure
20-70-20]. NOTE: The relief valve block assembly (Item 2)
[Figure 20-70-22] and the relief valves are not
serviceable. If any of these parts are
damaged, order a new relief valve block
assembly.

261 of 726
2
Figure 20-70-23
2 4
5 2
4 3 1
3
1
3
3
1
B-14491
2
1 Remove the spring (Item 1), the poppet (Item 2) and the
B-14813 check ball (Item 3) [Figure 20-70-25] from both ends of
the spool.
Remove the plugs (Item 1), O-rings (Item 2), springs Figure 20-70-26
(Item 3) and washers (Item 4) [Figure 20-70-23] from

both ends of the spool. 2
Remove the spool (Item 5) [Figure 20-70-23]. 6
Figure 20-70-24
5
1
4
B-14814
Remove the fitting (Item 1) and O-ring (Item 2). Remove

the plug (Item 3), O-ring (Item 4), spring (Item 5) and
spool (Item 6) [Figure 20-70-26].
B-14492
To disassemble the spool, insert a hardened pin through

the hole in the spool and use a vise with protective jaws
to hold the spool [Figure 20-70-24].
NOTE: Do not use any type of tool to grip the spool or

damage to the spool will result.
Remove the plug from both ends of the spool [Figure 20-
70-24].

262 of 726
Figure 20-70-27
1
B-14817
Remove the bearing (Item 1) [Figure 20-70-29] with a

B-14815 bearing puller.
Figure 20-70-30
Remove the bolts and motor cover [Figure 20-70-27].

Figure 20-70-28
1
1
2
3
B-14818
B-14816 Remove the O-ring (Item 1) [Figure 20-70-30].
Remove the O-rings (Item 1) and the dowel pins (Item 2)

[Figure 20-70-28].
Remove the aligN•ment pin (Item 3) [Figure 20-70-28].

263 of 726
Figure 20-70-31
B-14821
Remove the piston assembly [Figure 20-70-33].

B-14819
Figure 20-70-34
Remove the valve plate (Item 1) [Figure 20-70-31].

Figure 20-70-32
1
1
B-14822
Remove the swash plate [Figure 20-70-34].

B-14820
Remove the rotating block and the three dowel pins (Item
1) [Figure 20-70-32].

264 of 726
Figure 20-70-35 1
B-14825
Remove the internal snap ring (Item 1) [Figure 20-70-37]

B-14823 that retain the bearing/drive shaft to the hub.
Push the drive shaft (Item 2) [Figure 20-70-37] from the

Remove the balls (Item 1) [Figure 20-70-35]. bottom to remove the shaft from the hub.

Figure 20-70-36 Figure 20-70-38
1 1
2 2 1
4 3 2
B-14824 B-14751
Remove the displacement control pistons (Item 1), the Remove the snap ring (Item 1), the bearing (Item 2) and
springs (Item 2) and the washers (Item 3) [Figure 20-70- the snap ring (Item 3) [Figure 20-70-38] from the drive
36]. shaft.
NOTE: To ease removal of the pistons, apply low air

pressure to the oil holes (Item 4) [Figure 20-
70-36].

265 of 726
TRAVEL MOTOR (CONT’D)
Figure 20-70-39
B-14826
Remove the seal (Item 1) [Figure 20-70-39] from the

hub.

266 of 726
Assembly

1
Inspect all parts and replace any that are damaged. If any
of the planetary gears are damaged, replace all the
planetary gears and the sun gear from the planetary
assembly that is damaged.
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. B-14827
The following tools will be needed to assemble the travel

motor: Apply oil to the inside diameter of the oil seal and install
the oil seal (Item 1) [Figure 20-70-41] in the hub.
MEL1519- Seal Installation Tool.
Figure 20-70-42
Figure 20-70-40

2
3
1
2
1
B-14828
B-14752
Install the drive shaft/bearing assembly (Item 1) [Figure

Install the snap ring (Item 1), bearing (Item 2) and snap 20-70-42] in the hub.
ring (Item 3) [Figure 20-70-40] on the drive shaft.
NOTE: Make sure the bearing is seated in the hub.
Install the snap ring (Item 2) [Figure 20-70-42].

267 of 726
Assembly (Cont’d)
Figure 20-70-43
3
3 2
2
1
B-14831
Install the swash plate in the hub [Figure 20-70-45].

B-14829
Figure 20-70-46
Install the washers (Item 1) and the springs (Item 2).

Apply oil on the displacement control pistons (Item 3)

[Figure 20-70-43] and install the pistons in the piston
bore.
2
Figure 20-70-44
1 1
B-14832
Install the dowel pins (Item 1) [Figure 20-70-46] in the

rotating block.
Apply oil to the piston assembly (Item 2) [Figure 20-70-

B-14830 46] and install the piston assembly in the rotating block.
Install the balls (Item 1) [Figure 20-70-44] in the hub.

268 of 726
Assembly (Cont’d)
Figure 20-70-47
0.118 - 0.150 inch

(3,5 - 3,8 mm)
B-14777
1
Figure 20-70-50
B-14833
Tip the motor housing on its side. Make sure the thick
side of the swash plate (Item 1) [Figure 20-70-47] is to 1

the bottom.
Install the rotating block assembly in the hub [Figure 20-

70-47].
Figure 20-70-48
1
B-14835
Press the bearing (Item 1) [Figure 20-70-49] & [Figure

20-70-50] in the motor cover.
The bearing (Item 1) [Figure 20-70-49] must extend from

the face of the motor cover 0.118 - 0.150 inch (3,5-3,8
mm).
B-14834
Apply oil to and install the O-ring (Item 1) [Figure 20-70-

48] on the hub.

269 of 726
Assembly (Cont’d)
Figure 20-70-51
3 2
B-14838
Lubricate the bearing with oil and install the motor cover
B-14836 on the hub with the bolts [Figure 20-70-53].
Tighten the bolts in a crisscross manner to 18-22 ft.-lb.

Apply oil to the two O-rings (Item 1) [Figure 20-70-51] (25-30 N•m) torque.
and install the O-rings on the motor cover.

Figure 20-70-54
Install the alignment pins (Item 2) and the valve plate pin
(Item 3) [Figure 20-70-51] on the motor cover. 3
1
Figure 20-70-52
2
4
5 3
1 B-14840
Apply oil to and install the two speed spool (Item 1) and
B-14837 spring (Item 2) [Figure 20-70-54].
Apply oil to and install the O-rings (Item 3) on the plug

Apply light grease to the valve plate. Install the valve (Item 4) and the adapter (Item 5). Install the plug (Item 4)
plate on the motor cover, over the valve plate alignment and the adapter (Item 5) [Figure 20-70-54].
pin (Item 1) [Figure 20-70-52].

270 of 726
Assembly (Cont’d) 4
2
1
Figure 20-70-55
2 3
4
2 5 5
3
2 5
4
5 3 4
1
B-14841
1 Apply oil to and install the spool (Item 1) [Figure 20-70-

3 B-14491 57] in the motor cover.
Install the washers (Item 2) and the springs (Item 3) on

Install the check ball (Item 1), the poppet (Item 2) and the both ends of the spool (Item 1) [Figure 20-70-57].
spring (Item 3) [Figure 20-70-55] in both ends of the

spool. Apply oil to and install the O-rings (Item 4) on the plugs
(Item 5) [Figure 20-70-57].
Apply oil to, and install the O-rings (Item 4) on the plugs
(Item 5) [Figure 20-70-55]. Install the plugs (Item 5) [Figure 20-70-57] in the motor
cover.
Figure 20-70-56
Figure 20-70-58
2
1
B-14492
B-14842
To assemble the spool, insert a hardened pin through the

hole in the spool and use a vise with protective jaws to Apply oil to and install the two O-rings (Item 1) [Figure
hold the spool [Figure 20-70-56]. 20-70-58].
NOTE: Do not use any type of tool to grip the spool or Install the relief valve block assembly (Item 2) and the
damage to the spool will result. bolts (Item 3) [Figure 20-70-58]. Tighten the bolts to 18-
Install the plug in both ends of the spool [Figure 20-70-
56].
Tighten the plugs to 18-22 ft.-lb. (25-30 N•m) torque.

271 of 726
TRAVEL MOTOR (CONT’D) NOTE: If either the top or bottom bearing has been
replaced, measure the thickness of the old
Assembly (Cont’d) and new bearing. If the difference is greater
than ± 0.002 inch (0,05 mm) add or subtract
To install the bearings, a bearing installation tool will be shims to match the new bearing thickness to
needed. the old bearing thickness.
This tool is placed on the top of the bearing inner and If shims are needed, order the appropriate shim(s) from
outer race and a press is used to seat the bearings. Bobcat Parts:
Figure 20-70-59 P/N 6669119 0.0079 inch (0,2 mm)

0.250 inch P/N 6669120 0.0118 inch (0,3)
(6,35 mm) P/N 6669121 0.0157 inch (0,4 mm)
P/N 6669122 0.0354 inch (0,9 mm)
P/N 6669123 0.0374 inch (0,95 mm)
Figure 20-70-61
6.688 inch
(170 mm)
2

1
B-14725
Obtain the tool locally [Figure 20-70-59].
The dimensions are as follows:
Diameter 6.688 inch (170 mm) B-14760

Thickness 0.250 inch (6,35 mm)
Figure 20-70-60 Install the spacer (Item 1) and snap ring (Item 2) [Figure
20-70-61].
Figure 20-70-62
B-14726
Lubricate the outer edge of the bearing and press the B-14761
bearing (Item 1) [Figure 20-70-60] in the housing, using
the bearing installation tool.
Turn the housing over and using a brass drift, seat the
bearing against the spacer [Figure 20-70-62].

272 of 726
Assembly (Cont’d)
2
Figure 20-70-63
B-14496
Install the O-ring (Item 1) on the seal ring (Item 2)

B-14762 [Figure 20-70-65].
NOTE: Inspect the seal ring for burrs before

Apply oil to and install the O-ring (Item 1) [Figure 20-70- installing the O-ring. Install the O-ring making
63]. sure it is not twisted. To remove any twists,

gently pull a section of the O-ring and let it
NOTE: Make sure the O-ring (Item 1) [Figure 20-70-63] snap back.
is correctly installed in the housing groove so
it is not damaged when the second bearing is The O-ring, seal ring and motor assembly must be clean
installed. and free of any dust, oil film or foreign matter.
Figure 20-70-64 Figure 20-70-66
B-14726 B-14843
Lubricate the outer edge of the second bearing (Item 1) Install the seal seating tool (MEL1519) on the seal ring
[Figure 20-70-64] and press the bearing in the housing. and O-ring assembly [Figure 20-70-66].
The O-ring and seal ring assembly has to be lubricated

with alcohol so the O-ring will slip past the housing
retaining ring and seal uniformly in the motor housing
radius [Figure 20-70-66]. Do not use oil to lubricate the
O-ring.
Dip the O-ring and seal ring assembly in a pan of alcohol.

273 of 726
TRAVEL MOTOR (CONT’D) NOTE: Do not get any oil on the rubber O-ring.
Assembly (Cont’d) Figure 20-70-69
Figure 20-70-67
B-14844
B-14493
Press the reduction unit and motor assembly in the
bearings [Figure 20-70-69]. The inner bearing may move
Shake off the excess alcohol and install the seal ring deeper into the housing as the motor assembly is
assembly on the motor [Figure 20-70-67]. pressed in the housing. If this happens, tap the inner

bearing down to its original position using a brass drift.
Use firm even pressure on the installation tool
(MEL1519) to install the O-ring in the motor housing. Figure 20-70-70
Figure 20-70-68
2
0.300 inch 0.300 inch 1
(7,62 mm) (7,62 mm)
B-14766
B-14494
Install the shim(s) (Item 1) and snap ring (Item 2) [Figure
20-70-70] in the motor reduction unit.
After the seal ring is installed, check the stand out height
[Figure 20-70-68] in four places, 90° apart. The shim(s) (Item 1) [Figure 20-70-70] are used to
remove any end play between the ring gear and
The stand out height is 0.300 ± 0.020 inches (7,62 ± 0,5 reduction unit.
mm).
The snap ring (Item 2) must be snug against the shim(s)
NOTE: If the seal ring does not meet the height (Item 1) [Figure 20-70-70] and fully seated in the snap
specifications inspect the O-ring for twists or ring groove.
obvious bulges. Remove and reinstall the seal
ring if the O-ring is twisted or bulged.
Apply a light film of oil to the seal ring and lapped face of
the bearing.

274 of 726
Assembly (Cont’d)
Figure 20-70-71
2
1
B-14769
Install the drive shaft (Item 1) [Figure 20-70-73].

B-14767
Figure 20-70-74
Install the planetary gears/bearings (Item 1) and the snap

rings (Item 2) [Figure 20-70-71].

5
NOTE: The second stage planetary gears/bearings
must be installed with the bearing race flare 4
facing down to match the shoulder on the 3
pins.
2
Figure 20-70-72
1
2
B-14770
Install the thrust washers (Item 1), planetary gears (Item

2), bearings (Item 3), anti-rotation washers (Item 4) and
snap rings (Item 5) [Figure 20-70-74].
1
Install the snap rings (Item 5) [Figure 20-70-74] so the
opening of the snap ring is towards the outside.
B-14768
Install the sun gear (Item 1) [Figure 20-70-72] into the

outer planetary carrier.
Install the snap ring (Item 2) on the sun gear (Item 1)

[Figure 20-70-72].

275 of 726
Assembly (Cont’d)
Figure 20-70-75
1
B-14778
Place a 0.500 inch (13 mm) long piece of 0.062 inch (1,5
B-14771 mm) solder (Item 1) [Figure 20-70-77] on the end of the
sun gear.
Install the planetary assembly in the hub [Figure 20-70- Seat the cover in the hub.
75].

Remove the cover and measure the solder.
Figure 20-70-76
If the clearance between the sun gear and cover bushing
does not meet specifications, order the appropriate
2 bushing shim from Bobcat Parts.
P/N 6669597 0.20 inch (0,5 mm)

P/N 6669598 0.30 inch (0,76 mm)
P/N 6669699 0.050 inch (1,27 mm)
1
Remove the bushing.
Install the correct shim under the bushing and install the
bushing.
NOTE: Make sure there are no burrs on the bushing

B-14676 face from bushing removal.
Repeat the procedure for checking clearance between

Inspect the cover bushing (Item 1) [Figure 20-70-76] for the sun gear and cover bushing.
wear.
If the bushing (Item 1) [Figure 20-70-76] needs to be

replaced, drill a hole, using a number 3 drill bit, in the
center of the bushing.
Thread the hole with a 0.250 x 28 inch NF tap.
Install a 0.250 x 28 inch bolt (Item 2) [Figure 20-70-76] in

the bushing and pull the bushing out of the cover.
Install the new bushing in the cover with the bevel down.
The clearance between the cover bushing and the sun

gear must be 0.016-0.024 inches (0,4-0,6 mm).

276 of 726
Assembly (Cont’d)
Figure 20-70-78
2
2
B-14498
Add approximately 0.55 quarts (0.5 L) of gear lube 90W

B-14772 to the top plug hole (Item 1) until the gear lube is at the
bottom of the plug hole (Item 2) [Figure 20-70-80].
Apply oil to and install the O-ring (Item 1) [Figure 20-70- Install and tighten the two plugs.
78] on the cover.

Install the cover (Item 2) [Figure 20-70-78] on the hub.
Figure 20-70-79
B-14773

277 of 726

278 of 726
SWIVEL JOINT Figure 20-80-1
Description
The swivel joint is a rotary hydraulic swivel which diverts 1

hydraulic oil, under pressure, to the travel motors and the
blade cylinder.
WARNING
Instructions are necessary before operating or
P-73384
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow Remove the hoses (Item 1) [Figure 20-80-1] from the top
warnings and instructions in the manuals when of the swivel joint.
correct function after adjustments, repairs or service. Remove the nut and swivel joint stop bolt (Item 1)
Untrained operators and failure to follow instructions [Figure 20-80-1].

W-2003-0903
to the swivel joint stop bolt and install the nut and the bolt
Remove the floormat and floor panel. (See Removal And in the swivel joint. Tighten the nut completely on the bolt
Installation on Page 40-90-1.) threads. Tighten the bolt to 110-125 ft.-lb. (150-175 N•m)
torque.
Figure 20-80-2
IMPORTANT
2
1 1
damage the system.
I-2003-0888
Mark the hoses for ease of installation.
P-55414
Remove the bolts (Item 1) [Figure 20-80-2].
Remove the access plate (Item 2) [Figure 20-80-2] from

the bottom of the undercarriage.

279 of 726
SWIVEL JOINT (CONT’D)
Figure 20-80-3
1 1
P-55415
Remove the hoses from the lower end of the swivel joint
[Figure 20-80-3].

Support the swivel joint with a jack.
Rotate the swivel joint 90° to allow clearance between

the swivel joint and the mount brackets.

to the bolts. Tighten the bolts to 55-60 ft.-lb. (75-85 N•m)
torque.
Lower the swivel joint through the bottom of the

undercarriage.

280 of 726
SWIVEL JOINT (CONT’D)
1. Bolt
2. Rotor
3. Plug
4. Seal
5. Seal
6. Seal
7. Body
8. O-Ring
9. Cover
10. Bolt
1
7

3
8
4
6 9
10
D-2250

281 of 726
SWIVEL JOINT (CONT’D) Figure 20-80-6
Disassembly
Clean the outside of the swivel joint before disassembly.

Mark the cover and body for ease of assembly.
Figure 20-80-4
P-5873
Remove the O-ring from the O-ring groove [Figure 20-

80-6].
Figure 20-80-7
P-5871

Remove the bolts from the cover [Figure 20-80-4].
Figure 20-80-5
P-5874
Clamp the swivel joint, base end down in a vise, and

drive the rotor out of the body with a soft faced hammer
[Figure 20-80-7].
P-5872
Remove all the O-rings and glid rings from the rotor.
Remove the cover [Figure 20-80-5]. NOTE: Use care not to scratch the rotor surface as
damage to the finished surface could cause
internal leakage.

282 of 726
Assembly

or damaged parts.

Figure 20-80-8
P-5877
Install the crown seal O-ring [Figure 20-80-10].
Figure 20-80-11

P-5875
Install the O-rings on the rotor [Figure 20-80-8].
Heat the glid rings and crown seal in hydraulic oil for
three minutes at 130° F (54° C).
Figure 20-80-9 P-5878
Stretch the heated crown seal to 4.500 inches (114,3

mm) [Figure 20-80-11].
P-5876
Stretch the heated glid rings to 4.0 inch (101,6 mm) and
install on the rotor [Figure 20-80-9].

283 of 726
Assembly (Cont’d)
Figure 20-80-12
P-5882
Seat the rotor using a soft faced hammer [Figure 20-80-

P-5879 14].
Figure 20-80-15
Work the crown seal on the rotor and down to the top
groove [Figure 20-80-12].

Figure 20-80-13
P-5883
Install the O-ring in the groove on the bottom of the body

P-5880 [Figure 20-80-15].
Press the wiper seal in the body [Figure 20-80-13].
Lubricate the inside of the body and the rotor with

hydraulic oil or light grease.
Slide the rotor in the body.

284 of 726
Assembly (Cont’d)
Figure 20-80-16
P-5886
Check the breakaway torque of the swivel joint [Figure

P-5884 20-80-18].
The breakaway torque of the swivel joint is 50-90 ft.-lb.

Install the cover on the body [Figure 20-80-16]. (68-122 N•m).

Figure 20-80-17
P-5885
Apply thread lock adhesive (Loctite® 242) to the bolt

threads, and install the cover bolts. Tighten the bolts to
18 ft.-lb. (24 N•m) torque [Figure 20-80-17].

285 of 726

286 of 726
SWING MOTOR Figure 20-90-2
Description
The swing motor is a hydraulic motor that receives

hydraulic fluid from the pump through the control valve to
swing the upperstructure left or right. The speed that the
swing motor rotates is related to the amount of hydraulic
fluid it receives. 1
1
1
Remove the seat and seat mount. (See Removal And 2

Remove the floor mat. (See Removal And Installation on P-73469

Page 50-20-1.)
Remove the heater. (See Removal And Installation on Remove the bolts (Item 1) and floor access panel (Item 2)
Page 40-90-1.) [Figure 20-90-2].
Remove the right console frame. (See Removal And

IMPORTANT

Remove the control pattern selector valve. (See Removal
And Installation on Page 50-20-1.)
Figure 20-90-1
damage the system.
I-2003-0888
Figure 20-90-3
1
1 1
2 1
P-73070
Remove the bolts (Item 1) and rear floor panel (Item 2) 1

[Figure 20-90-1].
P-73472
Remove the five hoses (Item 1) [Figure 20-90-3].

287 of 726
SWING MOTOR (CONT’D)
Figure 20-90-4
1
1
1
2
P-73473
Remove the four bolts (Item 1) [Figure 20-90-4].

to the bolt threads. Tighten the bolts to 78-85 ft.-lb. (105-
115 N•m) torque.
Remove the swing motor (Item 2) [Figure 20-90-4] from

the excavator.
Figure 20-90-5
P-73474

288 of 726
1. Seal
2. Housing
3. Drive Shaft
4. O-Ring
5. O-Ring
6. Geroler
7. Plate
8. Drive
9. Valve
10. Valve Plate
11. Spring
12. Crossport Relief Valve
7
13. Housing
14. Valve 5
15. Bolt 6
16. Plug
17. Poppet 5

2 3
4
14
12 15
13
5
14
11
1
10 12
17
1 4 16
11
8 9
MS1847S

289 of 726
SWING MOTOR (CONT’D) Figure 20-90-8
Disassembly
Figure 20-90-6
1
2
1
1
P-42252
1
Remove the two O-rings (Item 1) and backup ring (Item

P-42250 2) [Figure 20-90-8].
Mark the housing for ease of assembly.

Remove the crossport relief valves (Item 1) [Figure 20-
90-6]. Figure 20-90-9

Figure 20-90-7
1 1
1 1
P-42254
P-42251
Remove the glid ring (Item 1) [Figure 20-90-7].

290 of 726
1
Figure 20-90-10
P-42256
Remove the O-rings (Item 1) [Figure 20-90-12].

P-42255
Figure 20-90-13
Remove the valve housing (Item 1) [Figure 20-90-10].

Figure 20-90-11
2
2
1
P-42258
Remove the inner seal (Item 1) and outer seal (Item 2)

P-42257 [Figure 20-90-13].
Lift the housing straight up. If done carefully the springs

(Item 1) and balance ring sub-assembly (Item 2) [Figure
20-90-11] will remain on the valve for easy removal.
Remove the springs and balance ring.

291 of 726
Figure 20-90-14
1
P-42261
Remove the valve drive (Item 1) [Figure 20-90-16].

P-42259
Figure 20-90-17
Remove the valve (Item 1) and valve plate (Item 2)

[Figure 20-90-14].

1
Figure 20-90-15
P-42262

geroler.
P-42260
Turn the valve plate over and remove the O-ring (Item 1)
[Figure 20-90-15].

292 of 726
Figure 20-90-18
1
P-42265

P-42263 housing.
Figure 20-90-21
Remove the geroler (Item 1) [Figure 20-90-18].

Figure 20-90-19
1
P-42266
P-42264 Remove the drive shaft (Item 1) [Figure 20-90-21].
Turn the geroler over and remove the O-ring (Item 1)

[Figure 20-90-19].

293 of 726
Figure 20-90-22
2
1 2
P-42267

Use a tap to remove all the old thread adhesive from the
bolt hole threads (Item 2) [Figure 20-90-22].

294 of 726
Assembly
Check the components for damage or wear. 1
Always use new O-rings and seals.
Apply clean hydraulic oil to the components during

installation.
Figure 20-90-23
1
Figure 20-90-26

P-42267
Install the O-ring (Item 1) [Figure 20-90-23]. 1

Figure 20-90-24
P-42264
1
Install the O-ring (Item 1) [Figure 20-90-26] on the
geroler.
P-42266
Install the drive shaft (Item 1) [Figure 20-90-24].

295 of 726
Assembly (Cont’d)
Figure 20-90-27
1
2
P-42261
Install the valve drive (Item 1) [Figure 20-90-29] in the

P-42263 geroler.

Turn the geroler over and install the geroler (Item 1)
[Figure 20-90-27] on the housing. Figure 20-90-30

Timing the hydraulic motor:
The timing parts include: 1

1. Geroler
2. Valve drive
3. Valve plate
4. Valve
Figure 20-90-28
2 1
P-42260
Install the O-ring (Item 1) [Figure 20-90-30] on the valve

4 plate.
P-42268
Align the case drain hole (Item 1) and the pressure relief
hole (Item 2) [Figure 20-90-28] in the geroler with the
case drain hole and pressure relief hole in the housing.
Locate the largest opening in the geroler (Item 3), and

mark the location on the outside edge of the geroler (Item
4) [Figure 20-90-28].

296 of 726
Assembly (Cont’d)
Figure 20-90-31
1 1
2
P-42272
Apply clean grease on the three balance ring assembly

P-42269 springs (Item 1) [Figure 20-90-33] and install the springs
in the holes located inside of the valve housing.
Align the case drain hole (Item 1) in the valve plate (Item Figure 20-90-34
2) [Figure 20-90-31] with the case drain hole in the
geroler. Install the valve plate (seal side toward geroler)

on the geroler.
1
NOTE: Locate the slot opening (Item 3) [Figure 20-90-
31] in the valve plate which is in line with the
largest opening (marked earlier) in the
geroler.
Figure 20-90-32
1
1
P-42273
Install the O-rings (Item 1) [Figure 20-90-34] on the

2 valve housing.
P-42270
Install the valve (Item 1) [Figure 20-90-32].
Locate any one of the side openings of the valve (Item 2)

[Figure 20-90-32] that goes through to the face of the
valve.
Line up this side opening with the open slot of the valve
plate that is in line with the largest opening of the geroler
(marked earlier).
Rotate the valve clockwise until the spline teeth engage

in the valve.

297 of 726
Assembly (Cont’d)
Figure 20-90-35
Outer Outer
Seal Seal
Balance Plate
P-42275
Figure 20-90-38
Pin Inner Seal B-3046
Pin B-8732
‘
Install the inner and outer face seals on the balance ring
[Figure 20-90-35].
1

NOTE: Install the face seals as shown in [Figure 20-
90-35], or the motor will not operate properly.
Any damage to these seals will affect the
operation of the motor.
Figure 20-90-36
P-42255
1 Insert a small screw driver (Item 1) [Figure 20-90-37]

through the port in the housing. Apply pressure to side of
the balance ring assembly until the valve housing is in
place. Align the case drain hole in the housing with the
case drain hole in the valve plate. Install the valve
housing (Item 1) [Figure 20-90-38] against the valve
plate and remove the screwdriver.
NOTE: Check that the O-rings on the motor sections

P-42274 are in place before the bolts are installed. If
the O-rings are out of position the swing
motor will leak between the sections.
Align the balance ring assembly pins with the two holes
in the valve housing, and install the balance ring sub-
assembly (Item 1) [Figure 20-90-36] in the valve
housing.

298 of 726
Assembly (Cont’d)
Figure 20-90-39
1
1
3 2 1
P-42252
2 4
Install the O-rings (Item 1) and backup rings (Item 2)

P-42253 [Figure 20-90-41] on both crossport relief valves.
Figure 20-90-42
Install the four bolts. Tighten the bolts in sequence (Item
1, 2, 3, 4) [Figure 20-90-39] to 63 ft.-lb. (86 N•m) of

torque.
Follow these procedures:
Important: This motor requires Loctite® in threaded 1

holes of the mounting flange.
Figure 20-90-40
P-42251
Install the glid rings (Item 1) [Figure 20-90-42].
P-8418
Adequate Loctite® penetration and sealing depends

highly on cleanliness and dryness of the threads. Use a
non-petroleum base solvent to clean excess oil from
threads of the flange after disassembly. Apply two to
three drops of Loctite® 290 at the top of the threaded
holes [Figure 20-90-40].
NOTE: Allow the Loctite® five minutes for thread

penetration before installing the motor on the
swing motor carrier.

299 of 726
Assembly (Cont’d)
Figure 20-90-43
P-42250
Install the relief valves (Item 1) [Figure 20-90-43].

Figure 20-90-44
P-42278
Clamp the motor in a press. Turn the shaft in a clockwise

direction. If the motor is correctly timed, there will be
suction at the top port (Item 1) [Figure 20-90-44].

300 of 726
SWING MOTOR DRIVE CARRIER Removal And Installation
Description Remove the swing motor. (See Removal And Installation

on Page 20-90-1.)
The swing motor drive carrier is the mating connection
from the swing motor to the swing circle gear. Figure 20-91-1
The swing motor drive carrier contains a shaft that 1

rotates on two tapered roller bearings. The shaft has a 2
gear that turns the upperstructure on the swing circle
gear. Damaged or severely worn bearings can destroy a
swing motor drive carrier and swing motor. 1
2
1 2
1
P-73474
Mark and remove the eight bolts (Item 1) [Figure 20-91-

1].
NOTE: It is necessary to mark the bolts as the bolts

are two different lengths. The bolts must be
installed in the original positions.
Installation: Apply Loctite® 242 to the bolt threads and

tighten the bolts to 78-85 ft.-lb. (105-115 N•m) torque.

301 of 726
SWING MOTOR DRIVE CARRIER (CONT’D)
1. Snap Ring
2. Spacer Bearing
1
3. Bearing
4. Bearing Cup
5. Housing 2
6. Dowel Pin
7. O-Ring
8. Spacer 3
9. Seal
10. Snap Ring
11. Plug
4
12. Shaft

6
6
4
10
11
12
PE-1154

302 of 726
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-3
Disassembly
IMPORTANT
damage the system. 1
I-2003-0888
P-23266
Drain the lubrication oil from the assembly. Tip the carrier
over, allowing the oil to drain through the top bearing. Remove the snap ring (Item 1) [Figure 20-91-3] from the
bottom of the carrier.
Figure 20-91-2
Figure 20-91-4

1
P-23265
P-23267
Remove the snap ring (Item 1) and the spacer (Item 2)

[Figure 20-91-2] from the top of the drive shaft. Support the motor carrier on two support blocks and
press the drive shaft out the bottom of the carrier to
Remove the drain plug (Item 3) [Figure 20-91-2] from the remove the top bearing and bottom seal [Figure 20-91-
bottom of the drive shaft. 4].

303 of 726
Figure 20-91-5
P-23268
Using a hammer and brass punch, remove the bearing

P-6372 cups from the top and bottom of the carrier [Figure 20-
91-7].
Remove the bottom bearing and spacer by supporting Clean all parts in solvent and dry with compressed air.
the spacer and pressing the shaft through it [Figure 20-

91-5]. After cleaning, inspect the following components for
damage and wear:
Figure 20-91-6
Bearings and Bearing Cups
Drive Shaft
Housing
Washer
Spacer
Snap Rings
P-6373
Remove the O-ring located inside the spacer [Figure 20-

91-6].

304 of 726
Assembly
Figure 20-91-8
P-6376
Press the spacer (Item 1) and a new bearing (Item 2)

P-23269 [Figure 20-91-10] on to the drive shaft.
Install the drive shaft with the spacer and the new bearing
Apply a light film of grease to the outside of the new installed, through the bottom of the carrier.
bearing cups, and press the top and bottom cups into the

carrier [Figure 20-91-8]. Figure 20-91-11
Figure 20-91-9
P-23270
P-6373
Press a new bearing on the top of the drive shaft [Figure
20-91-11].
Oil and install a new O-ring inside the spacer [Figure 20-
91-9].

305 of 726
Assembly (Cont’d)
Figure 20-91-12
P-23271
1
Clamp the carrier in a vise that has padded jaws. Thread

P-23265 a bolt in the threaded hole in the carrier flange. Setup a
dial indicator so the end play of the drive shaft can be
checked, by placing a pry bar under the head of the
Install the washer (Item 1) and the snap ring (Item 2) installed bolt and across the end of the drive shaft
[Figure 20-91-12] on the drive shaft. [Figure 20-91-14].

Oil and install a new O-ring on the drain plug. End play should not be more than 0.009 inch (0,229 mm)
and the shaft should rotate smoothly.
Figure 20-91-13
If the end play is greater than 0.009 inch (0,229 mm) the
carrier assembly has to be disassembled and the
following components checked;
Snap Ring 0.078 ± 0.002 inch (1.98 ± 0,05 mm)

1
Washer 0.0178 ± 0.001 inch (4.52 ± 0,03 mm)
Spacer 0.472 ± 0.002 inch (12.0 ± 0,05 mm)
Figure 20-91-15
P-23272
Apply thread adhesive (Loctite® 242) on the plug threads

and install the plug (Item 1) [Figure 20-91-13] in the
bottom of the drive shaft.
3.3189” ± 0.0015”
(84,30 ± 0,038mm)
B-14413
Length of drive shaft from top of snap ring groove to top

of splined section 3.3189 inches ± 0.0015 inch (84,3 ±
0,038 mm) [Figure 20-91-15].

306 of 726
Assembly (Cont’d)
Figure 20-91-16
P-6381
0.765” ± 0.0015”
(19,44 ± 0,038mm) A seal installation tool can be made locally [Figure 20-
B-14412 91-18].
Dimensions of the seal installation tool:

Housing top bearing cup seat to bottom bearing cup seat
0.765 inch ± 0,0015 inch (19.44 ± 0,038 mm) [Figure 20- I.D. 3.250 inch (82,55 mm)

91-16].
O.D. 4.0 inch (101,6 mm)
Height 5.0 inch (127 mm)
Figure 20-91-17
Figure 20-91-19
1
P-23273
P-23266
Install the seal in the bottom of the carrier [Figure 20-91-
17].
Install the bottom snapring (Item 1) [Figure 20-91-19].
After the drive assembly has been installed in the

excavator, fill the carrier with enough hydraulic fluid to
cover the top bearing, before installing the swing motor.

307 of 726

308 of 726
CONTROL PATTERN SELECTOR VALVE Removal And Installation
Description Remove the right console cover. (See Console Cover

Removal And Installation on Page 40-50-1.)
The control pattern selector valve allow the operator to
quickly and easily change the joysticks hydraulic function Remove the right console base. (See Console Base
from ISO control pattern to the Standard control pattern. Cover Removal And Installation on Page 40-50-2.)
The control pattern selector valve in ISO control pattern Mark all hydraulic hoses for proper installation.
selection will allow the left joystick to operate the arm and
the right joystick to operate the boom.
The control pattern selector valve in Standard control

pattern selection will allow the left joystick to operate the IMPORTANT
boom and the right joystick to operate the arm.
damage the system.
I-2003-0888
Figure 20-100-1

1
2
P-73466
Remove the two bolts (Item 1) [Figure 20-100-1] from

the rear of the valve.
Remove the eight hydraulic hose from the control pattern

selector valve (Item 2) [Figure 20-100-1].
Remove the control pattern selector valve from the

excavator.

309 of 726
CONTROL PATTERN SELECTOR VALVE (CONT’D)
1. Handle
2. Roll Pin
3. Snap Ring
4. Spool
5. O-Ring
6. Valve Block
7. Washer
3
7
6

1
2
3
2
5
TS-1353A

310 of 726
CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-4
Disassembly and Assembly
Clean the outside of the valve before disassembly.
Figure 20-100-2
1
1 2
P-73380
Remove the wave washer (Item 1) and the spool (Item 2)

1 [Figure 20-100-4].
P-73382 Figure 20-100-5

Remove all the fittings (Item 1) [Figure 20-100-2].
Figure 20-100-3 1 1
P-73381
1
spool.
P-73383
Installation: Clean all parts in solvent and dry with
compressed air. Inspect all parts for wear or
Remove the snap ring (Item 1) [Figure 20-100-3]. damage. Replace any worn or damaged parts.
Always install new seals and O-rings. Lubricate
all seals and O-rings with clean hydraulic fluid
before installation.

311 of 726

312 of 726
RIGHT CONTROL LEVER (JOYSTICK) Figure 20-110-3
Description
The right control lever (joystick) operates using pilot

pressure to move the boom and/or bucket spools in the 1
control valve.
Testing
The following tools will be needed to do the procedure:
MEL1355 - Hydraulic Test Kit
Stop the engine.

P-73386
Figure 20-110-1
1 Disconnect the hydraulic hose (Item 1) [Figure 20-110-3]

from the control valve.
Figure 20-110-4

1
P-69925
Open the right side cover (Item 1) [Figure 20-110-1].
Figure 20-110-2 P-73385
From the test kit Install a 500 PSI (35 bar) gauge (Item 1)
[Figure 20-110-4] on the pilot line. Start the excavator,
and warm the hydraulic oil to operating temperature.
Engage the circuit to be tested. Record the operating

pressure.
The operating pressure should be approximately 435 PSI

(30 bar).
If the operating pressure is correct, check the valve

section spool for proper operation. If the operating
P-73104 pressure is incorrect, remove the pressure reducing
valve, clean, install and retest. (See Testing And
Adjusting The Pressure Reducing Valve on Page 20-33-
At the control valve assembly [Figure 20-110-2], find the 1.)
pilot line of the control lever (joystick) that is to be
checked. (Boom, Arm, Slew, Bucket) If the pressure is still incorrect replace the pressure
reducing valve. (See Testing And Adjusting The Pressure
Reducing Valve on Page 20-33-1.)

313 of 726
RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-7
Handle Removal And Installation
Figure 20-110-5
1
P-50874
Remove the screw (Item 1) [Figure 20-110-7] from the

P-50876 cup holder.
Figure 20-110-8
Remove the cover (Item 1) [Figure 20-110-5] from the
arm rest.

Figure 20-110-6
1
1
P-50873
Remove the nut (Item 1) [Figure 20-110-8] from the key

P-50875 switch. Allow the keyswitch to drop inside the console.
Lift the console cover up and over the joystick.

the arm rest.
Remove the arm rest.

314 of 726
Handle Removal And Installation (Cont’d)
Figure 20-110-9
P-21732
Turn the controller to allow it to pass through the console

P-50872 cover [Figure 20-110-11].
Figure 20-110-12
Installation: Install the keyswitch and nut (Item 1)
[Figure 20-110-9] before installing the controller.

Figure 20-110-10
1
1
P-52068
Disconnect the electrical connector (Item 1) [Figure 20-

P-21730 110-12] from the excavator wiring harness.
Disconnect the accessory outlet electrical connector

(Item 1) [Figure 20-110-10].
Depress the four tabs (Item 2) [Figure 20-110-10] and

remove the controller.

315 of 726
Figure 20-110-13
P-21668
Installation: The wires [Figure 20-110-15] must be

P-21666 installed in the proper locations in the wire connector,
listed below.
Remove the lock (Item 1) [Figure 20-110-13] from the A Green

electrical connector. B Brown

C Pink
Figure 20-110-14 D Black
E White
Check each wire to be certain the tab locks into position.
2 Figure 20-110-16
1
P-21671S 1
With a small piece of wire, depress the wire terminal tabs

(Item 1) [Figure 20-110-14]. 2
P-52069
Carefully remove the individual wires from the back of the
electrical connector.
Pull the boot (Item 1) [Figure 20-110-16] up.
Installation: Use a small piece of wire and re-bend the
tab (Item 2) [Figure 20-110-14]. on each wire before Installation: The top of the boot is molded to fit over the
installing the electrical connector. flange of the joystick. It has tabs that fit between the
handle and joystick flange (Item 2) [Figure 20-110-16].
Install the boot properly before installing the console
cover.

