E10 6986788 enUS SM

Service Manual
Dealer Copy -- Not for Resale
Compact Excavator
S/N A33P11001 & Above
S/N B4PD11001 & Above
S/N B4K911001 & Above
6986788enUS (12-18) (C) Printed in U.S.A. ©2018 Bobcat Company. All rights reserved.
EU T2 S5 NA T4-K
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MAINTENANCE SAFETY
Training is necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (stickers) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 RI075 RI072

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

RI076 RI073 RI077
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
RI074 RI071 B-19798

Stop, cool and clean engine of Keep body, jewellery and clothing Lead-acid batteries produce
flammable materials before away from moving parts, electrical flammable and explosive gases.
checking fluids. contact, hot parts and exhaust. Keep arcs, sparks, flames and
Never service or adjust machine Wear eye protection to guard from lighted tobacco away from
with the engine running unless battery acid, compressed springs, batteries.
instructed to do so in the fluids under pressure and flying Batteries contain acid which
manual. debris when engines are running burns eyes or skin on contact.
Avoid contact with leaking or tools are used. Use eye Wear protective clothing. If acid
hydraulic fluid or diesel fuel protections approved for type of contacts body, flush well with
under pressure. It can penetrate welding. water. For eye contact flush well
the skin or eyes. Keep tailgate closed except for and get immediate medical
Never fill fuel tank with engine service. Close and latch tailgate attention.
running, while smoking, or when before operating the excavator.
near open flame.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW33-0409
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CONTENTS
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
UPPERSTRUCTURE AND SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Excavator Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15


FOREWORD
This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the excavator has had service or repair:
1. Check that the ROPS/TOPS/ 9. Safety treads must be in good
FOPS is in good condition condition.
and is not modified.
2. Check that ROPS/TOPS 10. Check for correct function of

mounting hardware is indicator lamps.
tightened and is Bobcat
approved.
3. The seat belt must be 11. Check all machine fluid

correctly installed, functional levels.
and in good condition.

4. Machine signs (decals) must 12. Inspect for fuel, oil or
be legible and in the correct hydraulic fluid leaks.
location.
5. Travel levers, control levers 13. Lubricate the excavator.

and foot pedals must return to
neutral. Check that the pedal
locks are in working order.
6. Check for correct function of 14. Check the condition of the

the work lights. battery and cables.
7. Enclosure door latches must 15. Inspect the air cleaner for
open and close freely. damage or leaks. Check the
condition of the element.
8. Attachment locking pins must 16. Check the electrical charging

function correctly and be in system.
good condition.
FW EXC-0119 SM
1-7 E10 Service Manual

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17. Check tracks for wear and 21. Check the control console
tension. Use only approved interlocks for correct function.
tracks.
18. Inspect for loose or broken 22. Inspect the X-Change™ for
parts or connections. wear or damage. Repair or
replace damaged parts.
19. Check for any field 23. Check function or condition of

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

is returned to service.
FW EXC-0119 SM

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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.
AVOID INJURY OR DEATH
Instructions are necessary before operating or • Machine signs (decals) instruct on the safe operation
servicing machine. Read and understand the and care of your Bobcat machine or attachment. The
Operation & Maintenance Manual, Operator’s signs and their locations are shown in the Operation
Handbook and signs (decals) on machine. Follow & Maintenance Manual. Replacement signs are
warnings and instructions in the manuals when available from your Bobcat dealer.
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or • An Operator’s Handbook fastened to the operator
service. Untrained operators and failure to follow cab. It’s brief instructions are convenient to the
instructions can cause injury or death.

operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT • The AEM Safety Manual delivered with the machine

gives general safety information.
This notice identifies procedures which must be • The Service Manual and Parts Manual are available
followed to avoid damage to the machine. from your dealer for use by mechanics to do shop-
I-2019-0284 type service and repair work.
• The Compact Excavator Operator Training Course is

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

WARNING available from your Bobcat dealer or at Bobcat.com/
training or Bobcat.com.
The signal word WARNING on the machine and in the

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI EXC-1016 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.
Cutting or drilling concrete containing sand or rock

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

Dial 811 (USA Only)

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI EXC1016 SM

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FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use gasoline or diesel

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

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

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs. These starting aids can cause explosion and
injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Spark Arrester Exhaust System
The spark arrester exhaust system is designed to control

the emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
Check all electrical wiring and connections for damage. hot.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or Check the spark arrester exhaust system regularly to
frayed. make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
Battery gas can explode and cause serious injury. Use cleaning the spark arrester muffler (if equipped).
the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI EXC-1016 SM

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FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnect

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

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as

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

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI EXC-1016 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.
Earlier 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.
Excavator Serial Number
Figure 1
1 R0089
The engine serial number is located as a plate (Item 1)

1 on the top of the engine [Figure 2].
Figure 3

R0088
The excavator serial number plate (Item 1) [Figure 1] is

located on the frame of the machine in the location
shown.
Explanation of excavator Serial Number:

1
Module 2 - Production
Sequence (Series)
Module 1 - Model / Engine R0090

Combination P-90175
It also appears engraved on the side of the engine (Item

1. The four digit Model / Engine Combination Module 1) [Figure 3].
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 4
B-16315
The delivery report [Figure 4] contains a list of items that

must be explained or shown to the owner or operator by
the dealer when the Bobcat excavator is delivered.
The delivery report must be reviewed and signed by the

owner or operator and the dealer.

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EXCAVATOR IDENTIFICATION
15
21
14
13
3 2
4 16
1
22
17
12
6
5
7 19
20
23
8

10 18
11 R1015
9 R1016
ITEM DESCRIPTION ITEM DESCRIPTION

1 Operator’s Handbook 15 Tip-Over Protective Structure (TOPS)
2 Boom Cylinder 16 Operation & Maintenance Manual
3 Arm Cylinder 17 Tailgate
4 Auxiliary Quick Couplers 18 Tracks
5 Boom 19 Tie Downs
6 Arm 20 Tie Downs / Lift Point (Both Sides)
7 Bucket Cylinder 21 Lift Point
8 Bucket Link / Attachment Coupler (If Equipped) 22 Right Side Cover
9 Bucket [A] 23 Track Frames
10 Blade Cylinder
11 Blade
12 Upperstructure
13 Control Levers (Joysticks)
14 Operator’s Seat with Seat Belt
[A] BUCKET - Several different buckets and other attachments are available for the Bobcat excavator.

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TRANSPORTING THE EXCAVATOR ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-2
FOLD-DOWN TOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TOPS Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TOPS Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Lowering The Fold Down TOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Raising The Fold Down TOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-2

TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Opening And Closing The Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Contents Of The Inspection Checkbook (Logbook) . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing The Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing The Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
LUBRICATION OF THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-2
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . 10-200-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
MOTION ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
REMOTE START TOOL KIT - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . . . . . . . . . . . . . . . . . . . . 10-221-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221-1
Remote Start Tool (Service Tool) - 7003030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221-2
Excavator Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221-3
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221-4

LIFTING AND BLOCKING THE EXCAVATOR Figure 10-10-3
Procedure
Always park the machine on a level surface.
Figure 10-10-1
S8758 S8759
The machine must be blocked up as shown in [Figure

10-10-3].
Stop the engine.
WARNING
S8452
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.

Raise one side of the machine (approximately 100 mm Failure to block up the machine may allow it to move
[4 in]) using the boom and arm as shown in [Figure 10- or fall and result in injury or death.
10-1]. W-2218-1195
Figure 10-10-2
WARNING
1 Do not loosen the grease fitting more than one
complete rotation. Also, be careful not to loosen any
part other than the grease fitting. If the grease fitting
1 or any part is loosened too much, it can fly off under
S8756 S8757
high pressure. If the grease does not ooze smoothly,
try moving the machine back and forth for a short
Raise the blade fully and install wooden blocks (Item 1) distance.
[Figure 10-10-2] or jackstands under the blade and the W-2143-0189
track frame. Lower the machine until all machine weight
is on the wooden blocks or jackstands.
Rotate the upperstructure 180 degrees and repeat

procedure for other side.
21 of 698 10-10 Service Manual-1 E10 Service Manual

22 of 698 10-10 Service Manual-2 E10 Service Manual

UPPERSTRUCTURE SLEW LOCK
Operation
Figure 10-20-1
P-86587
Move the slew lock pin (Item 1) [Figure 10-20-1] to the

right and down to engage the upperstructure slew lock.

When the slew lock is engaged (locked), the
upperstructure of the excavator is locked to the track
frame and will not rotate.
NOTE: The upperstructure must be in the straight

forward or straight backward position for the
upperstructure to lock.
Move the slew lock pin (Item 1) [Figure 10-20-1] up and

to the left to disengage (unlock) the upperstructure from
the track frame. Secure the lever in the unlocked position.
WARNING
AVOID INJURY
The upperstructure slew lock lever must be engaged
when transporting the machine.
W-2197-0904
23 of 698 10-20-1 E10 Service Manual


LIFTING THE EXCAVATOR Figure 10-30-2
Procedure
Fully extend the cylinders of the bucket, arm and boom.
Raise the blade all the way.
Turn the upperstructure so that the boom is at the

opposite end as the blade.
Put all the controls in neutral and engage the swing lock.
(See UPPERSTRUCTURE SLEW LOCK on Page 10-20-
1.)
S8818
WARNING
The maximum angle between the front and rear chains
AVOID INJURY OR DEATH must not exceed 45° [Figure 10-30-2].
• Use chains and lifting equipment 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 upperstructure slew lock.
• Never lift with operator on machine.
• Never lift with the blade angled (if equipped).
W-2580-0607
Figure 10-30-1
R0041 R0040
Fasten the chains to the ends of the blade (Item 1)

[Figure 10-30-1] and up to a lifting fixture above the
canopy.
Fasten a chain in the hook of the boom (Item 2) [Figure

10-30-1] and up to the lifting fixture.


TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
When transporting the machine, observe the rules, motor

vehicle laws, and vehicle limit ordinances. Use a
transport and towing vehicle of adequate length and
capacity.
Secure the parking brakes and block the wheels of the

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

Secure the ramps to the truck bed and be sure ramp
angle does not exceed 15 degrees.
Use metal loading ramps with a slip resistant surface.
Use ramps that are the correct length and width and can
support the weight of the machine.
The rear of the trailer must be blocked or supported when

loading or unloading the machine to prevent the front of
the transport vehicle from raising.
Determine the direction of the track movement before

moving the machine (blade forward).

Figure 10-40-1
R0038
Move the machine forward onto the transport vehicle

[Figure 10-40-1].
Do not change direction of the machine while it is on the

ramps.
Lower the boom, arm, bucket and blade to the transport

vehicle.
Stop the engine and remove the key.
Put blocks under the front and rear of the tracks shoes.

TRANSPORTING THE EXCAVATOR ON A TRAILER Figure 10-40-4
(CONT’D)
Fastening
Figure 10-40-2
3
1
RI062
Fasten chains to the front corners of the blade (Item 1)

[Figure 10-40-2], to both sides of the track frame (Item 2)
P19508 [Figure 10-40-3] or to the tie down loop at the rear of the
track frame (Item 3) [Figure 10-40-4].
Figure 10-40-3 Use chain binders to tighten the chains and then safely

tie the chain binder levers to prevent loosening.
2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807
P1010474

FOLD-DOWN TOPS Lowering The Fold Down TOPS
TOPS Position Figure 10-50-2
WARNING 3
1
Use the Tip Over Protective Structure (TOPS). TOPS 2
changes not approved by Bobcat Company can
cause loss of operator protection and result in injury
or death. The TOPS must be in the raised position
with the seat belt fastened. There is no tip-over
protection when the TOPS is in the lowered position.
W-2742-0608
P-86589
The excavator can be operated temporarily with the
TOPS lowered for access through height restricted
openings. Do not fasten seat belt when the TOPS is in Remove the retaining clip (Item 1) and washer (Item 2)
the DOWN position. [Figure 10-50-2] (both sides).
Stop the engine, exit the machine and put the TOPS in Figure 10-50-3

the UP and LOCKED position after passing through
height restricted opening.
TOPS Approved
Figure 10-50-1
2
P113990
Securely grasp the TOPS (Item 1) [Figure 10-50-1] with

one hand and remove the pin (Item 3) [Figure 10-50-2]
(both sides) and lower the TOPS (Item 1) [Figure 10-50-
R0012 3] to the down position.
The excavator has an operator canopy (TOPS) (Tip-Over

Protective Structure) (Item 1) (meets ISO 12117) as
standard equipment [Figure 10-50-1].
The canopy provides operator protection if the excavator

tips over. The seat belt must be worn for TOPS
protection.

FOLD-DOWN TOPS (CONT’D) Figure 10-50-6
Lowering The Fold Down TOPS (Cont’d)
Figure 10-50-4
1
3
2
3
1
2 P-86589
Reinstall the pin (Item 1) and the washer (Item 2) on the

P-86591 retainer clip (Item 3) [Figure 10-50-6] into the TOPS for
storage.
Reinstall the pin (Item 1) and the washer (Item 2) on the

retainer clip (Item 3) [Figure 10-50-4] into the TOPS for
WARNING

storage.
Raising The Fold Down TOPS

Figure 10-50-5 The Tip Over Protective Structure (TOPS) must be
properly secured in the raised position. Make sure
the pins are correctly installed through the mounting
frame and the TOPS tube and secured with the
retainer pins. Improperly installed fasteners will
cause loss of TOPS protection.
W-2753-0808
1
P113990
Remove the retainer clip (Item 3) and the washer (Item 2)

from the pin (Item 1) [Figure 10-50-4] (both sides).
Securely grasp the TOPS (Item 1) [Figure 10-50-5] and

raise to the upright position and install the pin (Item 1)
[Figure 10-50-6] (both sides).

TAILGATE Figure 10-60-2
Opening And Closing The Tailgate
WARNING 1
AVOID INJURY OR DEATH 2

Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 10-60-1
P113996
Raise the tailgate (Item 1) until the rod (Item 2) [Figure

10-60-2] is in the engaged position.
To close the tailgate, lift up slightly on the tailgate (Item 1)

until the rod can be moved to the disengaged position
(Item 2) [Figure 10-60-2]. Slowly lower the tailgate until it

1 is completely lowered and in the latched position.
NOTE: The tailgate can be locked using the start key.
R0010
Release the latch (Item 1) [Figure 10-60-1] and pull the

tailgate open.


SERVICE SCHEDULE
Maintenance Intervals
Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early
failures.
The SERVICE SCHEDULE is a guide for correct

maintenance of the Bobcat excavator.
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
See inside page of the back cover for symbols and

identification.
Every 10 Hours (Before Starting The Excavator)
• Engine Oil - Check level and add as needed.

• Engine Air Filters and Air System - Check the condition indicator. Service only when required. Check for leaks and
damaged components.
• Engine Cooling System - Clean debris from oil cooler, radiator and grille. Check coolant level COLD and add
premixed coolant as needed.
• Seat Belt, Seat Belt Retractors, Seat Belt Mounting hardware, Control Console Lockout - Check the condition
of seat belt and mounting hardware. Clean or replace seat belt retractors as needed. Check the control console
lockout lever for proper operation. Clean dirt and debris from moving parts.
• Motion Alarm - Check for proper function (if equipped).
• TOPS - Check condition and mounting hardware.
• Indicators and Lights - Check for correct operation of all indicators and lights.
• Safety Signs and Safety Tread - Check for damaged signs (decals) and safety tread. Replace any signs and safety
treads that are damaged.
• Hydraulic Fluid - Check fluid level and add as needed.
• Track Tension - Check tension and adjust as needed.
• Pivot Points - Grease all machinery pivot points.
First 50 Hours
• Engine Oil and Filter - Replace oil and filter.

• Drive Belts (Alternator / Fan) - Check condition. Replace as needed.
Every 50 Hours
• Swing Bearing - Grease swing bearing and swing pinion. Service every 10 hours when operating in water.
• Battery - Check cables, connections, and electrolyte level; add distilled water as needed.
• Fuel Tank - Drain water and sediment from fuel tank and fuel filter.

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
First 100 Hours
• Alternator and Starter - Check connections.

• Drive Motors (Final Drive) - Replace fluid.
• Hydraulic Filter - Replace the hydraulic filter.
Every 100 Hours
• Spark Arrestor Muffler - Clean spark chamber.

• Drive Belts (Alternator / Fan) - Check condition. Replace as needed.
Every 250 Hours Or Every 12 Months
• Fuel Filter - Replace filter.

• Drive Motors (Final Drive) - Check fluid level and add as needed.
• Engine Oil and Filter - Replace oil and filter.

• Cooling System - Clean debris from radiator, hydraulic fluid cooler (if equipped).

• Hydraulic Filter and Hydraulic Reservoir Breather Cap - Replace the hydraulic filter, and the reservoir breather
cap.
• Alternator and Starter - Check connections.
• Engine Valves - Adjust the engine valve clearance.
• Hydraulic Fluid and Filters - Replace hydraulic fluid and filters.

• Drive Motors (Final Drive) - Replace fluid.
Every 24 Months
• Coolant - Replace the coolant.
SS EXC E08-E10 S5-K 07-18

SERVICE SCHEDULE (CONT’D)
Contents Of The Inspection Checkbook (Logbook)
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Excavator.
The Inspection Checkbook contains the following information:
• Doosan Trading Limited Warranty Conditions
• Protection Plus Extended Warranty Conditions
• General Parts Policy
• General Information
• First Inspection
• Scheduled Services
• Authorised Identification
• Lubricants and Fluids Table

• Service Parts Charts
Your local dealer can order the Inspection Checkbook.

Part number: 4420310.


AIR CLEANER SERVICE Figure 10-80-2
See the SERVICE SCHEDULE for correct service

intervals. (See SERVICE SCHEDULE on Page 10-70-1.)
Daily Check
Figure 10-80-1
1
1
R0051
2
Pull the outer filter (Item 1) [Figure 10-80-2] from the air
cleaner housing.
3
Check the housing for damage.
R0060
Clean the housing and the seal surface. DO NOT use

Check the condition indicator (Item 1) [Figure 10-80-1]. If compressed air.
the red ring shows in the condition indicator, the filter
needs to be replaced. Install a new outer filter.
Replacing The Filter Elements Install the dust cup (Item 3) [Figure 10-80-1] and turn it
clockwise about 1/8 turn.
Outer Filter
Push the locking tab in (Item 2) [Figure 10-80-1].
Pull out the locking tab (Item 2) [Figure 10-80-1].
Check the air intake hose and the air cleaner housing for
Turn the dust cup (Item 3) [Figure 10-80-1] damage. Make sure all connections are tight.
counterclockwise about 1/8 turn.
After the outer filter has been replaced, press the button
Remove and clean the dust cup (Item 1) [Figure 10-80-1] 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.

AIR CLEANER (CONT’D)
Replacing The Filters (Cont’d)
Inner Filter
Only replace the inner filter under the following

conditions:
• Replace the inner filter every third time the outer filter
is replaced.
• After the outer filter has been replaced, press the

button on the top of the condition indicator (Item 1)
[Figure 10-80-1] 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 10-80-3

1
R0052
Remove the dust cup (Item 3) [Figure 10-80-1], the outer

filter (Item 1) [Figure 10-80-2] and the inner filter (Item 1)
[Figure 10-80-3].
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 reset the

condition indicator (Item 1) [Figure 10-80-1] (the red ring
will not show anymore).

ENGINE COOLING SYSTEM Figure 10-90-1
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
Cleaning
Open the tailgate. (See Opening And Closing The

Tailgate on Page 10-60-1.)
Use low air pressure or water pressure to clean the

1
radiator and oil cooler.
Checking Level
R0095
WARNING The coolant level must be between the marks (Item 1)

[Figure 10-90-1] on the coolant recovery tank.
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203 IMPORTANT

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

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-3
Removing And Replacing The Coolant
See the SERVICE SCHEDULE for correct service

intervals. (See SERVICE SCHEDULE on Page 10-70-1.)
Stop the engine. Open the tailgate. (See Opening And

Closing The Tailgate on Page 10-60-1.)
WARNING 1
AVOID BURNS R0095

The coolant level must be between the marks (Item 1)
W-2070-1203
[Figure 10-90-3] on the coolant recovery tank.
When the engine is cool, remove the radiator cap. Mix the coolant in a separate container.
Figure 10-90-2 The correct mixture of coolant to provide a -37°C (-34°F)

freeze protection is 5 L propylene glycol mixed with 4,4 L

of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
Add premixed coolant; 47% water and 53% propylene

glycol to the recovery tank if the coolant level is low.
Use a refractometer to check the condition of propylene

1 glycol in your cooling system.
Add premixed coolant until the level is correct.
Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level and add as needed.
Be sure the radiator cap is tight.
R0122
Add coolant to the recovery tank as needed.

Open the drain valve (Item 1) [Figure 10-90-2] on the Close the tailgate.
engine block and drain the coolant into a container.
After all the coolant is removed, close the drain valve.
NOTE: Fluids such as engine oil, hydraulic fluid,

IMPORTANT
coolant, etc. must be disposed of in an AVOID ENGINE DAMAGE
environmentally safe manner. Some Always use the correct ratio of water to antifreeze.
regulations require that certain spills and
leaks on the ground must be cleaned in a Too much antifreeze reduces cooling system
specific manner. See local, state and federal efficiency and may cause serious premature engine
regulations for correct disposal. damage.
Recycle or dispose of the used coolant in an Too little antifreeze reduces the additives which
environmentally safe manner. protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
U.S. Standard (ASTM D975)
• Biodiesel blend fuel is an excellent medium for
Use only clean, high quality diesel fuel, Grade Number microbial growth and contamination that can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.
Ultra low sulfur diesel fuel must be used in this machine. • Use of biodiesel blend fuel may result in premature
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur failure of fuel system components, such as: plugged
maximum. fuel filters and deteriorated fuel lines.
The following is one suggested blending guideline that • Shorter maintenance intervals may be required, such
should prevent fuel gelling during cold temperatures: as: cleaning the fuel system and replacing fuel filters
and fuel lines.
TEMPERATURE GRADE 2-D GRADE 1-D
• Using biodiesel blended fuels containing more than
Above -9°C (+15°F) 100% 0%
five percent biodiesel can affect engine life and cause
Down to -21°C (-5°F) 50% 50% deterioration of hoses, tubelines, injectors, injector
Below -21°C (-5°F) 0% 100% pump, and seals.

NOTE: Biodiesel blend fuel may also be used in this Apply the following guidelines if biodiesel blend fuel is
machine. Biodiesel blend fuel must contain used:
no more than five percent biodiesel mixed
with ultra low sulfur petroleum based diesel. • Ensure the fuel tank is as full as possible at all times
This biodiesel blend fuel is commonly to prevent moisture from collecting in the fuel tank.
marketed as B5 blended diesel fuel. B5
blended diesel fuel must meet ASTM • Ensure that the fuel tank cap is securely tightened.
specifications.
• Biodiesel blend fuel can damage painted surfaces,
E.U. Standard (EN590) remove all spilled fuel from painted surfaces
immediately.
Use only clean, high quality diesel fuel that meets the
EN590 specifications listed below: • Drain all water from the fuel filter daily before
operating the machine.
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10
ppm) sulfur maximum. • Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Diesel fuel with cetane number of 51.0 and above.
• Before vehicle storage; drain the fuel tank, refill with
NOTE: Biodiesel blend fuel may also be used in this 100% petroleum diesel fuel, add fuel stabilizer, and
machine. Biodiesel blend fuel must contain operate the engine for at least 30 minutes.
no more than seven percent biodiesel mixed
with ultra low sulfur petroleum based diesel. NOTE: Biodiesel blend fuel does not have long term
This biodiesel blend fuel is commonly stability and should not be stored for more
marketed as B7 blended diesel fuel. B7 than 3 months.
blended diesel fuel must meet EN590
specifications.

FUEL SYSTEM (CONT’D) Fuel Filter
Filling The Fuel Tank Removing Water

WARNING
Figure 10-100-2
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
WARNING 1

Always clean up spilled fuel or oil. Keep heat, flames, R0054
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause

explosion or fire. Loosen the drain (Item 1) [Figure 10-100-2] at the
W-2103-0508 bottom of the filter to drain water from the filter.
Replacing The Fuel Filter

Figure 10-100-1
Remove the filter (Item 2) [Figure 10-100-2].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter. Install the fuel filter and tighten
by hand.
1 Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-3.)
P113997
Remove the fuel fill cap (Item 1) [Figure 10-100-1] using

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

fuel only in an area that has a free movement of air and
no flames or sparks. NO SMOKING!
Install and tighten the fuel fill cap.
(See SERVICE SCHEDULE on Page 10-70-1.) for the

correct service interval.

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Draining The Fuel Tank After replacing the fuel filter or when the fuel tank has run
out of fuel, air must be removed from the fuel system
Open the tailgate. (See Opening And Closing The before starting the engine.
Figure 10-100-3
Remove the fuel line at the engine and put the end of the
hose in a fuel can. Squeeze the primer bulb (if equipped)
and drain the fuel tank that way (siphon action).
1
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
2
R0091

Open the fuel filter vent (Item 1) [Figure 10-100-3].
Operate the hand pump (priming bulb) (Item 2) [Figure

10-100-3] until the fuel flows from the vent with no air
bubbles.
Close the vent (Item 1) [Figure 10-100-3] on the fuel filter

housing.
Start the engine and let it run at low idle. It can be

necessary to open the vent at the fuel injection pump
(Item 3) [Figure 10-100-3] briefly until the engine runs
smoothly.
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
from a doctor familiar with this injury.
W-2072-EN-0909


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2
Check the engine oil every day before starting the engine ENGINE OIL
for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-110-1 CRANKCASE)
TEMPERATURE RANGE ANTICIPATED BEFORE

NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CJ-4 OR BETTER)
R0057 [1] Bobcat Synthetic Oil – 5W-40.
Bobcat engine oils are recommended for use in this

Open the tailgate and remove the dipstick (Item 1) machine. If Bobcat engine oil is not available, use a good
[Figure 10-110-1]. quality engine oil that meets API Service Classification of
CJ-4 or better [Figure 10-110-2].
Keep the oil level between the marks on the dipstick.
Use a good quality motor oil that meets the correct API
Service Classification.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Put clean oil on the filter gasket.
Replacing Oil And Filter Install the filter and tighten by hand.
See the SERVICE SCHEDULE for the service interval for Install and tighten the oil drain plug.
replacing the engine oil and filter. (See SERVICE
SCHEDULE on Page 10-70-1.) Figure 10-110-5
Run the engine until it is at operating temperature. Stop

the engine.

Figure 10-110-3 1
R0058
Remove the fill cap (Item 1) [Figure 10-110-5].

Put in 2,8 L (3.0 qt) of oil into the engine.
Use a good quality motor oil that meets the correct API
Service Classification [Figure 10-110-2]. (See Engine Oil
R0056
Chart on Page 10-110-1.)
Remove the drain plug (Item 1) [Figure 10-110-3]. Drain Install the fill cap.
the oil into a container and recycle or dispose of used oil
in an environmentally safe manner. Start the engine and let it run for several minutes.
Figure 10-110-4 Stop the engine. Check for leaks at the oil filter. Check
the oil level.
Add oil as needed if it is not at the top mark on the

dipstick.
WARNING
1
explosion or fire.
W-2103-0508
S5261
Remove the oil filter (Item 1) [Figure 10-110-4] and clean

the filter housing surface.
Use a genuine Bobcat filter.

HYDRAULIC SYSTEM Figure 10-120-2
Checking And Adding Fluid
Put the machine on a level surface.

1
Retract the arm and bucket cylinders, put the bucket on
the ground, lower the blade to the ground and retract the
tracks. Stop the engine.
Figure 10-120-1
R0066
Open the tailgate. Remove the oil fill cap (Item 1) [Figure
1 10-120-2]. Check the condition of the screen in the fill
neck of the reservoir. The screen must be installed in the
fill neck when adding oil.
Add the correct fluid to the reservoir until it is at the

center of the sight gauge (Item 1) [Figure 10-120-1].

Install the cap. Close the tailgate. (See Opening And
P113999 Closing The Tailgate on Page 10-60-1.)
The fluid must be at the center of the sight gauge (Item 1)

[Figure 10-120-1].
WARNING
explosion or fire.
W-2103-0508

HYDRAULIC SYSTEM (CONT’D) Removing And Replacing The Hydraulic Filter
Hydraulic / Hydrostatic Fluid Chart See the SERVICE SCHEDULE for the correct service
Figure 10-120-3
HYDRAULIC / HYDROSTATIC FLUID Tailgate on Page 10-60-1.)
RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI) Figure 10-120-4
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130

R0050
[2] VG 46; Minimum VI 150
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid Remove the hydraulic filter (Item 1) [Figure 10-120-4].
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid
(Unlike biodegradable fluids that are vegetable based, Clean the housing where the filter gasket makes contact.
Bobcat biodegradable fluid is formulated to prevent
oxidation and thermal breakdown at operating Put clean hydraulic fluid on the gasket. Install the new
temperatures.) filter and tighten by hand only.
Use only recommended fluid in the hydraulic system Start the engine. Run the excavator through the hydraulic
[Figure 10-120-3]. functions. Stop the engine. Check the fluid level at the
sight gauge (Item 2) [Figure 10-120-4] and add as
needed. Check the filter area for leaks.

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

IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants,
Retract the arm and bucket cylinders, lower the bucket to grease, etc. must be disposed of in an
the ground. Stop the engine. environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
Figure 10-120-5 must be cleaned in a specific manner. See local
regulations for the correct disposal.
I-2067-EN-0711
1
3 1
IMPORTANT
2 If the fluid is being drained because of a system
failure, remove and clean all hydraulic lines.
I-2045-0788
1
2

Install the cap again.
2
P132094 Add fluid to the reservoir until it is at the center of the
sight gauge (Item 3) [Figure 10-120-1].
To gain access to drain the hydraulic fluid, loosen the
Run the excavator through the hydraulic functions. Stop
three bolts (Item 1) from the cover. Pivot the cover
the engine. Check the fluid level and add as needed.
downward. Then remove the black protection on the floor
by loosening the bolts (Item 2 [Figure 10-120-5]. Replace the black protection and the cover.
Figure 10-120-6
R0124
Before removing the cap, place a container under the

drain plug (Item 1) [Figure 10-120-6] to collect the oil.
Remove the cap and drain the hydraulic fluid.


LUBRICATION OF THE EXCAVATOR Figure 10-130-3
Lubrication Locations
Lubricate the hydraulic excavator as specified in the

service schedule for the best performance of the
machine. (See SERVICE SCHEDULE on Page 10-70-1.)
Record the operating hours each time you lubricate the

Hydraulic Excavator.
Always use a good quality lithium based multipurpose

3
grease when lubricating the excavator. Apply the
lubricant until extra grease shows.
Figure 10-130-1 R0080
3. Boom Swing Cylinder, Rod End, every 8 - 10 hours

(Item 3) [Figure 10-130-3].
Figure 10-130-4

1
R0082
5
1. Blade Cylinder-Base End, every 8 - 10 hours (Item 1)

[Figure 10-130-1].
Figure 10-130-2 R0079
4. Boom Cylinder, Rod End (Item 4) [Figure 10-130-4].
5. Boom Swing Pivot, every 8 - 10 hours (Item 5)

[Figure 10-130-4].
R0081
2. Blade Pivots, every 8 - 10 hours (Item 2) [Figure 10-

130-2].

LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-130-7
Lubrication Locations (Cont’d)
Figure 10-130-5
6 6
R0076
9. Arm Cylinder, Rod End, every 8 - 10 hours (Item 9)

R0078 [Figure 10-130-7].
Figure 10-130-8
6. Boom, Base Pivot, every 8 - 10 hours (Item 6) [Figure
10-130-5].

Figure 10-130-6
8 10
7
R0075
10. Arm Pivot, every 8 - 10 hours (Item 10) [Figure 10-

R0077 130-8].
7. Boom Cylinder, Base End, every 8 - 10 hours (Item 7)

[Figure 10-130-6].
8. Arm Cylinder, Base End, every 8 - 10 hours (Item 8)

[Figure 10-130-6].

LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-130-11
Lubrication Locations (Cont’d) 14
Figure 10-130-9
15
15
11
R0118
14. Bucket Link Pivot, every 8 - 10 hours (Item 14)

R0074 [Figure 10-130-11].
15. Bucket Pivots, every 8 - 10 hours (Item 15) [Figure

11. Bucket Cylinder, Base End, every 8 - 10 hours (Item 10-130-11].
11) [Figure 10-130-9].

Figure 10-130-12
Figure 10-130-10
16
17
13 12 13
R0083
R0073
16. Swing Circle Bearing, every 50 hours (Item 16)

12. Bucket Cylinder, Rod End, every 8 - 10 hours (Item [Figure 10-130-12].
12) [Figure 10-130-10].
17. Swing Circle Pinion (Item 17) [Figure 10-130-12].
13. Bucket Link, Bucket Cylinder Pivot, every 8 - 10 hours Pump 4 times with a grease gun. Rotate the
(Item 13) [Figure 10-130-10]. upperstructure 180° and repeat.
NOTE: Do not over-grease the swing circle; damage

to the seal could result. Pump 4 - 5 times with
a grease gun. Rotate the upperstructure 90°
and repeat three more times.

LUBRICATING THE EXCAVATOR (CONT’D)
Lubrication Locations (Cont’d)
Lubricate the following locations on the hydraulic

excavator AS REQUIRED:
Figure 10-130-13
18 18
P59012
R0083

18. Track Expansion Tube (Item 18) [Figure 10-130-13].
NOTE: Spread lubriplate gearshield extra heavy

grease evenly on wear surfaces on both sides
of excavator as required.

TRAVEL MOTOR Removing And Replacing Oil
Checking And Adding Oil See the SERVICE SCHEDULE for the correct service
Figure 10-140-1
Put the machine on a level surface with the plugs
positioned as shown (Items 1 and 2) [Figure 10-140-1].
Remove the bottom plug (Item 2) and top plug (Item 1)

[Figure 10-140-1] and drain into a container. Recycle or
dispose of the used lubricant in an environmentally safe
manner.
After all the gear lube is removed, install the bottom plug
1
(Item 2) [Figure 10-140-1].
Add gear lube to the top plug hole (Item 1) [Figure 10-
140-1] until the gear lube level is at the bottom edge of
the plug hole.
2
S5240
Install and tighten the top plug.
Put the machine on a level surface with the plugs Repeat the procedure for the other side.
positioned as shown (Items 1 and 2) [Figure 10-140-1].

Remove the top plug (Item 1) [Figure 10-140-1]. The oil
level should be at the bottom edge of the plug hole.
Add gear lube through the plug hole if the oil level is
below the hole.
Install and tighten the top plug.
Repeat the procedure for the other side.


SPARK ARRESTER MUFFLER wood over the outlet of the muffler (the carbon deposits
will be forced out of the muffler cleanout hole).
Cleaning Procedure
Stop the engine. Install and tighten the plug.
Figure 10-150-1
Install the cover (Item 2) [Figure 10-150-1].
1
tighten the bolts (Item 1) [Figure 10-150-1].
Close the tailgate. (See Opening And Closing The

1
1
2
WARNING
1 Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
P132095 Failure to obey can cause serious injury.
W-2011-1285
Remove the four bolts (Item 1) [Figure 10-150-1].
Remove the cover (Item 2) [Figure 10-150-1].

WARNING

When the engine is running during service, the
steering levers must be in neutral.
Do not operate the excavator with a defective exhaust
system.
Failure to do so can cause injury or death.
W-2203-0595
Stop the engine. Open the tailgate. (See Opening And
Closing The Tailgate on Page 10-60-1.)
Figure 10-150-2
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
1
R0119
Remove the plug (Item 1) [Figure 10-150-2] from the

bottom of the muffler.
Start the engine and run for about 10 seconds while a

second person, wearing safety glasses, holds a piece of


ALTERNATOR BELT Figure 10-160-3
Belt Adjustment
Replace the belt if it has stretched or there are cracks in

the belt. Replace the pulley if the belt makes contact with
the bottom of the groove in the pulley.
Stop the engine.
Figure 10-160-1
S8279
2
Loosen the upper alternator bolt [Figure 10-160-3].
1
Figure 10-160-4
1
2

P-86611
Remove the two bolts (Item 1) and remove the fan guard
(Item 2) [Figure 10-160-1].
Remove the fill cap (Item 3) [Figure 10-160-1] from the

hydraulic reservoir.
Figure 10-160-2
1
1 S8243
1
Loosen the lower alternator mounting and adjustment
bolt (Item 1) [Figure 10-160-4].
S7554
Remove the cover.

ALTERNATOR BELT (CONT’D) Belt Replacement
Belt Adjustment (Cont’d) Remove components to access the alternator belt. (See
Belt Replacement on Page 10-160-2.)
Figure 10-160-5
Loosen the alternator mounting and adjustment bolts
(Item 1) [Figure 10-160-4] and loosen the belt fully.
Remove the belt and install a new belt.
Adjust the belt. (See Belt Adjustment on Page 10-160-1.)
S8247
If a belt tension tool is available, move the alternator

toward the front of the machine (Item 2) [Figure 10-160-

4] until the belt (Item 1) [Figure 10-160-5] has (New belt
= 56 - 60 lbf or Used belt = 48 - 52 lbf) tension.
If a belt tension tool is not available, move the alternator

toward the front of the machine (Item 2) [Figure 10-160-
4] until the belt (Item 1) [Figure 10-160-5] has 13 mm
(0.50 in) movement at the middle of the belt span with 58
N (13 lb) of force.
Tighten the mounting and adjustment bolts.
Install the cover, fill cap and fan guard.

SEAT BELT Figure 10-170-1
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.
The items below are referenced in [Figure 10-170-1]. B-22283
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 correct operation.

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

by extending the seat belt webbing to determine if it
looks correct and that it spools out and retracts the
webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength can have deteriorated.
See your dealer for approved seat belt system

replacement parts for your machine.


CONTROL CONSOLE LOCKOUTS Figure 10-180-2
Inspection And Maintenance
Figure 10-180-1
P-86593
Sit in the operator's seat, fasten the seat belt and start
R0032 the engine.
Raise the right console (Item 1) [Figure 10-180-1]. The

When a console is raised [Figure 10-180-1], the green light (Item 1) [Figure 10-180-2] on the console will
hydraulic control joysticks and traction system must not turn off.

function.
Move the joystick control levers. There should be no
movement of the boom, arm, slew or bucket.
Move the travel control levers. There should be no

movement of the excavator tracks.
Lower the left console. Raise the right console and

repeat the inspection procedure.
The joystick control levers and traction system must be

deactivated when either console is raised.
Service the system if these controls do not deactivate

when a control console is raised.


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.


STOPPING THE ENGINE AND LEAVING THE Figure 10-200-3
EXCAVATOR
Procedure
OFF
Figure 10-200-1 ON
PREHEAT
START
P113994
Turn the key (Item 1) [Figure 10-200-3] to the OFF

position.
P113989
Stop the engine.
Stop the machine on level ground. Lower the work Raise the control console(s).

equipment and the blade to the ground [Figure 10-200-
1]. Disconnect the seat belt.
Figure 10-200-2 Remove the key from the switch to prevent operation of
machine by unauthorized personnel.
1 Exit machine.
R0023
Move the engine speed control lever (Item 1) [Figure 10-

200-2] fully down and run the engine at idle speed for
about 5 minutes to allow it to cool.


MOTION ALARM The motion alarm is located on the lower part of the
frame, on top of the swing cylinder.
Description
Figure 10-210-2
This excavator may be equipped with a motion alarm
system. The motion alarm will sound when the operator
moves the travel control levers in either the forward or
reverse direction. Slight movement of the steering levers 2
in either the forward or reverse direction is required with
hydraulic components before the motion alarm will
sound.
Inspecting
Figure 10-210-1 1
R0131
Inspect the motion alarm connections (Item 1), wire

harness (Item 2) [Figure 10-210-2] and motion alarm
switch (Item 1) [Figure 10-210-3] for tightness and
1

damage. Repair or replace any damaged components.
If the motion alarm switch requires adjustment, see

information below.
P-86598B
Inspect for damaged or missing motion alarm decal (Item

1) [Figure 10-210-1]. Replace if damaged.
Sit in the operator’s seat. Turn Start key to ON position

but DO NOT start the engine.
WARNING
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
Move the travel control levers in the forward direction.

The motion alarm must sound. Move the travel control
levers in the reverse direction. The motion alarm must
sound.
Turn the Start key to the OFF position.

MOTION ALARM (CONT’D)
Adjusting Switch Position
Stop the engine. Remove the floor mat and floorplate.
Figure 10-210-3
R0133

Place the travel control levers in the NEUTRAL position.
Loosen the screws (Item 1) [Figure 10-210-3] securing

the motion alarm switch.
Position the motion alarm switch roller (Item 2) so that it

makes contact with bearing (Item 3) until it opens the
switch circuit. (Listen for the click of the switch.) Tighten
the screws (Item 1) [Figure 10-210-3] securing the
switch to the bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).
Inspect the motion alarm system for correct operation

after adjustment.
WARNING
This machine is equipped with a motion alarm.
ALARM MUST SOUND!
when operating forward or backward.
Failure to maintain a clear view in the direction of

travel could result in serious injury or death.
The operator is responsible for the safe operation of

this machine.
W-2786-0309

REMOTE START TOOL KIT - MEL1563 Figure 10-220-2
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

are: 1
MEL1563 - Remote Start Tool

MEL1566 - Service Tool Harness Communicator
(Computer Interface)
Figure 10-220-1
1
P16117
The three function buttons (Item 1) [Figure 10-220-2] are

non-functional for excavators.
NOTE: Excavators can not be started by using the

Remote Start Tool.

Figure 10-220-3
P16114
1
The Remote Start Tool (Item 1) [Figure 10-220-1] is
used for excavators.
The Remote Start Tool is required when the service

technician is checking the service codes.
Remote Start Tool is a link between the excavator and

the Service PC.
P16116
The 10-pin rectangular connector (Item 1) [Figure 10-

220-3] is not used for an excavator application.

REMOTE START TOOL KIT - MEL1563 (CONT'D) Figure 10-220-5
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-220-4
2
1 1
P-98952

P16114 excavator harness connector.
Connect the service tool harness to the excavator

The service tool harness communicator (Item 1) [Figure harness.
10-220-4] is used to connect the Remote Start Tool to the

Service PC. Connect the service tool harness communicator
(MEL1566) to the designated serial port on the Service
Remove the service tool harness (Item 2) [Figure 10- PC.
220-4] from the cover.
NOTE: Make all connections with the key or keyless

panel in the OFF position.
Open the right side cover.

REMOTE START TOOL KIT - MEL1563 (CONT'D) Key Switch
Service Tool Harness Communicator - MEL1566 Figure 10-220-7
NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.
Figure 10-220-6
P-9289
Turn the key (Item 1) [Figure 10-220-7] to the RUN

position on the excavator.
P16119 NOTE: DO NOT start the excavator.

Figure 10-220-8
The Service Tool Harness Communicator (Item 1)
[Figure 10-220-6] is required to connect the Service PC
to the remote start tool.
P-21334

position on the Remote Start Tool.

REMOTE START TOOL KIT - MEL1563 (CONT'D)
Service Tool Harness Communicator - MEL1566

(Cont’d)
Keyless Start
Figure 10-220-9
P16616

Press the ENTER CODE button (Item 1) [Figure 10-220-
9] to turn power on.
NOTE: DO NOT start the excavator.
Figure 10-220-10
P-21334

position on the Remote Start Tool.

REMOTE START TOOL (SERVICE TOOL) KIT -
7003031
Description
The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL1563 Remote Start Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7003031,

can be used to service excavators using the supplied
harness P/N 6689747.
A computer can be connected to the Remote Start Tool

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the excavator harness.

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-221-2
7003031 (CONT’D)
1
Remote Start Tool (Service Tool) - 7003030
Tools that will be needed to complete the following steps 1 1

are:
Order from Bobcat Parts P/N: 7003031 - Remote Start 1 1

Tool (Service Tool) Kit
Kit Includes:
7003030 - Remote Start Tool (Service Tool)
6689747 - Excavator Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
Figure 10-221-1
The five function buttons (Item 1) [Figure 10-221-2] are

non-functional for excavators.
NOTE: Excavators can not be started by using the

Remote Start Tool.

1
P-76678
The Remote Start Tool (Item 1) [Figure 10-221-1] is

used for excavators.
The Remote Start Tool is required when the service

technician is checking the service codes.
Remote Start Tool is a link between the excavator and

the Service PC.

7003031 (CONT’D)
Excavator Service Tool Harness - 6689747

2 1
Figure 10-221-3
3
P-76450
2
NOTE: The Remote Start Tool (Service Tool)

connection harness has two connectors (Item
P-76678 1) and (Item 2). The main connector (Item 1)
[Figure 10-221-5] is always used for
connection to the excavator harness.
The service tool harness control (Item 1) [Figure 10-221-
3] is used to connect the Remote Start Tool (Item 2)

The second connector (Item 2) [Figure 10-221-
[Figure 10-221-3] to the electrical system on the 5] is not used for excavator applications. This
excavator. connector has a cap attached to it to prevent
damage or corrosion when not in use.
The service tool harness communicator (Item 3) [Figure
10-221-3] is used to connect the Remote Start Tool to the Connect the Remote Start Tool (Service Tool) connector
Service PC. (Item 1) [Figure 10-221-5] to the excavator harness
connector.
NOTE: Make all connections with the key or keyless
panel in the OFF position. NOTE: The Key Switch or Keyless Instrument Panel
must be in the RUN position or the Remote
Open the right side cover. Start Tool (Service Tool) will not operate.
Figure 10-221-4
P-98952

excavator harness connector.

7003031 (CONT’D)
Computer Service Tool Harness - 6689746
NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.
Figure 10-221-6 1 2
P-76441
The gear icon with the left facing arrows (Item 1) [Figure
10-221-7] will illuminate and blink when the excavator key
is in the RUN position or excavator keyless panel is ON
and the excavator is communicating with the service tool.
2 NOTE: DO NOT start the excavator.

P-76450
The computer icon with the right facing arrows (Item 2)
[Figure 10-221-7] will illuminate and blink when the
The Computer Service Tool Harness (Item 1) [Figure 10- Remote Start Tool (Service Tool) is transmitting data to
221-6] is required to connect Remote Start Tool (Service and from the computer.
Tool) to the Service PC (Item 2) [Figure 10-221-6].

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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting The Swing (Upperstructure Slew) Circuit . . . . . . . . . . . . . . . . . . . . 20-10-7
Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-8
CYLINDER (BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
CYLINDER (ARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
CYLINDER (BOOM SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7
CYLINDER (BLADE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-6
CYLINDER (TRACK FRAME EXPANSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-9

VALVE (MAIN RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
VALVE (PORT RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

VALVE (PRESSURE REDUCING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Left Travel Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Slew Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Arm Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-19
Boom Swing Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-40-23
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Blade Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Bucket Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-36

Boom Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-40
Right Travel Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 20-40-45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-48
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-10
MANIFOLD ASSEMBLY / ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11

SWIVEL JOINT (S/N 133P14286 & ABOVE, B4K911001 & ABOVE AND B4PD11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-7
SWIVEL JOINT (S/N A33P13634 - A33P14285) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81-7

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82-7

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-83-7
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-14
CONTROL PATTERN SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
CONTROL LEVER (JOYSTICK) (RIGHT) (S/N A33S13155 & ABOVE, B4K911001 & ABOVE
AND B4PD11001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-10

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N A33P11001 - A33P13154) . . . . . . . . . 20-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-10
CONTROL LEVER (JOYSTICK) (LEFT) (S/N A33P13155 & ABOVE, B4K911001 & ABOVE
AND B4PD11001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-10
CONTROL LEVER (JOYSTICK) (LEFT) (S/N A33P11001 - A33P13154) . . . . . . . . . . 20-121-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-11
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
ELECTRIC BLADE / TRACK EXPAND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-2
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-3
TRACK EXPAND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151-1
Control Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151-2

BUILD-UP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
TWO SPEED CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-3


HYDRAULIC/HYDROSTATIC SCHEMATIC
E10 (S/N A33P11001 AND ABOVE)
(PRINTED OCTOBER 2017)
V-1214legend
LEGEND
1 HYDRAULIC RESERVOIR with FILL STRAINER 15 PORT RELIEF / ANTICAVITATION VALVE
Reservoir Capacity: . . . . . . . 2,6 L (2.75 qt) Boom Cylinder (Base End)
System Capacity to centre of site gauge: 23200 kPa (232 bar) (3365 psi)
. . . . . . . 10,1 L (10.7 qt)
16 PORT RELIEF / ANTICAVITATION VALVE
Arm Cylinder (Base End)
2 BREATHER/FILL CAP with FILTER 22500 kPa (225 bar) (3262 psi)
17 SLEW MOTOR - CROSS PORT RELIEF
3 HYDRAULIC FILTER ELEMENT VALVE . . . . 8400 kPa (84 bar) (1218 psi)
10 Micron
18 ANTICAVITATION VALVE
Boom Swing Cylinder (Rod End)
4 FILTER BY-PASS 17200 kPa (1,72 bar) (25 psi)
ANTICAVITATION VALVE: Arm Cylinder (Rod End)
19
5 – Early Models Only
HYDRAULIC PUMP - 2 Section Gear Pump:
PLUGGED PORT – Later Models Only
Pump Section 1

10,0 Lpm (2.6 gpm) at High Engine Idle 20 CHECK VALVE
Pump Section 2
10,0 Lpm (2.6 gpm) at High Engine Idle
21 ORIFICE . . . . . . . . . . 1,2 mm (0.047 in)
6 SOLENOID VALVE - SYSTEM BY-PASS 22 ORIFICE . . . . . . . . . . 1,1 mm (0.043 in)
7 MAIN RELIEF VALVE: 23 ORIFICE . . . . . . . . . . 1,1 mm (0.043 in)

18400 – 19200 kPa (184 - 192 bar) (2660 - 2770 psi)
8 PRESSURE REDUCING VALVE: 24 TRAVEL MOTOR SPOOL

3000 kPa (30 bar) (435 psi)
9 25 TWO SPEED VALVE - Travel Motor
SOLENOID VALVE - CONSOLE (Joystick)
LOCK OUT
10 26 CHECK VALVE (Later Models Only)
ACCUMULATOR
Nitrogen . . . . . 1100 kPa (11 bar) (165 psi) 27 ORIFICE . . . . . . . . . . 1,2 mm (0.047 in)
non-rechargeable
(Later Models Only)
11 TEST PORT - "F" Port - Gauge Test Port
12 TEST PORT - “PS1” Port - Pilot Pressure Bucket Cylinder (Base End) – (Later Models Only)
Test Port 23200 kPa (232 bar) (3365 psi)
13 CHECK VALVE
14 BUILD UP VALVE: 2700 kPa (27 bar) (391 psi)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1214 (10-25-17)
85 of 698
Printable Version Click Here
9 12
HYDRAULIC/HYDROSTATIC SCHEMATIC P2 10
PB
PS1
E10 S/N A33P11001 AND ABOVE
13
(PRINTED OCTOBER 2017) RH TRAVEL
V-1214 PS2
A 11
5
8 13
R.H. TRAVEL MOTOR B F
TWO PUMP 1
PS 25 SPEED 20 V2
VALVE 13
V1
BOOM
24 BOOM PUMP 2
CYLINDER
A
HYDRAULIC
P1 T1 20 15 PUMP
B
P2
20 6
21
T
BUCKET 7
22
A
BLADE 28 RH JOYSTICK
CYLINDER 1
H2
F BUCKET 4
F B
CYLINDER
A A
20
B B 23
P
H1 H BLADE
TRACK
J1 EXPAND A T
VALVE
J
J2
E1 E AUXILIARY MALE B 3
E2 HYDRAULIC (RETURN)
COUPLERS A
C C 2
D TWO WAY
D
G G
FLOW FEMALE
(OPTIONAL) (PRESSURE)
B Dealer Copy -- Not for Resale 1
14
CENTER PB 4
AUX
SWIVEL JOINT
AUXILIARY MALE T1 CV T
EXPAND HYDRAULIC (RETURN) P
CYLINDER COUPLERS
ONE WAY 20
T
FLOW A
FEMALE BUILD-UP
(STANDARD) 18
(PRESSURE) BOOM VALVE
SWING
3
CYLINDER
BOOM SWING 2
20 LH JOYSTICK
PS 25
B
19 2
24
P1
16
B ARM 1
P2 T1
RESERVOIR
ARM 3
CYLINDER
20
SLEW 17
MOTOR UPPERSTRUCTURE
L.H. TRAVEL MOTOR 27
TURNS CCW A
B
17
26
A COOLER
UPPERSTRUCTURE B (OPTIONAL WITH 4
TURNS CW DEMOLITION KIT)
SLEW FILTER W/ BY-PASS
20
ENCLOSURE
A
PUMP SUPPLY
WORKING CIRCUITS
B PILOT PRESSURE
LH TRAVEL SYSTEM RETURN LINES
INTERSECTION OF
HYDRAULIC LINES
INDICATED BY JUNTION DOT
P1
86 of 698 V-1214 (10-25-17)
HYDRAULIC/HYDROSTATIC SCHEMATIC
E10 (S/N B4K911001 AND ABOVE)
(PRINTED OCTOBER 2017)
V-1213legend
LEGEND
1 HYDRAULIC RESERVOIR 17 SLEW MOTOR - CROSS PORT RELIEF
(PRESSURIZED) with FILL STRAINER VALVE: 8400 kPa (84 bar) (1218 psi)
Reservoir Capacity: . . . . . . . 2,6 L (2.75 qt)
System Capacity to center of site gauge: 18 ANTICAVITATION VALVE
. . . . . . . 10,1 L (10.7 qt) Boom Swing Cylinder (Rod End)
2 BREATHER/FILL CAP - with FILTER 19 NOT USED ON THIS MODEL
3 HYDRAULIC FILTER ELEMENT

10 Micron 20 CHECK VALVE
4 FILTER BY-PASS: 172 kPa (1,72 bar) (25 psi)
21 ORIFICE . . . . . . . . . . 1,2 mm (0.04 in)
5 HYDRAULIC PUMP - 2 Section Gear Pump:
22 ORIFICE . . . . . . . . . . 1,1 mm (0.043 in)
Pump Section 1

10,0 Lpm (2.6 U.S. gpm) at High Engine Idle
Pump Section 2 23 ORIFICE . . . . . . . . . . 1,1 mm (0.043 in)
10,0 Lpm (2.6 U.S. gpm) at High Engine Idle
24 TRAVEL MOTOR SPOOL
6 SOLENOID VALVE - SYSTEM BY-PASS
25 TWO SPEED VALVE - Traval Motor
7 MAIN RELIEF VALVE: 18400 – 19200 kPa
(184 - 192 bar) (2660 - 2770 psi) 26 CHECK VALVE (S/N AB4711177 & Above)
8 PRESSURE REDUCING VALVE 27 ORIFICE . . . . . . . . . . 1,2 mm (0.047 in)

3000 kPa (30 bar) (435 psi)
9 SOLENOID VALVE - CONSOLE (Joystick) 28 PORT RELIEF / ANTICAVITATION VALVE
LOCK OUT
Bucket Cylinder (Base End): 23200 kPa
10 ACCUMULATOR (232 bar) (3365 psi)
Nitrogen: 1100 kPa (11 bar) (165 psi)
non-rechargeable
11 TEST PORT - "F" Port - Gauge Test Port
12 TEST PORT – “PS1” Port - Pilot Pressure

Test Port
13 CHECK VALVE
14 BUILD UP VALVE: 2700 kPa (27 bar) (391 psi)

Boom Cylinder (Base End): 33200 kPa
(232 bar) (3365 psi)
Arm Cylinder (Base End): 22500 kPa
(225 bar) (3262 psi)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-1213le (10-25-17)
87 of 698
Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC PB
9 12
P2
E10 S/N B4K911001 AND ABOVE 10
PS1
13
(PRINTED OCTOBER 2017) RH TRAVEL
V-1213 PS2
A 11
5
8 13
R.H. TRAVEL MOTOR B F
TWO PUMP 1
PS 25 SPEED 20 V2
VALVE 13
V1
BOOM
24 BOOM PUMP 2
CYLINDER
A
HYDRAULIC
P1 T1 20 15 PUMP
B
P2
20 6
21
T
BUCKET 7
22
A
BLADE RH JOYSTICK
CYLINDER 28
1
H2
F 4
F B
A A
BUCKET 20
B B CYLINDER 23
P
H1 H BLADE
J1 TRACK T
EXPAND A
J
J2 VALVE
E1 E MALE B 3
E2 AUXILIARY (RETURN)
A
HYDRAULIC 2
C C
D D
COUPLERS
B
FEMALE 1
G G TWO WAY
(PRESSURE) 14 R3
FLOW PB
CENTER AUX R3 ISO 4
(OPTIONAL)
SWIVEL JOINT
T1 CV T R1
EXPAND R1 P
A STD ISO ISO
CYLINDER 18
20 FRON
B L1 T T
AUXILIARY L1
BUILD-UP ISO
HYDRAULIC BACK
VALVE
COUPLERS
BOOM SWING L3 L3 3
MALE ISO
BOOM 20
(RETURN)
SWING 2
CYLINDER STD / ISO LH JOYSTICK
VALVE
PS 25
FEMALE A
(PRESSURE)
2
24
FILL CAP
B
16
P1 ARM ARM
CYLINDER 1
P2 T1
20 RESERVOIR
OIL COOLER 3
SLEW 17
(OPTIONAL – INSTALL
MOTOR UPPERSTRUCTURE 27 KIT FOR BREAKER
TURNS CCW A
APLICATIONS)
L.H. TRAVEL MOTOR B
26 17
A
UPPERSTRUCTURE B
TURNS CW
SLEW 4
FILTER W/ BY-PASS
20
A
ENCLOSURE
PUMP SUPPLY
WORKING CIRCUITS
B
PILOT PRESSURE
LH TRAVEL SYSTEM RETURN LINES
INTERSECTION OF
HYDRAULIC LINES
INDICATED BY JUNTION DOT
88 of 698 P1
V-1213 (10-25-17)
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
(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.

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).


NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for the
allows free flow in one direction only. 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 DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
OUT IN T Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
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.


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).

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. Check, 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.
Hydraulic speed too slow. Hydraulic oil level or viscosity incorrect. Refill or replace.
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 (if equipped) or radiator fins plugged. Clean oil cooler (if equipped)
or radiator external surface.
Hydraulic oil level low. Refill or replace.
Non recommended hydraulic oil Replace.
Relief valve excessively activated. Use proper operating
procedures.
One or more relief valves not set correctly. Test, readjust or replace.

Extreme operating conditions. High ambient
temperature (e.g. enclosed structure).
Alternator belt loose. Tighten alternator belt.

Troubleshooting The Cylinder Circuit
TROUBLESHOOTING THE CYLINDER CIRCUIT

Cylinder inoperable. Control console(s) raised. Lower control console.
Loose fittings or broken hoses. Repair or replace.
Lever linkage misadjusted. Readjust.
Control console lockout switch. Readjust or replace.
Cylinder internal leakage excessive. Repair or replace.
Control lever (joystick) manifold solenoid coil Test, repair or replace.
defective.
Control lever (joystick) manifold solenoid valve Test, repair or replace.
defective.
Control lever (joystick) manifold pressure reducing Test, repair or replace.
valve defective.
Control lever (joystick) internal leakage excessive. Repair or replace.
Cylinder force insufficient. Main relief valve pressure too low. Readjust or replace.
Work port relief pressure too low. Readjust or replace.
Cylinder speed too slow. Lever linkage misadjusted. Readjust.
Cylinder internal leakage excessive. Repair or replace.
Control lever (joystick) manifold solenoid valve Repair or replace.

defective.
Control lever (joystick) manifold pressure reducing Repair or replace.
valve defective.
Control valve internal leakage excessive. Repair or replace.
Cylinder drift excessive. Cylinder internal leakage excessive. Repair or replace.
Work port relief valve seals leaking. Test, repair or replace.

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

Swing not operating. Control console(s) raised. Lower control console(s).
Control console lockout switch defective. Readjust or replace.
Swing lock pin engaged. Disengage lock pin.
Control lever (joystick) manifold pressure reducing Repair or replace.
valve defective.
Control lever (joystick) manifold solenoid coil Replace.
defective.
Control lever (joystick) manifold solenoid valve Repair or replace.
defective.
Swing motor gear defective. Repair or replace.
Control lever (joystick) internal leakage excessive. Repair or replace
Swing motor defective. Repair or replace.
Swing force. Main relief valve set too low. Readjust or replace.
Swing motor cross port relief valve pressure too Readjust or replace.
low.
Swing speed too slow. Pump flow low. Check, repair or replace.
Blocked or restricted line to swing motor. Replace.

Swing motor internal leakage excessive. Repair or replace.
Swing over run excessive. Control valve spool sticking. Repair or replace.
Control lever (joystick) spool sticking. Repair or replace.
Swing motor cross port relief valve set too low. Repair or replace.
Swing motor internal leakage excessive. Repair or replace.

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 counterbalance 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.
Speed too slow. Lever linkage incorrectly adjusted. Readjust.
Swivel joint internal leakage excessive. Repair or replace.
Low pump pressure. Check, repair or replace.
Travel motor internal leakage excessive. Repair 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.
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 misadjusted. 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.

CYLINDER (BOOM) Figure 20-20-3
Testing
Lower the boom / bucket and blade to the ground.
Stop the engine. Raise the control console.
Figure 20-20-1
1
2
S7489
Remove the bolt and nut (Item 1) [Figure 20-20-3] from

the rod end pivot pin.
Remove the pivot pin (Item 2) [Figure 20-20-3].
S7660 Figure 20-20-4

Support the boom using a chain hoist [Figure 20-20-1].
Figure 20-20-2
S7490
Lower control console and fasten the seat belt. Start the
engine and retract the boom cylinder.
S7488
With the key in the ON position and the engine stopped,
move the hydraulic controls to release the hydraulic
Support the boom cylinder [Figure 20-20-2]. pressure. Raise the control console.
Disconnect the boom cylinder base end hose (Item 1)

[Figure 20-20-4] from the boom cylinder.

CYLINDER (BOOM) (CONT’D) Removal And Installation
Testing (Cont’d) Lower the boom / bucket and blade to the ground. Stop
the engine.
WARNING Figure 20-20-6
Hydraulic fluid escaping under pressure can have

sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-20-5
S7660
1

With the key in the ON position, move the hydraulic
controls to release the hydraulic pressure.
IMPORTANT
S7491
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Install a cap (Item 1) [Figure 20-20-5] on the hose fitting parts clean. Always use caps and plugs on hoses,
and tighten. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Lower control console and fasten seat belt. Start the I-2003-0888
engine and retract the boom cylinder.
If there is any leakage from the base end fitting on the

boom cylinder, remove the cylinder for repair or
replacement.

CYLINDER (BOOM) (CONT’D) Figure 20-20-9
Removal And Installation (Cont’d)

3 2
Figure 20-20-7
1
S7488
Disconnect and cap the two hoses (Item 1) [Figure 20-

S7488 20-9] from the boom cylinder.

Support the boom cylinder [Figure 20-20-7]. the boom cylinder base end pin.

Figure 20-20-8 Remove the boom cylinder base end pin (Item 3) [Figure
20-20-9].
Remove the boom cylinder.
WARNING
1
2
S7489
immediately.
W-2145-0290


IMPORTANT
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

CYLINDER (BOOM) (CONT’D)
Parts Identification
1. Piston Seal
2. Head
3. Wiper
4. Rod Seal
5. Cylinder Housing
6. Plug
7. Nut
8. Piston
9. Shaft
10. O-ring
11. O-ring* B-14213A B-14213B
12. Back-up Ring*

13. O-ring
* 11 and 12 are replaced
by one seal on later
models
8
7 10 1

6
5
11 12 4 13 2 3
B-13593A
S8456

Disassembly
2 3
Clean the outside of the boom cylinder before
1
disassembly.
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.
S7678
Put the base end of the cylinder in a vise.
Figure 20-20-10 Remove the head and the rod assembly from the cylinder
[Figure 20-20-11]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), and head (Item
3) [Figure 20-20-11].
1

Figure 20-20-12
1
2
1
N-22352A
Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-20-10] to loosen the head.
S7679
Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-20-12].

Disassembly (Cont’d)
Figure 20-20-13
4
2
1
2
1
S7681
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-20-

N-22356 15].
Remove the O-ring (Item 1) and the back-up ring (Item 2)

from the groove in the head (Item 3) [Figure 20-20-13].

NOTE: O-ring (Item 1) and back-up ring (Item 2)
[Figure 20-20-13] are replaced by one seal on
later models.
Remove the O-ring (Item 4) [Figure 20-20-13].
Figure 20-20-14
2
1
S7680
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-20-14].

Assembly
Use the following tools to assemble the cylinder:

2
MEL1396 - Universal Seal Expander 1
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Clean all parts in solvent and dry with compressed air. 3
Inspect all parts for wear or damage. Replace any worn

or damaged parts. S7679
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-20-17].
Figure 20-20-16
Figure 20-20-18

S7682
N-22358
Install new seal on the tool and slowly stretch it until it fits
the piston [Figure 20-20-16]. 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 3 minutes [Figure 20-20-18].
on the piston.

Assembly (Cont’d)
Figure 20-20-19
S7683
Install the wiper seal with the wiper (Item 1) [Figure 20-
P-7427 20-21] toward the outside of the head.
Figure 20-20-22
Install the rod seal on the rod seal tool [Figure 20-20-19].

NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
1
Rotate the handles to collapse the rod seal [Figure 20- 3 2
20-19].
Figure 20-20-20
N-22356
Install the O-ring (Item 1) [Figure 20-20-22].
Install the back-up ring (Item 2) and O-ring (Item 3) into

the groove on the head (Item 4) [Figure 20-20-22].

P-7425 [Figure 20-20-22] are replaced by one seal on
later models. Use a ring compressor to
compress the seal to the correct size. Leave
Install the rod seal in the head [Figure 20-20-20]. the piston in the compressor for about 3
minutes.

CYLINDER (BOOM) (CONT’D) Tighten the base end fitting plug to 50 N•m (37 ft-lb)
torque.
Assembly (Cont’d)
Tighten the rod end fitting plug to 20 N•m (15 ft-lb)
Figure 20-20-23 torque.
Put the base end of the hydraulic cylinder in a vise.
2 1 Figure 20-20-25
3
S7678
1
Install the head (Item 1) and the piston (Item 2) [Figure

N-22352A
20-20-23] on the rod as shown.

Grease the piston where the nut contacts the piston. Do Insert the adjustable gland nut wrench into the two holes
not get grease on the threads. (Item 1) [Figure 20-20-25] to tighten the head. Head to
be torqued until flush with end of the housing.
Provide an adequate support for the cylinder before
tightening.
Install the nut (Item 3) [Figure 20-20-23].
NOTE: Clean and dry the rod threads, from the kit
install a NEW NUT with preapplied Loctite®.
Tighten the nut to 406 N•m (300 ft-lb) torque.
Figure 20-20-24
2
S7681
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

20-24].


CYLINDER (ARM)
Testing
WARNING
Figure 20-21-1
immediately.
1 W-2145-0290
Figure 20-21-3
S7959


the rod end pivot pin. S7494
Figure 20-21-2
engine and retract the arm cylinder.
Stop the engine. With the key in the ON position, move

1 the hydraulic controls to release the hydraulic pressure.
Raise the control console.
Disconnect the arm cylinder base end hose (Item 1)

[Figure 20-21-3] from the arm cylinder.
S7958
Support the arm cylinder [Figure 20-21-2].

CYLINDER (ARM) (CONT’D)
Testing (Cont’d)
Figure 20-21-4
S7495
Install a plug (Item 1) [Figure 20-21-4] on the hose and

tighten.

engine and retract the arm cylinder.

arm cylinder, remove the cylinder for repair or
replacement.

Removal And Installation

WARNING
Lower the boom / bucket and blade to the ground. Stop
the engine.
Figure 20-21-5
explosion or fire.
2 W-2103-0508
Figure 20-21-6
1 3 1
1
S7496 2


controls to release the hydraulic pressure. S7667
IMPORTANT the arm cylinder rod end pin.
Remove the cylinder rod end pin (Item 2) [Figure 20-21-

When repairing hydrostatic and hydraulic systems, 6].
parts clean. Always use caps and plugs on hoses, Remove the arm cylinder.
damage the system.
I-2003-0888
Remove and plug the two hoses (Item 1) [Figure 20-21-

5] from the arm cylinder.

the arm cylinder base end pin.
Remove the cylinder base end pin (Item 3) [Figure 20-

21-5].

1. Piston Seal
2. Head
3. O-ring
4. Wiper
5. Rod Seal
6. Piston
7. Plug
8. Tube Assembly
9. Nut
10. Shaft
B-14213A B-14213B
11. O-ring
12. O-ring*
13. Back-up Ring*
* 12 and 13 are 9 11 1 6
replaced by one seal
on later models

7
10
12 13 3 2 5 4
B-13593A
S8458

CYLINDER (ARM) (CONT’D) Figure 20-21-8
Disassembly
Clean the outside of the arm cylinder before disassembly. 3

2
Use the following tools to disassemble the cylinder: 1

MEL1075-2 - Special Offset Pins
Put the base end of the cylinder in a vise. S7967
Figure 20-21-7
Remove the head and the rod assembly from the cylinder
1 3) [Figure 20-21-8].

Figure 20-21-9
1 2
1
S7968
S7966
Standard Piston: Remove the seal (Item 1) and O-ring

(Item 2) from the piston (Item 3) [Figure 20-21-9].

Figure 20-21-10
4
2
1
2
1
S7681

N-22356 12].


later models.
Figure 20-21-11
S7680


Assembly
3
2 1
MEL1396 - Universal Seal Expander
Clean all parts in solvent and dry with compressed air.


and O-rings with clean hydraulic fluid before installation. Standard Piston: Install the O-ring (Item 1) and seal (Item
2) on the piston (Item 3) [Figure 20-21-14].
Figure 20-21-13
Figure 20-21-15

P-7424
N-22358
Install the seal on the tool and slowly stretch it until it fits
on the piston.

Assembly (Cont’d)
Figure 20-21-16
S7683
Figure 20-21-19

4
1
Rotate the handles to collapse the rod seal [Figure 20- 2
21-16]. 3
Figure 20-21-17
N-22356


N-7425 [Figure 20-21-19] are replaced by one seal on
Install the rod seal in the head [Figure 20-21-17]. the head in the compressor for about 3
minutes.

Assembly (Cont’d)
Figure 20-21-20
1
2
3
1
2
S7681

S7967 21-21].
Tighten the plug to 20 N•m (15 ft-lb) torque.

20-21-20] on the rod. Put the base end of the hydraulic cylinder in a vise.

Grease the piston where the nut contacts the piston. Do Figure 20-21-22
not get grease on the threads.

tightening.
1
Reclean thread area for Loctite® residue.

1
S7968
(Item 1) [Figure 20-21-22] to tighten the head. Head to


CYLINDER (BOOM SWING) Remove the lower right hand side cover. (See Lower
Right Side Cover Removal And Installation on Page 40-
Testing 210-3.)
Lower the boom / bucket and blade to the ground. Figure 20-22-3
Figure 20-22-1
1
S6784
Remove the base end hose (Item 1) [Figure 20-22-3]

S6782 from the boom swing cylinder.

Figure 20-22-4
Remove the pivot pin from the rod end of the cylinder. 2
Figure 20-22-2
S6785
1
Install a cap (Item 1) [Figure 20-22-4] on the base end
hose and tighten.
S6783 Lower control console and fasten the seat belt. Start the
engine and retract the cylinder.
Lower the control console and fasten the seat belt. Start If there is any leakage from the base end fitting (Item 2)
the engine and retract the boom swing cylinder (Item 1) [Figure 20-22-4] on the cylinder, remove the boom swing
[Figure 20-22-2]. cylinder for repair or replacement.

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

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-5
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888
S6782
WARNING Remove the bolt and nut (Item 1) [Figure 20-22-5] from
Hydraulic fluid escaping under pressure can have Remove the pivot pin from the rod end of the cylinder.
penetrating the skin. This can cause serious injury Figure 20-22-6

immediately.
W-2145-0290
WARNING
explosion or fire.
S6789
W-2103-0508
Swing the upperstructure so the pin in the base end of Lower the control console and fasten the seat belt.
the cylinder is located between the tracks.
Start the excavator and fully retract the boom swing
Lower the boom / bucket and blade to the ground. Stop cylinder [Figure 20-22-6].
the engine.
Stop the engine.

Remove the lower right hand side cover. (See Lower

Right Side Cover Removal And Installation on page 40-
210-3) 1
Figure 20-22-7
S6787
Remove the snap ring and washer (Item 1) [Figure 20-

1 22-9].
Figure 20-22-10
S6784

Remove the base end hose (Item 1) [Figure 20-22-7] 3 2
from the boom swing cylinder.
Figure 20-22-8
S6788
Remove the bolt (Item 1) and the retaining plate (Item 2)

1
[Figure 20-22-10].
Remove the pivot pin (Item 3) [Figure 20-22-10] from the

base end of the boom swing cylinder.
S6786
Remove the boom swing cylinder from the excavator.
Remove the rod end hose (Item 1) [Figure 20-22-8] from

the boom swing cylinder.

CYLINDER (BOOM SWING) (CONT’D)
1. Piston Seal * 11 and 12 are replaced

2. Wiper by one seal on later
3. Rod Seal models
4. Piston
5. Plug
6. Cylinder Housing
7. Head
8. Nut
9. Shaft
10. O-ring
B-14213A B-14213B
11. O-ring*
12. Back-up Ring*
13. O-ring
6 8 10 1 4

5
11 12 13 7 3 2 B-13593A
S8455

Disassembly
2 3
Clean the outside of the boom swing cylinder before 1
disassembly.

S7964
3) [Figure 20-22-12].

1 Figure 20-22-13
1 2
S7965
S7963
Standard piston: Remove the seal (Item 1) and O-ring


Figure 20-22-14
2 3
1
1
S7681

S7962 16].

[Figure 20-22-14].

later models.
Figure 20-22-15
2
1
S7680


Assembly
3
2 1


(Item 3) [Figure 20-22-18].
Figure 20-22-17
Figure 20-22-19

S7960
P-22358
on the piston.

Assembly (Cont’d)
Figure 20-22-20
S7961
Figure 20-22-23

2 1
3
Rotate the handles to collapse the rod seal [Figure 20-
22-20].
Figure 20-22-21
S7962
Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-22-23].

minutes.

Assembly (Cont’d)
Figure 20-22-24
2 1
3
2
S7681
Install O-ring (Item 1) and plug (Item 2) [Figure 20-22-

S7964 25].



tightening.
Install the nut (Item 3) [Figure 20-22-24]. 1
Tighten the nut to 407 N•m (300 ft-lb) torque. 1
S7965


CYLINDER (BUCKET) Figure 20-23-3
Testing
Figure 20-23-1
S7670
engine and retract the bucket cylinder [Figure 20-23-3].

the hydraulic controls to release the hydraulic pressure.
S7660 Raise the control console.

Figure 20-23-2
WARNING
1 immediately.
W-2145-0290
S7699
Remove the retaining pin (Item 1) and washers (Item 2)

[Figure 20-23-2] from the outside pivot pin.

CYLINDER (BUCKET) (CONT’D) Removal And Installation
Testing (Cont’d) Lower the boom / bucket and blade to the ground. Stop
the engine.
Figure 20-23-4
Support the boom using a chain hoist.

controls to release the hydraulic pressure.
1
Figure 20-23-5
S7668
2
Remove the bucket cylinder base end hose (Item 1)
[Figure 20-23-4] and install a plug on the hose fitting and

tighten.
S7669
engine and retract the bucket cylinder.
Remove the hose clamp (Item 1) [Figure 20-23-5] from
If there is any leakage from the base end fitting on the the bucket cylinder.
bucket cylinder, remove the cylinder for repair or
replacement. Remove and plug the bucket cylinder rod end hose (Item
2) [Figure 20-23-5].
Figure 20-23-6
S7668
Remove and plug the bucket cylinder base end hose

(Item 1) [Figure 20-23-6].

CYLINDER (BUCKET) (CONT’D)
Figure 20-23-7
IMPORTANT
damage the system.
I-2003-0888
1 WARNING
S7667 sufficient force to enter a person’s body by
Remove the bolt and nut (Item 1) [Figure 20-23-7] from physician familiar with this injury is not received
the base end pivot pin. immediately.

W-2145-0290
Remove the base end pivot pin (Item 2) [Figure 20-23-7]
and lower the base end of the cylinder to the floor.
Figure 20-23-8
WARNING
1 1
2 Always clean up spilled fuel or oil. Keep heat, flames,
3
explosion or fire.
W-2103-0508
S7901
Remove the two snap rings and washers (Item 1) [Figure

20-23-8].
Remove the bucket link (Item 2) [Figure 20-23-8].
Remove the bucket link pins (Item 3) [Figure 20-23-8].
Remove the bucket cylinder.

CYLINDER (BUCKET) (CONT’D)
1. Piston Seal
2. Head
3. Piston
4. Cylinder Housing
5. Rod Wiper
6. Rod Seal
7. Plug
8. Shaft
9. O-ring
10. Nut
B-14213A B-14213B
11. O-ring
12. O-ring*
13. Back-up Ring*
* 12 and 13 are replaced
models
4 10 11 1 3

7
12 13 9 2 6 5 8
B-13593A
S8461

CYLINDER (BUCKET) (CONT’D) Figure 20-23-10
Disassembly
2 3
Clean the outside of the bucket cylinder before
1
disassembly.

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

1 Figure 20-23-11
2
1 1
N-22434
N-22414


Figure 20-23-12
4
1 2
2
N-22364

N-22356 14].


later models.
Figure 20-23-13
2
1
N-22357


Assembly
3
1
2

or damaged parts. N-22414

Figure 20-23-15
Figure 20-23-17

P-7424
N-22358
on the piston.

Assembly (Cont’d)
Figure 20-23-18
N-22359
Figure 20-23-21

NOTE: During installation the spring side of the seal 4
1
Rotate the handles to collapse the rod seal [Figure 20- 2
3
23-18].
Figure 20-23-19
N-22356


N-7425 [Figure 20-23-21] are replaced by one seal on
minutes.

Assembly (Cont’d)
Figure 20-23-22
2 1
3
N-22364

23].
N-22436


Be careful no to damage the cylinder tube.
Grease the piston where the nut contacts the piston. Do
not get grease on the threads. Figure 20-23-24
tightening.
NOTE: Clean and dry the rod threads, from the kit 1

1
N-22434
be torqued until flush with end of cylinder housing.


CYLINDER (BLADE)
Testing WARNING
Swing the upperstructure out of the way. Lower the boom
/ bucket to the ground. Raise the blade up until it stops. Hydraulic fluid escaping under pressure can have
Stop the engine. penetrating the skin. This can cause serious injury
Figure 20-24-1 physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-24-3

S8711
Support the blade. With the key in the ON position, move

the blade control to release the hydraulic pressure. Raise
the control console. S7903
Figure 20-24-2 Remove the blade cylinder base end hose (Item 1)
[Figure 20-24-3].
Figure 20-24-4
S7902
Loosen the top nut (Item 1) and the bottom nut (Item 2) S7904
[Figure 20-24-2] fastening the shield to the blade
cylinder. Install a plug (Item 1) [Figure 20-24-4] on the hose fitting
and tighten.
Remove the blade cylinder shield from the blade cylinder.
Lower control console. Start the engine and retract the
blade cylinder.

blade cylinder, remove the cylinder for repair or
replacement.

CYLINDER (BLADE) (CONT’D) Figure 20-24-6
Lower the boom / bucket and blade to the ground. Stop

the engine. 1
With the key in the ON position, move the blade control to

release the hydraulic pressure. Raise the control console.
Figure 20-24-5
2
S7903
2
Remove and plug the blade cylinder hoses (Item 1)

[Figure 20-24-6].
1 Remove the snap ring and washers (Item 2) [Figure 20-

24-6] from the blade cylinder base end pin.

S7902 Remove the blade cylinder base end pin (Item 3) [Figure
20-24-6].
Loosen the top nut (Item 1) and the bottom nut (Item 2)
[Figure 20-24-5] fastening the shield to the blade Figure 20-24-7
cylinder.
Remove the blade cylinder shield from the blade cylinder.
IMPORTANT 1

clean the work area before disassembly and keep all 2
damage the system.
I-2003-0888 S7905
Remove the snap ring and washer (Item 1) [Figure 20-

24-7] from the blade cylinder rod end.
WARNING Remove the blade cylinder rod end pin (Item 2) [Figure
20-24-7].
Always clean up spilled fuel or oil. Keep heat, flames, Remove the blade cylinder.
explosion or fire.
W-2103-0508

CYLINDER (BLADE) (CONT’D)
1. Piston Seal
2. Head
3. Wiper
4. Rod Seal
5. Piston
6. Plug
7. Cylinder Housing
8. Shaft
9. Nut
10. O-ring
11. O-ring* B-14213D B-14213B
12. Back-up Ring*

13. O-ring
* 11 and 12 are
replaced by one seal
on later models
6 9 10 1 5

6 7
12 11 3 13 2 4 B-13593A
S8451

Disassembly
Clean the outside of the blade cylinder before 3

disassembly. 2
1

N-22413A
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-24-9].

Figure 20-24-10
1 3
2
1
1
N-22442A
N-22414


Figure 20-24-11
4
1 2
2
N-22364

N-22356
13].


later models.
Figure 20-24-12
2
1
N-22357


Assembly
3

1
MEL1033 - Rod Seal Installation Tool 2


Figure 20-24-14
Figure 20-24-16

N-07424
N-22358
on the piston.

Assembly (Cont’d)
Figure 20-24-17
P-22359
Figure 20-24-20

1
Rotate the handles to collapse the rod seal [Figure 20- 3 2
24-17].
Figure 20-24-18
N-22356


P-07425
minutes.

Assembly (Cont’d)
Figure 20-24-21
1
2
3
1
N-22364

N-22413A
22].

Install the head (Item 1) and piston (Item 2) [Figure 20-
24-21] on the rod. Put the base end of the hydraulic cylinder in a vise.


tightening.
NOTE: Clean and dry the rod threads, from the kit 1

1
N-22442A

CYLINDER (TRACK FRAME EXPANSION) Figure 20-25-3
Testing
Retract the track frame fully.
Figure 20-25-1
S8253
Remove the expansion cylinder base end hose (Item 1)

[Figure 20-25-3].
S8352
WARNING

Place blocks under the excavator tracks. Lower the
bucket to the ground and the blade on the blocks [Figure Hydraulic fluid escaping under pressure can have
20-25-1]. sufficient force to enter a person’s body by
Stop the engine. Raise the control console. and possible death if proper medical treatment by a
Figure 20-25-2 immediately.
W-2145-0290
Figure 20-25-4
1 1
2 1
S8250
Remove the two bolts (Item 1) and access plate (Item 2) S8257
[Figure 20-25-2] on the right side of the undercarriage.
Install a plug (Item 1) [Figure 20-25-4] on the hose fitting
and tighten.
engine and retract the expansion cylinder.

expansion cylinder, remove the cylinder for repair or
replacement.

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-7
Expand the track frame fully.
Figure 20-25-5
S8251
Remove the hose (Item 1) [Figure 20-25-7] from the

cylinder rod end.
S8352
IMPORTANT

Place blocks under the excavator tracks for increased
access to the expansion cylinder [Figure 20-25-5].
Figure 20-25-6 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
1 1
WARNING
2 sufficient force to enter a person’s body by
S8250
immediately.
W-2145-0290
Remove the bolts (Item 1) [Figure 20-25-6].
Remove the access plate (Item 2) [Figure 20-25-6].
NOTE: Remove the access plates on both sides of the

undercarriage.

Figure 20-25-8
1
1 S8254
Plug the base end hose (Item 1) [Figure 20-25-10].

S8252
Install a hose (Item 2) [Figure 20-25-10] on the cylinder
base end. Place the other end of the hose in a drain pan.
Install a hose (Item 1) [Figure 20-25-8] on the cylinder
rod end. Place the other end of the hose in a drain pan. Figure 20-25-11

Figure 20-25-9
1 S8255
S8253
Remove the bolt (Item 1) [Figure 20-25-11].
Remove the hose (Item 1) [Figure 20-25-9] from the Remove the rod end pivot pin (Item 2) [Figure 20-25-11].
cylinder base end.
Remove the rod end of the cylinder from the
undercarriage.

Figure 20-25-12
2 S8895
1
Gently lift one side of the undercarriage until the
S8256 excavator tracks are free of the blocks [Figure 20-25-14].
Figure 20-25-15

Remove the base end pivot pin (Item 2) [Figure 20-25-
12].
Remove the base end of the cylinder from the

undercarriage.
Figure 20-25-13
S8896
1
Place blocks under the undercarriage [Figure 20-25-15].
Gently lower the excavator onto the blocks, then remove

the jacks.
S8475
Remove the nut (Item 1) [Figure 20-25-13] from the track

frame.
Installation: Tighten the nut to 305 N•m (225 ft-lb)

torque.

CYLINDER (TRACK FRAME EXPANSION) (CONT’D)
Figure 20-25-16
S8897
Move the tracks frame towards the outside of the

excavator to provide extra clearance for track frame

expansion cylinder removal [Figure 20-25-16].
Remove the track frame expansion cylinder from the side

by using the opening between undercarriage and track
frame.
WARNING
explosion or fire.
W-2103-0508

CYLINDER (TRACK FRAME EXPANSION) (CONT’D)
1. Piston Seal
2. Head
3. Piston
4. Rod Wiper
5. Rod Seal
6. Plug
7. Cylinder Housing
8. Nut
9. Shaft
10. O-ring
11. O-ring*
12. Back-up Ring*
13. O-ring
* 11 and 12 are replaced 6 7 8 10 1 3
models
9 Dealer Copy -- Not for Resale
12 11 13 2 5 4 S8462

Disassembly
3
Clean the outside of the expansion cylinder before 2
disassembly. 1

N-22416
3) [Figure 20-25-18].
1

Figure 20-25-19
2
1
1
S7968
N-22418
Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-25-19].

Figure 20-25-20
4
2
1 2
N-22364

N-22356 22].


later models.
Remove the thin O-ring (Item 4) [Figure 20-25-20].
Figure 20-25-21
2
1
N-22357


Assembly
3
MEL1396 - Universal Seal Expander 1

MEL1033 - Rod Seal Installation Tool 2


(Item 3) [Figure 20-25-24].
Figure 20-25-23
Figure 20-25-25

P-07424
N-22358
on the piston.

Assembly (Cont’d)
Figure 20-25-26
N-22359
Figure 20-25-29

1
Rotate the handles to collapse the rod seal [Figure 20-
25-26]. 3 2
Figure 20-25-27
N-22356
Install the back-up ring (Item 2) and thick O-ring (Item 3)

into the groove on the head (Item 4) [Figure 20-25-29].

minutes.

Assembly (Cont’d)
Figure 20-25-30
1
2
3
1
N-22364

25-31].
N-22416


tightening.
1
1
S7968


VALVE (MAIN RELIEF) There is one diagnostic coupler (Item 1) [Figure 20-30-1]
(F port) on the manifold assembly for checking each of
Testing And Adjusting the pump section pressure.
All testing is done with the hydraulic oil at operating The following tools will be needed for the testing at the
temperature and the engine at high speed setting of 2500 diagnostic coupler:
rpm Maximum.
MEL1355 - Test Kit includes the following:
Figure 20-30-1 MEL1355-3 - 5000 psi Gauge
MEL1355-12 - Coupler
MEL1355-9 - Thermometer
System Pressures At Gauge Port Specifications

1
TEST CONDITIONS
1. Engine High Idle Speed
2. Warm oil over relief function to minimum 66C

(150F. Cycle all functions during warm up
procedure.
Warm oil until the pressure build-up valve stabilizes
near its target pressure.
S8560

 TEST TARGET kPa
SYSTEM CHECK FUNCTION TO ENGAGE CIRCUIT PRESSURIZED PORT (bar) (psi) ACCEPTABLE RANGE kPa
(bar) (psi)
JOYSTICK PILOT PRESSURE ANY JOYSTICK FUNCTION JOYSTICK PILOT PS1 299,9 (30) (45) 2799,3 - 3102,6 (28 - 31)
(406 - 450)
SYSTEM BYPASS NONE - CONSOLE UP DUMP TO TANK F 284,2 (2,5) (36) MAXIMUM ALLOWED
448,2 (4,5) (65)
MAIN RELIEF ON MANIFOLD BLOCK BUCKET P2 F 18202,1 (182) 17698,7 - 18698,6 (177 - 187)
(2640) (2567 - 2712)
MAIN RELIEF ON MANIFOLD BLOCK AUXILIARY P1 and P2 F 19002 (190) 18498,6 - 19498,8 (185 - 195)
(2756) (2683 - 2828)
MAIN RELIEF ON MANIFOLD BLOCK ARM P1 F 18202,2 (182) 17698,8 - 18698,6 (177 - 187)
(2640) (2567 - 2712)
SWING MOTOR - PORT RELIEF SLEW RIGHT P1 F 8397,8 (84) 7997,9 - 8797,7 (80 - 88)
(1218) (1160 - 1276)
SWING MOTOR - PORT RELIEF SLEW LEFT P1 F 8397,8 (84) 7997,9 - 8797,7 (80 - 88)
(1218) (1160 - 1276)

VALVE (MAIN RELIEF) (CONT’D) Boom up:
17,7 - 18,7 MPa (177 - 187 bar) (2567 - 2712 psi)
Testing And Adjusting The Main Relief Valve (Cont’d)
Bucket in:
Figure 20-30-2 17,7 - 18,7 MPa (177 - 187 bar) (2567 - 2712 psi)
Arm in:
1 17,7 - 18,7 MPa (177 - 187 bar) (2567 - 2712 psi)
Auxiliary:
18,5 - 19,5 MPa (185 - 195 bar) (2683 - 2828 psi)
Stop the engine.
Figure 20-30-3
S8561
1
Connect the test gauge coupler from the test kit (Item 1)
[Figure 20-30-2] to the “F” diagnostic port. 2

Lower the control console and fasten seat belt.
Start the engine and run at low rpm until hydraulic fluid is
at operating temperatures 66°C (150°F).
S8559
With the hydraulic fluid at operating temperature, run
engine at full rpm.
If adjustment is needed, loosen the nut (Item 1) [Figure
Operate the following circuits over relief and record the 20-30-3].
pressure for each circuit.
Turn the adjustment bolt (Item 2) [Figure 20-30-3]
NOTE: Do not operate the blade circuit due to a clockwise to increase the pressure or counterclockwise
bypass orifice in spool. to decrease the pressure.
The main relief valve pressure at “F” diagnostic port Tighten the nut (Item 1) [Figure 20-30-3].
[Figure 20-30-2] should be as follows:
Retest the main relief valve after adjustment.

VALVE (PORT RELIEF) Figure 20-31-2
Testing And Adjusting
Figure 20-31-1
3 2
S8459
4 1
A portable hydraulic hand pump will be used to test the
S8040 work port relief valves. The hand pump must be clean
and contain the correct Bobcat hydraulic fluid.
Install the hand pump hose and a pressure gauge

Boom Port Relief set at: (minimum of 5000 psi) into the valve section work port in

which the port relief valve is located [Figure 20-31-2].
Base End (Item 1) [Figure 20-31-1] 23,2 MPa
Slowly pressurize this section with the hand pump until
(232 bar)
the port relief valve opens and make a note of the
(3365 psi)
pressure reading.
Arm Port Relief set at:
Base End (Item 2) [Figure 20-31-1] 22,5 MPa NOTE: Pumping the hand pump too fast will alter the
(225 bar) pressure readings up to 344,7 kPa (3,4 bar) (50
(3263 psi) psi).
Slew Port Relief set at:
If the port relief pressure setting is incorrect, replace the
CW (Item 3) [Figure 20-31-1] 8,4 MPa port relief valve.
(84 bar)
(1160 psi)
CCW (Item 4) [Figure 20-31-1] 8,4 MPa
(84 bar) WARNING
(1218 psi)
Traction and Chain Drives must be adjusted so that
neutral is at the location of the Neutral Start Switch.
Trencher or Chain can move suddenly when engine
starts if neutral adjustments are not correct. Start
trencher only from operator position.
W-2109-1186


VALVE (PRESSURE REDUCING) Lower control console and fasten seat belt.
Testing And Adjusting Start the engine and warm the hydraulic fluid to operating
temperatures 66°C (150°F).
The following tools will be needed for testing the pressure
reducing valve: With the hydraulic fluid at operating temperature, run
engine at full rpm.
MEL1355 - Test Kit includes the following:
MEL1355-2 - 1000 psi Gauge Operate the circuit over relief and record the pressure.
MEL1355-9 - Thermometer
The pressure reducing valve pressure at the test port
Open the tailgate. (See Opening And Closing The (Item 1) [Figure 20-32-2] (PS1) should be as follows:
3,0 MPa (30 bar) (435 psi) with an acceptable range of
Figure 20-32-1 2,8 - 3,1 MPa (28 - 31 bar) (406 - 450 psi)
Stop the engine.
Figure 20-32-3
1

S8560
Locate the test port (Item 1) [Figure 20-32-1] (PS1) on

the front side of the manifold.
S8245
Figure 20-32-2
If adjustment is needed, remove the cap (Item 1) [Figure
20-32-3] from the pressure reducing valve.
S8592
Install a 6,9 MPa (69 bar) (1000 psi) gauge on the test
port (Item 1) [Figure 20-32-2] (PS1).

VALVE (PRESSURE REDUCING) (CONT’D) Figure 20-32-5
Testing And Adjusting The Pressure Reducing Valve

(Cont’d)
Figure 20-32-4
2
1
S8246
Figure 20-32-6
S8246
Loosen the nut (Item 1) [Figure 20-32-4] on the pressure 1

reducing valve.

Turn the adjustment screw (Item 2) [Figure 20-32-4]
clockwise to increase the pressure or counterclockwise
to decrease the pressure.
Tighten the nut (Item 1) [Figure 20-32-4].
Retest the pressure reducing valve after adjustment.
If pressure is still incorrect, remove the pressure reducing S7506
valve from the manifold assembly and inspect.

Inspect the O-rings and back-up rings on the pressure
Inspect the port of the pressure reducing valve on the reducing valve (Item 1) [Figure 20-32-5] and [Figure 20-
manifold assembly to verify no damage. If damaged 32-6]. If O-rings and back-up rings are worn or damaged,
replace manifold assembly. replace O-rings and back-up rings.
Reinstall the pressure reducing valve in the manifold

assembly.
Repeat pressure reducing valve test.
If the O-rings and back-up rings were not worn or

damaged and the pressures at the test port could not be
achieved, replace pressure reducing valve.

HYDRAULIC CONTROL VALVE Figure 20-40-1
Description
The hydraulic control valve has a 23,2 MPa (232 bar) 1

(3365 psi) work port relief valve for the boom (base end)
section. The hydraulic control valve has a 22,5 MPa (225
bar) (3263 psi) work port relief valve for the arm (base
end) section. The hydraulic control valve has two 8,4
MPa (84 bar) (1218 psi) work port relief valves for the
slew section. 1
1
S8009
With the engine off, turn the Start key to the ON position
and move the hydraulic control levers to relieve hydraulic
pressure. Remove the four bolts (Item 1) [Figure 20-40-1] from the
cover.
Figure 20-40-2
IMPORTANT

damage the system.
I-2003-0888
Remove the instrument panel. (See Removal And

Installation on Page 40-220-1.)
1
S8008
WARNING
Remove the bolts (Item 1) [Figure 20-40-2] and remove
Hydraulic fluid escaping under pressure can have the cover.
penetrating the skin. This can cause serious injury Remove the floor panels. (See FLOOR PANELS on Page
and possible death if proper medical treatment by a 40-120-1.)
immediately.
W-2145-0290

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-5
Figure 20-40-3
1 1 2 2
2 1
S8035
Remove the cotter pins (Item 1) and the pins (Item 2)

S8069 [Figure 20-40-5].
Figure 20-40-6
Mark all tubes and hoses for ease of assembly [Figure
20-40-3].

Figure 20-40-4
2
1 1 1 1
2
1 1
S8036
Remove the hoses (Item 1) [Figure 20-40-6].

S8013
Remove the cotter pins (Item 1) and the pins (Item 2)

[Figure 20-40-4].

Figure 20-40-7
1
1
1 S7541
Disconnect the tubeline (Item 1) [Figure 20-40-9] from

S8037 the slew motor.
Figure 20-40-10
Remove the hoses (Item 1) [Figure 20-40-7].

Figure 20-40-8
S7543
S7540 Cut the tie-strap (Item 1) [Figure 20-40-10].

the slew motor.

Figure 20-40-11
S7562
1

S7544 the control valve.
Remove the tubeline from the excavator for easy access

Remove the tie-strap (Item 1) [Figure 20-40-11] from the to other tubelines and hoses.
two hoses.

Figure 20-40-14
Push the hoses aside.
Figure 20-40-12
1
1
S7563
S7560 Disconnect the tubeline (Item 1) [Figure 20-40-14] from

the control valve.

the control valve.

to other tubelines and hoses.

Figure 20-40-15
S8051


Disconnect the tubeline (Item 1) [Figure 20-40-15] from to other tubelines and hoses.
the swivel joint.

Figure 20-40-18
Figure 20-40-16
S8050
1
Disconnect the tubeline (Item 1) and hose (Item 2)

S8052 [Figure 20-40-18] from the control valve.

the swivel joint.

Figure 20-40-19
1
1
S8048

1 S8049 the swivel joint.
Figure 20-40-22
Disconnect the six hoses (Item 1) [Figure 20-40-19] from
the control valve.

Figure 20-40-20
1
S8047


Remove the clamp (Item 1) [Figure 20-40-20] from the to other tubelines and hoses.
tubeline.

Removal And Installation (Cont’d) 1

Figure 20-40-23
1 1
S8045
Disconnect the four hoses (Item 1) [Figure 20-40-25]

S8053 from the control valve.
Figure 20-40-26
the track expand valve.

Figure 20-40-24
2
1
1
S8044
Disconnect the tubeline (Item 1) and hose (Item 2)

S8046 [Figure 20-40-26] from the control valve.

the control valve.


Figure 20-40-27
S8041

S8043 the build-up valve.

Disconnect the tubeline (Item 1) [Figure 20-40-27] from to other tubelines and hoses.
the control valve.

Figure 20-40-30
Figure 20-40-28
2 3
S8460
S6745
Remove the two bolts (Item 1) [Figure 20-40-30].

Remove the nut and bolt (Item 1) [Figure 20-40-28] from
the hose bracket. Remove the bolt and nut (Item 2) from the mounting
bracket (Item 3) [Figure 20-40-30] and push the speed
Push the boom swing hoses aside. control cable aside.

HYDRAULIC CONTROL VALVE (CONT’D)
Figure 20-40-31
1
1
1 1
S8042

Remove the control valve from the excavator.

Item Description
1. Left Travel Section
2. Slew Section
3. Arm Section
4. Boom Swing Section
5. Auxiliary Section
6. Blade Section
7. Bucket Section
8. Boom Section
9. Right Travel Section
10. Port Relief - 8,4 MPa (84 bar) (1218 psi)

9
11 8
10 7
5 6
4
3
1 2
12
10
S8039

Disassembly
Clean the outside of the hydraulic control valve before

disassembly. 1
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1 S8039
damage the system.
I-2003-0888
Remove the tie rod nuts and lock washers (Item 1)
Figure 20-40-32 [Figure 20-40-33].

1 2 3 4 5 6 7 8 9
S8040
Remove all the fittings from the control valve. Mark the
valve sections for ease of assembly [Figure 20-40-32].
1. Left Travel Valve

2. Slew Valve
3. Arm Valve
4. Boom Swing Valve
5. Auxiliary Valve
6. Blade Valve
7. Bucket Valve
8. Boom Valve
9. Right Travel Valve

Left Travel Valve Section Disassembly And Assembly
IMPORTANT
1
damage the system.
I-2003-0888
2
S8070
Inspect all parts for wear or damage. Replace any worn Remove the bolts (Item 1) and retaining plate (Item 2)
or damaged parts. [Figure 20-40-35].
Always install new seals and O-rings. Lubricate all seals Installation: Tighten the bolts to 6,5 N•m (58 in-lb)
and O-rings with clean hydraulic fluid before installation. torque.

Figure 20-40-34 Figure 20-40-36
2
1
1
S8038 S8071
Remove the left travel valve section (Item 1) [Figure 20- Loosen the bolts (Item 1) and remove cap and screw
40-34] from the valve assembly. assembly (Item 2) [Figure 20-40-36].
Installation: Tighten the bolts to 6,5 N•m (58 in-lb)

torque.


Cut
(Cont’d)
Figure 20-40-37
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
38.1 mm
(1.500”) 19.05 mm
2 (0.750”)
B-14674
1
To remove the spring assembly from the spool a holding

fixture will have to be made from a 19 mm thick x 38 mm
S8072 wide x 51 mm long (0.750 in thick x 1.500 in wide x 2.0 in
long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole in
the center of the hardwood block. Cut the block
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- lengthwise [Figure 20-40-39].

40-37].
Figure 20-40-40
Figure 20-40-38
3 2
2
1 1
S8765
S8760
Using the wood blocks clamp the spool and spring

Remove the spool and spring assembly (Item 1), assembly (Item 1) [Figure 20-40-40] in a vise.
retaining plate (Item 2), seal (Item 3), O-ring (Item 4)
[Figure 20-40-38]. NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
The spool and valve section are not serviced separately. damaged.
NOTE: When the spool is removed, use care not to Loosen the bolt (Item 2) [Figure 20-40-40].
scratch the spool surface. Do not interchange
spools and valve sections. Installation: Apply Loctite® 243 or equivalent and
tighten the bolt to 6 N•m (53 in-lb) torque.


(Cont’d)
Figure 20-40-41
1
1
S8075
Remove the O-rings (Item 1) [Figure 20-40-43] from the

plugs.
S8766
Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-41].
Figure 20-40-42
1
S8074
Remove the plugs (Item 1) [Figure 20-40-42].
Installation: Tighten the plugs to 40 - 45 N•m (29 - 33 ft-

lb) torque.

Slew Valve Section Disassembly And Assembly
IMPORTANT
damage the system. 1
I-2003-0888
S8079
Inspect all parts for wear or damage. Replace any worn Remove the O-ring (Item 1) [Figure 20-40-45] from the
or damaged parts. slew valve section.
Always install new seals and O-rings. Lubricate all seals Figure 20-40-46
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-44
1 1
2
S8081
Loosen the bolts (Item 1) and remove cap and screw

S8078
assembly (Item 2) [Figure 20-40-46].
Remove the slew valve section (Item 1) [Figure 20-40- Installation: Tighten the bolts to 6,5 N•m (58 in-lb)
44] from the valve assembly. torque.


(Cont’d)
Figure 20-40-47
S8084
1 Remove the O-ring (Item 1) [Figure 20-40-49] from the

cap.
S8082
Figure 20-40-50
Remove the O-ring (Item 1) [Figure 20-40-47] from the

cap.
Figure 20-40-48
S2994
1 Remove the spool and spring assembly (Item 1) [Figure

20-40-50] from the valve section.
S8083
The spool and valve section are not serviced separately.
Loosen the bolts (Item 1) and remove cap and screw NOTE: When the spool is removed, use care not to
assembly (Item 2) [Figure 20-40-48]. scratch the spool surface. Do not interchange
spools and valve sections.
torque.


(Cont’d) 4
3 2
Figure 20-40-51
1
Cut
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
S8086
38.1 mm Remove the bolt (Item 1), spring seat (Item 2), spring
(1.500”) 19.05 mm (Item 3) and spring retainer (Item 4) [Figure 20-40-53].
(0.750”)
B-14674
Figure 20-40-54

wide x 51 mm long (0.750 in thick x 1.500 in wide x 2.0 in
lengthwise [Figure 20-40-51].
Figure 20-40-52
S8087
1 Remove the relief valve assemblies (Item 1) [Figure 20-

2 40-54].
Installation: Tighten the relief valve assemblies to 40 -

45 N•m (29 - 33 ft-lb) torque.
S8712

assembly (Item 1) [Figure 20-40-52] in a vise.
NOTE: Do not use anything other than hardwood

damaged.
Loosen the bolt (Item 2) [Figure 20-40-52].
Installation: Apply Loctite® 243 or equivalent and



(Cont’d)
Figure 20-40-55
S8076
1
Remove the check valve (Item 1) [Figure 20-40-57].
S8088 Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.
Remove the plug (Item 1) [Figure 20-40-55] from both Figure 20-40-58

relief valves.
Installation: Tighten the plugs to 25 N•m (18 ft-lb)

torque.
Figure 20-40-56
1
1
S8077

check valve.
1
S8089
Remove the O-rings (Item 1) [Figure 20-40-56].

Arm Valve Section Disassembly And Assembly
IMPORTANT
I-2003-0888
S8091
or damaged parts. arm valve section.

Figure 20-40-59
1
1
2
1
S8092

S8090
Remove the arm valve section (Item 1) [Figure 20-40-59] Installation: Tighten the bolts to 6,5 N•m (58 in-lb)
from the valve assembly. torque.


(Cont’d)
Figure 20-40-62
S8095

cap.
S8093
Figure 20-40-65

cap.
Figure 20-40-63
1
2
S2995
Remove the spool and spring assembly (Item 1) [Figure

1
S8094
torque.


(Cont’d) 4
3 2
Figure 20-40-66
1
Cut
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
S8086
(1.500”) 19.05 mm (Item 3) and spring retainer (Item 4) [Figure 20-40-68].
(0.750”)
B-14674
Figure 20-40-69

Figure 20-40-67
1
S8097
1 Remove the plug (Item 1) and port relief valve (Item 2)

2 [Figure 20-40-69].
Installation: Tighten the plug to 40 - 45 N•m (29 - 33 ft-

lb) torque.
S8712 Installation: Tighten the port relief valve to 40 - 45 N•m

(29 - 33 ft-lb) torque.


damaged.



(Cont’d)
Figure 20-40-70
1
1
S8089

Figure 20-40-73
S8098

plug.
Figure 20-40-71 1
S8076
1 Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.
Figure 20-40-74
S8088

port relief valve.
Installation: Tighten the plug to 25 N•m (18 ft-lb) torque.
S8077

check valve.

Boom Swing Valve Section Disassembly And

Assembly
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
S8100

Inspect all parts for wear or damage. Replace any worn side of the boom swing valve section.
or damaged parts.
Figure 20-40-77

Figure 20-40-75
S8101
Remove the bolts (Item 1) and retaining plate (Item 2)

[Figure 20-40-77].
S8099

Remove the boom swing valve section (Item 1) [Figure torque.
20-40-75] from the valve assembly.