316 of 726
Figure 20-110-17
2
1
1
P-32521
Pull the boot (Item 1) [Figure 20-110-19] down.

P-52070
Installation: The top of the boot is molded to fit over the
flange of the joystick. It has tabs that fit between the
Lift the grommet (Item 1) [Figure 20-110-17] from the handle and joystick flange (Item 2) [Figure 20-110-19].
mount plate. Install the boot properly before installing the console

cover.
Figure 20-110-18
Figure 20-110-20
1 1
P-33820
P-32521
Remove the wire and grommet (Item 1) [Figure 20-110-

18]. Loosen the nut (Item 1) [Figure 20-110-20].
Remove the handle.

317 of 726
Figure 20-110-21
P-50874

P-50876 cup holder.
Figure 20-110-24
arm rest.

Lift up on the rear of the cover and slide the cover ahead
to remove it.
Figure 20-110-22
1 1
P-50873
Remove the nut from the key switch (Item 1) [Figure 20-
110-24] (if equipped). Allow the switch to drop inside the
1 console.
P-50875 Lift the console up and over the joystick.

the arm rest. Remove the arm rest.

318 of 726
Figure 20-110-25
P-21732
1

P-50872 cover [Figure 20-110-27].
Remove the console cover.

Installation: Install the keyswitch and nut (Item 1)
[Figure 20-110-25] before installing the controller. Figure 20-110-28

Figure 20-110-26
1
1
P-33821
P-21730
Mark the hoses for proper installation. Remove the six
hoses (Item 1) [Figure 20-110-28] from the housing.
(Item 1) [Figure 20-110-26].
Remove the controller from the console cover by

pressing the mounting tabs (Item 2) [Figure 20-110-26]. IMPORTANT
damage the system.
I-2003-0888

319 of 726
RIGHT CONTROL LEVER (JOYSTICK) (CONT'D)
Figure 20-110-29
1
3
3
2 P-52070
Pull the boot (Item 1) [Figure 20-110-29] up.

Installation: The bottom of the boot is molded to fit over
the flange of the joystick. It has tabs that fit between the
joystick flange (Item 2) [Figure 20-110-29] and the
mounting plate. Position the boot properly before
installing the console cover.
Remove the four mount bolts (Item 3) [Figure 20-110-29]

from the housing.
Figure 20-110-30
P-52068

(Item 1) [Figure 20-110-30].
Remove the joystick assembly.

320 of 726
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)
1. Handle
2. Dust Boot
3. Coupler
4. Control Plate
5. U-Joint
6. Grommet 1
7. Plate
8. Plunger
9. Spool
10. Spring
11. Housing
12. Wire Harness 2
13. Lock
14. Connector
4
6

5
10
11
12
13
14
MS-1352

321 of 726
Disassembly
Remove the right handle. (See Handle Removal And

2
Clean the outside of the control lever before disassembly.
Figure 20-110-31
1
1
P-32576
Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-110-33].
Figure 20-110-34

P-32560 1
Remove the boot (Item 1) [Figure 20-110-31].

2
Figure 20-110-32
3
2
3
P-32574
1
Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-110-34] for ease of assembly.
P-32568
Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-110-32] for correct assembly.

322 of 726
Disassembly (Cont'd)
1
Figure 20-110-35
1 2
P-32578
Mark the plate and housing for correct installation.

P-32574 Remove the U-joint (Item 1) [Figure 20-110-37].
NOTE: The plate (Item 2) [Figure 20-110-37] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-joint is
2) [Figure 20-110-35]. removed.

Figure 20-110-36 Figure 20-110-38
2
1
1
2
P-32577 P-32582
Remove the control plate (Item 1) from the U-Joint (Item Remove the plate (Item 1) [Figure 20-110-38].
2) [Figure 20-110-36].
NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-110-38] are spring
loaded.

323 of 726
1
Figure 20-110-39
P-32588
Remove the spool assemblies (Item 1) [Figure 20-110-

P-32583 41].
Figure 20-110-42
Remove the plunger assemblies (Item 1) [Figure 20-110-
39].

Figure 20-110-40 1
1
2
3
P-32591
Compress the spring (Item 1) and remove the seat (Item

P-32587 2) [Figure 20-110-42].
Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-110-40].

324 of 726
1
Figure 20-110-43 1
2 1
P-32579
Remove the two bolts (Item 1) [Figure 20-110-45].

P-32590
Figure 20-110-46
Remove the spring (Item 1) and shim (Item 2) from the 1

spool (Item 3) [Figure 20-110-43].

Figure 20-110-44
P-32593
Remove the end cap (Item 1) [Figure 20-110-46].
P-32592
Remove the springs (Item 1) [Figure 20-110-44] from the

housing.
Clamp the housing in a vise that is equipped with padded

jaws.

325 of 726
Figure 20-110-47
P-32594
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

110-47].

326 of 726
Assembly 1

or damaged parts.

Figure 20-110-48
P-32593
1
2
Install the end cap (Item 1) [Figure 20-110-49].
Figure 20-110-50

1 1
P-32594
Clamp the housing in a vise equipped with padded jaws.

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
110-48].
P-32580
Install the two bolts (Item 1) [Figure 20-110-50].
Turn the housing over.

327 of 726
Assembly (Cont'd)
Figure 20-110-51 2
P-32591
Compress the spring (Item 1) and install the spring seat

P-32592 (Item 2) [Figure 20-110-53].
Figure 20-110-54
Install the springs (Item 1) [Figure 20-110-51].

Figure 20-110-52
1
2
P-32588
P-32590 Install the spool assemblies (Item 1) [Figure 20-110-54]

into the housing.
Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-110-52].

328 of 726
Assembly (Cont'd)
1
Figure 20-110-55
1
2
P-32583
Install the plunger assemblies (Item 1) [Figure 20-110-

P-32586 57] into the housing.
Figure 20-110-58
Install the plunger (Item 1) into the bushing (Item 2)
[Figure 20-110-55].

Figure 20-110-56 1
P-32582
Install the plate (Item 1) [Figure 20-110-58].

P-32584
NOTE: Spring pressure can dislodge the plunger
assemblies until the plate is secured in place.
bushing.

329 of 726
Assembly (Cont'd)
1
Figure 20-110-59
3 2
P-32574
Align the coupler (Item 1) with the control plate (Item 2)

P-32578 and plate (Item 3) [Figure 20-110-61]. Tighten the
coupler.
Press down on the plate (Item 1) keeping the plunger Figure 20-110-62
assemblies (Item 2) fully seated and install the U-joint

(Item 3) [Figure 20-110-59].
1
Figure 20-110-60 3
1
2
P-32573
2
Install the connector (Item 1) [Figure 20-110-62].

P-32577
Align the connector with the coupler (Item 2) and tighten
the nut (Item 3) [Figure 20-110-62].
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-110-
60].

330 of 726
Assembly (Cont'd)
Figure 20-110-63
P-32560
Install the tabs of the boot in between the joystick flange

and mounting plate (Item 1) [Figure 20-110-63].

Install the handle. (See Handle Removal And Installation
on Page 20-110-2.)

331 of 726

332 of 726
LEFT CONTROL LEVER (JOYSTICK) Figure 20-111-3
Description
The left control lever (joystick) operates using pilot

pressure to move the arm and/or slew spools in the
control valve. The left control lever (joystick) will be 1
moveable in a canopy or cab equipped excavator. The
left control lever (joystick) has a microswitch which will
lockout the hydraulic functions in the raised position and
enable the hydraulic functions in the down (locked)
position.
Testing
The following tools will be needed to do the procedure:
P-73388
MEL1355 - Hydraulic Test Kit
Stop the engine.
Disconnect the hydraulic hose (Item 1) [Figure 20-111-3]
Figure 20-111-1 from the control valve.
1 Figure 20-111-4

1
P-69925
Open the right side cover (Item 1) [Figure 20-111-1]. P-73387
Figure 20-111-2
From the test kit Install a 1000 PSI (69 bar) gauge (Item
1) [Figure 20-111-4] on the pilot line.
Start the excavator, and warm the hydraulic oil to

operating temperature of 150° F (66° C).
Engage the circuit to be tested. Record the operating

pressure.
The operating pressure should be approximately 435 PSI

(30 bar) with an acceptable range of 406-450 PSI (28-31
bar).
If the operating pressure is correct, check the valve

P-73104 section spool for proper operation. If the operating
pressure is incorrect, remove the pressure reducing
valve, clean, install and retest. If the pressure is still
At the control valve assembly [Figure 20-111-2], find the
incorrect replace the pressure reducing valve.
pilot line of the control lever (joystick) that is to be
checked. (Boom, Arm, Slew, Bucket.)

333 of 726
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-7
Handle Removal And Installation
Figure 20-111-5
1 1
P-21737
1
P-21734 arm rest.

Remove the seven mounting bolts (Item 1) [Figure 20-
111-5] from the lower half of the operator console. Raise the top of the console cover.

Remove the bottom of the console. Figure 20-111-8
Lower the console.
Figure 20-111-6
1
1
P-21738
Disconnect the wire harness (Item 1) [Figure 20-111-8].

P-21736
NOTE: These connectors are keyed so they can be
plugged in only one way.
arm rest. Remove the console cover.

334 of 726
Figure 20-111-9
1
2
P-32914
1
Using a small piece of wire, depress the wire terminal
P-33832 tabs (Item 1) [Figure 20-111-11].
Carefully remove the individual wires from the back of the

Disconnect the wire harness (Item 1) [Figure 20-111-9]. electrical connector.

Figure 20-111-10 Remove the control handle (joystick) assembly from the
excavator.
1
Installation: Use a small piece of wire and rebend the
tab on each wire before installing it in the electrical
connector.
Figure 20-111-12
P-32915
Remove the lock (Item 1) [Figure 20-111-10] from the

electrical connector.
1
P-32916
Installation: The wires [Figure 20-111-12] must be

installed in the proper locations in the wire connector,
listed below.
C Red
D Black
Check each wire to be certain the tab (Item 1) [Figure

20-111-12] locks into position.

335 of 726
Figure 20-111-13
1 1
3
P-32521
2
Remove the boot (Item 1) [Figure 20-111-15] from the
P-32513 joystick handle.
Installation: Align the top of the dust boot (Item 1) with

Raise the boot (Item 1) and pull the grommet (Item 2) up the groove (Item 2) [Figure 20-111-15].
[Figure 20-111-13].

Hold the boot down and loosen the nut (Item 3) [Figure
Figure 20-111-14 20-111-15].
Remove the handle.
P-32517
Remove the grommet and wire (Item 1) [Figure 20-111-

14] from the mount plate.

336 of 726
Figure 20-111-16
1 1
P-21737
1
P-21734 arm rest.

111-16] from the bottom of the operator console. Raise the top of the console cover.

Remove the bottom of the console cover. Figure 20-111-19
Lower the console.
Figure 20-111-17
1
1
P-21738

P-21736
arm rest. Remove the console cover.

337 of 726
Figure 20-111-20 1
2
2
P-32513
1
Pull the boot (Item 1) [Figure 20-111-22] up from the
P-33832 mounting plate.

Disconnect the wire harness (Item 1) [Figure 20-111-20]. mounting plate.

Figure 20-111-21 Remove the joystick assembly.
P-33834
Mark and remove the hoses [Figure 20-111-21].
IMPORTANT
damage the system.
I-2003-0888

338 of 726
LEFT CONTROL LEVER (JOYSTICK) (CONT’D)
1. Handle
2. Boot
3. Coupler
4. Control Plate
5. U-Joint
6. Grommet 1
7. Plate
8. Plunger
9. Spool
10. Spring
11. Housing
12. Wire Harness
13. Lock 2
14. Pin
15. Connector
3
4
6

5
10
11
12
13
14
15
MS1354

339 of 726
Disassembly
Remove the left handle. (See Handle Removal And 2

Clean the outside of the control lever before disassembly.
Figure 20-111-23
1
1
P-32576
Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-111-25].
Figure 20-111-26
1

P-32560
2
Remove the boot (Item 1) [Figure 20-111-23].
Figure 20-111-24
2 3
3
1 P-32574
Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-111-26] for ease of assembly.
P-32568
Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-111-24] for ease of assembly.

340 of 726
1
Figure 20-111-27
1 2
P-32578
Mark the plate and housing for correct installation.

P-32574 Remove the U-joint (Item 1) [Figure 20-111-29].
NOTE: The plate (Item 2) [Figure 20-111-29] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-joint is
2) [Figure 20-111-27]. removed.

Figure 20-111-28 Figure 20-111-30
2
1 1
P-32577 P-32582
Remove the control plate (Item 1) from the U-joint (Item Remove the plate (Item 1) [Figure 20-111-30].
2) [Figure 20-111-28].
NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-111-30] are spring
loaded.

341 of 726
1
Figure 20-111-31
P-32588
Remove the spool assemblies (Item 1) [Figure 20-111-

P-32583 33].
Figure 20-111-34
31].

1
Figure 20-111-32
1
2
3
P-32591
Compress the spring (Item 1) and remove the seat (Item

P-32587 2) [Figure 20-111-34].
Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-111-32].

342 of 726
1
Figure 20-111-35 1
2
1
P-32579
Clamp the housing in a vise that is equipped with padded

P-32590 jaws [Figure 20-111-37].

Remove the spring (Item 1) and shim (Item 2) from the
spool (Item 3) [Figure 20-111-35]. Figure 20-111-38

Figure 20-111-36
1
P-32593
P-32592
Remove the end cap (Item 1) [Figure 20-111-38].
Remove the springs (Item 1) [Figure 20-111-36] from the

housing.

343 of 726
Figure 20-111-39
P-32594

111-39].

344 of 726
Assembly
1

or damaged parts.

Figure 20-111-40
P-32593
1 2
Install the end cap (Item 1) [Figure 20-111-41].
Figure 20-111-42

1
1
P-32594
Clamp the housing in a vise equipped with padded jaws.

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
111-40].
P-32580
Install the bolts (Item 1) [Figure 20-111-42].
Turn the housing over.

345 of 726
Assembly (Cont’d)
Figure 20-111-43 2
P-32591
Compress the spring (Item 1) and install the spring seat

P-32592 (Item 2) [Figure 20-111-45].
Figure 20-111-46
Install the springs (Item 1) [Figure 20-111-43].
1

Figure 20-111-44
1
2
P-32588
P-32590 Install the spool assemblies (Item 1) [Figure 20-111-46]

into the housing.
Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-111-44].

346 of 726
Assembly (Cont’d)
1
Figure 20-111-47
1
2
P-32583
Install the plunger assemblies (Item 1) [Figure 20-111-

P-32586 49] into the housing.
Figure 20-111-50
Install the plunger (Item 1) into the bushing (Item 2)
[Figure 20-111-47].

1
Figure 20-111-48
P-32582

P-32584
NOTE: Spring pressure can dislodge the plunger
assemblies until the plate is secured in place.
bushing.

347 of 726
Assembly (Cont’d) 1
Figure 20-111-51
3 2
3
2
P-32574
Align the coupler (Item 1) with the control plate (Item 2)

P-32578 and plunger (Item 3) [Figure 20-111-53]. Tighten the
coupler.
Press down on the plate (Item 1) keeping the plunger Figure 20-111-54
assemblies (Item 2) fully seated and install the U-joint

(Item 3) [Figure 20-111-51].
1 3
Figure 20-111-52
1
2
P-32573
2
Install the connector (Item 1) [Figure 20-111-54].
P-32577
Align the connector with the coupler (Item 2) and tighten
the nut (Item 3) [Figure 20-111-54].
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-111-52].

348 of 726
Assembly (Cont’d)
Figure 20-111-55
P-32560
Install the tabs of the boot in between the joystick flange

and the mounting plate (Item 1) [Figure 20-111-55].

Install the handle. (See Handle Removal And Installation
on Page 20-111-2.)

349 of 726

350 of 726
TRAVEL CONTROL VALVE
Removal and Installation
Remove the floor mat and floor plates. (See Removal

IMPORTANT
Figure 20-112-1 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
Figure 20-112-3
P-73390

Remove the linkage nuts (Item 1) [Figure 20-112-1].
(Both sides)
Figure 20-112-2 MS2052
Installation: Install the hoses on the correct port [Figure

20-112-3].
Remove the travel control valve from the excavator.
2
1
P-73389
Mark the hydraulic hoses for proper installation.
Remove the ten hydraulic hoses (Item 1) [Figure 20-112-

2] from the travel control valve.
Remove the three bolts and nuts (Item 2) [Figure 20-

112-2] from the travel control valve.
Lower the valve.

351 of 726
TRAVEL CONTROL VALVE (CONT'D)
1. Dust Boot
2. Coupler
3. Control Plate
4. Swivel Joint
5. Plate
6. Plunger Assembly
7. Spool Assembly
8. Spring
9. Housing 1

4
MS1351S

352 of 726
TRAVEL CONTROL VALVE (CONT'D) Figure 20-112-6
Clean the outside of the travel control valve before 1

disassembly.
1
Mark the outside of the travel control valve for ease of
assembly.
1
Figure 20-112-4
1
P-50920
1

6] from the housing.
NOTE: Install the plunger assemblies in the same

bore from which they are removed.

Figure 20-112-7
P-50918
Remove the swivel joint (Item 1) [Figure 20-112-4].
Figure 20-112-5
2
1
3
P-50921
Remove the plunger (Item 1) from the plunger body (Item

2) [Figure 20-112-7].
P-50919 Remove the O-ring (Item 3) [Figure 20-112-7].
Remove the plate (Item 1) [Figure 20-112-5].

353 of 726
TRAVEL CONTROL VALVE (CONT'D) Figure 20-112-10
Disassembly And Assembly (Cont'd)
Figure 20-112-8
4
3 2
1
P-50924
Remove the piston (Item 1), spring (Item 2) and washer

P-50922 (Item 3) from the spool (Item 4) [Figure 20-112-10].
Figure 20-112-11
Remove the 4 spool assemblies (Item 1) [Figure 20-112-
8].

NOTE: Install the spool assemblies in the same bore
from which they are removed.
Figure 20-112-9
1
P-50925
Remove the 4 centering springs (Item 1) [Figure 20-112-

11].
P-50923
Compress the spring (Item 1) [Figure 20-112-9].

354 of 726
TRAVEL CONTROL VALVE (CONT'D) Assembly
Disassembly And Assembly (Cont'd) Clean all parts in solvent and dry with compressed air.
Figure 20-112-12 Inspect all parts for wear or damage. Replace any worn
or damaged parts.

1 1
P-50926

Separate the housing sections.
Figure 20-112-13
P-50927

112-13] from the housing.

355 of 726

356 of 726
HYDRAULIC FILTER Housing Removal And Installation
Description
The hydraulic filter removes contaminants from the

hydraulic fluid when the hydraulic systems are operating. IMPORTANT
The hydraulic filter system consists of one main hydraulic When repairing hydrostatic and hydraulic systems,
filter located under the tailgate and removes the clean the work area before disassembly and keep all
contaminants after the oil cooler. parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Open the tailgate.
Figure 20-120-1

1
P-73272
Remove and cap the two hoses (Item 1) [Figure 20-120-

1].

357 of 726
HYDRAULIC FILTER (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-120-2
P-73273
Remove the bolts (Item 1) [Figure 20-120-2] and support

the hydraulic housing filter.

Figure 20-120-3
1
2
P-73274
Disconnect and remove the wire harness (Item 1)

[Figure 20-120-3].
Remove the wire harness (Item 2) [Figure 20-120-3]

from the sending unit.
Remove the hydraulic filter.

358 of 726
CASE DRAIN FILTER Removal And Installation
Description
The case drain filter removes contaminants from the case

drain fluid when the hydraulic systems are operating. IMPORTANT
The case drain filter system consists of one main When repairing hydrostatic and hydraulic systems,
hydraulic filter located under the right side cover below clean the work area before disassembly and keep all
the hydraulic reservoir. parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888

Figure 20-121-1

2 1
P-73001
Remove the hose (Item 1) [Figure 20-121-1].
Remove the case drain filter (Item 2) [Figure 20-121-1].

359 of 726

360 of 726
HYDRAULIC RESERVOIR Removal And Installation
Description Drain the reservoir. (See Removing And Replacing The

Hydraulic Fluid on Page 10-100-3.)
The hydraulic reservoir is a storage container for the
excavators hydraulic fluid. The reservoir contains a Open the right side cover and tailgate.
vented fill cap with a fluid screen to prevent contaminants
from entering the reservoir while adding fluid. Figure 20-130-1
The hydraulic reservoir is located behind the tailgate on

the left side of the excavator.
1
2
1
P-73397

Remove and cap the hoses (Item 1) [Figure 20-130-1].
Remove the case drain filter (Item 2) [Figure 20-130-1].
Figure 20-130-2
2
P-73398
Remove the suction hose (Item 1) [Figure 20-130-2].
Remove the drain hose (Item 2) [Figure 20-130-2].

361 of 726
HYDRAULIC RESERVOIR (CONT’D)
Figure 20-130-3
P-73399
Remove the bolt and hose clamp (Item 1) [Figure 20-

130-3] from the side of the reservoir.

Installation: Tighten the bolt to 10 ft.-lb. (7,4 N•m)
torque.
Figure 20-130-4
P-73396
Remove the hydraulic reservoir (Item 2) [Figure 20-130-

4].

362 of 726
OIL COOLER Removal And Installation
Description
The oil cooler is used to cool the excavators hydraulic

fluid. Oil passages are coiled into a heat exchanger. The IMPORTANT
air is forces around these passages cooling the oil.
damage the system.
I-2003-0888
Open the tailgate.

Figure 20-140-1

2
1
P-69941
Remove the four screws (Item 1) and remove the left side
cover (Item 2) [Figure 20-140-1].

363 of 726
OIL COOLER (CONT’D) Figure 20-140-4
Figure 20-140-2
1 1
1
P-73401

P-69942 the top of the oil cooler.
Remove the oil cooler from the rear of the excavator.

Remove and cap the hoses (Item 1) [Figure 20-140-2]
from the top of the oil cooler.

Figure 20-140-3
P-73400
Remove the bolt (Item 1) [Figure 20-140-3] from the

bottom of the oil cooler.

364 of 726
DIRECT TO TANK VALVE Figure 20-150-2
Desciption
The direct to tank valve provides a minimal back

pressure route for the auxiliary return oil back to the
hydraulic tank. This valve is only needed when the
excavator is equipped with certain attachments.
The direct to tank valve is located under the right side

cover bolted to the upperstructure.

1
Replacing The Hydraulic Fluid on Page 10-100-3.) P-73417

Remove the two nuts (Item 1) [Figure 20-150-2]
fastening the direct to tank valve to the excavator frame.
IMPORTANT Figure 20-150-3

damage the system.
I-2003-0888
Figure 20-150-1
1
P-73405
Remove direct to tank valve and bracket assembly from

the excavator and remove the hose (Item 1) [Figure 20-
150-3].
1 Remove the direct to tank valve and bracket assembly

from the excavator.
P-73418
Remove the two tubelines (Item 1) [Figure 20-150-1].

365 of 726
DIRECT TO TANK VALVE (CONT’D)
1 Control Knob
2 Washer
3 Snap Ring
4 Spool
5 O-Ring
6 Housing

3
3 6
4
2 5
5
1
b-13660

366 of 726
DIRECT TO TANK VALVE (CONT’D) Figure 20-150-6

1
Clean the outside of the direct to tank valve before
disassembly.
Figure 20-150-4
N-23863
Remove the snap ring (Item 1) [Figure 20-150-6].
2 Figure 20-150-7
1
P-73406

Remove the mount bracket bolts (Item 1) [Figure 20-
150-4]. 1
Remove the mount bracket (Item 2) [Figure 20-150-4]

from the valve.
Figure 20-150-5
1
N-23864
Remove the spool (Item 1) [Figure 20-150-7] from the

valve.
P19996
Remove the control knob (Item 1) [Figure 20-150-5] from

the valve spool.

367 of 726
DIRECT TO TANK VALVE (CONT’D)
Figure 20-150-8
1
N-23865
Remove the O-rings (Item 1) [Figure 20-150-8].


or damaged parts.
Always install new O-rings. Lubricate the spool, valve

spool bore and O-rings with clean hydraulic fluid before
installation.

368 of 726
NON-PRESSURIZED ACCUMULATOR
Desciption
The non-pressurized accumulator is installed on the load

sense line on the end of the control valve to hold a
specific volume of hydraulic fluid for proper control of
functions.
IMPORTANT
damage the system.
I-2003-0888

Figure 20-160-1
P-73500
Remove the non-pressurized accumulator (Item 1)

[Figure 20-160-1].

369 of 726

370 of 726
HYDRAULIC X-CHANGE VALVE Figure 20-150-2

1
1
IMPORTANT
parts clean. Always use caps and plugs on hoses, 2 2
damage the system.
P-77574
I-2003-0888
Lower the boom and blade to the ground. Remove the hoses (Item 1) from the A & B ports (Item 2)
[Figure 20-150-2] of the X-change valve.
move both control levers to relieve hydraulic pressure. Figure 20-150-3

Remove the battery. (See Removal And Installation on
Page 50-20-1.)
Mark all hoses for proper installation.

1
Figure 20-150-1
2
P-77573
Remove the hoses (Item 1) from the P port (Item 2)

1
P-77575
Remove the hose (Item 1) from the T port (Item 2)


371 of 726
HYDRAULIC X-CHANGE VALVE (CONT’D) Figure 20-150-6
Figure 20-150-4
1 1 P-77571
Remove the two nuts (Item 1), bolts and the X-change
2 P-77555 valve (Item 2) [Figure 20-150-6].
Remove the hose (Item 1) from the LS port (Item 2)


Figure 20-150-5
1
1
2
2
P-71932
Disconnect the two harness connectors (Item 1) from the

solenoid connectors (Item 2) [Figure 20-150-5] on the X-
change valve.
NOTE: Mark the wire connectors for correct

installation.

372 of 726
HYDRAULIC X-CHANGE VALVE (CONT'D)
1
1. Nut
2. Solenoid
3. Spool
4. O-Ring
5. Actuator Assembly 2
6. Plug
7. Valve
8. Poppet
9. Flat Washer 2
10. Spring
11. Screen
12. Snap Ring
13. Ball

4
4 5
10
6
9 4
8 10
13
7
11 4
12
6
4
8
9 6
10
6
MS-1461S

373 of 726
Disassembly
Figure 20-150-7
P-77579
1 Remove the spool (Item 1) [Figure 20-150-9].

P-77459
Figure 20-150-10
Remove the nut (Item 1) [Figure 20-150-7].

Figure 20-150-8
P-71192
1
P-77578
Remove the two solenoids (Item 1) [Figure 20-150-8].
NOTE: Mark the solenoids for correct assembly.

374 of 726
Figure 20-170-11
1
P-77198

P-77580 fitting.
Figure 20-170-14
Remove the actuator assembly (Item 1) [Figure 20-170-
11].

Figure 20-170-12
1
1
P-71198

P-71196
Remove the fitting (Item 1) [Figure 20-170-12].

375 of 726
Figure 20-150-15
P-77586

P-71199
Figure 20-170-18

plug.

Figure 20-170-16
3
2 P-71197
1
fitting.
P-71409
Remove the spring (Item 1), flat washer (Item 2) and

poppet (Item 3) [Figure 20-170-16].

376 of 726
Figure 20-150-19
P-77590
1

P-77585 fitting.
Figure 20-170-22
Remove the snap ring (Item 1) and screen (Item 2) from
the “S” port (Item 3) [Figure 20-150-19].

Figure 20-150-20
P-77604
1
P-77587

377 of 726
Figure 20-150-23
P-77198

P-77590 fitting.
Figure 20-170-26
fitting.

Figure 20-170-24
1
1
P-71210

P-77589

378 of 726
Figure 20-150-27
1
-P-71215

P-71212
Figure 20-170-30

plug.

Figure 20-170-28
1
2
3 1
P-71216

plug.
P-71214
Remove the spring (Item 1), flat washer (Item 2) and

poppet (Item 3) [Figure 20-170-28].

379 of 726
Figure 20-150-31
3
1
1
P-71219
Remove the spring (Item 1) and ball (Item 2) from port 5

P-71217 (Item 3) [Figure 20-170-33].
Figure 20-170-34

Figure 20-170-32
P-71220
1
P-71218 Remove the plug (Item 1) [Figure 20-170-34].

plug.

380 of 726
HYDRAULIC X-CHANGE VALVE (CONT’D)
Figure 20-150-35
P-71221

plug.

381 of 726
Assembly

or damaged parts.

and O-rings with clean hydraulic fluid before installation. 1
Figure 20-170-36
2
P-71219
Install the ball (Item 1) and spring (Item 2) into port 5

(Item 3) [Figure 20-170-38].
Figure 20-170-39

1
P-71221
Install the O-ring (Item 1) [Figure 20-170-36] on the plug.
Figure 20-170-37
P-71218
1
P-71220
Install the plug (Item 1) [Figure 20-170-37].

382 of 726
Assembly (Cont'd)
Figure 20-170-40
1
P-71215

P-71217
Figure 20-170-43

Figure 20-170-41
P-71214
1
Install the poppet (Item 1), flat washer (Item 2) and spring
P-71216 (Item 3) [Figure 20-170-43].

383 of 726
Assembly (Cont'd)
Figure 20-170-44
P-71209
1

P-71212 fitting.
Figure 20-170-47

Figure 20-170-45
75891208
1
P-71210 Install the fitting (Item 1) [Figure 20-170-47].

384 of 726
Assembly (Cont'd)
Figure 20-170-48
1
P-77590

P-77590 fitting.
Figure 20-170-51
fitting.

Figure 20-170-49
1
P-77587
Install the fitting (Item 1) [Figure 20-170-51].

P-71207

385 of 726
Assembly (Cont'd)
Figure 20-170-52
P-77586
2

P-77585
Figure 20-170-55
Install the screen (Item 1) and the snap ring (Item 2) into
the “S” port (Item 3) [Figure 20-170-52].

Figure 20-170-53
P-71409
1
Install the poppet (Item 1), flat washer (Item 2) and spring
(Item 3) [Figure 20-170-55].
P-71197

fitting.

386 of 726
Assembly (Cont'd)
Figure 20-170-56
1
1
P-77198

P-71199 fitting.
Figure 20-170-59

Figure 20-170-57
P-71196
1
P-71198 Install the fitting (Item 1) [Figure 20-170-59].

387 of 726
Assembly (Cont'd)
Figure 20-170-60
1
P-77579
Install the spool (Item 1) [Figure 20-170-61].

P-77580
Figure 20-170-63
Install the actuator assembly (Item 1) [Figure 20-170-

60].

Figure 20-170-61
1
P-71190
Install the solenoids (Item 1) [Figure 20-170-63].
P-71192
Install the O-ring (Item 1) [Figure 20-150-62] from the

spool.

388 of 726
HYDRAULIC X-CHANGE VALVE (CONT’D)
Assembly (Cont'd)
Figure 20-150-64
P-71189

Do not overtighten.

389 of 726

390 of 726
UNDERCARRIAGE
BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
SWING CIRCLE GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

TRACK FRAME COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 UNDERCARRIAGE

Adjusting Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Checking Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Coil Spring Assembly And Cylinder Disassembly And Assembly 30-20-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Idler (Front) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-15
Idler (Front) Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-13
Idler (Front) Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-12
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . 30-20-11
Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-23
Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-21
Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-20

Roller Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-19
Rubber Track Removal And Installation. . . . . . . . . . . . . . . . . . . . . 30-20-5
Steel Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 30-20-8
Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-26
Track Guide Removal And Installation. . . . . . . . . . . . . . . . . . . . . 30-20-25
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

391 of 726

392 of 726
BLADE Removal And Installation
Description Lower the blade and bucket to the ground.
The blade is used for backfilling and stabilizing the Remove the blade cylinder. (See Removal And
excavator during excavating operation. The blade is Installation on Page 20-24-3.)
hydraulically raised or lowered by use of a sinlge cylinder
controlled by the blade lever in the cab or canopy. Figure 30-10-1
P-22607

washer from the blade arm pivot pin (both sides).
Figure 30-10-2
P-22608
Remove the blade arm pivot pin (Item 1) [Figure 30-10-

2] (both sides).
Remove the blade.

393 of 726

394 of 726
TRACK FRAME COMPONENTS Track Lug Height
Description Rubber Track
The track frame consists of front idler, track rollers, track, The lug height of a new rubber track is 0.984 inch (25,0
drive sprocket and the track frame. The track frame is a mm).
fixed undercarriage, which the left and right track frames
do not expand and retract. The track tension is Figure 30-20-1
maintained by a grease cylinder pushing the front idler
against the track.
Straight Edge
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 measure 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 0.787 inch (20,0 mm)

0.787
0.984 x 100 = 80
80% of the track lug is remaining with 20% wear on the

track lugs.

395 of 726
TRACK FRAME COMPONENTS (CONT’D) Rubber Track Clearance
Checking Tension Figure 30-20-3
Figure 30-20-2
1
P-69960
P-69958A
Figure 30-20-4
Raise one side of the machine (Approximately four

inches) using the boom and arm [Figure 30-20-2]. Track Frame

Raise the blade fully and install jackstands under the
blade and track frame (Item 1) [Figure 30-20-2]. Lower
the boom until all machine weight is on the jackstands.
0.39 - 0.59 in.
(11.9 - 14.9 mm)
Stop the engine.
Track
Roller
WARNING Track
B-14067
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension. Measure the clearance at the middle track roller. Do not
W-2142-0903 get fingers into pinch points between the track and the
track roller. Use a bolt or a dowel of the appropriate size
to check the gap between the contact edge of the roller
and the top edge of the track guide [Figure 30-20-3] &
[Figure 30-20-4].
Rubber Track Clearance - 0.39 - 0.59 in. (11,9 - 14,9 mm)

396 of 726
TRACK FRAME COMPONENTS (CONT’D) Adjusting Tension
Checking Tension (Cont’d) Figure 30-20-6
Steel Track Clearance
Figure 30-20-5 1
1
Track Frame
0.68 - 1.18 in.

(17.3 - 30 mm)
Track P-69962
Loosen the two bolts from the cover (Item 1) [Figure 30-
B-15022 20-6]. Pivot the cover downward.
Figure 30-20-7

Measure the track clearance at the middle track roller. Do
not get fingers into pinch points between the track and
the track roller. Us a bolt or dowel of the appropriate size
to check the gap between the contact edge of the roller 1 2
and the top edge of the track guide [Figure 30-20-5].
Steel Track Clearance - 0.680 - 1.180 in. (17,3 - 30 mm)
P-69993
Add grease to the fitting (Item 1) [Figure 30-20-7] until

the track tension is correct.

397 of 726
TRACK FRAME COMPONENTS (CONT’D)
Adjusting Tension (Cont’d)
Figure 30-20-8
P-69994
Use tool MEL1560 (Item 1) [Figure 30-20-8] to loosen

the bleed fitting (Item 2) [Figure 30-20-7] to release

tension from the track.
NOTE: Do not loosen the grease fitting (Item 1)

[Figure 30-20-7].
Repeat the procedure for the other side.
6804114

398 of 726
Rubber Track Removal And Installation
Lift and block both sides of the machine as follows:

WARNING
Put jackstands under the blade and rear corners of
Raise the blade fully.
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
Figure 30-20-9
or fall and result in injury or death.
W-2218-1195
Stop the engine.
Figure 30-20-11
1
1
1 P-73503

Use the boom and arm to lift the blade end of the
machine up about 3.0 inches (75 mm) and install jack
stands (Item 1) [Figure 30-20-9] under the blade.
P-49116
Raise the boom.
Figure 30-20-10 Loosen the two bolts (Item 1) [Figure 30-20-11] on the
cover. Pivot the cover downwards.
P-69595
Swing the upperstructure 180° and use the boom and

arm to slowly lift the opposite end of the undercarriage
and install jack stands under the undercarriage [Figure
30-20-10].
Raise the boom until the weight of the machine is

supported by the jackstands.

399 of 726
TRACK FRAME COMPONENTS (CONT’D) Figure 30-20-14
Rubber Track Removal And Installation (Cont’d)
Figure 30-20-12
2 1
P-22617
Insert a steel rod or pipe (Approximately 1.250 inch [30

P-69489 mm] diameter) between the track and the idler wheel
[Figure 30-20-14].
Figure 30-20-13 Figure 30-20-15

1
P-69490
P-22618
Using MEL-1650, loosen the bleed fitting (Item 1) [Figure Insert a second steel rod or pipe, at a distance of two
30-20-12] and [Figure 30-20-13] (a maximum of 1-1/2 lugs, between the track and the idler wheel [Figure 30-
turns) to release the tension from the grease spring. 20-15]. Continue to turn the track until the first pipe
contacts the track frame.
NOTE: Do not loosen the grease fitting (Item 2)
[Figure 30-20-12]. Stop the engine.
Start the engine.
Slowly turn the track in the forward direction.

400 of 726
Rubber Track Removal And Installation (Cont’d)
Figure 30-20-16
P-22619
Insert a pry bar between the track and the idler wheel and
pry out on the track until the track slides off the idler

wheel [Figure 30-20-16].
Remove the track.
To install the rubber track:
Put the track over the rear drive sprocket lugs.
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 Checking Tension
on Page 30-20-2.)

401 of 726
Steel Track Removal And Installation
With the excavator raised and the bleed fitting loosened, Stepped Diameter
start the excavator. (See Checking Tension on Page 30- This Area
20-2.)
Slowly turn the track. This will force more grease out of
the grease spring.
Stop the engine.
WARNING CD-13032

Keep fingers and hands out of pinch points when There is no master link or master connecting pin with this
removing the track. track. The connecting pins have a stepped diameter
W-2173-0195 [Figure 30-20-18]. The smaller diameter is a slip fit into
the track connecting links and the larger diameter is a
press fit.
The track can be removed either as a complete assembly

or by removing a connecting pin and separating the track. To remove a connecting pin, hold a heavy steel block on
the connecting link near the pin being removed. Use a
Figure 30-20-17 heavy hammer and a punch to drive out the connecting
pin.
WARNING
W-2019-1285
CD-9482
To remove the track as a compete assembly, install a pry

bar between the track and the front idler wheel and pry
out on the track [Figure 30-20-17].
Installation: Put the track over the drive sprocket lugs.

Then position the front of the track over the front idler
wheel.

and for checking track clearance. (See Checking Tension
on Page 30-20-2.)
To remove the track by removing a connecting pin:

402 of 726
Steel Track Removal And Installation (Cont’d)
Figure 30-20-19
Forward
B-13788
With the help of a second person, start the excavator.