Assembly (Cont’d)
Figure 20-40-78
3
4
1 2
2
S8761
Remove the spool and spring assembly (Item 1),

retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
1 S8102 [Figure 20-40-80].


assembly (Item 2) [Figure 20-40-78]. NOTE: When the spool is removed, use care not to
Installation: Tighten the bolts to 6,5 N•m (58 in-lb) spools and valve sections.
torque.
Figure 20-40-81
Figure 20-40-79
Cut
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
2
1
38.1 mm
(1.500”) 19.05 mm
(0.750”)
B-14674
S8103

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- fixture will have to be made from a 19 mm thick x 38 mm
40-79]. wide x 51 mm long (0.750 in thick x 1.500 in wide x 2.0 in


Assembly (Cont’d)
Figure 20-40-82
2
1
2
1
S8105
Remove the plug (Item 1) and valve assembly (Item 2)

[Figure 20-40-84].
S8765
lb) torque.

assembly (Item 1) [Figure 20-40-82] in a vise. Installation: Tighten the valve assembly to 40 - 45 N•m
(29-33 ft-lb) torque.
blocks to grip the spool, or the spool will be Figure 20-40-85
damaged.

Figure 20-40-83
2 1
1
1
S8106
S8766

(Item 2) [Figure 20-40-83].


Assembly (Cont’d)
Figure 20-40-86
S8109
1
S8107 Figure 20-40-89

valve assembly.
Figure 20-40-87
1
1
S8110
1 2 3 4
S8108
Remove the bolt (Item 1), washer (Item 2), spring (Item 3)
and valve (Item 4) [Figure 20-40-87].
Installation: Tighten the bolt to 1,5 N•m (13 in-lb) torque.


Assembly (Cont’d)
Figure 20-40-90
S8076

Installation: Tighten the check valve to 20 N•m (15 ft-lb)
torque.
Figure 20-40-91
S8077

check valve.

Auxiliary Valve Section Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
S8112
or damaged parts. auxiliary valve section.

Figure 20-40-92
2
1
1
S8113

S8111
[Figure 20-40-94].
Remove the auxiliary valve section (Item 1) [Figure 20- Installation: Tighten the bolts to 6,5 N•m (58 in-lb)
40-92] from the valve assembly. torque.


(Cont’d)
Figure 20-40-95
3
1
4
2
1
2
S8762

retaining plate (Item 2), seal (Item 3), and O-ring (Item 4)
1 S8154 [Figure 20-40-97].


assembly (Item 2) [Figure 20-40-95]. NOTE: When the spool is removed, use care not to
Installation: Tighten the bolts to 6,5 N•m (58 in-lb) spools and valve sections.
torque.
Figure 20-40-98
Figure 20-40-96
Cut
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
2
1
38.1 mm
(1.500”) 19.05 mm
(0.750”)
B-14674
S8155

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- fixture will have to be made from a 19 mm thick x 38 mm
40-96]. wide x 51 mm long (0.750 in thick x 1.500 in wide x 2.0 in


(Cont’d)
Figure 20-40-99
1
2
1
S8157
Remove the two plugs (Item 1) [Figure 20-40-101].
S8765 Installation: Tighten the plugs to 40 - 45 N•m (29 - 33 ft-

lb) torque.
Using the wood blocks, clamp the spool and spring Figure 20-40-102

NOTE: Do not use anything other than hardwood 1

damaged. 1

Figure 20-40-100
S8158
1 Remove the O-rings (Item 1) [Figure 20-40-102].
S8766

(Item 2) [Figure 20-40-100].


(Cont’d)
Figure 20-40-103
1
1
2
1
S8161
Remove the spring (Item 1) and spring seat (Item 2)

[Figure 20-40-105].
S8159
Figure 20-40-106

Figure 20-40-104 1
S8162

S8160

torque.

Blade Valve Section Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
S8115
or damaged parts. blade valve section.

Figure 20-40-107
S8116

S8114
blade valve section.
Remove the blade valve section (Item 1) [Figure 20-40-

107] from the valve assembly.


(Cont’d)
Figure 20-40-110
1 2
1
S8119
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

2 40-112].
1 S8117
Figure 20-40-113

[Figure 20-40-110].

torque.
3 2
1
Figure 20-40-111
S8763
1
2
retaining plate (Item 2), seal (Item 3), and O-ring (Item 4)
[Figure 20-40-113].

1
S8118
NOTE: When the spool is removed, use care not to
Loosen the bolts (Item 1) and remove cap and screw spools and valve sections.
assembly [Figure 20-40-111].

torque.


(Cont’d)
Figure 20-40-114 2
1
Cut
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
S8766
38.1 mm Remove the spring assembly (Item 1) from the spool

(1.500”) 19.05 mm (Item 2) [Figure 20-40-116].
(0.750”)
B-14674
Figure 20-40-117

Figure 20-40-115
1
S8121
2
1 Remove the check valve (Item 1) [Figure 20-40-117].

torque.
S8765


damaged.



(Cont’d)
Figure 20-40-118
S8122

check valve.

Bucket Valve Section Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888 1
S8124
or damaged parts. bucket valve section.

Figure 20-40-119
1
2
1 1
S8125

S8123
assembly [Figure 20-40-121].
Remove the bucket valve section (Item 1) [Figure 20-40- Installation: Tighten the bolts to 6,5 N•m (58 in-lb)


(Cont’d)
Figure 20-40-122
1
S8128
1 Remove the O-ring (Item 1) [Figure 20-40-124].
S8126 Figure 20-40-125

Figure 20-40-123
1
2
S8129

1 20-40-125] from the valve section.
S8127
assembly [Figure 20-40-123]. scratch the spool surface. Do not interchange
torque.


(Cont’d) 4
3 2
Figure 20-40-126
1
Cut
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
S8086
(1.500”) 19.05 mm (Item 3), spring retainer (Item 4) [Figure 20-40-128].
(0.750”)
B-14674
Figure 20-40-129

1
Figure 20-40-127
1
S8130
1 Remove the plugs (Item 1) [Figure 20-40-129].

2
lb) torque.
S8712


damaged.



(Cont’d)
1
Figure 20-40-130
1
1
S8133

plug.
S8131

plugs.
Figure 20-40-131
3
2
5
4
S8132
Remove the spring seat (Item 1), spring (Item 2), spring
seat (Item 3), spring (Item 4), and plug (Item 5) [Figure
20-40-131].

Boom Valve Section Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
S8135
or damaged parts. boom valve section.

Figure 20-40-133
1
2
1
1
S8136

S8134
Remove the boom valve section (Item 1) [Figure 20-40- Installation: Tighten the bolts to 6,5 N•m (58 in-lb)


(Cont’d)
Figure 20-40-136
1
S8139
1 Remove the O-ring (Item 1) [Figure 20-40-138].
S8137 Figure 20-40-139

Figure 20-40-137
1
2
S8140

1
S8138
torque.


(Cont’d) 4
3 2
Figure 20-40-140
1
Cut
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
S8086
(1.500”) 19.05 mm (Item 3), spring retainer (Item 4) [Figure 20-40-142].
(0.750”)
B-14674
Figure 20-40-143

the center of the hardwood block. Cut the block 1
2
Figure 20-40-141
S8141
Remove the plug (Item 1) and relief valve (Item 2)

1 2 [Figure 20-40-143].

lb) torque.
S8712 Installation: Tighten the relief valve to 40 - 45 N•m 



damaged.



(Cont’d) 1
1
Figure 20-40-144 1
1
1
S8144
S8142 Figure 20-40-147

Figure 20-40-145
S8145
S8143 Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.

relief valve.


(Cont’d)
Figure 20-40-148
S8146

check valve.

Right Travel Valve Section Disassembly And

Assembly
IMPORTANT 1

I-2003-0888
S8148

Inspect all parts for wear or damage. Replace any worn [Figure 20-40-150].
or damaged parts.
Always install new seals and O-rings. Lubricate all seals torque.

Figure 20-40-151
Figure 20-40-149
1
2
1
S8149
S8147

Remove the right travel valve section (Item 1) [Figure 20- assembly (Item 2) [Figure 20-40-151].
40-149] from the tie rods.
torque.


Cut
Assembly (Cont’d)
Figure 20-40-152
11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
38.1 mm
1 (1.500”) 19.05 mm
(0.750”)
B-14674

2
S8150 wide x 51 mm long (0.750 in thick x 1.500 in wide x 2.0 in
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- lengthwise [Figure 20-40-154].

40-152].
Figure 20-40-155
Figure 20-40-153
3
1
2
1
4
2
S8765
S8764

Remove the spool and spring assembly (Item 1), assembly (Item 1) [Figure 20-40-155] in a vise.
retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
[Figure 20-40-153]. NOTE: Do not use anything other than hardwood
The spool and valve section are not serviced separately. damaged.
NOTE: When the spool is removed, use care not to Loosen the bolt (Item 2) [Figure 20-40-155].
spools and valve sections. Installation: Apply Loctite® 243 or equivalent and
tighten the bolt to 6 N•m (53.1 in-lb) torque.


Assembly (Cont’d)
1
Figure 20-40-156 1
S8153

plugs.
S8766

(Item 2) [Figure 20-40-156].
Figure 20-40-157
S8152
Remove the plugs (Item 1) [Figure 20-40-157].

lb) torque.

Assembly
IMPORTANT
damage the system.
I-2003-0888
S8135
Inspect all parts for wear or damage. Replace any worn Install the O-ring (Item 1) [Figure 20-40-160] on the
or damaged parts. boom valve section.

Figure 20-40-159
1 S8134
Install the boom valve section (Item 1) [Figure 20-40-

S8147
161] on the tie rods.
Install the tie rods (Item 1) on the right travel valve

section (Item 2) [Figure 20-40-159].

Assembly (Cont’d)
Figure 20-40-162
1 S8116
Install the O-ring (Item 1) [Figure 20-40-164] on the

S8124 blade valve section.
Figure 20-40-165
bucket valve section.

Figure 20-40-163
1 S8115

S8123 blade valve section.
Install the bucket valve section (Item 1) [Figure 20-40-


Assembly (Cont’d)
Figure 20-40-166
S8111
1
Install the auxiliary valve section (Item 1) [Figure 20-40-

S8114 168] on the tie rods.
Figure 20-40-169
Install the blade valve section (Item 1) [Figure 20-40-

Figure 20-40-167
1 S8100

S8112 boom swing valve section.

auxiliary valve section.

Assembly (Cont’d)
Figure 20-40-170
1
S8090
Install the arm valve section (Item 1) [Figure 20-40-172]

S8099 on the tie rods.
Figure 20-40-173
Install the boom swing valve section (Item 1) [Figure 20-
40-170] on the tie rods.

Figure 20-40-171
1
S8079
Install the O-ring (Item 1) [Figure 20-40-173] on the slew

S8091 valve section.
Install the O-ring (Item 1) [Figure 20-40-171] on the arm

valve section.

Assembly (Cont’d)
Figure 20-40-174
1
1 S8039
1
Install the washers and nuts (Item 1) [Figure 20-40-176]
S8078 on the tie rods, finger tight.
Be sure the valve assembly does not rock on a flat

Install the slew valve section (Item 1) [Figure 20-40-174] surface.
on the tie rods.

Initially tighten the tie rod nuts (Item 1) [Figure 20-40-
Figure 20-40-175 176] to 13 N•m (10 ft-lb) torque in a crisscross manner.
Final tighten the tie rod nuts (Item 1) [Figure 20-40-176]

1 to 25 N•m (18 ft-lb) torque.
The valve assembly must not have any spacing between

the valve sections and the spools must be free when
pushed in and released.
The spools must not stick, if the spools do stick, loosen

the tie rod nuts and tighten per above information.
Recheck the control valve assembly for level settings.
Install the hoses and fittings.

S8038
Install the left travel valve section (Item 1) [Figure 20-40-


HYDRAULIC PUMP Figure 20-50-1
Description
The hydraulic gear pump is attached to the end of the

engine flywheel at the left side of the motor.
The hydraulic gear pump is a double gear pump that

provides hydraulic flow to the hydraulic systems. The first
gear pump section, located nearest the engine, provides
flow to the right travel, boom, bucket, blade and auxiliary
functions. The second gear pump section provides flow
to the auxiliary, boom swing, arm, slew and left hand
travel functions.
Testing The Hydraulic Pump S6720
The hydraulic pump flow is 10 L/min (2.64 U.S. gpm) for

both pump sections at 2370 rpm. Remove the outlet hose, of the section to be tested, from
the hydraulic pump section for testing [Figure 20-50-1].
NOTE: Pump Section 1 is closest to the engine.
Figure 20-50-2
The following tool will be needed for the hydraulic pump
test:

MEL10003 - Hydraulic Tester 1
Stop the engine.

2
Remove the upper left hand side cover. (See Upper Left
Side Cover Removal And Installation on Page 40-210-1.)
Remove the lower left hand side cover. (See Lower Left
S8241
Connect the hose removed from the pump (Item 1)

[Figure 20-50-2] to the outlet of the tester.
Connect the inlet hose of the tester to the fitting on the

pump (Item 2) [Figure 20-50-2].
NOTE: The tester connections will be the same for

each pump section.

HYDRAULIC PUMP (CONT’D)
Testing The Hydraulic Pump (Cont’d)
Figure 20-50-3
P-16671
NOTE: Open the flow control knob on the hydraulic

tester (Item 1) [Figure 20-50-3] fully to prevent

pump damage.
Start the engine and run at low rpm until the hydraulic
fluid is warm 66°C (150°F). Make sure the tester is
connected correctly. If no flow is indicated at the tester,
the hoses are connected wrong.
Increase the engine speed to full rpm.
Record the pump free flow L/min (U.S. gpm).
Close the flow control knob (Item 1) [Figure 20-50-3]

slowly to approximately 700 kPa (7,0 bar) (100 psi) below
the relief valve setting which is 18,4 - 19,2 MPa (184 -
192 bar) (2669 - 2785 psi).
Record the pump high pressure flow L/min (U.S. gpm).
NOTE: The high pressure flow must be at least 80% of

free flow.
HIGH PRESSURE FLOW (L/MIN) x 100

%=
FREE FLOW (L/MIN)
If the high pressure flow is less than 80% of free flow,

remove the hydraulic pump for repair or replacement.
Repeat the testing procedure for each pump section.

HYDRAULIC PUMP (CONT’D) Figure 20-50-4
Relieve hydraulic pressure.

1 1
Drain the hydraulic reservoir. (See Removing And
Replacing The Hydraulic Filter on Page 10-100-2.)
IMPORTANT
S6720
parts clean. Always use caps and plugs on hoses, Remove the two pressure hoses (Item 1) [Figure 20-50-
tubelines and ports to keep dirt out. Dirt can quickly 4]. Cap and plug the hoses and fittings.
damage the system.
I-2003-0888 Figure 20-50-5

WARNING
2
immediately. 1
W-2145-0290
Remove the upper left hand side cover. (See Upper Left S6721
Remove the lower left hand side cover. (See Lower Left Remove the hose clamp (Item 1) and inlet hose (Item 2)
Side Cover Removal And Installation on Page 40-210-2.) [Figure 20-50-5].

Figure 20-50-6
1
S6722
Remove the fitting (Item 1) [Figure 20-50-6] from the

pump.

Remove the bolts (Item 2) [Figure 20-50-6] from the
pump flange.
Installation: Tighten the bolts to 71 - 79 N•m (52 - 58 ft-

lb) torque.
Remove the hydraulic pump from the excavator.

1. Body 17. Pin

2. Body 18. Pin
3. Flange
4. Cover
5. Block
6. Gear
7. Gear
8. Gear
9. Plate 12 5 8 11 9
10. Coupling
11. Seal
12. Seal
13. O-ring
14. Seal-up
15. Ring
16. Screw
16 16 4

7 5 12
1 13 11
17 13 14 15
16 16 13
12 18
12 6 5
11 18 13 2 17 3
11 5 10 7
S8236

Disassembly 1
Clean the outside of the gear pump before disassembly.
IMPORTANT
damage the system.
S7511
I-2003-0888
Figure 20-50-7 Put the pump, mounting flange down, in a protected jaw
vise. Remove the four assembly bolts (Item 1) [Figure
2 3 4 20-50-8].
1
NOTE: The pump has only one inlet port. The pump
5 section with the inlet port is located closest to

the input shaft.
Figure 20-50-9
S7510
2
Mark both sides of each separation point (Items 1-4)

[Figure 20-50-7] on the inlet side of the pump, as shown,
with the corresponding separation point number.
Tape the shaft splines (Item 5) [Figure 20-50-7] to make

sure that the splines will not damage the oil seal when S7512
the shaft is removed.
Remove the end cap (or separating plate) (Item 1)

[Figure 20-50-9].

top of the gear housing.

1
Figure 20-50-10
Remove the O-
1 ring from the end
of the housing
S7515
Remove the drive and idler gears (Item 1) [Figure 20-50-

S7513 12].
Figure 20-50-13
Remove the gear housing (Item 1) [Figure 20-50-10].

end of the gear housing.
Figure 20-50-11
Back-up Ring
(Black) O-ring seal 2
1
S7516
Remove the lower bearing (Item 1) [Figure 20-50-13].
Remove the back-up ring and O-ring seal (Item 2)

S7514 [Figure 20-50-13] from the bearing.
Remove the upper bearing (Item 1) [Figure 20-50-11].
Remove the back-up ring and O-ring seal from the

bearing.

Figure 20-50-14
S7517
Remove the coupling (Item 1) [Figure 20-50-14].

Repeat step [Figure 20-50-9 on Page 6] through step
[Figure 20-50-14] to disassemble the second pump
section. Keep the parts from each section separate from
the other section.
NOTE: The gear housing, two bearings, drive gear

and idler gear in each pump section are not
serviced separately. These parts are matched
sets which are run in at the factory. If any part
is damaged, the entire section must be
replaced.
Figure 20-50-15
4
1
CD-0209
Remove the snap ring (Item 1) from the mounting flange,

(Item 2). Using a seal puller (Item 3), remove the oil seal
(Item 4) [Figure 20-50-15].

Assembly Open side of O-

2 ring seal must go
Clean all parts in solvent and dry with compressed air. towards the inlet
port
or damaged parts.
1
and O-rings with clean hydraulic fluid and all O-ring seals
with assembly lube before installation.
Use the correct size driver and install the oil seal (seal
lips to the inside of the pump) (Item 4) into the mounting
flange (Item 2). Install the snap ring (Item 1) [Figure 20- S7519
50-15].
Figure 20-50-16 Put the mounting flange, oil seal side down (Item 1)
[Figure 20-50-17] in a protected jaw vise.
Install the lower bearing (Item 2) [Figure 20-50-17], seal

2 side down, on the mounting flange (or separating plate).
The open side of the O-ring seal must point toward the

inlet port side (marked side) of the pump.
3
Figure 20-50-18
1
S7518
1
Install an O-ring seal (Item 1) [Figure 20-50-16] stepped

side up, into each O-ring seal groove. Push each O-ring
seal down into the groove.
Install the back-up ring (Item 2) [Figure 20-50-16] into

the groove made by the O-ring seal and bearing. Push S7520
the back-up ring down flush with the O-ring seal.
NOTE: There is a notch (Items 3 and 4) [Figure 20-50- Tape the splined end (Item 1) [Figure 20-50-18] of the
16] in the center of the back-up ring and O- drive gear to make sure that the splines will not damage
ring seal. When installing the back-up ring, the oil seal during installation.
make sure that these notches are aligned. If
the back-up ring or O-ring seal are not Apply oil to the drive gear and idler gear and to the side
installed correctly the back-up ring will not sit faces of the gears. Install the gears into the lower bearing
flush with the O-ring seal. [Figure 20-50-18].

Assembly (Cont’d)
Figure 20-50-19
Open side of O-
ring seal must go 1
1
towards the inlet
port
2
2
S7517
Apply oil to the coupling (Item 1) [Figure 20-50-21].

S7521
Install the coupling into the drive gear (Item 2) [Figure
20-50-21].
Install the upper bearing (Item 1), seal side up, on the
drive and idler gears (Item 2) [Figure 20-50-19]. The Figure 20-50-22

open side of the O-ring seal must point toward the inlet
port side (marked side) of the pump.
Figure 20-50-20 2
Upper bearing
must be slightly Oil passages
lower than must align to
housing supply to
section one
1
1
S7523
NOTE: When installing the first section gear housing

S7522 (Item 1) (with inlet port), make sure that the oil
passage in the housing and the separation
plate align. Section two gear housing (Item 2)
Install O-rings (Item 1) [Figure 20-50-20] on each end of [Figure 20-50-22] must receive oil flow
the gear housing. through this passage from section one gear
housing.
Align the marks made during disassembly on the gear
housing and mounting flange (or separating plate).
Carefully install the gear housing over the bearings and
gears [Figure 20-50-20].
NOTE: The upper bearing must be slightly lower than

the gear housing. If the bearing is higher than
the housing, disassemble the pump section to
verify that the O-ring seal, back-up ring, or O-
ring have not moved out of position.

Assembly (Cont’d) 1
Figure 20-50-23
1
1
S7511
Install the four assembly bolts (Item 1) [Figure 20-50-25].

S7529
Evenly tighten the bolts to a final torque of 52 - 58 N•m
(38 - 43 ft-lb).
Align the marks made during disassembly on the
separating plate and gear housing. Install the separating Rotate the input shaft periodically while tightening the

plate (Item 1) [Figure 20-50-23]. bolts to make sure the pump is assembled correctly.
Repeat step [Figure 20-50-16 on Page 9] through step Using a locking plier, rotate the pump shaft to be sure
[Figure 20-50-20 on Page 10] to assemble pump section there is no binding.
2.
NOTE: Use care not to damage the pump shaft.
Figure 20-50-24
S7512
Align the marks made during disassembly on the end cap

and gear housing. Install the end cap (Item 1) [Figure
20-50-24].


MANIFOLD ASSEMBLY / ACCUMULATOR Figure 20-60-1
Description
The manifold body contains a system bypass solenoid

valve, a console (joystick) lockout solenoid valve, a
pressure reducing valve and a safety relief valve.
The body is connected to the accumulator.
The manifold supplies 3,0 MPa (30 bar) (435 psi) to the 1
joysticks to activate the control valve spools.
The accumulator provides short term reserve pressure

for joystick function with the engine off and the key in the
ON position. S6728

Remove the accumulator (Item 1) [Figure 20-60-1] from
Lower the boom / bucket and blade to the ground. the manifold.
Installation: Tighten the accumulator and O-ring to 29 -

WARNING

Figure 20-60-2

physician familiar with this injury is not received 1
immediately.
W-2145-0290
IMPORTANT
When repairing hydrostatic and hydraulic systems, S6729
tubelines and ports to keep dirt out. Dirt can quickly Remove the O-ring (Item 1) [Figure 20-60-2] from the
damage the system. accumulator.
I-2003-0888
From the operator's seat, drain the residual pressure

from the accumulator by stroking a function with the
engine off and the key in the run position.
Open the tailgate.
Remove the rear counterweight. (See Rear

Counterweight Removal And Installation on Page 40-
200-1.)
NOTE: All counterweights are removed for photo

clarity!

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-5
Figure 20-60-3
1
S9748
Mark and remove the hoses (Item 1) [Figure 20-60-5].

S9750
Figure 20-60-6
Mark and disconnect the wire harnesses (Item 1) [Figure

20-60-3] from the coils.

Figure 20-60-4
1
1 S9747
Mark and remove the tubeline (Item 1) [Figure 20-60-6].
S9749 Figure 20-60-7
Mark and remove the hose (Item 1) [Figure 20-60-4].
S9746
Mark and remove the hoses (Item 1) [Figure 20-60-7].

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D)
Figure 20-60-8
S9745

Figure 20-60-9
1
1
S6736

undercarriage.
Remove the manifold.

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D)
1. Block 17. O-ring + Back-up Ring

2. Valve 18. O-ring
3. Valve 19. O-ring + Back-up Ring
4. Valve 20. O-ring + Back-up Ring
5. Accumulator 21. O-ring
6. O-ring
7. Valve
8. Valve
9. Plug
10. Plug 4 11 8 8 8
11
11. Nut
12. O-ring
13. Solenoid
14. O-ring
15. O-ring
16. O-ring + Back-up Ring
12

13
14 12
13
7
14
15
3
16
18
17
19
6
20 21 2
5 9 1 10 10
S8223

Disassembly
Figure 20-60-10 3
2 1
1 1
1 1
S7505
1 Remove the O-ring (Item 1) and the back-up ring (Item 2)

S9744 [Figure 20-60-12] from the main relief valve.

Mark the locations and orientation of the nine fittings. main relief valve.

Remove the nine fittings (Item 1) [Figure 20-60-10] from Figure 20-60-13
the manifold.
Figure 20-60-11
1
S6793
S6791 Remove the protective cover (Item 1) [Figure 20-60-13]

from the pressure reducing valve.
Remove the main relief valve (Item 1) [Figure 20-60-11]

from the manifold.

Figure 20-60-14 1
S6794
Remove the plastic nut (Item 1) from the console

S6792 (joystick) lockout solenoid (Item 2) [Figure 20-60-16].
Figure 20-60-17
Remove the pressure reducing valve (Item 1) [Figure 20-
60-14] from the manifold.

Figure 20-60-15
3
1 1
S6975
2 2
Remove the coil (Item 1) [Figure 20-60-17] from the

S7506 solenoid stem.
Remove the two O-rings (Item 1) and the two back-up

rings (Item 2) [Figure 20-60-15] from the pressure
reducing valve.

pressure reducing valve.

Figure 20-60-18
S7509
Remove the solenoid stem (Item 1) [Figure 20-60-20].

S7504
Figure 20-60-21

coil.

Figure 20-60-19 1
1
1
2
S7502
Remove the two O-rings (Item 1) and the back-up ring

(Item 2) [Figure 20-60-21] from the solenoid stem.
S6796

solenoid stem.

Figure 20-60-22
1
1
S7504

coil.
S6797
Figure 20-60-25
Remove the plastic nut (Item 1) from the system bypass
solenoid (Item 2) [Figure 20-60-22].

Figure 20-60-23
1
S6799

S6798
solenoid stem.
Remove the coil (Item 1) [Figure 20-60-23] from the

solenoid stem.

Figure 20-60-26
1
1
S7499

manifold.
S7498
Figure 20-60-29

Figure 20-60-27
1
1
1 1
S7501
2 2 2
S7503 Remove the O-ring (Item 1) [Figure 20-60-29] from the

plug.
Remove the three O-rings (Item 1) and the four back-up

rings (Item 2) [Figure 20-60-27] from the solenoid stem.

Figure 20-60-30
1 1
1
3
1 2
S7507
Remove the plug (Item 1), spring (Item 2) and the ball
S6800
(Item 3) [Figure 20-60-32] from the valves.
Figure 20-60-33
Remove the three valves (Item 1) [Figure 20-60-30] from
the manifold.

Figure 20-60-31 1
S7508
2 Remove the O-ring (Item 1) and the back-up ring (Item 2)

S7500 [Figure 20-60-33] from the plugs.
Remove the two O-rings (Item 1) and the back-up ring

(Item 2) [Figure 20-60-31] from the valves.

Assembly
Inspect all parts for wear or damage. Replace any worn 1

or damaged parts.
Always install new back-up rings and O-rings. Lubricate

all back-up rings and O-rings with clean hydraulic fluid
before installation.
Figure 20-60-34
2
S7500
1
Install the two O-rings (Item 1) and the back-up ring (Item
2) [Figure 20-60-36] on the valves.
Figure 20-60-37

2
S7508
1
Install the O-ring (Item 1) and the back-up ring (Item 2)
[Figure 20-60-34] on the plugs.
Figure 20-60-35
S6800
Install the three valves (Item 1) [Figure 20-60-37].
Tighten the valves to 60 N•m (44 ft-lb) torque.

1
3
2
S7507
Install the ball (Item 1), spring (Item 2) and plug (Item 3)
[Figure 20-60-35] in the valves.

Assembly (Cont’d)
Figure 20-60-38
1
1
1
1 2 2 2
S7503
Install the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-60-40] on the solenoid stem.
S7501
Figure 20-60-41
Install the O-ring on the plug (Item 1) [Figure 20-60-38].

Figure 20-60-39
S7498
S7499 Install the solenoid stem (Item 1) [Figure 20-60-41].
Tighten the solenoid stem to 30 N•m (22 ft-lb) torque.

Install the plug (Item 1) [Figure 20-60-39] on the side of
the manifold.

Assembly (Cont’d)
Figure 20-60-42
S6798
Install the coil (Item 1) [Figure 20-60-44] on the solenoid

stem.
S6799
Figure 20-60-45
solenoid stem.

1
Figure 20-60-43
2
S6797
Install the plastic nut (Item 1) on the system bypass

S7504 solenoid (Item 2) [Figure 20-60-45].
Tighten the nut to 6 N•m (53.1 in-lb) torque.

Install the O-ring (Item 1) [Figure 20-60-43] on the coil.
NOTE: Overtightening the nut (Item 1) [Figure 20-60-
45] may cause solenoid or coil failure.

Assembly (Cont’d)
Figure 20-60-46
1
1
1
S6796
2
S7502 solenoid stem.
Figure 20-60-49
Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-60-46] on the solenoid stem.

Figure 20-60-47
1
S7504
Install the O-ring (Item 1) [Figure 20-60-49] on the coil.

S7509
Install the solenoid stem (Item 1) [Figure 20-60-47].
Tighten the solenoid stem to 50 N•m (37 ft-lb) torque.

Assembly (Cont’d)
Figure 20-60-50 1
1 1
2 2
S7506
Install the O-rings (Item 1) and back-up rings (Item 2)

S6975 [Figure 20-60-52] on the pressure reducing valve.
Figure 20-60-53
Install the coil (Item 1) [Figure 20-60-50] on the solenoid
stem.

Figure 20-60-51
1
S6792
Install the pressure reducing valve (Item 1) [Figure 20-

S6794 60-53] on the manifold.
Tighten the valve to 25 - 30 N•m (18.4 - 22.1 ft-lb) torque.

Install the plastic nut (Item 1) on the console (joystick)
lockout solenoid (Item 2) [Figure 20-60-51].
Tighten the nut to 6 N•m (53.1 in-lb) torque.


Assembly (Cont’d)
Figure 20-60-54
1 1
S6791
Install the main relief valve (Item 1) [Figure 20-60-56] on

S6793 the manifold.
Tighten the valve to 60 N•m (44 ft-lb) torque.

Put the protective cover (Item 1) [Figure 20-60-54] over
the pressure reducing valve.

Figure 20-60-55
3
2 1
S7505
Install the O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-60-55] on the main relief valve.
Install the O-ring (Item 3) [Figure 20-60-55] on the main

relief valve.

TRAVEL MOTOR Figure 20-70-2
Description
The travel motor is a hydraulic motor which receives

hydraulic fluid from the hydraulic pump through the
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 two-speed 2
section. 1
The traditional bench mark for the drift is less than 3,0 m
(10 ft) of “drift” in 30,5 m (100 ft) of travel.

1
P-59087
Remove the track. (See Track Removal And Installation
on Page 30-20-4.)
Remove the hoses (Item 1) [Figure 20-70-2] from the
travel motor.
IMPORTANT Remove the travel motor mounting bolts (Item 2) [Figure

20-70-2].

When repairing hydrostatic and hydraulic systems, Installation: Tighten the bolts to 40 - 50 N•m (29 - 37 ft-
clean the work area before disassembly and keep all lb) torque.
tubelines and ports to keep dirt out. Dirt can quickly Remove the travel motor.
damage the system.
I-2003-0888 The drive sprocket can be removed without removing the
travel motor.
Figure 20-70-1
If removing the sprocket from a travel motor that has
been removed from the track frame, clamp the motor in a
1 vise.
Figure 20-70-3
1
2
1
1
S7943

track frame cover.
P-59088
lb) torque.
Remove the sprocket bolts (Item 1) and the sprocket
Remove the cover. (Item 2) [Figure 20-70-3].
Mark the hoses for correct installation. Installation: Tighten the bolts to 65 - 75 N•m (48 - 55 ft-
lb) torque.

TRAVEL MOTOR (CONT’D)
1. Housing 15. Plug 27. Washer 38. Plumbing Kit 49. Pin
2. Cover 16. Carrier 28. Spring 39. Bolt 50. Bearing
3. Gear 17. Gear 29. Piston 40. Washer 51. Plug
4. Gear 18. Gear 30. Ball 41. Distributor 52. O-ring
5. Ring 19. Pin 31. Swash plate 42. Cover 53. Fitting
6. Ring 20. Washer 32. Pin 43. Seal 54. Spring
7. Ring 21. Washer 33. Valve kit Assembly 44. Ring 55. O-ring
8. Ring 23. Ring 34. O-ring 45. Bearing 56. Piston
9. Ring 24. Roller 35. Washer 46. Ring
10. O-ring 25. O-ring 36. Spring 47. Shaft
11. Seal 26. Hub 37. Plug 48. O-ring
12. Bearing
13. Bearing 33 39 40 42 52 53 55 47
14. Shim Kit
41 38 31 30
37 34 36 35
46 45 44 43

51 52 54 56 49 25 32 50
11 8 13 7
48 44
29 28
16 19 20 24
27 26
18 21 22
10 2 9 15
3 12 6
17 23 4
14 5
S8596

TRAVEL MOTOR (CONT’D) Figure 20-70-5
Disassembly
IMPORTANT
damage the system.
I-2003-0888
P-62502
Clean the outside of the travel motor before disassembly.
Drain the lubricant from the travel motor. Figure 20-70-6
Figure 20-70-4
2
1

1
P-62503
P-62500
To remove the cover, lift the cover up using screwdrivers
in the upper groove [Figure 20-70-5] or install two
Remove the drain plugs (Item 1) and snap ring (Item 2) threaded pins in the drain holes and lift the cover off
[Figure 20-70-4] securing the reduction gear cover. [Figure 20-70-6].
Drain the excess oil into a container.

Disassembly (Cont’d) 1
2
Figure 20-70-7
3
P-62506
Remove the retaining rings (Item 1), anti-rotation washer

1
P-62504 (Item 2), planetary gears (Item 3), needle bearings (Item
4) and thrust washer (Item 5) [Figure 20-70-9] from the
first stage planetary carrier assembly.
cover. Figure 20-70-10

Figure 20-70-8
1
1
2
3
P-62507
P-62505
Remove the retaining ring (Item 1) from the second
reduction sun gear (Item 2) [Figure 20-70-10] and push
Remove the retaining ring (Item 1), shims (Item 2) and the gear down to remove from planetary carrier.
sun gear (Item 3) [Figure 20-70-8].
Remove the first stage planetary carrier (Item 4) [Figure

20-70-8] using your hands.

1
Figure 20-70-11
P-62510
Remove the retaining ring (Item 1) [Figure 20-70-13]

P-62508 from the hub to free the two bearings, ring gear and
motor.
Remove the second stage planetary carrier (Item 1) Figure 20-70-14

[Figure 20-70-11] using your hands.

Figure 20-70-12
1
1
4 2
P-62511
P-62509 Remove the hub (Item 1) [Figure 20-70-14] from the ring
gear.
Remove the retaining rings (Item 1), anti-rotation washer

(Item 2), planetary gears (Item 3), needle bearings (Item
4) and thrust washer (Item 5) [Figure 20-70-12] from the
first stage planetary carrier assembly.

Figure 20-70-15
3
1
4
EM9352
Remove the lapped bearing / front seal (Item 1) [Figure

P-62512 20-70-17].
NOTE: Be careful not to damage the bottom

Remove the O-ring (Item 1) from the ring gear (Item 2) polished / lapped surface of the bearing
and the retaining ring (Item 3) securing the bearing (Item [Figure 20-70-17].

4) [Figure 20-70-15].
NOTE: A bearing puller and supporting cap, as
Figure 20-70-16 shown, will be required for bearing removal
[Figure 20-70-17]. Be careful not to damage
the bottom polished / lapped surface of the
1 bearing.
Figure 20-70-18
P-62513
Remove the ball bearing (Item 1) [Figure 20-70-16] by

pushing from underneath.
P-62515
Remove the front seal ring (Item 1) [Figure 20-70-18].

1
2
Figure 20-70-19
3
3
1
2
1
4
3
1
2
P-62518
Remove the six screws and washers (Item 1) [Figure 20-

P-62516 70-21].
Remove the cover (Item 2) [Figure 20-70-21].

Remove the plugs (Item 1), springs (Item 2), washers
(Item 3) and counterbalance valve (Item 4) [Figure 20- NOTE: Removal of pin (Item 3) [Figure 20-70-21] is

70-19]. optional.
Figure 20-70-20 Figure 20-70-22
4 3 2
1
4 3
1
5
2
5
P-62517 P-62519
Remove the plug (Item 1), springs (Item 2), piston valve Remove large O-ring (Item 1), small O-rings (Item 2), pin
(Item 3), and plug (Item 4) [Figure 20-70-20]. (Item 3), and needle bearing (Item 4) [Figure 20-70-22]
from the cover.
Remove the valves (Item 5) [Figure 20-70-20] from the
motor cover. NOTE: Removal of pin (Item 3) [Figure 20-70-22] is
optional.

Figure 20-70-23 1
B-14821
Remove the piston assembly (Item 1) [Figure 20-70-25].

P-62520
NOTE: The rotating group components are not
available separately. Service as a complete
Remove the valve plate (Item 1) [Figure 20-70-23]. assembly only.

Figure 20-70-24 Figure 20-70-26
3 1
1
4 2
2 5
B-14820 P-62522
Remove the rotating block (Item 1) and the three dowel Remove the swash plate (Item 1) [Figure 20-70-26].
pins (Item 2) [Figure 20-70-24].
Remove the two balls (Item 2), pistons (Item 3), springs
(Item 4), and washers (Item 5) [Figure 20-70-26].

TRAVEL MOTOR (CONT’D)
Figure 20-70-27
2 1
P-62523
Remove the retaining ring (Item 1) and bearing / drive

shaft assembly (Item 2) [Figure 20-70-27].

Remove the oil seal (Item 3) [Figure 20-70-27].
Figure 20-70-28
2
1
3
P-62524
Remove the retaining ring (Item 1), ball bearing (Item 2)

and the second retaining ring (Item 3) [Figure 20-70-28].

Assembly
2
Inspect all parts and replace any that are damaged. If
any of the planetary gears (first or second) are damaged,
replace the damaged planetary stage assembly (first or 1
second) complete with the sun gear that the damaged
gear is from. One damaged gear can cause microscopic
fatigue cracks in mating gear teeth and cause premature
failure after servicing. Apply oil to all O-rings and light
grease to the ball and roller bearings before installation.
Figure 20-70-29
P-62527
3
Install the bearing / drive shaft assembly (Item 1) [Figure

2 20-70-31].
1
Install the retaining ring (Item 2) [Figure 20-70-31].
Figure 20-70-32

4 5
3 1
P-62525
2
Install the retaining ring (Item 1) [Figure 20-70-29] on the
drive shaft.
Install the ball bearing (Item 2) and the retaining ring

(Item 3) [Figure 20-70-29].
Figure 20-70-30 P-62528
1
Install the two balls (Item 1), washers (Item 2), springs
(Item 3) and pistons (Item 4) [Figure 20-70-32].
Install the swash plate (Item 5) [Figure 20-70-32].
P-62526
Install the oil seal (Item 1) [Figure 20-70-30] in the hub.

Figure 20-70-33
1 1
P-62530
Install the valve plate (Item 1) [Figure 20-70-35].

B-14832
Figure 20-70-36
Install the dowel pins (Item 1) [Figure 20-70-33] in the 1 4 3

rotating block.

2
Apply oil to the piston assembly (Item 2) [Figure 20-70-
33] and install the piston assembly in the rotating block.
Figure 20-70-34
P-62531
2
Install the needle bearing (Item 1) [Figure 20-70-36] in

the cover so the bearing edge extends from the face of
1 the cover 2,5 - 2,8 mm (0.98 - 0.110 in).
Install the large O-ring (Item 2), small O-rings (Item 3)

B-14833 and pin (Item 4) [Figure 20-70-36] in the cover.
Tip the motor housing on its side. Make sure the thick
side of the swash plate (Item 1) [Figure 20-70-34] is
towards the bottom.
Install the rotating block assembly (Item 2) [Figure 20-

70-34] in the hub.
NOTE: The rotating group components are not

available separately. Service as a complete
assembly only.

Assembly (Cont’d)
2
Figure 20-70-37
3
4
1
2
1
4
3
P-62534
Install the counterbalance valve (Item 1), washers (Item

P-62532 2), springs (Item 3) and plugs (Item 4) [Figure 20-70-39].
Figure 20-70-40

Install the six screws and washers (Item 2) [Figure 20-
70-37].
Tighten the screws in a crisscross manner to 40 - 50 N•m

Figure 20-70-38
1 2
4
5
3
5
P-62533
EM9350
Install the plug (Item 1), piston valve (Item 2), springs
(Item 3) and plug (Item 4) [Figure 20-70-38].
Install the valves (Item 5) [Figure 20-70-38] in the motor

cover.

Assembly (Cont’d)
Figure 20-70-41 1
P-62537
Using the bearing installation tool [Figure 20-70-40],

P-62535 install the second bearing (Item 1) [Figure 20-70-43]
keeping the lapped face up. Use extreme care not to
damage the lapped face of the bearing.
Install the ball bearing (Item 1) [Figure 20-70-41] using
the bearing installation tool [Figure 20-70-40]. Figure 20-70-44

Figure 20-70-42
2
2
1
1
P-62550
P-62536
Install the O-ring (Item 1) [Figure 20-70-44] on the seal
ring (Item 2) [Figure 20-70-44].
Install the retaining ring (Item 1) and O-ring (Item 2)
[Figure 20-70-42]. NOTE: Inspect the seal ring for burrs before
installing the O-ring. Install the seal ring
making sure it is not twisted. To remove any
twists, gently pull a section of the O-ring and
let it snap back.
The O-ring, seal ring and motor assembly must be clean

and free of any dust, oil film or foreign matter.

Assembly (Cont’d)
Figure 20-70-45
B-14594
Use firm even pressure on the installation tool

(MEL1468) to pop the O-ring into the motor housing
B-14594
[Figure 20-70-47].
Install the seal seating tool (MEL1468) on the seal ring Figure 20-70-48
[Figure 20-70-45].

Figure 20-70-46
EM9351
After the seal ring is installed, check the stand out height
P-62555
[Figure 20-70-48] in four places, 90° apart.
The seal ring assembly [Figure 20-70-46] must be The stand out height is 1,00 mm (0.04 in).
lubricated with alcohol, so the O-ring will slip past the
housing retaining ring and seal uniform in the motor NOTE: If the seal ring does not meet the height
housing radius. specifications inspect the torque ring for
twists or obvious bulges.
The O-ring [Figure 20-70-46] on the seal ring assembly
must be lubricated with alcohol. Apply a light film of oil to the seal ring and lapped face of
the bearing.
This will allow the O-ring to slide on the motor housing
sealing surface without twisting. NOTE: Do not get any oil on the O-ring.
Dip the O-ring [Figure 20-70-46] and seal ring assembly

in a pan of alcohol.
Shake off the excess alcohol and install the seal ring
assembly on the motor [Figure 20-70-46].

4
Figure 20-70-49
3
P-62541
Install the thrust washers (Item 1), planetary gears (Item

P-62539 2), needle bearing (Item 3) anti-rotation washers (Item 4),
and external snap rings (Item 5) [Figure 20-70-51].
Press the reduction unit and motor assembly into the NOTE: Install the snap rings so the opening of the
seat of the bearings [Figure 20-70-49]. snap ring is towards the outside.

Figure 20-70-50 Figure 20-70-52
1
1
P-62540 P-62542
Install the external snap ring (Item 1) [Figure 20-70-50] Install the planetary assembly (Item 1) [Figure 20-70-
in the motor reduction unit. 52].

Assembly (Cont’d)
Figure 20-70-53 1
P-62545
1
Install the outer planetary assembly (Item 1) [Figure 20-
P-62543 70-55].
Figure 20-70-56
Install the sun gear (Item 1) into the planetary carrier and
lock with the retaining ring (Item 2) [Figure 20-70-53]. 3

2
1
Figure 20-70-54
5
4
P-62505
Install the sun gear (Item 1), shims (theoretical shimming

P-62544 0,5 mm [0.02 in]) (Item 2), and retaining ring (Item 3)
[Figure 20-70-56].
Install the thrust washers (Item 1), planetary gears (Item

2), needle bearings (Item 3), anti-rotation washers (Item
4), and external snap rings (Item 5) [Figure 20-70-54].
NOTE: Install the snap rings so the opening of the

snap ring is towards the outside.

2
Figure 20-70-57
2
P-62500
Install the snap ring (Item 1) [Figure 20-70-59] securing

2
P-62504 the reduction gear cover.
Figure 20-70-60
Install the O-ring (Item 1) [Figure 20-70-57] on the cover.

Figure 20-70-58 1
P-62605
P-62548 Add 0,4 L (0.42 qt) of gear lube 90W to the top plug hole
(Item 1) until the gear lube is at the bottom of the plug
hole (Item 2) [Figure 20-70-60].
Install the cover (Item 1) [Figure 20-70-58] in the
housing. Install and tighten the two plugs (Item 2) [Figure 20-70-
59].


SWIVEL JOINT (S/N 133P14286 & ABOVE,
B4K911001 & ABOVE AND B4PD11001 & ABOVE)
Description
WARNING
The swivel joint is located under the floor panels and Hydraulic fluid escaping under pressure can have
mounted to the upperstructure or undercarriage. The sufficient force to enter a person’s body by
swivel joint directs hydraulic fluid to the undercarriage penetrating the skin. This can cause serious injury
components while allowing the upperstructure to rotate. and possible death if proper medical treatment by a
Removal And Installation immediately.
W-2145-0290
Expand the track frame fully.
Mark all hoses and tubelines for ease of assembly.
Figure 20-80-1
Figure 20-80-2

1
S8253
S8258
Place blocks under the excavator tracks and blade

[Figure 20-80-1]. Remove the two tubelines (Item 1) [Figure 20-80-2] from
the top of the swivel joint.
Lower the boom / bucket to the ground.
Remove the muffler. (See Removal And Installation on

Page 60-20-1.)
Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)

Replacing Hydraulic Fluid on Page 10-120-3.)

SWIVEL JOINT (S/N 133P14286 & ABOVE, Figure 20-80-5
(CONT’D)
Figure 20-80-3
1
1
1 1 S8261
Remove the tubeline (Item 1) [Figure 20-80-5] from the

side of the swivel joint.
S8259 Figure 20-80-6
Remove the three tubelines (Item 1) [Figure 20-80-3]

from the top of the swivel joint.
Figure 20-80-4
1
1
1
S8262
Remove the two tubelines (Item 1) [Figure 20-80-6] from

the side of the swivel joint.
S8260 Remove the track frame expansion cylinder. (See Block

Removal And Installation on Page 20-150-1.)

(CONT’D)
Figure 20-80-7
1
2
1
2
2
S8263
Remove the six hoses (Item 1) [Figure 20-80-7] from the

left side of the swivel joint.

right side of the swivel joint.
NOTE: Support the swivel joint on the bottom side of

the excavator to prevent the swivel joint from
falling when the three nuts are being
removed.
Figure 20-80-8
1 1
NA9179
While supporting the swivel joint, remove the nuts (Item

1) [Figure 20-80-8].
Remove the swivel joint Item 2) [Figure 20-80-8] out

through the bottom of the excavator.

SWIVEL JOINT (S/N 133P14286 & ABOVE, B4K911001 & ABOVE AND B4PD11001 & ABOVE) (CONT’D)
1. Plug
2. Snap Ring
3. Washer
4. Housing
5. Seal
6. Seal
7. Back-up Ring
8. Stop
9. Spool
9
5

7
8 6
6
7
3
7
6
6
7
4
6
6
3
5
2
1
NA12011S

SWIVEL JOINT (S/N A33P14286 & ABOVE AND Figure 20-80-11
B4K911001 & ABOVE) (CONT’D)
Disassembly
Figure 20-80-9
1
P-59180
Tap the end of the rotor (Item 1) [Figure 20-80-11] with a

1 rubber mallet to drive the rotor out of the housing.
P-59178
Figure 20-80-12
Remove the snap ring (Item 1) [Figure 20-80-9] from the

1

bottom of the swivel joint.
Figure 20-80-10
P-59181
1
Remove the outer and inner seals (Item 1) [Figure 20-
80-12].
P-59179
Remove the nylon washer (Item 1) [Figure 20-80-10].

SWIVEL JOINT (S/N A33P14286 & ABOVE AND
Figure 20-80-13
1 1 1 1
1
P-59184
Remove the seals, back-up seals and O-rings (Item 1)

[Figure 20-80-13].
Figure 20-80-14
2
P-59184
Remove the outer and inner seals (Item 1). Remove the
nylon washer (Item 2) [Figure 20-80-14].

SWIVEL JOINT (CONT’D) Figure 20-80-17
Assembly
1 1 1 1
1
Inspect the rotor and housing for scratches or wear that

could cause internal leakage. Always install new seals
and back-up seals. Lubricate all seals and back-up seals
with clean hydraulic fluid before installation.
Figure 20-80-15
P-62345
P-59184
Install the O-rings under the seals (Item 1) [Figure 20-

80-17].
Heat the seals in hydraulic fluid for 3 minutes at 54°C

(130°F).

Install the seals and back-up seals (Item 1) [Figure 20-
1 80-17].
P-59184
NOTE: The seal and O-ring are serviceable as one
part number.
Install the nylon washer (Item 1) [Figure 20-80-15].
Figure 20-80-18
Figure 20-80-16
1
1
P-62346 P-59181
P-62345 P-59184

Heat the seals in hydraulic fluid for 3 minutes at 54°C (130°F).
(130°F).
Install the inner and outer seals (Item 1) [Figure 20-80-
Install the inner and outer seals (Item 1) [Figure 20-80- 18].
16].
NOTE: The inner and outer seal are serviceable as
NOTE: The inner and outer seal are serviceable as one part number.
one part number.

SWIVEL JOINT (S/N A33P14286 & ABOVE AND Figure 20-80-21
Assembly (Cont’d)
Figure 20-80-19
P-59179
P-59185 Figure 20-80-22
NOTE: A ring compressor (Item 1) [Figure 20-80-19]

may be used to install the seals into the seal
grove. Compress the seals for 3 minutes.
Figure 20-80-20
1
P-59178
Install the snap ring (Item 1) [Figure 20-80-22] from the

1
P-59180
Apply hydraulic fluid to the rotor. Install the rotor (Item 1)

[Figure 20-80-20] in the housing.

SWIVEL JOINT (S/N A33P13634 - A33P14285)
Description WARNING
The swivel joint is located under the floor panels and
mounted to the upperstructure or undercarriage. The Hydraulic fluid escaping under pressure can have
swivel joint directs hydraulic fluid to the undercarriage sufficient force to enter a person’s body by
components while allowing the upperstructure to rotate. penetrating the skin. This can cause serious injury
Removal And Installation physician familiar with this injury is not received
immediately.
Expand the track frame fully. W-2145-0290
Figure 20-81-1 Mark all hoses and tubelines for ease of assembly.
Figure 20-81-2

1
S8253
S8258
[Figure 20-81-1].
Lower the boom / bucket to the ground. the top of the swivel joint.

Page 60-20-1.)

40-120-1.)


SWIVEL JOINT (S/N A33P13634 - A33P14285) Figure 20-81-5
(CONT’D)
Figure 20-81-3
1
1
1 1
S8261

S8259
Figure 20-81-6

Figure 20-81-4
1 1
1
S8262

S8260
Remove the track frame expansion cylinder. (See Block

(CONT’D)
Figure 20-81-7
1
2
1
2
2
S8263



falling when the three nuts are being
removed.
Figure 20-81-8
1
1
NA9179
While supporting the swivel joint, remove th nuts (Item 1)

[Figure 20-81-8].
Slide the swivel joint out through the bottom of the

excavator.

SWIVEL JOINT (S/N A33P13634 - A33P14285) (CONT’D)
1. Plug
2. Snap Ring
3. Washer
4. Housing
5. Seal
6. Seal
7. Back-up Ring
8. Stop
9. Spool
9
5
8

6
6
3
6
6
7
4
6
6
3
5
2
1
NA8994S

(CONT’D)
Disassembly
Figure 20-81-9
1
P-59180

1 rubber mallet to drive the rotor out of the housing.
P-59178
Figure 20-81-12
Remove the snap ring (Item 1) [Figure 20-81-9] from the

1

Figure 20-81-10
P-59181
1
81-12].
P-59179

(CONT’D)
Figure 20-81-13
1 1 1 1
1
P-59184
Remove the seals, back-up seals and O-rings (Item 1)

[Figure 20-81-13].
Figure 20-81-14
2
P-59184

(CONT’D)
Assembly 1 1 1 1
1

Figure 20-81-15
P-62345
P-59184

81-17].

(130°F).

81-17].
1
P-59184 NOTE: The seal and O-ring are serviceable as one
part number.
Install the nylon washer (Item 1) [Figure 20-81-15]. Figure 20-81-18
Figure 20-81-16
1
P-62346 P-59181
P-62345 P-59184
(130°F).
(130°F). Install the inner and outer seals (Item 1) [Figure 20-81-
18].
16]. NOTE: The inner and outer seal are serviceable as
one part number.
one part number.

(CONT’D)
Assembly (Cont’d)
Figure 20-81-19
P-59179
P-59185 Figure 20-81-22

Figure 20-81-20
1
P-59178
Remove the snap ring (Item 1) [Figure 20-81-22] from

the bottom of the swivel joint.
1
P-59180


Description WARNING
mounted to the upperstructure. The swivel joint directs Hydraulic fluid escaping under pressure can have
hydraulic fluid to the undercarriage components while sufficient force to enter a person’s body by
allowing the upperstructure to rotate. penetrating the skin. This can cause serious injury
immediately.
Figure 20-82-2

1
S8253
S8258
[Figure 20-82-1].

Page 60-20-1.)

40-120-1.)


(CONT’D)
Figure 20-82-3
1
1
1 1
S8261

S8259
Figure 20-82-6

Figure 20-82-4
1 1
1
S8262

S8260

(CONT’D)
Figure 20-82-7
1
1
2
1
2
2
S8265
Remove the bolt and nut (Item 1) [Figure 20-82-9].
S8263 Figure 20-82-10



falling when the three nuts are being 1
removed.
Figure 20-82-8
S8266
1 Remove the bolt and nut (Item 1) [Figure 20-82-10].

excavator.
S8264

1. Plug
2. Snap Ring
3. Washer
4. Housing
5. Seal
6. Back-up Ring
7. Seal
8. Spool
5
9. Washer 10
10. Stop
7
9
6
7
8
6
7

6
6
7
6
3 6
7
6
6
7
6
4 6
7
6
6
3 7
6
2 7
6
1 5
NA8006S

(CONT’D)
Disassembly
Figure 20-82-11
1
1
1
P-59178

S6083
Figure 20-82-14
Mark fitting orientation. Remove the fittings (Item 1)

[Figure 20-82-11].
Figure 20-82-12
1 1
2
1
1
P-59179
S6084
Remove the three bolts (Item 1). Remove the mount

(Item 2) [Figure 20-82-12].

SWIVEL JOINT(S/N A33P12838 - A33P13633) Figure 20-82-17
(CONT’D)
Disassembly (Cont’d) 1 1 1 1
1
Figure 20-82-15
P-59184
1 Remove the seals, back-up seals and O-rings (Item 1)

[Figure 20-82-17].
P-59180
Figure 20-82-18

1

rubber mallet to drive the rotor out of the housing.
Figure 20-82-16
2
P-59184
P-59181

82-16].

(CONT’D))
Assembly 1 1 1 1
1

Figure 20-82-19
P-62345
P-59184

82-21].

(130°F).

82-21].
1
part number.
Figure 20-82-20
1
P-62346 P-59181
P-62345 P-59184
(130°F).
22].
one part number.
one part number.

(CONT’D)
Assembly (Cont’d)
Figure 20-82-23
P-59179
P-59185 Figure 20-82-26

Figure 20-82-24
1
P-59178

1
P-59180


(CONT’D)
1
Figure 20-82-27
2
2
S6083
Install the fittings (Item 1) [Figure 20-82-28] and

orientate accordingly.
S6084
Install the mount (Item 1) [Figure 20-82-27] on the swivel

joint.
Apply Loctite® 242 to each bolt (Item 2) [Figure 20-82-

27].
Install the bolts (Item 2) [Figure 20-82-27]. Tighten the

bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.


Description WARNING
mounted to the upperstructure. The swivel joint directs Hydraulic fluid escaping under pressure can have
hydraulic fluid to the undercarriage components while sufficient force to enter a person’s body by
allowing the upperstructure to rotate. penetrating the skin. This can cause serious injury
immediately.
Figure 20-83-2

1
S8253
S8258
[Figure 20-83-1].

Page 60-20-1.)

40-120-1.)


(CONT’D)
Figure 20-83-3
1
1
1 1
S8261

S8259
Figure 20-83-6

Figure 20-83-4
1 1
1
S8262

S8260

(CONT’D)
Figure 20-83-7
1
1
2
1
2
2
S8265
S8263 Figure 20-83-10



falling when the three nuts are being 1
removed.
Figure 20-83-8
S8266
1 Remove the bolt and nut (Item 1) [Figure 20-83-10].

excavator.
S8264

1. Seal and O-ring

2. Back-up Seal
3. O-ring
4. Inner / Outer Seals
5. Washer 8
6. Snap Ring
7. Housing
8. Rotor
9. Plug
5
3

9
4
1
2
1
2
1
2
2
4
1
2
2
1
2
2
7 1
2
2
1
2
2
5 1
2
1
6 2

(CONT’D)
Disassembly
Figure 20-83-11
1
1
1
P-59178

S6083
Figure 20-83-14
Mark fitting orientation. Remove the fittings (Item 1)

[Figure 20-83-11].
Figure 20-83-12
1 1
2
1
1
P-59179
S6084
Remove the three bolts (Item 1). Remove the mount

(Item 2) [Figure 20-83-12].

(CONT’D)
Disassembly (Cont’d) 1 1 1 1
1
Figure 20-83-15
P-59184
1 Remove the seals, back-up seals and O-rings (Item 1)

[Figure 20-83-17].
P-59180
Figure 20-83-18

1

rubber mallet to drive the rotor out of the housing.
Figure 20-83-16
2
P-59184
P-59181

83-16].

(CONT’D)
Assembly 1 1 1 1
1

Figure 20-83-19
P-59184

83-21].

(130°F).

83-21].
1
part number.
Figure 20-83-20
1
P-62346 P-59181
P-62345 P-59184
(130°F).
22].
one part number.
one part number.

(CONT’D)
Assembly (Cont’d)
Figure 20-83-23
P-59179
P-59185 Figure 20-83-26

Figure 20-83-24
1
P-59178

1
P-59180


(CONT’D)
1
Figure 20-83-27
2
2
S6083
Install the fittings (Item 1) [Figure 20-83-28] and

orientate accordingly.
S6084
Install the mount (Item 1) [Figure 20-83-27] on the swivel

joint.
Apply Loctite® 242 to each bolt (Item 2) [Figure 20-83-

27].
Install the bolts (Item 2) [Figure 20-83-27]. Tighten the

bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.


SWING MOTOR Figure 20-90-2
Description
The slew motor is a hydraulic motor that receives

hydraulic fluid from the gear pump through the control
valve to swing the upperstructure left or right. The speed
that the slew motor rotates is related to the amount of
hydraulic fluid it receives.
IMPORTANT 1
S7541

clean the work area before disassembly and keep all Mark and remove the tubeline (Item 1) [Figure 20-90-2].
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-90-3
damage the system.
I-2003-0888

40-120-1.)

1
Figure 20-90-1
S7542
1 Remove the two fittings (Item 1) [Figure 20-90-3] from

the slew motor.
S7540

SWING MOTOR (CONT’D) Figure 20-90-6
Figure 20-90-4
1
S7544
Cut the tie-strap (Item 1) [Figure 20-90-6] from the two

S7559 hoses.
Push the hoses aside.

Mark and remove the tubeline (Item 1) [Figure 20-90-4]
from the swivel joint. Figure 20-90-7

Figure 20-90-5
S7560
S7543
Cut the tie-strap (Item 1) [Figure 20-90-5].

Figure 20-90-8
1
1
S7563

Figure 20-90-11
Cut the tie-strap (Item 1) [Figure 20-90-8] from the two
hoses.

Figure 20-90-9
1
1
S7564
Mark and remove the tubeline (Item 1) [Figure 20-90-

S7562 11].

Figure 20-90-12
1
1
S7568
Remove the clamp from the tubeline (Item 1) [Figure 20-

S7565 90-14].
Figure 20-90-15
Mark and remove the hose (Item 1) [Figure 20-90-12]
from the control valve.

Figure 20-90-13
S7570
1 Mark and remove the tubeline (Item 1) [Figure 20-90-15]

Mark and remove the hose (Item 1) [Figure 20-90-13]

from the control valve.

Figure 20-90-16
1
1
S7569
Mark and remove the tubeline (Item 1) [Figure 20-90-

S7567 18].
Figure 20-90-19
from the swivel joint.

Reposition the tubeline for easy access to the slew 1
motor.
Figure 20-90-17
1
S7545
Remove the three bolts (Item 1) [Figure 20-90-19] from

the slew motor.

S7571 lb) torque.

from the track expand valve.

SWING MOTOR (CONT’D)
Figure 20-90-20
S7546

the slew motor.

lb) torque.
Remove the slew motor from the excavator.

SWING MOTOR (CONT’D)
1. Bearing Housing 24. Steel Ball

2. Pinion Gear 25. Plug
3. Ball Bearing 26. O-ring
4. Ball Bearing 27. Plug 23 30 31 29
5. Plug 28. O-ring
6. Seal 29. Hexagon Bolt
7. Retaining ring 30. Name Plate
8. O-ring 31. Rivet
9. Shaft Face Seal 32. Plug
10. Wear Plate 33. O-ring
11. Valve Plate
12. O-ring 7 20 8 21 11 12 13 14 17 15
13. Valve
14. Balancing ring
15. Spring
16. Inner Seal
17. Pin
18. Outer Seal
19. Drive 24 26 25

20. Housing Motor
16 18 22 28 27
21. Valve Drive
22. O-ring
23. Valve Housing
22
5 32 33
19 9 10 22 8
2 3 1 6 4 8
S8448

Disassembly
Clean the outside of the slew motor before disassembly.
Mark the outside of the slew motor for ease of assembly.

1
1
Figure 20-90-21
1 1
S7686
Remove the balls (Item 1) [Figure 20-90-23].
Figure 20-90-24
S7684

Remove the plugs (Item 1) [Figure 20-90-21] from the
slew motor.
Figure 20-90-22
1
S7687

slew motor.
S7685

plugs.

Figure 20-90-25
1
S7690

S7688 plug.
Figure 20-90-28
plug.

2
Figure 20-90-26
1 1
1 1
S7691
1

S7689

slew motor.

1
Figure 20-90-29 2
2
1
1
2
2
3
S6421
Remove the springs (Item 1) and pins (Item 2) [Figure

S6419 20-90-31].
Figure 20-90-32
Remove the top of the motor (Item 2) [Figure 20-90-28]
by lifting straight up. If done carefully, the springs (Item

1), pins (Item 2) and balance ring assembly (Item 3)
[Figure 20-90-29] will remain on the valve for easy 1
removal.
Figure 20-90-30
S6422
Remove the balance ring (Item 1) [Figure 20-90-32].
S7692

Figure 20-90-33
2
1
S6425
Remove the drive (Item 1) [Figure 20-90-35].

S6423
Figure 20-90-36
Remove the inner seal (Item 1) and outer seal (Item 2)

[Figure 20-90-33].

1
Figure 20-90-34
S6426
Remove the valve plate (Item 1) [Figure 20-90-36].
S6424
Remove the valve (Item 1) [Figure 20-90-34].

Figure 20-90-37
1
1 2
S6429

P-59820
Remove the valve plate (Item 2) [Figure 20-90-39].
Remove the O-ring (Item 1) [Figure 20-90-37] from the Figure 20-90-40
valve plate.

Figure 20-90-38
1
S6430
S6428 Remove the seal (Item 1) [Figure 20-90-40] from the

valve plate.
Remove the Geroler® (Item 1) [Figure 20-90-38].
NOTE: Do not disassemble the Geroler®.

Figure 20-90-41
1
1
2
3
P-59827
Press the bearing (Item 1) [Figure 20-90-43] off of the

shaft.
S6431
Figure 20-90-44
Remove the drive (Item 1) and O-ring (Item 2) [Figure

20-90-41].

1
Remove the snap ring (Item 3) [Figure 20-90-41].
Figure 20-90-42
S6433
Remove the bearing (Item 1) [Figure 20-90-44] from the

housing.
Figure 20-90-45
S6432
1
Press the shaft out of the housing [Figure 20-90-42].
S6434
Remove the seal (Item 1) [Figure 20-90-45] from the

housing.

Assembly

or damaged parts.
1
Figure 20-90-46 2
S6435
1
Press the shaft (Item 1) [Figure 20-90-48] in the housing.
Apply assembly lube to the bearing and press the

bearing (Item 2) [Figure 20-90-48] in the housing.
Figure 20-90-49

3
S6434
2
Install the seal (Item 1) [Figure 20-90-46] in the housing. 1
Figure 20-90-47
S6431
1
Install the snap ring (Item 1) and O-ring (Item 2) [Figure

20-90-49].
Install the drive (Item 3) [Figure 20-90-49].
P-59830
Press the bearing (Item 1) [Figure 20-90-47] on the

shaft.

Assembly (Cont’d)
1
Figure 20-90-50
S6428
Install the Geroler® (Item 1) [Figure 20-90-52].

S6430
Figure 20-90-53
Install the seal (Item 1) [Figure 20-90-50] in the valve

1
plate.

Figure 20-90-51
2
1
P-59820
Install the O-ring (Item 1) [Figure 20-90-53] on the valve

plate.
S6429
Install the valve plate (Item 1) [Figure 20-90-51].

Motor Timing
The direction that the output shaft rotates is determined

by timing. Time the motor as follows:
Figure 20-90-54
S6425
Install the drive (Item 1) [Figure 20-90-56].
Figure 20-90-57

S6428
1
Locate the largest open pocket in the Geroler® (Item 1)
[Figure 20-90-54].
Figure 20-90-55
S6424
NOTE: Picture position has changed 180°.
Align one of the side openings (Item 1) [Figure 20-90-57]

in the valve with the valve plate slot that is over the
largest open Geroler® pocket.
Engage the valve with the valve drive by rotating it 15

S6426 clockwise until the spline teeth mesh.
NOTE: If the valve is turned clockwise the motor will

Install the valve plate and locate the open slot (Item 1) rotate in the opposite direction.
[Figure 20-90-55] that is over the largest open Geroler˝®
pocket.

Assembly (Cont’d)
Figure 20-90-58 2
1
2 1
S6423
Figure 20-90-61
S7693

3

Apply assembly lube to the springs, and install the 1
2
springs (Item 2) [Figure 20-90-58].
Figure 20-90-59
Balance Ring
1
B-13495A
Install the inner (Item 1) and outer (Item 2) [Figure 20-

1 90-60] and [Figure 20-90-61] face seals on the balance
ring as shown.
S7694
Install the pins (Item 1) [Figure 20-90-59].

Assembly (Cont’d)
Figure 20-90-62 1
1 2
S7697
Install the housing (Item 1) [Figure 20-90-64] on the

S7695 motor.
Remove the screwdriver (Item 2) [Figure 20-90-64].

Install the balance ring (Item 1) [Figure 20-90-62]. Make
sure the pins engage the pin notches (Item 3) [Figure Figure 20-90-65

20-90-61] in the balance ring.
Figure 20-90-63
1 1
S7691
S7696 Install the bolts (Item 1) [Figure 20-90-65]. Tighten the

bolts to 53 N•m (39 ft-lb) torque in a crisscross pattern.
Insert a small screw driver through the port in the Installation: Tighten bolts to 53 N•m (39 ft-lb) torque.
housing. Apply pressure to the side of the balance ring
assembly until the valve housing is in place [Figure 20-
90-63].

Assembly (Cont’d)
Figure 20-90-66
1
S7688
Install the O-ring (Item 1) [Figure 20-90-68] on the plug.

S7690
Figure 20-90-69
Install the O-ring (Item 1) [Figure 20-90-66] on the plug.

Figure 20-90-67
S7687
Install the plug (Item 1) [Figure 20-90-69].

S7689
Installation: Tighten to 10 N•m (88.50 in-lb) torque.
Install the plug (Item 1) [Figure 20-90-67].

Assembly (Cont’d)
Figure 20-90-70
1
1
S7684
Install the plugs (Item 1) [Figure 20-90-72].

S7686
Install the balls (Item 1) [Figure 20-90-70]. Clamp the motor in a vise.

Figure 20-90-71 Figure 20-90-73
S7685 S7977
Install the O-ring (Item 1) [Figure 20-90-71] on the plugs. Turn the shaft (Item 1) [Figure 20-90-73] in a clockwise
direction.
If the motor is correctly timed, there will be suction at the

top port (Item 2) [Figure 20-90-73].

CONTROL PATTERN SELECTOR VALVE Figure 20-100-1
Description
The control pattern selector valve changes the control

patterns from ISO to STD. 1
The control pattern selector valve is located under the

1
drivers seat, next to the fuel tank on the left side of the
excavator.
Removal And Installation 1
With the engine off, turn the start key to the ON position S8022
and move blade lever to relieve hydraulic pressure.
Mark and disconnect the eight hoses (Item 1) [Figure 20-

100-1].
IMPORTANT Figure 20-100-2

damage the system.
I-2003-0888
Remove the battery. (See Removal and Installation on

Page 50-20-3.)
Remove the fuel tank. (See Removal And Installation on

Page 40-130-1.)
1
S8021
WARNING Remove the two bolts (Item 1) [Figure 20-100-2].
Hydraulic fluid escaping under pressure can have Remove the control pattern selector valve from the
sufficient force to enter a person’s body by excavator.
immediately.
W-2145-0290

CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-4
Disassembly And Assembly
IMPORTANT
1
damage the system.
I-2003-0888
S7993
WARNING Remove the snap ring (Item 1) [Figure 20-100-4].
Figure 20-100-5

immediately.
W-2145-0290
1
Figure 20-100-3
S7992
1 Remove the wave washer (Item 1) [Figure 20-100-5].

1
1
1
S7994
Remove the eight fittings (Item 1) [Figure 20-100-3] from

the control pattern selector valve.
Installation: Tighten the fittings to 25 N•m (18 ft-lb)

torque.

CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-8
Disassembly And Assembly (Cont’d)
Figure 20-100-6
1 1 2
1
4
3
S7989
Remove the two O-rings (Item 1), snap ring (Item 2), and
S7991 pin (Item 3) [Figure 20-100-8] from the shaft.

Remove the axle (Item 1) [Figure 20-100-6]. the shaft.

Figure 20-100-7
S7990
Remove the two pins (Item 1) [Figure 20-100-7] from the

control pattern selector valve.


CONTROL LEVER (JOYSTICK) (RIGHT) (S/N Figure 20-110-1
A33S13155 & ABOVE, B4K911001 & ABOVE AND
B4PD11001 & ABOVE)
Description
The right control lever (joystick) operates using pilot 2

1
pressure to move the boom and / or bucket spools in the
control valve. The right control lever (joystick) is movable.
The right control lever (joystick) has a microswitch that
will lockout the hydraulic functions in the raised position
and enable the hydraulic functions in the down (locked)
position.
Testing
S8165
Check the pressure reducing valve for the correct
pressure. (See Testing And Adjusting on Page 20-32-1.)
At the bottom of the right control lever (joystick), find the
The following tools will be needed to do the procedure: pilot hose connected to Port 1 (Item 1) and Port 4 (Item
2) [Figure 20-110-1] labeled on the side of the right
MEL1355 - Hydraulic Test Kit control lever (joystick) casting. Port 1 is the pilot pressure
for the Boom function and Port 4 is the pilot pressure for
Lower the boom / bucket and blade to the ground. the Bucket function.

Stop the engine. Figure 20-110-2
Remove the console cover. (See Joystick Console Cover

IMPORTANT 2

S8166
damage the system.
I-2003-0888
Remove the pilot hose [Figure 20-110-2] from the
bottom of the control lever (joystick) that is to be checked.
From the test kit, install a fitting and gauge hose (Item 1)
WARNING [Figure 20-110-2] to the control lever (joystick) fitting.
Hydraulic fluid escaping under pressure can have Cap the pilot hose (Item 2) [Figure 20-110-2].
immediately.
W-2145-0290

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N Handle Removal And Installation
B4PD11001 & ABOVE) (CONT’D) Figure 20-110-4
Testing (Cont’d)
Figure 20-110-3
1
S8163
Remove the dust boot (Item 1) from the handle (Item 2)

S8167 [Figure 20-110-4].
Figure 20-110-5
Install a 6,9 MPa (69 bar) (1000 psi) gauge on the hose

[Figure 20-110-3].
2
Lower the right console to the locked position. Also lower
the left console to the locked position if in the vertical
position.
1
Start the engine and warm the hydraulic oil to operating
temperature 66°C (150°F).
Check the gauge with the control levers (joystick) in

neutral. The hydraulic pressure should be 0 kPa (0 bar) 
(0 psi).
Engage the circuit to be tested. Record the operating

P-66943
pressure.
The operating pressure should be as follows: Installation: Align the top of the dust boot (Item 1) with the
groove (item 2) [Figure 20-110-5] in the control handle.
2,8 - 3,1 MPa (28 - 31 bar) (406 - 450 psi).
If the operating pressure is correct, check the valve

section spool for proper operation.
If the operating pressure is incorrect, remove the

pressure reducing valve, clean, install and retest. (See
Testing And Adjusting on Page 20-32-1.)
If the pressure is still incorrect replace the pressure

reducing valve. (See Testing And Adjusting on Page 20-
32-1.)

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N Removal And Installation
B4PD11001 & ABOVE) (CONT’D) Lower the boom / bucket and blade to the ground.
Handle Removal And Installation (Cont’d)
Stop the engine.
Figure 20-110-6

2
IMPORTANT
1 parts clean. Always use caps and plugs on hoses,
P-66944 damage the system.
I-2003-0888
Hold the dust boot (Item 1) down and loosen the jam nut

(Item 2) [Figure 20-110-6].
Figure 20-110-7 WARNING

1
immediately.
W-2145-0290
S8164
Remove the handle (Item 1) [Figure 20-110-7].

B4PD11001 & ABOVE) (CONT’D)
Figure 20-110-8
1
1
1 S8169

control lever (joystick) mounting plate.
S8165 Remove the control lever (joystick) from the console.
Mark the hoses for ease of assembly [Figure 20-110-8].

Remove the hoses while the control lever (joystick) is
bolted to the console [Figure 20-110-8].
IMPORTANT
Figure 20-110-9 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
1
2
S8168
Raise the dust boot (Item 1) up from the mounting plate

(Item 2) [Figure 20-110-9].

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N A33S13155 & ABOVE, B4K911001 & ABOVE AND B4PD11001 &
ABOVE) (CONT’D)
1. Handle
2. Boot
3. Nut
4. Nut
5. U-Joint
6. Bellow Flange
7. Plunger
8. Intermediate Flange
9. Valve
10. Inferior Flange 2
11. Spring
12. Housing

3
7 8
10
11
14
12
NA8062S

Disassembly
Remove the right handle. (See Handle Removal And 2

Clean the outside of the control lever before disassembly.

1
Figure 20-110-11
P117234
3
2
Mark the coupler (Item 1), control plate (Item 2), and
1
plate (Item 3) [Figure 20-110-13] for ease of assembly.
Figure 20-110-14
1 2

P117233
Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-110-11] for ease of assembly.
Figure 20-110-12
2
P117234
1
Remove the coupler (Item 1) from the control plate (Item
2) [Figure 20-110-14].
P117233
Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-110-12].

Disassembly (Cont'd)
1
Figure 20-110-15
P117237
2 Remove the plate (Item 1) [Figure 20-110-17].
Figure 20-110-18
P117235
Remove the control plate (Item 1) from the U-Joint (Item

2) [Figure 20-110-15]. 1
Figure 20-110-16
2 P117238
Remove the plunger assemblies (Item 1) [Figure 20-110-

18].
P117236
Mark the plate and housing for correct installation.

Remove the U-joint (Item 1) [Figure 20-110-16].
NOTE: The plate (Item 2) [Figure 20-110-16] is spring

loaded and will come up as the U-joint is
removed.

Disassembly (Cont'd) 1
Figure 20-110-19
1
2 3
P-32591
Compress the spring (Item 1) and remove the seat (Item

2) [Figure 20-110-21].
P-32587 Figure 20-110-22
Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-110-19].
Figure 20-110-20
2
2
1 1 1
P-32590
Remove the spring (Item 1) and shim (Item 2) from the

spool (Item 3) [Figure 20-110-22].
P117239
Remove the spool assemblies (Item 1) [Figure 20-110-

20].

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N
Figure 20-110-23
P117240
Remove the springs (Item 1) [Figure 20-110-23]from the

housing.
Figure 20-110-24
P1174241
Remove the plate (Item 1) [Figure 20-110-24].

Assembly

or damaged parts.
3
1
Figure 20-110-25
P-32590
Install the shim (Item 1) and spring (Item 2) on the spool

1 (Item 3) [Figure 20-110-27].
Figure 20-110-28

P117241
Install the plate (Item 1) [Figure 20-110-25]. 1
Figure 20-110-26
2
P-32591
1 Compress the spring (Item 1) and install the spring seat

(Item 2) [Figure 20-110-28].
P117240
Install the springs (Item 1) [Figure 20-110-26].

Figure 20-110-29
P-32584

bushing.
P117239 Figure 20-110-32
Install the spool assemblies (Item 1) [Figure 20-110-29]

into the housing.
Figure 20-110-30 1
3 2
P117238
Install the plunger assemblies (Item 1) [Figure 20-110-

32] into the housing.
P-32586
Install the O-ring (Item 1) into the bushing (Item 2). Install
the plunger (Item 3) [Figure 20-110-30] into the bushing.

Assembly (Cont'd)
1
Figure 20-110-33
P117235
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-110-
35].
P117237
Figure 20-110-36
Install the plate (Item 1) [Figure 20-110-33].

NOTE: Spring pressure can dislodge the plunger 1
assemblies until the plate is secured in place.
2
Figure 20-110-34
3
3
P117234
2
1 Align the coupler (Item 1) with the control plate (Item 2)

and plate (Item 3) [Figure 20-110-36]. Tighten the
coupler.
P117236
Press down on the plate (Item 1) keeping the plunger

assemblies (Item 2) fully seated and install the U-joint
(Item 3) [Figure 20-110-34].

Assembly (Cont'd)
Figure 20-110-37
P117233
Install the connector (Item 1) [Figure 20-110-37].

Align the connector with the coupler (Item 2) and tighten
the nut (Item 3) [Figure 20-110-37].
Install the handle. (See Handle Removal And Installation

on Page 20-110-2.)


A33P11001 - A33P13154)
Description
The right control lever (joystick) operates using pilot

pressure to move the boom and / or bucket spools in the 1 2
control valve. The right control lever (joystick) is movable.
The right control lever (joystick) has a microswitch that
position.
Testing

S8165
The following tools will be needed to do the procedure: At the bottom of the right control lever (joystick), find the
pilot hose connected to Port 1 (Item 1) and Port 4 (Item
MEL1355 - Hydraulic Test Kit 2) [Figure 20-111-1] labeled on the side of the right
control lever (joystick) casting. Port 1 is the pilot pressure
Lower the boom / bucket and blade to the ground. for the Boom function and Port 4 is the pilot pressure for
the Bucket function.

Stop the engine.
Figure 20-111-2

1
IMPORTANT 2
damage the system. S8166
I-2003-0888

WARNING From the test kit, install a fitting and gauge hose (Item 1)
[Figure 20-111-2] to the control lever (joystick) fitting.
Cap the pilot hose (Item 2) [Figure 20-111-2].
immediately.
W-2145-0290

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N Handle Removal And Installation
A33P11001 - A33P13154) (CONT’D)
Figure 20-111-4
Testing (Cont’d)
Figure 20-111-3 2
S8163
S8167 Remove the dust boot (Item 1) from the handle (Item 2)
[Figure 20-111-4].
Install a 6,9 MPa (69 bar) (1000 psi) gauge on the hose Figure 20-111-5

[Figure 20-111-3].
Lower the right console to the locked position. Also lower 2

the left console to the locked position if in the vertical
position.
Start the engine and warm the hydraulic oil to operating 1


neutral. The hydraulic pressure should be 0 kPa (0 bar) 
(0 psi).

pressure.
P-66943
The operating pressure should be as follows:

Installation: Align the top of the dust boot (Item 1) with
3,0 MPa (30 bar) (435 psi) with an acceptable range of the groove (Item 2) [Figure 20-111-5] in the control
2,8 - 3,1 MPa (28 - 31 bar) (406 - 450 psi). handle.



32-1.)

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N Removal And Installation
A33P11001 - A33P13154) (CONT’D)
Stop the engine.
Figure 20-111-6

2 Removal And Installation on Page 40-40-1.)
1
IMPORTANT
P-66944
damage the system.
I-2003-0888
Hold the dust boot (Item 1) down and loosen the jam nut
(Item 2) [Figure 20-111-6].

Figure 20-111-7
WARNING
immediately.
W-2145-0290
S8164
Remove the handle [Figure 20-111-7].

A33P11001 - A33P13154) (CONT’D)
Figure 20-111-8
1
1
1 S8169

control lever (joystick) mounting plate.
S8165
Remove the control lever (joystick) from the console
frame.

Remove the hoses while the control lever (joystick) is
bolted to the console [Figure 20-111-8].
Figure 20-111-9
S8168

(Item 2) [Figure 20-111-9].

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N A33P11001 - A33P13154) (CONT’D)
1. Handle
2. Dust Boot
3. Coupler
4. Actuator Control Plate 1
5. U-Joint
6. Plate
7. Plunger Assembly
8. Spool
9. Spring
10. Housing

3
10
MS1353

A33P11001 - A33P13154) (CONT’D)
Disassembly
Remove the right handle. (See Handle Removal And

Installation on Page 20-111-2.) 2
Figure 20-111-11 1
1 P-32576

2 2) [Figure 20-111-13].
Figure 20-111-14

P-32560
1
Remove the boot (Item 1) from the control lever (joystick)

(Item 2) [Figure 20-111-11].
2
Figure 20-111-12
2 3
P-32574
3
1 plate (Item 3) [Figure 20-111-14] for correct installation.
P-32568
Mark the coupler (Item 1) nut (Item 2), and connector

(Item 3) [Figure 20-111-12] for correct assembly.

A33P11001 - A33P13154) (CONT’D)
1
Figure 20-111-15
2
1
P-32578

P-32574
Remove the coupler (Item 1) from the control plate (Item removed.
2) [Figure 20-111-15].

Figure 20-111-18
Figure 20-111-16
2
1
1
2
P-32582
P-32577

2) [Figure 20-111-16]. NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-111-18] are spring
loaded.

A33P11001 - A33P13154) (CONT’D)
Figure 20-111-19
P-32588

21].
P-32583
Figure 20-111-22

19].
1
Figure 20-111-20
1
2
3
P-32591

2) [Figure 20-111-22].
P-32587

NOTE: Mark the spool assemblies for installation in

their original location.

A33P11001 - A33P13154) (CONT’D)
1
1
Figure 20-111-23
2 1
P-32579
P-32590 Figure 20-111-26
1

Figure 20-111-24
P-32593
Remove the end cap (Item 1) [Figure 20-111-26].
P-32592
Remove the springs (Item 1) [Figure 20-111-24] from the

housing.
Clamp the housing in a vise that is equipped with padded

jaws.

CONTROL LEVER (JOYSTICK) (RIGHT) (S/N Assembly
A33P11001 - A33P13154) (CONT’D)
Figure 20-111-27 or damaged parts.

2
Figure 20-111-28
1
1 2
P-32594
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

111-27].
P-32594
Clamp the housing in a vise equipped with padded jaws.

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
111-28].
Figure 20-111-29
P-32593
Install the end cap (Item 1) [Figure 20-111-29].

A33P11001 - A33P13154) (CONT’D)
Assembly (Cont'd)
3
Figure 20-111-30
1
2
1 1
P-32590

(Item 3) [Figure 20-111-32].
P-32580
Figure 20-111-33
Install the bolts (Item 1) [Figure 20-111-30].

Turn the housing over. 2
Figure 20-111-31
1 1
P-32591
Compress the spring (Item 1) and install the spring seat

(Item 2) [Figure 20-111-33].
P-32592

A33P11001 - A33P13154)(CONT’D)
Assembly (Cont'd)
1
Figure 20-111-34
P-32584

bushing.
P-32588
Figure 20-111-37

into the housing. 1
Figure 20-111-35
1
2
P-32583

P-32586
Install the plunger (Item 1) into the bushing (Item 2)

[Figure 20-111-35].

A33P11001 - A33P13154) (CONT’D)
Assembly (Cont'd)
1
Figure 20-111-38
P-32577
contact with all 4 plungers (Item 2) [Figure 20-111-40].
P-32582
Figure 20-111-41

assemblies until the plate (Item 1) [Figure 20-
111-38] is secured in place.
2
Figure 20-111-39
1 3
P-32574
2
Align the coupler (Item 1) with the control plate (Item 2)
coupler.
P-32578
Press down on the plate (Item 1) to seat the plunger

assemblies (Item 2). Install the U-joint (Item 3) [Figure
20-111-39].

A33P11001 - A33P13154)(CONT’D)
Assembly (Cont'd)
Figure 20-111-42
1
3
P-32573

Figure 20-111-43
P-32560
Install the tabs of the boot (Item 1) in between the joystick

flange and mounting plate (Item 2) [Figure 20-111-43].

on Page 20-100-2.)

CONTROL LEVER (JOYSTICK) (LEFT) (S/N Figure 20-120-2
A33P13155 & ABOVE, B4K911001 & ABOVE AND
B4PD11001 & ABOVE)
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) is movable.
The left control lever (joystick) has a microswitch which 1
position.
Testing
S39889
The following tools will be needed to do the procedure:
MEL1355 - Hydraulic Test Kit Disconnect the hydraulic fitting (Item 1) [Figure 20-120-
2] from the control valve.
Stop the engine.
Figure 20-120-3
Remove the left upperstructure cover.

Figure 20-120-1
1
S39890
S39888 From the test kit install a 7 MPa (70 bar) (1000 psi) gauge
(Item 1) [Figure 20-120-3] on the pilot line. Start the
excavator, and warm the hydraulic fluid to operating
At the control valve assembly (Item 1) [Figure 20-120-1], temperature.
find the pilot line of the control lever (joystick) that is to be
checked (Arm, Slew) (Slew Shown). Engage the circuit to be tested. Record the operating
pressure.
The operating pressure should be approximately 3,2 - 3,5

MPa (32 - 35 bar) (464 - 508 psi).

section spool for proper operation. If the operating
pressure is incorrect, remove the pilot pressure relief
valve, clean, install and retest. (See Testing And
Adjusting on Page 20-32-1.)
If the pressure is still incorrect replace the pilot pressure

relief valve. (See Testing And Adjusting on Page 20-32-
1.)

Handle Removal And Installation
Remove the left console cover. (See Joystick Console

Cover Removal And Installation on Page 40-50-1.)
Figure 20-120-4
2
S8183
Disconnect the joystick wire harness (Item 1) [Figure 20-

120-6].
1 Figure 20-120-7

S8182

[Figure 20-120-4].
2
Figure 20-120-5
2
1
2 P131226
3
Raise the dust boot (Item 1) and remove the bolts (Item
1
2) [Figure 20-120-7].
P-66949

the groove (Item 2) [Figure 20-120-5].
Hold the dust boot (Item 1) down and loosen the nut
(Item 3) with the groove (Item 2) [Figure 20-120-5].


2
Figure 20-120-8
P-32521
1
Pull the boot down and pull the wire harness (Item 1) out
of the boot. Loosen the nut (Item 2) [Figure 20-120-10]
and remove the handle.
P129225
Raise the joystick and remove the wire harness (Item 1)

[Figure 20-120-8] from the console.
Figure 20-120-9
P129226
Slide the grommet / wire harness (Item 1) [Figure 20-

120-9] out of the joystick body.

Stop The Engine.
Remove the left console cover.
IMPORTANT S8179
When repairing hydrostatic and hydraulic systems, Mark and remove the hoses [Figure 20-120-12].
parts clean. Always use caps and plugs on hoses, Remove the hoses while the control lever (joystick) is
tubelines and ports to keep dirt out. Dirt can quickly bolted to the console.
damage the system.
I-2003-0888 Figure 20-120-13

3
WARNING 1
immediately.
W-2145-0290
3 2
S8184
Figure 20-120-11
(Item 2) [Figure 20-120-13].
Remove the joystick assembly.
S8183
Disconnect the wire harness (Item 1) [Figure 20-120-

11].

CONTROL LEVER (JOYSTICK) (LEFT) (S/N A33P13155 & ABOVE, B4K911001 & ABOVE AND B4PD11001 &
ABOVE) (CONT’D)
1. Handle
2. Boot
3. Lock
4. Coupler
5. Connector
6. Control Plate 1
7. U-joint
8. Square Flange
9. Intermediate Flange
10. Plunger
11. Inferior Flange
12. Spool
13. Spring
14. Housing

3
5 4
9 10
12
11
13
14
NA8065S

Disassembly
Remove the left handle. (See Handle Removal And 2


1
Figure 20-120-14
P117234
3
2
1
plate (Item 3) [Figure 20-120-16] for ease of assembly.
Figure 20-120-17
1 2

P117233
Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-120-14] for ease of assembly.
Figure 20-120-15
2
P117234
1
Remove the coupler (Item 1) from the control plate (Item
2) [Figure 20-120-17].
P117233

2) [Figure 20-120-15].

1
Figure 20-120-18
P117237
2 Remove the plate (Item 1) [Figure 20-120-20].
Figure 20-120-21
P117235

2) [Figure 20-120-18]. 1
Figure 20-120-19
2 P117238

21].
P117236


removed.

Figure 20-120-22
1
2 3
P-32591

2) [Figure 20-120-24].
P-32587 Figure 20-120-25

Figure 20-120-23
2
2
1 1 1
P-32590

P117239

23].

CONTROL LEVER (JOYSTICK) (LEFT) (S/N
Figure 20-120-26
P117240
Remove the springs (Item 1) [Figure 20-120-26]from the

housing.
Figure 20-120-27
P1174241

Assembly

or damaged parts.
3
1
Figure 20-120-28
P-32590

1 (Item 3) [Figure 20-120-30].
Figure 20-120-31

P117241
Install the plate (Item 1) [Figure 20-120-28]. 1
Figure 20-120-29
2
P-32591
1 Compress the spring (Item 1) and install the spring seat

(Item 2) [Figure 20-120-31].
P117240

Figure 20-120-32
P-32584

bushing.
P117239 Figure 20-120-35

into the housing.
Figure 20-120-33 1
3 2
P117238

P-32586
Install the O-ring (Item 1) into the bushing (Item 2). Install
the plunger (Item 3) [Figure 20-120-33] into the bushing.

Assembly (Cont'd)
1
Figure 20-120-36
P117235
38].
P117237
Figure 20-120-39

assemblies until the plate is secured in place.
2
Figure 20-120-37
3
3
P117234
2
1 Align the coupler (Item 1) with the control plate (Item 2)

coupler.
P117236
Press down on the plate (Item 1) keeping the plunger

assemblies (Item 2) fully seated and install the U-joint
(Item 3) [Figure 20-120-37].

Assembly (Cont'd)
Figure 20-120-40
P117233


on Page 20-120-2.)


A33P11001 - A33P13154)
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) is movable. 2
The left control lever (joystick) has a microswitch which
1
position.
Testing

S8179
The following tools will be needed to do the procedure: At the bottom of the left control lever (joystick), find the
pilot hose connected to Port 1 (Item 1) and Port 2 (Item
MEL1355 - Hydraulic Test Kit 2) [Figure 20-121-1] labeled on the side of the left
control lever (joystick) casting. Port 1 is the pilot pressure
Lower the boom / bucket and blade to the ground. for the Arm function and Port 2 is the pilot pressure for
the Swing (Slew) function.

Stop the engine.
Figure 20-121-2

IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system. S8180
I-2003-0888

WARNING From the test kit, install a fitting and gauge hose (Item 1)
[Figure 20-121-2] to the control lever (joystick) fitting.
Hydraulic fluid escaping under pressure can have Cap the pilot hose (Item 2) [Figure 20-121-2].
immediately.
W-2145-0290

A33P11001 - A33P13154) (CONT’D)
Testing (Cont’d)
Figure 20-121-3
S8181
Install a 6,9 MPa (69 bar) (1000 psi) gauge on the hose

[Figure 20-121-3].
Lower the left console to the locked position. Also lower

the right console to the locked position if in the vertical
position.
Start the engine and warm the hydraulic oil to operating


neutral. The hydraulic pressure should be 0 kPa (0 bar)
(0 psi).

pressure.
The operating pressure should be as follows:

2,8 - 3,1 MPa (28 to 31 bar) (406 - 450 psi).



32-1.)

A33P11001 - A33P13154) (CONT’D)
Handle Removal And Installation

1
Figure 20-121-4
2
S8183
1
Disconnect the wire harness (Item 1) [Figure 20-121-6].
Figure 20-121-7
1
S8182

[Figure 20-121-4].
Figure 20-121-5
P-32915
2
3 Remove the lock (Item 1) [Figure 20-121-7] from the
1 electrical connector.
P-66949

the groove (Item 2) [Figure 20-121-5].
Hold the dust boot (Item 1) down and loosen the nut
(Item 3) [Figure 20-121-5].

A33P11001 - A33P13154) (CONT’D)
Figure 20-121-8 1
2
3
S8184
Raise the dust boot (Item 1) and pull the grommet (Item
1
2) up through the plate (Item 3) [Figure 20-121-10].
P-32914
Figure 20-121-11
With a small piece of wire, depress the wire terminal tabs

(Item 1) [Figure 20-121-8].

Remove the individual wires from the back of the
electrical connector.
Figure 20-121-9
1
1
S8185
Remove the grommet and wire (Item 1) [Figure 20-121-

11] from the mount plate.
1
Remove the handle from the control lever.
P-32916
Installation: Use a small piece of wire and rebend the

tab (Item 1) [Figure 20-121-9] on each wire before
installing in the electrical connector.
Installation: The wires 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 locks into position.

A33P11001 - A33P13154) (CONT’D)
Stop the engine.

S8179
IMPORTANT
clean the work area before disassembly and keep all Remove the hoses while the control lever (joystick) is
parts clean. Always use caps and plugs on hoses, bolted to the console.
damage the system. Figure 20-121-14

I-2003-0888
WARNING 3

physician familiar with this injury is not received 3
immediately.
W-2145-0290 2
S8184
Figure 20-121-12
Raise the dust boot (Item 1) up from the plate (Item 2)

[Figure 20-121-14].

joystick plate.
1
Remove the joystick.
S8183
Disconnect the wire harness (Item 1) [Figure 20-121-

12].

CONTROL LEVER (JOYSTICK) (LEFT) (S/N A33P11001 - A33P13154) (CONT’D)
1. Handle
2. Dust Boot
3. Coupler
4. Actuator Control Plate
5. U-Joint
6. Grommet 1
7. Plate
8. Plunger Assembly
9. Spool
10. Spring
11. Housing
12. Wire Harness
13. Lock 2
14. Pin
15. Connector

4
6
10
11
12
13
14
15
MS-1354

A33P11001 - A33P13154) (CONT’D)
Disassembly
Remove the left handle. (See Handle Removal And

Installation Page 20-101-3.) 2
Figure 20-121-15 1
1 P-32576

2 2) [Figure 20-121-17].
Figure 20-121-18

P-32560
1
Remove the boot (Item 1) from the control lever (joystick)

(Item 2) [Figure 20-121-15].
2
Figure 20-121-16
2 3
P-32574
3
1 plate (Item 3) [Figure 20-121-18] for correct installation.
P-32568
Mark the coupler (Item 1) nut (Item 2), and connector

(Item 3) [Figure 20-121-16] for correct assembly.

A33P11001 - A33P13154) (CONT’D)
1
Figure 20-121-19
2
1
P-32578

P-32574
Remove the coupler (Item 1) from the control plate (Item removed.
2) [Figure 20-121-19].

Figure 20-121-22
Figure 20-121-20
2
1
1
2
P-32582
P-32577

2) [Figure 20-121-20]. NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-121-22] are spring
loaded.

A33P11001 - A33P13154) (CONT’D)
Figure 20-121-23
P-32588

25].
P-32583
Figure 20-121-26

23].
1
Figure 20-121-24
1
2
3
P-32591

2) [Figure 20-121-26].
P-32587

NOTE: Mark the spool assemblies for installation in

their original location.

A33P11001 - A33P13154) (CONT’D)
1
Figure 20-121-27
2 1
P-32579
Figure 20-121-30
P-32590
1

Figure 20-121-28
P-32593
Remove the end cap (Item 1) [Figure 20-121-30].
Figure 20-121-31
P-32592
2
Remove the springs (Item 1) [Figure 20-121-28] from the

housing.
Clamp the housing in a vise that is equipped with padded

jaws.
1
P-32594
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

121-31].

A33P11001 - A33P13154) (CONT’D)
Assembly
Clean all parts in solvent and dry with compressed air. 1 1

or damaged parts.

Figure 20-121-32
P-32580
1
2
Install the bolts (Item 1) [Figure 20-121-34].
Turn the housing over.
Figure 20-121-35

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-
121-32].
Figure 20-121-33
1
P-32592
P-32593
Install the end cap (Item 1) [Figure 20-121-33].

A33P11001 - A33P13154) (CONT’D)
Assembly (Cont'd) 1
Figure 20-121-36
1
2
P-32588

into the housing.
P-32590
Figure 20-121-39

(Item 3) [Figure 20-121-36].

1
Figure 20-121-37 2
1
P-32586
Install the plunger (Item 1) into the bushing (Item 2)

[Figure 20-121-39].
P-32591
Compress the spring (Item 1) and install the spring seat

(Item 2) [Figure 20-121-37].

A33P11001 - A33P13154) (CONT’D)
Assembly (Cont'd)
1
Figure 20-121-40
P-32582
P-32584 NOTE: Spring pressure can dislodge the plunger

assemblies until the plate (Item 1) [Figure 20-
121-42] is secured in place.

bushing. Figure 20-121-43
Figure 20-121-41
3
1 1
P-32578
P-32583
Press down on the plate (Item 1) to seat the plunger
assemblies (Item 2). Install the U-joint (Item 3) [Figure
Install the plunger assemblies (Item 1) [Figure 20-121- 20-121-43].

A33P11001 - A33P13154) (CONT’D)
Assembly (Cont'd) 1
3
Figure 20-121-44
1 2
P-32573
2
P-32577 Align the connector with the coupler (Item 2) and tighten
Install the control plate (Item 1) until the plate makes light Figure 20-121-47

44]. 1
Figure 20-121-45
2
2
P-32560
3
Install the tabs of the boot (Item 1) in between the joystick

P-32574 flange and mounting plate (Item 2) [Figure 20-121-47].

Align the coupler (Item 1) with the control plate (Item 2) Page 20-101-3.)
coupler.

HYDRAULIC RESERVOIR Figure 20-130-2
Description
The hydraulic reservoir is a storage container for the

excavators hydraulic fluid. The reservoir contains a
vented fill cap.
The hydraulic reservoir is located behind the radiator on 1

the right side of the excavator.
With Oil Cooler
Open the tailgate. (See Opening And Closing The S8705

Drain the hydraulic reservoir. (See Removing And Remove the nut and bolt (Item 1) [Figure 20-130-2].
Figure 20-130-3
Remove the radiator. (See Radiator Removal And

Drain the oil cooler. (See Removal And Installation on
Page 20-140-1.)
Figure 20-130-1
1 1
S8706
1 Remove the nut and bolt (Item 1) [Figure 20-130-3].
Remove the bracket.
S8704
Proceed with [Figure 20-130-4].
Remove the nuts and bolts (Item 1) [Figure 20-130-1].

HYDRAULIC RESERVOIR (CONT’D) Disconnect the hose (Item 2) [Figure 20-130-5] from the
two-speed control valve.
Figure 20-130-6
Without Oil Cooler


Replacing The Hydraulic Filter on Page 10-120-2.)
1
Remove the radiator. (See Radiator Removal And
Remove the right side floor panel. (See Right Floor Panel
Figure 20-130-4
S8724
2 Reposition the hose (Item 1) [Figure 20-130-6] as shown

for easier access.
1
Figure 20-130-7

1 1
S8655
2
Remove the bolt and nut (Item 1) to remove the harness
(Item 2) [Figure 20-130-4] from the two-speed control
valve.
S8658
Figure 20-130-5
Remove the two bolts and nuts (Item 1) to remove the

2 fuel filter (Item 2) [Figure 20-130-7] from the frame.
S8656
Reposition the harness (Item 1) [Figure 20-130-5] as

shown for easier access.

HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-10
Without Oil Cooler (Cont’d)
Figure 20-130-8
S8725

the two-speed control valve.
S8659 Rotate the tubeline clockwise while lifting it to easily

remove the tubeline from the excavator.

Reposition the fuel filter (Item 1) [Figure 20-130-8] as Figure 20-130-11
shown for easier access.
Figure 20-130-9
1
S8726
S8721 Remove the nuts and bolts (Item 1) [Figure 20-130-11].
Remove the cover plate (Item 2) [Figure 20-130-11] from

Disconnect the tubeline (Item 1) [Figure 20-130-9] from the bracket.
the hydraulic filter.

HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-14
Figure 20-130-12
1
1
S7601
Put a hose clamp (Item 1) [Figure 20-130-14] on the

lower reservoir hose.
S7599 Figure 20-130-15

Mark and remove the hoses (Item 1) [Figure 20-130-12]
from the back side of the hydraulic reservoir.
Figure 20-130-13
2
1
2
S7602
1
Remove the hose clamp (Item 1) and hose (Item 2)
[Figure 20-130-15].
S8303 NOTE: There still can be a small amount of hydraulic

fluid in the hose. Use a container when
removing lower reservoir hose.
[Figure 20-130-13]. Recycle or dispose of the used hydraulic fluid in an
environmentally safe manner.

HYDRAULIC RESERVOIR (CONT’D)
Figure 20-130-16
1
1
S7603

Remove the four bolts (Item 1) [Figure 20-130-16] and
remove the fan.
NOTE: Fan belt will become loose when removing

bolts.
Figure 20-130-17
S8708
Gently pull hydraulic reservoir towards you and slide it

out of its positioning bracket [Figure 20-130-17].


OIL COOLER Figure 20-140-2
Description
The oil cooler is needed for breaker applications and is

not included with the excavator. If using the excavator for
breaker applications, the oil cooler kit needs to be 1
installed. See your dealer for kit.
The oil cooler is used to cool the excavators hydraulic

fluid. Oil passages are coiled into a heat exchanger. The
air is forced around these passages cooling the oil.
Drain hydraulic reservoir. (See Removing And Replacing S6766

Hydraulic Fluid on Page 10-120-3.)
Remove the upper right hand side cover. (See Upper Remove the tubeline (Item 1) [Figure 20-140-2] from the
Right Side Cover Removal And Installation on Page 40- bottom of the oil cooler.
210-1.)
Figure 20-140-3
Remove the lower right hand side cover. (See Lower Left

Figure 20-140-1
1 S6767
Remove the bolt (Item 1) [Figure 20-140-3] from the oil

S6769
cooler frame.

top of the oil cooler.

OIL COOLER (CONT’D)
Figure 20-140-4
S6768
Remove the bolt (Item 1) [Figure 20-140-4] from the oil

cooler frame.

Remove the oil cooler from the frame.

ELECTRIC BLADE / TRACK EXPAND VALVE Figure 20-150-1
Description
The blade / track expand valve diverts hydraulic fluid to

either the blade or track expansion function with the 2
control handle situated in the middle of the floor panels.
The blade / track expand valve is located directly

underneath the floor panels in the middle of the
excavator.
1
Block Removal And Installation

S9734
Disconnect the track expansion valve harness (Item 1)
from the mainframe harness (Item 2) [Figure 20-150-1].

I-2003-0888

40-120-1.) 2
1
WARNING P116552
Hydraulic fluid escaping under pressure can have Mark all tubelines and hoses for ease of assembly.
penetrating the skin. This can cause serious injury Disconnect the tubelines (Item 1) [Figure 20-150-2].
physician familiar with this injury is not received Remove the two bolts (Item 2) and the blade / track
immediately. expansion valve (Item 3) [Figure 20-150-2] from the
W-2145-0290 excavator

(CONT’D)
Solenoid Removal And Installation
With the engine off, turn the start key to the ON position
IMPORTANT 1

clean the work area before disassembly and keep all S9734

tubelines and ports to keep dirt out. Dirt can quickly Disconnect the wire harness (Item 1) [Figure 20-150-3]
damage the system. from the excavator harness.
I-2003-0888
Remove the blade / track expand valve.
Figure 20-150-4

WARNING
and possible death if proper medical treatment by a 2 1
immediately.
W-2145-0290
P116552
Remove the solenoid nut (Item 1), O-ring and coil (Item
2) [Figure 20-150-4] from the expansion block.

ELECTRIC BLADE / TRACK EXPAND VALVE Block Disassembly And Assembly
(CONT’D)
Solenoid Removal And Installation (Cont’d)
Figure 20-150-5 IMPORTANT

1 damage the system.
I-2003-0888
Inspectallparts for wearordamage.
Replace any worn or damaged parts.
P122534
Always install new O-rings and back-up rings. Lubricate
all O-rings and back-up rings with clean hydraulic fluid
Remove the solenoid stem (Item 1) [Figure 20-150-5]. before installation.

Installation: Tighten the solenoid stem to 50 N•m (37 ft- Figure 20-150-7
lb) torque.
Figure 20-150-6
2 2
1
P-66866
1
Remove the nut (Item 1)[Figure 20-150-7] from the
P-62378
solenoid.
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-150-6].

(CONT’D)
Block Disassembly And Assembly (Cont’d)

1
Figure 20-150-8 2
1
1
2
P-62378
2

[Figure 20-150-10] from the solenoid stem.
P-66867
Remove the O-ring (Item 1) and solenoid (Item 2)

[Figure 20-150-8].
Figure 20-150-9
1
P-66868
Remove the solenoid stem (Item 1) [Figure 20-150-9]

from the block.
Installation: Tighten the solenoid stem to 50 N•m (37 ft-

lb) torque.

TRACK EXPAND VALVE Figure 20-151-1
Description
The blade / track expand valve diverts hydraulic fluid to

either the blade or track expansion function with the
control handle situated in the middle of the floor panels.
The blade / track expand valve is located directly

underneath the floor panels in the middle of the
excavator.
Block Removal And Installation
Lower the boom / bucket and blade to the ground. 1

S6749
the underside of the valve.

damage the system.
I-2003-0888
Remove the floor panels. (See FLOOR PANELS on Page 1

40-120-1.)
WARNING S6748
Disconnect the tubelines (Item 1) [Figure 20-151-2].

immediately.
W-2145-0290

TRACK EXPAND VALVE (CONT’D) Control Handle Removal And Installation
Block Removal And Installation (Cont’d) Lower the boom / bucket and blade to the ground.
Figure 20-151-3 With the engine off, turn the Start key to the ON position

40-120-1.)
Figure 20-151-4
S6750
Remove the nuts and bolts (Item 1) [Figure 20-151-3].