B-13786 Make sure that the slew locking lever is in the locked
position. Use the travel lever (on which side the track is
being installed) to slowly turn the drive motor in the
Installation: Put the steel track under the track frame so forward direction. Hold the end of the track upwards as
the front end of the track extends approximately three the drive motor slowly moves the track forward. Guide

links in front of idler wheel [Figure 30-20-19]. the end of the track over the top of the guide block and up
to the front idler wheel [Figure 30-20-21].
Figure 30-20-20
Stop the engine.
WARNING
Sprocket Drive motor must be operated slowly to avoid any
sudden movements that could cause injury or death.
W-2174-0195
B-13787
Pull the opposite end of the track up and forward and

position the end links of the steel track onto the sprocket
[Figure 30-20-20].

403 of 726
Steel Track Removal And Installation (Cont’d)
Position the two ends of the track together and use a drift
pin to hold the links together.
Figure 30-20-22
B-13789

Insert the connecting link pin (Item 1) [Figure 30-20-22]
into the track link hole. Tap the end of the pin until the
press fit diameter contacts the connecting link hole.
Hold a heavy steel block on the back side of the track

connecting link and use a hammer to drive the
connecting link pin into the track link until the head of the
pin is flush with the track link.

and for checking track clearance. (See Checking Tension
on Page 30-20-2.)

404 of 726
Idler (Front) Removal And Installation
Use the following procedure to remove the different parts

from the track frame. 1
Remove the track. (See Rubber Track Removal And

Figure 30-20-23
P-8557
Remove the recoil spring (Item 1) [Figure 30-20-24].
Figure 30-20-25

P-8556
Slide the front track idler out of the track frame [Figure
30-20-23].
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 1) [Figure 30-20-24].
1
TS-1348A
WARNING Remove the four guide plates (two per side) (Item 1)
[Figure 30-20-25] from the track frame (steel tracks
only).
P-62574

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly.
W-2617-1004

405 of 726
Idler (Front) Parts Identification
1. Roll Pin
2. Block
3. Seal
4. Snapring
5. Bearing
6. Shaft
7. Idler
4
2
3

1
3
1
5 7
PE1801S

406 of 726
Idler (Front) Disassembly 1
The following tools must be fabricated for this procedure:
Figure 30-20-26
2
4.500”
0.30” (0,75 mm) (115 mm)
chamfer 3 places
3.500”
(90 mm)
P-47351
Remove any corrosion or paint from both ends of the

2.700” exposed shaft (Item 1) [Figure 30-20-28] that could
1.600” (70 mm) Dia. affect seal removal or damage the new seal during
(40 mm) Dia.
B-14205 installation.
Remove the seal (Item 2) [Figure 30-20-28] from both

1. Driver Tool - see figure [Figure 30-20-26]. sides of the idler.
2. Support Fixture - Tube, 3.0 inch ID x 0.250 inch wall Figure 30-20-29
x 6.0 inch long. (90 mm ID x 6,35 mm wall x 162,4 mm
long)
Figure 30-20-27 1
1 2
P-29393

CD-0230 both sides of the idler.
Remove the roll pin (Item 1) and block (Item 2) from both
sides of the shaft [Figure 30-20-27].

407 of 726
Idler (Front) Disassembly (Cont’d)
Figure 30-20-30
P-29395
1
Turn the idler over, and using a bearing driver, remove
P-29394 the second bearing [Figure 30-20-32].
Place the idler on the support fixture (Item 1) [Figure 30-

20-30].

Using a soft faced hammer, tap the shaft (Item 2) [Figure
30-20-30] and bearing out the bottom of the idler.
Figure 30-20-31
P-29396
Slide the bearing (Item 1) [Figure 30-20-31] off the shaft.

408 of 726
Idler (Front) Assembly
Figure 30-20-33
P-47353
2 Using a bearing driver, install the bearing in the idler

1 1 [Figure 30-20-35].
P-29398 Figure 30-20-36

Inspect the bearings (Item 1) and shaft (Item 2) [Figure
30-20-33] for wear or damage.
The bearings are sealed. If the bearings do not roll

smoothly, or if the seals are damaged, replace the 1
bearings.
Replace any worn or damaged parts.
Figure 30-20-34
P-61215
P-29399
Remove all paint and corrosion from the seal surface

(Item 1) [Figure 30-20-34] on both sides of the idler.

409 of 726
Idler (Front) Assembly (Cont’d)
Figure 30-20-37
1
2
1
P-29405

P-29403
Figure 30-20-40
Turn the idler over and place the idler on the support
fixture (Item 1) [Figure 30-20-37].

Install the shaft (Item 2) [Figure 30-20-37]. 1
Figure 30-20-38
1 P-29456
Apply assembly lube to the inside diameter (Item 1)

[Figure 30-20-40] of the seal.
Apply a small bead of high temperature silicone sealant

P-29404 around the flange surface (Item 2) [Figure 30-20-40] of
the seal.
Install the bearing (Item 1) [Figure 30-20-38]. Use a

brass drift to seat the bearing.

410 of 726
Idler (Front) Assembly (Cont’d)
Figure 30-20-41
P-47352
Using the driving tool, install the seal (Item 1) [Figure 30-
20-41] on both sides of the idler.

Figure 30-20-42
2 1
CD-0230
Install the block (Item 1) and roll pin (Item 2) [Figure 30-
20-42] on both sides of the shaft.

411 of 726
Coil Spring Assembly And Cylinder Disassembly

And Assembly
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 2) [Figure 30-20-43].
WARNING 1
2
P-11644
Remove the seal (Item 1) back-up ring (Item 2) and O-

ring (Item 3) [Figure 30-20-44] from the cylinder.
P-62574
Installation: Apply oil to the O-ring, back-up ring and
AVOID INJURY OR DEATH seal before installation.
• Spring loaded components under pressure can

cause serious injury or death.
• Do not disassemble the coil spring assembly.
W-2617-1004
Figure 30-20-43
1
2
P-8558
Slide the cylinder (Item 1) [Figure 30-20-43] off the shaft.

412 of 726
Roller Removal and Installation
Figure 30-20-45
P-8561
Loosen the nuts on the track roller on both sides of the

track frame [Figure 30-20-45].

Installation: Tighten the nuts to 125-140 ft.-lb. (170-190
N•m) torque.
Figure 30-20-46
P-8562
Remove the track roller [Figure 30-20-46].

413 of 726
Roller Parts Identification
1. Nut
2. Lock Washer
3. Washer
4. Seal
5. Snapring
6. Bearing 7
7. Roller
8. Shaft

2
2
3
4
PE1914S

414 of 726
Roller Disassembly
The following tools must be fabricated for this procedure:
Figure 30-20-47
1
4.500”
0.30” (0,75 mm) (115 mm)
chamfer 3 places
3.500”
(90 mm)
P-29459

2.700” both sides of the roller.
1.600” (70 mm) Dia.
(40 mm) Dia.
B-14205

1. Driver Tool - See [Figure 30-20-47].
2. Support Fixture - Tubing, 3.0 inch ID x 0.250 inch wall

x 6.0 inch long. (76,2 mm ID x 6,35 mm wall x 152,4
mm long)
Figure 30-20-48
P-46606
Support the roller in the support fixture (Item 1). Remove

the seal (Item 2) [Figure 30-20-48] from both sides of the
roller.

415 of 726
Roller Disassembly (Cont’d)
Figure 30-20-50
P-46607
Tap the shaft (Item 1) [Figure 30-20-50] and bearings out

of the roller.

Figure 30-20-51
P-29461
Press the bearings (Item 1) [Figure 30-20-51] off the

shaft.

416 of 726
Roller Assembly
Figure 30-20-52
P-29462
2
1 1 Press the bearings (Item 1) [Figure 30-20-54] on the

shaft.
P-29463 Figure 30-20-55

Inspect the bearings (Item 1) and shaft (Item 2) [Figure 2
30-20-52] for wear or damage.
The bearings are sealed. If the bearings do not roll

smoothly or if the seals are damaged, replace the
bearings.
Replace any worn or damaged parts.

1
Figure 30-20-53
P-29464
Place the roller on the support fixture (Item 1) [Figure 30-

20-55].
1 Tap the shaft and bearing assembly (Item 2) [Figure 30-

20-55] into the roller.
P-29465
Remove all paint and corrosion from the seal surface

(Item 1) [Figure 30-20-53] on both sides of the roller.

417 of 726
Roller Assembly (Cont’d)
Figure 30-20-56 1
P-46606
Using the driving tool, install the seal (Item 1) [Figure 30-
P-29466 20-58] on both sides of the roller.

Figure 30-20-57
P-29456
Apply assembly lube to the inside diameter (Item 1)

[Figure 30-20-57] of the seal.
Apply a small bead of high temperature silicone sealant

around the flange surface (Item 2) [Figure 30-20-57] of
the seal.

418 of 726
TRACK FRAME COMPONENTS (CONT’D) Sprocket Removal And Installation
Track Guide Removal And Installation Figure 30-20-60
Figure 30-20-59
1
1 1
2
P-69495A
P-8560
Remove the drive sprocket bolts (Item 1) [Figure 30-20-
60].
Remove the guide block bolts (Item 1) [Figure 30-20-59].
Installation: Tighten to 75-85 ft.-lb. (105-115 N•m)

Remove the guide block (Item 2) [Figure 30-20-59]. torque.
Remove the drive sprocket from the travel motor (Item 2)

[Figure 30-20-60].

419 of 726
Track Damage Identification
Figure 30-20-61
PI-13035
Causes of the damage:

P-3864
When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
Figure 30-20-62 of the embedded steel cords causes steel cords to be
cut:

When the rubber track is detracting, the idler or
sprocket rides on the projections of the embedded
metal [Figure 30-20-63].
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.
Furthermore, when moisture invades through a cut on

Steel Cords PI-13034 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.
Cutting Of Steel Cords
Prevention:
The following pages show photos and illustrations of
track damage and the probable cause of the damage. It The following preventions should be taken to minimize
is intended to be used for identifying the reason for track the risk of this damage:
damage and how to avoid future track damage.
Periodical checking on site of the recommended track
Damage: tension. (See Checking Tension on Page 30-20-2.)
Embedded steel cords are cut off [Figure 30-20-61] Avoiding quick turns on bumpy and rocky fields.
& [Figure 30-20-62].
Drive carefully to avoid having stones and other
Replacement: articles clog the rubber tracks.
Replacement is required [Figure 30-20-61] & [Figure Driving over sharp objects should be avoided. If this
30-20-62]. is impossible, do not make turns while driving over
sharp objects.

420 of 726
TRACK FRAME COMPONENTS (CONT’D) Causes of the damage:
Track Damage Identification (Cont'd) When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Figure 30-20-64 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 generate a
heavy load for rubber tracks, and when they are operated
P-3865 under a sandy field condition for a long time.
Figure 30-20-66
Abrasion Of Embedded Metals

Damage:
In proportion to the service time, embedded metals

will gradually wear away by friction [Figure 30-20-64].
Figure 30-20-65
Abrasion
P-4379
Separation Of Embedded Metals
Damage:
D D1 = 0.67D
Extraordinary outer forces applied to embedded
PI-13037 metals cause their separation from the rubber track's
body [Figure 30-20-66].
Replacement: Replacement:
Replacement is required when the width of the Even a partial separation of embedded metals
embedded metals (D1) becomes 67% of their original requires replacement of the track.
width (D) [Figure 30-20-65].

421 of 726
Track Damage Identification (Cont'd)
Figure 30-20-67
Idler Abrasion
Rubber
track
PI-13041
Abnormally worn sprockets as shown will pull

PI-13039 embedded metals out [Figure 30-20-69].
Prevention:
Similar to the prevention against the cutting of the steel

Embedded metals are adhered between the steel cords cords:
and the rubber body. The following cases generate
external forces greater than the adhesion strength, Recommended track tension should be periodically
causing separation of the embedded metals: checked. (See Checking Tension on Page 30-20-2.)
When the idler continually rides on the projections of Quick turns on bumpy and rocky fields should be
embedded metals, the embedded metals will avoided.
eventually peel off [Figure 30-20-67].
If abnormal wear of sprockets is observed, they
Figure 30-20-68 should be immediately replaced.
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
30-20-68].

422 of 726

Embedded metal
Figure 30-20-70
Good
Separation of bonded
rubber cover
PI-13043

P-4378
Embedded metals are bonded to the rubber body. The
following operating conditions cause embedded metals
Separation Of Embedded Metals Due To Corrosion to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals

Damage: from the rubber body [Figure 30-20-71].
Due to corrosion of embedded metals, the adhesion Excessively salty fields, like the sea shore
to the rubber body deteriorates, resulting in complete
separation [Figure 30-20-70]. Strong acidic or alkali soil conditions
Replacement: Compost spread grounds
Even a partial separation of embedded metals On tracks that are out of adjustment, the track rollers,
requires a rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at track roller side, 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), they 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 replacement of
the rubber track.

423 of 726
Figure 30-20-72 Cuts
PI-13045

P-4377
When rubber tracks drive over projections or sharp
stones in the fields, the concentrated forces applied
Cuts On The Lug Side Rubber cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface

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 often occurs as one of the steel cords' breakage due to their corrosion. It is highly
most typical failure modes [Figure 30-20-72]. recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 30-20-73].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately Machine operators are requested to drive with great
repaired 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.

424 of 726
Track Damage Identification (Cont'd) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Figure 30-20-74 especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
even small external cracks. Also 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. However,
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
P-4382 should be paid to the following instructions for
maintenance:
Figure 30-20-75 Avoid exposing stored tracks to direct sun light.

Avoid exposing stored tracks to direct rain and snow
fall.
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Cracks On The Lug Side Rubber Due To Fatigue
Damage:
Small cracks around the root of the lug as a result from

operation fatigue [Figure 30-20-74] & [Figure 30-20-75].
Replacement:
When the cracks reach so deep that they expose the

steel cords, track replacement is required.

425 of 726
Track Damage Identification (Cont'd) Lug abrasion is more or less inevitable. Even if lug
abrasion is proceeding, the rubber track can be used.
Figure 30-20-76 However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
abraded tracks with new ones when the lug height
becomes less than 5 mm.
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.

P-4381
Making frequent turns on paths covered with rocks
and wood.
Figure 30-20-77
Cracks And Cuts On The Lug Side Rubber

Figure 30-20-78
Lug abrasion
t
PI-13049
Lug Abrasion
CD-13050
Damage:
Damage:
As its service time proceeds, the lug side inevitably
undergoes abrasion [Figure 30-20-76] & [Figure 30- Sometimes cracks and cuts on the lug side rubber at
20-77]. the edges of the embedded metals can be observed
[Figure 30-20-78].
Replacement:
Replacement:
No replacement is required.
Basically, 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.

426 of 726
TRACK FRAME COMPONENTS (CONT’D) Damage:
Track Damage Identification (Cont'd) The rubber surface on which track rollers run is
gradually abraded. It will end in the exposure of the
Figure 30-20-79 embedded metals [Figure 30-20-80].
Replacement:
It is recommended to replace the rubber track when

more than half of the embedded metals are
Crack at the edge of completely exposed.
Cut on lug side
embedded metal rubber
Figure 30-20-81
Track roller
PI-13051
Abrasion

When rubber tracks drive over sharp projections,
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
[Figure 30-20-79].
PI-13053
Prevention:
To avoid extensive stress applied to the lug root where The abrasion of the track roller side rubber surface
metals are embedded, machine operators are requested occurs because of sand and gravel being clogged
to avoid driving over stumps and ridges. between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against
Abrasion Of The Track Roller Side the side of the rubber track to cause the abrasion [Figure
30-20-81].
Figure 30-20-80
The level of abrasion is highly dependent on terrain
conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
an extended period of abrasion, it will be more likely for
exposed embedded metals to catch moisture through 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 to the track rollers
P-4383 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.

427 of 726
Cuts On The Edges Of Track Roller Side
Figure 30-20-82
P-4384

Figure 30-20-83
Edge Edge
PI-13055
Damage:
Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 30-20-82] &
[Figure 30-20-83].
Replacement:
In such case, the rubber track does not have to be

replaced.
This damage is caused by objects on the field or by

interference with the machine frame.

428 of 726
TRACK FRAME COMPONENTS (CONT’D) In case of damage by interference with the machine
frame
If a machine continues operating with rubber tracks
Figure 30-20-84 being detracted, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
in damage. Furthermore, 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 30-20-85].
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
PI-13056 detracted, the machine should be stopped immediately
for retracting.
Figure 30-20-85

Cut
Tear
PI-13057
In case of damage by objects on the operating ground:
The edges of rubber track are often deformed largely

due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. Especially, when a machine
drives over concrete ridges, this type of damage
easily occurs [Figure 30-20-84].

429 of 726

430 of 726
SWING CIRCLE GEAR Figure 30-30-3

1
Remove the upperstructure. (See Removal on Page 40-
10-1.) OUTER RACE
Soft zone is at
Figure 30-30-1 INNER RACE the Ball Bearing
Soft zone is filler plug
identified by a
1 letter “S”
stamped on ring
PI-13677
Figure 30-30-4
P-69615

1
Install a C-clamp (Item 1) [Figure 30-30-1] to prevent the
swing bearing from turning while being removed.
Figure 30-30-2
P-69617
If reusing the existing swing bearing, use top, side and

edge aligning marks to put the swing bearing in the
1
correct location. If installing a new swing bearing find the
soft zone area (Item 1) [Figure 30-30-3] & [Figure 30-
30-4].
Install the swing bearing so the inside soft zone (Item 1)

P-69616 [Figure 30-30-3] & [Figure 30-30-4] is at the right hand
side of the excavator.
Remove the 24 bolts and nuts that hold the swing bearing NOTE: Do not put the soft zone to the front or rear of
to the track frame (Item 1) [Figure 30-30-2]. the excavator.
Remove the swing bearing.

431 of 726
SWING CIRCLE GEAR (CONT’D)
Figure 30-30-5
P-69617
Install the swing bearing bolts (Item 1) [Figure 30-30-5]

and lock nuts.

Tighten the bolts to 78-85 ft.-lb. (105-115 N•m) torque.
Put lubriplate grease or equivalent on the swing bearing

gear.

432 of 726
UPPERSTRUCTURE & SWING SECTION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . 40-160-2
Arm To Bucket And Bucket Link Bushing Removal And Installation 40-160-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
BLADE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Linkage Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 40-70-4
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-70-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
UPPERSTRUCTURE
& SWING
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 SECTION
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
BOOM SWING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-2

Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-100-4
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Removal And Installation (Bolt-On X-Change) . . . . . . . . . . . 40-170-7
Removal And Installation (Pin-On Attachment) . . . . . . . . . . 40-170-13
Removal And Installation (Pin-On X-Change) . . . . . . . . . . . . 40-170-1
Bucket Side Cutting Edge Removal And Installation . . . . . . 40-170-15
Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . 40-170-14
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-30-6
Front Window Removal And Installation . . . . . . . . . . . . . . . . . 40-30-7
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-13
Glass Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-11
Right Side Front And Rear Sliding Window Weather Strip Removal
And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-12
Right Side Front And Rear Sliding Window Wiper Strip Removal And
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-12
Right Side Front Sliding Window Removal And Installation. . 40-30-10
Right Side Rear Sliding Window Removal And Installation . . 40-30-10
CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

433 of 726
UPPERSTRUCTURE & SWING SECTION (CONT’D)
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Removal And Installation (Long Arm Counterweight) . . . . . . . 40-210-1
Removal And Installation (Standard Counterweight) . . . . . . . . 40-210-2
FLOOR MAT AND FLOOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Compression Spring Disassembly And Assembly . . . . . . . . . . . 40-60-3
Compression Spring Removal And Installation . . . . . . . . . . . . . 40-60-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Joystick Console Cover (Bottom) Removal And Installation . . . 40-60-1
Joystick Console Cover (Top) Removal And Installation . . . . . . 40-60-2
Joystick Console Frame Disassembly And Installation . . . . . . . 40-60-8
Joystick Console Frame Removal And Installation . . . . . . . . . . 40-60-7
Left Rear Console Cover Removal And Installation. . . . . . . . . . 40-60-9
Left Rear Console Frame Disassembly And Assembly . . . . . . 40-60-12
Left Rear Console Frame Removal And Installation . . . . . . . . 40-60-10
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5
LEFT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1

RIGHT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Console Base Cover Removal And Installation . . . . . . . . . . . . 40-50-2
Console Cover Removal And Installation . . . . . . . . . . . . . . . . . 40-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1

Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Seat Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2

434 of 726
UPPERSTRUCTURE & SWING SECTION (CONT’D)
SWING FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-140-1

Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . .40-140-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-140-1
Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-140-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .40-140-1
Swing Frame Bushing Removal And Installation . . . . . . . . .40-140-6
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-180-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . .40-180-1
TRAVEL LEVER / PEDALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 40-110-2
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-110-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-1
UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . .40-80-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-80-1
X-CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-190-1
Pin-On Disassembly and Assembly. . . . . . . . . . . . . . . . . . .40-190-2
Pin-On Removal And Installation . . . . . . . . . . . . . . . . . . . . .40-190-1
X-CHANGE (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-191-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-191-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-191-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-191-4

435 of 726

436 of 726
UPPERSTRUCTURE Removal
Description Figure 40-10-1
The upperstructure includes all the components in or

attached to the frame and connects to the slew bearing.
The slew bearing divides the upperstructure from the
undercarriage, which includes the track frame
components.
P-73514
Fully extend the cylinders of the bucket, arm, and boom

so that the excavator is in the position as shown [Figure
40-10-1].

Lower the blade all the way.
Put all the control levers in neutral.
The boom must be in full raised position and centered to

the front of the excavator [Figure 40-10-1].
WARNING
• 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. Engage
the swing locking lever.
• Never lift with operator on machine.
W-2202-0595

437 of 726
UPPERSTRUCTURE (CONT’D) Figure 40-10-4
Removal (Cont’d)
Figure 40-10-2
P-73504
Mark the upperstructure to the swing bearing and to the

P-73505 track frame for assembly (Item 1) [Figure 40-10-4].
Fasten chains to the rear of the upperstructure on both

sides (Item 1) [Figure 40-10-2] and up to a lifting fixture
IMPORTANT

above the canopy/cab [Figure 40-10-1]. The lifting fixture
must extend over the sides of the canopy/cab to prevent
the chains from hitting the ROPS/TOPS.
Figure 40-10-3 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
P-69911
Install a one inch (25 mm) bolt and nut (Grade 5 or 8)

through the hole at the boom (Item 1) [Figure 40-10-3].
Fasten a chain from the bolt to the lift fixture [Figure 40-
10-1].
Remove the swing motor. (See Removal And Installation

on Page 20-90-1.)
Remove the swing motor drive carrier. (See Removal


438 of 726
Removal (Cont’d)
Figure 40-10-5
P-73507
Lift the upperstructure off of the swing bearing. Put the

P-73384 upperstructure on suitable supporting stands or blocks
[Figure 40-10-7].
Mark and remove the hoses [Figure 40-10-5] from the

swivel joint.

Figure 40-10-6
P-73504
Partially disassemble the upperstructure from the swing

bearing by removing all but four bolts which are spaced
at 90° from each other (Item 1) [Figure 40-10-6].
The upperstructure must be rotated to gain access to the

bolts for removal. With the help of a second person,
manually turn the upperstructure to provide clearance for
bolt removal.
NOTE: For disassembly safety a minimum of four

evenly spaced bolts must remain installed, to
be removed later.
Apply a small amount of lifting pressure to the

upperstructure with the lift sling. Remove the four
remaining bolts holding the upperstructure to the swing
bearing.

439 of 726
Installation
Figure 40-10-8
1
3.0 in. (76 mm)
INNER RACE OUTER RACE

Soft zone is Soft zone is
identified by a at the
letter “S” ball bearing
stamped on filler plug
ring
B-13678
FRONT OF MACHINE
Make three alignment pins by using M12 X 110 mm long
PI-13677 bolts. Cut the head off of these bolts at 3.0 inch (76 mm),
then taper the end of the bolts [Figure 40-10-10].
Figure 40-10-9 Figure 40-10-11

1
1 1
P-69614 P-55105
Rotate the swing bearing so the outside soft zone (Item Install the pins (Item 1) [Figure 40-10-11] into the
1) [Figure 40-10-8] & [Figure 40-10-9] is to the right upperstructure at approximately 120° apart. These will
hand side of the excavator. act as alignment pins while lowering the upperstructure
onto the swing bearing.
NOTE: The upperstructure can only be installed on
the swing bearing in one position. Match the Install the upperstructure onto the swing bearing using
mount holes in the swing bearing to the the alignment marks and the alignment pins.
mount holes in the upperstructure.
Use a tap (12 mm) in the holes in the upperstructure to

remove any dried thread lock adhesive.

440 of 726
Installation (Cont’d)
Figure 40-10-12 1 2
P-55104
Apply thread adhesive (LOCTITE® #242) to the threads

B-13693 of the bolts. Install the bolts into all holes (except the
three with the alignment bolts installed). Tighten these
bolts to 78-85 ft.-lb. (106-115 N•m) torque.
Make sure the swivel joint is centered into the
upperstructure access hole [Figure 40-10-12]. Remove the three alignment bolts. Install the three

remaining bolts. Tight these bolts to 78-85 ft.-lb. (106-115
Figure 40-10-13 N•m) torque.
Figure 40-10-15
2
P-55103
P-73384
Install the three tapered head alignment bolts (Item 1)
[Figure 40-10-13] through the swing bearing and into the
upperstructure. These bolts should be spaced at Install the hoses [Figure 40-10-15] on the swivel joint.
approximately 120°.
Remove the chains and lifting fixture.
This procedure will correctly align the upperstructure for
correct swing motor gear to swing bearing ring gear Install the swing motor drive carrier. (See Removal And
clearance. Installation on Page 20-91-1.)
Tighten these three tapered bolts to 60 ft.-lb. (81 N•m) Check the backlash between the gears by moving the
torque. frame back and forth at several points throughout 360° of
frame rotation. There must be some backlash present.
Remove the three alignment pins (Item 2) [Figure 40-10-
13] from the upperstructure. Install the swing motor. (See Removal And Installation on
Page 20-90-1.)

441 of 726

442 of 726
CANOPY
Build the service lifting bracket used to remove and install the ROPS canopy. Use the dimensions shown [Figure 40-20-
1] to build the service lifting bracket.
Figure 40-20-1
Material: 2 X 2 - .25 inch wall hot rolled steel tubing

.25 inch hot rolled steel plate
MS1933

443 of 726
CANOPY (CONT’D) Figure 40-20-3
Figure 40-20-2 1
1
P-53362
Adjust the lifting bracket to the proper width by moving

P-53361 the bracket (Item 1) [Figure 40-20-3].
Figure 40-20-4
Install the chain hoist (Item 1) in the end hole of the lifting
bracket (Item 2) [Figure 40-20-2].

Install the cab/canopy service lifting bracket on the
canopy [Figure 40-20-2].
NOTE: Use a chain hoist of sufficient capacity.
WARNING 1
1
Never use the cab/canopy service lifting bracket to

lift the excavator. The bracket is not strong enough P-53360
and can fail causing serious injury or death.
W-2384-1000
Remove the bolts and washers (Item 1) [Figure 40-20-4]
from the front of the canopy.
Installation: Tighten the bolts to 118-133 ft.-lb. (160-180

N•m) torque.
Remove the canopy.

444 of 726
CANOPY (CONT’D)
Figure 40-20-5
P-53359
Figure 40-20-6

1
P-53358
Remove the bolts and washers (Item 1) [Figure 40-20-5]

& [Figure 40-20-6] from the rear of the canopy.

N•m) torque.
Raise the hoist.
Remove the canopy.

445 of 726

446 of 726
CAB
Build the service lifting bracket used to remove and install the cab. Use the dimensions shown [Figure 40-30-1] to build
the service lifting bracket.
Figure 40-30-1
Material: 2 X 2 - 0.25 in. wall hot rolled steel tubing

0.25 in. hot rolled steel plate
MS1933

447 of 726
CAB (CONT’D) Figure 40-30-3
Remove the upperstructure light. (See Upperstructure

Light Removal And Installation on Page 50-50-1.)
1
Figure 40-30-2
P-55915
Adjust the lifting bracket to the proper width by moving

the bracket (Item 1) [Figure 40-30-3].
The cab may be equipped with either the A/C or heater

P-55916 duct.

A/C Duct (If Equipped)
Install the chain hoist (Item 1) in the end hole of the lifting
bracket (Item 2) [Figure 40-30-2]. Figure 40-30-4
Install the cab/canopy service lifting bracket on the cab 3

[Figure 40-30-2].
NOTE: Use a chain hoist of sufficient capacity.

2
2
WARNING 1
Never use the cab/canopy service lifting bracket to

lift the excavator. The bracket is not strong enough
and can fail causing serious injury or death.
W-2384-1000 P-42588
Pull down on the lock (Item 1), remove the screws (Item
2), and remove the A/C duct (Item 3) [Figure 40-30-4].

448 of 726
Figure 40-30-5 1
P-73511
2
Remove the grommet (Item 1) [Figure 40-30-7] from the
1 P-69871 left rear corner of the cab.
Figure 40-30-8
Remove the screws (Item 1). Remove the air manifold
(Item 2) [Figure 40-30-5].

1
Heater Duct
1
Figure 40-30-6
P-73512
Remove the wire harness from the cab frame.

P-69871
Remove the screws and pull straight up to remove the

heater duct (Item 1) [Figure 40-30-6].

449 of 726
Figure 40-30-9
1 1
1
P-73510
Remove the bolts and washers (Item 1) [Figure 40-30-

P-53070 11] from the rear of the cab.

Remove the windshield washer hose (Item 1) [Figure 40- N•m) torque.
30-9] from the nozzle.

Figure 40-30-12
Figure 40-30-10
1 1 1
P-69872
P-73508
Remove the bolts and washers (Item 1) [Figure 40-30-

Remove the upperstructure light from the upperstructure. 12] from the front of the cab.
Disconnect the cab wire harness (Item 1) [Figure 40-30-
10]. Installation: Tighten the bolts to 118-133 ft.-lb. (160-180
N•m) torque.

450 of 726
CAB (CONT’D)
Figure 40-30-13
P-53069
Installation: Install the cab mounts (Item 1) [Figure 40-

30-13] on the four corners of the cab.

451 of 726
CAB (CONT’D)
Door Removal And Installation
Figure 40-30-14

P-68465
The door can be removed from the cab by slowly

swinging the door back and forth while lifting up on the
door [Figure 40-30-14].
Installation: Align the hinges and swing the door back

and forth until the door weight settles the hinges to full
engagement.
NOTE: Early style door with one piece glass is

shown. Later model doors have two pieces of
glass. The procedure is the same for both
styles of doors.

452 of 726
Front Window Removal And Installation
Figure 40-30-15
1
1
P-52936
Remove the nuts (Item 1) [Figure 40-30-17].

P-52934
Figure 40-30-18

Figure 40-30-16 2
2
1
P-52937
Remove the wiper assembly (Item 1) from the pivot

P-52935 mounts (Item 2) [Figure 40-30-18].
Remove the wire harness (Item 1) from the channel (Item

2) [Figure 40-30-16].

453 of 726
Front Window Removal And Installation (Cont’d)
Figure 40-30-19
1 2
1 1
1
P-52941
Remove the seals (Item 1) [Figure 40-30-21].

P-52938
Figure 40-30-22
Remove the nuts and washers (Item 1) [Figure 40-30-

19].

Remove the bolt (Item 2) [Figure 40-30-19].
NOTE: Support the wiper motor before removing the

mounting hardware.
1
Figure 40-30-20
3
P-52942
Remove the bolt (Item 1) [Figure 40-30-22] holding the

wire harness clamp to the top of the front window.
1
P-52939
Remove the plate (Item 1), washer (Item 2), and wiper
motor (Item 3) [Figure 40-30-20].

454 of 726
Front Window Removal And Installation (Cont’d)
Figure 40-30-23
1
4 3
2
P-52946
1
With the help of a second person supporting the front

P-52943 window, remove the retainer (Item 1), spring (Item 2),
roller (Item 3), and handle (Item 4) [Figure 40-30-25]
from both sides of the front window.
Remove the bolt (Item 1) [Figure 40-30-23] holding the
wire harness clamp to the bottom of the front window. Figure 40-30-26

Figure 40-30-24
1
2
P-52948
P-52945
Tilt the front window (Item 1) [Figure 40-30-26]. Remove
the front window from the cab frame.
Remove the wire harness (Item 1) from the channel (Item
2) [Figure 40-30-24].

455 of 726
CAB (CONT’D) Right Side Front Sliding Window Removal And
Installation
Right Side Rear Sliding Window Removal And
Installation NOTE: The rear sliding window must be removed
before the front sliding window can be
Close and latch the front and rear sliding windows. removed.
Figure 40-30-27 Unlatch the front sliding window and slide the window
open until it stops.
Figure 40-30-29
P-52949

Use a pick to pull the felt (Item 1) [Figure 40-30-27] from
P-52951
the top window channel.
Unlatch the rear sliding window and slide the window Use a pick to pull the felt (Item 1) [Figure 40-30-29] from
open until it stops. the inside top window channel.
Figure 40-30-28 Figure 40-30-30
P-52950 P-52952
Lift the window up into the top channel and tilt the bottom Lift the window up into the channel and tilt the bottom
edge out [Figure 40-30-28]. Remove the window from edge out [Figure 40-30-30]. Remove the window from
the cab. the cab.

456 of 726
CAB (CONT’D)
Glass Removal
Use the following procedure to remove the glass from the

cab and right side window assembly.
Figure 40-30-31
P-52953

Push a small diameter wire (Item 1) [Figure 40-30-31]
through the adhesive. Pull the wire around the perimeter
of the glass to cut the adhesive.
Remove the glass.
NOTE: The right side window frame is aluminum and

will be destroyed when removed.

457 of 726
CAB (CONT’D) Right Side Front And Rear Sliding Window Wiper
Strip Removal And Installation
Right Side Front And Rear Sliding Window Weather
Strip Removal And Installation Figure 40-30-34
Remove the window.
Figure 40-30-32
P-63661
1
Remove the wiper strip (Item 1) [Figure 40-30-34] from
P-63659 the window channel.

Remove the weather strip (Item 1) [Figure 40-30-32]
from the bottom channel of the window.
Installation: Clean the bottom channel. Apply a bead of

adhesive in the channel.
Figure 40-30-33
2 2
1
P-63660
Install the new weather strip (Item 1). Cut the weather
strip flush with the ends of the window channel (Item 2)
[Figure 40-30-33].
Remove the window.

458 of 726
CAB (CONT’D) Shake the combo primer for one minute.
Glass Installation Apply one coat of the combo primer to the perimeter of
the cab and glass (Item 2) [Figure 40-30-36].
Rear and Front Lower Glass
NOTE: See your Bobcat dealer for the correct Allow the combo primer to dry for at least 15 minutes.
Excess primer can be removed from the glass using a
urethane adhesive, combo primer, glass
razor blade.
cleaner and bumpers for correctly installing
the new glass.
Cut the tip of the adhesive tube to the desired shape and
Remove the majority of the old urethane adhesive from size to provide a bead height sufficient to give good
the perimeter of the cab. contact with the glass around the entire perimeter.
Figure 40-30-37
NOTE: Leave a thin film (0.03 in. (0,79 mm) thick) of
the old urethane on the cab frame, fresh
urethane will bond to the remaining film.
1
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purposes adhesive

cleaner. Clean the glass surface with glass cleaner.
Figure 40-30-35
1
1

2
MS1993
Apply a 0.25 X 0.375 in (6.4 X 9.5 mm) triangle shaped

bead of urethane adhesive (Item 1) [Figure 40-30-37] to
1 the perimeter of the cab.
Figure 40-30-38
2
PE2199S
1
Figure 40-30-36
MS1994
2 Install the glass and seal assembly (Item 1) [Figure 40-

30-38]. Press the glass into the cab to make complete
contact with the adhesive. Tape the glass in place.
Allow the adhesive to cure for a minimum of twelve hours

at 70° F and 20% relative humidity.
MS1992
Remove the tape after the adhesive is cured.

Install the seal (Item 1) on the glass (Item 2) [Figure 40-
30-35] & [Figure 40-30-36].

459 of 726
CAB (CONT’D)
Glass Installation (Cont’d)

Top, Right Side and Left Side Glass IMPORTANT
NOTE: See your Bobcat dealer for the correct If the glass has direct contact with the metal frame,
urethane adhesive, combo primer, glass
cleaner and bumpers for correctly installing the glass may break due to machine vibration.
the new glass. I-2236-0105
Remove the majority of the old urethane adhesive from

the perimeter of the cab. Figure 40-30-40
NOTE: Leave a thin film (0.03 in. (0,79 mm) thick) of

the old urethane on the cab frame, fresh 1
urethane will bond to the remaining film.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purposes adhesive

cleaner. Clean the glass surface with glass cleaner.
Shake the combo primer for one minute.

1
Figure 40-30-39

2
MS1993
Cut the tip of the adhesive tube to the desired shape and
1 size to provide a bead height sufficient to give good
contact with the glass around the entire perimeter.

2 bead of urethane adhesive (Item 1) [Figure 40-30-40] to
the perimeter of the cab.
Figure 40-30-41
2
2
1
PE2198S
Apply the combo primer to the perimeter of the cab

opening (Item 1) and glass (Item 2) [Figure 40-30-39]. MS1995
Allow the combo primer to dry for at least 15 minutes.

Excess primer can be removed from the glass using a Install the glass (Item 1) [Figure 40-30-41]. Press the
razor blade. glass into the cab to make complete contact with the
adhesive. Tape the glass in place.
Install the bumpers evenly around the perimeter of the
cab opening. (The bumpers are used to space the glass Allow the adhesive to cure for a minimum of twelve hours
at 70° F and 20% relative humidity.
away from the metal so there is no glass to metal
contact.) Remove the tape after the adhesive is cured.

460 of 726

Door and Front Window Glass
NOTE: The door and front windows are supplied as

kits that include the glass, urethane adhesive,
combo primer, glass cleaner and bumpers for 1
correctly installing the new glass.
Remove the front window or door that is to be repaired

from the excavator.
Figure 40-30-42
P-61219
Place the glass on a flat surface with the painted side of

the glass (Item 1) [Figure 40-30-44] facing up.
Thoroughly clean the entire glass with glass cleaner.
Figure 40-30-45
1

1
P-61216
Remove the broken glass (Item 1) [Figure 40-30-42].
Figure 40-30-43
P-61220
Apply one coat of combo primer (Item 1) [Figure 40-30-

1 45] on the painted edge of the glass.
2 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.

P-61218
Excess primer may be removed from the glass using a
razor blade.
Cut and remove the old urethane adhesive (Item 1)
leaving less than a 0.03 in. (0.79 mm) thick layer (Item 2)
[Figure 40-30-43] for the new adhesive to bond to.
NOTE: Use care not to scratch the paint on the frame.

461 of 726

Door and Front Window Glass (Cont’d)
Figure 40-30-46
1
1 1
1 P-61224
1

bead of urethane adhesive (Item 1) [Figure 40-30-48]
around the front window/door frame.
P-61222
Apply the adhesive directly on top of the old adhesive.

Figure 40-30-47

Figure 40-30-49
1
1 1 1
P-61223
P-61225
Install the bumpers (Item 1) [Figure 40-30-46] on the

Place the frame (Item 1) [Figure 40-30-49] on the glass.
front window frame or (Item 1) [Figure 40-30-47] on the
The frame must be centered on the glass, and the glass
door frame. (The bumpers are used to space the glass
must not have direct contact with the front window/door
away from the metal so there is no glass to metal
frame.
contact.)

styles of doors.
IMPORTANT
If the glass has direct contact with the metal frame,
the glass may break due to machine vibration.
I-2236-0105

462 of 726
CAB (CONT’D) Clamp the frame and glass together [Figure 40-30-50] &
[Figure 40-30-51].
Place the clamps over the frame where the rubber
Door and Front Window Glass (Cont’d)
bumpers are installed.
Figure 40-30-50 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)

styles of doors.
P-61226
Figure 40-30-51

P-61227

463 of 726

464 of 726
SEAT AND SEAT MOUNT Figure 40-40-3
Seat Mount Removal And Installation
Figure 40-40-1 1
1
1 2
2
1
1
P-69624
2 Remove the bolts (Item 1) [Figure 40-40-3] from the seat

P-73008 mount rails.
Remove the rails (Item 2) [Figure 40-40-3].

Remove the seat (Item 1) by releasing the lever (Item 2)
[Figure 40-40-1] and pulling the seat forward off the seat Figure 40-40-4

mount.
Figure 40-40-2
2 1
P-69623
P-69621 Remove the seat belt mounting bolt (Item 1) [Figure 40-
40-4].
Remove the top bolt (Item 1) [Figure 40-40-2]. (Both Remove the seat belt.
sides)
Loosen the bottom bolt (Item 2) [Figure 40-40-2]. (Both

sides)
Remove the seat mount from the excavator.

SEAT AND SEAT MOUNT (CONT’D) Seat Removal And Installation
Seat Mount Removal And Installation (Cont’d) Figure 40-40-6
Figure 40-40-5
2
1
1
1 2
1
1 P-69625
P-69622
Remove the bolts (Item 1) [Figure 40-40-6] from the seat
rails.
Remove the seat belt mounting bolt (Item 1) [Figure 40-
40-5]. Remove the rails (Item 2) [Figure 40-40-6].

Remove the seat belt.

RIGHT CONSOLE Console Cover Removal And Installation
The right joystick console is in a fixed position, in either a

canopy or cab option, and contains the throttle lever,
display panel, keyswitch, blade lever, accessory outlet,
and cup holder. 1
P-21133

arm rest.
Lift up on the rear of the cover and slide the cover ahead
to remove it.

Remove the key and nut from the key switch (Item 2)
[Figure 40-50-1] (if equipped). Allow the switch to drop
inside the console.
NOTE: The key switch must be removed to remove

and install the console cover. It interferes with
the arm rest bracket.
Figure 40-50-2
2
1
P-21729
Remove the two bolts (Item 1) [Figure 40-50-2] from the

arm rest.

cup holder.
Lift the console cover up and over the joystick lever.

RIGHT CONSOLE (CONT'D) Console Base Cover Removal And Installation
Console Cover Removal And Installation (Cont’d) Remove the right console cover. (See Console Cover
Figure 40-50-3
Remove the floor mat. (See Removal And Installation on
Page 40-90-1.)
Figure 40-50-5
1
1
2
1 1
P-21730

(Item 1) [Figure 40-50-3]. 2
P-73373

Remove the controller from the console cover by
pressing the four mounting tabs (Item 2) [Figure 40-50- Remove the three screws (Item 1) [Figure 40-50-5].
3].
Remove the duct (Item 2) [Figure 40-50-5].
Figure 40-50-4
Figure 40-50-6
P-21732
P-52225

cover [Figure 40-50-4]. Remove the hose (Item 1) [Figure 40-50-6].
Remove the console cover (Item 1) [Figure 40-50-4].

RIGHT CONSOLE (CONT'D) Figure 40-50-9
Console Base Cover Removal And Installation

(Cont’d)
Figure 40-50-7
1
1
1
P-73375A
Slide the console base cover (Item 1) [Figure 40-50-9]

forward and remove it from the excavator.
P-73374

Figure 40-50-8
1
P-73375
Remove the two bolts (Item 1 & 2) [Figure 40-50-8].


LEFT CONSOLE Joystick Console Cover (Bottom) Removal And
Installation
Description
Figure 40-60-1
An excavator equipped with a canopy or cab, the left
console contains a moveable joystick console and a rear
console in a cab contains the blower fan and temperature
control for the heater.
1 1
1
1 1
1 P-73423
Remove the screws (Item 1) [Figure 40-60-1] from the

bottom of the console cover.
Remove the bottom of the console cover.

Lower the console.

LEFT CONSOLE (CONT’D) Figure 40-60-4
Joystick Console Cover (Top) Removal And

Installation
Remove the lower console cover. (See Joystick Console 1

Cover (Bottom) Removal And Installation on Page 40-60-
1.)
Figure 40-60-2
1 P-21738
Disconnect the electrical connector(s) (Item 1) [Figure

40-60-4] on cab equipped excavators.


P-73424 Remove the console cover.

arm rest.
Figure 40-60-3
P-21737
Remove the bolts (Item 1) [Figure 40-60-3] from the arm

rest.
Raise the top of the console cover.

LEFT CONSOLE (CONT'D) Compression Spring Disassembly And Assembly
Compression Spring Removal And Installation Figure 40-60-7
Remove the lower console cover. (See Joystick Console

1.)
Lower the console.
Figure 40-60-5
P-52261
Figure 40-60-8

1
P-52259
Install a pin (Item 1) [Figure 40-60-5] in the top of the

compression spring rod.
Figure 40-60-6
1
2 P-24008
Apply pressure against the spring, and remove the pin

(Item 1) [Figure 40-60-8] from the shaft.
1
Release the pressure from the spring.
P-73425
Support the console in the raised position. Remove the

bolt (Item 1) [Figure 40-60-6].
Remove the spring assembly (Item 2) [Figure 40-60-6]

from the console.

LEFT CONSOLE (CONT'D) Figure 40-60-11
Compression Spring Disassembly And Assembly

(Cont’d)
Figure 40-60-9
2
3
P-52264
1
Remove the sleeve (Item 1) and washer (Item 2) from the

shaft (Item 3) [Figure 40-60-11].
P-52262

Figure 40-60-10
P-52263
Remove the spring (Item 1) from the shaft (Item 2)

[Figure 40-60-10].

Lever Removal And Installation

1
1.) 2
Remove the upper console cover. (See Joystick Console
Cover (Top) Removal And Installation on Page 40-60-2.)
1
Remove the compression spring assembly from the
console. (See Compression Spring Disassembly And
Assembly on Page 40-60-3.) 1
Remove the left rear console cover. (See Left Rear
Console Cover Removal And Installation on Page 40-60- P-73427
9.)
Figure 40-60-12 Remove the bolts (Item 1) and the side cover (Item 2)
[Figure 40-60-13].
Figure 40-60-14

2
1
P-73426
2
Raise and support the console. P-73428
Pull the floor mat back (Item 1) and remove the bolt (Item
2) [Figure 40-60-12] from the side cover. Remove the bolt (Item 1) and the lock lever bearing (Item
2) [Figure 40-60-14].
Lower the console.

Lever Removal And Installation (Cont’d)
Figure 40-60-15
1 2
1 P-73431
Remove the roll pin (Item 1) and the pin (Item 2) [Figure
P-73429 40-60-17] from the lever assembly.
Figure 40-60-18
Remove the spring (Item 1) [Figure 40-60-15].
Figure 40-60-16

2
1
1
P-73432
P-73430 Remove the rubber handle (Item 1) [Figure 40-60-18]

from the lever assembly.
Remove the tie straps (Item 1) [Figure 40-60-16].
Remove the lever (Item 2) [Figure 40-60-18].

Joystick Console Frame Removal And Installation
Remove the seat and seat mount. (See SEAT AND SEAT
MOUNT on Page 40-40-1.)

1.)

Remove compression spring. (See Compression Spring

Remove the lever. (See Lever Removal And Installation

on Page 40-60-5.)
Raise and support the console.
Figure 40-60-19

1
P-73435
Remove the six hoses (Item 1) [Figure 40-60-19] from

the joystick.
NOTE: Mark hoses to joystick fitting to aid in the

installation procedure.

LEFT CONSOLE (CONT'D) Joystick Console Frame Disassembly And
Installation
Joystick Console Frame Removal And Installation
(Cont’d) Figure 40-60-22
Figure 40-60-20
P-52790
P-69649A
Remove the bolts (Item 1). Remove the bracket (Item 2)
[Figure 40-60-22].
Lower the console. Disconnect the joystick wire harness

(Item 1) [Figure 40-60-20].
Figure 40-60-21
3
P-69650A
Remove the roll pin (Item 1) [Figure 40-60-21].
Remove the joystick console frame (Item 3) [Figure 40-

60-21].

LEFT CONSOLE (CONT'D)
Left Rear Console Cover Removal And Installation
Figure 40-60-23
1 1
P-73437
Remove the four console cover screws (Item 1) [Figure

40-60-23].

Figure 40-60-24
P-73436
Lift the console cover and disconnect the harness (Item

1) [Figure 40-60-24] from the potentiometer harness. (If
equipped with Heater.)
Disconnect the harness (Item 2) [Figure 40-60-24] from

the blower switch. (If equipped with Heater.)
Remove the console from the excavator.

Left Rear Console Frame Removal And Installation
Remove the seat and seat mount. (See SEAT AND SEAT 1
MOUNT on Page 40-40-1.)
Installation on Page 40-90-1.) 1
1.)

Remove the left rear console cover. (See Left Rear P-73439
Console Cover Removal And Installation on Page 40-60-
9.)
Pull the wire harness out and disconnect the wire
Remove the compression spring. (See Compression harness (Item 1) [Figure 40-60-26].
Spring Removal And Installation on Page 40-60-3.)
Figure 40-60-27
Remove the lever. (See Lever Removal And Installation
on Page 40-60-5.)

Remove the joystick console frame. (See Joystick
Console Frame Removal And Installation on Page 40-60-
7.) 1
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly P-73440
damage the system.
I-2003-0888
Disconnect the wire harness (Item 1) [Figure 40-60-27]
from the console lockout switch.
Figure 40-60-25
P-73438
Remove the grommet (Item 1) [Figure 40-60-25].


(Cont’d)
Figure 40-60-28
1
P-73443
Remove the hose clamp (Item 1) [Figure 40-60-30].
P-73441 Figure 40-60-31

1

Figure 40-60-29
1 1
1
2
3 P-73444
P-73442
Remove the bolt (Item 1) the console base cover (Item 2)

[Figure 40-60-29].
Remove the tie strap (Item 3) [Figure 40-60-29].

LEFT CONSOLE (CONT'D) Left Rear Console Frame Disassembly And
Assembly
(Cont’d) Figure 40-60-34
Figure 40-60-32
1 1
P-52788
P-73445
Remove the dust boot (Item 1) [Figure 40-60-34].

Figure 40-60-33
P-52780A
Remove the console [Figure 40-60-33].

BLADE CONTROL Disassembly And Assembly
Removal And Installation Figure 40-70-3
Remove the right console cover. (See Console Cover

Figure 40-70-1
1
P-24241

two piece handle.
P-24238
Remove the connector (Item 2) [Figure 40-70-3].

Disconnect the two speed wire harness (Item 1) [Figure Figure 40-70-4
40-70-1].
1
Figure 40-70-2
2
1
N-23079
1
P-55642 Remove the two halves of the handle (Item 1) [Figure

40-70-4].
Loosen the bolts (Item 1) [Figure 40-70-2]. Remove the two speed switch and wire assembly (Item
2) [Figure 40-70-4] from the tube.

483 of 726
BLADE CONTROL (CONT’D) Figure 40-70-7
Linkage Removal And Installation
Remove the blade control lever. (See Removal And 1

Remove the right console cover. (See Console Cover

Figure 40-70-5
P-73493
Remove the hoses (Item 1) [Figure 40-70-7].
Figure 40-70-8

P-24242
NOTE: The console base has been removed for photo

clarity.
Figure 40-70-6
1
P-73108
1 Remove the nut (Item 1) [Figure 40-70-8] bolt, washers

and spacer.
Remove the cotter pin (Item 2) and clevis pin (Item 3)

[Figure 40-70-8]. Remove the linkage.
P-24239
Remove the bolt (Item 1) [Figure 40-70-6] from the blade

control pivot mount.
Remove the blade control pivot mount.

484 of 726
Linkage Removal And Installation (Cont’d)
Figure 40-70-9
2
1
P-55840
3
Remove the nuts (Item 2) [Figure 40-70-9] & [Figure 40-

P-61161A 70-11] and bolts.
NOTE: Access the bolt (Item 2) [Figure 40-70-11]

Remove the nut, bolt, washer, and spacer (Item 1) through the right console in the cab.
[Figure 40-70-9].

Remove the linkage assembly (Item 3) [Figure 40-70-9].
Figure 40-70-10
P-24245
Remove the linkage bar (Item 1) [Figure 40-70-10] from

the top.
NOTE: The console base has been removed for photo

clarity.

485 of 726
Linkage Disassembly And Assembly
Figure 40-70-12
1
N-23856
Remove the washers (Item 1) [Figure 40-70-14] from the

P-24243 pivot mount.
Figure 40-70-15
Remove the nut (Item 1) from the mount plate (Item 2)
[Figure 40-70-12].

Figure 40-70-13
2
2
1
N-23857
3
Remove the sleeve (Item 1) [Figure 40-70-15] from the
P-24244 pivot mount.
Inspect the O-rings (Item 2) [Figure 40-70-15] and

Remove the pivot mount (Item 1) bolt (Item 2) and replace parts as needed.
washers (Item 3) [Figure 40-70-13].

486 of 726
UPPERSTRUCTURE SLEW LOCK Figure 40-80-3
Removal and Installation
Remove the floor mat and floor panels. (See FLOOR

MAT AND FLOOR PANEL on Page 40-90-1.)
Figure 40-80-1 1
2
2
P-73485
Remove the bolt, nut, and spacer (Item 1) [Figure 40-80-

3] from the slew lock lever assembly.
1
Remove the brackets (Item 2) [Figure 40-80-3].
1 P-73483
Figure 40-80-4

Remove the bolts (Item 1) and the slew lock lever
assembly (Item 2) [Figure 40-80-1] from the machine.
Figure 40-80-2
1
P-73486
2
1 Remove the bolt, nut, and spacer (Item 1) [Figure 40-80-
4].
P-73484
Remove the lever (Item 2) [Figure 40-80-4] from the
bracket.
Remove the bolt, nut, and spacer (Item 1) [Figure 40-80-
2] from the slew lock lever assembly.
Remove the pin (Item 2) [Figure 40-80-2] from the slew

lock lever assembly.

487 of 726
UPPERSTRUCTURE SLEW LOCK (CONT’D) Figure 40-80-6
Removal and Installation (Cont’d) 8 7

6
Figure 40-80-5 5
4
3
3 1
P-73490
2
Items listed below from [Figure 40-80-6].

P-73488
Item 1 nut
Remove the bolt, nut, and spacer (Item 1) [Figure 40-80- Item 2 Lever
5].

Item 3 Wave Washers
Remove the link (Item 2) [Figure 40-80-5] from the
bracket. Item 4 Bracket
Remove the two nuts (Item 3) [Figure 40-80-5]. Item 5 Friction Washer
Item 6 Throttle Spacer
Item 7 Lever
Item 8 Bolts

488 of 726
FLOOR MAT AND FLOOR PANEL Removal And Installation
Description NOTE: The removal and installation of floor panels

for a cab equipped excavator use the same
The floor of the excavator (cab or canopy) is divided into procedure with the additional removal of the
three floor panels covered by a mat. The front floor panel heater unit under the seat.
provides access to travel levers, foot pedal, fuel filters,
fuel pump and fuel tank. The rear floor panel provides Figure 40-90-1
access to the swivel joint, swing motor and heater valve
(if equipped). The right side panel provides access to
upperstructure slew lock.
1
P-73050

Remove the three bolts (Item 1) [Figure 40-90-1].
Remove the retaining plate (Item 2) [Figure 40-90-1].
Figure 40-90-2
P-73051
Remove the floor mat (Item 1) [Figure 40-90-2].

489 of 726
FLOOR MAT AND FLOOR PANEL (CONT’D) Rear Floor Panel
Removal And Installation (Cont’d) Figure 40-90-5
Figure 40-90-3
1
1
1 1
P-73070
P-73052
NOTE: If the excavator is equipped with a heater
remove heater.
Remove the floor mat insulation (Item 1) [Figure 40-90-
3]. Remove the five mount bolts (six bolts if not heater is

installed) (Item 1) [Figure 40-90-5] from the rear floor
Front Floor Panel panel.
Figure 40-90-4 Remove the rear floor panel.
Right Floor Panel

1
Figure 40-90-6
1
1 1
1
P-73053 1
Remove the seven mount bolts (Item 1) [Figure 40-90-4]

from the front floor panel.
P-73083
Remove the front floor panel.

Remove the bolt and nut (Item 1) [Figure 40-90-6] from
the boom swing pedal linkage.

490 of 726
FLOOR MAT AND FLOOR PANEL (CONT’D)
Right Floor Panel (Cont’d)
Figure 40-90-7
3
2
1
1
1
P-73084

Remove the four mount bolts (Item 1) [Figure 40-90-7]
from the right floor panel.
Remove the washer hose (Item 2) [Figure 40-90-7] from

the nozzle and slide down through the floor panel.
Slide the upperstructure slew (Item 3) [Figure 40-90-7]

lockdown through the floor panel.
Figure 40-90-8
P-73078
Remove the mount bolt (Item 1) [Figure 40-90-8] from

the right floor panel.
Remove the right floor panel.

491 of 726

492 of 726
BOOM SWING PEDAL Removal And Installation
Description Remove the floor mat and floor panel. (See Removal And
The boom swing pedal is attached to the right side floor
panel and controls the direction the boom swings. The
boom swing pedal is connected to the control valve via
mechanical linkages.

493 of 726
BOOM SWING PEDAL (CONT'D) Figure 40-100-3
Figure 40-100-1
3
2
1
P-50991
Remove the rear pedal (Item 1) bushing (Item 2) and

P-73506 wave washer (Item 3) [Figure 40-100-3].
Figure 40-100-4
Remove the bolt (Item 1) [Figure 40-100-1] and nut.

Remove the right pedal.
Figure 40-100-2
1
1
P-50992
Remove the front pedal (Item 1) [Figure 40-100-4].
P-50990
Remove the nut and washer (Item 1) [Figure 40-100-2].

494 of 726
Figure 40-100-5
P-50995
1
P-50993 pedal lock.
NOTE: Do not lubricate the O-rings (Item 1) [Figure

Remove the dust cover (Item 1) [Figure 40-100-5]. 40-100-6] and [Figure 40-100-7]. The O-rings
provide a friction fit to prevent the lock from

Figure 40-100-6 moving freely.
P-50994

pedal lock.
Remove the pedal lock from the pedal mount.

495 of 726
Remove the right console cover.
Figure 40-100-8
1
1
1 1
P-73493
1 Remove and cap the hoses (Item 1) [Figure 40-100-10].
Figure 40-100-11

P-69685
Figure 40-100-9 2
1
P-61161B
1
Remove the nut and washer (Item 1). Remove the cotter
pin and clevis pin (Item 2). Remove the linkage (Item 3)
[Figure 40-100-11].
P-69683
Looking down into the bottom of the right console [Figure

40-100-8] and removing the bolt (Item 1) [Figure 40-100-
9] and nut (Item 1) [Figure 40-100-8].

496 of 726
TRAVEL LEVER / PEDALS Figure 40-110-3
Description
The travel levers / pedals control the movement of the

excavator.

1
Remove the floor mat & floor panel. (See Removal And
Figure 40-110-1
P-73516
Remove the travel controls.

1 2
P-73515
Remove the nut (Item 1) from both the left and right
linkage rods. Remove the linkage rods (Item 2) [Figure
40-110-1].
Figure 40-110-2
1
1
1
P-73518
Remove the bolts (Item 1) and lower the travel control

valve (Item 2) [Figure 40-110-2].

497 of 726
TRAVEL LEVERS / PEDALS (CONT’D) Figure 40-110-6
Figure 40-110-4 2
1
2
2
2 1
3
P-61210
1
3 Remove the bolts (Item 1) and nuts. Remove the left and
P-61208
right travel levers (Item 2) [Figure 40-110-6].
Figure 40-110-7
Remove the bolts (Item 1), spacers (Item 2) and linkage
bars (Item 3) [Figure 40-110-4].

Installation: Tighten the nut to eliminate side play while
allowing free travel of the pedals.
Figure 40-110-5
1
1
2 P-61211
Remove the bolt and washer (Item 1) [Figure 40-110-7].
P-61209
Remove the bolts (Item 1) and stop plates (Item 2)

[Figure 40-110-5].

498 of 726
TRAVEL LEVERS / PEDALS (CONT’D) Assembly
Disassembly And Assembly (Cont’d) Clean all parts in solvent and dry with compressed air.
Figure 40-110-8 Inspect all parts for wear or damage. Replace any worn
or damaged parts.
3
2
1
P-61212
Remove the foot pedal (Item 1), bushing (Item 2) and

wave washer (Item 3) [Figure 40-110-8].

Figure 40-110-9
1
2
P-61213
Remove the lower mount (Item 1) from the control lever

(Item 2) [Figure 40-110-9].
NOTE: After the lever components are installed in the

excavator, the levers must be adjusted for
neutral, forward, and reverse. (See
Adjustment on Page 40-100-4.)
Installation: Clean the bolt threads and apply thread

lock adhesive (Loctite® 242). Tighten the bolts to 32-35
ft.-lb. (43-47 N•m) torque.

499 of 726
TRAVEL LEVERS / PEDALS (CONT'D) Forward Lever Stop:
Adjustment Figure 40-110-12
Remove the floor mat & floor panel. (See Removal And
Neutral
Figure 40-110-10
1
1
P-73520
2.8 in. Loosen the bolts (Item 1) on the rear pedal stop (Item 2)
(71,16 mm) [Figure 40-110-12].
2 Hold both travel levers in the forward position.

P-73519
Figure 40-110-13
Neutral position is 2.8 in. (71,16 mm) from the travel lever 1
(Item 1) to the top of the pedal mount plate (Item 2)
[Figure 40-110-10] on the travel linkage.
4
Figure 40-110-11
2.04 in.
(51,91 mm)
4 2
3
P-73520
1
Forward position is 2.04 in. (51,91 mm) from the travel
3 lever (Item 1) to the top of the pedal mount plate (Item 2)
2 [Figure 40-110-13].
P-73515
Slide the rear pedal stop (Item 3) forward until it contacts
both travel levers. Tighten the bolts (Item 4) [Figure 40-
Remove the nut (Item 1) and linkage rod (Item 2). Loosen 110-13].
the nut (Item 3) and turn the ball joint (Item 4) [Figure 40-
110-11] to adjust the linkage rod length.
Tighten the nut and install the linkage rod.
Repeat the procedure for the opposite travel lever.

500 of 726
TRAVEL LEVERS / CONTROLS (CONT'D)
Adjustment (Cont'd)
Reverse Lever Stop:
Figure 40-110-14
2 P-73521
Loosen the bolts (Item 1) on the front pedal stop (Item 2)

[Figure 40-110-14].
Hold both travel levers in the reverse position.
Figure 40-110-15
4
3.54 in.
(89,94 mm)
2 3 P-73521
Reverse position is 3.54 in. (89,9 mm) from the travel

lever (Item 1) to the top of the pedal mount plate (Item 2)
[Figure 40-110-15].
Slide the front pedal stop (Item 3) rearward until it

contacts both travel levers. Tighten the bolts (Item 4)
[Figure 40-110-15].

501 of 726
TRAVEL LEVERS / PEDALS (CONT'D) Figure 40-110-18
Installation on Page 40-90-1.) 2 1 1 2
Remove travel levers/pedals. (See Removal And

Figure 40-110-16
5.45 in.
(138,5 mm)
1
P-61203
2 Loosen the nuts (Item 1). Remove the ball joints (Item 2)
[Figure 40-110-18].
3
Installation: The distance between the linkage ball joints
is 5.45 in. (138,5 mm) [Figure 40-110-18].

The travel controls must be adjusted for neutral, forward
P-61229
and reverse. (See Adjustment on Page 40-110-4.)
Hold the nut (Item 1). Remove the bolts and washer (Item
2) [Figure 40-110-16].
Remove the control linkage (Item 3) [Figure 40-110-16]

from the excavator.
Figure 40-110-17
2 2
1 1
P-61230
Remove the nuts (Item 1) and the linkage rods (Item 2)

[Figure 40-110-17] from the mounting plate.
Inspect the ball joints, and replace as needed.

502 of 726
FUEL TANK Figure 40-120-1
1
Remove the travel controls. (See Removal And
Remove the seat and seat mount. (See SEAT AND SEAT
MOUNT on Page 40-40-1.) 1
Remove the heater unit (If equipped) (See Removal And

P-73462
Remove the joystick console cover. (See Joystick
Console Cover (Bottom) Removal And Installation on
Page 40-60-1.) Remove the bolts (Item 1) Take new Photo when
Reassembling [Figure 40-120-1].
Remove the joystick console cover. (See Joystick
Console Cover (Top) Removal And Installation on Page Figure 40-120-2
40-60-2.)

9.)
2
Remove the boom swing cylinder. (See Removal And
1
Drain the fuel tank. (See Draining The Fuel Tank on Page
10-80-4.)
WARNING P-73463
Always clean up spilled fuel or oil. Keep heat, flames, Remove the bolt (Item 1) and cover (Item 2) [Figure 40-
sparks or lighted tobacco away from fuel and oil. 120-2].
W-2103-1285

503 of 726
FUEL TANK (CONT’D) Figure 40-120-5
Removal And Installation (Cont’d) 1
Figure 40-120-3
1
2
1
P-73444

P-73442
Figure 40-120-6
Remove the bolts (Item 1) and loosen the bolt (Item 2)

[Figure 40-120-3]

Figure 40-120-4
2
1
P-61189A
Reposition the left console as shown [Figure 40-120-6].
P-61192
Loosen the bolt (Item 1) and remove the console side

frame (Item 2) [Figure 40-120-4].

504 of 726
FUEL TANK (CONT’D) Figure 40-120-9
Figure 40-120-7
2
2 1
2
3
1
2 1
3 P-73458
4
Remove the hose clamps (Item 1) remove the two hoses
P-58372 (Item 2) and the two bolts [Figure 40-120-9].
Figure 40-120-10
Remove the fuel sending unit wire harness (Item 1) the
two hoses (Item 2) and remove the foam pads [Figure

40-120-7].
Installation: Install the pads (Item 3) under the nuts

(Item 4) [Figure 40-120-7] to prevent the floor plate bolts
from damaging the fuel tank.
Figure 40-120-8
P-58340
1
Remove the fuel tank (Item 1) [Figure 40-120-10].
2
P-58342
Remove the two bolts (Item 1) and the bracket (Item 2)

[Figure 40-120-8].

505 of 726

506 of 726
HORN Figure 40-130-2
Removal And Installation 1
Figure 40-130-1
1
P-73680
2
Disconnect the wire harness from the horn (Item 1)
[Figure 40-130-2].
P-73679 Remove the nut (Item 2) [Figure 40-130-2] and remove

the horn.

For cab equipped: Remove the bolt (Item 1). Remove the
windshield washer fluid bottle (Item 2) [Figure 40-130-1]
to access the horn below.

507 of 726

508 of 726
SWING FRAME Removal And Installation
Description Rotate the upperstructure so the blade is to the rear of

the excavator.
The swing frame is the casting connected to the boom
swing cylinder and the boom with the top mounted boom Remove the attachment. (See BUCKET on Page 40-170-
cylinder. The swing casting provides the pivot point for 1.)
the boom in the offset function and the up down motion of
the boom. The swing frame is connected to the Remove the arm. (See Removal And Installation on Page
upperstructure by a top and bottom pivot pin. 40-160-1.)
Remove the boom. (See Removal And Installation on

Page 40-150-1.)
Figure 40-140-1
1 1

2
P-23472
Remove the bolts (Item 1) and the clamp (Item 2) [Figure

40-140-1].
NOTE: When the hoses have been removed from the

clamped position, the hoses must be
measured for correct clamped length and
position. (See Hose Routing on Page 40-140-
5.)

509 of 726
SWING FRAME (CONT’D) Figure 40-140-4

2
Figure 40-140-2
2
1
P-23475
Install the boom pin (Item 1) using spacers to position a

lifting clevis (Item 2) [Figure 40-140-4] on the center of
P-71548A the boom pin.
NOTE: The spacers will prevent the clevis from
Remove the snap ring (Item 1), washer, and pin (Item 2) sliding on the boom pin causing the swing
[Figure 40-140-2] from the swing frame. frame to tip from side to side.

Figure 40-140-5
Figure 40-140-3
1
1
P-23476
P-23474

Remove the hose bracket (Item 1) [Figure 40-140-3]. washer from the top pin.
Reposition the hoses to provide access for pin removal.
IMPORTANT
Do Not use a porta-power to press out the swing
frame pivot pins without the lower pin being
supported. Excess pressure can cause the swing
frame casting to crack.
I-2092-1204

510 of 726
Figure 40-140-6
1
P-23566
Support the bottom pin with a jack.

Install a porta-power between the top and bottom pins

and press the top pin out [Figure 40-140-6].
Figure 40-140-7
P-23568
Use a large punch (Item 1) [Figure 40-140-8] and drive

the bottom swing frame pin out.
NOTE: Do not use a porta-power to press out the

1
bottom pin because the top casting cannot be
supported and possible damage to the
casting could occur.
P-23567

washer from the pin.
Install a spacer tube (Item 2) [Figure 40-140-7] and jack

under the swing frame to support the casting. The spacer
tube must be large enough to allow the pin to be driven in
the center of the spacer for pin removal.

511 of 726
Figure 40-140-9
1
P-23567
1
Installation: Align the boom swing frame and install the
P-23569 lower pin. Install the washer and snap ring (Item 1)
[Figure 40-140-11]. Lift up on the boom swing frame.
Remove the top and bottom spacer (Item 1) [Figure 40- Figure 40-140-12
140-9] from the swing frame.

Remove the swing frame.
Inspect the bushings for damage. Replace damaged

bushings as necessary. (See Swing Frame Bushing
Figure 40-140-10
P-23476
1
Installation: Install the top pin, washer and snap ring

(Item 1) [Figure 40-140-12].
P-23569
Installation: Install the top and bottom spacer (Item 1)

[Figure 40-140-10] on the swing frame. Install the swing
frame.

512 of 726
Hose Routing
Figure 40-140-13
2 5
1
6
3
4
P-23470A
Route the hoses through the swing frame as follows

[Figure 40-140-13]:

1. Bucket Base End Hose
2. Arm Base End Hose
3. Male Quick Coupler Hose
4. Female Quick Coupler Hose
5. Arm Rod End Hose
6. Bucket Rod End Hose
P-23471A
Install the hoses and hose clamp (Item 7) [Figure 40-
140-13]. Do not tighten the clamp at this time.
Measure the length of the hoses from the top of the
clamp to the end of each hose [Figure 40-140-14].
Tighten the clamp bolts when the auxiliary hoses are 29

inches (737 mm) and the arm and bucket hoses are 31
inches (787 mm) from the top of the clamp.

513 of 726
SWING FRAME (CONT’D) Swing Frame Bushing Removal And Installation
Bushing Removal And Installation
Figure 40-140-15
IMPORTANT
Do Not point (hammer) on the boom swing bracket.
Excess pressure can cause the casting to crack.
I-2095-1195
The following parts will be needed for removal and

installation of the swing frame bushings:
1. Bolt - 3/4 x 6 inches or (19 x 153 mm) long.
2. Nut - 3/4 inch or (19 mm).
P-23573
3. Washer -7/8 I.D. x 3-1/8 O.D. x 3/8 inch thick or (22
mm I.D. x 79 mm O.D. x 10 mm thick.
Figure 40-140-16 4. Washer - 7/8 I.D. x 3-1/2 O.D. x 3/8 inch thick or (22
mm I.D. x 89 mm O.D. x 10 mm thick).

5. Washer - 7/8 I.D. x 4-1/2 O.D. x 1/2 inch thick or (22
mm I.D. 114 mm O.D. x 13 mm thick).
6. Spacer - 3-1/2 I.D. x 4-1/4 O.D. x 1-1/2 inch thick or

(89 mm I.D. x 108 mm O.D. x 38 mm thick).
P-23572
The same procedure is used to remove and install the

bushings in the frame castings [Figure 40-140-15] &
[Figure 40-140-16].

514 of 726
Swing Frame Bushing Removal And Installation

(Cont’d)
Figure 40-140-17
4 5
1
2
1
2
3
4 P-23571
3
Put the washer (Item 1) [Figure 40-140-18] over the

5 flanged end of the bushing.
P-23570
Put the spacer (Item 2) and the washer (Item 3) [Figure
40-140-18] over the bushing hole casting. Center the
Install the spacer (Item 1) and washer (Item 2) [Figure spacer and the washer over the bushing hole.

40-140-17] over the flanged end of the bushing.
Install the bolt (Item 4) through the washers, the spacer
The spacer (Item 1) [Figure 40-140-17] must be and the bushing. Install the nut (Item 5) [Figure 40-140-
centered over the bushing to avoid contact between the 18].
bushing and the spacer during removal.
Tighten the bolt and nut until the bushing is seated in the
Install the washer (Item 3) [Figure 40-140-17] onto the casting.
opposite end of the bushing. This washer must be
centered on the bushing and must not contact the
casting.
Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
140-17] through the washers and the spacer.
Tighten the bolt and nut to remove the bushing from the
casting.
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.

515 of 726

516 of 726
BOOM Removal And Installation
Description Remove the arm. (See Removal And Installation on Page

40-160-1.)
The boom is the section that is connected to the swing
frame and the arm. The boom has the boom and arm Remove the boom cylinder. (See Removal And
cylinders mounted on the top of the boom. Installation on Page 20-20-4.)
Figure 40-150-1
P-73040

Cut and remove the cable ties (Item 2) [Figure 40-150-

1].
IMPORTANT
damage the system.
I-2003-0888

517 of 726
BOOM (CONT’D) Figure 40-150-4
Figure 40-150-2
P-53229
2
Remove the boom [Figure 40-150-4].
P-53227
Figure 40-150-5
Remove the tubeline clamp (Item 1) [Figure 40-150-2].

Mark and remove the hoses (Item 2) [Figure 40-150-2].
Figure 40-150-3
2 1
P-53230
1 Remove the seals (Item 1) [Figure 40-150-5] from both

sides of the boom.
P-53228 Remove the bushings from both sides of the boom.
Install the new bushings in the boom.

Remove the snap ring (Item 1), washers (Item 2) [Figure
40-150-3] and pin.

518 of 726
BOOM (CONT’D)
Figure 40-150-6
0.197 in. (5 mm)
TS-1614A
Install the bushings until they are seated 0.197 inch (5

mm) in the pin boss [Figure 40-150-6]. (Both sides)

Install new seals on both sides of the boom.

519 of 726

520 of 726
ARM Removal And Installation
The arm is the section that is connected to the end of the

boom section and the bucket/bucket link.
P-55989
Support the boom [Figure 40-160-1].
Remove the arm cylinder. (See Removal And Installation

on Page 20-21-3.)

Support the arm with a chain hoist.
Figure 40-160-2
1
1
P-6997
Disconnect the bucket cylinder hoses (Item 1) [Figure

40-160-2].
Remove the nut (Item 2) [Figure 40-160-2] and the

washer (Item 3) [Figure 40-160-2] from the boom
mounting pin.
Installation: Tighten the lock nut until it is seated firmly

against the boom. Do not over tighten and deflect the
boom mounting plates. The arm must pivot freely.
Remove the arm.

521 of 726
ARM (CONT’D) Arm To Bucket And Bucket Link Bushing Removal
And Installation
Arm To Boom Bushing Removal And Installation
Figure 40-160-5
Remove the dust seal (if equipped) from both sides of the
arm.
Figure 40-160-3
1
N-16507
Remove the dust seals (Item 1) [Figure 40-160-5] from

N-16505 both sides of the arm.

Figure 40-160-6
Remove the bushings (Item 1) [Figure 40-160-3] from
both sides of the arm.
Figure 40-160-4
N-16506
Remove the bushings (Item 1) [Figure 40-160-6] from

0.197” (5 mm) TS-1614 both sides of the arm.
Install the bushings until they are seated 0.197 inches (5

mm) in the pin boss [Figure 40-160-4] (both sides).
Install new dust seals (if equipped).

522 of 726
ARM (CONT’D)
Arm To Bucket And Bucket Link Bushing Removal

And Installation (Cont’d)
Figure 40-160-7
0.197” (5 mm) TS-1614
Install the bushings until they are seated 0.197 inches (5

mm) in the pin boss [Figure 40-160-7] (both sides).
Install the dust seals (Item 1) [Figure 40-160-5] on both

sides of the arm.

523 of 726

524 of 726
BUCKET Figure 40-170-2
Removal And Installation (Pin-On X-Change)
Installation
WARNING
Never use attachments or buckets which are not
approved by Bobcat Company. Buckets and
attachments for safe loads of specified densities are
approved for each model. Unapproved attachments
W-2052-0500
Figure 40-170-1
2 1

2
P-49836
Start the engine and move the arm toward the bucket
P-49705 [Figure 40-170-2].
Inspect the pin (Item 1) [Figure 40-170-1] for wear or

damage. Replace the pin as needed.
Apply a light coat of grease to the ends of the pin (Item 2)

[Figure 40-170-1].

525 of 726
BUCKET (CONT’D) Figure 40-170-4
Removal And Installation (Pin-On X-Change) (Cont’d)
Figure 40-170-3

1
2
3
P-49837
Raise the boom and extend the bucket cylinder until the
X-Change contacts the attachment back [Figure 40-170-
4].
P-49835
With the arm vertical, lower the boom until the hooks
(Item 1) of the bucket disengage the pins (Item 2) of the
Raise the boom until the pins (Item 1) engage the hooks X-Change and the plate (Item 3) [Figure 40-170-4] fully
(Item 2) [Figure 40-170-3] on the bucket. engages in the bucket crossmember.
WARNING
Keep all bystanders 20 feet (6 m) away from
equipment when operating. Contact with moving
parts, a trench cave-in or flying objects can cause
injury or death.
W-2119-0788

526 of 726
Figure 40-170-5 1
P-49708
1 Install the retainer pin (Item 1) [Figure 40-170-6].
Check for proper installation.