Remove the blade / track expand valve.
S6749
Remove the bolt (Item 1) and washer (Item2) [Figure 20-

151-4] from the control handle.
Remove the control handle.

BLADE / TRACK EXPAND VALVE (CONT’D) Figure 20-151-6
Block Disassembly And Assembly
IMPORTANT
I-2003-0888 1
S7525

Remove the washer (Item 1) and control handle (Item 2)
Inspect all parts for wear or damage. Replace any worn [Figure 20-151-6].
or damaged parts.
Figure 20-151-7

before installation.
Figure 20-151-5 1
1 S7528
Remove the bolt (Item 1) and washer (Item 2) [Figure

20-151-7] from the valve.
S7524

TRACK EXPAND VALVE (CONT’D)
Figure 20-151-8
S7527
Remove the spool (Item 1) [Figure 20-151-8] from the

valve.

Figure 20-151-9
1
1
2
2 S7526

[Figure 20-151-9] from the spool.

BUILD-UP VALVE Figure 20-160-1
Description
The build-up valve is used to generate back pressure in

the hydraulic system. If the pressure in the control 2
system (accumulator) decreases under 2,7 MPa (27 bar)
(391 psi), the build-up valve will generate back pressure
of 1,2 MPa (12 bar) (174 psi) to provide pressurized oil
for pilot control system.
The build-up valve is located under the floor panels on

the right side of the excavator. 1
S6743
With the engine off, turn the Start key to the ON position Mark and disconnect the hose (Item 1) [Figure 20-160-
and move blade lever to relieve hydraulic pressure. 1].
Remove the nut and bolt (Item 2) [Figure 20-160-1] and

push the harness bracket aside.
IMPORTANT

Figure 20-160-2

damage the system.
I-2003-0888
1
WARNING S6744

Mark and disconnect the tubelines (Item 1) [Figure 20-
160-2] from the valve.
immediately.
W-2145-0290

BUILD-UP VALVE (CONT’D) Figure 20-160-5
Figure 20-160-3
S6747

S6745 the valve.
Remove the build-up valve.

the hose bracket.

Figure 20-160-4
S6746
Push the boom swing hoses aside (Item 1) [Figure 20-

160-4].
Mark and disconnect the tubeline (Item 2) [Figure 20-

160-4].

BUILD-UP VALVE (CONT’D) Figure 20-160-6
IMPORTANT
I-2003-0888
1
S7536
Remove the plug (Item 1), spring (Item 2) and spring seat
WARNING (Item 3) [Figure 20-160-6].

sufficient force to enter a person’s body by Figure 20-160-7

immediately.
W-2145-0290
1
S7537

plug.


TWO SPEED CONTROL VALVE Figure 20-170-1
Description
The two speed control valve operates at pilot pressure

and uses a solenoid to direct flow to the travel motor for
shifting between single and two speed. (The pressure is
directed to the swash plate to change its angle, which
causes a change of flow and displacement).
2
Block Removal And Installation 1
S6751
Cut the tie-strap (Item 1) and disconnect the wire

IMPORTANT harness (Item 2) [Figure 20-170-1] from the excavator
harness.
When repairing hydrostatic and hydraulic systems, Figure 20-170-2


damage the system.
I-2003-0888 2
1
WARNING
Hydraulic fluid escaping under pressure can have S6752

Remove the hose (Item 1) and tubeline (Item 2) [Figure
20-170-2] from the valve.
immediately.
W-2145-0290

210-3.)

TWO SPEED CONTROL VALVE (CONT’D) Figure 20-170-5
Block Removal And Installation (Cont’d)
Figure 20-170-3
S6755
Remove the nuts and bolts (Item 1) [Figure 20-170-5]

S6753 from the valve.
Remove the two speed control valve.

valve.

Figure 20-170-4
S6754

valve.

Solenoid Removal And Installation
and move travel controls to relieve hydraulic pressure.
2
1
IMPORTANT
clean the work area before disassembly and keep all S6751

Cut the tie-strap (Item 1) and disconnect the wire
damage the system.
I-2003-0888
harness (Item 2) [Figure 20-170-6] from the excavator
harness.
Figure 20-170-7

WARNING
penetrating the skin. This can cause serious injury 1
immediately.
W-2145-0290
2
210-3.) S7530
Remove the solenoid nut (Item 1) [Figure 20-170-7].
Remove the O-ring and coil (Item 2) [Figure 20-170-7]

from the solenoid stem.
Installation: Tighten the nut to 5 N•m (4 ft-lb) torque.


TWO SPEED CONTROL VALVE (CONT’D) Block Disassembly And Assembly
Solenoid Removal And Installation (Cont’d)
Figure 20-170-8
IMPORTANT
damage the system.
I-2003-0888

1
or damaged parts.
S7531
Remove the solenoid stem (Item 1) [Figure 20-170-8]. before installation.

Installation: Tighten the solenoid stem to 50 N•m (37 ft- Figure 20-170-10
lb) torque.
Figure 20-170-9
1 1
1 1
1
S7532
2 2
2
S7535 Remove the nut (Item 1) [Figure 20-170-10] from the

solenoid.
Remove the O-rings (Item 1) and back-up rings (Item 2) Installation: Tighten the nut to 5 N•m (44.25 in-lb)
[Figure 20-170-9] from the solenoid stem. torque.



1 1
Figure 20-170-11 1 1
2 2
2
S7535
2
1 Remove the O-rings (Item 1) and back-up rings (Item 2)
S7533 [Figure 20-170-13] from the solenoid stem.
Remove the O-ring (Item 1) and solenoid (Item 2)

[Figure 20-170-11] from the valve.

Figure 20-170-12
S7534
Installation: Tighten the solenoid stem to 50 N•m 

(37 ft-lb) torque.


UNDERCARRIAGE
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Extension Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Blade Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
TRACK UNDERCARRIAGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-10
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-10
Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11

Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-12
Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-13
Removal And Installation Of Expandable Track Frame . . . . . . . . . . . . . . . . . . . . . . 30-20-15
TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1



BLADE Extension Removal And Installation
Description Figure 30-10-2
The blade extensions are used to match the track width

to the blade width. Retract the blade extensions when
transporting the excavator or when a narrow operating
width is needed. Under normal operating conditions, the 2
blade width should match the track width. 1
Figure 30-10-1
1 2
S7677
2 Put a block (Item 1) [Figure 30-10-2] under the blade.
Fully lower the blade to the block.

Stop the engine.
S7675
Remove the pin (Item 2) [Figure 30-10-2] from the blade
extensions.
The blade extensions (Items 1 and 2) [Figure 30-10-1]
are located on the blade. Figure 30-10-3
S7676
Remove the blade extensions (Item 1) [Figure 30-10-3]

from the blade.

BLADE (CONT’D)
Blade Removal And Installation
Expand the tracks.
Lower the blade to the ground.
Remove the blade cylinder. (See Removal And

Figure 30-10-4

1
S7658
Figure 30-10-5
2
1
S7657
Remove the snap ring (Item 1) [Figure 30-10-4] and

[Figure 30-10-5] and washer from the blade arm pivot
pins (both sides).
Remove the blade arm pivot pins (Item 2) [Figure 30-10-

4] and [Figure 30-10-5].
Remove the blade from the excavator.

TRACK UNDERCARRIAGE COMPONENTS Track Lug Height
Description Rubber Track
The track undercarriage components consist of the front The lug height of a new rubber track is 25,0 mm (0.984
idler, rollers, drive motor and track frame. inch).
Figure 30-20-1
Straight Edge
B-14489

To find the percentage of wear on an 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 20,0 mm (0.787 in)

0.787
0.984 x 100 = 80
80% of the track lug is remaining with 20% wear on the

track lugs.
The rubber track should be replaced when lug height

measures 6,25 mm (0.246 in) from the base of the track
to the top of the lug.

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)
Checking Tension
WARNING
NOTE: The wear of undercarriage parts vary with
working conditions and types of soil
AVOID INJURY
conditions. Maintain the correct track tension
Keep fingers and hands out of pinch points when
by inspecting regularly. (See SERVICE
checking the track tension.
SCHEDULE on Page 10-70-1.) W-2142-0903
Figure 30-20-2
Figure 30-20-4

S8452 S7954
Raise one side of the machine (approximately four inches

[102 mm]) using the boom and arm as shown in [Figure Figure 30-20-5
30-20-2].
RUBBER
Figure 30-20-3 Track Frame
Rubber
Track Sag
0.33-0.53 inch
(8-13 mm) Track
1 Roller
1
S8756 S8757
Rubber
Track S8710
Raise the blade fully and install wooden blocks (Item 1)
[Figure 30-20-3] or jackstands under the blade and the
track frame. Lower the machine until all machine weight Measure the rubber track sag at the middle track roller
is on the wooden blocks or jackstands. [Figure 30-20-4]. Do not get your fingers into pinch
points between the track and the track roller. Use material
Stop the engine. of appropriate size to check the gap between the contact
edge of the roller and top edge of the track guide lug
[Figure 30-20-4] and [Figure 30-20-5].

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-8
Adjusting Tension
Figure 30-20-6 1
1 1
S8887
Use tool MEL1560 (Item 1) [Figure 30-20-8] to loosen

S7954 the bleed fitting (Item 2) [Figure 30-20-7] (one turn
maximum) to release tension from the track.
Loosen the two bolts (Item 1) [Figure 30-20-6] on the Repeat the procedure for the other side.
cover. Pivot the cover downward.

If the track tension is still loose after adjusting to the
Figure 30-20-7 mentioned limit, it indicates the track is worn.
WARNING
Do not loosen the grease fitting more than one
complete rotation. Also, be careful not to loosen any
1 2 part other than the grease fitting. If the grease fitting
or any part is loosened too much, it can fly off under
high pressure. If the grease does not ooze smoothly,
try moving the machine back and forth for a short
distance.
W-2143-0189
S7953
Add grease to the fitting (Item 1) [Figure 30-20-7] until

the track tension is correct.

Track Removal And Installation
Lift and block the side of the machine where the track will 1
be removed. (See Procedure on Page 10-10 Service
Manual-1.)
Figure 30-20-9
1 1 S8887
Use tool MEL1560 (Item 1) [Figure 30-20-11] to loosen

the bleed fitting (Item 1) [Figure 30-20-10] (one turn
maximum) to release tension from the track.
NOTE: Apply additional pressure to the track by

S7954 standing on the lower track span so all the

tension is released from the grease cylinder
for easier removal of the track.
Loosen the two bolts (Item 1) [Figure 30-20-9] on the
cover. Pivot the cover downward. Figure 30-20-12
Figure 30-20-10
S7952
S7953
Install a round bar (Approximately 30 mm [1.25 in]
diameter) between the drive lugs [Figure 30-20-12].

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Idler Removal And Installation
Track Removal And Installation (Cont’d) Remove the track. (See Track Removal And Installation
on Page 30-20-4.)
Figure 30-20-13
Figure 30-20-14
S7951
S7950
Turn the track until the bar contacts the frame [Figure 30-
20-13]. Slide the front track idler out of the track frame to remove

it [Figure 30-20-14].
Pry the track off the idler wheel.
Remove the track from the drive sprocket.
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 Checking Tension on Page 30-20-2.) for adding

grease to the grease spring and for checking track
tension.

Idler Parts Identification
1. Washer
2. Tensioner
3. Idler
4. Shaft
5. Seal
6. Bearing
7. Pin
8. Ring
7 1 2

4
8
7
S8280

Idler Disassembly
1
The following tools must be fabricated for this procedure:
Figure 30-20-15
90 mm
70 mm (3.5”)
(2.75”)
S7939
Remove the seal (Item 1) [Figure 30-20-17] from both

0,75 mm 30 mm sides of the idler.
(0.03”) (1.18”) Dia.
Chamfer Figure 30-20-18
3 Places 46 mm
(1.81”) Dia. B-14204

1. Driver Tool - see [Figure 30-20-15].
1
Figure 30-20-16
1
S7937

both sides of the idler.
Figure 30-20-19
S7940
Remove the roll pin (Item 1) [Figure 30-20-16] from each

end of the shaft.
1
Using a suitable driver, gently tap the shaft (Item 2)
[Figure 30-20-16] out of the track idler and bracket.
Remove the track idler from the bracket.
S7936
Using a suitable bearing puller, remove the bearing (Item

1) [Figure 30-20-19] from both sides of the idler.

Idler Assembly
Figure 30-20-20
S7933
Using a press or driving tool, install the bearing in the

idler [Figure 30-20-22] on both sides of the idler.
1 2 1
S7935 Figure 30-20-23

Inspect the bearings (Item 1) and shaft (Item 2) [Figure
30-20-20] for wear or damage. Replace any worn or
damaged parts.
The bearings are sealed. If the bearings do not roll

smoothly, or if the seals are damaged, replace the 1
bearings.
Figure 30-20-21
S7937
Install the snap ring (Item 1) [Figure 30-20-23] on both

sides of the idler.
S7934
Remove all paint and corrosion from the bearing and seal
surface (Item 1) [Figure 30-20-21] on both sides of the
idler. If necessary, replace the track idler.
NOTE: Left-Hand Side Idler and Right-Hand Side Idler

are different. For ordering, a different P/N
exists for each side.

Idler Assembly (Cont’d)
Figure 30-20-24
1
2
1
S7940
2
Apply assembly lube to the shaft.
S7932
Using a soft faced hammer, gently tap the shaft (Item 1)
[Figure 30-20-26] in the idler and bracket.
Apply assembly lube to the inside diameter (Item 1)
[Figure 30-20-24] of the seal. Install the roll pin (Item 2) [Figure 30-20-26] on each end

of the shaft.
Apply a small bead of high temperature silicone sealant
around the flange surface (Item 2) [Figure 30-20-24] of Track Tensioner Removal And Installation
the seal.
Figure 30-20-27
Figure 30-20-25
S7949
S7939
Slide the grease cylinder forward and remove it from the

Using the driving tool, install the seal (Item 1) [Figure 30- track frame [Figure 30-20-27].
20-25] on both sides of the idler.

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Roller Removal And Installation
Track Tensioner Disassembly And Assembly Figure 30-20-30
Figure 30-20-28
1 S7948
S7945
Loosen the nuts (Item 1) [Figure 30-20-30] from the
track roller on both sides of the track frame.
Remove the rod (Item 1) [Figure 30-20-28] from the
grease cylinder. Installation: Tighten the nuts to 170 - 190 N•m (125 -

140 ft-lb) torque.
Figure 30-20-29
Remove the track roller (Item 2) [Figure 30-20-30].
2
P-15318
Remove the seal (Item 1), back-up ring (Item 2), and O-
ring (Item 3) [Figure 30-20-29] from the cylinder.

Roller Parts Identification
1. Washer
2. Shaft
3. Roller
4. Seal
5. Bearing
6. Screw
7. Ring

4
7 4 1
2
6
S8444

Roller Disassembly
The following tools must be fabricated for this procedure:
Figure 30-20-31 1
90 mm
(3.50 in)
60 mm
0,75 mm (2.25 in) S7930
(0.03 in)
Chamfer
3 places
Remove the seal (Item 1) [Figure 30-20-33] from both
30 mm sides of the track roller.
46 mm (1.18 in) Dia.
(2.81 in) B-14203 Figure 30-20-34

1. Driver Tool - see [Figure 30-20-31].
1
Figure 30-20-32
S7929

both sides of the track roller.
S7931
Using a soft faced hammer, gently tap the shaft (Item 1)

[Figure 30-20-32] from the track roller.

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Roller Assembly
Roller Disassembly (Cont’d) Clean all parts in solvent and dry with compressed air.
Figure 30-20-35 Figure 30-20-36
2
1
1
S7928 S7927
Using a suitable bearing puller, remove the bearing (Item Inspect the bearings (Item 1) and shaft (Item 2) [Figure
1) [Figure 30-20-35] from both sides of the track roller. 30-20-36] 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.
Figure 30-20-37
S7926
Remove all paint and corrosion from the seal surface

(Item 1) [Figure 30-20-37] on both sides of the track
roller.

Roller Assembly (Cont’d)
Figure 30-20-38
1
2
1
S7932
Apply assembly lube to the inside diameter (Item 1)

S7925 [Figure 30-20-40] of the seal.
Apply a small bead of high temperature silicone sealant

Using a press or driving tool, install the bearing (Item 1) around the flange surface (Item 2) [Figure 30-20-40] of
[Figure 30-20-38] on both sides of the track roller. the seal.

Figure 30-20-39 Figure 30-20-41
S7929 S7930
Install the snap ring (Item 1) [Figure 30-20-39] both Using the driving tool, install the seal (Item 1) [Figure 30-
sides of the track roller. 20-41] on both sides of the track roller.

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Removal And Installation Of Expandable Track Frame
Roller Assembly (Cont’d) Remove the track expansion cylinder. (See Removal And
Figure 30-20-42
Remove the track. (See Track Removal And Installation
on Page 30-20-4.)
Figure 30-20-43
1
1
2
S7931
Apply assembly lube to the shaft. 1

S7943

Using a soft faced hammer, gently tap the shaft [Figure
30-20-42] in the track roller.
Remove the bolts (Item 1) and the travel motor cover
(Item 2) [Figure 30-20-43] from the travel motor.
Figure 30-20-44
1
P-59087
Remove the hoses (Item 1) [Figure 30-20-44] from the

travel motor.

Removal And Installation Of Expandable Track Frame

(Cont’d)
Figure 30-20-45
S7946
Remove the nut (Item 1) [Figure 30-20-45] from the track

expansion stop rod.
Figure 30-20-46
S7944
Install a chain hoist on the track frame [Figure 30-20-46].

Lift the frame a small amount while pulling the frame
away from the excavator.
Using a 10 X 1,5 mm tap, clean the track frame bolt holes

to remove the old thread locking compound.

TRACK MAINTENANCE Causes Of The Damage
Track Damage Identification When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
The following pages show photos and illustrations of of the embedded steel cords causes steel cords to be
track damage and the probable cause of the damage. It cut:
is intended to be used for identifying the reason for track
damage and how to avoid future track damage. Figure 30-30-3
Cutting Of The Steel Cords
Damage:
Figure 30-30-1
PI-13035

When the rubber track is detracking, the idler or sprocket
rides on the projections of the embedded metal [Figure
30-30-3].
P-03864
When the rubber track is detracted, projections of rubber
tracks get stuck between the frame of the undercarriage.
Figure 30-30-2
The rubber track is clogged with stones or foreign
obstacles.
When moisture penetrates through a cut on the lug side

rubber surface, the embedded steel cords will corrode.
The deterioration of the design strength may lead to the
breaking off of the steel cords.
Prevention
The following preventions should be taken to minimize

the risk of this damage:
Steel Cords
Periodically check on site, recommended track tension.
PI-13034 (See Checking Tension on Page 30-20-2.)
Avoid quick turns on bumpy and rocky fields.

Damage:
Drive carefully to avoid having stones and other articles
Embedded steel cords are cut off [Figure 30-30-1] and clog the rubber tracks.
[Figure 30-30-2].
Avoid driving over sharp objects. If this is impossible, do
Replacement: not make turns while driving over sharp objects.
Replacement is required.

TRACK MAINTENANCE (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
Abrasion of Embedded Metals inevitable. The following cases sometimes accelerate
rubber track abrasion:
Figure 30-30-4
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
under a sandy field condition for a long time.
P-3865

Damage:
In proportion to the service time, embedded metals will

gradually wear away by friction [Figure 30-30-4].
Figure 30-30-5
Abrasion
D D1 = 0.67D
PI-13037
Replacement:
Replacement is required when the width of the

embedded metals (D1) becomes 67% of their original
width (D) [Figure 30-30-5].

TRACK MAINTENANCE (CONT’D) Causes Of The Damage:
Track Damage Identification (Cont’d) Embedded metals adhere between the steel cords and
the rubber body. The following cases generate external
Separation Of Embedded Metals forces greater than the adhesion strength, causing
separation of the embedded metals:
Figure 30-30-6
Figure 30-30-7
Idler
Rubber
Track
P-04379
PI-13039
Damage:

When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded metals embedded metals, the embedded metals will eventually
cause their separation from the rubber track's body peel off [Figure 30-30-7].
[Figure 30-30-6].
Figure 30-30-8
Replacement:
Even a partial separation of embedded metals requires

replacement of the track. Guide
PI-13040
When a rubber track is detracted, it becomes stuck

between the guide or the undercarriage frame, causing
the separation of embedded metals [Figure 30-30-8].

TRACK MAINTENANCE (CONT’D)
Track Damage Identification (Cont’d)
Separation Of Embedded Metals
Figure 30-30-9
Abrasion
PI-13041

Abnormally worn sprockets as shown will pull embedded
metals out [Figure 30-30-9].
Prevention:
Similar to the prevention against the cutting of the steel

cords:
Track tension should be periodically checked.
Quick turns on bumpy and rocky fields should be

avoided.
If abnormal wear of sprockets is observed, they should

be immediately replaced.

TRACK MAINTENANCE (CONT’D) Causes Of The Damage
Track Damage Identification (Cont’d) Figure 30-30-11
Separation Of Embedded Metals Due To Corrosion Embedded metal
Figure 30-30-10
Good
Separation of bonded
rubber cover
PI-13043
Embedded metals are bonded to the rubber body. The

P-04378 following operating conditions cause embedded metals to
corrode, causing deterioration of the bonding, and finally
resulting in separation of the embedded metals from the

Damage: rubber body [Figure 30-30-11].
Due to corrosion of embedded metals, the adhesion to Excessively salty fields, like the sea shore.
the rubber body deteriorates, resulting in complete
separation [Figure 30-30-10]. Strong acidic or alkali soil conditions
Replacement: Compost spread grounds
Even a partial separation of embedded metals requires a On tracks that are out of adjustment, the track rollers,
rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at 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.

Track Damage Identification (Cont’d) Figure 30-30-13
Cuts On The Lug Side Rubber
Figure 30-30-12 Cuts
PI-13045
When rubber tracks drive over projections or sharp

P-04377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface

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 breakage of steel cords due to corrosion. It is highly
most typical failure modes [Figure 30-30-12] recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 30-30-13].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately repaired Machine operators should drive with great attention to the
with cold vulcanization rubber. ground 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, quick

high speed turns and overloading should be avoided.

Track Damage Identification (Cont’d) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Damage: even small external cracks.
Figure 30-30-14 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 damage on the lug side rubber, increases the
possibility of cracking. Machine operators should observe
soil conditions when driving, to prevent external damage
to the lug side rubber. In order to minimize the
occurrence of ozone cracks, follow these maintenance
instructions:
P-04382 Avoid exposing stored tracks to direct sun light.

Avoid exposing stored tracks to direct rain and snowfall.
Figure 30-30-15
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Small cracks around the root of the lug are a result from
operation fatigue [Figure 30-30-14] and [Figure 30-30-
15]
Replacement:
When the cracks become deep enough to expose the

steel cords, track replacement is required.

Track Damage Identification (Cont’d) Lug abrasion will occur as operation time increases.
Even as lug abrasion increases, the rubber track can be
Lug Abrasion used. However, as the traction performance deteriorates,
it is highly recommended to replace the abraded tracks
Figure 30-30-16 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, the following operating conditions
should be avoided:
Making quick and repeated turns on concrete and

asphalt roads.
Driving up and down hilly paths with slippage.
Making frequent turns on paths covered with rocks and

P-04381 wood.

Figure 30-30-17
Lug abrasion
t
PI-13049
Damage:
As operation time increases, the lug side undergoes

abrasion [Figure 30-30-16] and [Figure 30-30-17].
Replacement:
No replacement is required.

TRACK MAINTENANCE (CONT’D) Figure 30-30-19
Cracks And Cuts On The Lug Side Rubber
Figure 30-30-18 Crack at the edge Cut on lug side

of embedded rubber
PI-13051
Causes of the damage:
When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals

Damage: [Figure 30-30-19].
Sometimes cracks and cuts on the lug side rubber at the Prevention:
edges of the embedded metals can be observed [Figure
30-30-18]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators should avoid
Replacement: driving over stumps and ridges.
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.

Abrasion Of The Track Roller Side

Track roller
Figure 30-30-20
Abrasion
PI-13053
Causes Of The Damage:
The abrasion of the track roller side rubber surface

P-04383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against

Damage: the side of the rubber track to cause the abrasion [Figure
30-30-21].
The rubber surface on which track rollers run is gradually
abraded. It will result in the exposure of the embedded The level of abrasion is highly dependent on terrain
metals [Figure 30-30-20]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when more an extended period of abrasion, it will be more likely for
than half of the embedded metals are completely exposed embedded metals to catch moisture through the
exposed. 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
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.

Cuts On The Edges Of The Track Roller Side
Figure 30-30-22
Edge Edge
PI-13056
In case of damage by objects on the operating ground:
The edges of rubber track are often deformed largely due

PI-13055 to a bumpy ground surface, stones and other objects,
which causes extensive stress on the edges resulting in
the damage. When driving a machine over concrete

Figure 30-30-23 ridges, this type of damage easily occurs [Figure 30-30-
24].
Figure 30-30-25
Cut
Tear
P-04384
Damage:
PI-13057
Both edges of a rubber track [Figure 30-30-22] have no

special reinforcement. During operation the edges may In case of damage by interference with the machine
become cut or torn off [Figure 30-30-23] and [Figure 30- frame.
30-24].
If a machine continues operating with rubber tracks being
Replacement: detracked, the rubber tracks may get caught up in the
machine frame or undercarriage parts resulting in
In such case, the rubber track does not have to be damage. Furthermore, when a machine travels along
replaced. side slopes, the rubber tracks are deformed so much that
they come into contact with the machine frame and
Causes Of The Damage: undercarriage parts, which causes cutting, gouging and
rubbing of rubber tracks in the end [Figure 30-30-25].
This damage is caused by objects on the ground or by
interference with the machine frame.

TRACK MAINTENANCE (CONT’D)
Cuts On The Edges Of The Track Roller Side (Cont’d)
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for detracking.
Remove the track. (See Checking Tension on Page 30-

20-2.)

SWING CIRCLE GEAR Figure 30-40-3
Remove the upperstructure from the swing circle gear.

(See Removal on Page 40-10-1.) 1
S
Figure 30-40-1
S
2
S
1 S8299
S
Remove the bolts and nuts from the swing circle gear
[Figure 30-40-3].
Installation: Tighten the bolts and nuts to 105 - 115 N•m

S8299 (78 - 85 ft-lb) torque.

Figure 30-40-2
S
2
1
S
S8298
The swing gear and outer ring both have a soft zone. The
swing gear soft zone is identified with an S (Item 1)
stamped in the swing gear. The outer ring soft zone is
identified with an S (Item 2) [Figure 30-40-1] and [Figure
30-40-2] stamped in the outer ring.
The soft zones of both the swing gear and outer ring
must be positioned 180° of each other.


UPPERSTRUCTURE AND SWING SECTION
UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-5
TOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
RIGHT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Joystick Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2
Compression Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-3
Joystick Console Frame Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-4
Joystick Console Frame Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 40-40-4

LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Joystick Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Compression Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-3
Joystick Console Frame Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-4
Joystick Console Frame Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 40-50-4
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-3
Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5
BLADE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-3
Two Speed Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-4
SWING LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
RIGHT PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Linkage Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-3

TRAVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Right Hand Travel Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Right Hand Travel Control Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 40-100-1
Left Hand Travel Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Left Hand Travel Control Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 40-100-3
LEFT PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
Control Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
Control Linkage Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-3
FLOOR PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Left Floor Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Right Floor Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1

SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-2
Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-3
Boom Pivot Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-4
Boom Pivot Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-4
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-2
Arm To Bucket And Bucket Link Bushing Removal And Installation . . . . . . . . . . . . 40-170-2
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-2

COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
Rear Counterweight Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
Left Side Counterweight Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
Right Side Counterweight Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-200-2
SIDE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1

Upper Left Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Upper Right Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Lower Left Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-2
Lower Right Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-3
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1

QUICK COUPLER (KLAC™ SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230-7
QUICK COUPLER (LEHNHOFF® SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-1
Removal (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-2
Installation (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-3
Parts Identification (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-4
Disassembly And Assembly (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-5
Parts Identification (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-6
Disassembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-7
Assembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-231-10


UPPERSTRUCTURE Figure 40-10-1
Description
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.
Removal 1
Fully extend the cylinders of the bucket and arm. Fully

retract the cylinder of the boom.
1
Lower the blade to the ground. S8267

Page 50-20-3.) Remove the two tubelines (Item 1) [Figure 40-10-1] from
the swivel joint.
Remove the TOPS. (See Removal And Installation on
Page 40-20-1.) Figure 40-10-2

Remove the seat. (See Removal And Installation on

1
Page 40-30-1.)

40-120-1.)
1
Remove the slew motor. (See Removal And Installation
on Page 20-90-1.)
Remove the track expand valve.

S8268
Page 60-20-1.)
Remove the lower right hand side cover. (See Lower the swivel joint.
210-3.)

UPPERSTRUCTURE (CONT’D) Figure 40-10-5
Removal (Cont’d)
Figure 40-10-3
1
S8269

S8050 the swivel joint.

Disconnect the tubeline (Item 1) [Figure 40-10-3] from to the swing circle gear bolts.
the control valve.

Figure 40-10-6
Figure 40-10-4
1
1
S8271
S8278

Disconnect the tubeline (Item 1) [Figure 40-10-4] from the swivel joint.
the control valve.
to the swing circle gear bolts.

Removal (Cont’d)
Figure 40-10-7
1
1
1
S8274
1

the cable bracket.
S8272
Move the cable bracket aside for easy access to swing

Disconnect the two tubelines (Item 1) [Figure 40-10-7]. circle gear bolts.
Figure 40-10-10

Figure 40-10-8
1
1
S8402
S8273
Install chains (Item 1) [Figure 40-10-10] in the rear

Disconnect the two tubelines (Item 1) [Figure 40-10-8]
TOPS mounting holes. Fasten the chains to the chain
from the swivel joint.
hoist.
Remove the tubelines from the excavator for easy access
Install chains (Item 2) [Figure 40-10-10] at the top of the
to the swing circle gear bolts.
boom. Fasten the chains to the chain hoist.

Removal (Cont’d)
WARNING
• Use a lifting fixture with sufficient capacity for 1
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 upperstructure slew lock. S8277
• Never lift with operator on machine.
W-2202-0607
Figure 40-10-14
Figure 40-10-11

1
1
S8276
S8275
Remove the 18 bolts (Item 1) [Figure 40-10-13] and
[Figure 40-10-14] from the upperstructure.
Mark the upperstructure to the swing bearing and to the
track frame for ease of assembly [Figure 40-10-11]. Lift the upperstructure off the swing bearing. Position the
Figure 40-10-12 upperstructure onto supporting stands or blocks.
NOTE: Keep tension on the chain hoist to support the

boom and arm when the upperstructure is
supported on stands or blocks.
S8276
Remove the three swivel joint mount nuts (Item 1)

[Figure 40-10-12].

Installation
Install the lower right hand side cover. (See Lower Right
Side Cover Removal And Installation on Page 40-210-3.) 2
S
Install the muffler. (See Removal And Installation on
Page 60-20-1.) 1
S
Install the track expand valve.
Install the slew motor. (See Removal And Installation on

Page 20-90-1.)
Install the floor panels. (See FLOOR PANELS on Page S8299

40-120-1.)
Install the seat. (See Removal And Installation on Page Figure 40-10-16
40-30-1.)
Fill the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-3.) S
2

Install the TOPS. (See Removal And Installation on Page
40-20-1.)
Install the battery. (See Removal and Installation on Page

1
50-20-3.)
S
S8298
The swing gear and outer ring both have a soft zone. The
swing gear soft zone is identified with an S (Item 1)
stamped in the swing gear. The outer ring soft zone is
identified with an S (Item 2) [Figure 40-10-15] and
[Figure 40-10-16] stamped in the outer ring.
The soft zones of both the swing gear and outer ring
must be positioned 180° of each other.
NOTE: Clean out the old excess Loctite® from all the
18 threaded holes in the slew bearing prior to
installing the upperstructure.

Installation (Cont’d)
Figure 40-10-17
1
1
S8277
Figure 40-10-20
S8774
Lower the upperstructure frame onto the swing bearing

aligning the two pins (Item 1) [Figure 40-10-17]. Maintain

a slight amount of weight on the hoist.
Figure 40-10-18 1
1
S8276
Apply Loctite® 243 or equivalent to bolts and install the

18 bolts and washers (Item 1) [Figure 40-10-19] and
[Figure 40-10-20] through the upperstructure frame and
into the swing bearing.
S8275 Tighten the bolts to 57 - 63 N•m (42 - 47 ft-lb) torque.
Check that upperstructure is properly aligned to the

swing bearing and track frame [Figure 40-10-18].

Figure 40-10-21
1
S8273
Connect the two tubelines (Item 1) [Figure 40-10-23] on

S8276 the swivel joint.
Figure 40-10-24
Install the three swivel joint mount nuts (Item 1) [Figure
40-10-21].

Figure 40-10-22
1 S8272
1
Connect the two tubelines (Item 1) [Figure 40-10-24].

S8274
Install the bolt and nut (Item 1) [Figure 40-10-22] from

the cable bracket.

Figure 40-10-25
1
S8278
Connect the tubeline (Item 1) [Figure 40-10-27] on the

S8271 control valve.
Figure 40-10-28
swivel joint.

Figure 40-10-26
1
1
S8050

S8269 control valve.

swivel joint.

UPPERSTRUCTURE (CONT’D)
Figure 40-10-29
S8268
Install the two tubelines (Item 1) [Figure 40-10-29] on the

swivel joint.

Figure 40-10-30
1
S8267
Install the two tubelines (Item 1) [Figure 40-10-30] on the

swivel joint.


TOPS
Figure 40-20-1
S8001
Put a strap around the TOPS to support while removing

[Figure 40-20-1].

Figure 40-20-2
S7957
Remove the pin (Item 1), bolt and nut (Item 2) [Figure
40-20-2] from both sides of the TOPS.
Installation: Tighten the bolts to 215 N•m (159 ft-lb)

torque.
Remove the TOPS from the excavator.


SEAT Figure 40-30-3
Move the seat to the rear most position using the seat
adjustment lever.

Figure 40-30-1
1 1
2 2 S8220
Open the tailgate.
Remove the two nuts (Item 2) [Figure 40-30-1] and bolts

(Item1) [Figure 40-30-3].
1 1 Remove the seat and seat rails from the tailgate.

S6737 Figure 40-30-4
Figure 40-30-2
1 1
1
1
S8221
Remove the two nuts (Item 1) [Figure 40-30-1] and bolts

(Item1) [Figure 40-30-2].
Close the tailgate and move the seat completely forward

using the seat adjustment lever.

SEAT (CONT’D)
Figure 40-30-5
1 1
S8222

Remove the seat rails from the seat.

RIGHT CONSOLE Figure 40-40-3
Joystick Console Cover Removal And Installation
Figure 40-40-1
1
1 S8172
Raise the right console.

S8170
Remove the bolt (Item 1) [Figure 40-40-3] from the
joystick console cover.
joystick console cover. Remove the joystick console cover.

Figure 40-40-2
1
2
S8171


the armrest bracket.

RIGHT CONSOLE (CONT'D) Compression Spring Removal And Installation
Gas Spring Removal And Installation Figure 40-40-5
Remove the joystick console cover. (See Joystick

Console Cover Removal And Installation on Page 40-40-
1.)
Raise and support the console.
Figure 40-40-4
1
S8208
Raise the console.
Remove the nut (Item 1) [Figure 40-40-5] from the

1 compression spring.

S8186 Figure 40-40-6
Remove the two clips (Item 1) [Figure 40-40-4] from the

gas spring.
Remove the gas spring from the top and bottom of the
console.
WARNING 1
2
3
Cylinder contains high pressure gas. Do not open.

Opening cylinder can release rod and cause injury or S8192
death.
W-2113-0288
Remove the spring seat (Item 1), spring (Item 2), and bolt
(Item 3) [Figure 40-40-6] from the console.

RIGHT CONSOLE (CONT'D) Figure 40-40-9
Lever Removal And Installation 2

1.)
Raise the console. 3 1

Figure 40-40-7
S8189
Remove the bushing (Item 1), linkage (Item 2), and bolt
(Item 3) [Figure 40-40-9].
Figure 40-40-10
1

S8187
Remove the retaining clip (Item 1) [Figure 40-40-7] from

the linkage.
2
Figure 40-40-8
1
S8190
1
Remove the retaining clip (Item 1) [Figure 40-40-10].
Remove the lever (Item 2) [Figure 40-40-10] from the

console.
S8188
Remove the nut (Item 1) [Figure 40-40-8].

RIGHT CONSOLE (CONT'D) Joystick Console Frame Disassembly And Assembly
Joystick Console Frame Removal And Installation Figure 40-40-12

1.)
1
Remove the microswitch. (See Right Console
Microswitch Removal And Installation on Page 50-60-3.)
Remove the compression spring. (See Compression

Spring Removal And Installation on Page 40-40-2.)
Remove the gas spring. (See Gas Spring Removal And

2
Remove the lever. (See Lever Removal And Installation S8194
on Page 40-40-3.)
Remove the roll pin (Item 1) and pivot pin (Item 2)

[Figure 40-40-12].

damage the system.
I-2003-0888
2 1
Figure 40-40-11
1 S8195
2 Remove the bushing (Item 1) [Figure 40-40-13].
Remove the pin and nut (Item 2) [Figure 40-40-13].
S8193

40-40-11] from the console frame.
Remove the console frame from the excavator.

Joystick Console Frame Disassembly And Assembly

(Cont’d)
Figure 40-40-14
1
S8199
1
S8196 Figure 40-40-17

Figure 40-40-15
1 2
1
S8201
Remove the spring (Item 1) and pin (Item 2) [Figure 40-

40-17].
S8197
Remove the two bushings (Item 1) [Figure 40-40-15].


(Cont’d)
Figure 40-40-18
1
1
S8198
Raise the dust boot.
S8200 Remove the screws (Item 1) [Figure 40-40-20] from the

joystick bracket.
Remove the clevis end (Item 1) [Figure 40-40-18]. Remove the joystick from the console frame.

Figure 40-40-19
1 2
S8202

40-19].

LEFT CONSOLE Figure 40-50-3
Joystick Console Cover Removal And Installation
Figure 40-50-1
1
1
1
S8204
Raise the left console.

S8205
joystick console cover. Remove the joystick console cover.

Figure 40-50-2
S8203


the armrest bracket.

LEFT CONSOLE (CONT'D) Compression Spring Removal And Installation
Gas Spring Removal And Installation Figure 40-50-5

1.)
Raise and support the console.
Figure 40-50-4
1
1
S8206
Raise the console.
1 Remove the nut (Item 1) [Figure 40-50-5] from the

compression spring.

S8207 Figure 40-50-6
Remove the two clips (Item 1) [Figure 40-50-4] from the

gas spring.
Remove the gas spring from the top and bottom of the
console.
WARNING 1
2
3
Cylinder contains high pressure gas. Do not open.

Opening cylinder can release rod and cause injury or S8192
death.
W-2113-0288
Remove the spring seat (Item 1), spring (Item 2), and bolt
(Item 3) [Figure 40-50-6] from the console.

LEFT CONSOLE (CONT'D) Figure 40-50-9
Lever Removal And Installation 2

1.)
Raise the console. 3 1

Figure 40-50-7
S8189
1 Remove the bushing (Item 1), linkage (Item 2) and bolt

(Item 3) [Figure 40-50-9].
Figure 40-50-10

S8210
Remove the retaining clip (Item 1) [Figure 40-50-7] from

the linkage.
2
Figure 40-50-8
1
S8212
1 Remove the retaining clip (Item 1) [Figure 40-50-10].
Remove the lever (Item 2) [Figure 40-50-10] from the

console.
S8211

LEFT CONSOLE (CONT'D) Joystick Console Frame Disassembly And Assembly
Joystick Console Frame Removal And Installation Figure 40-50-12

1.)
1
Remove the microswitch. (See Left Console Microswitch
Remove the compression spring. (See Compression

Spring Removal And Installation on Page 40-50-2.)
Remove the gas spring. (See Gas Spring Removal And

Remove the lever. (See Lever Removal And Installation S8214
on Page 40-50-3.)
Remove the roll pin (Item 1) and pivot pin (Item 2)

[Figure 40-50-12].

damage the system.
I-2003-0888
1
Figure 40-50-11
S8215
Remove the bushing (Item 1) [Figure 40-50-13].

1
2
S8213

40-50-11] from the console frame.
Remove the console frame from the excavator.


(Cont’d)
Figure 40-50-14
1
1 S8199
S8216 Figure 40-50-17

Figure 40-50-15
1 2
1
S8201

50-17].
S8217
Remove the two bushings (Item 1) [Figure 40-50-15].


(Cont’d)
Figure 40-50-18
1
1
1
S8198
Raise the dust boot.
S8218 Remove the screws (Item 1) [Figure 40-50-20] from the

joystick bracket.
Remove the clevis end (Item 1) [Figure 40-50-18]. Remove the joystick from the console frame.

Figure 40-50-19
1 2
S8202

50-19].

ENGINE SPEED CONTROL Figure 40-60-3
Figure 40-60-1
1
1
1
S7980

S7978 the right hand side of the instrument panel.
Figure 40-60-4
Remove the two bolts (Item 1) [Figure 40-60-1] from the
throttle lever.

Installation: Tighten the two bolts (Item 1) [Figure 40-
60-1] evenly until the throttle lever moves back and forth
at a comfortable tension. 1
Figure 40-60-2
1 3
2
1
S7979

the left hand side of the instrument panel.
Move the instrument panel to one side to provide extra

clearance for easy access to engine speed control.
S7924
Remove the lever (Item 1), the two wave washers (Item
2), and the spacer (Item 3) [Figure 40-60-2].

ENGINE SPEED CONTROL (CONT’D)
Figure 40-60-5
1
2
S7971
Remove the bolt (Item 1) and bracket (Item 2) [Figure

40-60-5].

Remove the nut (Item 3) [Figure 40-60-5] from the
throttle linkage and remove throttle cable.
Remove the spacer (Item 4) [Figure 40-60-5] from the

throttle lever.

ENGINE SPEED CONTROL (CONT’D) Figure 40-60-8
Cable Removal
Figure 40-60-6
1
1
1
S7980

Figure 40-60-9
throttle lever.

Figure 40-60-7
1
1 3
2
S7979

S7924 the left side of the instrument panel.

Remove the lever (Item 1), the two wave washers (Item clearance for easy access to engine speed control.

Cable Removal (Cont’d)
Figure 40-60-10
1 1 2
S7581
1
Loosen the nuts (Item 1) [Figure 40-60-12] fastening the
S7971 cable to the bracket.
Disconnect the linkage (Item 2) [Figure 40-60-12] from

Remove the nut (Item 1) [Figure 40-60-10] from the the bracket.
throttle linkage and remove throttle cable.

Move the cable away from the engine.
Figure 40-60-11
Figure 40-60-13
1
2
1
7970
S7969
Remove the bolt and nut (Item 1) and bracket (Item 2)

[Figure 40-60-11]. Pull the cable (Item 1) [Figure 40-60-13] out the back of
the excavator.

Cable Installation
Figure 40-60-14
2
1
S7971
Insert the throttle cable (Item 1) [Figure 40-60-16]

S7969 through the throttle linkage.

Position the throttle cable (Item 1) [Figure 40-60-14].
Figure 40-60-17

Figure 40-60-15
2
1
1
S7979
7970
Install the three bolts (Item 1) [Figure 40-60-17] on the

Install the bracket (Item 1) and bolt and nut (Item 2) left side of the instrument panel.
[Figure 40-60-15].

Cable Installation (Cont’d)
Figure 40-60-18
1 1
S7978
1
Install the two bolts (Item 1) [Figure 40-60-20] and
S7980 tighten evenly until the throttle lever moves back and forth
at a comfortable tension.
Install the three bolts (Item 1) [Figure 40-60-18] on the Figure 40-60-21
right side of the instrument panel.

Figure 40-60-19
3 1
2
2 2 1
S7581
S7924 Connect the linkage (Item 1) [Figure 40-60-21] to the

injection pump control lever.
Install the spacer (Item 1), the two wave washers (Item 2) Slightly tighten the nuts (Item 2) [Figure 40-60-21] by
and lever (Item 3) [Figure 40-60-19]. hand.

Cable Installation (Cont’d)
Figure 40-60-22
1 1 1
S7581
Move throttle lever (Item 1) [Figure 40-60-22] and check

S7978 if injection pump control lever (Item 1) reaches both end
positions (Item 2) [Figure 40-60-23].
Check if throttle lever (Item 1) does not interfere with If not, set the correct end position of the throttle lever by
space in front of 12V socket (Item 2) [Figure 40-60-22]. using the nuts (Item 1) [Figure 40-60-24].

Figure 40-60-23 When correct setting is obtained fully tighten the nuts
(Item 1) [Figure 40-60-24].
1 2
S8777


BLADE CONTROL Figure 40-70-3

Figure 40-70-1 2
1 1
3
S7907
1
Remove the cotter pin (Item 1) and pin (Item 2) [Figure
40-70-3].
1

Figure 40-70-4
Remove the four bolts (Item 1) [Figure 40-70-1] from the
cover. 1
Figure 40-70-2
1
1
S7908
1
Remove the cotter pins (Item 1) [Figure 40-70-4].
S8008
Remove the pin (Item 2) and remove the linkage (Item 3)
[Figure 40-70-4] from the control valve.
cover.
Remove the cover from the excavator.

BLADE CONTROL (CONT’D) Figure 40-70-7
Figure 40-70-5
2
1
2
1
S7911
1 Remove the pin (Item 1) [Figure 40-70-7].

S7909
Remove the bellcrank (Item 2) [Figure 40-70-7].
Remove the bolts and nuts (Item 1) [Figure 40-70-5]. Figure 40-70-8

Remove the travel control and blade control (Item 2)
[Figure 40-70-5].
Figure 40-70-6
1
S7912
Remove the pin (Item 1) [Figure 40-70-8].
S7910 Remove the blade control handle (Item 2) [Figure 40-70-

8].
Remove the two bearings (Item 1) [Figure 40-70-6].

Figure 40-70-9
S8230
Remove the lock (Item 1) [Figure 40-70-11] from the

S7913 electrical connector.
Figure 40-70-12
Remove the two bushings (Item 1) [Figure 40-70-9] from
the blade control handle.

Figure 40-70-10
1
S8231

S7914 (Item 1) [Figure 40-70-12].
Mark and remove the individual wires from the back of

Remove the screws (Item 1) [Figure 40-70-10] and the electrical connector.
plastic handle halves.

BLADE CONTROL (CONT’D) Two Speed Switch Removal And Installation
Disassembly And Assembly (Cont’d) Remove the instrument panel. (See Removal And
Figure 40-70-13
Figure 40-70-15
1
1
1
P-32916
S8234
Installation: Use a small piece of wire and bend the tab

(Item 1) [Figure 40-70-13] on each wire before installing Remove the electrical connector (Item 1) [Figure 40-70-

in the electrical connector. 15] from the excavator electrical harness.
Installation: The wires must be installed in the proper Figure 40-70-16

locations in the wire connector.
Figure 40-70-14
1 1
S8230
Remove the lock (Item 1) [Figure 40-70-16] from the

electrical connector.
S7915
Remove the two speed switch (Item 1) [Figure 40-70-14]

from the blade control handle.

Two Speed Switch Removal And Installation (Cont’d)
Figure 40-70-17
1 Remove the screws (Item 1) [Figure 40-70-19] and

S8231 plastic handle halves.
Figure 40-70-20
(Item 1) [Figure 40-70-17].

Mark and remove the individual wires from the back of
the electrical connector.
Figure 40-70-18
1
S8233
Remove the two speed switch (Item 1) [Figure 40-70-20]

from the blade control handle.
1
P-32916
Installation: Use a small piece of wire and bend the tab

(Item 1) [Figure 40-70-18] on each wire before installing
in the electrical connector.
Installation: The wires must be installed in the proper

locations in the wire connector.


SWING LOCK Disassembly And Assembly
Removal And Installation Figure 40-80-2
Remove the right floor panel. (See Right Floor Panel

Removal And Installation on Page 40-120-1.) 2
Remove the instrument panel. (See Removal And 1

Figure 40-80-1 3
S8003
1
Remove the nut (Item 1) from the swing lock lever (Item
2). Remove the pin (Item 3) [Figure 40-80-2].

S8002
Remove the upperstructure slew lock lever (Item 1)

[Figure 40-80-1] from the upperstructure.


RIGHT PEDAL AND LINKAGE Linkage Removal And Installation
Pedal Removal And Installation Remove the instrument panel. (See Removal And
Figure 40-90-1
Figure 40-90-2
4
1
2
3
1
1
1
S8034
S8009
Remove the cotter pin (Item 1) and washer (Item 2)

[Figure 40-90-1] from the pedal assembly. Remove the four bolts (Item 1) [Figure 40-90-2] from the

cover.
Remove the pin (Item 3) and remove the auxiliary pedal
(Item 4) [Figure 40-90-1]. Figure 40-90-3
S8008

cover.
Remove the cover.

RIGHT PEDAL AND LINKAGE (CONT’D) Figure 40-90-6
Linkage Removal And Installation (Cont’d)


210-3.)
Figure 40-90-4
S8032
2 Remove the nut (Item 1) [Figure 40-90-6].
Remove the control linkage assembly from the excavator.

S8013
Remove the cotter pin (Item 1) and the pin (Item 2)

[Figure 40-90-4].
Disconnect the linkage from the bellcrank.
Figure 40-90-5
1 1
S8033
Disconnect the two hoses (Item 1) [Figure 40-90-5] from

the control valve.

RIGHT PEDAL AND LINKAGE (CONT’D) Figure 40-90-9
Linkage Disassembly And Assembly

1 1
Figure 40-90-7
S8029
1
Remove the two pivot pins (Item 1) [Figure 40-90-9].

S8031
Figure 40-90-10
Remove the nut (Item 1) and linkage (Item 2) [Figure 40-

90-7].

Installation: Tighten the nut to 5,5 N•m (48.67 in-lb)
torque.
Figure 40-90-8
1
1 S8028
1 Installation: Tighten the nut to 5,5 N•m (48.67 in-lb)

torque.
S8030
Remove the two nuts (Item 1) [Figure 40-90-8].
Installation: Tighten the nuts to 5,5 N•m (48.67 in-lb)

torque.

RIGHT PEDAL LINKAGE (CONT’D) Figure 40-90-13
Linkage Disassembly And Assembly (Cont’d)
Figure 40-90-11
1
3 3
1
S8025

4 4
S8027 Figure 40-90-14
Remove the lever (Item 1), pedal assembly (Item 2),

spacers (Item 3) and bolts (Item 4) [Figure 40-90-11].

Figure 40-90-12
2
S8024

2 [Figure 40-90-14].
1
Figure 40-90-15
S8026

2
[Figure 40-90-12].
S8023
Remove the pin (Item 1) and pedal (Item 2) [Figure 40-

90-15] from the bracket.

TRAVEL CONTROLS Left Hand Travel Control Removal And Installation
Right Hand Travel Control Removal And Installation Remove the instrument panel. (See Removal And
Installation on Page 40-220-1.))
Remove the blade control. (See Removal And Installation
on Page 40-80-1.) Figure 40-100-3
Figure 40-100-1
1 1
S8009
S7916
Remove the four bolts (Item 1) [Figure 40-100-3] from

the cover.
Remove the pin (Item 1) [Figure 40-100-1] from the right
hand travel control. Figure 40-100-4
Right Hand Travel Control Disassembly And

Assembly
Figure 40-100-2
1
1
1
S8008

cover.
S7917
Remove the cover from the excavator.
Remove the right hand control knob (Item 1) [Figure 40-

100-2].

TRAVEL CONTROLS (CONT’D) Figure 40-100-7
Left Hand Travel Control Removal And Installation

(Cont’d)
Figure 40-100-5
S7920
1
Remove the two bearings (Item 1) [Figure 40-100-7].

3
S7918 Figure 40-100-8

40-100-5].

the control valve.
Figure 40-100-6 1
2 S7921
1 1 Remove the pin (Item 1) [Figure 40-100-8].
Remove the bellcrank (Item 2) [Figure 40-100-8].
S7919
Remove the bolts and nuts (Item 1) [Figure 40-100-6].
Remove the left hand travel control (Item 2) [Figure 40-

100-6].

TRAVEL CONTROLS (CONT’D)
Left Hand Travel Control Disassembly And Assembly
Figure 40-100-9
S7917
Remove the left hand control knob (Item 1) [Figure 40-

100-9].


LEFT PEDAL AND LINKAGE Control Linkage Removal And Installation
Pedal Removal And Installation Remove the instrument panel. (See Removal And
Figure 40-110-1
Figure 40-110-2
4
1
1
1
3
2 1
S8010
S8009

[Figure 40-110-1]. Remove the four bolts (Item 1) [Figure 40-110-2] from

the cover.
Remove the pin (Item 3) and remove the boom swing
pedal (Item 4) [Figure 40-110-1]. Figure 40-110-3
S8008

cover.
Remove the cover.

LEFT PEDAL AND LINKAGE (CONT’D) Figure 40-110-6
Control Linkage Removal And Installation (Cont’d)
Figure 40-110-4
2 S8013
1

S8011
Figure 40-110-7

40-110-4].