P-49706
Lift the attachment and fully extend and retract the bucket
cylinder.

Stop the engine. Turn the start key to the ON position and
pressure.
Drive the pin (Item 1) [Figure 40-170-5] through the

bucket mount and X-Change.

527 of 726
Removal
Use the pin on X-Change when installing new

attachments that are equipped with the pin on X-Change
bracket.
NOTE: Removal and installation of the bucket is

shown. The procedure is the same for other
attachments. Disconnect any hydraulic lines
that are operated by hydraulic power before
removing any attachments (breaker, auger,
etc.).
WARNING

W-2052-0500
P-49838
Park the excavator on a flat level surface. Put the bucket

on the ground [Figure 40-170-7].
hydraulic pressure.

528 of 726
Removal (Cont’d)
Figure 40-170-8
P-49710
Remove the retainer pin (Item 1) [Figure 40-170-8].

Figure 40-170-9
P-49835
1 Start the engine, raise the boom approximately one foot

and retract the bucket cylinder until the X-Change pins
(Item 1) engage the hooks (Item 2) [Figure 40-170-10]
on the bucket.
P-49711
Drive the pin (Item 1) [Figure 40-170-9] out of the bucket

and X-Change mount.
WARNING
W-2019-1285

529 of 726
BUCKET (CONT’D)
Removal (Cont’d)
Figure 40-170-11

2
1
P-49836
Fully retract the bucket cylinder and lower the boom and
arm until the bucket is on the ground, and the X-Change
pins (Item 1) are disengaged from the hooks (Item 2)
[Figure 40-170-11].
Move the arm toward the excavator until the X-Change

pins are clear of the bucket.

530 of 726
Removal And Installation (Bolt-On X-Change)
Installation
1 1
1
Use the bolt on X-Change components when
installing older attachments that do not have the pin
retention provision. Bolt on components are
supplied with the excavator and are stored under the
right side cover.
NOTE: Removal and installation of the bucket is

shown. The procedure is the same for other
attachments. Disconnect any hydraulic lines
that are operated by hydraulic power before P-49714
removing any attachments (breaker, auger,
etc.).
Remove the three plugs (Item 1) [Figure 40-170-13].
Figure 40-170-14
WARNING

W-2052-0500
Figure 40-170-12
1 1
P-49715
Apply grease to the O-rings (Item 1) [Figure 40-170-14].
P-49713A
Fully retract the bucket cylinder and lower the arm to the
ground [Figure 40-170-12].
hydraulic pressure.

531 of 726

(Cont’d)
Figure 40-170-15
2 1
P-49716

Install the pin (Item 1) in the X-Change. Orientate the bolt
holes (Item 2) [Figure 40-170-15] as shown.
Figure 40-170-16
P-49835
1 Start the engine and move the arm toward the bucket.
Raise the boom until the pins (Item 1) engage the hooks
(Item 2) [Figure 40-170-17] on the bucket.
P-49717
Install the bolt (Item 1) [Figure 40-170-16] and washer

through the X-Change and into the pin.

532 of 726
BUCKET (CONT’D)

(Cont’d)
WARNING
Installation (Cont’d) Keep all bystanders 20 feet (6 m) away from
Figure 40-170-18 parts, a trench cave-in or flying objects can cause
injury or death.
W-2119-0788
Figure 40-170-19

P-49718
1
2
3
P-49837
Raise the boom, and extend the bucket cylinder until the
bucket is in the position shown [Figure 40-170-18].
With the arm vertical, lower the boom until the hooks
(Item 1) of the bucket disengage the pins (Item 2) of the
X-Change and plate (Item 3) [Figure 40-170-18]
engages in the bucket crossmember.
Stop the engine. Turn the start key to the ON position and
pressure.

533 of 726
BUCKET (CONT’D)

(Cont’d)
Figure 40-170-20
1 1
P-49719

Install the bolts (Item 1) [Figure 40-170-20] through the
plate and into the X-Change.
Tighten the bolts to 130 ft.-lb. (177 N•m) torque. Re-

torque the bolts after every eight hours of operation.
Check for proper installation.
Lift the attachment and fully extend and retract the bucket
cylinder.
WARNING
Keep all bystanders 20 feet (6 m) away from
parts, a trench cave-in or flying objects can cause
injury or death.
W-2119-0788

534 of 726

(Cont’d)
Removal
Figure 40-170-21
1 2 1
P-49719
Remove the two bolts (Item 1) and plate (Item 2) [Figure

40-170-22].
Figure 40-170-23

P-49838
2
Park the excavator on a flat, level surface. Put the bucket
on the ground [Figure 40-170-21]. 1
hydraulic pressure.
P-49835
Start the engine, raise the boom approximately one foot

and extend the bucket cylinder until the X-Change pins
(Item 1) engage the hooks (Item 2) [Figure 40-170-23]
on the bucket.

535 of 726
BUCKET (CONT’D)

(Cont’d)
Removal (Cont’d)
Figure 40-170-24

1
P-49836
Fully retract the bucket cylinder and lower the boom and
arm until the bucket is on the ground, and the X-Change
pins (Item 1) are disengaged from the hooks (Item 2)
[Figure 40-170-24].
Move the arm toward the excavator until the X-Change

pins are clear of the bucket.

536 of 726
Removal And Installation (Pin-On Attachment)
Installation
WARNING 1

Stop the machine on a firm flat surface. When
removing or installing attachments (such as a 1
bucket), always have a second person in the
P-11050
operator’s seat, give clear signals and work carefully.
W-2140-0189
Install the two retainer pins (Item 1) [Figure 40-170-26].
Installation Install grease in the grease fittings.
Figure 40-170-25 Removal
Park the excavator on a flat surface and lower the bucket

fully.

Remove the two retainer pins (Item 1) [Figure 40-170-
26].
1
Remove the washers and pins (Item 1 & 3) [Figure 40-
170-25].
Do not damage the dust seals in the arm.

3 2
P-11051
WARNING
Install the arm into the bucket and align the mounting
hole. Never use attachments or buckets which are not
Install the pin (Item 1) [Figure 40-170-25] and washers. attachments for safe loads of specified densities are
Install the link (Item 2) in the bucket and align the can cause injury or death.
W-2052-0500
mounting hole. Install the pin (Item 3) [Figure 40-170-
25] and washers

537 of 726
Bucket Teeth Removal And Installation
WARNING
• Pressurized fluids and springs or other stored
energy components. 2
• Tools are being used. P-23376
W-2505-0604
Remove the two nuts (Item 1) and bolts from the tooth
Position the bucket so the bucket teeth are at a 30° angle
shank (Item 2) [Figure 40-170-28]. Remove the tooth
up from the ground for accessibility to the teeth.
shank.
Lower the boom until the bucket is fully on the ground.
Installation: Tighten the nuts to 90 - 100 ft. - lb. (125 - 135
N•m) torque.
Stop the engine and exit the excavator.

Later Style Bucket Teeth
NOTE: The later style tooth points and retaining pins
can be used on the early style shanks.
Figure 40-170-29
Early Style Bucket Teeth 1
Figure 40-170-27
1 2
1
2
3
P-69201A
3 The removal and installation procedure for the later style

P-23374 tooth point and tooth shank is the same as the early style.
The later style tooth has a unique retaining pin (Item 1).
Remove the retaining pin (Item 1) from the tooth point
The retaining pin must be installed as shown [notch (Item
(Item 2) [Figure 40-170-27].
2) to the front] for proper fit and tooth retention. The side
of the tooth point (Item 3) [Figure 40-170-29] also shows
Remove the tooth point (Item 2) from the shank (Item 3)
the correct orientation of the retaining pin.
[Figure 40-170-27].
Installation: Position the new tooth point on the shank
Installation: Position the new tooth point on the shank
and install a new retaining pin. Install the retaining pin
and install a new retaining pin. Install the retaining pin
until it is flush with the top of the point.
until it is flush with the top of the point.

538 of 726
BUCKET (CONT’D)
Bucket Side Cutting Edge Removal And Installation
Figure 40-170-30
P-23377
The bucket side cutting edges (Item 1) [Figure 40-170-

30] are reversible.

Figure 40-170-31
1
2
P-23373
Remove the bolts and nuts (Item 1) [Figure 40-170-31].
Installation: Tighten the nuts to 90-100 ft.-lb. (125-135

N•m) torque.
Remove the cutting edge (Item 2) [Figure 40-170-31].

539 of 726

540 of 726
TAILGATE Latch Removal And Installation
Open the tailgate.
Figure 40-180-1
2
1
1
P-69924
Raise and support the right side cover.

P-69922
Remove the two bolts (Item 1) and the latch [Figure 40-
180-3].

Open the tailgate (Item 1) [Figure 40-180-1].
Figure 40-180-2
P-73482
Support the tailgate.
Remove the bolt and nut (Item 1) [Figure 40-180-2].
Remove the cotter pin and washer (Item 2) [Figure 40-

180-2].
Remove the Tailgate.
Installation: Tighten the nuts (Item 2) to 28 - 30 ft.-lb. (35

- 40 N•m [Figure 40-180-2].
40-180-1 425 Service Manuall

541 of 726

542 of 726
X-CHANGE Figure 40-190-3
Pin-On Removal And Installation
Remove the bucket. (See BUCKET on Page 40-170-1.)

1
Lower the boom and support the X-Change mount. 1
Figure 40-190-1
P-69708
Remove the bolts and spacers (Item 1) [Figure 40-190-

3].
Figure 40-190-4
P-73040

Support the boom with a hoist [Figure 40-190-1].
Figure 40-190-2
1
1
3
1 4
2 P-69710
2 Remove the pins (Item 1 & 2), and the X-Change mount
(Item 3) [Figure 40-190-4].
Installation: Apply grease to the bushings before

P-69707 installing pins and grease the fittings (Item 4) [Figure
40-190-4] after installing the X-Change mount.
Remove the lock pin rings (Item 1) and washers (Item 2) NOTE: Verify the two O-rings (Item 1) [Figure 40-190-
[Figure 40-190-2]. 5] on either side of the arm are present when
removing the pin (Item 1) [Figure 40-190-4].

543 of 726
X-CHANGE (CONT’D) Pin-On Disassembly and Assembly
Pin-On Removal And Installation (Cont’d) Figure 40-190-6
Figure 40-190-5
1
P-69713
P-69712
Remove the bushings (Item 1) [Figure 40-190-6].
Remove the O-ring (Item 1) [Figure 40-190-5] (both Figure 40-190-7

sides).

Installation: Use grease to hold the O-rings in place
during installation.
2
P-69706
Remove the three bolts (Item 1) and O-rings (Item 2)

[Figure 40-190-7].

544 of 726
X-CHANGE (HYDRAULIC) Figure 40-191-3
Remove the bucket. (See Operation & Maintenance

Manual for the correct removal procedure.)
Figure 40-191-1
1 1
P-77353
Remove the washers (Item 1) [Figure 40-191-3].
Figure 40-191-4
P-30306

Support the boom with a hoist (Item 1) [Figure 40-191-1]
and release the pressure on the boom cylinder.
Figure 40-191-2
1
1
P-77351
Remove the plate (Item 1) [Figure 40-191-4].

1
P-77352
Remove the snap rings (Item 1) [Figure 40-191-2].

X-CHANGE (HYDRAULIC) (CONT'D) Figure 40-191-7
Removal And Installation (Cont'd)
Figure 40-191-5
P-71245
Remove the bolt, washer and spacer (Item 1) [Figure 40-

P-77035 191-7].
Figure 40-191-8
Remove the two hydraulic hoses (Item 1) [Figure 40-
191-5] from the bulkhead fittings.

Figure 40-191-6
P-71244

P-77354
Remove the hydraulic X-Change.

X-CHANGE (HYDRAULIC) (CONT'D)
Removal And Installation (Cont'd)
Figure 40-191-9
P-71252

arm.

1. Seal
2. Bushing
3. Grease Fitting 1
4. Bucket Link 2 8
1 7
5. Nut
3
6. Rubber Block
7. Cover 4
8. Bolt
9. Swivel End 1 6
2
10. Wear Ring 1
11. O-Ring 1
12. Swivel Base
13. Retaining Ring 1 2 2
14. Piston Head 22 5 1
15. Piston 9
16. Spring 11
10
17. X-Change 1 8
Assembly
18. Clip 12

19. Pin 1
20. Spacer 10
21. Washer 11
9
22. Dowel Pin
23. Expansion Plug 22
1
2
13 2
1
1 1 2
14
11
1
19
15
3
1
17 18
16
19
20
23 21
8 8
3
19
1 20
15 21
8
1
11
14
1
13
PE-3359S

Disassembly
Figure 40-191-10
2
P-77461A
Remove the pin (Item 1) and the bucket link (Item 2)

P-77316 [Figure 40-191-12].
Figure 40-191-13
Remove the bolt (Item 1) and the cover (Item 2) [Figure
40-191-10]. 1

Figure 40-191-11
1
1 1
1
P-71241
Remove the dust seals and bushings (Item 1) [Figure

P-77461 40-191-13] from the bucket link.
Remove the bolt (Item 1) [Figure 40-191-11] washer and

spacer.

Figure 40-191-14
P-71227
1
Remove the bolt (Item 1), nut, and the swivel assembly
P-71226 (Item 2) [Figure 40-191-16].
Figure 40-191-17
Remove the two hydraulic hoses (Item 1) [Figure 40-
191-14] from the swivel ends.

Figure 40-191-15
P-71230
Remove the O-rings (Item 1) [Figure 40-191-17] from

P-71228 the swivel assembly.

Figure 40-191-18
1 3
1
P-71235
1
Remove the seals (Item 1), wear ring (Item 2) and the O-
P-71231 ring (Item 3) [Figure 40-191-20] from the swivel end.
Figure 40-191-21
Remove the screws (Item 1) [Figure 40-191-18] and
nuts from the swivel assembly.

Figure 40-191-19
1
1
P-81236
Remove the dust seal (Item 1) [Figure 40-191-21]. (Both

P-71234 swivel ends)
Remove the two swivel ends (Item 1) [Figure 40-191-

19].

Figure 40-191-22
1 1
MS-2247
Remove the retaining ring (Item 1) [Figure 40-191-24].

P-71238 (Both sides)
Figure 40-191-25
Remove the four bushings (Item 1) [Figure 40-191-22].

Figure 40-191-23
1
2
1
MS-2248
P-71529 Remove the piston head (Item 1) and the piston (Item 2)
[Figure 40-191-25]. (Both sides)
Apply inward pressure on the piston (Item 1) [Figure 40- Separate the piston head (Item 1) and the piston (Item 2)
191-23]. (Both sides) [Figure 40-191-25]. (Both sides)

Figure 40-191-26
1
2
1
MS-2251
Remove the piston seal (Item 1) [Figure 40-191-28] from

MS-2249 the piston.
Figure 40-191-29
Remove the back-up ring (Item 1) and the O-ring (Item 2)
[Figure 40-191-26] from the piston head.

Figure 40-191-27
1
1
MS-2252
Remove the compression spring (Item 1) [Figure 40-

MS-2250 191-29].
Remove the two pin seals (Item 1) [Figure 40-191-27]

from inside the piston head.

Assembly
Clean all parts in solvent and dry with compressed air. 1
Inspect the cylinder parts for wear or damage. Replace

any worn or damaged parts. 1
Always install new O-rings and seals.
Lubricate all O-rings and seals with hydraulic oil during

installation.
Figure 40-191-30
MS-2250
Install the two pin seals (Item 1) [Figure 40-191-32] on

the inside of the piston head.
Figure 40-191-33

1
1
2
MS-2252
Install the compression spring (Item 1) [Figure 40-191-

30].
Figure 40-191-31
MS-2249
Install the O-ring (Item 1) and back-up ring (Item 2)

1 [Figure 40-191-33] on the piston head.
MS-2251
Install the piston seal (Item 1) [Figure 40-191-31] on the

piston.

Assembly (Cont'd)
Figure 40-191-34
1
2
P-71239
1
Install the bushings (Item 1) [Figure 40-191-36].

MS-2248
Figure 40-191-37
Install the piston (Item 1) and the piston head (Item 2)

[Figure 40-191-34]. 1

Figure 40-191-35
P-71238
1
Install the bushings (Item 1) [Figure 40-191-37].
MS-2247
Apply inward pressure on the piston and install the

retaining ring (Item 1) [Figure 40-191-35].

Assembly (Cont'd)
1
Figure 40-191-38 1
P-71231
Install the swivel ends (Item 1) [Figure 40-191-40] onto

P-71235 the base.
Figure 40-191-41
Install the dust seal (Item 1) [Figure 40-191-38] on the
swivel.

Figure 40-191-39
1
2
1
1 P-71230
3
Install the screws (Item 1) [Figure 40-191-41] and nuts in

P-71234 the swivel assembly. Do not tighten at this time.
Install the O-ring (Item 1) wear ring (Item 2) and the seals
(Item 3) [Figure 40-191-39].

Assembly (Cont'd)
Figure 40-191-42
P-72156
Using a marker, mark the three screw holes on the

P-72164A washer [Figure 40-191-44].
Repeat for the opposite side.

It is necessary to fabricate a preload tool to get the
proper torque on the swivel assembly screws. The tool Figure 40-191-45

consists of a 5/8 x 5 in. course thread bolt, two 5/8 x 2 in.
flat washers and a 5/8 course thread nut [Figure 40-191-
42].
NOTE: This procedure must be followed to ensure the

swivel assembly screws are tightened to the
proper torque value.
Figure 40-191-43
P-72167
Using a grinder, remove material identified in the

previous step [Figure 40-191-45].
P-72155 WARNING
Eye and body protection is required when welding or
Center a 2 in. flat washer on one side of the swivel
grinding. Wear approved goggles, helmet and
assembly [Figure 40-191-43].
clothing. Failure to wear eye and body protection can
result in serious injury.
W-2009-1285

Assembly (Cont'd)
Figure 40-191-46
2
P-72162A
3
Turn the swivel assembly over and install the remaining 2

P-72160A in. flat washer (Item 1) and nut (Item 2) [Figure 40-191-
48].
Install a 2 in. flat washer (Item 1) onto the bolt (Item 2) Figure 40-191-49
[Figure 40-191-46].

Figure 40-191-47
P-72163A
P-72189A NOTE: Ensure the notches in both washers are

aligned with the screw holes on the swivel
assembly [Figure 40-191-49].
Insert the bolt through the center of the swivel assembly
aligning the notches in the flat washer with the screw Tighten the preload tool nut (Item 1) [Figure 40-191-49]
holes [Figure 40-191-47]. to 83 ft.-lb. (112.5 N•m) torque.

Assembly (Cont'd)
Figure 40-191-50
1 1
P-71228
1 Install the swivel assembly (Item 1) using the bolt (Item 2)

P-72157A [Figure 40-191-52].
Figure 40-191-53
Tighten the swivel assembly screws (Item 1) [Figure 40-
191-50] to 10.4-11.6 ft.-lb. (14,2-15,8 N•m) torque.

NOTE: This procedure must be followed to ensure the
swivel assembly screws are tightened to the
proper torque value.
1
Remove the preload tool.
Figure 40-191-51
1 P-71226
Install the bolt (Item 1) [Figure 40-191-53] and nut.
P-71227
Install the two O-rings (Item 1) [Figure 40-191-51] into

the swivel assembly.

Assembly (Cont'd) 2
Figure 40-191-54
P-77461A
1
Install the bucket link (Item 1) and pin (Item 2) [Figure

P-71226 40-191-56].
Figure 40-191-57
Install the hydraulic hoses (Item 1) [Figure 40-191-54]
onto the swivel ends.

Figure 40-191-55
1
1
1
P-77461
1 Install the spacer, flat washer and bolt (Item 1) [Figure

P-71241 40-191-57].
Install the bushings (Item 1) [Figure 40-191-55] and dust

seals into the bucket link.

Assembly (Cont'd)
Figure 40-191-58
P-71172
Install the foam block and cover (Item 1) using the bolt
(Item 2) [Figure 40-191-58] and nut.


RIGHT SIDE COVER Latch Removal And Installation
Figure 40-200-1
1
1
P-69927
P-69925
Raise and support the right side cover.
Open the right side cover (Item 1) [Figure 40-200-1]. Remove the two bolts (Item 1) and the latch (Item 2)
[Figure 40-200-3].

Figure 40-200-2
2
1
P-73478
Support the right side cover.
Remove the bolt and nut (Item 1) [Figure 40-200-2].
Remove the nut (Item 2) and remove the hinge (Item 3)

[Figure 40-200-2].
Slide the right side cover towards the rear of the machine
and remove [Figure 40-200-2].
Installation: Tighten the nuts (Item 2) to 28 - 30 ft.-lb. (35

- 40 N•m [Figure 40-200-2].

563 of 726

564 of 726
COUNTERWEIGHT Removal And Installation (Long Arm Counterweight)
Figure 40-210-1
2
P-73095
P-69922
Remove the plugs from the threaded holes and install the
lifting rings (Item 1) [Figure 40-210-2].
The counterweight is the casting connected to the rear of
the machine. The inner counterweight (Item 1) [Figure Figure 40-210-3

40-210-1] is standard on excavators with standard arms.
Excavators installed with a long arm option have an
additional counterweight (Item 2) [Figure 40-210-1]
attached to the inner counterweight. Weight of the inner
counterweight is 389.5 lb. (176,7 kg) and the weight of
the long arm option counterweight is 390.3 lb. (177 kg).
2 2
3 P-73096
Install the chain hoist to the lifting rings (Item 1) [Figure

40-210-3].
Remove the two bolts and nuts (Item 2) [Figure 40-210-

3].
Remove the counterweight (Item 3) [Figure 40-210-3].
Installation: Tighten the bolts to 470 - 520 ft.-lb. (640 -

700 N•m).

565 of 726
COUNTERWEIGHT (CONT’D) Figure 40-210-6
Removal And Installation (Standard Counterweight)
Figure 40-210-4 1
P-73102
Remove the bolt, washer and nut (Item 1) [Figure 40-

P-73098 210-6] from the center of the counterweight.
Installation: Tighten the bolts to 470- 520 ft.-lb. (640 -

Remove the plugs from the threaded holes and install the 700 N•m).
lifting rings (Item 1) [Figure 40-210-4].

Figure 40-210-7
Figure 40-210-5
1
1
2 3
2
P-73099
P-73099

Install the chain hoist to the lifting rings (Item 1) [Figure the counterweight.
40-210-5].
Remove the counterweight (Item 3) [Figure 40-210-7]
from the machine.
Installation: Tighten the bolts to 470 - 520 ft.-lb. (640 -

700 N•m).

566 of 726
LEFT SIDE COVER
Figure 40-220-1
1 1
P-69941
Remove the four bolts (Item 1) and side cover (Item 2)

[Figure 40-220-1].

Installation: During installation the left side cover must
be installed behind the cab seal.

567 of 726

568 of 726
ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5
Alternator Regulator Test With Voltmeter. . . . . . . . . . . . . . . . . . . . 50-30-5
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Full Field Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-7
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2 ELECTRICAL
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . 50-20-3 SYSTEM AND
ANALYSIS
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . 50-10-7
Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-6
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 50-50-2
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Upperstructure Light Disassembly And Assembly . . . . . . . . . . . . . 50-50-1
Upperstructure Light Removal And Installation . . . . . . . . . . . . . . . 50-50-1
MAGNETIC LOCKOUT SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Left Console Magnetic Lockout Sensor Removal And Installation 50-60-2
Testing Left Console Magnetic Lockout Sensor. . . . . . . . . . . . . . . 50-60-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

569 of 726

570 of 726
CONTROL MODULE CONNECTORS J1-J5
WORKGROUP D25 AND D31

SWITCHED POWER RELAY
PWM WORKGROUP D37

J3 J4 J1 J5 J2
SPARE KEYLESS SOL

WIRING SCHEMATIC
SENSOR POWER (+8V)

RED = RED
SPARE RELAY OUT

WIRES CONNECT BY LETTER BATTERY FEED 1000-1999 RED, RED/WHT, RNG
ENGINE SPEED HALL

GLOW PLUG STATUS
FUEL PULL STATUS

RNG = ORANGE
ENGINE SPEED VR
STARTER STATUS
ACROSS CONNECTORS
HYD X-CHANGE
SENSOR GROUND
GROUND 2000-2999 BLK
LOAD MOMENT
BLK = BLACK
2 SPEED PWM
425 (S/N A1HW11001 AND ABOVE)
HYD OIL FILTER
ENG OIL PRESS
FRONT BASE
R POT SIGNAL
ENGINE TEMP
GLOW PLUG
LBL = LIGHT BLUE
FRONT ROD
SPARE ANG #1
FUEL SENDER
MONITORING 3000-3999 LBL
FUEL HOLD
L POT SIGNAL
R SKI DOWN
PIEZO OUT
CAN SHIELD
L SKI DOWN
A B
FUEL PULL
DBL = DARK BLUE
STARTER
BATTERY
BATTERY
GROUND
GROUND
CAN HIGH
CAN LOW
HYD TEMP
HYDRAULIC 4000-4999 LGN
CONSOLE
R SKI UP
LGN = LIGHT GREEN
2 SPEED
B A
L SKI UP
DETENT
LIGHT
CRANK
ATTACHMENT CONTROLS 5000-5999 YEL DGN = DARK GREEN
(PRINTED NOVEMBER 2006) YEL = YELLOW
KEY
LIGHTS 6000-6999 PNK PNK = PINK
V-0853 SOME CONNECTOR ACCESSORIES 7000-7999 WHT WHT = WHITE K G J B C D A E F H J H K A B F E G D C
K J G E C H D A B F
BODIES NOT SHOWN BRN = BROWN F G D C H A B E F K G H D A B J C E
ENGINE 8000-8999 TAN TAN = TAN
FOR DRAWING CLARITY
Printable Version Click Here COMMUNICATION 9000-9999 PUR PUR = PURPLE
GRY = GRAY
RIGHT HAND CONSOLE
4330
4340
3710
9320
4500
4450
4970
HARNESS 7130798
9700
9600
4320
4960
4920
2100
2110
9500
8000
8110
8150
6210
9370
1110
1120
8510
3600
3430
3500
8550
9350
8120
9330
9360
4830
4300
3900
3300
4310
3100
3200
C158
LEFT HANDLE A A 3100
FUEL SENDER 20-270 ohm RIGHT HANDLE
B B 3310
3100 B B 3100
A A 4830 3310 C C 3310 4920 B B BRN
B A DETENT
RED C C 1720 4830 D D 4830 4960 1780 1770 C C RED
C467
C456
D D 4400 4370 E TWO-SPEED
E 4370
(BLADE LEVER)
4360 E E WHT
E 4390 4380 F
C457
E F 4380 4320 A A GRN
PWM
HORN
BRN B B 9200 3900 H H 3900 4350 D D BLK
LOAD MOMENT
9200 G G 9200 (OPTIONAL)
3700 J J 3700 3700 3710
3910
A 1730 A A 1730
LH CONSOLE CONSOLE
C 3920 K K 9200
SENSOR
HARNESS B 3900
HORN
7130797
1 2 1720
C458
3700
3
A 7130
1730
FRAME B 2650
4
2900 LIGHT TRAVEL
6 5 LOAD MOMENT
2610
9320
2950 (OPTIONAL) ALARM
2950 6230
(OPTIONAL)
HYD TEMP
-
+
t
SENDER
3300
1 2 538-1824 ±30
6310
3
6300
1
B A ohm 3320 BUZZER
1460 2
4 3
C470
7120
C413
1750 B A A 4450
2930 6 5 HYD FILTER HYDRAULIC X-CHANGE
4 SWITCH 3430
2900 7110 OPTION CONNECTOR B 2450
7100
BEACON 5 6
SWITCH TWO-SPEED
C414
(OPTIONAL) A A 4970
WIPER SWITCH 8 ohm nominal at 12VDC YELLOW TIE STRAP
(OPTIONAL) 6230 E E 6230 B B 2480
7110 F F 7110
1460 D D 1460
6300 C C 6300
C461
2930 J J 2930
6240 B B 6240
2790 G G 2790
6400 A A 6400
C100
FUEL + + 2700 H H 2700 WORK GROUP
7120
7100
6240
2950
6400
6310
1750
PUMP - - 8700 K K 8700 LOCKOUT

2960
C415
8 ohm nominal A A 4500
GREEN TIE STRAP
at 12 VDC B B 2500
AUX
SOCKET FRONT ROD
B A B A C C A B
C419
6400 6 ohm nominal A A 4330
C465
1 BLUE TIE STRAP
C463 C469 C464 7210 at 12 VDC B B 2330
CAB HARNESS 2 2840
7102833
A B B A C A C B
Dealer Copy -- Not for Resale 6 ohm nominal
FRONT BASE
A A 4340
C418
RED TIE STRAP
(IF EQUIPPED) at 12 VDC
6400
6310
6240
1750
GRN
2950
BRN
YEL
WIPER B B 2340
C462
DOME LIGHT HARNESS + 7110
2880 6400
7100772 - 2820
WASHER I
1000 WHT
BOTTLE 9330 C C
B RED
C455
8 A A
RADIO CONNECTOR
7 2975 9340 B B
A
C460
6220 A
GRN
BRN
9 6220 ST
YEL
1750 9400 D D DGN

2 2980 _ LEFT 2940 B B 2940
+
6 7980 SPEAKER
BOOM LIGHT
5 2990 _ RIGHT A C B
+
HARNESS
4 7990 SPEAKER A B
OPE C624 6808415 START
1 N
OPE A C B RUN
6240
2860
3 N OFF
A B
PARK
C619
BRN A A 6310
IGNITION
B A SWITCH
BLK B B 2870
M
V
HIGH
C625
6220
2940
BEACON B A
WORK LIGHT GROUND
HARNESS 120 ohm
MOTOR WIPER
2860
6240
BOOM
LEFT WORK RIGHT WORK LIGHT
2090
2090
LIGHT (OPT) LIGHT (OPT) ACD & REMOTE START
C626
C627
A A PNK PNK A A CONNECTOR

1150
B B BLK BLK B B
1070 1040
1330
A B C D G E F POWER LEADS
1310
FUEL SHUT OFF
WHT TO BLK = 0.26 ohm
(EARLY MODEL FUEL FUEL SOLENOID ENGINE HARNESS C453 1060 1030
RED TO BLK = 10.9 ohm SHUTOFF ONLY) HARNESS 6814830 7130796 A B C D G E F 1360
HOLD 8150 A A 8150 A
C101
8100 B B 8100 B
9500
9600
9700
2710
1320
1140
PULL 2800 C
2000, 2330, 2340, 2450, 2480, 2500, 2650,
2310
2710, 2820, 2830, 2940
GROUNDS
0.33 OHM HOLD
(LATER MODEL A A 8150 8150 A A 8150
C450
C101
FUEL SHUTOFF) B B 8100 8100 B B 8100 2300

2100, 2110, 2610, 2740,
24.5 OHM PULL 2790, 2840, 2930, 2700
C C 2800 8500 C C 8500
GLOW PLUGS HR 8500

0.4 ohm
8550
K K 15A 25A 25A
8550 C C 8550 AUX ACD FUEL
GLOW FUEL
C160
3600 A A 3600 3600 G G 3600 FUSE 12 FUSE 4 FUSE 8

SPEED
STARTER LIGHTS
20A PLUGS PULL 25A 5A
SENSOR (VR) 3630 B B 3630 3630 H H 3630
LIGHTS ALT HEATER IGN
C451
3500 D D 3500 FUSE 11 FUSE 3 FUSE 7

3200 E E 3200 25A 20A 25A
ENGINE OIL 3500
PRESSURE 3210 F F 3210 ACD SW POWER HEATER
FUSE 10 SWITCH FUSE 2 FUSE 6

SWITCH 9360 J J 9360
RADIO 25A POWER 5A
9390 A A 9390
CONTROLLER WIPER
MEMORY
8100
8120
ENGINE COOLANT
t 1480 B B 1480 FUSE 9 FUSE 1 FUSE 5
C159
3200 A A 3200 FUSE 4

SENDER ACD POWER 25A 1
500-3000 ± 30 ohm B
8110
3210 B 3210
1320
6200
6210
FUEL
FUSE 1 SHUTOFF
STARTER WIPER POWER
7210
7220
5A 87A 87 86 LIGHT
8000
8500
8510
1460 RELAY
B M C161
9390
9380
S C B A FUSE 3 SWITCHED 86 87 87A GLOW

1080 9360 HEATER
GROUNDS 9390 ALT / HEATER 25A POWER 30 85 PLUG
2060 1480 1050 STARTER
2010
2030
85 30 87A 87 86
2800
2740
1190
1740
87A 87 86 87A 87 86
S 1740
1140
G EXC FUSE 2
2030
2040
30 85
1080 1480 SWITCH POWER 20A
30 85 30 85
1350
7200
1110
1120
7220
9400
2040
2050
1060
ALTERNATOR
1370
6300
25A
1330
2000
2010
1070
7200
2050
FUSE 10
1150
25A 1470 + RADIO 25A
BATTERY FUSE 6 2830 - CONN FUSE 8 25A 15A 5A

1310
20A
+ - RELAY GROUNDS 2000-2050
FUSE 9 FUSE 12 FUSE 7
1310
FUSE 11
1150
1360
1310
1360
ARE CONNECTED IN SERIES

571 of 726
1030
1040
V-0853 (10-23-06)
WIRING SCHEMATIC
OPTIONS
425 (S/N A1HW11001 AND ABOVE)
(PRINTED NOVEMBER 2006)
V-0854
HERE OR TO OPTIONS
HEATER
(HVAC JUMPER)
VALVE
A
C613
OFF DBL A A 3200 1300 A
WHT B B 7200 D D M
C614
LOW
MEDIUM BLK C C 2110 2130 C C
HIGH POTENTIOMETER B B
C631
B 2310 E E
A 7010 F F
AIR CONDITIONER TO OPTIONS (AC
1110 SWITCH HARNESS 6818334)
C 3100 3100 A A
C621
7000 ELECTRONIC
7010 B B THERMOSTAT
B 2120 C C
1000 2100
L
5000 5000 C C YEL
M
C611
1200 1200 B B RED
H 1010 1010 A A RNG M

2200 D D BLK
BLOWER
BLOWER SWITCH HEATER RELAY SWITCH
POWER RELAY MOTOR
TO OPTIONS
86
85
(DELUXE ACCESSORY)
2210
1740 A
C161
87
1190 B
1000
2740 C
87A
30
HVAC HARNESS -
6818333
TO RIGHT HAND
CONSOLE HARNESS
C458
B A
C635
2650 7130 A A
7140 7140 B B
MOTION VALVE SWITCH

ALARM
HARNESS
MOTION
ALARM
V-0854 (10-23-06)
572 of 726
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

573 of 726
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch to
warn personnel.
BUZZER - Audible alarm. Sounds at

1 SWITCH - Light - Multi position switch a predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 oh m magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

574 of 726
Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown
in the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
B FUEL SENDER - Provides a variable

resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A SPEED SENSOR - magnetic pickup -

detects RPM.
B

575 of 726
Harness Connectors
MS2309S

576 of 726
Harness Connectors (Cont’d)
MS2310S

577 of 726
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat service personnel Operation & Maintenance Manual, Operator’s
only. Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
Untrained operators and failure to follow instructions
W-2003-0903
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
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.

578 of 726
ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Location / Identification
Description A decal is inside the cover to show location and amp

ratings.
Figure 50-10-1
Remove the cover to check or replace the fuses and
relays.
1
Figure 50-10-2
P-69946
The excavator has a 12 volt, negative ground electrical

system. The electrical system is protected by fuses
B-19812

located under the right side cover of the excavator (Item
1) [Figure 50-10-1]. The fuses will protect the electrical
system when there is an electrical overload. The reason The location and sizes are shown below and [Figure 50-
for the overload must be found before starting the engine 10-2].
again.
REF DESCRIPTION AMP REF DESCRIPTION AMP
The battery cables must be clean and tight. Check the 1 Not Used -- 11 Lights 20
electrolyte level in the battery. Add distilled water as 2 Heater 25 12 ACC Plug 15
needed. Remove acid or corrosion from the battery and 3 Ignition 5
cables with a sodium bicarbonate and water solution. 4 Fuel Solenoid 25
5 Wiper 10
Put Battery Saver P/N 6664458 or grease on the battery 6 Switch Power 20
terminals and cable ends to prevent corrosion. 7 Alternator/ 25
Heater
8 ACD 25
9 Controller 25
WARNING 10 ACD 25
Always replace fuses using the same type and capacity.

Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and REF DESCRIPTION
rubber gloves to keep acid off body. E Switch Power
F Fuel Solenoid
In case of acid contact, wash immediately with water. G Lights
In case of eye contact get prompt medical attention H Glow Plug
and wash eye with clean, cool water for at least 15 J Starter
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296

579 of 726

580 of 726
BATTERY

WARNING
Figure 50-20-1
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
2
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
1 and wash eye with clean, cool water for at least 15
minutes.

W-2065-1296
3 P-69949

Disconnect the negative (-) cable (Item 1) [Figure 50-20-
1] first.
Disconnect the positive (+) cable (Item 2) [Figure 50-20-

1].
Remove the bolt (Item 3) [Figure 50-20-1] and remove

the hold down clamp.
Remove the battery.
Always clean the terminals and the cable ends, even

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 1) [Figure 50-20-1] last to prevent sparks.

581 of 726
BATTERY (CONT’D) Check for broken or loose connections.
Servicing If the battery cables are removed for any reason,

disconnect the negative (-) cable first. When installing the
Open the right side cover. battery cables, make the last connection the negative (-)
cable to the battery.
Figure 50-20-2
The original equipment battery is maintenance free. If a
replacement battery is installed, check the electrolyte
level in the battery.
1 If the electrolyte level is lower than 0.50 inch (13 mm)

above the plates, add distilled water only.
WARNING
P-69947

The battery (Item 1) [Figure 50-20-2] in the front of the In case of eye contact get prompt medical attention
right side upperstructure. and wash eye with clean, cool water for at least 15
minutes.
Figure 50-20-3
W-2065-1296
P9589 P9590
The battery cables must be clean and tight [Figure 50-

20-3]. Remove acid 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 prevent corrosion.

582 of 726
BATTERY (CONT’D) Start the engine. After the engine has started, remove the
ground (-) cable first (Item 2) [Figure 50-20-4].
Using A Booster Battery (Jump Starting)
Disconnect the cable from the excavator starter (Item 1)
[Figure 50-20-4].
IMPORTANT
If jump starting the excavator from a second
WARNING
machine:
When jump starting the excavator from a battery contact. Wear goggles, protective clothing and
installed in a second machine, make sure the engine rubber gloves to keep acid off body.
is NOT running while using the glow plugs. High
voltage spikes from a running machine can burn out In case of acid contact, wash immediately with water.
the glow plugs. In case of eye contact get prompt medical attention
I-2060-0906 and wash eye with clean, cool water for at least 15
minutes.
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables.
W-2065-1296

Be sure the key switch is OFF. The booster battery must
be 12 volt.
Open the tailgate.
Figure 50-20-4
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
2 • Battery cables are connected when using a fast
charger or when welding on the excavator.
1 (Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2223-0903
P-73194
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 50-20-4] of the excavator starter.
Connect one end of the second cable to the negative (-)

terminal of the booster battery. Connect the other end of
the same cable to the negative excavator cable (Item 2)
[Figure 50-20-4] where it is fastened to the frame.