Disconnect the linkage from the bellcrank.
1
Figure 40-110-5
S8014

the control valve.
S8012

LEFT PEDAL AND LINKAGE (CONT’D) Control Linkage Disassembly And Assembly
Control Linkage Removal And Installation (Cont’d) Figure 40-110-9
Remove the left floor panel. (See Left Floor Panel

Figure 40-110-8 1
1
S8015

shaft.
S7559
Figure 40-110-10

the swivel joint.
1
Reposition the tubeline for easy removal of the control
linkage assembly.
Remove the control linkage assembly.
S8016
Remove the pin (Item 1) and bellcrank (Item 2) [Figure

40-110-10] from the shaft.

LEFT PEDAL AND LINKAGE (CONT’D) Figure 40-110-13
Linkage Disassembly And Assembly (Cont’d)
Figure 40-110-11
1
2
S8019
2
Remove the bearing (Item 1) and pin (Item 2) [Figure 40-
S8017 110-13] from the shaft.

[Figure 40-110-11] from the shaft.

Figure 40-110-12
S8018
Remove the pin (Item 1) and pedal (Item 2) [Figure 40-

110-12].

FLOOR PANELS Right Floor Panel Removal And Installation
The floor of the excavator is divided into two floor panels.

Both floor panels provide accessibility to the hydraulic
components, electrical components and the fuel tank.
Left Floor Panel Removal And Installation
Figure 40-120-1 1
S6726
1 Remove the nut and bolt (Item 1) [Figure 40-120-3].
Figure 40-120-4

S6717
Remove the nut and bolt (Item 1) [Figure 40-120-1].
Figure 40-120-2
1
S6719
1 1 Remove the bolts (Item 1) [Figure 40-120-4] from the

right floor panel.
Remove the right floor panel.
S6717
Remove the bolts (Item 1) [Figure 40-120-2] from the left

floor panel.
Remove the left floor panel.


FUEL TANK Figure 40-130-3
Drain the fuel tank. (See Draining The Fuel Tank on Page
10-100-3.)
Remove the left floor panel. (See Left Floor Panel

Figure 40-130-1
S6760
1 Remove the bolt (Item 1) [Figure 40-130-3] from the

mounting bracket.
Figure 40-130-4

S6756
1
fuel tank.
Remove the lower left hand side cover. (See Lower Left 2
Figure 40-130-2
S6761
Remove the bolt (Item 1) and mounting bracket (Item 2)

[Figure 40-130-4].
1
Remove the fuel tank.
2
S6764
Disconnect the fuel level sender (Item 1) [Figure 40-130-

2] from the fuel tank.

fuel tank.


HORN

Figure 40-140-1
S6742

Remove the wire (Item 1) [Figure 40-140-1] from the
horn.
Remove the horn.


SWING FRAME Figure 40-150-2
Description
The swing frame is the casting connected to the boom

swing cylinder and the boom with top mounted boom
cylinder. The swing casting provides the pivot point for
the boom in the offset function and the up down motion of
the boom. The swing frame is connected to the 2
upperstructure by a top and bottom pivot pin.
1
Remove the bucket. (See Removal And Installation on

Page 40-180-1.)
S7672
Remove the arm. (See Removal And Installation on Page
40-170-1.)
Install the pivot pin (Item 1), nut and bolt (Item 2) [Figure
Remove the boom. (See Removal And Installation on 40-150-2].
Page 40-160-1.)
Install a chain hoist on the swing frame [Figure 40-150-
Figure 40-150-1 2].

Figure 40-150-3
2
S6782
S7673
Remove the bolt, washers and spacer (Item 1) [Figure
Remove the pivot pin (Item 2) [Figure 40-150-1] from the 40-150-3] from the top pivot pin.
rod end of the cylinder.
Remove the top pivot pin (Item 2) [Figure 40-150-3] from
the swing frame.

SWING FRAME (CONT’D) Bushing Removal
Removal And Installation (Cont’d) Figure 40-150-5
Figure 40-150-4
S7973
1
2 S7674
Remove the bottom bushing (Item 1) [Figure 40-150-5]
and top bushing (Item 2) [Figure 40-150-5] from the
Remove the bolt and washers (Item 1) [Figure 40-150-4] upperstructure by using a bolt, washers and nut.
from the bottom pivot pin.

The following parts will be needed for removal and
Remove the bottom pivot pin (Item 2) [Figure 40-150-4] installation of the bushings.
from the swing frame.
Bolt - 15,875 x 114,3 mm long (0.625 x 4.5 in long)
Remove the swing frame from the excavator.
Nut - 15,875 mm (0.625 in)
Washer - 15,875 mm I.D. x 38,0 mm O.D. x 6,35 mm
thick (0.625 in I.D. x1.496 in O.D. x 0.25 in thick)
Washer - 15,875 mm I.D. x 74,295 mm O.D. x 6,35
mm thick (0.625 in I.D. x 2.925 in O.D. x 0.25 in thick)
Spacer - 57,15 mm I.D. x 74,295 mm O.D. x 40,0 mm
thick (2.600 in I.D. x 2.925 in O.D. x 1.575 in thick)

SWING FRAME (CONT’D) Bushing Installation
Bushing Removal (Cont’d) Apply a film of grease to the outer diameter of the
bushing and the inner diameter of the casting.
Figure 40-150-6
Center the bushing in the casting hole.
2
NOTE: Make sure the bushing is centered into the
3 casting hole and is started in the hole evenly
and square.
Put the washer (Item 3) over the flanged end of the

bushing. Put the washer (Item 2) [Figure 40-150-6] over
the bushing hole casting, center the washer over the
bushing hole.
5 4 Install the bolt (Item 4) through the washers and the

bushing and install the nut (Item 5) [Figure 40-150-6].
1
S7972 Tighten the bolt and nut until the bushing is seated in the
casting.
Install the spacer (Item 1) and washer (Item 2) [Figure
40-150-6] over the flanged end of the bushing.

The spacer (Item 1) [Figure 40-150-6] must be centered
over the bushing to avoid contact between the bushing
and the spacer during removal.
Install the washer (Item 3) [Figure 40-150-6] on the

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-
150-6] through the washers and spacer.
Tighten the bolt and nut to remove the bushing from the
casting.
Install the bushing so the flanged edge of bushing is

seated in the casting. The flanged edge of the bushings
must be installed from the top and bottom of the
upperstructure casting.

SWING FRAME (CONT’D) Boom Pivot Bushing Installation
Boom Pivot Bushing Removal Apply a film of grease to the outer diameter of the
bushing and the inner diameter of the casting.
The following parts will be needed for removal and
installation of the boom pivot bushings. Center the bushing in the casting hole.
Bolt - 15,875 x 114,3 mm long (0.625 x 4.5 in long) NOTE: Make sure the bushing is centered into the
Nut - 15,875 mm (0.625 in) casting hole and is started in the hole evenly
and square.
Washer - 15,875 mm I.D. x 34,925 mm O.D. x 6,35
mm thick (0.625 in I.D. x1.375 in O.D. x 0.25 in thick) Put the washer (Item 3) over the flanged end of the
Washer - 15,875 mm I.D. x 67,31 mm O.D. x 6,35 bushing. Put the washer (Item 2) [Figure 40-150-7] over
mm thick (0.625 in I.D. x 2.625 in O.D. x 0.25 in thick) the bushing hole casting, center the washer over the
Spacer - 57,15 mm I.D. x 66,675 mm O.D. x 38,1 mm bushing hole.
thick (2.250 in I.D. x 2.625 in O.D. x 1.5 in thick)
Install the bolt (Item 4) through the washers and the
bushing and install the nut (Item 5) [Figure 40-150-7].
Figure 40-150-7
Tighten the bolt and nut until the bushing is seated in the
2 casting.

5 4
1
S7972
Install the spacer (Item 1) and washer (Item 2) [Figure

40-150-7] over the flanged end of the bushing.
The spacer (Item 1) [Figure 40-150-7] must be centered

over the bushing to avoid contact between the bushing
and the spacer during removal.
Install the washer (Item 3) [Figure 40-150-7] on the

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-
150-7] through the washers and spacer.
Tighten the bolt and nut to remove the bushing from the
casting.

BOOM Figure 40-160-2
Description
The boom is the section that is connected to the swing

frame and the arm. The boom has the boom and arm
cylinders mounted on the top of the boom.
Figure 40-160-1 2
1
S7665
Remove the tie strap (Item 1) on the light wire harness.

Disconnect the harness (Item 2) [Figure 40-160-2].
Figure 40-160-3

S7660
Install a chain hoist on the boom [Figure 40-160-1]. 1

Page 40-180-1.)
2
Remove the arm cylinder. (See Removal And Installation
on Page 20-21-3.) 1
Remove the arm. (See Removal And Installation on Page S7659

40-170-1.)
Remove the boom cylinder. (See Removal And Remove the nut and bolt (Item 1) [Figure 40-160-3] from
Installation on Page 20-20-2.) the pivot pin.

BOOM (CONT’D)
Figure 40-160-4
S7671
Mark and remove the two hoses (Item 1) [Figure 40-160-

4] from the fittings.

Figure 40-160-5
S7666
Lift the boom from the swing frame [Figure 40-160-5].

Carefully move the boom while removing the hoses from
the center of the boom.
Installation: Feed the two arm cylinder hoses, the two

boom cylinder hoses and the two auxiliary hoses (Item 1)
through the inside of the boom and come out at the base
pivot of the arm cylinder. Continue feeding the two bucket
cylinder hoses (Item 2) through the end of the boom
(Item 3) [Figure 40-160-5].

ARM Figure 40-170-2
Description
1
The arm is the section that is connected to the end of the
boom section and the bucket / bucket link. The excavator
comes with a standard length but has an optional long
arm.

2
Figure 40-170-1
S7661

Remove the rod end of the cylinder from the arm.

Figure 40-170-3
S7660
Support the boom with a chain hoist [Figure 40-170-1].

2
1
Page 40-180-1.)
Remove the bucket cylinder. (See Removal And

4
IMPORTANT S7663

clean the work area before disassembly and keep all Install a strap (Item 1) [Figure 40-170-3] to support the
parts clean. Always use caps and plugs on hoses, arm.
damage the system. Move the bucket cylinder hoses (Item 2) [Figure 40-170-
I-2003-0888 3] away from the arm.

the arm pivot pin.
Remove the arm.

ARM (CONT’D) Arm To Bucket And Bucket Link Bushing Removal
And Installation
Arm To Boom Bushing Removal And Installation
Figure 40-170-6
Figure 40-170-4
1 1
P-60648
S7664
Remove the dust seals and bushings (Item 1) [Figure 40-

Remove the dust seals and bushings (Item 1) [Figure 40- 170-6] from both sides of the arm.
170-4] from both sides of the arm.

Figure 40-170-7
Figure 40-170-5
1
1
P-60650
P-60650
5 mm (0.197 in)
5 mm (0.197 in) TS-01614
TS-01614
Install the bushings until they are seated 5 mm (0.197 in)

Install the new bushings until they are seated 5 mm in the pin boss [Figure 40-170-7].
(0.197 in) in the pin boss [Figure 40-170-5].
NOTE: Install the new bushings with the tapered end
NOTE: Install the new bushings with the tapered end first (Item 1) [Figure 40-170-7].
first (Item 1) [Figure 40-170-5].
Install new dust seals with the lip facing out.
Install new dust seals with the lip facing out.

BUCKET Figure 40-180-2
WARNING
Stop the machine on a firm flat surface. When
removing or installing attachments (such as a
bucket), always have a second person in the
operator’s seat, give clear signals and work carefully. 1
W-2140-0189
2 S6228
Park the excavator on a flat level surface. Put the bucket
on the ground.
Remove the washer (Item 1) [Figure 40-180-2].
Figure 40-180-1
Remove the pivot pins (Item 2) [Figure 40-180-2].
Keep the pins clean. Do not damage the dust seals in the
arm when removing the bucket.

Install the arm into the bucket and align the hole.
Install the pivot pin.
Extend the bucket cylinder until the connecting link aligns

with the other bucket pin hole and install the pivot pin.
1 Install the washer (Item 1) [Figure 40-180-2].
S6227 Install the pin retainer clips (Item 1) [Figure 40-180-1].
Add grease to the pivot pins before operation.

Remove the pin retainer clips (Item 1) [Figure 40-180-1].
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
can cause injury or death.
W-2052-0907


TAILGATE Figure 40-190-3
Remove the seat. (See Removal And Installation on 1

Page 40-30-1.)

Figure 40-190-1
1
S8227

1 1 from the hinges.
Move the tailgate slightly to the right to free it from the

support, then remove it from the excavator.

Figure 40-190-4
S8226 S8224
Install and tighten two c-clamps (Item 1) [Figure 40-190- 2

1] equally spaced from the sides on the top of the
tailgate.
NOTE: To prevent paint damage use rubber pads on 1

the c-clamps.
Figure 40-190-2
S8229
Remove the cotter pins and washers (Item 1) [Figure 40-

190-4] from the support.
Remove the support (Item 2) [Figure 40-190-4] from the

excavator.
S8225
Install chains to the c-clamps and chain hoist [Figure 40-

190-2].

TAILGATE (CONT’D)
Latch Removal And Installation

Figure 40-190-5
1 2
S8228

Remove the bolt (Item 1) and bracket (Item 2) [Figure
40-190-5].
Remove the key lock assembly (Item 3) [Figure 40-190-

5] from the tailgate.

COUNTERWEIGHTS Left Side Counterweight Removal And Installation
Rear Counterweight Removal And Installation Remove the rear counterweight. (See Rear
Counterweight Removal And Installation on Page 40-
Open the tailgate. (See Opening And Closing The 200-1.)
Remove the lower left hand side cover. (See Lower Left
Figure 40-200-1 Side Cover Removal And Installation on Page 40-210-2.)
Figure 40-200-2
S8304

S7556
from the rear counterweight.
Remove the bolt (Item 1) and nut (Item 2) [Figure 40-
Installation: Tighten the bolts and nuts to 105 - 115 N•m 200-2] from the counterweight.
Installation: Tighten the bolts and nuts to 105 - 115 N•m
Remove the rear counterweight. (78 - 85 ft-lb) torque.
NOTE: Approximate weight of the rear counterweight Remove the left hand counterweight.
is 20 kg (44 lb).
NOTE: Approximate weight of the left hand
counterweight is 20 kg (44 lb).

COUNTERWEIGHTS (CONT’D) Right Side Counterweight Removal And Installation
Left Side Counterweight Removal And Installation Remove the rear counterweight. (See Rear
(Cont’d) Counterweight Removal And Installation on Page 40-
200-1.)
Figure 40-200-3
210-3.)
1
Figure 40-200-4
P103123
2
NOTE: For S/N A33P11535 & Below, the top bolt has

a spacer (Item 1) [Figure 40-200-3] between
the counterweight and frame. Failure to install
S7558
the spacer could result in cracking of the
counterweight.
Remove the bolt (Item 1) and nut (Item 2) [Figure 40-
200-4] from the counterweight.
Installation: Tighten the bolts and nuts to 215 N•m (159

ft-lb) torque.
Remove the right hand counterweight.
NOTE: Approximate weight of the right hand

counterweight is 20 kg (44 lb).

COUNTERWEIGHTS (CONT’D)
Right Side Counterweight Removal And Installation

(Cont’d)
Figure 40-200-5
P103123
NOTE: For S/N A33P11535 & Below, the top bolt has

a spacer (Item 1) [Figure 40-200-5] between
the counterweight and frame. Failure to install
the spacer could result in cracking of the
counterweight.


SIDE COVERS Upper Right Side Cover Removal And Installation
Upper Left Side Cover Removal And Installation Figure 40-210-2
Figure 40-210-1
1
1
2
1
S7956
S7553
upper right hand side cover.
Remove the fuel fill cap (Item 1) [Figure 40-210-1] from
the fuel tank. Remove the upper right hand side cover.

upper left hand side cover.
Remove the upper left hand side cover.

SIDE COVERS (CONT’D) Figure 40-210-5
Lower Left Side Cover Removal And Installation
Figure 40-210-3
1
S6781

S6717 undercarriage.
Figure 40-210-6
the floorplate.

Figure 40-210-4
1 1
S7555
Remove the nut (Item 1) [Figure 40-210-6] from the side

S6715 cover.
Remove the lower left hand side cover.

[Figure 40-210-4] Remove the bolt (Item 1) from the
front of the side cover.

SIDE COVERS (CONT’D) Figure 40-210-9
Lower Right Side Cover Removal And Installation
Figure 40-210-7
1
1
1
1 S7557
Remove the nut (Item 1) [Figure 40-210-9] from the side

S6719 cover.
Remove the lower right hand side cover.

the floorplate.

Figure 40-210-8
S6716

undercarriage.


INSTRUMENT PANEL Figure 40-220-3

1
Figure 40-220-1
1
1
S7980

S7978 right hand side of the instrument panel.
Figure 40-220-4
Remove the two bolts (Item 1) [Figure 40-220-1] from
the throttle lever.

Installation: Tighten the two bolts (Item 1) [Figure 40- 1
Figure 40-220-2
1
1 3
2
1
S7979

S7924
2) and the spacer (Item 3) [Figure 40-220-2].

INSTRUMENT PANEL (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 40-220-6
Figure 40-220-5 4
1 2 3
S8953
S7997
Remove the light switch (Item 1), switch plug (Item 2),
battery light (Item 3), and temperature light (Item 4)
Pull back the instrument panel, mark and disconnect all [Figure 40-220-6] from the instrument panel.
connectors [Figure 40-220-5].

Figure 40-220-7
Remove the instrument panel.
1
1
S7986
Remove the two nuts (Item 1) and bracket (Item 2)

[Figure 40-220-7] from the fuel gauge.
Remove the fuel gauge from the instrument panel.

INSTRUMENT PANEL (CONT’D) Figure 40-220-10
Disassembly And Assembly (Cont’d)
Figure 40-220-8
S7984
1 1
Remove the nut (Item 1) [Figure 40-220-10] from the key

S7987 switch.
Remove the key switch from the instrument panel.

Remove the two nuts (Item 1) [Figure 40-220-8] from the
hourmeter. Figure 40-220-11

Remove the hourmeter from the instrument panel.
Figure 40-220-9
1 1
1
S7982
Remove the accessory socket (Item 1) [Figure 40-220-

S7985 11] from the instrument panel.
Remove the two washers (Item 1) [Figure 40-220-9]

from the LED warning lights.
Remove the LED warning lights from the instrument

panel.


QUICK COUPLER (KLAC™ SYSTEM)
Troubleshooting

Coupler does not seat properly on the Mud, dirt, stones or debris are lodged Remove mud, dirt, stones and debris
attachment mounting frame. between the coupler and the from between the coupler and the
attachment mounting frame. attachment mounting frame.
Worn locking mechanism. Repair or replace worn pins and
locking mechanisms.
Attachment mounting frame damaged. Repair or replace the attachment
mounting frame.
Daily Inspection
Figure 40-230-1

1
P-72274
Inspect the quick coupler for wear or damage. Inspect the

quick locking shaft (Item 1) and the hooks (Item 2)
[Figure 40-230-1] (on the attachment) for wear or
damage.
Repair or replace damaged parts.

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-230-3
Figure 40-230-2
Unlatched Position Latched Position
P-72283
Install the tool (Item 1) [Figure 40-230-3] in the quick

P-72272 P-72272 coupler as shown. Push down on the tool until the latch
snaps closed.
Remove the attachment.

The quick coupler must be in the latched position [Figure
40-230-2] for disassembly. WARNING
Inspect the quick coupler to make sure the latch is in the
latched position.
of the following conditions exist:
If the latch is in the unlatched position, see [Figure 40-
• When fluids are under pressure.
230-3] for additional information.
• Flying debris or loose material is present.
If the latch is in the latched position, proceed to [Figure
• Tools are being used.
40-230-3]. W-2019-0907
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
latching and unlatching the attachment quick
coupler.
W-2541-1106

Figure 40-230-4
1
P-72265
Raise the arm and bucket link until the coupler is free
P-72270 [Figure 40-230-6].
Installation: Align the arm and bucket link with the

Remove the bolts (Item 1) [Figure 40-230-4] and nuts. coupler [Figure 40-230-6]. Lower the arm and bucket link
into the coupler.

Installation: Align the holes of the connecting pins with
the holes in the coupler. Install the two bolts (Item 1) NOTE: Place the coupler on the ground with the
[Figure 40-230-4] and nuts. Tighten the nuts securely mounting pin (Item 1) [Figure 40-230-6] facing
against the couple. towards the excavator.
Figure 40-230-5
P-72269
Remove pins (Item 1) [Figure 40-230-5].

QUICK COUPLER (KLAC™ SYSTEM) (CONT'D)
1. Coupler Body
2. Spring
3. Locking Plate
4. Tool
4
2
P-88398

Disassembly
1
WARNING
• Pressurized fluids and springs or other stored
energy components.
1
W-2505-0604 P-72284
Figure 40-230-7 Remove the spring end hook (Item 1) [Figure 40-230-8]
from the quick coupler.
2 1 3
Figure 40-230-9

2
3 1
1
P-72285
The two springs (Item 1) [Figure 40-230-7] have different P-72294

style of end hooks.
The spring hook (Item 2) [Figure 40-230-7] are full circle Remove the opposite end of the two springs (Item 1)
hooks. [Figure 40-230-9].
The spring hook (Item 3) [Figure 40-230-7] are partial

circle hooks.
The spring ends must be positioned as shown when

assembled.

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D)
Figure 40-230-10
1 1
P-72295
Remove the two roll pins (Item 1) [Figure 40-230-10].

Drive the roll pins inwards to remove.

Figure 40-230-11
P-72296
Remove the latch (Item 1) [Figure 40-230-11].

Assembly
Figure 40-230-12
P-72294
1
Install the partial circle hook end of the spring (Item 1)

P-72296 [Figure 40-230-14].
Figure 40-230-15
Install the latch (Item 1) [Figure 40-230-12].

Figure 40-230-13 1
1 1
1
P-72284
P-72295 Install the full circle end of the spring hook (Item 1)
[Figure 40-230-15] on the quick coupler.
Install the two roll pins (Item 1) [Figure 40-230-13]. Drive Do not lubricate the quick coupler. Lubrication will cause
the roll pins inwards until the roll pins are flush with the dirt to collect and interfere with proper movement of the
outside edge of the quick coupler. quick coupler.


QUICK COUPLER (LEHNHOFF® SYSTEM)
Troubleshooting

Coupler does not seat properly on the Mud, dirt, stones or debris are lodged Remove mud, dirt, stones and debris
attachment mounting frame. between the coupler and the from between the coupler and the
attachment mounting frame. attachment mounting frame.
Worn locking mechanism. Repair or replace worn pins and
locking mechanisms.
Attachment mounting frame damaged. Repair or replace the attachment
mounting frame.
Daily Inspection
Figure 40-231-1
(MS03 & MS08)

2
P-88183
Inspect the quick coupler for wear or damage. Inspect the

hooks (Item 1) and coupler locking shaft (Item 2) [Figure
40-231-1] (on the attachment) for wear or damage.
Repair or replace damaged parts.

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-231-3
Removal (MS03 And MS08)
WARNING
of the following conditions exist: 2
1
• Tools are being used. P-88001
W-2019-0907
Remove the two connecting pins (Item 1) and O-rings

Figure 40-231-2 (Item 2) [Figure 40-231-3].
2 Figure 40-231-4

1
1
1
P-88003
P-88000
Remove the four nuts (Items 1). Remove the two bolts
(Item 2) [Figure 40-231-2].
Raise the arm and bucket link until the quick coupler is
free [Figure 40-231-4].

Installation (MS03 And MS08)

1
Figure 40-231-5 1
2
2
P-88003
1 Install the two bolts (Item 1) [Figure 40-231-7].

P-88000
Install nuts (Item 2) [Figure 40-231-7] just until contact is
made with the coupler.
Place the coupler on the ground with the hooks (Item 1)
[Figure 40-231-5] facing towards the excavator. NOTE: Do Not tighten nuts (Item 2) [Figure 40-231-7]
against the coupler. The retaining bolt must

Align the arm and bucket link with the coupler [Figure 40- rotate freely.
231-5].
Install and tighten nuts (Item 3) securely against the two
Figure 40-231-6 nuts (Item 2) [Figure 40-231-7]. The retaining bolts must
rotate freely.
2
3
P-88001
Install the O-rings (Item 1) [Figure 40-231-6] between

the coupler pivot point and the arm and bucket link when
lowering into position.
NOTE: The O-rings will prevent dirt and debris from

entering the pivot points of the coupler.
Align the holes of the connecting pins with the holes

(Item 2) [Figure 40-231-6] in the coupler.
Install the two pins (Item 3) [Figure 40-231-6] through

the coupler, arm and bucket link.

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT'D)
Parts Identification (MS03)
1. Bolt
2. Lock Washer
3. Coupler Housing
4. Pressure Spring
5. Locking Mechanism 1

4
P-88114

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)
Disassembly And Assembly (MS03)
Figure 40-231-8
P-88004
Remove the two bolts (Item 1) [Figure 40-231-8] and

lock washers.

Figure 40-231-9
P-88005
Turn the threaded spindle (Item 1) counterclockwise until

the locking mechanism (Item 2) [Figure 40-231-9] is free
from the housing.

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT'D)
Parts Identification (MS08)
1. Housing
2. Bushing
3. Bushing
4. O-ring
5. Cover
6. O-ring
7. O-ring 1
8. Reversing Lever
9. Threaded Pin
10. Pressure Spring 2
11. Pin
12. Pivoting Journal
13. Spring Washer
14. Bolt
15. Bearing Block 26 3
16. Locking Pin
4
17. Pressure Spring
18. Thrust Journal 3
19. Pin 25
20. O-ring 24
21. Driving Fork

22. Control Shaft
23. Bolt
24. Snap Ring 5
25. Bushing
6
26. Bushing
7
23
22
8
9
21 10 11
20
19
12
20 17
19 18
16
15 13
14
P-88115

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) NOTE: Do not scratch the mounting surface while
removing sealant.
Disassembly (MS08)
Figure 40-231-12
WARNING 1

W-2019-0907
P-88010
Figure 40-231-10
Figure 40-231-13
2

1
1
P-88009
2
Remove the eight bolts (Item 1) and cover (Item 2) P-88011

[Figure 40-231-10].
Tilt the bearing block and pivoting journal (Item 1) up and
Figure 40-231-11
remove from the spring guide (Item 2) [Figure 40-231-
13].
1
Figure 40-231-14
P-88122
Remove all sealant (Item 1) [Figure 40-231-11] from the

P-88012
housing and cover.
Remove the pivoting journal (Item 1) [Figure 40-231-14]
from the bearing block.

Disassembly (MS08) (Cont’d)
Figure 40-231-15
2
1
P-88014
NOTE: Before removing the control shaft, note the

position of each of the components so that
P-88017
when the coupler is reassembled all
components are positioned correctly on the
control shaft [Figure 40-231-17].
Remove the pressure spring (Item 1) from the spring
guide (Item 2) [Figure 40-231-15].
Figure 40-231-18

Figure 40-231-16
P-88015
P-88013
Remove the control shaft (Item 1) [Figure 40-231-18].
Remove the snap ring (Item 1) [Figure 40-231-16].
Figure 40-231-19
P-88016
Remove O-rings (Item 1) [Figure 40-231-19].

Disassembly (MS08) (Cont’d)

3
Figure 40-231-20 6
4
5
2 1
P-88021
3
2
Remove the snap ring (Item 1) and pin (Item 2). Remove
P-88018 the driving fork (Item 3) [Figure 40-231-22].
Remove the snap ring (Item 4) and pin (Item 5). Remove
Remove the snap ring (Item 1) and pin (Item 2). Remove the reversing lever (Item 6) [Figure 40-231-22].
the spring guide (Item 3) from the driving fork (Item 4)
[Figure 40-231-20]. Repeat the procedure for the other locking pin.

Figure 40-231-21 Figure 40-231-23
2 3
1
P-88019 P-88022
Remove the locking pin assemblies [Figure 40-231-21]. Remove the bushing (Item 1), O-ring (Item 2), and
bushing (Item 3) [Figure 40-231-23] from both locking
pin bores.

Assembly (MS08)
Figure 40-231-24
2 1
P-88019
3
Install the locking pin assemblies [Figure 40-231-26].
P-88022
NOTE: Position the locking levers with the flat side
down and away from the cover.
Install bushing (Item 1), O-ring (Item 2) and bushing (Item
3) [Figure 40-231-24] in both locking pin bores. Figure 40-231-27

Figure 40-231-25
1
4 3
3 1
4
2
2
5 6 P-88018
P-88021
Install the driving fork (Item 1), pin (Item 2) and snap ring
(Item 3) on the spring guide (Item 4) [Figure 40-231-27].
Install reversing lever (Item 1), pin (Item 2) and snap ring
(Item 3) [Figure 40-231-25] on the locking pin.
Install the driving fork (Item 4), pin (Item 5) and snap ring
(Item 6) [Figure 40-231-25] on the reversing lever.
Repeat the procedure for the other locking pin.

Assembly (MS08) (Cont’d)
Figure 40-231-28
P-88023
Install the control shaft through the first locking lever

P-88016 driving fork (Item 1) [Figure 40-231-30].
Figure 40-231-31
Install the O-rings (Item 1) [Figure 40-231-28].
Figure 40-231-29

1
1
P-88024
P-88015 Install the control shaft through the spring guide driving
fork (Item 1) [Figure 40-231-31].
Install the control shaft (Item 1) [Figure 40-231-29].

Figure 40-231-32
1 P-88011
Install pressure spring (Item 1) on the spring guide. Tilt

P-88025 the bearing block and pivoting journal (Item 2) [Figure
40-231-34] down and install on the spring guide.
Install the control shaft through the second locking lever Figure 40-231-35
driving fork (Item 1) [Figure 40-231-32].

NOTE: Check proper alignment of all three driving
forks on the control shaft. If not aligned 1
properly, repeat the procedure.
Figure 40-231-33
P-88010
1
Install the two bolts (Item 1) [Figure 40-231-35].
P-88013
Install the snap ring (Item 1) [Figure 40-231-33].

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)
Figure 40-231-36
P-88026
Apply a bead of sealant around the cover mounting

surface (Item 1) [Figure 40-231-36].

Figure 40-231-37
P-88009
Apply Loctite® 242 on the eight bolts.
Install the eight bolts (Item 2) [Figure 40-231-37].


ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5
Fuel Timer Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-6
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-5
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Full Field Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3

Alternator Regulator Test With Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Light Bulb Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Light Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
MICROSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Testing Left Console Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Left Console Microswitch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2
Testing Right Console Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-3
Right Console Microswitch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-60-3
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1


1710 1345
1345
1710
2875
1340
1640
1471 1470
1590
6010 2210 8090

6000 6000 1330
2000 2000
3010
1380
1400
2020
3030
2300 1590
2310
6310 1440 3000
2210
2300
1340 2310
6310 1450 8080

2320
2870
2890
2220
2870
2220 1460 8060
1440
1450
1460
2320
6020
3040
1490
1430 8040
2090 1430
1610 1490 1350
1670 1630
1660
2110
1670
1610
1520
1630
6020
6000 1510 PANEL
1660 6010 GROUND
2110
2090
1650 1510
1620
1600
1520
2190
2200
1300
1620 2200 1300
1500
1500
2890
1330
1500
1590
6000
1350
3040
1300
1510
1520
8040
8060
8080
8090
3000
2190
1600
1500
1590
6000
1350
3040
1300
1510
1520
8040
8060
8080
8090
3000
2100
2190
2895
1600
1640 2070 2070

2890
1390 1700
2940
1335
1360
1330
1700
1360
1000
1640 1640
1500
1590
1390
1480 1470
1410 1410
1550 1550 1550
1330
1500
1590
2890
1340 1340 1010
1640 1640 1640 8010
1470 1470 1470
1590 1590 1590
1550 1550 1550
1380
1400
1560 1560 1560 1010

1020 2230
1350
8020 8020 2020
1420
3000
2190
2170
1590
2890
1600
2180
1560
2010
2900
1570
8090
2170
8000 2000
2950
2160
1580
2180 2050
8060 8080
3020 8070 8070
8050 3010 2040
3030
2910
2030
1475 1475 1470 2080

1680 1680 1640 8040
1485
8050
1690
3040 1310 RED WHT 8030 8030

2160 1320 BLU RED 8100 8100
2080 BLK BLK 2880 2880
1690
1020
2950 Printable Version Click Here
1130 1110
1370
1140
1120
2010
1370
1300
1310
1340
1420
1485
1320
1330
1130 1120 1110

1150 8000 8010
1500 2050 1540 2040 1530 2030

1060
1100
1040
1030
1050
1070
1090
1080
(PRINTED DECEMBER 2017)

1140
1150
1510
1540
1520
1530
7158259 (G)
549 of 698
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 harness to a component. The internally grounded.

3510 B B 3510
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
pins can be numbered alphabetical
C107
A A (shown) or numerical (1, 2, 3 etc.).
3500 3500
3520
C C
3520
The harness wires numbers are
B B
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
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT -
Indicates battery ground circuit.
on switch application.)
SWITCH - Double Pole - Double

Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G 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.

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 the solenoid coils are listed next to
B
switch to activate various start 0.5 ohm A the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
HORN - Audible alarm. Sound is

START
RUN activated manually by a switch to
OFF
warn personnel.
BUZZER - Audible alarm. Sounds at a

1 SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
positions.
3
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 MOTOR - Wiper - Single or multi
control a high amp component. A speed motor.
30 85 B
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

harness from an overloaded circuit. M
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3700 3710
SPLICE (•) - Used to show when
3110 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 o h m - +
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 o h m magnetically. (The ohm rating and gauge are marked with a icon that
12V S
voltage of the solenoid coil is listed I
represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+ PRESSURE SENDER - Provides a

A
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B listed to show volt at high and low
0.5 - 7.5 V
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.)
FUEL SENDER - Provides a variable

B
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

Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE
1. Engine accessory drive 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.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Location / Identification
Figure 50-10-1
4 8
2 6
3
1 7
1 5
B-14855
S8237
1. Power Socket - 15A (UNSW) Accessory Socket
The excavator has a 12 volt, negative ground electrical 2. Ignition - 10A (UNSW) Key Switch, Switched Power
system. The electrical system is controlled by fuses (Item Relay, Glow Plugs Relay and Starter Relay

1) and relays (Item 2) [Figure 50-10-1] located in the
engine compartment just below the tailgate. The fuses 3. Timer - 25A (UNSW) Fuel Solenoid
will protect the electrical system when there is an
electrical overload. The reason for the overload must be 4. Beacon - 10A (UNSW) Beacon Light (Optional)
found before starting the engine again.
5. Switch Power - 10A (SW) Hourmeter, Alternator
Lamp, Engine Water Temperature Lamp, Engine Oil
Pressure Lamp and Fuel Gauge
6. Valves / Horn - 10A (SW) Joystick Lockout Solenoid,

System Bypass Lockout Solenoid, Two Speed
Module Consoles Down Lamp and Horn
7. Timer Power - 10A (SW) Fuel Solenoid Timer and

Fuel Solenoid
8. Light - 10A (SW) Fuel Gauge Light, Working Light

and Working Light Switch [Figure 50-10-2]
Always replace fuses using the same type and capacity.
The three electrical relays (Item 2) [Figure 50-10-1] are

located in the engine compartment below the tailgate to
the right. The three relays control the starter, glow plugs
and switched power circuits.

Fuel Timer Location / Identification
Figure 50-10-3
S8238
The fuel shutoff timer (Item 1) [Figure 50-10-3] is located

in the engine compartment below the tailgate to the right.

Figure 50-10-4
S0915
There are 2 diodes in the harness behind the starter

(Item 1) [Figure 50-10-4]. The starter is located next to
the cleaner, behind the access panel under the seat. The
diodes are for alternator feedback protection and the
glow plug during start function.

BATTERY Servicing
Location See the SERVICE SCHEDULE for the correct service

interval. (See Maintenance Intervals on Page 10-70-1.)
Figure 50-20-1
The Bobcat brand battery supplied with your machine is
sealed and does not require watering. Proper charging
and storage are important to maximize the life of all
batteries.
Figure 50-20-3
1
S6770
The battery (Item 1) [Figure 50-20-1] is located behind

the upper left side cover.

Figure 50-20-2
P9589 P9590
Simple steps for reliability and long battery life:
• Keep battery posts and terminals clean [Figure 50-

20-3].
• Keep terminals tight.

1
• Remove corrosion from battery and terminals with
sodium bicarbonate (baking soda) and water solution.
• Put Bobcat Battery Saver or grease on the battery

terminals and cable ends to prevent corrosion.
S6771
• Operate the machine for at least 15 minutes to
recover from the battery drain caused by engine
Battery cables (Item 1) [Figure 50-20-2] are accessible startup whenever practical.
by opening the tailgate.
• Maintain the battery charge level. This is a key factor
for long battery life.
• Charge a severely discharged battery with a battery

charger instead of relying on the machine charging
system.

BATTERY (CONT’D) Battery Testing
Servicing (Cont’d) Figure 50-20-4
• Check the battery state of charge every 30 days on

machines that are not frequently used.
WARNING 1

Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water. P-30836

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes. The simplest and most common check to determine
battery state of charge is to use a digital multimeter or
If electrolyte is taken internally drink large quantities voltmeter (Item 1) [Figure 50-20-4].
of water or milk! DO NOT induce vomiting. Get
A battery found below 12.4 volts must be charged to

prompt medical attention.
W-2065-0807 100% charge per the battery charger’s recommendation.
Allow at least 60 minutes after operating the machine
or charging the battery to get an accurate reading.
Maintaining Battery Charge Level
If the reading is less than 12.4 volts after the battery has
All batteries will self-discharge over time. This machine
been charged for several hours, see your Bobcat dealer
has features that require battery power even when the
to have a more thorough battery test performed.
machine is not being used. Use of a quality battery
maintainer is highly recommended to ensure that your
The freezing point of battery electrolyte is dependent on
machine is ready to start when you need it and avoid
the battery state of charge. Keeping the battery voltage
costly battery replacement.
above 12.4 volts will help prevent batteries from freezing,
even at extremely low temperatures.
Battery Maintainers
If the battery freezes, the internal grid may be damaged
Use a good quality battery maintainer to keep the battery
and the case will be distorted or cracked. If this happens,
above 12.4 volts for machines that are not frequently
dispose of the battery according to local regulations.
used. Batteries below 12.4 volts must first be charged
using a battery charger. Solar maintainers should have a
minimum capacity of 10 watts to be effective.
Battery Service During Machine Storage
Remove the battery if storing the machine for an

extended period of time. Fully charge the battery. Store
the battery in a cool dry place above freezing and boost
charge periodically. If battery removal is not desired, a
good quality battery maintainer must be used to
compensate for battery self-discharge and parasitic loads
from machine controllers, accessories, and features such
as connected machine intelligence.

BATTERY (CONT’D) Removal And Installation
Servicing (Cont’d) Remove the upper left hand side cover. (See Upper Left
Battery Charging
Figure 50-20-5
A battery charger designed for 12 volt charging systems
is recommended. Follow the battery charger
manufacturer’s instructions to charge the battery to 12.6
volts (100% charge). Batteries should be charged at
room temperature to avoid an undercharge or overcharge
condition. Never attempt to charge a frozen battery.
The following table can be used to identify the 1

approximate amount of time required to charge a
discharged battery. Allow at least 60 minutes after
operating the machine or charging the battery to get an
accurate reading.
STATE CHARGER MAXIMUM RATE

BATTERY S6763
OF
VOLTAGE
CHARGE 30 Amps 20 Amps 10 Amps
12.6 V 100% READY TO USE Disconnect the negative (-) cable (Item 1) [Figure 50-20-

12.4 V 75% 0.9 hr. 1.3 hr. 2.5 hr. 5] first.
12.2 V 50% 1.9 hr. 2.7 hr. 5.1hr.
Figure 50-20-6
12.0 V 25% 2.9 hr. 4.3 hr. 7.8 hr.
11.8 V 0% 4.0 hr. 5.7 hr. 10.7 hr.
NOTE: Use a good quality automatic charger to avoid

battery damage from overcharging.
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away S6765
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Disconnect the positive (+) cable (Item1) [Figure 50-20-
Do not jump start or charge a frozen or damaged 6].
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910

BATTERY (CONT’D)
Figure 50-20-7
S6762

hold down clamp and remove the 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 50-20-5] last to prevent sparks.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

prompt medical attention.
W-2065-0807

BATTERY (CONT’D) Figure 50-20-9
Using A Booster Battery (Jump Starting)
IMPORTANT
If jump starting the excavator from a second
machine: 1
When jump starting the excavator from a battery
installed in a second machine, make sure the engine
is NOT running while using the glow plugs. High
voltage spikes from a running machine can burn out
R0092
the glow plugs.
I-2060-0906
Connect one end of the second cable to the negative (-)
If it is necessary to use a booster battery to start the terminal of the booster battery. Connect the other end of
engine. BE CAREFUL! There must be one person for the same cable to the bolt at the front left corner of the
starting the excavator and one person to connect and excavator (Item 1) [Figure 50-20-9].
disconnect the battery cables.

Engage the upperstructure slew lock. Be sure the key
switch is OFF. The booster battery must be 12 volt.
IMPORTANT
Figure 50-20-8
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2223-0903
1
Start the engine. After the engine has started, remove
the negative (-) cable first (Item 1) [Figure 50-20-9].
Disconnect the cable from the battery (Item 1) [Figure

R0063 50-20-8].
Remove the cover to the left of the operator’s seat to

access the battery.
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 50-20-8] on the excavator battery.


ALTERNATOR Tests
Description Perform the following alternator tests in this order:
Figure 50-30-1 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 50-30-2

1
3 2
4
5 P-10023
The output terminal (Item 1) [Figure 50-30-1] and

[Figure 50-30-2].
The battery or power sensing terminal (Item 2) [Figure

50-30-1] and [Figure 50-30-2].
The ignition terminal (Item 3) [Figure 50-30-1] and

[Figure 50-30-2].
Open terminal not used in the excavator harness (Item 4)

[Figure 50-30-1] and [Figure 50-30-2].
Access hole for full field test (Item 5) [Figure 50-30-1]

and [Figure 50-30-2].

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 50-30-4

Figure 50-30-3
P-10021
S8239 Place a small screw driver in the test port (Item 1)

[Figure 50-30-4] 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 50-30-3] 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 amp.
The ammeter reading should be above 35 amp.
If the ammeter reading is less than 35 amp do the full
field test. If the ammeter reading is low, repair or replace the
alternator.
WARNING
WARNING
When an engine is running in an enclosed area, fresh AVOID INJURY OR DEATH
air must be added to avoid concentration of exhaust When an engine is running in an enclosed area, fresh
fumes. If the engine is stationary, vent the exhaust air must be added to avoid concentration of exhaust
outside. Exhaust fumes contain odorless, invisible fumes. If the engine is stationary, vent the exhaust
gases which can kill without warning. outside. Exhaust fumes contain odorless, invisible
W-2050-0807 gases which can kill without warning.
W-2050-0807

ALTERNATOR (CONT’D) Alternator Regulator Test With Voltmeter
Alternator Regulator Test Figure 50-30-5
Disconnect the fuel stop solenoid connector.
Turn the lights on (if equipped) and crank the engine for 2
30 seconds to discharge the battery.
1
Connect the fuel stop solenoid connector.
Start the engine and run at full rpm.
The ammeter reading should be around 35 amp and

slowly decrease with alternator output.
If ammeter reading is low or does not decrease with time,

replace the alternator's regulator. S8240
Disconnect the negative (-) cable from the battery.

Connect the positive (+) voltmeter lead to the positive (+)
Reconnect the alternator wires. battery terminal (Item 1) [Figure 50-30-5].
Reconnect the negative (-) cable from the battery. Connect the negative (-) voltmeter lead to the negative (-)

battery terminal (Item 2) [Figure 50-30-5].
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 volt.
If the voltmeter reading is not within this range, replace

the alternator's regulator.
IMPORTANT
disconnected.
charger or when welding on the loader. (Remove
both cables from the battery.)
connected wrong.
I-2023-1285

ALTERNATOR (CONT’D) Figure 50-30-8

Figure 50-30-6
S6763
Disconnect the negative (-) cable (Item 1) [Figure 50-30-

8] from the battery.
Figure 50-30-9
S6774

1
Remove the fill cap (Item 1) [Figure 50-30-6] from the
hydraulic reservoir.
Figure 50-30-7
1
1
2
S8242
1 Disconnect the red wire (Item 1) [Figure 50-30-9].
1 Disconnect the wire harness connector (Item 2) [Figure

50-30-9].
S7554
Remove the cover.
NOTE: Allow the muffler to cool down before

removing the alternator.

ALTERNATOR (CONT’D)
Figure 50-30-10
S8243
Remove the upper alternator bolt (Item 1) and lower

mounting bolt (Item 2) [Figure 50-30-10].

NOTE: Alternator will fall if not supported while
removing bolts.
Figure 50-30-11
1 2 3 4
P-29995
NOTE: The lower alternator mounting bolt (Item 1) is

assembled with a washer (Item 2) spacer (Item
3) and retaining bracket with nut (Item 4)
[Figure 50-30-11] which will fall during
disassembly.
Remove belt from the alternator pulley.
Remove alternator.

ALTERNATOR (CONT’D) If the charging system malfunctions check the following:
Charging System Inspection Check the condition and tension of the alternator belt.
(See Belt Adjustment on Page 10-160-1.) If belt is worn
or deteriorated replace.
WARNING Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
Batteries contain acid which burns eyes and skin on Check the fuse for the alternator in the fuse panel. If fuse
contact. Wear goggles, protective clothing and is burned, find the cause and repair / replace. If fuse is in
rubber gloves to keep acid off body. doubt, remove it and check for continuity.
In case of acid contact, wash immediately with water. Check the electrolyte level in the battery. Add distilled
In case of eye contact get prompt medical attention water as needed. (Does not apply to maintenance free
and wash eye with clean, cool water for at least 15 batteries.)
minutes.
Verify the charge of the battery. Make sure battery is fully
If electrolyte is taken internally drink large quantities charged.
prompt medical attention. Disconnect the battery cables (negative first, then
W-2065-0807 positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and

cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
WARNING prevent corrosion. Reconnect the cable to the positive

terminal.
BATTERY GAS CAN EXPLODE AND CAUSE

SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
IMPORTANT
disconnected.
charger or when welding on the loader. (Remove
both cables from the battery.)
connected wrong.
I-2023-1285

ALTERNATOR (CONT’D)
1. Alternator 15. Nut

2. Frame Assembly 16. Insulator
3. Plate 17. Bolt
4. Screw 18. Screw
5. Bearing 19. Nut
6. Stud 20. Nut
7. Frame End 21. Rotor Assembly
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


STARTER Figure 50-40-3
Stop the engine. 1
Remove the air cleaner. (See Removal And Installation

on Page 60-30-1.)
Figure 50-40-1
1
1
S8007
Remove the mounting bolts (Item 1) [Figure 50-40-3]

from the starter.
Installation: Tighten the bolts to 25 N•m (18 ft-lb) torque.
Remove the starter from the bell housing.

S6763
Disconnect the negative (-) cable (Item 1) [Figure 50-40-

1] from the battery.
Mark the starter wires for ease of assembly.
Figure 50-40-2
S8020
Disconnect the wires (Item 1) [Figure 50-40-2] from the

starter.

STARTER (CONT’D) Cleaning And Inspection
Figure 50-40-4 WARNING

1 of the following conditions exist:
2 • When fluids are under pressure.
4
3 W-2019-0907
Use a brush and air pressure to clean the drive, field

5 coils, armature and starter housing.
10
NOTE: Do not use solvent to clean the drive
assembly. The solvent will remove the
lubricant and the drive will slip.
7
Check the following items:

6
Armature
1. Starter
Broken or burned insulation.
2. Frame 8 Loose connections at commutator.
3. Brush
Open or grounded circuits.
4. Armature 9
Worn shaft or bearings.
5. Yoke
Rough commutator.
6. Housing
7. Pinion
Field Coils
8. Clutch
Broken or burned insulation.
9. Housing
Electrical continuity.
10. Plunger B-19162
Brush connections.
Drive Gear
Worn teeth.
Tooth engagement (drive gear must engage ring gear
by half the depth of the ring gear tooth).
Brush Holders
Broken springs.
Broken insulation.
Spring tension.

LIGHTS Light Bulb Removal And Installation
Boom Light Removal And Installation Figure 50-50-3
Figure 50-50-1
3
1
1 S7547
S7547
Cut the tie-strap (Item 1) [Figure 50-50-1]. Disconnect the wire harness (Item 2) [Figure 50-50-3].

Disconnect the wire harness (Item 2) [Figure 50-50-1]. Turn the light bulb assembly (Item 3) [Figure 50-50-3]
counterclockwise and remove from the housing.
Figure 50-50-2
Figure 50-50-4
S7548
S7549
Remove the nut and bolt (Item 1) [Figure 50-50-2] and

remove the boom light. Complete light bulb assembly [Figure 50-50-4].
NOTE: The light bulb can not be removed from the

light bulb assembly. If light bulb is broken, the
entire assembly must be replaced.

LIGHTS (CONT’D) Figure 50-50-7
Light Switch Removal And Installation
Figure 50-50-5
1
1
1
S7980

Figure 50-50-8
throttle lever.

at a comfortable tension. 1
Figure 50-50-6
1 3
2
1
S7979

S7924

LIGHTS (CONT’D)
Light Switch Removal And Installation (Cont’d)
Figure 50-50-9
S7998
Pull back the instrument panel and disconnect the light

switch connector (Item 1) [Figure 50-50-9].

Figure 50-50-10
S8952
Remove the light switch (Item 1) [Figure 50-50-10] from

the instrument panel.


MICROSWITCH The microswitch is normally open.
Testing Left Console Microswitch With the console raised the gauge reading should show
no current.
Console Cover Removal And Installation on Page 40-50- By pushing the actuator on the microswitch, the gauge
1.) reading should show a completed circuit. If not, the
microswitch is faulty and must be replaced.
Lower the control console.
Figure 50-60-1

S8173
Disconnect the microswitch harness (Item 1) [Figure 50-

60-1] from the control harness.
Figure 50-60-2
S8174
Use a continuity tester to check the microswitch prior to

removal. Test the continuity between the black and white
wire pins (Item 1) [Figure 50-60-2].

MICROSWITCH (CONT’D)
Left Console Microswitch Removal And Installation

1.)
Figure 50-60-3
S8173

Figure 50-60-4
S8175
Remove the nuts, lock washers and bolts (Item 1)

[Figure 50-60-4] fastening the microswitch.
Remove the microswitch.
NOTE: The microswitch does not have an adjustment

procedure. The microswitch is mounted to the
frame in a fixed location.

MICROSWITCH (CONT’D) Right Console Microswitch Removal And Installation
Testing Right Console Microswitch Remove the joystick console cover. (See Joystick
Remove the joystick console cover. (See Joystick 1.)
1.)
Figure 50-60-7
Lower the control console.
Figure 50-60-5
S8176

S8176 Disconnect the microswitch harness (Item 1) [Figure 50-
Figure 50-60-8
Figure 50-60-6
1 S8178
S8177
Remove the nuts, lock washers and bolts (Item 1)
[Figure 50-60-8] fastening the microswitch.
Use a continuity tester to check the microswitch prior to
removal. Test the continuity between the black and white Remove the microswitch.
wire pins (Item 1) [Figure 50-60-6].
NOTE: The microswitch does not have an adjustment
The microswitch is normally open. procedure. The microswitch is mounted to the
frame in a fixed location.
With the console raised the gauge reading should show
no current.
By pushing the actuator on the microswitch, the gauge

reading should show a completed circuit. If not, the
microswitch is faulty and must be replaced.


FUEL LEVEL SENDER Testing
Removal And Installation Use an ohmmeter to check the resistance of the fuel level
sender.
Side Cover Removal And Installation on Page 40-210-1.) Figure 50-70-3
Figure 50-70-1
INSERT ONE
OHM TESTER
FUEL SENDER LEAD INTO
TOP VIEW EACH OF THE
FUEL SENDER
CONNECTIONS
1 FUEL SENDER
TOP VIEW
S6764

Disconnect the wire harness (Item 1) [Figure 50-70-1]
from the fuel level sender.
Figure 50-70-2
B-14140
Insert one of the ohm tester leads into each of the fuel
sender electrical connectors in the end of the fuel sender
[Figure 50-70-3].
With the fuel sender in the position shown [Figure 50-70-

S7923 3], read the ohm in the empty position. Slide the float
upwards and the ohm reading will decrease. See
resistance chart below.
Remove the sender (Item 1) [Figure 50-70-2] from the
fuel tank. The approximate resistance should read as follows:
FULL: 15 - 35 ohm
HALF: 130 - 150 ohm
EMPTY: 230 - 250 ohm


ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-19
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-20
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2

Thermostat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Oil Pump - Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Fuel Shutoff Timer Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-3
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-5
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-7
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-7
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-8
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-9
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-11

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-4
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-5
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-6
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-6
Valve And Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-8
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-9
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-10
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-10
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-4
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Timing Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-6
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Hydraulic Pump Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Rear End Plate Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3

ENGINE INFORMATION
Description
The E10z Excavator has a Kubota® direct injected D722-

E2B diesel engine with a displacement of 0,719 L (43.88
in³). The engine is rated at 7,4 kWh (9.9 hp) and has an
open crankcase ventilation system.
The engine has three cylinders and the rotation is

counterclockwise (viewed from the flywheel side). 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
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. The cooling fan is belt driven. The speed of the
fan is determined by the engine speed.