583 of 726

584 of 726
ALTERNATOR Belt Replacement
Belt Adjustment Figure 50-30-2
Open the tailgate.

1
Figure 50-30-1
2
1
P-73197
Remove the two bolts (Item 1) and remove the shield

P-73196 assembly (Item 2) [Figure 50-30-2].
Figure 50-30-3

Using a belt tension gauge, measure the belt tension
midway between the crankshaft pulley and alternator
1
pulley [Figure 50-30-1].
Belt tension is as follows:

New belt 70 - 80 ft. lb. (311 - 356 N)
Used belt 56 - 66 ft. lb. (249 - 294 N)
WARNING 2

• Do Not Operate with damaged or missing P-73199
screens, shields or rubber deflectors.
• Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can Loosen the bolts (Items 1 & 2) [Figure 50-30-3] until the
cause injury or death. alternator can be moved toward the engine. Remove the
W-2528-0406 old belt and install a new belt.
Adjust the alternator outward until the belt tension is

correct. Tighten the two bolts (Items 1 & 2) [Figure 50-
30-3].

585 of 726
ALTERNATOR (CONT’D)
Charging System Inspection
If the charging system malfunctions check the following:

WARNING
Keep arcs, sparks flames and lighted tobacco away
Check the condition and tension of the alternator belt. from batteries. When jumping from booster battery
(See Belt Adjustment on Page 50-30-1.) If belt is worn or make final connection (negative) at machine frame.
deteriorated replace.
Do not jump start or charge a frozen or damaged
Inspect the alternator wiring harness and connectors at battery. Warm battery to 60°F (16°C) before
alternator. Harness and connectors must be clean and connecting to a charger. Unplug charger before
tight. connecting or disconnecting cables to battery. Never
Check the fuse for the alternator in the fuse panel. If fuse lean over battery while boosting, testing or charging.
is burned, find the cause and repair/replace. If fuse is in
doubt, remove it and check for continuity. Battery gas can explode and cause serious injury.
W-2066-0705
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. IMPORTANT
Disconnect the battery cables (negative first, then

positive). Inspect the cable clamps and battery posts for Damage to the alternator can occur if:
corrosion. Remove acid or corrosion from the battery and • Engine is operated with battery cables
cables with a sodium bicarbonate and water solution. Put disconnected.
grease on the cable ends and battery terminals to • Battery cables are connected when using a fast
prevent corrosion. Reconnect the cable to the positive charger or when welding on the loader. (Remove
terminal. both cables from the battery.)
connected wrong.
I-2023-1285
WARNING

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

W-2065-1296

586 of 726
ALTERNATOR (CONT’D) Tests
Description Perform the following alternator tests in this order:
Figure 50-30-4 Alternator Output Test: Tests the alternator and regulator
output.
3
4 2
Full Field Test: Tests the maximum amperage output of
1 the alternator.
Alternator Regulator Test: Tests the regulator voltage

output.
P-10018
Figure 50-30-5

1
3 2
4
5 P-10023
The output terminal (Item 1) [Figure 50-30-4] & [Figure

50-30-5].
The ignition terminal (Item 3) [Figure 50-30-4] & [Figure

50-30-5].
Open terminal not used in the excavator harness (Item 2

and 4) [Figure 50-30-4] & [Figure 50-30-5].
Access hole for full field test (Item 5) [Figure 50-30-4] &
[Figure 50-30-5].

587 of 726
ALTERNATOR (CONT’D) Full Field Test
Alternator Output Test Start the engine and run at full RPM.
Check the battery and battery connections. (See Figure 50-30-7

Figure 50-30-6
1
P-73393
P-73391 Place a small screw driver in the test port (Item 1)

[Figure 50-30-7] to provide a ground to the alternator

case. This will give maximum amperage output from the
Use an induction meter and loop around the positive (+) alternator.
wire (Item 1) [Figure 50-30-6] at the alternator.
NOTE: The Full Field Test should only last long
Start the engine and run at full RPM. enough to get ammeter reading to prevent
damage to the alternator.
The ammeter reading should be between 35 and 40
amps. The ammeter reading should be above 35 amps.
If the ammeter reading is less than 35 amps do the full If the ammeter reading is low, repair or replace the
field test. alternator.
WARNING WARNING
When an engine is running in an enclosed area, fresh When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning. gases which can kill without warning.
W-2050-1285 W-2050-1285

588 of 726
ALTERNATOR (CONT’D) Alternator Regulator Test With Voltmeter
Alternator Regulator Test Figure 50-30-8
Disconnect the fuel stop solenoid connector.
Turn the lights on (if equipped) and crank the engine for
30 seconds to discharge the battery.
1
Connect the fuel stop solenoid connector.
Start the engine and run at full RPM.

2
The ammeter reading should be around 35 amps and
slowly decrease with alternator output.
If ammeter reading is low or does not decrease with time,

replace the alternator's regulator. P-73392
Disconnect the negative (-) cable from the battery.

Connect the positive (+) voltmeter lead to the positive (+)
Reconnect the alternator wires. battery terminal (Item 1) [Figure 50-30-8].
Reconnect the negative (-) cable from the battery. Connect the negative (-) voltmeter lead to the negative

(-) battery terminal (Item 2) [Figure 50-30-8].
NOTE: The alternator regulator test can also be run
using a voltmeter. Start the engine and run at full RPM.
The voltmeter should read between 13.9 and 14.7 volts.
If the voltmeter reading is not within this range, replace

the alternator's regulator.
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 loader. (Remove
both cables from the battery.)
connected wrong.
I-2023-1285

589 of 726
ALTERNATOR (CONT’D) Figure 50-30-10
Disconnect the battery. (See Removal And Installation on

Page 50-20-1.)
Open the tailgate.

2
Figure 50-30-9
P-73394
2 Remove the bolt and nut (Item 1) [Figure 50-30-10] from

the alternator.
1
3 Remove the alternator from the engine (Item 2) [Figure
50-30-10].

P-73395

from the alternator.
Disconnect the wire (Item 2) [Figure 50-30-9] from the

alternator.
Remove the bolts, nut, and wire (Item 3) [Figure 50-30-

9] from the alternator.

590 of 726
ALTERNATOR (CONT’D)
1. Alternator 15. Nut

2. Frame Assy. 16. Insulator
3. Plate 17. Bolt
4. Screw 18. Screw
5. Bearing 19. Nut
6. Stud 20. Nut
7. Frame End 21. Rotor Assy.
8. Holder 22. Bearing
9. Holder 23. Cover
10. Seal 24. Pulley
11. Brush 25. Spacer
12. Spring 26. Bolt
13. Regulator 27. Screw
14. Cover 28. Screw

6 3 23
2 5 22
21
28
24
14
26
27
25 10
20 9
15
16
19 28
12
7 11
18
1
13
17 8
C-3456

591 of 726

592 of 726
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.
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.

593 of 726
STARTER (CONT’D)
Open the tailgate.
Disconnect the negative (-) cable from the battery. (See

Figure 50-40-3

P-73271
Disconnect the wires (Item 1) [Figure 50-40-3] from the

starter.
Remove the bottom bolt (Item 2) and ground cable

[Figure 50-40-3].
Remove the top bolt (Item 3) [Figure 50-40-3].
Remove the starter.

594 of 726
STARTER (CONT’D)
1. Screw
2. Bolt
3. Brush Cover
4. Brush Holder 1
2
5. Bearing
6. Armature
7. Bearing 4
8. O-Ring
9. Frame 5
10. Bolt
11. Cover 6
12. Gasket
13. Switch
3
7 14. Nut
8 15. Nut
16. Housing
9 17. Idler Gear
18. Roller

8 19. Retainer
20. Spring
21. Ball
22. Pinion Shaft
11 10
12
14 13
15
20
17
15 21
19 18 22
23 23. Spring
16 24. Clutch
24 25. O-Ring
26. O-Ring
27. Washer
29
28. Bolt
29. Housing
31 30. Spring Seat
32 31. Spring
25
34 32. Pinion Gear
27 33. Collar
34. Snap Ring
30
26
33
28
D-2396

595 of 726

596 of 726
LIGHTS Upperstructure Light Disassembly And Assembly
Upperstructure Light Removal And Installation Figure 50-50-3
Figure 50-50-1
1
1
P-22943
P-73402
Remove the light bulb assembly (Item 1) [Figure 50-50-
3] from the lens.
To remove the upperstructure light, pivot the light (Item 1)
[Figure 50-50-1] back inside the frame.

Figure 50-50-2
P-73403

597 of 726
LIGHTS (CONT’D) Boom Light Disassembly And Assembly
Boom Light Removal And Installation Figure 50-50-5
Figure 50-50-4 1
3
2
2
1
P-16882
P-22944
Remove the screw, (Item 1) remove the cover, (Item 2)
and lens assembly (Item 3 [Figure 50-50-5].
To remove the boom light, disconnect the wire harness
(Item 1) and remove the nut and bolt (Item 2) [Figure 50- Figure 50-50-6

50-4].
1
3
P-16883
Remove the light bulb assembly (Item 1) from the lens

assembly (Item 2) [Figure 50-50-6].
Disconnect the wire connector (Item 3) [Figure 50-50-6]

from the light bulb assembly.

598 of 726
MAGNETIC LOCKOUT SENSOR Figure 50-60-2
Testing Left Console Magnetic Lockout Sensor
Remove the left rear console cover. (See Left Rear 5

9.) 4
Remove the magnetic lockout sensor. (See Left Console

Magnetic Lockout Sensor Removal And Installation on
Page 50-60-2.)
3
Leave the sensor plugged into the wire harness.
Figure 50-60-1
1 2
P-69727
B Turn the key to the on position, do not start the engine.

A C
Back probe the connector on Pin B and C (Item 1 and 2)
[Figure 50-60-2].
With magnetic lockout sensor (Item 3) and the magnet

(Item 4) together, the voltage should read around 2.4
1
VDC (Item 5) [Figure 50-60-2].
Figure 50-60-3
P-69729
4
Pull back the rubber gasket from the wire harness
connector (Item 1) [Figure 50-60-1].
3
A = Input Power
B = Signal
C = Ground
1
1 2 P-69728
Back probe the connector (Item 3), Pin B and C (Item 1

and 2) [Figure 50-60-3].
Remove the magnet.
The voltage should read around 7.7 VDC (Item 4).

[Figure 50-60-3].

599 of 726
MAGNETIC LOCKOUT SENSOR (CONT’D) Figure 50-60-6
Left Console Magnetic Lockout Sensor Removal And

Installation

9.)
1
Raise and support the console.
Figure 50-60-4
P-73441
Loosen the bolt (Item 1) [Figure 50-60-6].

2
Figure 50-60-7
1

1
P-73426
Pull the floor mat back (Item 1) and remove the bolt (Item
2) [Figure 50-60-4] from the side cover.
2
Figure 50-60-5
1 P-73442
2 Loosen the bolt (Item 1) and remove the cover (Item 2)

[Figure 50-60-7].
P-73427
Remove the bolts (Item 1) and the side cover (Item 2)

[Figure 50-60-5].

600 of 726
MAGNETIC LOCKOUT SENSOR (CONT’D) Figure 50-60-10
Left Console Magnetic Lockout Sensor Removal And

2
Figure 50-60-8
1
2
1
P-58948
Remove the screws (Item 1) and nuts. Remove the

magnet (Item 2) [Figure 50-60-10].
P-58945
NOTE: When removing the screws from the magnet,
the two nuts can fall out of the case.
Loosen the screws (Item 1), raise the console, and
remove the magnetic lockout sensor (Item 2) [Figure 50-

60-8] from the frame.
Figure 50-60-9
P-58947
Disconnect the wire harness (Item 1) from the magnetic

lockout sensor (Item 2) [Figure 50-60-9].

601 of 726

602 of 726
FUEL LEVEL SENDER
Remove the negative battery cable. (See Removal And

Figure 50-70-1

P-73404
Disconnect the harness connector (Item 1) [Figure 50-

70-1] from the fuel sender.
Remove the fuel sender (Item 2) [Figure 50-70-1]. The

sender threads into the tank, use a wrench to remove the
sender.

603 of 726
FUEL LEVEL SENDER (CONT’D) Figure 50-70-4
Testing
Use an ohmmeter to check the resistance of the fuel

sender.
Figure 50-70-2 1
P11767
Inspect the O-ring (Item 1) [Figure 50-70-4] and replace

as needed.
1
P11765

Insert one of the ohm tester leads into each of the fuel
sender electrical connectors (Item 1) [Figure 50-70-2] in
the end of the fuel sender.
Figure 50-70-3
P11766
With the fuel sender in the position shown [Figure 50-70-

3], read the ohms in the empty position. Slide the float
upwards and the ohm reading will decrease. See
resistance chart below.
The resistance should read as follows:
FULL: 15-35 Ohms.

HALF: 82-97 Ohms.
EMPTY: 230-250 Ohms.

604 of 726
DIAGNOSTIC SERVICE CODES
Description
Figure 50-80-1
P-16616B
The right console contains the instrument panel [Figure

50-80-1].

For models with a key switch, turn the key to the ON
position but do not start the engine. For keyless models,
press the enter code button.
The display will become lighted and there will be two

short beeps.
NOTE: Corroded or loose grounds can cause

multiple service codes and/or abnormal
symptoms. All instrument panel lights
flashing, alarm sounding and lights flashing,
could indicate a bad ground. The same
symptoms could apply if the voltage is low,
such as loose or corroded battery cables. If
you observe these symptoms, check grounds
and positive leads first.
Press and hold LIGHTS Button (Item 1) [Figure 50-80-1]

for two seconds to view SERVICE CODES in the
HOURMETER/CODE DISPLAY (Item 2) [Figure 50-80-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.

605 of 726
DIAGNOSTIC SERVICE CODES (CONT’D)
Service Codes List
CODE CODE
02-16 Hydraulic charge filter not connected 20-02 Two speed output error ON
02-17 Hydraulic charge filter plugged 20-03 Two speed output error OFF
03-09 Battery voltage low 21-02 Glow plug output error ON

03-10 Battery voltage high 21-03 Glow plug output error OFF
03-11 Battery voltage extremely high
03-14 Battery voltage extremely low 22-02 Starter relay output error ON
03-22 Battery voltage out of range low 22-03 Starter relay output error OFF
04-14 Oil pressure extremely low 26-02 Front base output error ON
04-15 Oil pressure shutdown level 26-03 Front base output error OFF
05-09 Hydraulic charge pressure low 27-02 Front rod output error ON
05-14 Hydraulic charge pressure extremely low 27-03 Front rod output error OFF
05-15 Hydraulic charge pressure shutdown level
05-21 Hydraulic charge pressure out of range high 28-02 Diverter output error ON
05-22 Hydraulic charge pressure out of range low 28-03 Diverter output error OFF

06-10 Engine speed high 30-28 Watch dog failure
06-11 Engine speed extremely high
06-15 Engine speed shutdown level 31-28 Recovery mode failure
06-18 Engine speed out of range high
33-23 Controller not calibrated
07-10 Hydraulic oil temperature high
07-11 Hydraulic oil temperature extremely high 35-05 Hydraulic fan solenoid short to battery
07-15 Hydraulic oil temperature shutdown level 35-06 Hydraulic fan solenoid short to ground
07-21 Hydraulic oil temperature out of range high
07-22 Hydraulic oil temperature out of range low 60-21 Sec. aux. thumbswitch out of range high
60-22 Sec. aux. thumbswitch out of range low
08-10 Engine coolant temperature high 60-23 Sec. aux. thumbswitch not calibrated
08-11 Engine coolant temperature extremely high
08-15 Engine coolant temperature shutdown level 62-04 Load moment monitoring in error
08-21 Engine coolant temperature out of range high
08-22 Engine coolant temperature out of range low 63-05 Work group/travel console sensor
63-06 Work group/travel console sensor
09-09 Fuel level low
09-21 Fuel level out of range high 64-05 Switched power/acc. relay short to battery
09-22 Fuel level out of range low 64-06 Switched power/acc. relay short to ground
64-07 Switched power/acc. relay open circuit
12-21 Primary auxiliary PWM switch out of range high
12-22 Primary auxiliary PWM switch out of range low 65-02 Work group/travel lockout solenoid error ON
12-23 Primary auxiliary PWM switch not calibrated 65-03 Work group/travel lockout solenoid error OFF
65-05 Work group/travel lockout solenoid short to battery
13-05 Fuel shut-off hold solenoid short to battery 65-06 Work group/travel lockout solenoid short to ground
13-06 Fuel shut-off hold solenoid short to ground 65-07 Work group/travel lockout solenoid open circuit
13-07 Fuel shut-off hold solenoid secondary open circuit
66-05 Travel solenoid short to battery
14-02 Fuel shut-off hold solenoid short to battery 66-06 Travel solenoid short to ground
14-03 Fuel shut-off hold solenoid short to ground

606 of 726
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

CAMSHAFT AND TIMING GEARS. . . . . . . . . . . . . . . . . . . . 60-100-1

Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Idler Gear And Shaft Removal And Installation . . . . . . . . 60-100-3
Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . . 60-100-6
Timing Gearcase Cover Removal And Installation . . . . . 60-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . 60-100-3
CRANKSHAFT AND PISTONS. . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . 60-90-6
Crankshaft And Bearings Removal And Installation . . . . . 60-90-6
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . 60-90-8
Cylinder Bore Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-5
Piston And Connecting Rod Removal And Installation . . . 60-90-1
Piston And Connecting Rod - Servicing. . . . . . . . . . . . . . . 60-90-3
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Cylinder Head Disassembly and Assembly . . . . . . . . . . . . 60-80-6 ENGINE
Cylinder Head Removal And Installation . . . . . . . . . . . . . . 60-80-4 SERVICE
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . 60-80-2
Glow Plug - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Reconditioning The Valve And Valve Seat. . . . . . . . . . . . . 60-80-8
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . 60-80-11
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-10
Valve Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-11
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-3
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Radiator Removal And Installation. . . . . . . . . . . . . . . . . . . 60-50-1
Radiator Disassembly and Assembly . . . . . . . . . . . . . . . . 60-50-3
Testing The Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Thermostat Housing Removal And Installation . . . . . . . . . 60-50-4
Water Pump Disassembly And Assembly . . . . . . . . . . . . . 60-50-4
Water Pump Removal And Installation . . . . . . . . . . . . . . . 60-50-3

607 of 726
ENGINE SERVICE (CONT’D)
ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . 60-10-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Flywheel Housing Removal And Installation . . . . . . . . . . 60-110-1
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . 60-110-3
Hydraulic Pump Coupler Removal And Installation . . . . . 60-110-2
Rear End Plate Removal And Installation . . . . . . . . . . . . 60-110-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Fuel Camshaft Governor Disassembly And Assembly . . . 60-70-1
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . 60-70-1
Fuel Injection Pump Removal And Installation . . . . . . . . . 60-70-4
Fuel Injector Nozzles Pressure - Checking . . . . . . . . . . . 60-70-10
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . 60-70-8
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . 60-70-2
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . 60-70-3
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-11
Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . 60-70-6
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-11
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . 60-60-3
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . 60-60-1
Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . 60-60-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . 60-30-1


608 of 726
ENGINE INFORMATION Figure 60-10-1
Description
The 425 has a Kubota V1505-E2B diesel engine [Figure

60-10-1] with a displacement of 91.4 cu.in. (1,50 L). The
engine is rated at an SAE Net 26.4 HP (19,7 kW) and has
a closed crankcase ventilation system.
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts.
The engine serial number is stamped on the engine and

is located near the injection pump. The model number is P-73492
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol/water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is belt driven off the crank
shaft.

609 of 726
ENGINE INFORMATION (CONT’D)
Specifications
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Injection Nozzles
Opening Pressure 1991 - 2134 PSI (137,3 - 147,1 bar)

Fuel Tightness Nozzle Seat Dry Nozzle at 1849 PSI (127,5 bar)
Fuel Injection Pump
Fuel Tightness Plunger 10 sec: initial pressure 1849 - 1991 PSI (127,5 - 137,3 bar)
Allowable Limit 5 seconds 1991 PSI (137,3 bar)
Injection Timing 18 degrees B.T.D.C.
High Idle 2600 RPM
Low Idle 850 - 950 RPM
Cylinder Head

Cylinder Head Surface Distortion 0.002 in (0,05 mm)
Top Clearance (Piston to Head) 0.0217 - 0.0276 in (0,55 - 0,70 mm)
Compression 412 - 469 PSI (28,4 - 32,3 bar)
Allowable Limit 327 PSI (22,5 bar)
Allowable Difference Between Cylinders 10% or less
Valves
Valve Seat Width (Intake & Exhaust) 0.0835 in (2,12 mm)

O.D. of Valve Stems 0.2741 - 0.2746 in (6,960 - 6,975 mm)
I.D. of Valve Guides 0.2760 - 0.2765 in (7,010 - 7,025 mm)
Clearance Between Valve Stem & Guide 0.0014 - 0.0025 in (0,035 - 0,065 mm)
Allowable Limit 0.0039 in (0,1 mm)
Valve Clearance (Cold) 0.00571 - 0.00728 in (0,145 - 0,185 mm)
Valve Recessing (Protrusion) 0.0020 in (0,05 mm)
(Recess) 0.0098 in (0,25 mm)
Allowable Limit (Recess) 0.0157 in (0,4 mm)
Valve Seat Angle (Int.) 60 degrees
Valve Seat Angle (Exh.) 45 degrees

610 of 726
Specifications (Cont’d)
parentheses.
Valve Springs
Free Length 1.457 - 1.476 in (37 - 37,5 mm)

Fitted Length 1.220 in (31 mm)
Compress to Fitted Length 26.4 lb. (117,4 N)
Allowable Limit 22.5 lb. (100 N)
Inclination Allowable Limit 0.039 in (1 mm)
Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.

(Close) 36 degrees A.B.D.C.
Exhaust Valve (Open) 45 degrees B.B.D.C.

(Close) 17 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 0.4714 - 0.4718 in (11,973 - 11.984 mm)

I.D. of Rocker Arm 0.4724 - 0.4731 in (12 - 12,018 mm)
Clearance Between Rocker Arm & Shaft 0.0006 - 0.0018 in (0,02 - 0,05 mm)
Camshaft
Journal O.D. 1.4147 - 1.4153 in (35,934 - 35,950 mm)

Cylinder Block Bore I.D. 1.4173 - 1.4183 in (36 - 36,025 mm)
Oil Clearance 0.00197 - 0.00358 in (0,05 - 0,091 mm)
Alignment Allowable Limit 0.0004 in (0,01 mm)
Cam Lobe Height (IN.) 1.1339 in (28,8 mm)
Allowable Limit (IN.) 1.1319 (28,75 mm)
Cam Lobe Height (EX.) 1.1417 in (29 mm)
Allowable Limit (EX.) 1.1398 in (28,95 mm)
End Clearance 0.0028-0.0087 in (0,07-0,22 mm)
Tappet
Clearance Between Tappet & Guide 0.0008 - 0.0024 in (0,02 - 0,062 mm)
Tappet O.D. 0.7858 - 0.7866 in (19,959 - 19,980 mm)
Tappet Guide I.D. 0.7874 - 0.7882 in (20 - 20,021 mm)

611 of 726
parentheses.
Cylinders
Cylinder Bore I.D. (Standard) 3.0709 - 3.0716 in (78 - 78,019 mm)

Allowable Limit (Standard) +0.006 in (+0,15 mm)
Cylinder Bore I.D. (Oversize) 3.0906 - 3.0913 in (78,5 - 78,519 mm)
Allowable Limit (Oversize) +0.006 in (+0,15 mm)
Piston Rings
Ring Gap (Top) 0.0098 - 0.0157 in (0,25 - 0,40 mm)

Ring Gap (2nd Ring) 0.0138-0.0197 (0,35-0,50)
Ring Gap (Oil Ring) 0.0079-0.0157 (0,20-0,40)
Allowable Limit (All Rings) 0.0492 in (1,25 mm)
Side Clearance of Ring Groove:

2nd Ring 0.0033 - 0.0044 in (0,085 - 0,112 mm)
Oil Ring 0.008 - 0.0021 in (0,02 - 0,055 mm)
Allowable Limit 0.006 (0,15)
Pistons
Piston Pin Bore 0.8661 - 0.8667 in (22 - 22,013 mm)

Connecting Rods
Piston Pin O.D. 0.8662 - 0.8666 in (22,002 - 22,011 mm)

Small End Bushing I.D. 0.8671 - 0.8677 in (22,025 - 22,040 mm)
Clearance Between Piston Pin & Small End Bushing 0.0006 - 0.0015 in (0,014 - 0,038 mm)
Connecting Rod Alignment Allowable Limit 0.002 in (0,05 mm)
Oil Pump
Oil Pressure at Rated RPM 28 - 64 PSI (1,96 - 4,41 bar)

Idle Speed Allowable Limit 7 PSI (0,49 bar)
Clearance Between Inner Rotor & Outer Rotor 0.0024 - 0.0071 in (0,06 - 0,18 mm)
Clearance Between Outer Rotor & Pump Body 0.0039 - 0.0071 in (0,1 - 0,180 mm)
End Clearance Between Inner Rotor & Cover 0.0010 - 0.0030 in (0,025 - 0,075 mm)

612 of 726
parentheses.
Crankshaft
Crankshaft Alignment 0.0008 in (0,02 mm)

Allowable Limit
Oil Clearance Between 0.0013 - 0.0045 in (0,034 -0,114 mm)
Journal & Bearing #1
Journal O.D. #1 1.8872 - 1.8878 in (47,934 - 47,950 mm)
Bearing I.D. #1 1.8891 - 1.8917 in (47,984 - 48,048 mm)
Oil Clearance Between 0.0013 - 0.0037 in (0,034 - 0,095 mm)
Journal & Bearing #2
Journal O.D. #2 1.8872 - 1.8878 in (47,934 - 47,950 mm)
Bearing I.D. #2 1.8891 - 1.8909 in (47,984 - 48,029 mm)

Oil Clearance Between 0.0011 - 0.0036 in (0,029 - 0,091 mm)
Crank Pin & Bearing
Crank Pin O.D. 1.5732 - 1.5738 (30,059 - 39,975 mm)
Crank Pin Bearing I.D. 1.5750 - 1.5768 in (40.004 - 40.500 mm)
Crankshaft Side 0.0059 - 0.0122 in (0,15 - 0,35 mm)
Clearance
Timing Gear
Timing Gear Backlash:

Crank Gear - Idle Gear 0.0013 - 0.0045 in (0,032 - 0,115 mm)
Idle Gear - Cam Gear 0.0014 - 0.0045 in (0,036 - 0 ,114 mm)
Idle Gear - Injection Pump Gear 0.0013 - 0.0046 in (0,034-0,116 mm)
0.0016-0.0043 (0,042-0,109) Crank Gear - Oil Pump Gear
Allowable Limit 0.006 (0,15)
Clearance Between Idle Gear Shaft & Idle Gear Bushing 0.0008 - 0.0021 in (0,020 - 0,054 mm)
Idler Gear Side Clearance 0.0079 - 0.0201 in (0,20 - 0,51 mm)
Thermostat
Valve Opening Temperature 157.1 - 162.5 °F (69.5 - 72.5°C)

Valve Fully Open 185°F (85°C)

613 of 726
Torque Values
Kubota Metric Engine Bolts
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 3 to 4 ft.-lb.
(4 to 5 N•m)
M6 x 1.0 6 to 7 ft.-lb. 6 to 9 ft.-lb.
(8 to 9 N•m) (8 to 12 N•m)
M8 x 1.25 6 to 9 ft.-lb. 11 to 16 ft.-lb. 18 to 25 ft.-lb.
(8 to 12 N•m) (15 to 22 N•m) (24 to 34 N•m)
(18 to 24 N•m) (30 to 41 N•m) (49 to 68 N•m)
(30 to 41 N•m) (54 to 73 N•m) (94 to 118 N•m)
(49 to 68 N•m) (79 to 108 N•m) (157 to 186 N•m)
Tightening Torques For General Use Screws, Bolts And Nuts

Grade Standard Screw and Bolt Special Screw and Bolt (7)
Nominal Unit (4)

Diameter N·m kgf·m ft.-lb. N·m kgf·m ft.-lb.
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 49.0 to 55.9 5.0 to 5.7 36.2 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to
tightening, be sure to check out the numbers as shown below.
Punched number Screw and bolt material grade

None or 4 Standard screw and bolt SS400, S20C
7 Special screw and bolt S43C, S48C (Refined)

614 of 726
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
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

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

615 of 726
ENGINE INFORMATION (CONT’D) Figure 60-10-3
Disconnect the negative ( - ) cable on the battery. (See

1
Remove the tailgate. (See Removal And Installation on
Page 40-180-1.)
Remove the counterweight. (See Housing Removal And

2
Drain the hydraulic reservoir. ((See Removing And
Replacing The Hydraulic Fluid on Page 10-100-3.).)
P-73321
Drain the radiator. (See Removing And Replacing
Coolant on Page 10-70-3.)
Remove the two nuts (Item 1) and remove the drip plate
Remove the muffler. (See Removal And Installation on (Item 2) [Figure 60-10-3].
Page 60-30-1.)
Figure 60-10-4
Remove the air cleaner. (See Removal And Installation
on Page 60-40-1.)

Remove the starter. (See Removal And Installation on 2
Page 50-40-2.)
Remove the hydraulic pump. (See Removal on Page 20-

50-5.)
Remove the hydraulic filter housing. (See

COUNTERWEIGHT on Page 40-210-1.)
Remove the seat and access panel. (See Seat Removal 1

P-73320
Figure 60-10-2
1 Remove the tie strap (Item 1) and disconnect the wire
harness (Item 2) [Figure 60-10-4].
1 P-73319
Remove the bolts (Item 1) and the ground cable (Item 2)

[Figure 60-10-2].

616 of 726
Figure 60-10-5
1
1
3
2 P-73324
Remove and cap the heater hose (Item 1) [Figure 60-10-

P-73201A 7].
Figure 60-10-8
Remove the two nuts and bolt (Item 1) and remove the
guard (Item 2) [Figure 60-10-5].

Remove and cap the radiator hose (Item 3) [Figure 60-
10-5].
Figure 60-10-6
1
P-73327
From inside the cab remove and cap the fuel line (Item 1)
[Figure 60-10-8].
P-73202A
Remove and cap the radiator hose (Item 1) [Figure 60-

10-6].

617 of 726
Figure 60-10-9
1
1
2
P-73331
Install a lifting bracket and chain (Item 1) and remove the

P-73328 motor mount nut (Item 2) [Figure 60-10-11].
Figure 60-10-12
Remove and cap the hose (Item 1) [Figure 60-10-9].

Figure 60-10-10
1
P-73332
P-73333 Attach a hoist to the chain (Item 1) [Figure 60-10-12]

slightly raise to support the engine.
Remove the bolt (Item 1), install a lifting bracket and

chain (Item 2) [Figure 60-10-10].

618 of 726
Figure 60-10-13
P-73326
1
Lift and rotate the pump side of the engine out away from
P-73330 the machine to access the engine speed cable [Figure
60-10-15].
Remove the bolt and nut (Item 1) [Figure 60-10-13] from Figure 60-10-16
the motor mount.

Figure 60-10-14
1
5.75 in.
(146,05 mm)
P-73334
P-73329 Remove the engine speed control cable (Item 1) [Figure

60-10-16] from the engine.
Remove the nut and bolt (Item 1) [Figure 60-10-14] from Remove the engine.
the motor mount.
Installation: Set the throttle cable distance from the top
of the bracket to the center of the ball joint stud to 5.75 in.
(146,05 mm).

619 of 726
Engine Mount Replacement
Remove the engine. (See Removal And Installation on

Page 60-10-8.)
Figure 60-10-17 4
1
2
3
2
1
1
5 P-73283
2
4
3
Right rear engine mount.
2
1
Use the parts shown to install the new engine mount
[Figure 60-10-18].
5
P-73282
Item 1 - Cup Snubber

Item 2 - Molded Engine Mount
Left rear engine mount. Item 3 - Tube Spacer
Item 4 - Nut
Use the parts shown to install the new engine mount Item 5 - Bolt
[Figure 60-10-17].

Item 3 - Tube Spacer
Item 4 - Nut
Item 5 - Bolt

620 of 726
ENGINE INFORMATION (CONT’D) Compression - Checking
Engine Mount Replacement (Cont’d) The tools listed will be needed to do the following
procedure:
Figure 60-10-19
MEL10630 - Engine Compression Kit
MEL 1352 - Compression Adapter
1
2 3 The engine must be at operating temperature.
1 2
Remove the glow plugs. (See Glow Plug Removal And
5
Figure 60-10-20
P-73284
Right front engine mount.

Use the parts shown to install the new engine mount
[Figure 60-10-19].

P-52702
Item 3 - Tube Spacer
Item 4 - Nut
Item 5 - Bolt Install the correct compression adapter into the cylinder
head [Figure 60-10-20].
Connect the compression gauge [Figure 60-10-20].
Make sure the speed control lever is at low engine idle.
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200-300 RPM.
Compression Pressure 412 - 469 PSI

(28,4 - 32,3 bar)
Allowable Limit 327 PSI
(minimum) (22,5 bar)
The compression must be no lower than the allowable

limit, with no more than 10% variance among cylinders.
Connect the fuel stop solenoid.

621 of 726

622 of 726
ENGINE SPEED CONTROL Figure 60-20-3
Remove the right upper console cover. (See Console

Cover Removal And Installation on Page 40-50-1.) 1
Figure 60-20-1
2
P-73077
Remove the wave washers (Item 1) [Figure 60-20-3].
Figure 60-20-4

P-73076
3
Remove the linkage cable nut (Item 1) [Figure 60-20-1]. 2 1
Remove the nuts (Item 2) [Figure 60-20-1].
Figure 60-20-2
P-55641
2
Remove the washer (Item 1) and spacer (Item 2) from
the lever (Item 3) [Figure 60-20-4].
P-55640
Remove the speed control lever (Item 2) [Figure 60-20-

2]

623 of 726

624 of 726
SPARK ARRESTOR MUFFLER Figure 60-30-3
Figure 60-30-1
1
2
1
P-73069
3
Remove the nuts and bolts (Item 1) [Figure 60-30-3]
P-73065 from the muffler.
Figure 60-30-4
Remove the bolt (Item 1) [Figure 60-30-1] from the tail
pipe bracket.

Remove the clamp (Item 2) and the tail pipe (Item 3)
[Figure 60-30-1] from the muffler.
2
Figure 60-30-2 1
1
2
P-73067

muffler bracket.
Remove the muffler (Item 2) [Figure 60-30-4].

P-73068

heat shield.
Remove the heat shield (Item 2) [Figure 60-30-2] from

the exhaust manifold.

625 of 726

626 of 726
AIR CLEANER
Open the tailgate.
Figure 60-40-1
2 1
P-73075

Loosen the two clamps (Item 1) and remove the two
hoses (Item 2) [Figure 60-40-1] from the air cleaner.
NOTE: Plug the intake manifold hole to prevent any

contamination from getting into the engine.
Figure 60-40-2
1
P-73074
Remove the hose (Item 1) [Figure 60-40-2] from the air

filter condition indicator.

air cleaner bracket.
Remove the air cleaner and intake hose assembly (Item

3) [Figure 60-40-2].

627 of 726

628 of 726
ENGINE COOLING SYSTEM Figure 60-50-2
Radiator Removal And Installation
Open the tailgate and right side cover. 2

2
Remove the left side cover. (See Removal And
Drain the radiator. (See Removing And Replacing

1
1 3
Figure 60-50-1 P-73200
Remove the hose (Item 1) [Figure 60-50-2] from the

radiator and frame.
Remove the two nuts (Item 2) [Figure 60-50-2] on the

top of the coolant bottle.

Remove the coolant bottle (Item 3) [Figure 60-50-2].
1 2
Figure 60-50-3
P-73204 3 1
Remove and cap the two hoses (Item 1 & 2) [Figure 60-
50-1] on the oil cooler.
1
2
P-73201
Remove the nuts and bolt (Item 1) [Figure 60-50-3] from

the fan guard.
Remove the fan guard (Item 2) [Figure 60-50-3] from the

fan shield.
Remove and cap the hose (Item 3) [Figure 60-50-3] from

the radiator and the engine.

629 of 726
ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-6
Radiator Removal And Installation (Cont’d)
Figure 60-50-4
P-73205

P-73202 bottom of the radiator bracket.
Figure 60-50-7
Remove and cap the hose (Item 1) [Figure 60-50-4] from
the radiator and the engine.

Figure 60-50-5
2
1
P-73206
Remove the two hoses (Item 1) [Figure 60-50-7] from

P-73203 the fan shield.
Remove the two bolts and nuts (Item 2) [Figure 60-50-7]

Remove and cap the lower heater hose (Item 1) [Figure from the top of the radiator bracket.
60-50-5] (If equipped with heater).
NOTE: Be careful not to damage the cooling fins when
removing the radiator assembly from the
excavator.
Remove the radiator and oil cooler assembly from the

excavator.

630 of 726
ENGINE COOLING SYSTEM (CONT’D) Water Pump Removal And Installation
Radiator Disassembly and Assembly Drain the radiator. (See Removing And Replacing
Figure 60-50-8
Remove the alternator. (See Removal And Installation on
Page 50-30-6.)
Figure 60-50-10
1
1
1
2
1
2 2
2
P-73222
2
Remove the three bolts (Item 1) [Figure 60-50-8]. 1
P13265

Remove the oil cooler (Item 2) [Figure 60-50-8].
Figure 60-50-9 Loosen the clamps and disconnect the hoses (Item 1)
[Figure 60-50-10] from the water pump.

50-10] from the water pump.
1
1 NOTE: The bolts may vary in length. Keep the bolts in
their original location.
Remove the water pump from the engine.

1
Installation: Always use a new gasket when installing
1 the water pump.
2
P-73221
Remove the four bolts (Item 1) [Figure 60-50-9].
Remove the fan shield (Item 2) [Figure 60-50-9] from the

radiator.

631 of 726
ENGINE COOLING SYSTEM (CONT’D) Thermostat Housing Removal And Installation
Water Pump Disassembly And Assembly Figure 60-50-12
Figure 60-50-11
2 4
1 3
5
1
P-73228
B-14859B
Remove the two bolts (Item 1) and remove the
thermostat housing (Item 2) [Figure 60-50-12].
Put the water pump in a vise.
Figure 60-50-13

Remove the pulley (Item 1) and press the shaft (Item 2)
[Figure 60-50-11] out of the pulley side of the water
pump. 2
Remove the seal (Item 3) and impeller (Item 4) [Figure

60-50-11].
Install a new seal when assembling the water pump.
P-73227
Remove the thermostat (Item 1) and the thermostat

housing gasket (Item 2) [Figure 60-50-13].
Installation: Make sure all gasket surfaces are clean.

Replace the gasket (Item 2) [Figure 60-50-13] before
installing the thermostat housing. Apply a liquid gasket
(Three Bond 1215 or equivalent) only at the thermostat
cover side of the gasket.

632 of 726
ENGINE COOLING SYSTEM (CONT’D)
Testing The Thermostat
Figure 60-50-14
P-37172
Hang the thermostats in a suitable container filled with

coolant [Figure 60-50-14].

Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
open.
If the thermostats do not operate correctly they must be

replaced.
NOTE: See specifications on the thermostat. (See

Specifications on Page 60-10-2.)

633 of 726

634 of 726
LUBRICATION SYSTEM Oil Pump Removal And Installation
Oil Pan Removal And Installation Figure 60-60-3
Remove the engine and hydrostatic pump assembly from

the loader. (See Removal And Installation on Page 60-
10-8.)
The engine will have to be on an engine stand or

suspended in the air safely to remove the oil pan.
1
Figure 60-60-1
1 1
P13272
Remove the timing gear case cover. See [Figure 60-60-

3].
Remove the mounting bolts (Item 1) [Figure 60-60-3]

Installation: Tighten the mounting bolts to 70 - 113 in.-lb.
P-66843
(7,9 - 12,8 N•m) torque.
Remove oil pan bolts securing oil pan. Slightly tapping on Remove the rear cover (Item 2) [Figure 60-60-3].
the oil pan with a soft mallet will break loose the oil pan
from the engine block. Figure 60-60-4
Installation: Use a liquid gasket adhesive to the oil pan

side of the oil pan gasket (Item 1) [Figure 60-60-1].
Tighten oil pan bolts to 29 - 33 ft.-lb. (39 - 75 N•m) torque.
Figure 60-60-2
2
P13273
Remove the oil pump rotor assembly (Item 1) [Figure 60-

60-4] and check for wear.
P-66844
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 60-60-2] from the engine block.
Installation: Apply oil to O-ring.

635 of 726
LUBRICATION SYSTEM (CONT’D) Figure 60-60-7
Oil Pump Inspection
Figure 60-60-5
P13273
Put a strip of plastigauge (Item 1) [Figure 60-60-7] onto

P13317 the rotor face.
Figure 60-60-8
Measure the clearance between the lobes of the inner
rotor and the outer rotor with a feeler gauge [Figure 60-

60-5].
Clearance 0.0024 - 0.0071 in

(0,06 - 0,18 mm)
Figure 60-60-6 1
P13272
Install the oil pump cover (Item 1) [Figure 60-60-8] and

tighten the bolts to 70 - 113 in.-lb. (7,9 - 12,8 N•m) torque.
P13316
Measure the clearance between the outer rotor and the

pump body with a feeler gauge [Figure 60-60-6].
Clearance 0.0039 - 0.0071 in

(0,100 - 0,180 mm)

636 of 726
LUBRICATION SYSTEM (CONT’D) Engine Oil Pressure - Testing
Oil Pump Inspection (Cont’d) Remove the oil pressure sender.
Figure 60-60-9 Figure 60-60-10
P13273 PI-10010
Remove the cover and measure the width of the pressed Install a pressure gauge [Figure 60-60-10].
plastigauge (Item 1) [Figure 60-60-9].

Start the engine and run until it is at operating
End Clearance 0.0010 - 0.0030 in temperature.
(0,025 - 0,075 mm)
If the oil pressure is less than the allowable limit, check
the following items:
* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable Limit 7 PSI (0,50 bar)

At Rated Speed 28 - 64 PSI (1,96 - 4,41 bar)

637 of 726

638 of 726
FUEL SYSTEM Fuel Camshaft Governor Disassembly And Assembly
Fuel Camshaft Removal And Installation The governor serves to keep the engine speed constant
by automatically adjusting the amount of fuel supplied to
Remove the timing gearcase cover. (See Timing the engine according to changes in the engine load.
Gearcase Cover Removal And Installation on Page 60-
100-1.) Figure 60-70-2
Remove the idler gear. (See Idler Gear And Shaft

Removal And Installation on Page 60-100-3.) 3 2
Figure 60-70-1 1
3
1
2
4
P-69859

Remove the external snap ring (Item 1) [Figure 60-70-2]
from the governor shaft.
P-69858
NOTE: When replacing the ball bearing from the
governor shaft (Item 2), securely fit the ball
Remove the fuel camshaft stopper (Item 1) [Figure 60- bearing (Item 3) to the crankcase, apply liquid
70-1]. adhehesive (Loctite®) to to the set screw
(Item 4), [Figure 60-70-2] and fasten the screw
Remove the fuel camshaft gear and fuel camshaft (Item 2 until its tappered parts contacts the
& 3) [Figure 60-70-1]. circumferential end of the ball bearing.
Installation: Apply a thin layer of engine oil to the fuel

camshaft before installation.

639 of 726
FUEL SYSTEM (CONT'D) Fuel Shutoff Solenoid - Checking
Fuel Camshaft Governor Disassembly And Assembly Figure 60-70-5

(Cont’d)
Figure 60-70-3
1
2
3
P-62622
1 P-69860 Disconnect the negative (-) cable from the battery.
1. Flyweight Disconnect the electrical connector (Item 1) [Figure 60-

70-5] from the fuel shutoff solenoid.

2. Fork Lever Shaft
Use an ohmmeter to check the fuel shutoff solenoid.
3. Max Torque Limitation
4. Start Spring Figure 60-70-6
5. Governor Spring
Figure 60-70-4
2
3
P-62626
1
The reading between electrical connector terminal C and

P-69861
terminal A must be approximately 15.6 ohms [Figure 60-
70-6].
1. For Lever Shaft
The reading between electrical connector terminal C and
2. Fork Lever 1
terminal B must be between approximately 0.35-0.4
3. Fork Lever 2 ohms.
4. Floating Lever
5. Torque Pin
Check all the parts for wear or damage and replace as
needed.

640 of 726
FUEL SYSTEM (CONT'D) Figure 60-70-9
Fuel Shutoff Solenoid Removal And Installation
Remove the rear access panel behind the seat.
Figure 60-70-7
1
P-62624
1 Remove the two mounting bolts (Item 1) [Figure 60-70-

9] from the fuel shutoff solenoid.
Remove the fuel shutoff solenoid.
P-62622

Disconnect the electrical connector (Item 1) [Figure 60-
70-7] from the fuel shutoff solenoid.
Figure 60-70-8
P-62623
Remove the tie strap (Item 1) [Figure 60-70-8].

641 of 726
Fuel Injection Pump Removal And Installation 3
Remove the fuel shutoff solenoid. (See Fuel Shutoff

Solenoid Removal And Installation on Page 60-70-3.)
2
IMPORTANT
Do not bend the high pressure fuel injection tubes 1
when removing or installing them.
I-2029-0289
P-62659
Clean the area around the injection pump thoroughly.
Figure 60-70-10 Remove and cap the fuel inlet hose (Item 1) and the fuel
return hose (Item 2) from the injection pump vent [Figure
60-70-11].
1 Remove the high pressure fuel lines (Item 3) [Figure 60-

70-11] from the injection pump.

Installation: Tighten the high pressure fuel line nuts to
18-25 ft.-lb. (24-33 N•m) torque.
Figure 60-70-12
1
P-62658 2
Disconnect the high pressure fuel lines (Item 1) [Figure

60-70-10] from the fuel injectors.

18-25 ft.-lb. (24-33 N•m) torque. 1
1
1
P-62661
Remove the eight mounting bolts (Item 1) from the intake

manifold (Item 2) [Figure 60-70-12].
Remove the intake manifold from the engine.
Installation: Replace the manifold gasket if it is worn or

damaged.

642 of 726
Fuel Injection Pump Removal And Installation

(Cont'd)
Figure 60-70-13
1 2
1
1 1
P-69916
1 Disconnect the starter spring (Item 1) from the thrust

lever (Item 2) [Figure 60-70-15].
P-62659
Figure 60-70-16
Remove the six mounting bolts (Item 1) [Figure 60-70-

13] from the injection pump.
3
Installation: Tighten the mounting bolts to 16-20 ft.-lb.
(22-27 N•m) torque.
1
Figure 60-70-14
2
2
P-69914
Align the control rack pin (Item 1) with the notch (Item 2)
and remove the pump (Item 3) [Figure 60-70-16].
1 P-69915
Remove the speed control plate (Item 1) and the

governor spring (Item 2) [Figure 60-70-14] from the
injection pump.
Installation: Apply a liquid gasket to both sides of the

solenoid cover gasket and control plate gasket.
NOTE: Be careful not to drop the governor springs

into the crankcase.

643 of 726
FUEL SYSTEM (CONT'D) Timing The Injection Pump
Fuel Injection Pump Removal And Installation

(Cont'd)
Figure 60-70-17
WARNING
1
W-2072-0496
P-69917
IMPORTANT
Installation: Use the same number of gasket shims, or Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.

new gasket shims with the same thickness.
I-2028-0289
Installation: When installing the injection pump, insert

the control rack pin (Item1) [Figure 60-70-16] firmly into Timing the injection pump is done by changing the
the grove (Item 1) [Figure 60-70-17] of the fork thrust number of shims between the injection pump and the
lever. injection pump mounting surface.
Remove the fuel lines and injectors. (See Fuel Injector

Remove the fuel shutoff sloenoid. (See Fuel Shutoff

Solenoid Removal And Installation on Page 60-70-3.)
NOTE: The flywheel is rotated counter clockwise

when standing at the flywheel end of the
engine.

644 of 726
Timing The Injection Pump (Cont’d)
Figure 60-70-18 1
P-62662
P-62667
P-69918
Continue to turn the engine slowly (for approximately one

P-55324
and three-quarter turn after fuel stops flowing from the
injection pump nozzle), until the timing mark on the side
of the flywheel (Item 1) is at the bottom edge of the timing
Install a short plastic tube (Item 1) [Figure 60-70-18] in hole (Item 2) [Figure 60-70-19] in the flywheel housing.
the number one cylinder port of the injection pump. The

tube should fit securely in the port and point upward. Slowly turn the engine counterclockwise: as soon as fuel
starts to flow at the top of the injection pump nozzle, stop
Move the fuel lever on the injection pump to full fuel turning the engine.
position (or full throttle).
At this point, look at the timing mark (Item 1) (located on
Turn the engine counterclockwise until fuel flows out of the flywheel) for proper alignment. When the timing mark
the injection pumps number 1 cylinder nozzle. (Install a is aligned with the mark in the sight hole (Item 2) [Figure
tool on the crankshaft at the front of the engine to turn the 60-70-19] the timing is correct for the injection pump,
engine.) which is 17°-19° B.T.D.C.
NOTE: The fuel must flow out of the nozzle for one Figure 60-70-20
firing cycle before timing can be attempted.
P13130
Add or subtract shim(s) (Item 1) [Figure 60-70-20] as

needed to adjust the fuel delivery timing.

645 of 726
FUEL SYSTEM (CONT'D) Fuel Injector Removal And Installation
Timing The Injection Pump (Cont’d) The tool listed will be needed to do the following
procedure:
Figure 60-70-21
MEL1485 - Socket
WARNING
1 Diesel fuel or hydraulic fluid under pressure can
(1) (2) (3) from a physician familiar with this injury.
W-2072-0496
P-51280
The size of shims (Item 1) [Figure 60-70-21] are

identified by a symbol on the shims.
IMPORTANT

(1) Two holes means 0.0079 in. (.20 mm) shim.
Do not bend the high pressure fuel injection tubes
(2) One hole means 0.0098 in. (.25 mm) shim. when removing or installing them.
I-2029-0289
(3) Without hole means 0.0118 in. (.30 mm) shim.
The following are some problems caused by faulty
NOTE: Increasing the thickness of the shim pack by injectors:
0.0020 in. (0,050 mm) retards the injection
timing by 0.500° (0.0087 rad). Decreasing the -Engine is hard to start or will not start
shim pack by 0.0020 in. (0,050 mm) advances -Rough engine operation and idle
the timing by 0.500° (0.0087 rad). -Engine will not have full power
-Excessive exhaust smoke

646 of 726
Fuel Injector Removal And Installation (Cont'd)
Figure 60-70-22
B-5970
1
Loosen the fuel injector with a special socket (MEL-1485)
P-62668
[Figure 60-70-24].
Installation: Tighten the injectors to 36-50 ft.lb. (49-68

Remove the injector tubelines (Item 1) [Figure 60-70-22] N•m) torque.
from the fuel injector pump.

Figure 60-70-25
18-25 ft.lb. (24-33 N•m) torque.
Figure 60-70-23
B-5971
2 2
Remove the fuel injector nozzle from the engine [Figure
P-62658
60-70-25].
Remove the injector tubelines (Item 1) [Figure 60-70-23]

from the injectors.
IMPORTANT
Remove the fuel return hoses (Item 2) [Figure 60-70-23]
from the fittings. Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
Installation: Tighten the high pressure fuel line nuts to tools.
18-25 ft.lb. (24-33 N•m) torque. I-2027-0284

647 of 726
Fuel Injector Nozzles Pressure - Checking

2
Remove the fuel lines and injectors. (See Fuel Injector
Removal And Installation on Page 60-70-8.) 3
4
5
1
6
WARNING
Diesel fuel or hydraulic fluid under pressure can 7
Use a piece of cardboard or wood to find leaks. Do P-62152

1. Nozzle Holder
W-2072-0496 2. Adjusting spacer
3. Nozzle Spring
The tool listed will be needed to do the following
procedure: 4. Push Rod

MEL 10018 - Injector Nozzle Tester 5. Distance Piece
6. Nozzle Piece
Figure 60-70-26
7. Nozzle Retaining Nut
Tighten the Nozzle Holder (Item 1) [Figure 60-70-27] to
25.3 - 28.9 ft-lb. (34,3 - 39,2 N•m) torque.
Tighten the Overflow pipe nut to 14.5 - 18.1 ft-lb. (19,6 -

24,5 N•m) torque.
Tighten the Nozzle Holder Assembly to 36.2 - 50.6 ft-lb.

(49,0 - 68.6 N•m) torque.
NOTE: You can adjust the release pressure of the

injector nozzle by adding or removing
spacers (Item 2) from the top of the nozzle
A-2513 spring (Item 3) [Figure 60-70-27] Spacers are
available in different thicknesses.
Connect the nozzle to the tester with the nozzle down

[Figure 60-70-26].
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 1991-2134 PSI

(137-147 bar)

648 of 726
FUEL SYSTEM (CONT'D) Valve Seat Tightness
Nozzle Spray Condition Figure 60-70-29
Figure 60-70-28
CORRECT WRONG
A-2513
A-2621
Connect the injector nozzle to the tester with the nozzle
in the down position [Figure 60-70-29].
Check that the spray pattern is correct [Figure 60-70-
28]. Check for inside leakage. Operate the hand lever until

the pressure reaches1849 PSI (127 bar). Make a record
1. Fuel does not come out the side of the nozzle. of the pressure. Release the hand lever. Check the
pressure decrease in 10 seconds. If any leak is found,
2. Drops of fuel are not present at the nozzle. replace the nozzle.
3. The injector has an even flow coming from the nozzle.
WARNING
W-2072-0496

649 of 726

650 of 726
CYLINDER HEAD Figure 60-80-3
Glow Plug - Testing
Figure 60-80-1
P-69747
Use an ohmmeter to check the glow plugs [Figure 60-80-

3].
P-52698 Touch one probe to the end of the glow plug and the
other probe to the body of the glow plug.

Disconnect the glow plug cables and leads. The reading should be approximately 0.9 ohms. If the
resistance is infinite, the coil of the glow plug is broken. If
Remove the nut and wire harness (Item 1) [Figure 60- the resistance is 0 the glow plug is short circuited.
80-1].
Repeat the procedure for each glow plug.
Figure 60-80-2
P-62625
Remove the nuts (Item 1) [Figure 60-80-2] from the top

of the glow plugs.
Remove the glow plug connecting strap (Item 2) [Figure

60-80-2].

651 of 726
CYLINDER HEAD (CONT'D) Valve Clearance Adjustment
Glow Plug Removal And Installation NOTE: The valve clearance must be checked and
adjusted when engine is cold.
Remove the glow plug wire harness and strap. (See
Glow Plug - Testing on Page 60-80-1.) Remove the valve cover.
Figure 60-80-4 Bring number 1 piston to “TDC” (Top Dead Center).
Figure 60-80-6
2
1
P-62627

P-62022
Loosen and remove the glow plugs (Item 1) [Figure 60-
80-4].
Remove the glow plug. (See Glow Plug Removal And
Installation: Tighten the glow plug to 5.8 - 10.8 ft.-lb. (7,8 Installation on Page 60-80-2.)
- 14,7 N•m) torque.
Remove the cylinder head cover. (See Cylinder Head
Figure 60-80-5 Removal And Installation on Page 60-80-4.)
Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [Figure 60-80-6].
Turn the adjustment screw (Item 2) [Figure 60-80-6] until

the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
60-80-6].
If adjustments are necessary, tighten lock nut before

moving on to the next rocker arm.
P-48708
Photo [Figure 60-80-5] shows the glow plug removed

from the engine. Inspect the glow plugs and replace
when necessary.

652 of 726
CYLINDER HEAD (CONT'D) Valve Timing - Checking
Valve Clearance Adjustment (Cont’d) Figure 60-80-9
Figure 60-80-7
1
0.0057-0.0073”
(O,145-0,185 MM)
P-69972
A-2730A
Remove the engine. (See Removal And Installation on
Page 60-10-8.)
Make sure the piston is at TDC when adjusting the
clearance at the valves. The correct clearance is 0.0057- Remove the timing gearcase cover. (See Timing

0.0073 inch (0,145-0,185 mm) cold clearance [Figure Gearcase Cover Removal And Installation on Page 60-
60-80-7]. 100-1.)
Figure 60-80-8 Make sure the timing marks (Item 1) are in correct
alignment [Figure 60-80-9].
P-62023A
With No. 1 piston at TDC (compression) both the intake

and exhaust valves are up. Set both No. 1 valves, No. 2
intake valve and No. 3 exhaust valve. [Figure 60-80-8].
Rotate the flywheel 360°, No.1 piston (overlap position).

Set No. 2 exhaust valve, No. 3 intake valve and both No.
4 valves [Figure 60-80-8].

653 of 726
CYLINDER HEAD (CONT'D) Figure 60-80-12
Cylinder Head Removal And Installation
Figure 60-80-10
1
1
P-47245
Installation: The push rod (Item 1) must be seated in the

P-51854 tappet (Item 2) [Figure 60-80-12] correctly or the push
rods will be damaged.
Remove the valve cover nuts (Item 1) [Figure 60-80-10]. After installing the rocker arm assembly and push rods,
the valve lash must be adjusted. (See Valve Clearance

Installation: Tighten the valve cover nuts to 5.1-8.3 in.- Adjustment on Page 60-80-2.)
lb. (6,9-11,3 N•m) torque.
Figure 60-80-13
Remove the valve cover and replace the gasket if
needed.
Remove the fuel injector nozzles. (See Fuel Injector 2

Remove the glow plugs. (See Glow Plug Removal And

Figure 60-80-11 1
1
P-47246
Remove the clamps (Item 1) and remove the hose (Item

2) [Figure 60-80-13] from the thermostat housing.
Remove the intake and exhaust manifolds.

2
2
2
B-14332
Remove the rocker arm and shaft assembly (Item 1) and

the push rod tubes (Item 2) [Figure 60-80-11].
Installation: Tighten the nuts to 16-17 ft.-lb. (22-27 N•m)

torque.

654 of 726
Cylinder Head Removal And Installation (Cont'd)
Figure 60-80-14
14 6 3 11
18 10 2 7 15
B-3643B
17 9 1 8 16
13 4 12
5
Remove the four mounting bolts at the coolant housing
P-47247 (Item 1) [Figure 60-80-16].
Remove the coolant housing from the head.

Remove the cylinder head bolts in order of #18 to #1
[Figure 60-80-14]. Figure 60-80-17

NOTE: (A) is the gearcase side, (B) is the flywheel
side.
Installation: Put oil on the bolt threads. Tighten the bolts

in the correct sequence to 47-51 ft.-lb. (64-69 N•m)
torque.
NOTE: Re-tighten the cylinder head bolts in the

correct sequence after the engine has been
run for 30 minutes.
Figure 60-80-15
1
P-47249A
When replacing just the gasket, use a new gasket that

has the same mark (Item 1) [Figure 60-80-17] as the
original gasket.
When replacing the gasket after an engine rebuild, the

piston protrusion must be measured.
See Cylinder Head Top Clearance on Page 60-80-7

1
After the gasket and cylinder head have been installed,
B-14334 turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.
Remove the cylinder head from the engine block.
Installation: Always use a new head gasket and new O-

ring. Make sure the O-ring (Item 1) [Figure 60-80-15] is
seated over the dowel.

655 of 726
CYLINDER HEAD (CONT'D) Cylinder Head - Servicing
Cylinder Head Disassembly and Assembly Clean the surface of the cylinder head.
Figure 60-80-18 Figure 60-80-20
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 60-80-20] on the
spring [Figure 60-80-18]. cylinder head.

Figure 60-80-19 NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [Figure 60-80-20] between

the straight edge and the surface of the cylinder head.
Figure 60-80-21
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the valve cap (Item 1) and valve spring collet

(Item 2) [Figure 60-80-18] & [Figure 60-80-19].
Remove the valve spring retainer (Item 3) and the spring

PI-9988
(Item 4) [Figure 60-80-18] & [Figure 60-80-19].
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
60-80-18] & [Figure 60-80-19]. and two diagonal as shown in figure [Figure 60-80-21].
The maximum distortion of the head surface is ± 0.002

inch (± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

656 of 726
CYLINDER HEAD (CONT'D) Valve Guide - Checking
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly and Assembly on Page
Figure 60-80-22 60-80-6.)
Remove the carbon from the valve guide.
2 Figure 60-80-23
1 3
P-51631
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 60-80-22] being checked at T.D.C.
B-14335

Put 3 pieces of 0.06 inch (1,5 mm) diameter solder (Item
2) [Figure 60-80-22] on the top of the piston. Use grease Measure the valve stem O.D. [Figure 60-80-23].
to hold them in position.
Measure the valve guide I.D. [Figure 60-80-23].
NOTE: Put the solder in position so they do not touch
the valves. Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Turn the piston to bottom dead center.
Valve Guide I.D 0.2760-0.2765 inch
Install the cylinder head. (See Cylinder Head Removal (7,01-7,025 mm)
And Installation on Page 60-80-4)
Valve Stem O.D 0.2741-0.2764 inch
Turn the crankshaft until the piston exceeds T.D.C. (6,960-6,975 mm)
Remove the cylinder head. Clearance Between 0.0014-0.0025 inch
Valve Stem and guide (0,035-0,065 mm)
Remove the solder wire (Item 3) [Figure 60-80-22] and Allowable Limit 0.0039 inch
measure it. (0,1 mm)
If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.0217-0.0276 inch (0,55-0,7 mm)

657 of 726
CYLINDER HEAD (CONT'D) Reconditioning The Valve And Valve Seat
Valve Guide - Checking (Cont’d) Figure 60-80-26
Figure 60-80-24
8.86” (225 mm)
0.787” 2.76” (70mm) 1.77”

(20 mm) (45 mm)
0.460-0.468”
(11,7-11,9 mm) 0.256-0.259”
(6,5-6,6 mm)
0.2” 0.350-0.358” 0.787”
(5,0 mm) (8.9-9.1 mm) (20,0 mm)
0.263-0.275” 0.98” PI-9993

0.490-0.50”
(6,7-7 mm) (25,0 mm) (12.5-12.8 mm)
MC-1364
Grind the valve face to the correct angle using a valve re-
facer [Figure 60-80-26].
To remove and replace the valve guide, make the driver
tool as shown in figure [Figure 60-80-24]. Clean the valve seat and combustion chamber.

Figure 60-80-25 Figure 60-80-27
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 60-80-25]. recessing or protrusion with a depth gauge [Figure 60-
80-27].
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 & 2)
[Figure 60-80-25], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

658 of 726
Reconditioning The Valve And Valve Seat (Cont’d) 1 2

15° Exhaust
Figure 60-80-28 30° Intake
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 60-80-30].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 60-80-28].
If the seat surface (b) is too wide, use a 30 degree cutter

(Item 2) on the intake, and a 15 degree cutter on the
Protrusion 0.002 inch (0,05 mm)
exhaust to get the correct width (Item 3) [Figure 60-80-
Recessing 0.0098 inch (0,25 30].
mm)
Allowable Limit (Recessing) 0.016 inch (0,4 mm) Valve Seat Width
Figure 60-80-29 Intake 0.0835 inch (2,12 mm)

Exhaust 0.0835 inch (2,12 mm)
Valve Seat & Face Angle
Intake 60°
Exhaust 45°
45° Exhaust
15° Exhaust 60° Intake
30° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 60-80-29].

659 of 726
Valve Spring
Figure 60-80-31
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 60-80-32].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the
measurement is less than the allowable limit, replace the spring.

spring [Figure 60-80-31].
Setting Length 1.22 in. (31,0 mm)
Free Length 1.457 - 1.476 in. (37 - 37,5 mm) Setting Load 26.4 lb. (117,4 N)
Allowable Limit 1.437 in. (36,5 mm) Allowable Limit 22.5 lb. (100,0 N)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 60-80-31].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 0.039 inch (1,0 mm)

660 of 726
CYLINDER HEAD (CONT'D) Rocker Arm And Shaft - Checking
Valve Tappets Figure 60-80-35
Figure 60-80-33
1
2
B-3697
P-47267
Measure the rocker arm I.D. (Item 1) [Figure 60-80-35]
with an inside micrometer.
Remove the valve tappets (Item 1) [Figure 60-80-33].
Measure the rocker arm shaft O.D. (Item 2) [Figure 60-

Figure 60-80-34 80-35] with an outside micrometer.
If the clearance exceeds the allowable limit, replace the

bushing.
If the clearance still exceeds the allowable limit after the

bushing is replace, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm

& Shaft 0.0006 - 0.0018 in.
(0,016 -0,045 mm)
Allowable Limit 0.004 in.
(0,10 mm)
Rocker Arm Shaft O.D. 0.4714 - 0.4718 in.
(11,973 - 11,984 mm)
P-47268 Rocker Arm I.D. 0.4724 - 0.4731 in.
(12 - 12,018 mm)
Measure the O.D. of the tappet [Figure 60-80-34].
Measure the ID of the tappet bore [Figure 60-80-34].

tappets.
Tappet OD 0.7858 - 0.7866 in. (19,959 - 19,980

mm)
Tappet Bore ID 0.7874 - 0.7882 in. (20 - 20,021 mm)
Clearance
Between Tappet
and Tappet Bore 0.0008-0.0024 inch (0,02-0,06 mm)
Allowable limit 0.0028 inch (0,07 mm)

661 of 726

662 of 726
CRANKSHAFT AND PISTONS Figure 60-90-2
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

Remove the top edge from the cylinder bore with a ridge
reamer.
1
Remove the oil pan. (See Oil Pan Removal And
Turn the flywheel and put a pair of connecting rods at

bottom dead center. A-2903
Remove the connecting rod bolts.

Installation: Make sure the marks on the connecting rod
Installation: Tighten the connecting rod bolts to 33-36 and bearing are aligned when installing the bearing cap
ft.-lb. (44-49 N•m) torque. (Item 1) [Figure 60-90-2].
Figure 60-90-1 Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block.

PI-10013
Remove the rod cap and bearing [Figure 60-90-1].
Use a hammer handle and push the piston/connecting

rod assembly out of the cylinder bore [Figure 60-90-1].
NOTE: Make sure the pistons are marked so they will

be returned to the same cylinder bore.

663 of 726
CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-4
Piston And Connecting Rod Removal And

2
Figure 60-90-3
4
1 3
1
5 2
3
7 1
PI-10015
Installation: When installing new rings, assemble the

ring so the mark (Item 1) near the gap faces the top of the
6 P-47270 piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 60-90-4].
Remove the snap ring (Item 1) and piston pin (Item 2)

[Figure 60-90-3]. Figure 60-90-5
Separate the piston (Item 3) from the connecting rod

(Item 4) [Figure 60-90-3]. 3
1
Remove the oil ring (Item 5) [Figure 60-90-3]. 2
Remove the second compression ring (Item 6) [Figure

60-90-3].
Remove the first compression ring (Item 7) [Figure 60-

90-3].
5
NOTE: Mark the piston (Item 3) [Figure 60-90-3] and 6 4
connecting rod (Item 4) [Figure 60-90-3] with
the same number to ensure correct P-47271
installation and proper cylinder placement.
Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
piston in clean engine oil to 176° F. (80° C.) and tap the
piston pin into position. Place the piston rings so that
there are gaps every 120° (Items 3, 4 & 5) [Figure 60-90-
5] with no gap facing the piston pin in the cylinder.
NOTE: Assemble the piston to the connecting rod

with the FW mark (Item 6) [Figure 60-90-5] is
facing the flywheel side and the connecting
rod mark (Item 1) [Figure 60-90-5] facing the
injection pump side.

664 of 726
Piston And Connecting Rod - Servicing

1
Figure 60-90-6
P-47273
Measure the O.D. of the piston pin (Item 1) [Figure 60-

P-47272 90-7].
Measure the I.D. of the connecting rod small end (Item 2)

Measure the I.D. of the piston pin bore in both horizontal [Figure 60-90-7].
and vertical directions [Figure 60-90-6].

Calculate the oil clearance. If the clearance exceeds the
If the measurement exceeds the allowable limit, replace allowable limit, replace the bushing. If it still exceeds the
the piston. specifications, replace the piston pin.
Piston Bore I.D. 0.8661 - 0.8667 in. Piston Pin O.D. 0.8662 - 0.8666 in.
(22,0 - 22,013 mm) (22,002 - 22,011 mm)
Allowable Limit 0.8673 in. (22,03 mm) Bushing I.D. 0.8671 - 0.8677 in.
(22,025 - 22,04 mm)
Oil Clearance Between 0.00055 - 0.00150 in.
Piston Pin & Bushing (0,014 - 0,038 mm)
(0,15 mm)
Figure 60-90-8
1.38” (35 mm)

1.063” (27 mm)
6.38” (162 mm)

1.378”
(35 mm)
1.098-1.1004”
(27,9-27,95 mm)
0.984-0.985”
(25,0-25,01 mm)
MC-1366
To replace the connecting rod small end bushing, make a

driver tool as shown in figure [Figure 60-90-8].

665 of 726
Piston And Connecting Rod - Servicing (Cont’d)
Figure 60-90-9
B-3622
Install a piston ring into the lower part of the cylinder

PI-10016
bore. Measure the ring gap with a feeler gauge [Figure
60-90-10].
Use a press and special driver tool to remove the small If the gap exceeds the allowable limit, replace the ring.
end bushing [Figure 60-90-9].

Top Ring Gap 0.0118 - 0.0177 in.
Installation: Clean the small end bushing and bore. Put (0,3 - 0,45 mm)
oil on the bushing and press into the connecting rod until Oil Ring Gap 0.0098 - 0.0157 in.
it is flush [Figure 60-90-9]. (0,25 - 0,40 mm)
Allowable Limit 0.0492 in. (1,25 mm)
Second Ring Gap 0.0118 - 0.0177 in.
(0,30 - 0,45 mm)

666 of 726
CRANKSHAFT AND PISTONS (CONT’D) Cylinder Bore Checking
Piston And Connecting Rod - Servicing (Cont’d) Figure 60-90-12
Figure 60-90-11
B-4066
PI-10017
Use a gauge to check the inside measurement of the
cylinder bore [Figure 60-90-12].
Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler Figure 60-90-13

gauge [Figure 60-90-11].

ring. If the clearance still exceeds the allowable limit,
replace the piston.
Compression Rings 0.0033 - 0.0044 in.

(0,085 - 0,112 mm)
Allowable Limit 0.0079 inch (0,2 mm)
Oil Ring 0.0008 - 0.0021 in.
(0,02 - 0,06 mm)
A-2717
Measure the six points as shown in figure [Figure 60-90-

13] to find the maximum wear.
The factory specifications are:
3.0709 - 3.0716 in. (78,0 - 78,019 mm)
The wear limit is: +0.0059 in. (+0,15 mm).
If the cylinder bore is not within specifications, re-bore the

cylinder for oversize piston.

667 of 726
CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings Removal And Installation
Connecting Rod Alignment Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
NOTE: The small end bushing is the basis of this Page 60-90-1.)
check, check the bushing for wear before
doing this check. Figure 60-90-15
Install the piston pin into the connecting rod.

2 5
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the 4
face plate.
Figure 60-90-14
1
P-47274

Mark and remove the inside screws (Item 1) first, then
remove the outside screws (Item 2) [Figure 60-90-15].
NOTE: The inside bolts are different length than the

outside bolts.
B-4067 Install two screws in the bearing case cover and remove
the cover (Item 3) [Figure 60-90-15].
If the gauge does not fit squarely against the face plate, Remove the two gaskets (Item 4) and oil seal (Item 5)
measure the space between the gauge and face plate [Figure 60-90-15] from the cover.
[Figure 60-90-14].
Figure 60-90-16
If the measurement exceeds the allowable limit, replace
the connecting rod. 1
2
Rod Alignment 0.002 in. (0,05 mm)
P-51872
Installation: Install the gaskets (Item 1 & 2) [Figure 60-

90-16] as shown.

668 of 726
Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 60-90-17
1
1
P-47278
Remove the main bearing case bolt (Item 1) [Figure 60-

90-19].
P-47276
Installation: Align the bearing case hole (Item 2) [Figure
60-90-19] with the hole in the block. Put oil on the bolt
Install the bearing case cover (Item 1) [Figure 60-90-17] threads and tighten to 36.2 - 39.8 ft.-lb. (49 - 53,9 N•m)

with the casting mark (Item 2) [Figure 60-90-17] in the torque.
upward position. Tighten the bolts to 7.2 - 8.3 ft.-lb. (9,8 -
11,3 N•m) torque. Figure 60-90-20
Figure 60-90-18
P-47279
P-47277
Remove the crankshaft/main bearing assembly from the
engine block [Figure 60-90-20].
Before removing the crankshaft/main bearings, check the
end play. Install a dial indicator. Move the crankshaft NOTE: Turn the crankshaft as needed to allow the
[Figure 60-90-18] to the flywheel side, zero the dial crank pin journals to pass through the cut out
indicator. Measure the end play by pulling the crankshaft (Item 1) [Figure 60-90-20] of the engine block.
toward the gear case side.
Mark the bearing case halves for correct installation.
If the measurement exceeds the allowable limit, replace
the thrust washers [Figure 60-90-18].
End Play 0.0059 - 0.0122 in.

(0,15 - 0,31 mm)
(0,5 mm)

669 of 726
Crankshaft And Bearings - Servicing
Figure 60-90-21
A-2763
Put the crankshaft on V-blocks. Install a dial indicator on

B-4092 the center journal [Figure 60-90-23].
Turn the crankshaft at a slow rate to obtain the

Remove the two bearing case bolts [Figure 60-90-21]. misalignment (one half of the alignment measurement).

Remove the bearing case and bearing. If the misalignment exceeds the allowable limit, replace
the crankshaft.
Installation: Tighten the bearing case bolts to 21.7 - 25.3
ft.-lb. (29.4 - 34.3 N•m) torque. Alignment 0.0008 in. (0,02 mm)
Figure 60-90-22 Tighten the connecting rod bolts to 20 - 22 ft.-lb. (27 - 30

N•m) torque.
Figure 60-90-24
120
PI-10021
Installation: When installing the main bearing case

A-2727
assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [Figure 60-90-22]. The thrust
washers oil grooves must face outward. Measure the crankpin bearing I.D. [Figure 60-90-24].

670 of 726
Crankshaft And Bearings - Servicing (Cont’d) 1
Figure 60-90-25
PI-10022
Check the wear on the crankshaft sleeve (Item 1) [Figure

60-90-26].
A-2716
If the wear exceeds the allowable limit or the seal leaks
oil, replace the sleeve.
Measure the crankpin O.D. [Figure 60-90-25].
Wear of Sleeve 0.0004 in. (0,1 mm)

Calculate the oil clearance.
The special tool set will be needed to replace the
Crankpin Bearing I.D. 1.5750 - 1.5768 in. crankshaft sleeve.
(40,004 - 40,050 mm)
Remove the sleeve.
Crankpin O.D. 1.5732 - 1.5738 in.
(39,959 - 39,975 mm) Figure 60-90-27
Oil Clearance 0.0011 - 0.0036 in.
(0,029 - 0,091 mm)
Allowable limit 0.0079 in. (0,2 mm)
2 2
1 3
PI-10023
Install the sleeve guide (Item 1) and stop (Item 2) [Figure

60-90-27].
Heat the sleeve to approximately 300° F (150° C). Install

the sleeve on the crankshaft using the special driver tool
(Item 3) [Figure 60-90-27].
NOTE: The sleeve is installed with the larger

chamfered surface to the front of the
crankshaft (Item 1) [Figure 60-90-26 on Page
9].

671 of 726
Crankshaft And Bearings - Servicing (Cont’d)
Figure 60-90-28
B-3618
Measure the O.D. of the crankshaft journal [Figure 60-

B-3631 90-30].
Calculate the oil clearance.

Measure the I.D. of the No. 1 crankshaft bearing [Figure
60-90-28]. If the clearance exceeds the allowable limit, replace the

crankshaft bearing.
Figure 60-90-29
Bearing 1:
Bearing I.D. 1.8891 - 1.8916 in. (47,984 - 48,048

mm)
Journal O.D. 1.8872 - 1.8878 in. (47,934 - 47,950
mm)
Oil Clearance 0.0013 - 0.0045 in. (0,034 - 0,114
mm)
Allowable Limit 0.0079 inch (0,2 mm)
Figure 60-90-31
Removal Tool
P-73019
5.31” (135 mm)
0.8”
(20 mm)
NOTE: Undersize dimensions of crankshaft journal 2.354-2.358”
[Figure 60-90-28]. (59,80-59.90 mm)
2.83”
Undersize 0.008 in. (0,2 mm) 0.016 in. (0,4 mm) (72 mm)
Dim. A 0.0906-0.1063 in. 0.0906-0.1063 in.
radius (2,3-2,7 radius (2,3-2,7
mm) radius mm) radius 0.8” (20 mm)
Dim. B 0.0394-0.0591 in. 0.0394-0.0591 in. 2.551-2.555
1.57” 0.4” (64,80-64,90 mm)
dia. (1,0-1,5 mm) dia. (1,0-1,5 mm)
(40 mm) (10 mm) MC-1367
dia. dia.
Dim. C 1.8793-1.8799 in. 1.8714-1.8720 in.
dia. (47,734- dia. (47,534- To remove the front bearing make the tool as shown in
47,750 mm) dia. 47,550 mm) dia. figure [Figure 60-90-31].
The crankpin must be fine-finished to higher than
(0.8-S)

672 of 726
Figure 60-90-32
Installation Tool
5.12” (130 mm)
0.8”
(20 mm)
0.16”
(4 mm)
2.551-2.555”
2.83” (64,80-64.90 mm)
(72 mm)
2.68”
(68 mm) PI-10025
0.8” (20 mm)

1.57” 2.354-2.358” Clean the crankshaft journal and bearing. Put a strip of
0.4” (59,80-59,90 mm)
(40 mm) (9mm) press gauge on the center journal.
MC-1365
Install the main bearing case halves and tighten the bolts.
To install the front bearing make the tool as shown in Remove the bearing case halves.
figure [Figure 60-90-32].