ENGINE INFORMATION (CONT’D)
Specifications
Fuel Injector Nozzles
Opening Pressure 13727 = 14713 kPa (137 - 147 bar) (1991 - 2134 psi)
Fuel Tightness Nozzle Seat 12748 kPa (127 bar) (1849 psi)
Fuel Injection Pump
Fuel Tightness of Pump Element 13727 kPa (137 bar) (1991 psi)
Fuel Tightness of Delivery Valve (factory spec) 10 Sec. Initial Pressure Drop From 13727 - 12748 kPa (137 - 127 bar)
(1991 - 1849 psi)
Fuel Tightness of Delivery Valve Limit Permitted 5 Sec. Initial Pressure Drop From 13727 - 12718 kPa (137 - 127 bar)
(1991 - 1849 psi)
Injection Timing @ 3600 rpm 19 - 21° B.T.D.C.
Cylinder Head

Cylinder Head Distortion Limit 0,05 mm (0.002 in)
Thickness of Gasket Free 1,15 - 1,30 mm (0.0415 - 0.0512 in)
Thickness of Gasket Tightened 1,05 - 1,15 mm (0.0413 - 0.0453 in)
Top Clearance 0,50 - 0,70 mm (0.0197 - 0.0276 in)
Valves
Valve Seat Angle 45 degrees

Valve Seat Width 2,12 mm (0.0835 in)
O.D. of Valve Stem 5,968 - 5,980 mm (0.23496 - 0.23543 in)
I.D. of Valve Guide 6,01 - 6,025 mm (0.23661 - 0.2372 in)
Clearance between Valve Stem and Guide 0,03 - 0,057 mm (0.00118 - 0.00224 in)
Limit Permitted 0,1 mm (0.0039 in)
Depth of Valve -0,10 - 0,10 mm (-0.0039 - 0.0039 in)
Valve Clearance (Cold) (Intake and Exhaust) 0,145 - 0,185 mm (0.00571 - 0.00728 in)
Valve Springs
Free Length 31,3 - 31,8 mm (1.232 - 1.252 in)

Fitted Length 27 mm (1.063 in)
Load to Compress to Fitted Length 6,6 kg mm (14.6 lb in)
Limited Permitted 5,6 kg mm (12.3 lb in)
Limited Permitted for Spring Tilt 1,2 mm (0.047 in)

Specifications (Cont'd)
Rocker Arms
O.D. of Rocker Arm Shaft 10,473 - 10,484 mm (0.41232 - 0.41276 in)

I.D. of Rocker Arm Bushing 10,5 - 10,518 mm (0.41339 - 0.4141 in)
Clearance between Rocker Arm Shaft and Bushing 0,016 - 0,045 mm (0.00063 - 0.00177 in)
Camshaft
O.D. of Camshaft Bearing Journal 32,934 - 32,95 mm (1.29661 - 1.29724 in)

I.D. of Camshaft Bearing 33,00 - 33,025 mm (1.29921 - 1.3002 in)
Clearance between Camshaft Bearing and Journal 0,05 - 0,091 mm (0.00197 - 0.00358 in)
Alignment of the Camshaft Limit Permitted 0,01 mm (0.0004 in)
Cam Lobe Height 26,88 mm (1.0583 in)

Idle Gear to Cam Gear Backlash 0,047 - 0,123 mm (0.00185 - 0.00484 in)
Cylinders
I.D. of Cylinder Liner 67,000 - 67,019 mm (2.63779 - 2.63854 in)

Rebore Size for Oversize Piston 67,250 - 67,269 mm (2.64764 - 2.64839 in)
Piston Rings
Ring Gap, Top and Oil 0,15 - 0,30 mm (0.0059 - 0.0118 in)
Ring Gap, 2nd 0,30 - 0,45 mm (0.0118 - 0.0177 in)
Side Clearance of Ring in Groove;
Top Ring Because of top ring design, measurement does not apply
2nd Ring 0,09 - 0,12 mm (0.00354 - 0.00472 in)
Oil Ring 0,04 - 0,08 mm (0.0016 - 0.0031 in)

Pistons
I.D. of Piston Pin Bore 20,00 - 20,013 mm (0.7874 - 0.78791 in)

O.D. of Piston Pin 20,002 - 20,011 mm (0.78748 - 0.78783 in)
Connecting Rods
I.D. of Connecting Rod Bushing (Small End, Fitted) 20,025 - 20,04 mm (0.78839 - 0.78897 in)
Clearance between Piston Pin and Bushing 0,014 - 0,038 mm (0.00055 - 0.0015 in)
Clearance between Piston Pin and Bushing Limit 0,10 mm (0.0039 in)
Permitted
Connecting Rod Alignment Limit Permitted 0,05 mm (0.002 in)
Crankshaft
Crankshaft Alignment Limit Permitted 0,02 mm (0.0008 in)

O.D. of Crankshaft Journal No. 1 (Water Pump Side) 39,934 - 39,95 mm (1.57221 - 1.57284 in)

I.D. of Crankshaft Bearing No. 1 39,984 - 40,04 mm (1.57417 - 1.57638 in)
Clearance between No. 1 Crankshaft Journal and Bearing 0,034 - 0,106 mm (0.00134 - 0.00417 in)
O.D. of Crankshaft Journal No. 2 (Flywheel Side) 43,934 - 43,95 mm (1.72968 - 1.73031 in)
O.D. of Crankshaft Journal No. 3 (Intermediate) 39,934 - 39,95 mm (1.57221 - 1.57284 in)
O.D. of Connecting Rod Journals 33,959 - 33,975 mm (1.33697 - 1.3376 in)
I.D. of Connecting Rod Bearings` 33,995 - 34,01 mm (1.33839 - 1.33898 in)
Clearance between Connecting Rod Journal and Bearing 0,02 - 0,051 mm (0.00079 - 0.00201 in)
Crankshaft End Play 0,15 - 0,31 mm (0.0059 - 0.0122 in)
Oil Pump
Oil Pressure @ Rated RPM 193,1 - 441,3 kPa (2 - 4,5 bar) (28 - 64 psi)
Limit Permitted 144,8 kPa (1,5 bar) (21 psi)
Oil Pressure @ Idle Speed 48,3 kPa (0,5 bar) (7 psi)
Clearance between Outer Rotor and Pump Body 0,07 - 0,15 mm (0.0028 - 0.0059 in)
End Clearance between Inner Rotor and Cover 0,075 - 0,135 mm (0.00295 - 0.00531 in)
Clearance between Inner Rotor and Outer Rotor 0,03 - 0,14 mm (0.0012 - 0.0055 in)

Thermostat
Opening Temperature
Starting 69,5 - 72,5°C (157.1 - 162.5°F)
Full Open 85°C (185°F)
Engine Bolt Torque
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 -5 N•m
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 to 9 ft-lb)
M8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)

M12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

Torque Values
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

N•m 0.250 9 -10 13 - 14
(in-lb) (80 - 90) (110 - 120)
0.3125 21 - 23 24 - 27
(180 - 200) (215 - 240)
 0.375 34 - 38 48 - 54
 (25 - 28) (35 - 40)
 0.4375 54 - 61 82 - 88
 (40 - 45) (60 - 65)

 0.500 88 - 95 125 - 135
 (65 - 70) (90 - 100)
N•m 0.5625 125 - 135 170 - 190
(ft-lb) (90 - 100) (125 - 140)
0.625 170 - 190 240 - 190

(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300-330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

Torque Values (Cont’d)

(Dia.) 8.8 10.9 12.9
M4 2,5 - 3,5 N•m 3,8 - 4,2 N•m 4,7 - 5,3 N•m
(2.0 - 2.5 ft-lb) (2.8 - 3.1 ft-lb) (3.5 - 3.9 ft-lb)
M5 5,5 - 6,5 N•m 8,4 - 7,6 N•m 8,5 - 9,5 N•m
(4.0 - 5.0 ft-lb) (5.6 - 6.2 ft-lb) (6.2 - 7.0 ft-lb)
M6 9,5 - 10,5 N•m 12,2 - 13,7 N•m 14,2 - 15,8 N•m
(7.0 - 7.5 ft-lb) (9.1 - 10.1 ft-lb) (10.4 - 11.6 ft-lb)
M7 15 - 17 N•m 20 - 22 N•m 23,7 - 26,3 N•m
(11.0 - 12.5 ft-lb) (16.2 - 14.7 ft-lb) (17.5 - 19.5 ft-lb)
M8 24 - 26 N•m 29,4 - 32,6 N•m 35 - 39 N•m
(18 - 19 ft-lb) (21.7 - 24.0 ft-lb) (25.5 - 28.5 ft-lb)
M10 43 - 47 N•m 57 - 63 N•m 71 - 79 N•m
(32 - 35 ft-lb) (42.0 - 46.5 ft-lb) (52.5 - 58.5 ft-lb)
M12 75 - 85 N•m 105 - 115 N•m 91 - 110 N•m
(55 - 60 ft-lb) (78 - 85 ft-lb) (91 - 110 ft-lb)
M14 125 - 140 N•m 118 - 133 N•m 140 - 155 N•m

(100 - 90 ft-lb) (118 - 133 ft-lb) (140 - 155 ft-lb)
M16 190 - 210 N•m 255 - 285 N•m 300 - 330 N•m
(140 - 155 ft-lb) (188 - 210 ft-lb) (225 - 245 ft-lb)
M18 260 - 290 N•m 345 - 385 N•m 420 - 460 N•m
(190 - 215 ft-lb) (255 - 285 ft-lb) (210 - 340 ft-lb)
M20 370 - 410 N•m 490 - 550 N•m 590 - 650 N•m
(275 - 300 ft-lb) (360 - 405 ft-lb) (440 - 490 ft-lb)
M22 500 - 550 N•m 740 - 760 N•m 800 - 880 N•m
(370 - 400 ft-lb) (554 - 560 ft-lb) (590 - 650 ft-lb)
M24 640 - 700 N•m 850 - 950 N•m 1000 - 1120 N•m
(470 - 520 ft-lb) (625 - 700 ft-lb) (730 - 830 ft-lb)
M27 930 - 1030 N•m 1230 - 1370 N•m 1470 - 1630 N•m
(680 - 760 ft-lb) (900 - 1000 ft-lb) (1100 - 1200 ft-lb)
M30 1260 - 1400 N•m 1700 - 1900 N•m 2000 - 2200 N•m
(930 - 1030 ft-lb) (1250 - 1400 ft-lb) (1500 - 1600 ft-lb)
M33 1720 - 1900 N•m 2300 - 2500 N•m 2700 - 3100 N•m
(1270 - 1400 ft-lb) (2300 - 2500 ft-lb) (2000 - 2300 ft-lb)
M36 200 - 2450 N•m 2900 - 3200 N•m 3500 - 3900 N•m
(1620 - 1800 ft-lb) (2200 - 2400 ft-lb) (2600 - 2900 ft-lb)

Troubleshooting
Chart
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

ENGINE INFORMATION (CONT’D) Figure 60-10-1
Open the tailgate. (See Opening And Closing The 1

Drain the fuel tank. (See Draining The Fuel Tank on Page
10-100-3.) 1
Drain and remove the hydraulic reservoir.
Remove the air cleaner. (See Removal And Installation

on Page 60-30-1.)
1
Remove the hydraulic pump. (See Removal And S7621
Remove the manifold assembly / accumulator. (See Remove the two nuts and bolts (Item 1) [Figure 60-10-1]
Removal And Installation on Page 20-60-1.) from the battery support.
Remove the muffler. (See Removal And Installation on Figure 60-10-2

Page 60-20-1.)

Page 50-20-3.)
IMPORTANT
S7622
damage the system.
I-2003-0888
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499

Figure 60-10-3
1
1
S7573

S7623
Figure 60-10-6

Figure 60-10-4
4
3 1
S7572
1 Remove the hose clamp (Item 1) and hose (Item 2)

S7624 [Figure 60-10-6].

Remove the battery support. hydraulic filter.
Remove the hydraulic filter

Figure 60-10-7
2
3
1
1
S7576
2
S7575 [Figure 60-10-9].

[Figure 60-10-7]. Figure 60-10-10

Figure 60-10-8
1
3
3
S7577
S7574
Remove the hose clamp (Item 1) and hose (Item 2) Remove the overflow bottle and bracket.
[Figure 60-10-8].
Remove the bolts (Item 3) [Figure 60-10-8] from the fuel

filter bracket.
Remove the fuel filter and bracket

Figure 60-10-11
S7618
Remove bolts and nuts (Item 1) [Figure 60-10-13].

S7615
Remove the bolts and nuts (Item 1) [Figure 60-10-11]. Figure 60-10-14

Figure 60-10-12
1
2
1
1
S7617

S7616
Remove the bolts and nuts (Item 1) [Figure 60-10-12]. Remove bolt (Item 2) [Figure 60-10-14] from ground
cable.
Installation: Tighten the bolt to 50 N•m (37 ft-lb) torque.

40-120-1.)

Figure 60-10-15
S7579
Remove the hose clamp (Item 1) and lower radiator hose

S7619 (Item 2) [Figure 60-10-17].
Figure 60-10-18

2
Figure 60-10-16
S7580
Remove the hose clamp (Item 1) and upper radiator hose

(Item 2) [Figure 60-10-18].
S7620
Carefully lift frame upward and tilt forward to clear back

frame.
Remove the back frame from the excavator.

Figure 60-10-19
1
2
2
1
S7582
Disconnect the red wire (Item 1) [Figure 60-10-21] from

S7578 the alternator.
Disconnect the wire connector (Item 2) [Figure 60-10-21]

Remove the hose clamp (Item 1) and air intake hose from the alternator.
(Item 2) [Figure 60-10-19] from the engine.

Figure 60-10-22
NOTE: Plug intake opening to prevent contamination
from getting into the engine.
Figure 60-10-20
1
2
S7583
1
Disconnect the wire connector (Item 1) [Figure 60-10-22]

S7581 from the oil pressure sending unit on the back side of the
engine.
Loosen the nuts (Item 1) [Figure 60-10-20] fastening the

throttle cable to the bracket.
Disconnect the throttle linkage (Item 2) [Figure 60-10-20]

from the throttle bracket.
Move the throttle cable out of the way of the engine.

Figure 60-10-23
1
S7586
Remove the grounding wires (Item 1) [Figure 60-10-25]

S7584 from the starter mounting bolt.
Figure 60-10-26
the alternator bracket.

Move the wire harness out of the way of the engine and
alternator.
Figure 60-10-24
1
1
S7587
Remove nut and bolt (Item 1) [Figure 60-10-26] from

cable clamp.
2
Move the wire harness out of the way of the engine.
S8306
Mark the wires for ease of installation.
Remove the wires (Item 1) and (Item 2) [Figure 60-10-

24] from the starter.

Figure 60-10-27
1 S7590
Remove the bolt (Item 1) [Figure 60-10-29] from the fuse

S7588 block and reposition away from the engine lifting bracket.
Figure 60-10-30
Cut the tie-strap (Item 1) and disconnect wire connector
(Item 2) [Figure 60-10-27] from the fuel shutoff.

Figure 60-10-28
1
2
1
S7591
Remove and cap the return fuel line (Item 1) [Figure 60-
S7589 10-30].
Remove and cap the fuel lines (Item 2) [Figure 60-10-

Remove the wire (Item 1) [Figure 60-10-28] from the 30].
water temperature sending unit.
Remove the nut (Item 2) [Figure 60-10-28] from the glow

plugs.
Move the wire harness out of the way of the engine.

Removal and Installation (Cont’d)
Figure 60-10-31
1 1
S7594
2 Remove the two engine mount bolts (Item 1) [Figure 60-

S7592 10-33].
Installation: Tighten the bolts to 5,5 N•m (48.68 in-lb)

Remove the bolt (Item 1) [Figure 60-10-31]. torque.

Installation: Tighten the bolt to 5,5 N•m (48.68 in-lb) Figure 60-10-34
torque.
Remove the exhaust extension (Item 2) [Figure 60-10-

31].
Figure 60-10-32
S7595
1
Remove the two engine mount bolts (Item 1) [Figure 60-

10-34].
S7593 Installation: Tighten the bolts to 5,5 N•m (48.68 in-lb)

torque.
Remove the two engine mount bolts (Item 1) [Figure 60- NOTE: The engine mounts are left assembled to the
10-32]. engine and will be removed with the engine.
Installation: Tighten the bolts to 5,5 N•m (48.68 in-lb)

torque.

Removal and Installation (Cont’d)
Figure 60-10-35
1
1
2
2
S7597
Connect a chain (Item 1) to the two engine lifting brackets

(Item 2) [Figure 60-10-35].

Figure 60-10-36
S7596
Lift and slide the engine out while turning the engine to
provide clearance during engine removal [Figure 60-10-
36].
NOTE: Protect the excavator from lifting chain

damage during engine removal.

Engine Mount Replacement
Figure 60-10-37
8
7
7
6 6
5 5
4 4 3
3 2
2
1 1
P-68740
Use the following procedure to install new side engine

S8436 mounts:
Remove the existing side mount from the engine. Refer to

Use the following procedure to install new front and rear engine removal and installation for engine mount
engine mounts: locations.

Remove the existing mount from the engine. Refer to Use the parts shown to install the new engine mount for
engine removal and installation for engine mount the side engine mount [Figure 60-10-38].
locations.
Item 1 - Mounting Bolt
Replace the two front and rear engine mounts. Item 2 - Mount Washer
Item 3 - Flat Washer
Use the parts shown to install the new engine mounts for Item 4 - Nut
the front and rear engine mounts [Figure 60-10-37]. Item 5 - Spacer
Item 6 - Mount
Item 1 - Mounting Bolt Item 7 - Screw
Item 2 - Mount Washer Item 8 - Nut
Item 3 - Flat Washer
Item 4 - Spacer Tighten the mounting bolt to 43 - 47 N•m (32 - 35 ft-lb)
Item 5 - Mount torque.
Item 6 - Screw
Item 7 - Nut
Tighten the mounting bolts to 43 - 47 N•m (32 - 35 ft-lb)

torque.

ENGINE INFORMATION (CONT’D) Turn the engine with the starter at 200 to 300 rpm. Run
the test for each cylinder more than twice for 5 to 10
Compression - Checking seconds each time and take the average reading. Make
sure you are using a fully charged battery.
The tool listed will be needed to do the following
procedure: The correct compression for the engine is 28 - 32 MPa
(28 - 32 bar) (412 - 469 psi) with no more than 10%
MEL10630 - Engine Compression Test Kit difference between the cylinders.
Warm the engine. If the pressures are not within 10% of each other, apply a
small amount of oil in the cylinders and retest.
Remove the glow plugs from the engine. (If testing
through glow plug hole.) If the pressures increase after applying oil, check cylinder
walls and piston rings.
Remove all injector nozzles. (If testing through injector
nozzle hole.) If the pressures do not increase after applying oil, check
top clearance, valve clearance and cylinder head.
Install the compression adapter in the cylinder head.
Figure 60-10-39

2
3
S7604
NOTE: Engine has been removed for photo clarity.
Connect the compression gauge (Item 1) to the adapter

(Item 2) [Figure 60-10-39].
Ensure the speed control lever is set at the low idle

setting.
Hold fuel shutoff lever (Item 3) [Figure 60-10-39] to no

fuel (shutoff). Shutoff solenoid does not need to be
removed.

MUFFLER Figure 60-20-3
Figure 60-20-1
1
1
S6740
1

S7554 the exhaust mounting bracket.
Remove the cover.

WARNING

Figure 60-20-2 AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
1 W-2050-0807
WARNING
Stop engine and allow the muffler to cool before
S6741 cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
Loosen the exhaust extension clamp (Item 1) [Figure 60-
20-2].
Installation: Tighten clamp to 8 - 10 N•m (70.80 - 88.5

in-lb) torque.
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

SPARK ARRESTER MUFFLER (CONT’D) Figure 60-20-6

1 3
2
Figure 60-20-4
1
1
S7924
S6739 2), and the spacer (Item 3) [Figure 60-20-6].
Figure 60-20-7
Remove the four bolts (Item 1) [Figure 60-20-4] from the
muffler mount flange.

Figure 60-20-5
1
1
1
S7980


throttle lever.


SPARK ARRESTER MUFFLER (CONT’D)
Figure 60-20-8
S7979


clearance for muffler removal.
Slide muffler off exhaust extension and remove the

muffler from the excavator.
NOTE: Plug the exhaust manifold hole after muffler

removal so no contamination can get into the
engine.


AIR CLEANER Figure 60-30-3

Remove the left hand side counterweight. (See Left Side

Counterweight Removal And Installation on Page 40- 1
200-1.)
Figure 60-30-1
S7552
2
Remove the two bolts (Item 1) [Figure 60-30-3] and

1 remove the air cleaner and hose assembly from the
excavator.
WARNING

S7550
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Remove the hose clamp (Item 1) and hose (Item 2) Failure to obey can cause serious injury.
[Figure 60-30-1] from the air cleaner. W-2011-1285
NOTE: Plug intake hose to avoid contamination from

getting in.
Figure 60-30-2
S7551

back of the air cleaner.


ENGINE COOLING SYSTEM Figure 60-40-2
Radiator Removal And Installation
WARNING 1 2
AVOID BURNS
W-2070-1203
Drain the radiator coolant. (See Removing And

Replacing The Coolant on Page 10-90-2.) S6774
Remove the right hand side counterweight. (See Right

Side Counterweight Removal And Installation on Page Open the tailgate. (See Opening And Closing The
40-200-2.) Tailgate on Page 10-60-1.)
Remove the upper right hand side cover. (See Upper Remove the bolts (Item 1) and the fan guard (Item 2)
Right Side Cover Removal And Installation on Page 40- [Figure 60-40-2].
210-1.)

Figure 60-40-3
Figure 60-40-1
2
2 1
S6777
S8700
Remove the hose clamp (Item 1) and filler neck hose

Remove the hose clamp (Item 1) and lower radiator hose (Item 2) [Figure 60-40-3].
(Item 2) [Figure 60-40-1].
NOTE: There is still a small amount of coolant

present in the radiator and hose. Use a
container when removing lower radiator hose.
Recycle or dispose of the used coolant in an

environmentally safe manner.

ENGINE COOLING SYSTEM (CONT’D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Put the water pump in a vise.
Drain the cooling system. Remove the pulley.
Remove the radiator. (See Radiator Removal And Press the shaft (Item 3) [Figure 60-40-4] out of the pulley
Installation on Page 60-40-1.) side of the water pump. Press out the shaft with the
impeller on it.
Remove the alternator belt.
Remove the seal (Item 4) and impeller (Item 5) [Figure
Remove the fan. 60-40-4].
Figure 60-40-4 Install a new seal when assembling the water pump.

2
1 B-14859A
Remove the water pump bolts (Item 1) [Figure 60-40-4].
Remove the water pump.
Installation: Always use a new gasket (Item 2) [Figure

60-40-4] when installing the water pump and apply
Liquid-Type Gasket (Three Bond 1215 or equivalent) to
both sides of new gasket.

ENGINE COOLING SYSTEM (CONT’D) Figure 60-40-6
Thermostat Removal And Installation

1
Figure 60-40-5
1 2
2
B-3643
Remove the housing and thermostat (Item 1) [Figure 60-

P-66480 40-6].
Remove the four mounting bolts at the coolant housing

Drain the engine coolant until it is below the thermostat (Item 2) [Figure 60-40-6].
level.

Remove coolant housing from the engine block.
Remove the hose (Item 1) [Figure 60-40-5].
Thermostat - Checking
Remove the bolts (Item 2) [Figure 60-40-5] and
thermostat housing. Hang the thermostats in a suitable container filled with
coolant.
Installation: Make sure all gasket surfaces are clean.
Replace the gasket before installing the thermostat Heat the coolant gradually. Use a thermometer to check
housing. Install liquid gasket to thermostat housing. 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

Cooling System on Page SPEC-20-1.)


LUBRICATION SYSTEM Figure 60-50-3
Oil Pan Removal And Installation
Remove the engine from the excavator. (See Removal

And Installation on Page 60-10-9.)
1
Figure 60-50-1
S7981
Remove the oil pump strainer (Item 1) [Figure 60-50-3].

1
Figure 60-50-4
2
S7983 1

Unscrew the oil pan mounting screws (Item 1) and
remove the oil pan (Item 2) [Figure 60-50-1].
Figure 60-50-2
P-62187
1
Installation: Check O-ring (Item 1) on strainer and use
hole 3 (Item 2) [Figure 60-50-4] when installing strainer.
Install the oil strainer, using care not to damage the O-
ring.
Apply liquid gasket to the oil pan (Item 1) [Figure 60-50-

2].
P-68745
Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
Carefully apply the adhesive evenly.
NOTE: When mounting the adhesive-applied parts,
take care to install them to the mating parts.
Assemble the adhesive-applied parts within
10 minutes.
To avoid uneven tightening, tighten mounting
screws in diagonal order from the center.
After cleaning the oil strainer, install it.
Attach the oil pan with its central drain plug
facing toward the air suction side.

LUBRICATION SYSTEM (CONT’D) Oil Pump - Service
Oil Pump Removal And Installation Figure 60-50-6
Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 60-
90-1.)
Remove the crankshaft gear.
Figure 60-50-5
B-3616
Measure the clearance between the lobes of the inner

2 rotor and outer rotor with a feeler gauge [Figure 60-50-
6].

Figure 60-50-7
B-3658
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 60-50-5].
Remove the oil pump mounting bolts. Remove the oil

pump (Item 2) [Figure 60-50-5].
Installation: Tighten the oil pump mounting bolts to 6,9 -

8,1 N•m (60 - 72 in-lb) torque.
A-2732
Measure the clearance between the outer rotor and

pump body with a feeler gauge [Figure 60-50-7].
If the clearance exceeds the factory limit, replace the oil

pump rotor assembly.
Clearance Between Inner and Outer Rotor

0,03 - 0,14 mm
(0.001 - 0.006 in)
Clearance Between Outer Rotor and Body
0,07 - 0,15 mm
(0.003 - 0.006 in)

LUBRICATION SYSTEM (CONT’D) Engine Oil Pressure - Testing
Oil Pump, Service, (Cont’d) Figure 60-50-9
Figure 60-50-8
B-14876
PI-10009
Remove the oil pressure sensor.
Put a piece of press gauge on the rotor face [Figure 60- Install a pressure gauge [Figure 60-50-9].
50-8].

Start the engine and run until it is at operating
Install the cover and tighten the bolts. temperature.
Remove the cover carefully. Measure the width of the Measure oil pressure at both idling and rated speeds.
press gauge [Figure 60-50-8].
If the oil pressure is less than the allowable limit, check
If the clearance exceeds the factory limit replace the oil the following item:
pump rotor assembly.
• Engine Oil Insufficient
End Clearance 0,08 - 0,14 mm • Oil Pump Defective
(0.003 - 0.005 in) • Oil Galley Plugged
• Oil Strainer Plugged
• Excessive Oil Clearance
• Foreign Matter in Relief Valve
• Oil Filer Cartridge plugged
At Idle Speed Allowable Limit 48,3 kPa

(0,48 bar) (7 psi)
At Rated Speed 193 - 441,3 kPa
(2 - 4 bar) (28 - 64 psi)
Allowable Limit 144,8 kPa
(1 bar) (21 psi)
Installation: After checking engine oil pressure, tighten

oil pressure sensor to 15 - 20 N•m (11 - 15 ft-lb) torque.
Relief Valve
The relief valve prevents damage of the lubricating

system due to high pressure. This relief valve is a ball
type.

LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure, Checking
Figure 60-50-10
3 2
4
C-3438
Remove the valve seat (Item 1) [Figure 60-50-10], ball

(Item 2) [Figure 60-50-10] and spring (Item 3) [Figure

60-50-10].
Check the parts for wear or damage and replace as

needed.
Spring Free Length

Factory Spec 32 mm (1.26 in)
Allowable Limit 28 mm (1.10 in)
Installation: Tighten the oil filter adapter (Item 4) [Figure

60-50-10] to 39 - 49 N•m (29 - 36 ft-lb) torque.

FUEL SYSTEM Fuel Shutoff Timer Removal And Installation
Fuel Shutoff Solenoid Removal And Installation The fuel shutoff timers function is to provide pull in
current to the fuel solenoid for only a short duration.
Figure 60-60-1
Figure 60-60-2
3 3
1
S7605
1 S7609

Disconnect the two wire harnesses (Item 1) [Figure 60-

Disconnect the wire connector from the solenoid (Item 2) 60-2] from the timer module.
[Figure 60-60-1].
Figure 60-60-3
Remove the solenoid mountings bolts (Item 3) [Figure
60-60-1].
Remove the solenoid

1
S7590

the timer module.
Remove the fuel shutoff timer.

FUEL SYSTEM (CONT’D) Figure 60-60-5
Fuel Injection Pump - Checking
NOTE: Never try to disassemble the injection pump

assembly. For repairs, you should contact a
Kubota-authorized pump service shop.
The tools listed will be needed to do the following

procedure: 2 3
MEL1237 - Adapter Fuel Line

MEL1173-1 - Pressure Gauge
1
WARNING B-8235
Connect a pressure gauge (Item 1)[Figure 60-60-5] to

AVOID INJURY OR DEATH the long leg of the test tubeline (Item 2) and tighten.
penetrate skin or eyes, causing serious injury or Connect the short leg of the tubeline to the fitting at the
death. Fluid leaks under pressure may not be visible. fuel injection pump (Item 3) [Figure 60-60-5].

not use your bare hand. Wear safety goggles. If fluid Set the speed control lever to the maximum engine
enters skin or eyes, get immediate medical attention speed position to allow full fuel delivery.
from a physician familiar with this injury.
W-2072-0807
Fuel Tightness Of Pump Element
Figure 60-60-4 With the starter, rotate the engine to increase the
pressure to 1991 psi (137 bar).
If the pressure cannot be reached, replace the pump with

a new one or send to a Kubota-authorized pump service
shop.
Fuel Tightness Of Delivery Valve
1 Manually turn the flywheel to raise the pressure to

approximately 13,7 MPa (137 bar) (1991 psi). Now turn
the flywheel back about 1/2 turn (to keep the plunger
free), and clock the time taken for the pressure to drop
from 13,7 - 12,7 MPa (137 - 127 bar) (1991 - 1849 psi).
S7607 The pressure should hold at 13,7 MPa (137 bar) (1991
psi), for at least 5 seconds or more.
To check the initial discharge pressure, remove a high If the time is less than the allowable limit, replace the
pressure tubeline (Item 1) [Figure 60-60-4] from the fuel pump with a new one, or send to a Kubota-authorized
injection pump. pump service shop.
Loosen the other end of the tubeline at the injector, so

that the tubeline can be turned away from the fitting.

Fuel Injection Pump Removal And Installation
IMPORTANT
2
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Clean the injection pump and area around it with a

cleaning solvent or steam cleaning.
S7605
IMPORTANT Disconnect the wire connector from the solenoid (Item 2)

[Figure 60-60-6].
Never steam clean or put cold water on an injection
pump while the engine is running or while it is hot. If Figure 60-60-7

you do it will cause serious damage to the injection
pump.
I-2135-0997
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Clean around the injection pump. S7606
Remove the fuel line clamps (Item 1) [Figure 60-60-7].

Fuel Injection Pump Removal And Installation

(Cont’d)
Figure 60-60-8
2 1
4 S7610
3 Figure 60-60-10
S7607
Disconnect the high pressure lines (Item 1) [Figure 60-

60-8] from the fuel injectors and fuel injection pump.
Disconnect the fuel return hose (Item 2) and the fuel feed
hose (Item 3) [Figure 60-60-8].
Remove the four injection pump mounting bolts (Item 4)

[Figure 60-60-8]. 1
Remove the injection pump.

S7611
Installation: Tighten the pipe retaining nuts to 25 - 34
N•m (18 - 25 ft-lb) torque.
Installation: When installing the injection pump, align the
pin (Item 1) [Figure 60-60-10] on the control rack with
the slot (Item 1) [Figure 60-60-9] on the fork lever
correctly. If both are not aligned correctly, the engine will
run over maximum speed and serious damage can
result.
NOTE: Make sure the same number shims are

installed under the injection pump. The shims
are used for engine timing.

Fuel Injection Pump - Timing
Timing the injection pump is done by changing the 1

number of shims between the injection pump and the
injection pump mounting surface.
Figure 60-60-11
S7607
2
Remove the number one cylinder high pressure line (Item
1) [Figure 60-60-13] from the fuel injection pump and
fuel injector.
S7605

IMPORTANT
Disconnect the wire connector from the solenoid (Item 2) Do not bend the high pressure fuel injection tubes
[Figure 60-60-11]. when removing or installing them.
I-2029-0289
Figure 60-60-12
IMPORTANT
1
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
S7606
Remove the fuel line clamp (Item 1) [Figure 60-60-12].

Fuel Injection Pump - Timing (Cont’d)
Figure 60-60-14
S8466
At this point look at the timing mark (located on the

S7625 flywheel) for proper alignment (Item 1) [Figure 60-60-
15]. When the timing mark is aligned as shown the timing
is correct for the injection pump, which is 19 - 21°
Install a short plastic tube (Item 1) [Figure 60-60-14] in B.T.D.C.
the number one cylinder port of the injection pump. The

tube should fit tight in the port and point upward. Figure 60-60-16
NOTE: The fuel must be in the tube before attempting

timing.
Move the fuel lever on the injection pump to full fuel

position (or full throttle).
Remove the muffler. (See Removal And Installation on 1

Page 60-20-1.) for easy access to flywheel.
NOTE: Engine has been removed for photo clarity.
Turn the flywheel counterclockwise (facing the flywheel)

slowly until the start of fuel rise in the plastic tube (Item 1)
[Figure 60-60-14]. B-14422
The correct engine timing for all Kubota® D722-E2B

engines is 19 - 21° B.T.D.C. Add or subtract shims (Item
1) [Figure 60-60-16] to time the engine to 19 - 21°
B.T.D.C. The engine is correctly timed when the 19 - 21°
B.T.D.C. mark on the flywheel is aligned with the notch in
the timing hole.
NOTE: Adding or reducing the shim thickness by

0,05 mm (0.0020 in) retards or advances the
injection timing by approximately 0.5°.
Some problems caused by faulty injector nozzles:
• The engine is hard to start or will not start.

• Rough engine operation at idle.
• The engine will not have full power.
• The engine exhaust smoke is black, white or blue.

FUEL SYSTEM (CONT’D) Fuel Camshaft Governor
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 load.
Gearcase Cover Removal And Installation on Page 60-
90-1.) Figure 60-60-18
Remove the idler gear. (See Cylinder Head Removal And

2
Figure 60-60-17
1 4
2
5
3
11
10
6
9
1

8
7
1. Start Spring
B-14342 2. Governor Spring
3. Fork Lever
Remove the bolt (Item 1) from the retainer plate (Item 2) 4. Fork Lever
[Figure 60-60-17]. 5. Fork Lever Shaft
6. Governor Sleeve
Installation: Tighten the bolt to 6,8 - 8,1 N•m (60 - 72 in- 7. Retaining Plate
lb) torque. 8. Bearing
9. Fuel Camshaft
Remove the fuel camshaft retainer plate (Item 2) [Figure 10. Bearing
60-60-17]. 11. Snap Ring
B-14875
Remove the fuel camshaft and fork lever assembly at the

same time. Disassemble and assemble the governor and fuel
camshaft as shown [Figure 60-60-18].
Check all the parts for wear or damage and replace as

needed.

Fuel Injector Removal And Installation
IMPORTANT
when removing or installing them. 2
I-2029-0289
1
Figure 60-60-19
S7607
1
Disconnect the high pressure fuel lines (Item 1) [Figure
60-60-21] from the injection pump.
Disconnect the return fuel hose (Item 2) [Figure 60-60-

21] from the injection pump.
2

Figure 60-60-22
1
S7605

3
Disconnect the wire connector from the solenoid (Item 1)
[Figure 60-60-19]. 4
3 2
Figure 60-60-20
4
3 S7608
1 Disconnect the high pressure fuel lines (Item 1) [Figure

60-60-22] from the fuel injectors.
Disconnect the return fuel hose (Item 2) [Figure 60-60-

22].
Remove the high pressure fuel lines.
Remove the retainer nut (Item 3) [Figure 60-60-22] from

the top of the fuel injectors.
S7606
Remove the fuel return pipe (Item 4) [Figure 60-60-22].
Remove the high pressure fuel line clamps (Item 1) Loosen the injector nozzle.
[Figure 60-60-20].
Remove the injector nozzle from the cylinder head.

Fuel Injector Removal And Installation (Cont’d)
Installation: Tighten the injector nozzle to 49 - 69 N•m

NOTE: Be sure to replace the copper washer and

nozzle cap anytime new or reconditioned fuel
injectors are installed.
Fuel Injector Nozzle Pressure - Checking

1
IMPORTANT 2
3
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing 4 (1) Nozzle Holder
tools. 5 (2) Adjusting Washer
I-2027-0284 (3) Nozzle Spring
6 (4) Push Rod
(5) Distance Piece

The tool listed will be needed to do the following
procedure: (6) Nozzle Piece
(7) Nozzle Retaining Nut
MEL10018 - Injector Nozzle Tester 7
PI-9981
The nozzle release pressure can be adjusted by adding

or removing washer(s) (Item 2) from the top of the nozzle
spring (Item 3) [Figure 60-60-23].
Each spacer will change the release pressure by about

234,4 kPa (2,3 bar) (34 psi).
Fuel Injection Pressure. 13,7 - 14,7 MPa (137 - 147 bar)

(1991 - 2134 psi)

Fuel Injector Nozzle Pressure - Checking (Cont’d)
Figure 60-60-24
CORRECT WRONG
A-2621
Check that the spray pattern is correct [Figure 60-60-25]:

A-2513
1. Fuel does not come out the side of the nozzle.
2. Drops of fuel are not present at the nozzle.
Assemble the injector nozzle. Connect the nozzle to the 3. The injector has an even flow coming from the
tester with the nozzle down [Figure 60-60-24]. nozzle.

Operate the hand lever at a slow rate and record the
opening pressure. If the pressure is not correct,
disassemble the nozzle and add or remove the spacer
(Item 2) [Figure 60-60-23] as needed.
NOTE: When assembling the injector nozzle, tighten

the retainer nut (Item 1) [Figure 60-60-23] to
25,3 - 28,9 N•m (23.5 - 28.9 ft-lb) torque. Any
higher torque will cause slow action of the
valve.
When the injector nozzle is assembled, tighten the nozzle

body to 49 - 69 N•m (36 - 51 ft-lb) torque.
Check for inside leakage. Operate the hand lever until the
pressure 12,7 MPa (127 bar) (1849 psi). Keep the nozzle
under this pressure for 10 seconds, check to see if fuel
leaks from the nozzle. If fuel leaks, replace the nozzle.
WARNING
W-2072-0807

FUEL SYSTEM (CONT’D)
Valve Seat Tightness
Figure 60-60-26
3EEABAC1P014A
Set the injection nozzle to a nozzle tester (Code No.

07909-31361) [Figure 60-60-26].

Raise the fuel pressure, and keep at 12,75 MPa (127,5
bar) (1849 psi) for 10 seconds.
If any fuel leak is found, replace the injection nozzle

assembly or repair at Denso service Shop.
Factory spec. Valve No fuel leak at 

seat 12,75 MPa
tightnes (127,5 bar)
s (1849 psi)


CYLINDER HEAD Installation: Tighten the glow plugs to 8 - 15 N•m (6 - 11
ft-lb) torque.
Glow Plug Removal And Installation
Figure 60-70-3
IMPORTANT
when removing or installing them.
I-2029-0289
Figure 60-70-1
B-15856
1 Connect an ohmmeter to the terminal end of the glow

1 2
1 plug, touch the other lead from the ohmmeter to the
heating end of the glow plug [Figure 60-70-3].

The reading will be approximately 0,9 ohm If the
resistance is zero ohm, the glow plug has a short circuit.
If the resistance is infinite, the coil of the glow plug is
broken.
S7613
Remove the nuts (Item 1) [Figure 60-70-1].
Remove the glow plug lead (Item 2) [Figure 60-70-1] and

nut.
Figure 60-70-2
S7614
Remove the glow plugs (Item 1) [Figure 60-70-2] from

the cylinder head.

CYLINDER HEAD (CONT’D) Figure 60-70-5
Valve Clearance Adjustment
NOTE: The valve clearance must be checked and

adjusted when the engine is cold.
Remove the cylinder head cover and the glow plugs.
Adjust the valve clearance as follows:
Figure 60-70-4
P-62023
2 With No. 1 piston at TDC (compression) both the intake

1 and exhaust valves are up. Set both No. 1 valves, No. 2
3 exhaust valve and No. 3 intake valve. [Figure 60-70-5].
Rotate the flywheel 360°, No. 1 (overlap position). Set

No. 2 intake valve and No. 3 exhaust valve. [Figure 60-

70-5].
P-62022 Figure 60-70-6
Loosen the locknut (Item 1) [Figure 60-70-4]. 0,145-0,185 mm

(0.0057 - 0.0073 in)
Turn the adjustment screw (Item 2) [Figure 60-70-4] until
the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
60-70-4].
If adjustments are necessary, tighten locknut before

moving on to the next rocker arm.
A-2730
Make sure the piston is at TDC when adjusting the

clearance at the valves. The correct clearance is 0,145 -
0,185 mm (0.0057 - 0.0073 in) cold clearance [Figure
60-70-6].

CYLINDER HEAD (CONT’D) Installation: Tighten the bolts to 7 - 11 N•m (62 - 97.3 in-
lb) torque. Gradually tighten center bolts before the end
Valve Timing - Checking bolts to avoid cracking valve cover.
Stop the engine and open the rear door. Remove the fuel injector nozzles. (See Fuel Injector
Remove the engine. (See Removal And Installation on
Page 60-10-9.) Remove the glow plugs. (See Glow Plug Removal And
Remove the timing gearcase cover. (See Timing
Remove the alternator. (See Removal And Installation on
Gearcase Cover Removal And Installation on Page 60- Page 50-30-4.)
80-1.)
Figure 60-70-9
Figure 60-70-7
2 1
4
6
3
5
6

2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear 3 S8000
(5) Camshaft B-14341
Remove the rocker arm bracket screws (Item 1) and shaft

Make sure the timing marks (Item 6) [Figure 60-70-7] are assembly (Item 2) [Figure 60-70-9].
in correct alignment.
Installation: Tighten the nuts to 9,8 - 11,3 Nm (7 - 8.3 ft-
Cylinder Head Removal And Installation lb) torque.
Figure 60-70-8 Remove the push rods (Item 3) [Figure 60-70-9].
3 Remove the intake and exhaust manifolds.

2 2
Figure 60-70-10
2 1
2 1 2
S7995
Remove the breather hose (Item 1) [Figure 60-70-8].

P-62174
Remove the four bolts (Item 2) from the valve cover and
remove the valve cover and gasket (Item 3) [Figure 60-
70-8]. Remove the water return hose [Figure 60-70-10].

CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly
Cylinder Head Removal And Installation (Cont’d) Figure 60-70-13
Figure 60-70-11
4 B-14418
B-14490
Use a valve spring compressor to compress the valve
spring [Figure 60-70-13].
Remove the cylinder head bolts in order of #14 to #1
[Figure 60-70-11]. Figure 60-70-14

Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence of #1 to #14 to 38 - 42 N•m (28 -
31 ft-lb) torque.
2
NOTE: Re-tighten the cylinder head bolts in the
correct sequence after the engine has been
run for 30 minutes.
Remove the cylinder head from the engine block.
Figure 60-70-12
1 2 3 4 5 6
B-4122
Remove the valve cap (Item 1) [Figure 60-70-14] and

valve spring collet (Item 2) [Figure 60-70-13] and
[Figure 60-70-14].
Remove the valve spring retainer (Item 3) [Figure 60-70-

13] and [Figure 60-70-14] and the spring (Item 4)
1 [Figure 60-70-13] and [Figure 60-70-14].
Remove the valve (Item 5) [Figure 60-70-13] and

P-62175
[Figure 60-70-14].
Installation: Always use a new head gasket and new O- Remove the seal (Item 6) [Figure 60-70-14].
ring. Make sure the O-ring (Item 1) [Figure 60-70-12] is
seated over the dowel.

CYLINDER HEAD (CONT’D) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly (Cont’d) Figure 60-70-16
Figure 60-70-15
1
1 A-2735
B-3643
Clean the surface of the cylinder head.
Remove the thermostat cover and thermostat from the Put a straight edge (Item 1) [Figure 60-70-16] on the
cylinder head. Remove the thermostat housing (Item 1) cylinder head.

[Figure 60-70-15].
NOTE: Do not put the straight edge across
Installation: Apply Liquid-Type Gasket (Three Bond combustion chambers.
1215 or equivalent) to both sides of the new thermostat
cover gasket and new thermostat housing gasket. Put a feeler gauge (Item 2) [Figure 60-70-16] between
the straight edge and the surface of the cylinder head.
Figure 60-70-17
PI-9988
Put the straight edge on the cylinder head's four sides

and two diagonal as shown in figure [Figure 60-70-17].
The maximum distortion of the head surface ± 0,05 mm

(± 0.002 in). If the measurement is more than the
specification, remove the combustion chambers, then
grind the cylinder head. Grind the same amount of
material from the bottom of the combustion chambers as
was removed from the head.

CYLINDER HEAD (CONT’D) Valve Guide - Checking
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head (See
Cylinder Head Removal And Installation on Page 60-70-
Figure 60-70-18 3.)
Clean the valve seat and combustion chamber.

2
Figure 60-70-19
1
3
PI-9989
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 60-70-18] being checked at T.D.C.
B-3634

Put three pieces of 1,5 mm (0.06 in) diameter solder
(Item 2) [Figure 60-70-18] on the top piston. Use grease Install the valve into the guide. Measure the valve
to hold them in position. recessing with a depth gauge [Figure 60-70-19].
NOTE: Put the solder in position so they do not touch Figure 60-70-20
the valves.
2
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque

in the correct sequence. (See Cylinder Head Removal
1
And Installation on Page 60-70-3.)
Turn the crankshaft until the piston exceeds T.D.C.

Remove the cylinder head.
1. Cylinder Head
Remove the solder wire (Item 3) [Figure 60-70-18] and
Surface
measure it.
2. Recessing
If the measurement exceeds the specifications, check the PI-9990
oil clearance of the crank pin journal or the piston pin.
Top clearance 0,50 - 0,70 mm (0.0197 - 0.0276 in) If the measurement exceeds the allowable limit, replace
the valve or cylinder head [Figure 60-70-20].
Recessing 0,10 mm (0.004 in)

Allowable Limit (Recessing) 0,30 mm (0.012 in)
Remove the carbon from the valve guide.

Valve Guide - Checking (Cont’d)
Figure 60-70-21
PI-9992
Press the used valve guide out of the cylinder head using
B-14335 the special driver tool [Figure 60-70-23]. (See previous
page for tool dimensions.)
Measure the valve stem O.D. [Figure 60-70-21]. Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the

Measure the valve guide I.D. [Figure 60-70-21]. top side. Use the special driver tools (Items 1 and 2)
[Figure 60-70-23], press the new guide until the tools
Calculate the clearance. If the clearance exceeds the contact the cylinder head.
allowable limit, replace the valve and / or valve guide.
Ream the valve guide to the correct specifications.
Valve Guide I.D 6,01 - 6,025 mm (0.2366 - 0.2372 in)
NOTE: Valve guide I.D. (Intake and Exhaust) factory
Valve Stem O.D 5,968 - 5,980 mm (0.2350 - 0.2354 in)
spec. is 6,01 - 6,025 mm (0.2366 - 0.2372 in)
Clearance Between Valve Stem and Guide
0,03 - 0,057 mm (0.0012 - 0.0022 in)
Allowable Limit 0,10 mm (0.0039 in)
Figure 60-70-22
200 mm (7.87 in)

40 mm
80 mm (3.15 in) (1.57 in)
20 mm
(0.79 in)
9,96 - 9,98 mm 5,5 - 5,7 mm

(0.3921 - 0.3929 in) (0.2165 - 0.2244 in)
5,0 mm 7,0 mm 18,0 mm

(0.2 in) (0.276 in) (0.71 in)
6,0 - 6,1 mm 15,0 mm 10,6 - 10,7 mm

(0.236 - 0.240 in) (0.59 in) (0.417 - 0.421 in)
MC-1364
To remove and replace the valve guide, make the driver

tools as shown in figure [Figure 60-70-22].

Valve And Valve Seat Reconditioning 1 2
Figure 60-70-24
15°
2,12 mm (0.0835”)
PI-9995
Check the seat surface and valve face (Item 1) [Figure

PI-9993 60-70-26].
If the seat surface is too wide, use a 15 degree cutter

Grind the valve face to the correct angle using a valve (Item 2) to get the correct width (Item 3) [Figure 60-70-
refacer [Figure 60-70-24] and [Figure 60-70-26]. 26].

Figure 60-70-25 Valve Seat Width
Intake 2,12 mm (0.0835 in)

Exhaust 2,12 mm (0.0835 in)
Valve Seat and Face Angle
Intake 45°
Exhaust 45°
15° 45° (30°)
PI-9994
Grind the valve surface in the cylinder head to the correct

angle [Figure 60-70-25].

Valve Spring
Figure 60-70-27
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 60-70-28].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the spring.
measurement is less than the allowable limit, replace the

spring [Figure 60-70-27]. Setting Length 27 mm (1.063 in)
Setting Load 64,7 N (14.6 lbf)
Free Length 31,3 - 31,8 mm (1.232 - 1.252 in)
Allowable Limit (setting load)
54,9 N (12.3 lbf)
Put the spring on a flat surface, place a square on the
side of the spring [Figure 60-70-27].
Rotate the spring and measure the maximum tilt. If the

measurement is in excess of the allowable limit, replace
the spring.
Tilt 1,2 mm (0.047 in)

CYLINDER HEAD (CONT’D) If the oil clearance exceeds the allowable limit or the
tappet is damaged, replace the tappet.
Valve Tappets
Oil clearance Factory 0,016 - 0,052 mm
Figure 60-70-29 between tappet spec. (0.00063 - 0.00205 in)
and guide Allowable 0,10 mm
1
limit (0.0039 in)
Tappet O.D. Factory 17,966 -17,984 mm

spec. (0.70732 - 0.70803 in)
Tappet guide Factory 18,000 - 18,018 mm
I.D. spec. (0.70866 - 0.70937 in)
Rocker Arm And Shaft - Checking
Figure 60-70-31
P-37202
Remove the tappets (Item 1) [Figure 60-70-29] from the

2 1
crankcase.

When reassembling replace the head gasket with a new
one.
Before installing the tappets (Item 1) [Figure 60-70-29],

apply engine oil thinly around them.
NOTE: Mark the cylinder number to the tappets to

B-3697
prevent interchanging.
Figure 60-70-30 Measure the rocker arm I.D. (Item 1) [Figure 60-70-31]
with an inside micrometer.
Measure the rocker shaft O.D. (Item 2) [Figure 60-70-31]

with an outside micrometer.
If the clearance exceeds the allowable limit, replace the

rocker arm and measure the clearance again.
If the clearance still exceeds the allowable limit after the

rocker arm is replaced, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm and Shaft

0,016 - 0,045 mm
(0.0006 - 0.0018 in)
P-37174
Rocker Arm Shaft 10,47 - 10,48 mm
Measure the tappet O.D. with an outside micrometer (0.4123 - 0.4128 in)
[Figure 60-70-30]. Rocker Arm I.D. 10,5 - 10,52 mm
(0.4134-0.4141 in)
Measure the I.D. of the tappet guide bore with a cylinder
gauge, and calculate the oil clearance [Figure 60-70-30].

CRANKSHAFT AND PISTONS Repeat the procedure to remove the other piston /
connecting rod assemblies from the engine block.
Piston And Connecting Rod Removal And
Installation Figure 60-80-3
Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 60-70-3.) 6 1
4
Remove the top edge from the cylinder bore with a ridge
reamer. 5 2
Figure 60-80-1 4
B-3621
Remove the first compression ring (Item 1) [Figure 60-

80-3].

Remove the second compression ring (Item 2) [Figure
60-80-3].
PI-10013
Remove the oil ring (Item 3) [Figure 60-80-3].
Remove the rod cap and bearing [Figure 60-80-1]. Remove the snap ring (Item 4) and piston pin (Item 5)
[Figure 60-80-3].
Use a hammer handle and push the piston connecting
rod assembly out of the cylinder bore [Figure 60-80-1]. Separate the piston (Item 6) from the connecting rod
(Item 7) [Figure 60-80-3].
NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore. NOTE: Make sure the piston and rod assembly is
marked so as not to change the piston rod
Figure 60-80-2 assembly with another piston or connecting
rod.
828
1
828
A-2903
Installation: Make sure the marks (Item 1) on the

connecting rod and bearing are aligned when installing
the bearing cap [Figure 60-80-2].

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-6

Installation (Cont’d) 6 1
4
Figure 60-80-4
5 2
2
4
7
180°
1 B-3621
3
Remove the first compression ring (Item 1) [Figure 60-
80-6].
PI-10015A PI-10015
Remove the second compression ring (Item 2) [Figure
60-80-6].
Installation: When installing new rings, assemble the

ring so the mark (Item 1) near the gap faces the top of the Remove the oil ring (Item 3) [Figure 60-80-6].
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
Remove the snap ring (Item 4) and piston pin (Item 5)
3) [Figure 60-80-4].
[Figure 60-80-6].
Figure 60-80-5
Separate the piston (Item 6) from the connecting rod
(Item 7) [Figure 60-80-6].
3 4
NOTE: Make sure the piston and rod assembly is
marked so as not to change the piston rod
1 assembly with another piston or connecting
rod.
2
Figure 60-80-7
PI-10014B 5 PI-10014A
180°
Installation: When reassembling, align the marks (Item 1
1) on the connecting rod and piston (Item 2). Heat the
piston in oil to 80°C (176°F) for 10 to 15 minutes and tap 3
the piston pin into position. Place the piston rings so that
there are gaps every 120° (Items 3, 4 and 5) [Figure 60-
80-5] with no gap facing the piston pin in the cylinder. PI-10015A PI-10015
Installation: When installing new rings, assemble the

ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 60-80-7].

CRANKSHAFT AND PISTONS (CONT’D)

Figure 60-80-8
3 4
1
2
PI-10014B 5 PI-10014A
Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
piston in oil to 80°C (176°F) for 10 - 15 minutes and tap
the piston pin into position. Place the piston rings so that
there are gaps every 120° (Items 3, 4 and 5) [Figure 60-
80-8] with no gap facing the piston pin in the cylinder.

CRANKSHAFT AND PISTONS (CONT’D) Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
Piston And Connecting Rod - Servicing specifications, replace the piston pin.
Figure 60-80-9
Piston Pin O.D. 20,002 - 20,011 mm
(0.7875 - 0.7878 in)
Bushing I.D. 20,025 - 20,04 mm
(0.7884 - 0.7890 in)
Oil Clearance between Piston Pin and Bushing
0,014 - 0,038 mm
(0.0006 - 0.0015 in)
Figure 60-80-11
20 mm (0.79”)
A-2733
145 mm (5.7”)
25 mm
Measure the I.D. of the piston pin bore in both horizontal (0.98”) 25 mm
and vertical direction [Figure 60-80-9]. (0.98”)

If the measurement exceeds the allowable limit, replace
the piston.
21,9 - 21,96 mm 19,9 - 19,95 mm
Piston Pin Bore I.D. 20,00 - 20,013 mm (0.8622 - 0.8642”) (0.7835 - 0.7854”)
0.7874 - 0.7879 in
MC-1366A
Figure 60-80-10 To replace the connecting rod small end bushing, make a
driver tool as shown in figure [Figure 60-80-11].
1
B-3633
Measure the O.D. of the piston pin (Item 1) [Figure 60-

80-10].
Measure the I.D. of the connecting rod small end (Item 2)

[Figure 60-80-10].

CRANKSHAFT AND PISTONS (CONT’D) If the gap exceeds the allowable limit, replace the piston
ring.
Piston And Connecting Rod, Servicing (Cont’d)
Top Compression Ring and Oil Ring
Figure 60-80-12
0,15 - 0,30 mm (0.006 - 0.012 in)
Second Compression Ring
Removing Installing
0,30 - 0,45 mm (0.012 - 0.018 in)
Figure 60-80-14
PI-10016
Use a press and special driver tool to remove the small

end bushing [Figure 60-80-12].

Installation: Clean the small end bushing and bore. Put
oil on the bushing and press into the connecting rod until B-14475
it is flush [Figure 60-80-12].
Figure 60-80-13 Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler
gauge [Figure 60-80-14].
Second ring 0,09 - 0,12 mm (0.0033 - 0.0045 in)

Oil ring 0,04 - 0,08 mm (0.0016 - 0.0031 in)
Allowable limit second ring
0,15 mm (0.0059 in)
Allowable limit oil ring
0,15 mm (0.0059 in)

piston.
B-3622
Install a new piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [Figure
60-80-13].

CRANKSHAFT AND PISTONS (CONT’D) Connecting Rod Alignment
Cylinder Bore - Checking NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 60-80-15 doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 60-80-17
B-10073
Check the inside diameter of the cylinder line [Figure 60-

80-15].

Figure 60-80-16
B-4067
If the gauge does not fit squarely against the face place,
measure the space between the gauge and face plate
[Figure 60-80-17].

the connecting rod.
Rod Alignment Allowable Limit

A-2717A
0,05 mm (0.002 in)
To find the maximum wear check the inside diameter in

six different locations [Figure 60-80-16].
When the cylinder bore is not within specifications, bore

and hone the cylinder for an oversize piston.
Cylinder Bore I.D. 67,0 - 67,02 mm (2.638 - 2.639 in)

NOTE: Make sure you use the correct oversize

pistons and rings.

Crankshaft And Bearings Removal And Installation
Remove the piston and connecting rod assemblies. (See 3

Piston And Connecting Rod Removal And Installation on 2
Page 60-80-1.)
1
Remove the engine flywheel. (See Cylinder Head
Remove the bolts which fasten the bearing case cover to

the block.
4
Installation: Tighten the bearing case cover bolts to 10 -
11 N•m (7 - 8 ft-lb) torque. Tighten bolts with even force P-62185
on the diagonal line.
Figure 60-80-18 Installation: When installing the cover (Item 4), make
sure the casting mark (Item 3) is in the up position.
Lightly oil inside lip of oil seal (Item 3) [Figure 60-80-19].
Figure 60-80-20

3
B-3648
Install two bolts into the bearing case cover and pull the 2 1
cover out [Figure 60-80-18]. P-62181
Installation: When installing the bearing case gasket

(Item 1) [Figure 60-80-19] and [Figure 60-80-20], and
the bearing case cover gasket (Item 2) [Figure 60-80-19]
and [Figure 60-80-20] make sure the mark (Item 3)
[Figure 60-80-20] is in the up position.


(Cont’d)
Figure 60-80-21
B-14878
Remove the crankshaft / main bearing assembly from the

engine block [Figure 60-80-23].
B-9565
Mark the bearing case halves for correct installation.
Before removing the crankshaft / main bearings, check Figure 60-80-24

the end play. Install a dial indicator. Measure the end play
by moving the crankshaft back and forth [Figure 60-80-
21].

the thrust washers.
End Play 0,15 - 0,31 mm (0.006 - 0.012 in)

Figure 60-80-22
B-4092
2
Remove the two bearing case bolts [Figure 60-80-24].
Remove the bearing case and bearing.
Installation: Tighten the bearing case bolts (Item 1)

[Figure 60-80-24] to 13 - 16 N•m (9 - 12 ft-lb) torque.
1
B-14346
Remove the main bearing case bolt (Item 1) [Figure 60-

80-22].
Installation: Align the bearing case hole (Item 2) [Figure

60-80-22] with the hole in the block. Put oil on the bolt
threads and tighten to 27 - 30 N•m (20 - 22 ft-lb) torque.

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings - Servicing
Crankshaft And Bearings Removal And Installation Figure 60-80-26

(Cont’d)
Figure 60-80-25
2
A-2763
3
P-62182 Put the crankshaft on V-blocks. Install a dial indicator on
the center journal [Figure 60-80-26].
Installation: When installing the main bearing case Turn the crankshaft at a slow rate.

assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [Figure 60-80-25]. Be sure the If the misalignment exceeds the allowable limit, replace
thrust washer with its oil grooves face outward. the crankshaft.
Identification marks on the main bearing case

Alignment 0,02 mm (0.0008 in)
assemblies are the alignment number (Item 2) and the
marking “1” or “2” (Item 3) [Figure 60-80-25] can be
found on the main bearing case assemblies to ensure Tighten the connecting rod cap bolts 27 - 30 N•m (20 - 22
proper assembly. ft-lb) torque.
Figure 60-80-27
120°
A-2727
Measure the crankpin bearing I.D. [Figure 60-80-27].

Crankshaft And Bearings Removal And Installation 130 mm

(Cont’d) (5.12”)
R 40 mm
Figure 60-80-28 (R 1.57”)
20 mm 39,90 - 39,95 mm
(0.79”)
(1.5709-1.5728”)
72 mm
(2.83”)
68 mm 24 mm
(62.68”) (0.95”)
9 mm
(0.35”) B-14879

front of the engine block with the removal tool shown in
A-2716 [Figure 60-80-30].
Installation: Clean the new bearing and bore and apply

Measure the crankpin O.D. [Figure 60-80-28]. oil to them. Install the new bearing with the installation

driver tool [Figure 60-80-29].
Calculate the oil clearance.
Clean the crankshaft journal and bearing. Put a strip of
Crankpin Bearing I.D. press gauge on the center journal.
33,99 - 34,01 mm (1.3389 - 1.3390 in)
Install the main bearing case halves and tighten the bolts
Crankpin O.D. 33,96 - 33,98 mm (1.3370 - 1.3376 in) to 12,7 - 15,7 N•m (9 - 12 ft-lb) torque. Remove the
Oil Clearance 0,020 - 0,051 mm (0.0008 - 0.0020 in) bearing case halves.
Allowable limit 0,15 mm (0.0059 in)
Figure 60-80-29
1
PI-10024B

CRANKSHAFT AND PISTONS (CONT’D)

(Cont’d)
Figure 60-80-31
PI-10025
Measure the flattened press gauge [Figure 60-80-31].

crankshaft bearing.
Crankshaft Journal O.D. (Flywheel side)

43,93 - 43,95 mm
(1.7297 - 1.7303 in)
Bearing I.D. 43,98 - 44,03 mm
(1.7317 - 1.7333 in)
Crankshaft Journal O.D. (Middle)
39,93 - 39,95 mm
(1.5722 - 1.5728 in)
Bearing I.D. 39,98 - 40,03 mm
(1.5742 - 1.5758 in)
Crankshaft journal O.D. (Front)
39,93 - 39,95 mm
(1.5722 - 1.5728 in)
Bearing I.D. 39,98 - 40,04 mm
(1.5714 - 1.5764 in)
Oil Clearance 0,034 - 0,106 mm
(0.0013 - 0.0042 in)


CAMSHAFT AND TIMING GEARS Figure 60-90-3
Timing Gearcase Cover Removal And Installation
Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 60-60-3.)
Figure 60-90-1 1
2
2
B-14870
Remove the bolt (Item 1) and disconnect the shaft spring

(Item 2) [Figure 60-90-3].
1
Figure 60-90-4
B-14868

Remove the cylinder head, rocker arms and push rods.
(See Cylinder Head Removal And Installation on Page
60-70-3.)
Remove the screws (Item 1) from the speed control plate

(Item 2) [Figure 60-90-1].
NOTE: Take care not to damage the spring.
Figure 60-90-2
B-14871
Remove the crankshaft pulley bolt.

1
Installation: Tighten the bolt 98 - 108 N•m (72 - 80 ft-lb)
torque.
Use a puller and remove the crankshaft pulley [Figure

60-90-4].
B-14869
Separate the speed control plate from the engine and

remove the spring (Item 1) [Figure 60-90-2].
Remove the speed control plate.

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-7
Timing Gearcase Cover Removal And Installation

(Cont’d)
Figure 60-90-5
Oil Seal O-rings
B-3617
Installation: Install three new O-rings and the oil seal

into the timing gearcase cover [Figure 60-90-7].
B-14872
When installing the crank shaft pulley, make sure the

alignment marks are aligned [Figure 60-90-5].
Remove the timing gearcase cover bolts.
Installation: Tighten the bolts to 10 - 11 N•m (7 - 8 ft-lb)

torque.
Figure 60-90-6
B-14873
Remove the timing gearcase [Figure 60-90-6].

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Camshaft Removal And Installation
Timing Gears Checking Backlash Figure 60-90-9
Figure 60-90-8
1
2
3
B-14341
PI-10005
Remove the snap ring (Item 1) and collar (Item 2) from
the idler gear shaft (Item 3) [Figure 60-90-9].
When the gears are installed, check the backlash of the
gears. Figure 60-90-10

Install a dial indicator with its tip on a gear tooth [Figure
60-90-8]. 1
Hold one gear while turning the other gear [Figure 60-
90-8].
If the backlash exceeds the allowable limit, check the oil

clearance of the shaft and gear. If the oil clearance is
correct, replace the gears.
Crank Gear and Idler Gear. 2

0,043 - 0,124 mm
(0.002 - 0.005 in)
B-3699
Cam Gear and Idler Gear
Remove the idler gear (Item 1) [Figure 60-90-10].
0,047 - 0,12 mm
(0.002 - 0.005 in) Remove idler gear mounting screws (Item 2) [Figure 60-
Allowable Limit 0,15 mm (0.006 in) 90-10].
Injection Pump Gear and Idler Gear
Installation: Tighten screws to 10 - 11 N•m (7 - 8 ft-lb)
0,046 - 0,124 mm torque.
(0.002 - 0.005 in)
Oil Pump Gear and Crankshaft Cover
0,041 - 0,123 mm
(0.002 - 0.005 in)

Idler Gear And Camshaft Removal And Installation

(Cont’d)
Figure 60-90-11
B-3620
Measure the camshaft bearing in the engine block

[Figure 60-90-13].
B-14874
Figure 60-90-14
Installation: Make sure the timing marks are in correct

alignment when installing the timing gears [Figure 60-90-
11].
Align the holes on the camshaft gear with the camshaft

retainer plate bolts.
Remove the bolts.
Figure 60-90-12
A-2761
Measure the camshaft journal [Figure 60-90-14].
Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the camshaft.
Bearing I.D. 33,00 - 33,03 mm

(1.299 - 1.300 in)
Journal O.D. 32,93 - 32,95 mm
B-3655
(1.2966 - 1.2972 in)
Clearance of Camshaft Journal
Remove the camshaft from the engine block [Figure 60-
0,05 - 0,09 mm
90-12].
(0.002 - 0.004 in)
Installation: Tighten the camshaft retainer bolts to 18 - Allowable Limit 0,15 mm (0.006 in)

Idler Gear And Camshaft Removal And Installation

(Cont’d)
Figure 60-90-15
A-2760
Put the camshaft in V-blocks. Install a dial indicator

[Figure 60-90-16].
B-5001
Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Measure the cam lobes at their highest point [Figure 60-

90-15].
Camshaft Alignment Allowable Limit
If the measurement is less than the allowable limit, 0,01 mm (0.0004 in)
replace the camshaft.
Cam Lob Height 26,88 mm (1.058 in)


Idler Gear And Shaft - Servicing

20 mm (0.79 in)
Figure 60-90-17
150 mm (5.91 in)
25 mm
(0.98 in) 30 mm
(1.18 in)
21,9 - 21,95 mm
(0.862 - 0.864”) 19,9 - 19,95 mm
(0.784 - 0.785 in)
MC-1366A
To replace the idler gear bushing, make a driver tool as

PI-10003 shown in figure [Figure 60-90-18].
Figure 60-90-19
Measure the O.D. of the idler gear shaft [Figure 60-90-
17].

Measure the I.D. of the idler gear bushing [Figure 60-90-
17].

bushing.
Idler Gear Shaft 19,97 - 19,98 mm

O.D. (0.786 - 0.787 in)
Idler Gear Shaft I.D. 20,00 - 20,05 mm
(0.787 - 0.789 in) 0 - 0,2 mm
(0 - 0.008 in)
Oil Clearance between Idler Shaft and Gear Bushing PI-10004
0,020 - 0,084 mm
(0.0008 - 0.0033 in)
Use a press and special driver tool, to remove the old
Allowable Limit 0,10 mm (0.004 in) bushing and install the new bushing [Figure 60-90-19].

FLYWHEEL AND HOUSING Figure 60-100-3
Remove the air cleaner. (See Removal And Installation 1

on Page 60-30-1.)
Remove the hydraulic pump. (See Removal And

Remove the spark arrester muffler. (See Removal And

1
1
Figure 60-100-1
S8469
Remove the four flywheel housing bolts (Item 1) [Figure

60-100-3].
1
lb) torque.

Figure 60-100-4
2
S8467
Install a chain hoist to the engine lifting eye to support the

engine (Item 1) [Figure 60-100-1].
Figure 60-100-2 1
S8468
1
Remove the accumulator (Item 1) [Figure 60-100-4] from

the manifold assembly.
Remove the three hoses (Item 1) [Figure 60-100-4] from

1 the manifold assembly.
Remove the flywheel housing.

S8466
Remove the mount bolts and nuts (Item 1) [Figure 60-

100-2].
Installation: Tighten the bolts and nuts to 24 - 26 N•m 


FLYWHEEL AND HOUSING (CONT’D) Flywheel Removal And Installation
Hydraulic Pump Coupler Removal And Installation Remove the flywheel housing. (See Removal And
Installation on Page 60-70-1)
Remove the flywheel housing. (See Removal And
Installation on Page 60-100-1.) Remove the hydraulic pump coupler. (See Hydraulic
Pump Coupler Removal And Installation on Page 60-70-
Figure 60-100-5 2)
1 Figure 60-100-6
1
2
S8470

S8471
the hydraulic pump coupler.
Remove the five bolts (Item 1) [Figure 60-100-6] from
Installation: Apply Loctite® 242 (Blue) to bolts and the flywheel.
tighten the bolts to 71 - 79 N•m (53 - 58 ft-lb) torque. Also
lubricate the bolt heads prior to installation. Installation: Lubricate the bolt heads prior to installation.
Tighten the bolts to 54 - 58 N•m (40 - 43 ft-lb) torque.
NOTE: Apply anti-seize compound on spline teeth
prior to pump installation. Remove the flywheel (Item 2) [Figure 60-100-6].
Remove the hydraulic pump coupler (Item 2) [Figure 60-

100-5].

FLYWHEEL AND HOUSING (CONT’D) Figure 60-100-8
Rear End Plate Removal And Installation

2
Remove the flywheel housing. (See Removal And 1
Remove the hydraulic pump coupler. (See Hydraulic

Pump Coupler Removal And Installation on Page 60-70-
2)
Remove the flywheel. (See Flywheel Removal And

Figure 60-100-7
P-68765
2
Remove the bolts (Item 1) from the rear end plate (Item
1 2) [Figure 60-100-7] and [Figure 60-100-8]. Remove
end plate from the side of the engine.

S8472


SPECIFICATIONS
EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Rated Lift Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Function Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Engine (S/N B4PD11001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Engine (S/N B4K911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Engine (S/N A33P11001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8

Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
TECHNICAL SERVICE GUIDE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Excavator Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-4
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
662 of 698 SPEC-01 E10 Service Manual

SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-5
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7
Certain specification(s) are based on engineering calculations and are not actual measurements. Specification(s)
are provided for comparison purposes only and are subject to change without notice. Specification(s) for your
individual Bobcat equipment will vary based on normal variations in design, manufacturing, operating conditions and
other factors.
663 of 698 SPEC-02 E10 Service Manual

EXCAVATOR SPECIFICATIONS
Machine Dimensions
• All dimensions are given in mm.

• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
550 mm
(21.6 in) 413 mm
(16.25 in)
1163 mm
(45.77 in) 1221 mm
(48.06 in)

471 mm
(18.5 in)
1121 mm
(44.2 in)
2793 mm
(110.0 in)
2153 mm
(84.75 in)
2209 mm
(87.0 in)
363 mm
(14.3 in)
992 mm
(39.1 in)
987 mm 180 mm
15 mm (38.9 in) (7.1 in)
968 mm 1100 mm
(0.6 in)
(38.1 in) 220 mm (43.3 in)
(8.6 in) EXTENDED
1280 mm
710 mm
(50.4 in)
(27. 95 in)
RETRACTED
NA9149
664 of 698 SPEC-10-1 E10 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)
Working Range
• All dimensions are given in mm.

• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
3145 mm
(123.8 in)
3093 mm
(121.8 in)
1374 mm
(54.1 in)
2685 mm
(105.7 in)

1818 mm
1899 mm (71.6 in)
(74.75 in)
196 mm
(7.7 in)
1383 mm
230 mm (54.4 in)
(9.1 in)
1820 mm
(71.7 in)
71543372

Rated Lift Capacity
7135259enUS-v

Performance
Digging force, arm (ISO 6015) 5550 N (1248 lbf)

Digging force, bucket (ISO 6015) 8294 N (1865 lbf)
Drawbar pull (theoretical at 90% efficiency) 9905 N (2227 lbf)
Ground pressure 28,8 kPa (0.28 bar) (4.18 psi)
Function Time
Boom raise time 4.2 s

Boom lower time 4.2 s
Bucket curl time 3.2 s
Bucket dump time 2.3 s
Arm retract time 3.9 s
Arm extend time 2.6 s
Boom swing left time 4.1 s
Boom swing right time 3.2 s
Blade raise time 1.7 s

Blade lower time 1.2 s
Slew rate 9 rpm
Undercarriage expand time 5.0 s
Undercarriage retract time 3.5 s
Weights
Operating weight with TOPS canopy, rubber 1176 kg (2593 lb)

tracks, 400 mm bucket
Controls
Engine Hand levers on right hand side

Starting Key-type starter switch and shutdown
Blade Right hand lever
Boom swing Right foot pedal
Hydraulics Two levers control boom, bucket, arm and upperstructure slew
Auxiliary hydraulics Left-hand foot pedal
Upperstructure slew brake Hydraulic lock on motor
Holding brake for upperstructure slew Pin lock
Steering Direction and speed controlled by two hand levers

Engine (S/N B4PD11001 & Above)
Make / Model Kubota® / D722-E4B-BCZ-6 (Stage 5)

Fuel Diesel
Cooling Liquid
Maximum power at 2000 rpm (ISO 9249) 7,4 kW (9.9 hp)
Maximum governed speed 2000 rpm
High idle speed 2370 rpm
Low idle speed 1300 – 1400 rpm
Torque at 1600 rpm (SAE Net) 39,1 N•m (28.8 lb-ft)
Number of cylinders 3
Displacement 0.72 L (43.9 in3)
Bore 67 mm (2.6 in)
Stroke 68 mm (2.7 in)
Lubrication Forced lubrication with cartridge type filter
Crankcase ventilation Closed breathing
Air filter Dual dry replaceable paper cartridge
Ignition Compression ignited (diesel)

Starting aid Glow Plug
Engine (S/N B4K911001 & Above)
Make / Model Kubota® / D722-E4B-BCZ-6 (Tier 4)

Fuel Diesel
Cooling Liquid
Bore 67 mm (2.6 in)
Starting aid Glow Plug
Engine Coolant Propylene Glycol / water mixture (53% PG / 47% water)

Engine (S/N A33P11001 & Above)
Make / Model Kubota® / D722-E2B-BCZ-6 (Tier 2)

Fuel Diesel
Cooling Liquid
Bore 67 mm (2.6 in)

Starting aid Intake air heater
Electrical
Alternator 12 V - 40 A - open frame with internal regulator

Battery 12 V - 500 cold cranking A at -18 °C, 90 min reserve capacity
Starter 12 V - reduction on drive - 1,4 kW
Hydraulic System
Pump Type Double gear pump

Pump capacity 2 @10 L/min @ 2000 RPM (2.6 U.S. gpm)
System relief pressure 19000 kPa (1910 bar) (2756 psi)
Joystick control pressure 3000 kPa (30 bar) (435 psi)
System relief pressure for slew circuits 8400 kPa (84 bar) (1218 psi)
Main hydraulic filter bypass 172 kPa (1.72 bar) (25 psi)
Boom base and arm rod port relief 23200 kPa (232 bar) (3365 psi)
Arm base port relief 22500 kPa (225 bar) (3263 psi)
Control valve Nine-spool parallel type, open centre
Hydraulic filter Full-flow replaceable
Fluid lines SAE standard tubelines, hoses, and fittings
Auxiliary flow 20 L/min (5.3 U.S. gpm)

Hydraulic Cylinders
Boom cylinder Cushion up

Boom cylinder bore 63,5 mm (2.5 in)
Boom cylinder rod 31,8 mm (1.3 in)
Boom cylinder stroke 312,4 mm (12.3 in)
Arm cylinder Cushion
Arm cylinder bore 50,8 mm (2.0 in)
Arm cylinder rod 31,8 mm (1.3 in)
Arm cylinder stroke 325,6 mm (12.8 in)
Bucket cylinder No cushion
Bucket cylinder bore 44,5 mm (1.8 in)
Bucket cylinder rod 25,4 mm (1.0 in)
Bucket cylinder stroke 385,1 mm (15.2 in)
Boom swing cylinder No cushion
Boom swing cylinder bore 57,1 mm (2.3 in)
Boom swing cylinder rod 31,8 mm (1.3 in)

Boom swing cylinder stroke 274,6 mm (10.8 in)
Blade cylinder No cushion
Blade cylinder bore 50,8 mm (2.0 in)
Blade cylinder rod 31,8 mm (1.3 in)
Blade cylinder stroke 96,8 mm (3.8 in)
Undercarriage cylinder No cushion
Undercarriage cylinder bore 44,5 mm (1.8 in)
Undercarriage cylinder rod 25,4 mm (1.0 in)
Undercarriage cylinder stroke 400,1 mm (15.8 in)
Drive System
Travel motor Each track is driven by hydrostatic axial piston motor

Drive reduction Two-stage planetary gear reduction 23,04:1

Traction
Track width, rubber, standard 180 mm (7.1 in)

Track adjusters Grease type adjusters, rubber
Track type, standard Half-pitch, rubber
Travel speed 2,1 km/h (1.3 mph)
Travel speed, high range (option) 2,8 km/h (1.7 mph)
Undercarriage Sealed track rollers with box section track roller frame
Number of track rollers per side 3
Gradeability travelling down or backing 25°
up slopes
Gradeability travelling on side slopes 15°
Gradeability travelling up side slopes 15°
Fluid Capacities
Cooling system 3,0 L (3.2 qt)

Engine lubrication plus oil filter 2,8 L (3.0 qt)

Fuel reservoir 16,0 L (16.9 qt)
Hydraulic reservoir 2,6 L (2.8 qt)
Hydraulic system with bucket and dipper cylinder 9,4 L (9.9 qt)
retracted, bucket on the ground, and blade down
Travel motor (each) 0,5 L (0.5 qt)
Instrumentation
• Hourmeter
• Fuel gauge
• Engine temperature gauge with audible alarm
• Engine oil pressure indicator with audible alarm
• Charging system indicator with audible alarm
• Glow Plug indicator lamp
• Console indicator
Environmental
DECLARED SINGLE-NUMBER NOISE EMISSION VALUES

In accordance with ISO 4871
Noise level per Directive 2000/14/EC - LwA 93 dB

Environmental (Cont’d)
DECLARED VIBRATION EMISSION VALUES

Ina accordance with EN 12096
Value Uncertainty
Whole-body vibration per ISO 2631-1 0,68 m/s 2
0,34 m/s2
Hand-arm vibration per ISO 5349-1 0,7 m/s2 ---
ENGINE CO2 EMISSION VALUES

CO2 emission (g/kWh) 1019,8
This CO2 measurement results from testing over a fixed test cycle under laboratory conditions a(n) (parent) engine representative of
the engine type (engine family) and shall not imply or express any guarantee of the performance of a particular engine.
Temperature Range
Operation and storage -17° – +43°C (-1.3° – +109.4°F)


TECHNICAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Oil Pressure at Low Idle 48 kPa (0,48 bar) (7 psi)

Engine Oil Pressure at High Idle 193 - 441 kPa (1,9 - 4,4 bar) (28 - 64 psi)
Firing Order 1-2-3
Location of Number 1 Cylinder Closest to water pump
Injection Timing 19° - 21° BTDC
Crankshaft Rotation (Facing
Clockwise
Crankshaft Pulley)
Compression at Cranking Speed 10% variance between pistons. 2800 -3200 kPa (28 - 32 bar) (412 - 469 psi)
Valve Clearance (Cold) Intake 0,145 - 0,185 mm (0.0057 - 0.0072 in)
Valve Clearance (Cold) Exhaust 0,145 - 0,185 mm (0.0057 - 0.0072 in)
NOTE: For additional engine specifications, (See Specifications on Page 60-10-2.)
Engine Torques
Engine Oil Drain Cap 33 - 37 N•m (24 - 27 ft-lb)

Fuel Injection Tubeline Nuts 25 - 34 N•m (18 - 25 ft-lb)
Glow Plugs 8 - 15 N•m (6 - 11 ft-lb)

Injection Pump Mounting Bolts/Nuts 22 - 27 N•m (16 - 20 ft-lb)
Valve Cover Bolts 7 - 11 N•m (5 - 8 ft-lb)
Head Bolts 93,2 - 98,0 N•m (68.8 - 72.3 ft-lb)
NOTE: For additional engine torques, (See Torque Values on Page 60-10-6.)
Cooling System
Coolant Type and Mix 47% Water and 53% Propylene Glycol
Radiator Cap Pressure 90 kPa (0,90 bar) (13 psi)
Thermostat Start Opening 69,5 - 72,5°C (157.1 - 162.5°F)
Thermostat Fully Open 85°C (185°F)
NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 60-40-1.)

TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONT’D)
Excavator Torques
Drive Motor To Frame Bolt 40 - 50 N•m (29 - 37 ft-lb)

Sprocket To Drive Motor 65 - 70 N•m (48 - 55 ft-lb)
Swing Bearing To Frame Bolt 105 - 115 N•m (78 - 85 ft-lb)
Swing Bearing To Upperstructure Bolt 57 - 63 N•m (42 - 47 ft-lb)
Swing Motor Mounting Bolts 40 - 50 N•m (29 - 37 ft-lb)
Swivel Joint Mounting Bolts 75 - 85 N•m (55 - 60 ft-lb)
NOTE: Additional excavator torques can be found in the relevant section of this manual.
Lubrication
Engine Oil DATA - 1

Hydraulic Oil DATA - 2
Travel Motor SAE - 80W90 Gear Lube

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

N•m 0.250 9,0 - 10,2 (80 - 90) 12,4 - 13,6 (110 - 120)
(in-lb) 0.3125 20,3 - 22,6 (180 - 200) 24,2 - 27,1 (215 - 240)
N•m 0.375 34 - 38 (25 - 28) 47 - 54 (35 - 40)
(ft-lb) 0.4375 54 - 61 (40 - 45) 81 - 88 (60 - 65)
0.500 88 - 95 (65 - 70) 122 - 136 (90 - 100)
0.5625 122 - 136 (90 - 100) 170 - 190 (125 - 140)
0.625 170 - 190 (125 - 140) 240 - 260 (175 - 190)
0.750 300 - 330 (220 - 245) 410 - 450 (300 - 330)
0.875 450 - 490 (330 - 360) 645 - 710 (475 - 525)
1.000 645 - 710 (475 - 525) 985 - 1085 (725 - 800)
1.125 880 - 975 (650 - 720) 1425 - 1600 (1050 - 1175)
1.250 1200 - 1360 (900 - 1000) 1475 - 1625 (2000 - 2200)

1.375 1630 - 1830 (1200 - 1350) 2720 - 2980 (2200 - 2400)
1.500 2040 - 2240 (1500 - 1650) 3530 - 3870 (2600 - 2850)
1.625 2720 - 2980 (2000 - 2800) 4680 - 5150 (3450 - 3800)
1.750 3390 - 3730 (2500 - 2750) 5830 - 6500 (4300 - 4800)
1.875 4270 - 4750 (3150 - 3500) 5830 - 6500 (5500 - 6100)
2.000 5150 - 5700 (3800 - 4200) 8800 - 9800 (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)
Torque For General Metric Bolts

(Dia.) 8.8 10.9 12.9
M4 2,5 - 3,5 N•m 3,8 - 4,2 N•m 4,7 - 5,3 N•m
(22.12 - 31 in-lb) (33.6 - 37.2 in-lb) (41.6 - 47 in-lb)
M5 5,5 - 6,5 N•m 8,4 - 7,6 N•m 8,5 - 9,5 N•m
(48.7 - 57.5 in-lb) (74.3 - 67.3 in-lb) (75.2 - 84 in-lb)
M6 9,5 - 10,5 N•m 12,2 - 13,7 N•m 14,2 - 15,8 N•m
(7.0 - 7.5 ft-lb) (9.1 - 10.1 ft-lb) (10.4 - 11.6 ft-lb)
M7 15 - 17 N•m 20 - 22 N•m 23,7 - 26,3 N•m
(11.0 - 12.5 ft-lb) (16.2 - 14.7 ft-lb) (17.5 - 19.5 ft-lb)
M8 24 - 26 N•m 29,4 - 32,6 N•m 35 - 39 N•m
(18 - 19 ft-lb) (21.7-24.0 ft-lb) (25.5 - 28.5 ft-lb)
M10 43 - 47 N•m 57 - 63 N•m 71 - 79 N•m
(32 - 35 ft-lb) (42.0 - 46.5 ft-lb) (52.5 - 58.5 ft-lb)
M12 75 - 85 N•m 105 - 115 N•m 91 - 110 N•m
(55 - 60 ft-lb) (78 - 85 ft-lb) (91 - 110 ft-lb)
M14 125 - 140 N•m 118 - 133 N•m 140 - 155 N•m

(100 - 90 ft-lb) (118 - 133 ft-lb) (140 - 155 ft-lb)
M16 190 - 210 N•m 255 - 285 N•m 300 - 330 N•m
(140 - 155 ft-lb) (188 - 210 ft-lb) (225 - 245 ft-lb)
M18 260 - 290 N•m 345 - 385 N•m 420 - 460 N•m
(190 - 215 ft-lb) (255 - 285 ft-lb) (210 - 340 ft-lb)
M20 370 - 410 N•m 490 - 550 N•m 590 - 650 N•m
(275 - 300 ft-lb) (360 - 405 ft-lb) (440 - 490 ft-lb)
M22 500 - 550 N•m 740 - 760 N•m 800 - 880 N•m
(370 - 400 ft-lb) (554 - 560 ft-lb) (590 - 650 ft-lb)
M24 640 - 700 N•m 850 - 950 N•m 1000 - 1120 N•m
(470 - 520 ft-lb) (625 - 700 ft-lb) (730 - 830 ft-lb)
M27 930 - 1030 N•m 1230 - 1370 N•m 1470 - 1630 N•m
(680 - 760 ft-lb) (900 - 1000 ft-lb) (1100 - 1200 ft-lb)
M30 1260 - 1400 N•m 1700 - 1900 N•m 2000 - 2200 N•m
(930 - 1030 ft-lb) (1250 - 1400 ft-lb) (1500 - 1600 ft-lb)
M33 1720 - 1900 N•m 2300 - 2500 N•m 2700 - 3100 N•m
(1270 - 1400 ft-lb) (2300 - 2500 ft-lb) (2000 - 2300 ft-lb)
M36 200 - 2450 N•m 2900 - 3200 N•m 3500 - 3900 N•m
(1620 - 1800 ft-lb) (2200 - 2400 ft-lb) (2600 - 2900 ft-lb)

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque

Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 9/16” - 18 18 (13)
IMPORTANT 3/8” 11/16” - 16 30 (22)
1/2” 13/16” - 16 54 (40)
clean the work area before disassembly and keep all 5/8” 1” - 14 81 (60)
parts clean. Always use caps and plugs on hoses, 3/4” 1 - 3/16” - 12 114 (84)
7/8” 1 - 3/16” - 12 133 (98)
damage the system.
I-2003-0888 1” 1 - 7/16” - 12 160 (118)
1 - 1/4” 1 - 11/16” - 12 209 (154)
Figure SPEC-40-1
1 - 1/2” 2” - 12 221 (163)

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 petroleum jelly to hold the O-ring in
position until the fittings are assembled [Figure SPEC-
40-1].

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-40-3
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-40-
3].

(CONT’D)
Flare Fitting Tightening Torque
Flare Fitting Tubeline x TORQUE
Outside x N•m
Figure SPEC-40-4 Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
1 3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1 - 1/16” - 12 114 (84)
7/8” 1 - 3/16” - 12 133 98)
1” 1 - 5/16” - 12 160 (118)
1 - 1/4” 1 - 5/8” - 12 209 (154)
1 - 1/2” 1 - 7/8” - 12 221 (163)
2” 2 - 1/2” - 12 342 (252)
TS-1619A
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-40-4]
Use the chart [Figure SPEC-40-5] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.

(CONT'D)
Port Seal and O-ring Boss
Port Seal Fitting
Tightening Torque
Figure SPEC-40-6 x TORQUE
x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1- 1/16” - 12 114 (84)
Nut Seals
To Fitting 1- 3/16” - 12 133 (98)
1 - 5/16” - 12 160 (118)
1 - 7/16” - 12 209 (154)
Nut Seals
1 - 5/8” - 12 221 (163)
To Port
Use the following procedure to tighten the port seal

fitting:

Secondary O-ring Seal P-13008
Port seal and nut, washer and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
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-40-6].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.

HYDRAULIC FLUID SPECIFICATIONS
Specifications
WARNING
Use Bobcat hydraulic fluid (P/N 6904842 - 5, 25, 209,
1000 L), (P/N 6904843 - 5, 25, 209, 1000 L).
During cold weather (0°C [32°F] and below), do not
operate machine until the engine has run for at least
5 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 -30°C (-20°F), 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 -18°C (0°F) if possible.
W-2027-0311
DO NOT use automatic transmission fluids in the

excavator or permanent damage to the hydraulic system
will result.
WARNING
W-2072-0807
When temperatures below -18°C (0°F) are common, the

excavator must be kept in a warm building. Extra warm-
up time must be used each time the excavator is started
during cold temperature conditions. Cold fluid will not
flow easily and it makes action of the hydraulic function
slower. Loss of fluid flow to the hydraulic system can
cause damage in less than 60 seconds.


CONVERSIONS
Decimal And Millimeter Equivalents

U.S. To Metric Conversion Chart


SERVICE TOOLS REQUIRED
The following is a list of service tools required for servicing excavators.
Remote Start Tools
TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool E20 - E55 This tool has been replaced by
the new remote start tool
7217666, see below. MEL1563
includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness Used with MEL1563 to connect
remote start tool to machine
MEL1566 Service Tool Harness Used with MEL1563 to connect

Communicator remote start tool to Service PC
7217666 Remote Start Tool Kit This tool replaced the original


remote start tool kit MEL1563,
(Was 7003031) 7003031 and 6689779. Kit
 7217666 includes: 7022042,
(Was 6689779) 6689747, 6689746 and
6689745.
7022042 Remote Start Tool This tool replaces remote start
 tool 6689778 and 7003030.
(Was 7003030)

(Was 6689778)
6689747 Remote Start Tool Used with 7022042 to connect
Harness remote start tool to machine.
6689746 Remote Start Tool Used with 7022042 to connect

Harness Service PC to remote start tool.
6689745 BOSS Service Tool

Harness
See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST EXC-1118

SERVICE TOOLS REQUIRED (CONT’D)
Hydraulic Tools
TOOL PART MODELS

NUMBER USED ON
MEL1744 Hydraulic Tester E08 - E85 Hydraulic tester MEL1744, MEL10003
(Flow Meter) or TWX-RFIK200-S-6 can be used for
hydraulic testing.
MEL10003 Hydraulic Tester MEL10003 and TWX-RFIK22-S-6 are

(Flow Meter) no longer available, order MEL1744.
TWX-RFIK200- Hydraulic Tester

S-6 (Flow Meter)
MEL1074 O-Ring Seal Hook

MEL1075 Adjustable Gland Nut Includes MEL1075-1 and MEL1075-2
Wrench
MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075-1 for disassembling
various cylinders
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075-1 for disassembling
various cylinders
MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2
MEL1396-2 Piston Ring

Compressor
MEL1418 Cylinder Hone =

2.00 in
OEM6275 Cylinder Hone =
2.75 - 3.00 in
3.00 - 3.50 in
3.50 - 4.00 in

ST EXC-1118

Hydraulic Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
MEL1033 Rod Seal Installation E08 - E85
Tool
MEL1355 Hydraulic Test Kit This test kit includes various gauges,
adapters, couplers and hoses that are
used when testing hydraulic functions.
MEL1355 Includes: MEL1355-1 thru
MEL1355-12
MEL1355-2 1000 psi gauge

MEL1355-3 5000 psi gauge
MEL1355-12 Coupler

MEL1412 Seal Installation Tool E32, E35 Used for installing Travel Motor Seal
MEL1413 Seal Installation Tool E26 Used for installing Travel Motor Seal
MEL1553 Travel Motor Tool Kit E42 - E55 MEL1553 Includes:

MEL1553-1 thru MEL1553-4
MEL1553-1 Motor Seal Included with MEL1553

Installation Tool

Installation Tool

Installation Tool

Installation Tool
6675936 Bleed Tool E08 - E55 Machines with two track tension
(MEL1560) fittings.

ST EXC-1118

Hydraulic Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
7277225 Bleed Tool E08 - E85 Machines with one track tension
fitting.
MEL1713 Hydraulic Fitting Kit E60, E63, This test kit includes various adapters
E80, E85 and couplers that are used when
testing hydraulic functions. MEL1713
Includes: MEL1713-1 thru MEL1713-
12
MEL1727 Spanner Wrench E60, E63 Used for removing and installing
bearing nut used in the Travel Motor
MEL1728 Seal Installation Tool E60, E63 Used for installing Travel Motor Seal

7323185 Spanner Wrench E32, E32i, Used for removing and installing
E35 & E35i bearing nut used in the Travel Motor
7335495 Hydraulic Fitting Kit E85 This test kit includes various adapters
and couplers that are used when
testing hydraulic functions. 7335495
Includes: 7335499 thru 7335505

ST EXC-1118

Engine Tools
TOOL PART MODELS

NUMBER USED ON
7009358 Bobcat Diagnostic E63, E85 Interface for using Yanmar SA-D No Image Available
Interface Box SmartAssist-Direct diagnostic service
software.
7031222 Bobcat Engine T4 Bobcat Includes: Diagnostic Service Tool
Analyzer Diagnostic Engine (7031223), Vehicle Cable 6 pin
Tool Kit Applications (7031398), Vehicle Cable 14 pin
(7031356), USB Cable (7031357) 

7031370 Rear Main Seal 1.8L & 2.4L Used for installing rear main seal
Installer Bobcat
Engine
Models
7031369 Front Seal Installer T4 Bobcat Used for installing front seal

Engine
Applications
7031371 Valve Spring T4 Bobcat Used for compressing valve springs

Compressor Engine
Applications
MEL10630 Engine Compression E08 - E55 Includes: MEL1352, MEL1433,

Test Kit MEL1489, MEL1546, MEL1551,
MEL1594, MEL1594,
MEL10630-1 - MEL10630-11 and
MEL10630-14

MEL1352 Compression E26, Used in glow plug port for testing

Adapter E42 - E55 compression - Included with
MEL10630
MEL1631 Compression E32, E35 Used in glow plug port for testing
Adapter compression, NOT included with
MEL10630
MEL1743 Compression E63, E85 Used in glow plug port for testing
Adapter compression, NOT included with
MEL10630
ST EXC-1118

Engine Tools (Cont’d)
TOOL PART MODELS

NUMBER USED ON
MEL1237 Fuel Line Adapter E25 - E55 Adapter used to test delivery valve at
the injection pump (Used with
pressure gauge MEL1173-1)
MEL1173-1 Pressure Gauge

10000 psi
4200 Injector Nozzle

Tester
7268212 Valve Lash Adjusting All Bobcat

Wrench Engine
Models

7255632 Valve Stem Seal Tool
7313843 Glow Plug 1.8L & 2.4L Used in glow plug port for testing
Compression Tool Bobcat compression.
Engine
Models
7299831 Injector Compression All Bobcat Used in injector port for testing
Tool Engine compression.
Models
7332314 Turbo and Oil Sensor 7332314 includes: 7332313 - Oil
Block Adapter Kit Sensor Block Adapter and 7332298 -
Turbo Oil Adapter.
ST EXC-1118

Electrical Tools
TOOL PART MODELS

NUMBER USED ON
7313846 Injector Signal Tester Excavators Used to test injector signal on
Was 7292829 equipped with Bobcat 1.8L and 2.4L engines.
Bobcat
engines
MEL1712 Push Button Starter E17 - E55

Switch
HVAC Tools
TOOL PART MODELS

NUMBER USED ON
MEL1581 HVAC Recover, E25 - E85 MEL1581 is no longer available,
Recycling, order MEL1735 or MEL1736

Recharging Machine
MEL1735 Deluxe HVAC

Recover, Recycling,
Recharging Machine
MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine
MEL1592 HVAC Refrigerant

Identification Tool
MEL1595 AC Compressor
Pulley Puller
ST EXC-1118


ALPHABETICAL INDEX
AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 ENGINE LUBRICATION SYSTEM . . .10-110-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . 60-30-1 ENGINE SPEED CONTROL . . . . . . . .40-60-1
ALTERNATOR BELT . . . . . . . . . . . . . 10-160-1 EXCAVATOR IDENTIFICATION . . . . . . . . 1-15
ALTERNATOR . . . . . . . . . . . . . . . . . . . 50-30-1 EXCAVATOR SPECIFICATIONS
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 EXCAVATOR STORAGE AND RETURN TO
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-190-1
BLADE CONTROL . . . . . . . . . . . . . . . . 40-70-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
FLOOR PANELS . . . . . . . . . . . . . . . .40-120-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
FLYWHEEL AND HOUSING . . . . . . .60-100-1
BUCKET . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
FOLD-DOWN TOPS . . . . . . . . . . . . . . .10-50-1
BUILD-UP VALVE . . . . . . . . . . . . . . . . 20-160-1
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CAMSHAFT AND TIMING GEARS . . . 60-90-1
FUEL LEVEL SENDER . . . . . . . . . . . .50-70-1
CONTROL CONSOLE 
LOCKOUTS . . . . . . . . . . . . . . . . . . . . 10-180-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
CONTROL LEVER (JOYSTICK) (LEFT) (S/N FUEL SYSTEM . . . . . . . . . . . . . . . . . . .60-60-1
A33P11001 - A33P13154) . . . . . . . . . 20-121-1 FUEL TANK . . . . . . . . . . . . . . . . . . . .40-130-1
CONTROL LEVER (JOYSTICK) (LEFT) (S/N HORN . . . . . . . . . . . . . . . . . . . . . . . . .40-140-1

A33P13155 & ABOVE, B4K911001 & ABOVE HYDRAULIC CONNECTION
AND B4PD11001 & ABOVE) . . . . . . . 20-120-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-40-1
CONTROL LEVER (JOYSTICK) (RIGHT) (S/N HYDRAULIC CONTROL VALVE . . . . . .20-40-1
A33P11001 - A33P13154) . . . . . . . . . 20-111-1
HYDRAULIC FLUID SPECIFICATIONS
CONTROL LEVER (JOYSTICK) (RIGHT) (S/N . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
A33S13155 & ABOVE, B4K911001 & ABOVE
AND B4PD11001 & ABOVE) . . . . . . . 20-110-1 HYDRAULIC PUMP . . . . . . . . . . . . . . .20-50-1
CONTROL PATTERN SELECTOR  HYDRAULIC RESERVOIR . . . . . . . . .20-130-1
VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1 HYDRAULIC SYSTEM 
CONVERSIONS . . . . . . . . . . . . . . . SPEC-60-1 INFORMATION . . . . . . . . . . . . . . . . . . .20-10-1
COUNTERWEIGHTS . . . . . . . . . . . . . 40-200-1 HYDRAULIC SYSTEM . . . . . . . . . . . .10-120-1
CRANKSHAFT AND PISTONS . . . . . . 60-80-1 INSTRUMENT PANEL . . . . . . . . . . . .40-220-1
CYLINDER (ARM) . . . . . . . . . . . . . . . . 20-21-1 LEFT CONSOLE . . . . . . . . . . . . . . . . .40-50-1
CYLINDER (BLADE) . . . . . . . . . . . . . . 20-24-1 LEFT PEDAL AND LINKAGE . . . . . . .40-110-1
CYLINDER (BOOM SWING) . . . . . . . . 20-22-1 LIFTING AND BLOCKING THE 
EXCAVATOR . . . . . . . . . . . . . . . . . . . . .10-10-1
CYLINDER (BOOM) . . . . . . . . . . . . . . . 20-20-1
LIFTING THE EXCAVATOR . . . . . . . . .10-30-1
CYLINDER (BUCKET) . . . . . . . . . . . . . 20-23-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1
CYLINDER (TRACK FRAME EXPANSION)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1 LUBRICATION OF THE 
EXCAVATOR . . . . . . . . . . . . . . . . . . . .10-130-1
CYLINDER HEAD . . . . . . . . . . . . . . . . 60-70-1
LUBRICATION SYSTEM . . . . . . . . . . .60-50-1
DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1
ELECTRIC BLADE / TRACK EXPAND 
VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1 MANIFOLD ASSEMBLY / ACCUMULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1
ELECTRICAL SYSTEM 
INFORMATION . . . . . . . . . . . . . . . . . . . 50-10-1 MICROSWITCH . . . . . . . . . . . . . . . . . .50-60-1
ENGINE COOLING SYSTEM . . . . . . . 10-90-1 MOTION ALARM . . . . . . . . . . . . . . . .10-210-1
ENGINE COOLING SYSTEM . . . . . . . 60-40-1 MUFFLER . . . . . . . . . . . . . . . . . . . . . . .60-20-1
ENGINE INFORMATION . . . . . . . . . . . 60-10-1 OIL COOLER . . . . . . . . . . . . . . . . . . .20-140-1
694 of 698 INDEX-01 E10 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) TRANSPORTING THE EXCAVATOR ON A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-230-1 TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
QUICK COUPLER (LEHNHOFF® SYSTEM) TRAVEL CONTROLS . . . . . . . . . . . . 40-100-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-231-1 TRAVEL MOTOR . . . . . . . . . . . . . . . 10-140-1
REMOTE START TOOL (SERVICE TOOL) KIT TRAVEL MOTOR . . . . . . . . . . . . . . . . 20-70-1
- 7003031 . . . . . . . . . . . . . . . . . . . . . .10-221-1
TWO SPEED CONTROL VALVE . . . 20-170-1
REMOTE START TOOL KIT - MEL1563
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-220-1 UPPERSTRUCTURE SLEW LOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
RIGHT CONSOLE . . . . . . . . . . . . . . . .40-40-1
UPPERSTRUCTURE . . . . . . . . . . . . . 40-10-1
RIGHT PEDAL AND LINKAGE . . . . . .40-90-1
VALVE (MAIN RELIEF) . . . . . . . . . . . . 20-30-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
VALVE (PORT RELIEF) . . . . . . . . . . . 20-31-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . .10-170-1
VALVE (PRESSURE REDUCING) . . . 20-32-1
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-1
SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
SERVICE SCHEDULE SYMBOLS . . . . . . . 1-4
SERVICE SCHEDULE . . . . . . . . . . . . .10-70-1
SERVICE TOOLS REQUIRED . . . . SPEC-70-1
SIDE COVERS . . . . . . . . . . . . . . . . . .40-210-1
SPARK ARRESTER MUFFLER . . . . .10-150-1

STARTER . . . . . . . . . . . . . . . . . . . . . . .50-40-1
STOPPING THE ENGINE AND LEAVING THE
EXCAVATOR . . . . . . . . . . . . . . . . . . .10-200-1
SWING CIRCLE GEAR . . . . . . . . . . . .30-40-1
SWING FRAME . . . . . . . . . . . . . . . . .40-150-1
SWING LOCK . . . . . . . . . . . . . . . . . . .40-80-1
SWING MOTOR . . . . . . . . . . . . . . . . . .20-90-1
B4K911001 & ABOVE AND B4PD11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
SWIVEL JOINT (S/N A33P11001 -
A33P12837) . . . . . . . . . . . . . . . . . . . . .20-83-1
A33P13633) . . . . . . . . . . . . . . . . . . . . .20-82-1
A33P14285) . . . . . . . . . . . . . . . . . . . . .20-81-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . . .10-60-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . .40-190-1
TECHNICAL SERVICE GUIDE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-20-1
TOPS . . . . . . . . . . . . . . . . . . . . . . . . . .40-20-1
TORQUE SPECIFICATIONS FOR 
BOLTS . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TRACK EXPAND VALVE . . . . . . . . . .20-151-1
TRACK MAINTENANCE . . . . . . . . . . .30-30-1
TRACK UNDERCARRIAGE COMPONENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-1


SERVICE SCHEDULE SYMBOLS
Check Engine Oil Check Gear Box and / or Travel Motor Fluid
Change Engine Oil and Filter Change Gear Box and / or Travel Motor Fluid

Check Engine Coolant Check Track Tension, Adjust As Needed
Change Engine Coolant Check Belt Tension, Adjust Or Replace As

Needed
Check Engine Air Filter, Change As Lubricate Grease Fittings

Necessary
Drain Contaminants From Fuel Filter Seat Belt
Drain Contaminants From Fuel Tank Cab / Canopy
Change Fuel Filter Spark Arrestor Muffler
Check Hydraulic Fluid
Change Hydraulic Fluid and Filter(s)
697 of 698
Bobcat®, the Bobcat logo and the colors of the Bobcat machine are registered trademarks of
Bobcat Company in the United States and various other countries.
698 of 698

E10 6986788 enUS SM

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Service Manual

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

P-90216 RI075 RI072

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

RI074 RI071 B-19798

3 of 698 1-1 E10 Service Manual

4 of 698 1-2 E10 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

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

UPPERSTRUCTURE AND SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

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

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

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

Dealer Copy -- Not for Resale

5 of 698 1-3 E10 Service Manual

6 of 698 1-4 E10 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Dealer Copy -- Not for Resale

EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7 of 698 1-5 E10 Service Manual

8 of 698 1-6 E10 Service Manual

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

3. The seat belt must be 11. Check all machine fluid

Dealer Copy -- Not for Resale

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

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

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

1-7 E10 Service Manual

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

Dealer Copy -- Not for Resale

1-8 E10 Service Manual

Dealer Copy -- Not for Resale

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Compact Excavator Operator Training Course is

• The Bobcat compact excavator Safety Video is

The signal word WARNING on the machine and in the

1-9 E10 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

1-10 E10 Service Manual

Check hydraulic tubes, hoses and fittings for damage

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

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

Dealer Copy -- Not for Resale

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

1-11 E10 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Dealer Copy -- Not for Resale