NOTE: DO NOT turn the crankshaft with the press
Figure 60-90-33 gauge installed. Incorrect measurements will
be obtained.
1. Seam 4 Measure the flattened press gauge [Figure 60-90-34].

2. Bearing
3. Engine Block If the clearance exceeds the allowable limit, replace the
4. Bearing Recession crankshaft bearing.
3
Crankshaft Bearing 2
Crankshaft Journal O.D. 1.8872 - 1.8878 in.
(47,934 - 47,950 mm)
Bearing I.D. 1.8891 - 1.8909 in.
2 1 2 (47,984-48,029 mm)
(0,034 - 0,095 mm)
P-48778
(0,2 mm)
Remove the front bearing with the special removal tool
[Figure 60-90-31]. Crankshaft Bearing 3
Crankshaft Journal O.D. 2.0441 - 2.0449 in.
Installation: Clean the new bearing (Item 2) and bore, (51,921 - 51,940 mm)
apply oil to the bearing and bore. Install the new bearing Bearing I.D. 2.0462 - 2.0480 in.
with the seam (Item 1) [Figure 60-90-33] towards the (51,974 - 52,019 mm)
exhaust manifold side, using the installation driver tool.
Check the depth (Item 4) of the bearing (Item 2) from the (0,034 - 0,098 mm)
face of the engine block (Item 3) [Figure 60-90-33]. This Allowable Limit 0.0079 in.
will ensure proper bearing alignment with the crankshaft. (0,2 mm)
Bearing Number 1 0.0 - 0.0118 in. (0,0 - 0,3

Recession mm)

673 of 726
CRANKSHAFT AND PISTONS (CONT’D)
Figure 60-90-35
P-73020
NOTE: Undersize dimensions of crankshaft journal

[Figure 60-90-28].

Undersize 0.008 in. (0,2 mm) 0.016 in. (0,4 mm)
Dim. A 0.0906-0.1063 in. 0.0906-0.1063 in.
radius (2,3-2,7 radius (2,3-2,7
mm) radius mm) radius
Dim. B 0.0394-0.0591 in. 0.0394-0.0591 in.
dia. (1,0-1,5 mm) dia. (1,0-1,5 mm)
dia. dia.
Dim. C 1.8793-1.8799 in. 1.8714-1.8720 in.
dia. (47,734- dia. (47,534-
47,750 mm) dia. 47,550 mm) dia.
Dim. D 2.0362-2.0370 in. 2.0284-2.291 in.
dia. (51,721- dia. (51,521-
51,740 mm) dia. 51,540 mm) dia.
The crankpin must be fine-finished to higher than
(0.8-S)

674 of 726
CAMSHAFT AND TIMING GEARS Figure 60-100-3
Timing Gearcase Cover Removal And Installation 1
Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 60-70-4.)
Remove the governor fork lever. (See Fuel Camshaft 1

Governor Disassembly And Assembly on Page 60-70-1.) 1 1
Figure 60-100-1
1 1
1
P13270
1 NOTE: The bolts may vary in length. Keep the bolts in

their original location
Remove the mounting bolts (Item 1) [Figure 60-100-3]

from the timing gear case cover, and remove the cover.

Installation: Tighten the mounting bolts to 7-8 in-lb. (10-
P13266 11 N•m) torque.
Clean the gasket surface of timing cover.

Remove the crankshaft pulley bolt (Item 1) [Figure 60-
100-1]. Figure 60-100-4
Installation: Tighten crankshaft pulley bolt to 101-116 ft.-

lb. (137-157 N•m) torque.
Figure 60-100-2
1
P13271
2
Remove the timing cover gasket (Item 1) [Figure 60-100-
4].
P13268
Remove the crankshaft pulley (Item 1) [Figure 60-100-2]

from the crankshaft.
Installation: When installing the crankshaft pulley on the

crankshaft, align the timing marks (Item 2) [Figure 60-
100-2].

675 of 726
CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-7
Timing Gear Case Cover Removal And Installation

(Cont’d)
1
Figure 60-100-5
1 2 P13279
1
Installation: Install the timing gear case cover, then
1
install the crankshaft collar with the tapered side (Item 1)
P13272 [Figure 60-100-7] toward the O-ring.
Figure 60-100-8
Installation: Install four new O-rings (Item 1) and the oil

seal (Item 2) into the timing gear case cover [Figure 60-
100-5].
Figure 60-100-6 1
2
P13276
1 NOTE: The idle adjustment spring (Item 1) [Figure 60-

100-8] is located inside the timing case cover.
P13345 Be careful not to damage.
Remove the crankshaft collar (Item 1) [Figure 60-100-6]

from the crankshaft.
NOTE: The collar may stay in the gearcase cover,

when the cover is removed.

crankshaft and replace with a new O-ring.

676 of 726
CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Shaft Removal And Installation
Timing Gears Backlash - Checking Remove the timing gearcase cover. (See Timing
When the gears are installed, check the backlash of the 100-1.)
gears.
Figure 60-100-10
Figure 60-100-9
1 2
P13269
P-47264

Remove the snap ring (Item 1) and flat washer (Item 2)
Install a dial indicator [Figure 60-100-9]. from the idler gear shaft [Figure 60-100-10].
Hold one gear while turning the other gear [Figure 60- Remove the idler gear (Item 3) [Figure 60-100-10].
100-9].
Figure 60-100-11
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is
correct, replace the gear. 2
Crank Gear & Idler Gear 1 0.0013 - 0.0045 in.

(0,032 - 0,115 mm)
(0,15 mm) 1
1
Cam Gear & Idler Gear 1 0.0014 - 0.0045 in.
(0,036 - 0,114 mm)
(0,15 mm)
Injection Pump Gear & Idler 0.0013 - 0.0046 in.
Gear 1 (0,034 - 0,116 mm)
P13346
(0,15 mm)
Injection Pump Gear & 0.0012 - 0.0046 in. Remove the mounting bolts (Item 1) [Figure 60-100-11]
Governor Gear (0,030 - 0,117mm) from the idler shaft.
(0,15 mm) Remove the idler shaft (Item 2) [Figure 60-100-11].
Installation: Tighten the camshaft retainer bolts to 14-15

ft.-lb. (18-21 N•m) torque.

677 of 726
Camshaft - Servicing
Remove the timing gearcase cover. (See Timing

100-1.)
Remove the cylinder head. (See Cylinder Head Removal

Figure 60-100-12
PI-10002B
1
Installation: Check the camshaft end play. If clearance
exceeds the allowable limit, replace the camshaft retainer
plate [Figure 60-100-13].
1 Camshaft End Play 0.0028 - 0.0087 in.

(0,07 - 0,22 mm)

P13344 Figure 60-100-14
Remove the tappets from the block.
Align the holes (Item 1) [Figure 60-100-12] in the gear

on the camshaft with the mounting plate bolts.
Remove the mounting bolts from the camshaft mounting

plate.
Installation: Tighten the mounting bolts to 89-100 in.-lb.

(9,8-11,3 N•m) torque.
Remove the camshaft.

P-47263
Measure the cylinder block bore in the engine block

[Figure 60-100-14].

678 of 726
CAMSHAFT AND TIMING GEARS (CONT’D) If the measurement is less than the allowable limit,
replace the camshaft.
Camshaft - Servicing (Cont’d)
Cam Height of Intake 1.1339 in. (28,8 mm)
Figure 60-100-15 Allowable Limit 1.1319 in. (28,75 mm)
Cam Height of Exhaust 1.1417 in. (29 mm)
Figure 60-100-17
A-2761
Measure the camshaft journal [Figure 60-100-15].

Calculate the oil clearance. If the clearance exceeds the A-2760
allowable limit, replace the camshaft.
Cylinder Block Bore I.D. 1.4173 - 1.4183 in. Put the camshaft in V-blocks. Install a dial indicator
(36 - 36,025 mm) [Figure 60-100-17].
Journal O.D. 1.4147 - 1.4153 in.
Turn the camshaft at a slow rate. If the misalignment
(35,934 - 35,950 mm)
exceeds the allowable limit, replace the camshaft.
Oil Clearance of Cam- 0.00197 - 0.00358 in.
shaft Journal (0,05 - 0,091 mm)
Camshaft Alignment Allowable Limit 0.0004 in.
(0,15 mm)
Figure 60-100-16
B-5001
Measure the cam lobes at their highest point [Figure 60-

100-16].

679 of 726
Idler Gear And Shaft Servicing 1.024”
(26 mm)
Figure 60-100-18
7.72” (196 mm)
5.91” (150 mm)
1.016-1.020” 0.787”
(28,8-28,9 mm) (20 mm)
1.016-1.020”
(25,8-25,9) P-62615A
To replace the idler gear bushing, make a driver tool as

P13368
shown in figure [Figure 60-100-20].
Measure the outside diameter of the idler gear shaft (Item Figure 60-100-21
1) [Figure 60-100-18].

Idler Gear Shaft 1.0223 - 1.0228 inch (25,967 - 25,98
O.D. mm)
Figure 60-100-19
1
2
PI-10004
Use a press and the driver tool, to remove the old

bushing and install the new bushing [Figure 60-100-21].
P13365
Check the inside diameter of the idler gear bushing (Item

1) [Figure 60-100-19].
Idler Gear Bushing I.D. 1.0236 - 1.0244 inch

(26,000 - 26,021 mm)
Oil Clearance Between Idler Gear 0.0008 - 0.0021 inch (0,020
and Bushing - 0,054 mm)
Allowable limit 0.0039 inch (0,10 mm)

bushing.
Align the oil hole in the bushing (Item 2) [Figure 60-100-

19] with oil hole in the gear, when installing the new
bushing.

680 of 726
FLYWHEEL AND HOUSING Figure 60-110-3
Flywheel Housing Removal And Installation
Open the tailgate.
Remove the starter. (See Removal And Installation on

Page 50-40-2.)
1
Remove the hydraulic pump. (See Removal on Page 20-
50-5.)
Remove the muffler. (See Removal And Installation on

Page 60-30-1.)
Figure 60-110-1 P-73118
Remove the top housing bolts (Item 1) [Figure 60-110-3]

from both sides of the engine.
Figure 60-110-4
1

1
P-73120
Install a lifting eye (Item 1) [Figure 60-110-1] and hoist

on the end of the engine.
Figure 60-110-2 P-73117
Remove the bottom housing bolts (Item 1) [Figure 60-

110-4] from both sides of the engine.
P-73119
Remove the right side engine mount bolt (Item 1) [Figure

60-110-2].

681 of 726
FLYWHEEL AND HOUSING (CONT’D) Hydraulic Pump Coupler Removal And Installation
Flywheel Housing Removal And Installation (Cont’d) Figure 60-110-6
Figure 60-110-5
2 1
P-73121
P-73126
Remove the five bolts (Item 1) [Figure 60-110-6] from
the hydraulic pump coupler.
Raise the left side of the engine and remove the housing
(Item 1) [Figure 60-110-5]. Installation: Coat the threads with a thread locking

adhesive Loctite® 242 or equivalent. Tighten the bolts to
NOTE: Make sure the engine mount assembly (Item 25 - 28 ft.-lb. (35 - 39 N•m) torque.
2) [Figure 60-110-5] is in the proper position
when the housing is installed.
Installation: Position the housing over the alignment

pins and tighten the bolts to 30-37 ft.-lb. (40-50 N•m)
torque.

682 of 726
FLYWHEEL AND HOUSING (CONT’D) Rear End Plate Removal And Installation
Flywheel Removal And Installation Remove the flywheel housing. (See Flywheel Housing
Figure 60-110-7
Remove the hydraulic pump coupler. (See Hydraulic
Pump Coupler Removal And Installation on Page 60-110-
1 2.)
Remove the flywheel. (See Flywheel Removal And

Figure 60-110-8
1
2
1
1
P-73122
Remove the six bolts (Item 1) [Figure 60-110-7] from the

flywheel.

Remove the flywheel.
Installation: Coat the threads with a thread locking

P-68764A
adhesive Loctite® 242 or equivalent. Tighten the bolts to
40-43 ft.-lb. (54-59 N•m) torque.
Remove the seven bolts (Item 1) from the rear end plate
(Item 2) [Figure 60-110-8]. Remove end plate from the
side of the engine.

683 of 726

684 of 726
HEATER
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-60-1
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-50-1

HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1

Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-40-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-1

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-1

Filter Element Removal And Installation . . . . . . . . . . . . . . . .70-20-1
Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-2

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . .70-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient70-30-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-30-2
HEATER

685 of 726

686 of 726
HEATER SYSTEM Figure 70-10-3
Description
1
The heater system includes the heater unit which is
located on the floor under the seat. The heater unit
includes the heater coil, fan motor, blower cage, and
filter.
Components
Figure 70-10-1 2 3
P-73560
Control Panel: The panel (Item 1) [Figure 70-10-3] has

two separate components.
Fan Switch: This is a four position rotary switch (Item

2) [Figure 70-10-3].

1 Temperature Switch: The temperature switch (Item 3)
[Figure 70-10-3] controls the Heat Valve from fully
P-73584 Off to fully On.
Figure 70-10-4
Heater Unit: The heater unit (Item 1) [Figure 70-10-1] is
located on the floor under the seat. The unit delivers the
warm air for heat into the cab.
Figure 70-10-2
2
P-73555
Heater Valve: The heater valve (Item 1) [Figure 70-10-4]

is manually controls the amount of engine coolant that
P-73624 flows to the heater coil.
Heater Coil: The heater coil (Item 1) [Figure 70-10-2]

supplies the warm air into the cab by passing air through
the coil.
Heater Fan: The fan (Item 2) [Figure 70-10-2] is used to

push air through the heater coil and into the cab.

687 of 726

688 of 726
REGULAR MAINTENANCE Figure 70-20-3
Filter Element Removal And Installation
The recirculation filter must be cleaned regularly. The

filter is located at the left of the operator seat.
The heater filter must be cleaned regularly. The filter is

located at the left of the operator seat. 1
Figure 70-20-1
P-73460
Installation: Install the filter with the arrows that indicate

air flow direction (Item 1) [Figure 70-20-3] pointing
towards the heater housing.
1
The filter must be cleaned regularly.
2

P-73459
Turn the fastener (Item 1) 1/4 turn and remove the cover
(Item 2) [Figure 70-20-1].
Figure 70-20-2
P-73461
Pull the filter (Item 1) [Figure 70-20-2] out of the heater

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

689 of 726
REGULAR MAINTENANCE (CONT’D)
Heater Coil
Remove the operator seat and seat mount. (See SEAT

AND SEAT MOUNT on Page 40-40-1.)
Figure 70-20-4
3
3
1
1
2
P-73584

heater unit front cover.
Remove the front cover (Item 2) [Figure 70-20-4] from

the unit.

heater cover and remove cover.
Figure 70-20-5
P-73624
The heater coil (Item 1) [Figure 70-20-5] can now be

cleaned with low pressure water or air. High pressure
may damage the fins of the heater coil.

690 of 726
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.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit 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 obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air hoses are properly hooked Repair of adjust.
to Louvers, and air ducts.

3. Plugged cab filters Check cab filter condition. Clean or replace filters.

691 of 726
TROUBLESHOOTING (CONT’D) If there is no voltage at the wiring harness, check the
harness for broken wires.
Electrical System
Figure 70-30-3
Figure 70-10-1
1 P-73603
P-73625
If there is voltage at the wiring harness, check the

Disconnect the wire harness (Item 1) [Figure 70-10-1]. resistance to the blower fan at the thermostat/blower fan
wiring connector (Item 1) [Figure 70-30-3].

Figure 70-30-2
Check the resistance between Pin 4 (BLACK wire #
2200) and Pin 3 (YELLOW wire # 5000).

2200) and Pin 2 (RED wire # 1200).

2200) and Pin 1 (ORANGE wire # 1010).
If there is no resistance value at any of these pins,

replace the blower fan. (See BLOWER FAN on Page 70-
60-1.)
1 If there is resistance value at any of the pins, check the

P-73605 climate controls at the control panel inside the Excavator
cab.
Check the wire harness (Item 1) [Figure 70-30-2] for
voltage to the blower fan.
In the cab, place the blower switch in position 1. Check

for voltage at the harness connector (Item 1) [Figure 70-
30-2], Pin 3. (YELLOW wire # 5000). The voltage should
be 12 volts.

30-2], Pin 2. (RED wire # 1200). The voltage should be
12 volts.

30-2], Pin 1. (ORANGE wire # 1010). The voltage should
be 12 volts.

692 of 726
TROUBLESHOOTING (CONT’D) Figure 70-30-6
Electrical System (Cont’d)
Figure 70-30-4
P-73562
Disconnect the wiring harness (Item 1) [Figure 70-30-6]

P-73560 from the blower switch.
Check the harness for voltage. The voltage should be

Remove the left rear console cover (Item 1) [Figure 70- approximately 12 volts.
30-4]. (See Left Rear Console Cover Removal And

Installation on Page 40-60-9.) If there is no voltage at the wiring harness, check the
harness for broken wires.
Figure 70-30-5
P-73561
Position the console and wiring harness in the cab so the

wiring harness can be checked [Figure 70-30-5].

693 of 726
Figure 70-30-7
C
H
M B
1
L
P-73563

N-22288 from the potentiometer.
Figure 70-30-9
If there is voltage at the wiring harness, check the blower
switch [Figure 70-30-7] for resistance.

With the switch in the OFF position, there should be zero
resistance between all terminals.
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal. And 1
also between the C terminal and the L terminal frame
[Figure 70-30-7].

resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 70-30-7]. P-73564

resistance between C terminal and the B terminal. And Check the wire harness (Item 1) [Figure 70-30-9] for
also between the C terminal and the H terminal frame voltage. Between pins A and C the voltage should be
[Figure 70-30-7]. approximately 12 volts.
If any of the above resistance tests fail, replace the If there is no voltage at the wiring harness, check the
blower switch. harness for broken wires.

694 of 726
Figure 70-30-10
C
A
N-22175
B
To check the resistance of the white wire, turn the

N-22290 potentiometer control (Item 1) [Figure 70-30-12] to the
full A/C position.
If there is voltage at the wiring harness, check the Figure 70-30-13

potentiometer [Figure 70-30-10] for resistance.

The resistance should be 10K ohms between wire
terminal A and wire terminal C frame [Figure 70-30-10].
If no resistance is found replace the potentiometer.

C
A
Figure 70-30-11
N-22290
The resistance between the wire terminal A and wire

terminal B frame [Figure 70-30-13] should be
1 approximately 49K ohms.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 70-30-13] should be
approximately 39K ohms.
The white wire B, (Item 1) [Figure 70-30-11], on the

potentiometer, is a resister wire.

695 of 726
Figure 70-30-14 2
1
P-73560
1
Turn the fan switch (Item 1) to the High Speed position.,
N-22175 Turn the temperature control (Item 2) [Figure 70-30-16]
to the High cold position, with the key switch OFF.
To check the resistance of the white wire, turn the Start the excavator and run at high idle, for ten minutes.
potentiometer control (Item 1) [Figure 70-30-14] to the

full heater position. Figure 70-30-17
Figure 70-30-15
C
A
B
1
P-73622
N-22290
Check the temperature of the heater hoses (Item 1)
[Figure 70-30-17].
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 70-30-15] should be If the hoses are hot, the heater valve is leaking internally,
approximately 39K ohms. and needs to be replaced.
Check the resistance between the wire terminal C and

wire terminal B frame [Figure 70-30-15] should be
approximately 49K ohms.
If the resistance is not found replace the potentiometer.

696 of 726
HEATER UNIT Figure 70-40-2
Drain the engine coolant. (See Removing And Replacing


4
Figure 70-40-1
2
1
1 3
P-73623
1
Remove the clamps (Item 2) [Figure 70-40-2] from the

heater hoses.
2 Cap and plug the hoses with the proper caps and plugs.

P-73584 Remove the heater hoses from the heater coil.
Remove the bolt (Item 3) [Figure 70-40-2] on the right

Remove the bolts (Item 1) [Figure 70-40-1] from the side of the heater unit.
Remove the bolts (Item 4) [Figure 70-40-2] from the left
Remove the front cover (Item 2) [Figure 70-40-1] from side of the heater unit and remove the unit from the
the unit. excavator.
Remove the floor mat and floor panel. (See FLOOR MAT
AND FLOOR PANEL on Page 40-90-1.)

697 of 726

698 of 726
HEATER COIL Figure 70-50-2

2

Figure 70-50-1
1
1 3
P-73625
Remove the clamps (Item 1) [Figure 70-50-2] from the

heater hoses.
1
Remove the heater hoses from the heater coil.
2
Cap and plug the hoses with the proper caps and plugs.

P-73584 Remove the heater coil (Item 2) [Figure 70-50-2].

Remove the front cover (Item 2) [Figure 70-50-1] from

the unit.

heater cover and remove cover.

699 of 726

700 of 726
BLOWER FAN Figure 70-60-3

1
Remove the heater unit. (See Removal And Installation
on Page 70-40-1.)
Figure 70-60-1
1
2
P-73634
1 Disconnect the wire connectors (Item 1) [Figure 70-60-

3].
Remove the blower fan (Item 2) [Figure 70-60-3].

P-73624A
Lift the heater coil (Item 1) [Figure 70-60-1] straight up

from the heater unit.
Figure 70-60-2
1
1
P-73631
Remove the four bolts (Item 1) [Figure 70-60-2] from the

blower fan housing.

701 of 726

702 of 726
HEATER VALVE


Remove the heater unit. (See Removal And Installation

on Page 70-40-1.)
Figure 70-70-1

P-73082

from the heater valve.
Figure 70-70-2
1
2
P-73082
Mark and remove the hoses (Item 1). Remove the two
bolts (Item 2) [Figure 70-70-2] from the heater valve.
Remove the heater valve from the excavator.
The heater valve is not serviceable and must be replaced

as a complete unit.

703 of 726

704 of 726
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . SPEC-50-1
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-30-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-30-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-4
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-30-2
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-40-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . SPEC-10-1

425 With Long Arm Option. . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
425 With Standard Arm . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Slew System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7 SPECIFICATIONS
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-20-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-20-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-20-1
SPEC-01 425 Service Manual

705 of 726
SPEC-02 425 Service Manual

706 of 726
EXCAVATOR SPECIFICATIONS
425 With Standard Arm

• 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.
p-73299
SPEC-10-1 425 Service Manual

707 of 726
EXCAVATOR SPECIFICATIONS (CONT’D)
425 With Standard Arm (Cont’d)
p-73495

708 of 726
425 With Long Arm Option
p-73305

709 of 726
425 With Long Arm Option (Cont’d)
p-73496

710 of 726
Performance
425 425 With Long Arm Option
Operating weight
(Canopy w/ 20 inch Bucket & Rubber 5849 lb. (2653 kg) 6257 lb. (2838 kg)
Tracks)
Operating weight
(Cab w/ Heater, 20 inch Bucket & 6154 lb. (2791 kg) 6562 lb. (2972 kg)
Rubber Tracks)
With Steel Tracks Add 158 lb. (72 kg)
Travel Speed - 2 Speed Low - 1.3 mph (2,1 km/hr.) Low - 1.3 mph (2,1 km/hr.)
High 2.3 mph (3,7 km/hr.) High 2.3 mph (3,7 km/hr.)
Digging Force (per ISO 6015)
Arm 3282 lbf. (14600 N) 2743 lbf. (12200 N)
Bucket 5058 lbf. (22500 N) 5530 lbf. (24600 N)
Boom Swing (Offset) Left 90° - Right 50° Left 90° - Right 50°
Controls
Steering Two hand levers or foot pedals
Hydraulics Two hand operated levers (joysticks) control boom, bucket, arm and

upperstructure slew
Auxiliary Hydraulics Electric switch in right joystick
Auxiliary Pressure Release Electric switch in right joystick
Engine Hand lever engine speed, key type start switch
Starting Aid Glow Plugs - activated by key switch
Brakes
Travel
Service & Parking Hydraulic lock in motor circuit
Swing
Service Hydraulic lock on motor
Holding Locking Pin
Engine
Make/Model Kubota V1505-IDI-NA
Fuel/Cooling Diesel / Liquid (Antifreeze mixture)
Horsepower (SAE Net) 26.4 HP (19,7 kW)
Torque @ 1600 RPM (SAE Net) 70.4 ft.lb. (95,5 N•m)
Number Of Cylinders Four
Displacement 91.4 cu.in. (1,5 L)
Bore / Stroke 3.04 x 3.07 in. (78,0 x 78,4 mm)
Lubrication Pressure System with Filter
Crankcase Ventilation Closed Breather
Air Cleaner Dual dry replaceable paper cartridges
Ignition Diesel Compression
Low Idle 1350 RPM
High Idle 2520 RPM
Engine Coolant Propylene Glycol / water mixture (53% PG / 47% water)

711 of 726
Hydraulic System
Pump Type Engine driven, dual outlet piston pump
Pump Capacity
Piston Pump 15.4 GPM (58,3 L/min.)
Auxiliary Flow 13.2 GPM (50 L/min.)
Hydraulic Filter Full flow replaceable, 2 micron synthetic media element
Control Valve 9 spool closed center individually compensated
Fluid Type Bobcat Fluid, Hydraulic/Hydrostatic
6903117 - (2.5 Gal.)
6903118 - (5 Gal.)
6903119 - (55 Gal.)
System Relief Pressure 425 425 With Long Arm Option
Travel Circuits, Blade
Boom, Arm, Bucket, Boom Swing,
Auxiliary Hydraulics 2610 PSI (180 bar) 2900 PSI (200 bar)
Joystick Control Pressure 435 PSI (30 bar) 435 PSI (30 bar)
Slew Relief Pressure 2030 PSI (140 bar) 2900 PSI (200 bar)
Auxiliary Relief 2610 PSI (180 bar) 2610 PSI (180 bar)

Arm Port Relief Base End and Rod End 3045 PSI (210 bar)
Boom Port Relief Base and Rod End 3335 PSI (230 bar)
Bucket Port Relief Base End and Rod End 3335 PSI (230 bar)
Main Hydraulic Filter Bypass 50 PSI (3,4 bar)
Hydraulic Cylinders
Bore Rod Stroke
Boom (Cushioned - Boom Up) 3.00 in. (76,2 mm) 1.63 in. (41,3 mm) 18.68 in. (474,5 mm)
Arm (Cushion retract) 3.00 in. (76,2 mm) 1.50 in. (38,1 mm) 19.12 in. (485,6 mm)
Bucket 2.50 in. (63,5 mm) 1.38 in. (35,1 mm) 18.34 in. (465,8 mm)
Blade 2.75 in. (69,9 mm) 1.50 in. (38,1 mm) 7.68 in. (195,1 mm)
Boom Swing (Cushioned - Both Directions) 2.38 in. (60,5 mm) 1.38 in. (35,1 mm) 20.65 in. (524,5 mm)
Hydraulic Cycle Times
Boom Raise 3.9 Seconds Lower 3.9 Seconds

Arm Retract 2.7 Seconds Extend 2.3 Seconds
Bucket Curl 2.7 Seconds Dump 1.9 Seconds
Blade Raise 2.1 Seconds Raise 2.1 Seconds
Boom Swing Left 5.4 Seconds Right 4.4 Seconds
Electrical
Starting Aid Glow Plugs

Alternator 12 volt, 40 Amp open frame w/ internal regulator
Battery 12 volt - 530 CCA @ 0° F (-18° C)
Starter 12 volt; gear reduction 2.7 HP (2.0 kW)
Instrumentation Fuel gauge, audible alarm, visual warning for engine functions and
hourmeter

712 of 726
Drive System
Final Drive Each track is independently driven by an Axial Piston Motor

Type of Reduction Two-stage planetary gear reduction
Slew System
Slew Motor Orbit Motor

Slew Circle Single row shear type ball bearing with internal gear
Slew Speed 9.9 RPM
Undercarriage
Crawler Track Design Sealed track rollers with boxed section track, Roller frame,
Grease type track adjuster
Width of crawler 59.8 in. (1520 mm)
Capacities
Fuel Tank 17.8 Gal. (67,4 L)

Hydraulic Reservoir Only (Center of 2.4 Gal. (9,1 L)

Sight Glass)
Hydraulic System (with Reservoir) 5.5 Gal. (20,7 L)
Cooling System 8.6 qt. (8,1 L)
Engine Oil and Filter 5.8 qt. (5,5 L)
Final Drive (each) 0.79 qt. (0,75 L)
Tracks
Type Rubber Steel

Width 12.6 in. (320 mm) 12.6 in. (320 mm)
Number Of Shoes Single Assembly (40) 41
Number of Track Rollers (per side) 4 4
Ground Pressure
Ground Pressure 425 425 With Long Arm

Rubber Track 3.71 PSI (0,256 bar) 3.94 PSI (0,272 bar)
Steel Track 3.80 PSI (0,262 bar) 4.04 PSI (0,278 bar)

713 of 726

714 of 726
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
INCH. .250 80-90 110-120
LB. (9-10) (13-14)
(N•m) .3125 180-200 215-240
(21-23) (24-27)
x .375 25-28 35-40
x (34-38) (48-54)
x .4375 40-45 60-65
x (54-61) (82-88)
x
x .500 65-70 90-100
x (88-95) (125-135)
x .5625 90-100 125-140
x (125-135) (170-190)
x .625 125-140 175-190
x (170-190) (240-190)
x
.750 220-245 300-330

FOOT
LB. (300-330) (410-450)
(N•m) .875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)
715 of 726 SPEC-20-1 425 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)
Torque For General Metric Bolts
Thread Size Material

(Dia. ) 8.8 10.9 12.9
M4 2.0-2.5 ft.-lb. 2.8-3.1 ft.-lb. 3.5-3.9 ft.-lb.
(2,5-3,5 N•m) (3,8-4,2 N•m) (4,7-5,3 N•m)
M5 4.0-5.0 ft.-lb. 5.6-6.2 ft.-lb. 6.2-7.0 ft.-lb.
(5,5-6,5 N•m) (8,4-7,6 N•m) (8,5-9,5 N•m)
M6 7.0-7.5 ft.-lb. 9.1-10.1 ft.-lb. 10.4-11.6 ft.-lb.
(9,5-10,5 N•m) (12,2-13,7 N•m) (14,2-15,8 N•m)
M7 11.0-12.5 ft.-lb. 16.2-14.7 ft.-lb. 17.5-19.5 ft.-lb.
(15-17 N•m) (20-22 N•m) (23,7-26,3 N•m)
M8 18-19 ft.-lb. 21.7-24.0 ft.-lb. 25.5-28.5 ft.-lb.
(24-26 N•m) (29,4-32,6 N•m) (35-39 N•m)
M10 32-35 ft.-lbs 42.0-46.5 ft.-lb. 52.5-58.5 ft.-lb.
(43-47 N•m) (57-63 N•m) (71-79 N•m)
M12 55-60 ft.-lb. 78-85 ft.-lb. 91-110 ft.-lb.
(75-85 N•m) (105-115 N•m) (91-110 N•m)
M14 100-90 ft.-lb. 118-133 ft.-lb. 140-155 ft.-lb.

(125-140 N•m) (118-133 N•m) (140-155 N•m)
M16 140-155 ft.-lb. 188-210 ft.-lb. 225-245 ft.-lb.
(190-210 N•m) (255-285 N•m) (300-330 N•m)
M18 190-215 ft.-lb. 255-285 ft.-lb. 210-340 ft.-lb.
(260-290 N•m) (345-385 N•m) (420-460 N•m)
M20 275-300 ft.-lb. 360-405 ft.-lb. 440-490 ft.-lb.
(370-410 N•m) (490-550 N•m) (590-650 N•m)
M22 370-400 ft.-lb. 554-560 ft.-lb. 590-650 ft.-lb.
(500-550 N•m) (740-760 N•m) (800-880 N•m)
M24 470-520 ft.-lb. 625-700 ft.-lb. 730-830 ft.-lb.
(640-700 N•m) (850-950 N•m) (1000-1120 N•m)
M27 680-760 ft.-lb. 900-1000 ft.-lb. 1100-1200 ft.-lb.
(930-1030 N•m) (1230-1370 N•m) (1470-1630 N•m)
M30 930-1030 ft.-lb. 1250-1400 ft.-lb. 1500-1600 ft.-lb.
(1260-1400 N•m) (1700-1900 N•m) (2000-2200 N•m)
M33 1270-1400 ft.-lb. 2300-2500 ft.-lb. 2000-2300 ft.-lb.
(1720-1900 N•m) (2300-2500 N•m) (2700-3100 N•m)
M36 1620-1800 ft.-lb. 2200-2400 ft.-lb. 2600-2900 ft.-lb.
(200-2450 N•m) (2900-3200 N•m) (3500-3900 N•m)
716 of 726 SPEC-20-2 425 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque

x x *
Tubeline x TORQUE
Outside x Ft.-lb.
Diameter Thread Size (N•m)
IMPORTANT 1/4” 9/16” - 18 13 (18)
3/8” 11/16” - 16 22 (30)
1/2” 13/16” - 16 40 (54)
parts clean. Always use caps and plugs on hoses, 5/8” 1” - 14 60 (81)
tubelines and ports to keep dirt out. Dirt can quickly 3/4” 1-3/16” - 12 84 (114)
damage the system.
I-2003-0888
7/8” 1-3/16” - 12 98 (133)
1” 1-7/16” - 12 118 (160)
Figure SPEC-30-1 1-1/4” 1-11/16” - 12 154 (209)
1-1/2” 2” - 12 163 (221)

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].

717 of 726
HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Straight Thread O-ring Fitting restrict flow, which will slow hydraulic action and cause
heat.
Figure SPEC-30-3
Replace hoses which show signs of wear, damage or
weather cracked rubber.
Always use two wrenches when loosening and tightening

Nut Nut hose or tubeline fittings.
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until

the washer is tight against the surface [Figure SPEC-30-
3].

718 of 726
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)
Flare Fitting
Figure SPEC-30-4
TS-1619
Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-30-4]
Use the chart [Figure SPEC-30-5] to find the correct

tightness needed (Item 2) [Figure SPEC-30-4]. If the
fitting leaks after tightening, disconnect it and inspect the
seat area for damage.
Figure SPEC-30-5
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x Ft.-lb.
Diameter Thread Size (N•m)
1/4” 7/16” - 20 13 (18)
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
2” 2-1/2” - 12 252 (342)

719 of 726
HYDRAULIC CONNECTION SPECIFICATIONS Port seal and nut, washer and O-ring (O-ring Boss)
(CONT'D) fittings use the same tightening torque valve chart.
Port Seal Fitting If a torque wrench cannot be used, use the following
method.
Figure SPEC-30-6
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Nut Seals NOTE: If a torque wrench cannot be used, use the

To Fitting hex flat tightening method as an approximate
guideline.
Nut Seals NOTE: Port seal fittings are not recommended in all
To Port applications. Use O-ring boss fittings in these
applications.

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.
Figure SPEC-30-7
Port Seal and O-ring Boss

Tightening Torque
x TORQUE
x Ft.-lb.
Thread Size (N•m)
7/16” - 20 13 18)
9/16” - 18 22 (30)
3/4” -1 6 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
1-3/16” - 12 98 (133)
1-5/16” - 12 118 (160)
1-7/16” - 12 154 (209)
1-5/8” - 12 163 (221)
Use the following procedure to tighten the port seal

fitting:

720 of 726
HYDRAULIC FLUID SPECIFICATIONS
Specifications
Use only Bobcat hydraulic fluid.
DO NOT use automatic transmission fluids in the

excavator or permanent damage to the hydraulic system
will result.
Bobcat hydraulic fluid is available in:
• 2.5 Gal. (9,5 L) qty. 2 (P/N 6903117)

• 5 Gal. (18,9 L) (P/N 6903118)
• 55 Gal. (208 L) (P/N 6903119)
WARNING

W-2072-0496
When temperatures below 0° F (-18°C) 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.
WARNING
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285

721 of 726

722 of 726
CONVERSIONS
Decimal And Millimeter Equivalents

U.S. To Metric Conversion Chart

723 of 726

724 of 726
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: 425-1

Date: 15 July 2007
Product: Bobcat Excavator
Model: 425
Manual No: 6904866 (11-06)
The following Sections are a revision to the above Service Manual
. Cover
Alphabetical Index

Hydraulic Schematics
Section 20-01
Section 20-170
Section 40-01
Section 40-191
Printed in U.S.A.
725 of 726
726 of 726
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Service Manual

425 Compact Excavator

Dealer Copy -- Not for Resale

6904866 (7-07) Printed in U.S.A. © Bobcat Company 2007

CORRECT CORRECT CORRECT

B-10731A B-19964 B-19959

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-19962 B-19958 B-19798

AIR CLEANER ........................................................ 60-01 HEATER COIL .........................................................70-01

Dealer Copy -- Not for Resale

DIAGNOSTICS SERVICE CODES......................... 50-01 OIL COOLER...........................................................20-01

ELECTRICAL SYSTEM INFORMATION ................ 50-01 PIVOT PINS ............................................................10-01

FLOOR MAT AND FLOOR PANELS ...................... 40-01

Continued On Next Page

425 Service Manual

SEAT AND SEAT MOUNT...................................40-01

TAILGATE .....................................................10-01, 40-01

Dealer Copy -- Not for Resale

425 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 UPPERSTRUCTURE

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01

Dealer Copy -- Not for Resale

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

I 425 Service Manual

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

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

Dealer Copy -- Not for Resale

5. Machine signs must be 13. Lubricate the excavator.

6. Steering levers, control levers 14. Check the condition of the

8. Check the electrical charging

III 425 Service Manual

IV 425 Service Manual

Dealer Copy -- Not for Resale

• The Compact Excavator Operator Training Course is

• The Bobcat Compact Excavator Safety Video is

V 425 Service Manual

The dealer and owner/operator review the recommended

Dealer Copy -- Not for Resale

VI 425 Service Manual

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

The spark arrestor muffler is designed to control the

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

Dealer Copy -- Not for Resale

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

VII 425 Service Manual

VIII 425 Service Manual

Always use the serial number of the excavator when Figure 2

The engine serial number (Item 1) is located on the

Dealer Copy -- Not for Resale

The excavator serial number plate (Item 1) is located on

Explanation of Excavator Serial Number: