Service Manual

Grader

(Grader 96) S/N ACW900101 & Above

(Grader 108) S/N AJ2E00101 & Above

Dealer Copy -- Not for Resale

6987469 (11-10) Printed in U.S.A. © Bobcat Company 2010

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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

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

CORRECT

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P-90216

Never service attachments / implements without

instructions. See Operation & Maintenance Manual and
Attachment / Implement Service Manual.

Cleaning and maintenance are required daily.

Never service or adjust attachment / implement with the
engine running unless instructed to do so in manual.

Always lower the attachment / implement to the ground

before lubricating or servicing.

Avoid contact with leaking hydraulic fluid or diesel fuel

under pressure. It can penetrate skin or eyes.
Stop, cool and clean engine of flammable materials before
checking fluids.
Keep body, loose objects and clothing away from moving
parts, electrical contacts, hot parts and exhaust.
Safety glasses are needed for eye protection from electrical
arcs, battery acid, compressed springs, fluids under
pressure and flying debris or when tools are used. Use eye
protection approved for type of welding.

MSW30-0409

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CONTENTS

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

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

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

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

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

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FOREWORD

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Attachment Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

ATTACHMENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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SAFETY &
SERIAL NUMBER LOCATION DELIVERY REPORT
MAINTENANCE
Attachment Serial Number Figure 2

Figure 1
HYDRAULIC
SYSTEM

DRIVE
SYSTEM
P-20022

P-94568
The delivery report [Figure 2] must be completed by the
dealer and signed by the owner or operator when the
Always use the serial number of the Bobcat grader when Bobcat grader is delivered. An explanation of the form
requesting service information or when ordering parts. must be given to the owner.

Dealer Copy -- Not for Resale

Early or later models (identification made by serial ELECTRICAL
number) may use different parts, or it may be necessary SYSTEM &
to use a different procedure in doing a specific service ANALYSIS
operation [Figure 1].

ENGINE
SERVICE

HVAC

SPECIFICATIONS

SPECIFICATIONS

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ATTACHMENT IDENTIFICATION

STEP MAIN FRAME BOLSTER

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MOUNTING FRAME CUTTING EDGE
TURNTABLE
DRAWBAR WHEELS
MOLDBOARD
DIRT SHIELD

P-94266

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SAFETY & MAINTENANCE

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Grader Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
BLR2 Receiver Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-2
Laser Beacon Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-3

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Attachment Mounting Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Bob-Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

LUBRICATING THE ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Turntable Clamp Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Turntable Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Laser System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-2

REMOVAL AND INSTALLATION OF CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

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Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

REMOVAL AND INSTALLATION OF TURNTABLE CLAMP . . . . . . . . . . . . . . . . . . . . . 10-51-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51-1

REMOVAL AND INSTALLATION OF TURNTABLE WEAR SLIDE . . . . . . . . . . . . . . . . 10-52-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52-1

ATTACHMENT STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

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TROUBLESHOOTING

Grader Chart

Instructions are necessary before operating or servicing machine. Read and

understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

If the grader is not working correctly, check the hydraulic system of the machine thoroughly before making any repairs on
the grader. Grader problems can be affected by a hydraulic system that is not operating to specifications. Connect a flow
meter to the machine to check the hydraulic pump output, relief valve setting and tube lines to check flow and pressure.
(See the machine’s Service Manual for the correct procedure to connect the flow meter.)

Use the following troubleshooting chart to locate and correct problems which most often occur with the attachment.

TROUBLESHOOTING THE GRADER

PROBLEM CAUSE CORRECTION

Grader does not mount properly on the Bob-Tach wedges are not fully Retract Bob-Tach wedges before
Bob-Tach. retracted prior to mounting. installation.

Dealer Copy -- Not for Resale

Mud, dirt or stones are lodged between Remove debris between Bob-Tach
the Bob-Tach and the Grader mount. and Grader mount.
Grader cut is not level. Moldboard is not properly positioned. Adjust moldboard to desired
position.
Cutting edge is worn. Reverse cutting edge or install new
cutting edge.
Grader blade does not maintain it’s Hydraulic cylinder has internal leakage. Test and repair cylinder.
position.
Control valve has internal leakage. Repair control valve.
Grader blade moves up and down Auxiliary flow is enabled and receiver is Disable auxiliary flow and check
uncontrollably. not properly connected. receiver connection.
Grader blade will not angle, oscillate or Electrical harness not connected. Connect electrical harness.
side shift.
Wires disconnected or broken at Repair or replace as needed.
control valve.
Control harness disconnected or Check harness and control module,
damaged ACD control module. repair or replace as needed.
Laser graded surface is uneven. Excessive ground speed. Drive slower.
Receivers are not setup level on poles. Adjust receivers. See Operation &
Maintenance Manual.
NOTE: For other problems, see Operation & Maintenance Manual or contact your Bobcat Dealer.

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TROUBLESHOOTING (CONT’D)

BLR2 Receiver Chart

TROUBLESHOOTING THE BLR2 RECEIVER

PROBLEM CAUSE CORRECTION

Unit will not turn on. No power to the unit. Make sure the system’s Power Cable
is connected to the machine’s battery.
Not enough power to the unit. Make sure the machine has enough
power (9v to 16v DC required).
Receiver cable loose. Make sure the receiver cable is secure
at both ends.
Bad fuse. Check the fuse.
Receiver cable is bad. If you have a spare, try a different
receiver cable.
Single green LED is lit and arrows Receiver is seeing laser beacon but Check 9xxx (purple) wires for correct
flash alternately. there’s no CAN communication with routing.
ACD. Check 9xxx (purple) wires for pushed
back terminals.
Receiver is damaged, replace receiver.

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All lights flash once and then go from Ambient light sensor on receiver is Replace receiver.
bright to dim. damaged.
Auto light goes not respond to trigger No CAN communication between Check 9xxx (purple) wires for correct
when used with 7 pin connector. receiver and ACD. routing.
Check 9xxx (purple) wires for pushed
back terminals.
Receiver is damaged, replace receiver.
Arrows do not respond to laser Receiver is not detecting laser Adjust laser beacon or receiver height
beacon and single LED does a beacon. to bring receiver within range.
double flash once every two Make sure laser beacon is at least 3 m
seconds. (10 ft) away from receiver.
Erratic display of arrows. Receivers are not properly initialized. Shut off carrier and restart.
ACD harness damaged. Replace the harness.
Receiver harness damaged or not Check connections or replace harness
properly installed. as required.
Valve harness has left and right Swap valve harness receiver
receiver connection points swapped. connection points. (Black tie strap /
‘RIGHT’ identification tag should be on
the right side of frame as viewed from
the operators position.)
Trimble Support Machine Control - Construction Instructions
Americas: 1 - 800 - 538 - 7800 (Option 3 For Support)
Outside Of Americas: 1 - 303 - 323 - 4111
E-Mail: [email protected]

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TROUBLESHOOTING (CONT’D)

Laser Beacon Chart

TROUBLESHOOTING THE LASER BEACON

PROBLEM CAUSE CORRECTION

Laser Beacon will not operate. No power. Press power button.
Batteries are bad. Check or replace batteries.
Laser needs servicing. Return laser to service center for
inspection.
Laser Beacon out-of-level indicator Laser not mounted securely. Make sure the laser is mounted to
does not shut off. stable surface.
Laser in wrong mode. Press the mode button so that the
laser is in automatic self-leveling or
grade mode.
Leveling screws not turning. Make sure the leveling screws are free
to turn.
Laser not level. Allow the laser to re-level.
Laser needs servicing. Return laser to service center for
inspection.

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SafeGuard LED is on. Calibration is off. Check and adjust laser plane
calibration as necessary.
Laser needs servicing. Return laser to service center for
inspection.
Laser Beacon plane not accurate. Calibration is off. Check and adjust laser plane
calibration as needed.
Laser needs servicing. Return laser to service center for
inspection.
NOTE: For other problems related to the laser products, see Trimble Operation Manual or contact your Bobcat Dealer.
Trimble Support Machine Control - Construction Instructions
Americas: 1 - 800 - 538 - 7800 (Option 3 For Support)
Outside Of Americas: 1 - 303 - 323 - 4111
E-Mail: [email protected]

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DAILY INSPECTION Figure 10-20-2

Attachment Mounting Frame

Figure 10-20-1

P-41502A
2 1

2 Push down on the Bob-Tach levers until they are fully

engaged in the locked position [Figure 10-20-2] (wedges
P-88814
fully extended through the attachment mounting frame
holes).

Inspect the Bob-Tach wedge mounts (Item 1), mounting The levers and wedges must move freely [Figure 10-20-
flange (Item 2) [Figure 10-20-1] and all welds on the 2].
grader mount for wear and damage each time the grader

Dealer Copy -- Not for Resale

is removed from the machine. Figure 10-20-3

Frequently inspect the grader to ensure that all

components are secure and that all bolts and nuts are
thoroughly tightened.

Bob-Tach

Hand Lever Bob-Tach

Bob-Tach wedge must

contact the lower edge
WARNING of the attachment
mounting frame hole.
P-79780
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers The wedges must extend through the holes in the
must be fully down and locked. Failure to secure attachment mounting frame, securely fastening the
wedges can allow attachment to come off. attachment to the Bob-Tach [Figure 10-20-3].
W-2715-0208
NOTE: If the wedge does not contact the lower edge
of the hole, the attachment will be loose and
can come off the Bob-Tach.

Inspect the mounting frame on the attachment. (See the

machine's Operation & Maintenance Manual for
inspecting the Bob-Tach). Replace any parts that are
damaged, bent or missing. Keep all fasteners tight. Look
for cracked welds. Contact your Bobcat dealer for repair
or replacement parts.

Lubricate the wedges. (See the machine’s Operation &

Maintenance Manual for the correct procedure.)

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DAILY INSPECTION (CONT’D) Figure 10-20-6

Bob-Tach (Cont’d)

Power Bob-Tach

WARNING
Bob-Tach wedge must
AVOID INJURY OR DEATH contact the lower edge
The Bob-Tach wedges must extend through the of the attachment
holes in the attachment mounting frame. Levers mounting frame hole.
must be fully down and locked. Failure to secure P-79780
wedges can allow attachment to come off.
W-2715-0208
The wedges must extend through the holes in the
attachment mounting frame, securely fastening the
Figure 10-20-4
attachment to the Bob-Tach [Figure 10-20-6].
Loader Switch NOTE: If the wedge does not contact the lower edge
of the hole, the attachment will be loose and
can come off the Bob-Tach.

Dealer Copy -- Not for Resale

Inspect the mounting frame on the attachment. (See the
machine's Operation & Maintenance Manual for
inspecting the Bob-Tach). Replace any parts that are
damaged, bent or missing. Keep all fasteners tight. Look
for cracked welds. Contact your Bobcat dealer for repair
or replacement parts.

Lubricate the wedges. (See the machine’s Operation &

1
B-15993A Maintenance Manual for the correct procedure.)

Figure 10-20-5

P-41500A

Push and hold the BOB-TACH “WEDGES DOWN” switch

(Item 1) [Figure 10-20-4] and until the levers are fully
engaged in the locked position [Figure 10-20-5] (wedges
fully extended through the attachment mounting frame
holes).

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LUBRICATING THE ATTACHMENT Figure 10-30-2

Lubrication Locations 2

IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, 3
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground 3
must be cleaned in a specific manner. See local, state
3
and federal regulations for the correct disposal. P-88801
I-2067-0499

2. Moldboard hanger / turntable lower pivot (Item 2)

[Figure 10-30-2].

3. Moldboard hanger, lower slide tube fittings (Item 3)

WARNING [Figure 10-30-2].

AVOID INJURY OR DEATH Figure 10-30-3

Dealer Copy -- Not for Resale

Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
4

Always use a good quality lithium base multi purpose

grease when lubricating the attachment. Apply lubricant
until extra grease shows. 5

Lubricate the following every 8 - 10 hours.

P-88804
Figure 10-30-1
4. Moldboard side shift hydraulic cylinder rod end (Item
4) [Figure 10-30-3].

5. Moldboard side shift hydraulic cylinder base end (Item

5) [Figure 10-30-3].

P-88802

1. Turntable upper pivot (Item 1) [Figure 10-30-1].

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LUBRICATING THE ATTACHMENT (CONT’D) Figure 10-30-6

Lubrication Locations (Cont’d)

Figure 10-30-4 9

P-88806
6
7
9. Drawbar front pivot mount (Item 9) [Figure 10-30-6].
P-88798

Figure 10-30-7
6. Moldboard angle hydraulic cylinder rod end (Both
Sides) (Item 6) [Figure 10-30-4].

Dealer Copy -- Not for Resale

7. Moldboard angle hydraulic cylinder base end (Both 10
Sides) (Item 7) [Figure 10-30-4].

Figure 10-30-5

10

8
8 P-88768 P-88800

10. Bolster pivot pin (Both Locations) (Item 10) [Figure

10-30-7].

P-88803

8. Moldboard elevation hydraulic cylinder mounts (Item

8) [Figure 10-30-5].

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LUBRICATING THE ATTACHMENT (CONT’D)

Lubrication Locations (Cont’d)

Figure 10-30-8

11

P-88809

11. Caster Wheel Spindle (Both Sides) (Item 11) [Figure

10-30-8].

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REGULAR MAINTENANCE ITEMS Turntable Clamp Slide

Cutting Edge Figure 10-40-2

WARNING
AVOID INJURY OR DEATH
Securely block up the attachment before working
underneath. 1
W-2795-0409

WARNING P-88808

AVOID INJURY OR DEATH Check the turntable clamp slide (Item 1) [Figure 10-40-
Wear safety glasses to prevent eye injury when any 2], replace if any damage or excessive wear is visible.
of the following conditions exist: (See REMOVAL AND INSTALLATION OF TURNTABLE
• When fluids are under pressure. CLAMP on Page 10-51-1.)

Dealer Copy -- Not for Resale

• Flying debris or loose material is present.
• Engine is running. Turntable Slide
• Tools are being used.
W-2019-0907 Figure 10-40-3

Figure 10-40-1 1

2
P-88808

1
Check the turntable slide (Item 1) [Figure 10-40-3],
P-88819
replace if any damage or excessive wear is visible. (See
REMOVAL AND INSTALLATION OF TURNTABLE
Inspect the cutting edge (Item 1), replace if any damage WEAR SLIDE on Page 10-52-1.)
or excessive wear is visible. Tighten or replace any loose
or missing bolts or nuts (Item 2) [Figure 10-40-1]. (See
REMOVAL AND INSTALLATION OF CUTTING EDGE on
Page 10-50-1.)

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REGULAR MAINTENANCE ITEMS (CONT’D) NOTE: Blow off any loose debris before cleaning any
surfaces to prevent scratching the optical
Laser System surfaces.

Store the laser receiver(s) and beacon in the carrying Always use a moist, clean cloth to wipe off any dust or
case(s) when not in use. dirt from the laser beacon and receiver's outer surface.

NOTE: Do not store the laser receiver or laser beacon

in a wet carrying case. If the case gets wet,
open it and let it dry before storing.

NOTE: Remove the batteries from the laser beacon

and laser receiver (if equipped) when storing
the equipment more than 30 days.

Figure 10-40-4

Dealer Copy -- Not for Resale

P-20904

Figure 10-40-5

P-83407

Always use a good quality glass cleaner and a clean soft

cloth only to clean all external optical components
[Figure 10-40-4] and [Figure 10-40-5].

NOTE: A dry cloth used on the laser exit windows,

laser receiving window, or displays could
scratch or damage these surfaces.

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REMOVAL AND INSTALLATION OF CUTTING EDGE

Procedure

WARNING
AVOID INJURY OR DEATH
Securely block up the attachment before working
underneath.
W-2795-0409

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.

Dealer Copy -- Not for Resale

• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

Figure 10-50-1

2
P-88819

NOTE: The cutting edge is reversible.

Remove the nuts and bolts (Item 1) and cutting edge

(Item 2) [Figure 10-50-1].

Rotate the cutting edge 180° and reinstall.

Installation: Tighten nuts and bolts to 170 - 190 N•m

(125 - 140 ft-lb) torque.

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26 of 120 10-50-2 Grader Service Manual

REMOVAL AND INSTALLATION OF TURNTABLE
CLAMP

Procedure

Figure 10-51-1

2
1

P-88808

Remove the two bolts (Item 1), turntable clamp (Item 2),
wear slide (Item 3) and spacers (Item 4) [Figure 10-51-

Dealer Copy -- Not for Resale

1].

Installation: Install spacers, new wear slide and

turntable clamp. Tighten bolts to 408 - 469 N•m (301 -
339 ft-lb) torque.

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28 of 120 10-51-2 Grader Service Manual

REMOVAL AND INSTALLATION OF TURNTABLE Figure 10-52-3
WEAR SLIDE

Procedure
1
Remove the moldboard. (See MOLDBOARD on Page
30-40-1.)
1
Figure 10-52-1

P-94236

Place jack stands (Item 1) [Figure 10-52-3] under the

front of the hanger to prevent the hanger from falling.

1
P-88834

Dealer Copy -- Not for Resale

Fasten chains and lifting device to the drawbar (Item 1)
[Figure 10-52-1].

Figure 10-52-2

2
1

P-88808

Remove the two bolts (Item 1), turntable clamp (Item 2),
clamp wear slide (Item 3) and spacers (Item 4) [Figure
10-52-2].

Installation: Install spacers, new wear slide and

turntable clamp. Tighten bolts to 408 - 469 N•m (301 -
339 ft-lb) torque.

29 of 120 10-52-1 Grader Service Manual

REMOVAL AND INSTALLATION OF TURNTABLE Figure 10-52-6
WEAR SLIDE (CONT’D)

Procedure (Cont’d)

Figure 10-52-4

1
3 2

2
1
2
P-88927

Remove snap rings (Item 1) and pins (Item 2) [Figure

10-52-6] from elevation cylinders. Swing cylinders out.
P-88802
Raise the drawbar (Item 3) [Figure 10-52-6] upward with
lifting device.
Figure 10-52-5

Dealer Copy -- Not for Resale

Installation: Lower drawbar into position. Connect
elevation cylinders, install pins and snap rings.

Figure 10-52-7

P-94235

Remove the roll pin (Item 1) and nut (Item 2) [Figure 10-
52-4]. Remove the bolt (Item 1) [Figure 10-52-5].
P-94232

Installation: Install bolt, nut and roll pin. Tighten to 407

N•m (300 ft -lb) torque. Remove turntable wear slide (Item 1) [Figure 10-52-7].

Installation: Install new turntable wear slide.

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ATTACHMENT STORAGE AND RETURN TO SERVICE Return To Service

Storage After the Bobcat attachment has been in storage, it is

necessary to follow a list of items to return the
Sometimes it may be necessary to store your Bobcat attachment to service.
attachment for an extended period of time. Below is a list
of items to perform before storage. • Be sure all shields and guards are in place.

• Thoroughly clean the attachment. • Lubricate the attachment.

• Lubricate the attachment. • Install and operate attachment, check for correct
function.
• Inspect the Bob-Tach wedge mounts, mounting
flange and all welds on the attachment for wear and • Check for leaks. Repair as needed.
damage.

• Check for loose hardware, missing guards, or

damaged parts.

• Replace worn or damaged parts.

• Check for damaged or missing decals. Replace if

necessary.

Dealer Copy -- Not for Resale

• Place the attachment in a dry protected shelter.

• Place the attachment flat on the ground.

• Put all controls in neutral position.

NOTE: In muddy conditions or to prevent the

attachment from freezing to the ground, put
the attachment on planks or blocks before
removing the attachment from the machine.

31 of 120 10-60-1 Grader Service Manual

Dealer Copy -- Not for Resale

32 of 120 10-60-2 Grader Service Manual

HYDRAULIC SYSTEM

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-9

LEVELING HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7

TURNTABLE HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-7

SIDE SHIFT HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7

33 of 120 20-01 Grader Service Manual

Dealer Copy -- Not for Resale

34 of 120 20-02 Grader Service Manual

HYDRAULIC CONTROL VALVE Figure 20-10-2

Removal And Installation

1

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

P-94096

Disconnect the electrical wiring from the control valve

IMPORTANT (Item 1) [Figure 20-10-2].

Installation: Connect the electrical wiring to the control

Contain and dispose of any oil leakage in an valve.
environmentally safe manner.
I-2066-0395
Figure 20-10-3

Dealer Copy -- Not for Resale

Figure 20-10-1 2

2
1

P-94097

P-88816 NOTE: Mark hoses before removal for proper

installation.
To access the control valve, remove the bolts (Item 1)
Remove the hydraulic hoses from the control valve (Item
and remove the cover (Item 2) [Figure 20-10-1].
1) [Figure 20-10-3].
Installation: Install cover and tighten bolts.
Remove the two bolts (Item 2) [Figure 20-10-3] holding
the control valve block to the frame, remove the control
valve.

Installation: Install the control valve block and tighten

bolts to 47 - 54 N•m (35 - 40 ft-lb) torque. Connect
hydraulic hoses and tighten. (See HYDRAULIC
CONNECTION SPECIFICATIONS on SPEC-40-1.)

35 of 120 20-10-1 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Parts Identification

1. Manifold Block
2. Logic Element
3. LS Check Valve
4. LS Solenoid Valve
5. Coil (Black)
6. Coil (Red)
7. Coil Spacer
8. Coil (Brown)
9. Coil (White)
10. Coil (Green) 9
11. Coil (Yellow) 6
12. Coil (Orange)
13. Coil (Blue)
14. Coil Spacer 7 10
15. Prop Solenoid Valve
12
16. Plug
5
17. Orifice

14
14

Dealer Copy -- Not for Resale

8 11

4
13

16
2
3
15

17

16

P-94202

36 of 120 20-10-2 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-4

Disassembly

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any 1
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-94113
W-2019-0907

Remove the two fittings (Item 1) [Figure 20-10-4].

Figure 20-10-5
WARNING

Dealer Copy -- Not for Resale

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

IMPORTANT P-94108

When repairing hydrostatic and hydraulic systems, Remove the O-rings (Item 1) [Figure 20-10-5] from the
clean the work area before disassembly and keep all two fittings.
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

37 of 120 20-10-3 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-9
Disassembly (Cont’d)
Figure 20-10-6

2 1

P-94135
1 3

P-94098 Remove the four fittings (Item 1) [Figure 20-10-9].

Figure 20-10-10
Remove the fitting (Item 1) and the 0.020 orifice (Item 2)
[Figure 20-10-6] located under the fitting.
Remove the fitting (Item 3) [Figure 20-10-6].

Dealer Copy -- Not for Resale

Figure 20-10-7

1
P-94107

Remove the O-rings (Item 1) [Figure 20-10-10] from the

P-94112
four fittings.
Figure 20-10-8

P-94111

Remove the O-rings (Item 1) [Figure 20-10-7] and

[Figure 20-10-8] from the two fittings.

38 of 120 20-10-4 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-14
Disassembly (Cont’d)
Figure 20-10-11

1
1

P-94134

1
P-94136
Remove the two fittings (Item 1) [Figure 20-10-14].

Figure 20-10-15
Remove the two fittings (Item 1) [Figure 20-10-11].

Figure 20-10-12

Dealer Copy -- Not for Resale

1

P-94110

P-94111

Remove the O-rings (Item 1) [Figure 20-10-15] from the

Figure 20-10-13 two fittings.

P-94112

Remove the O-rings (Item 1) [Figure 20-10-12] and

[Figure 20-10-13] from the two fittings.

39 of 120 20-10-5 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-18

Disassembly (Cont’d)

Figure 20-10-16

P-94121

Remove the four coil spacers (Item 1) [Figure 20-10-18].

P-94119
Figure 20-10-19

Remove the four nuts (Item 1) [Figure 20-10-16].

Dealer Copy -- Not for Resale

Figure 20-10-17

P-94122

NOTE: Mark solenoids before removal for proper

P-94120 installation.

Remove the four solenoid coils (Item 1) [Figure 20-10-

NOTE: Mark solenoids before removal for proper 19].
installation.

Remove the four solenoid coils (Item 1) [Figure 20-10-

17].

40 of 120 20-10-6 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-22

Disassembly (Cont’d) 1
Figure 20-10-20

2
3
3
P-94139
1

Remove the O-rings (Item 1), back-up rings (Item 2)

P-94123 [Figure 20-10-22] from the LS solenoid valve.

LS check valve (Item 3) [Figure 20-10-22] located under

Remove the three prop solenoid valves (Item 1), the LS the LS solenoid valve.
solenoid valve (Item 2) and the LS check valve (Item 3)

Dealer Copy -- Not for Resale

[Figure 20-10-20] located under the LS solenoid valve.

Figure 20-10-21

2
P-94124

Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-10-21] from the three prop solenoid valves.

41 of 120 20-10-7 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-25

Disassembly (Cont’d)

Figure 20-10-23 1

2
1 3
3

P-94127

Remove the plug (Item 1) [Figure 20-10-25].

P-94125
Remove the plug (Item 2) and 0.020 orifice (Item 3)
[Figure 20-10-25] located under the plug.
Remove the logic element valve (Item 1) [Figure 20-10-
23]. Figure 20-10-26

Dealer Copy -- Not for Resale

Figure 20-10-24

1 1

P-94129

2
P-94126
Remove the O-rings (Item 1) [Figure 20-10-26] from the
two plugs.
Remove the O-rings (Item 1) and the back-up rings (Item
2) [Figure 20-10-24] from the valve.

42 of 120 20-10-8 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-29

Assembly
1
NOTE: Always use new O-rings and seals when
assembling the hydraulic control valve. Put a
small amount of grease on all the O-rings and
seals for easier assembly.

Figure 20-10-27

1
2
P-94126

Install the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-10-29] on the valve.

Figure 20-10-30

Dealer Copy -- Not for Resale

P-94129

Install the O-ring (Item 1) [Figure 20-10-27] on the plugs.

1
Figure 20-10-28

P-94125

2 Install the logic element valve (Item 1) [Figure 20-10-30].

1
1 Installation: Tighten to 34 N•m (25 ft-lb) torque.

P-94127

Install the 0.020 orifice (Item 1), plug (Item 2) and (Item
3) [Figure 20-10-28].

Installation: Tighten plugs to 27 N•m (20 ft-lb) torque.

43 of 120 20-10-9 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) NOTE: Dip the valve cartridges in clean oil. Screw the
valve cartridge by hand until the top O-ring is
Assembly (Cont’d) met. Tighten to specifications.

Figure 20-10-31 Figure 20-10-33

1
3

2
P-94124 P-94123

Install the O-rings (Item 1), back-up rings (Item 2) Install the three prop solenoid valves (Item 1) [Figure 20-
[Figure 20-10-31] on the three prop solenoid valves and 10-33].

Dealer Copy -- Not for Resale

the LS solenoid valve.
Installation: Tighten to 34 N•m (25 ft-lb) torque.
Figure 20-10-32
Install the LS check valve (Item 2) and LS solenoid valve
1 (Item 3) [Figure 20-10-33].

Installation: Tighten to 27 N•m (20 ft-lb) torque.

2
3

P-94139

Install the O-rings (Item 1), back-up rings (Item 2)

[Figure 20-10-32] on the LS solenoid valve.

LS check valve (Item 3) [Figure 20-10-32] located under

the LS solenoid valve.

44 of 120 20-10-10 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-36

Assembly (Cont’d)

Figure 20-10-34

P-94120
1

Install the four solenoid coils (Item 1) [Figure 20-10-36].

P-94122
Figure 20-10-37

Install the four solenoid coils (Item 1) [Figure 20-10-34].

Dealer Copy -- Not for Resale

Figure 20-10-35

P-94119

Install the four nuts (Item 1) [Figure 20-10-37].

P-94121
Installation: Tighten to 5 - 7 N•m (4 - 5 ft-lb) torque.

Install the four coil spacers (Item 1) [Figure 20-10-35].

45 of 120 20-10-11 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-41

Assembly (Cont’d)
Figure 20-10-38

P-94110

P-94111 Install the O-rings (Item 1) [Figure 20-10-41] on the two

fittings.
Figure 20-10-39
Figure 20-10-42

Dealer Copy -- Not for Resale

1
1

P-94112

P-94134
Install the O-rings (Item 1) [Figure 20-10-38] and
[Figure 20-10-39] on the two fittings.
Install the two fittings (Item 1) [Figure 20-10-42].
Figure 20-10-40
Installation: Tighten to 29 - 33 N•m (22 - 24 ft-lb) torque.

1
P-94136

Install the two fittings (Item 1) [Figure 20-10-40].

Installation: Tighten to 29 - 33 N•m (22 - 24 ft-lb) torque.

46 of 120 20-10-12 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-10-45

Assembly (Cont’d)

Figure 20-10-43

P-94111
1
Figure 20-10-46

P-94107

Install the O-rings (Item 1) [Figure 20-10-43] on the four

fittings.

Dealer Copy -- Not for Resale

1
Figure 20-10-44

P-94112

Install the O-rings (Item 1) [Figure 20-10-45] & [Figure

20-10-46] on the two fittings.
1
Figure 20-10-47
1
2
P-94135

Install the four fittings (Item 1) [Figure 20-10-44].

2
Installation: Tighten to 29 - 33 N•m (22 - 24 ft-lb) torque.

3 1

P-94098

Install the fitting (Item 1), 0.020 orifice (Item 2) and fitting
(Item 3) [Figure 20-10-47].
Installation: Tighten fittings to 29 - 33 N•m (22 - 24 ft-lb)
torque.

47 of 120 20-10-13 Grader Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Assembly (Cont’d)

Figure 20-10-48

P-94108

Install the O-rings (Item 1) [Figure 20-10-48] on the two

fittings.

Dealer Copy -- Not for Resale

Figure 20-10-49

P-94113

Install the two fittings (Item 1) [Figure 20-10-49].

Installation: Tighten to 93 - 102 N•m (68 - 75 ft-lb)

torque.

48 of 120 20-10-14 Grader Service Manual

LEVELING HYDRAULIC CYLINDER Figure 20-20-1

Removal And Installation

1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 1

P-94145

Fully lower the moldboard to the ground. Remove the two

IMPORTANT hydraulic hoses (Item 1) [Figure 20-20-1].
Installation: Connect hydraulic hoses and tighten. (See
Contain and dispose of any oil leakage in an HYDRAULIC CONNECTION SPECIFICATIONS on
environmentally safe manner. SPEC-40-1.)
I-2066-0395

Dealer Copy -- Not for Resale

Figure 20-20-2

WARNING
AVOID INJURY OR DEATH
Securely block up the attachment before working
underneath.
W-2795-0409

WARNING P-94206

AVOID INJURY OR DEATH Remove the two fittings (Item 1) [Figure 20-20-2].
Wear safety glasses to prevent eye injury when any
of the following conditions exist: Installation: Replace the O-rings on the fittings with new
• When fluids are under pressure. O-rings. Install fittings.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

49 of 120 20-20-1 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Figure 20-20-5

Removal And Installation (Cont’d)

Figure 20-20-3

2 2

1
2

P-94152

Remove the snap ring (Item 1), cylinder pin (Item 2)

P-94208 [Figure 20-20-5] and remove the cylinder.

Repeat this procedure for the cylinder on the opposite

Remove the four bolts (Item 1) and cylinder clamp(s)
side of the grader.
(Item 2) [Figure 20-20-3].

Dealer Copy -- Not for Resale

Installation: Install cylinder, cylinder pin and snap ring.
Installation: Install cylinder clamp(s) and bolts. Tighten
bolts.
Figure 20-20-4

P-94150

Remove the two wear bushings (Item 1) [Figure 20-20-

4].

Installation: Install wear bushings.

50 of 120 20-20-2 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D)

Parts Identification

1. Case
2. Retainer Clip
3. Piston
4. Wear Ring
5. Seal
6. O-ring
7. Rod
8. Seal
9. Wear Ring
10. Seal
11. Wear Ring
12. Back-up Ring
13. O-ring
14. Head
15. Nut

Dealer Copy -- Not for Resale

2

5
14
15
11
4 9
6
13
12 7
10
8

P-94269

51 of 120 20-20-3 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Figure 20-20-7

Disassembly
2
NOTE: The photos may not show the cylinder exactly
1
as it appears, but the procedure is the correct.

The following tools will be needed to disassemble and

assemble the cylinder:

Spanner Wrench

Universal Seal Expander

Rod Seal Installation Tool

P-94157
Place the base end of the hydraulic cylinder in a drain
pan. Move the rod in and out to remove the fluid from the
cylinder. Move the rod slowly so the fluid will go directly Remove the rod assembly (Item 1) from the cylinder case
into the drain pan. (Item 2) [Figure 20-20-7].

Place the base end of the cylinder in a vise. Remove the cylinder case from the vise.
Place the rod end in the vise.
Figure 20-20-8

Dealer Copy -- Not for Resale

IMPORTANT
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-20-6

P-94161

Remove the nut (Item 1) from the piston end of the rod
1 and slide the piston (Item 2) [Figure 20-20-8] off the rod.

N-16873

Use a Spanner Wrench to turn the head

counterclockwise, and remove the retainer clip (Item 1)
[Figure 20-20-6].

NOTE: The retainer clip may need to be guided out as

the head is turned.

52 of 120 20-20-4 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Figure 20-20-11

Disassembly (Cont’d)
1
Figure 20-20-9

N-16895

Remove the back-up ring (Item 1) [Figure 20-20-11] from

the head.
P12855
Figure 20-20-12

Remove the head (Item 1) [Figure 20-20-9] from the rod.

Figure 20-20-10

Dealer Copy -- Not for Resale

1

N-16897

Remove the wiper seal (Item 1) [Figure 20-20-12] from

the head.
N-16894

Remove the O-ring (Item 1) [Figure 20-20-10] from the

head.

53 of 120 20-20-5 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Figure 20-20-15

Disassembly (Cont’d)

Figure 20-20-13

P12857

Remove the piston seal (Item 1) [Figure 20-20-15] from

N-16898 the piston.

Figure 20-20-16
Remove the oil seal (Item 1) [Figure 20-20-13] from the
head.

Dealer Copy -- Not for Resale

Figure 20-20-14

P12858

Remove the O-ring (Item 1) [Figure 20-20-16] from the

P12856 piston.

Remove the O-ring (Item 1) [Figure 20-20-14] from the

piston.

54 of 120 20-20-6 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Allow the O-ring to stretch for 30 seconds before
removing it from the tool.
Assembly
Figure 20-20-19
Clean all parts in solvent and dry with compressed air.

While servicing the cylinder, do not damage the parts.

Inspect for nicks, scratches or otherwise damaged or
bent parts before assembling the cylinder. Replace parts
that appear damaged in any way. The cylinder may not
function correctly if there is damage to any of the parts.

Discard all the used O-rings and seals and replace

them with NEW O-rings and seals.

Apply clean hydraulic fluid to all O-rings and seals before

installation. 1

Figure 20-20-17 P12857

Install the seal (Item 1) [Figure 20-20-19] on the piston.

Figure 20-20-20

Dealer Copy -- Not for Resale

1

P12858

Install the O-ring (Item 1) [Figure 20-20-17] on the

piston. P12856

Figure 20-20-18 Install the O-ring (Item 1) [Figure 20-20-20] in the piston.

P7424

Install the seal on the tool and stretch the seal until it fits
the piston [Figure 20-20-18].

55 of 120 20-20-7 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Figure 20-20-23

Assembly (Cont’d)

Figure 20-20-21

P7425

Install the oil seal in the head [Figure 20-20-23].

N-22358 Figure 20-20-24

Use a ring compressor to compress the seal to the

correct size [Figure 20-20-21]. Leave the piston in the
piston ring compressor for three minutes.

Dealer Copy -- Not for Resale

1
Figure 20-20-22

N-16896

Install the wiper seal (Item 1) [Figure 20-20-24] with the

lip toward the outside of the head.

P7427

Install the oil seal on the rod seal tool [Figure 20-20-22].

NOTE: The O-ring side of the oil seal goes toward the
inside of the cylinder.

56 of 120 20-20-8 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Figure 20-20-27

Assembly (Cont’d)

Figure 20-20-25 1

P12855

Install the head (Item 1) [Figure 20-20-27] on the rod.

N-16895
Figure 20-20-28
Install the back-up washer (Item 1) [Figure 20-20-25] on
the head. 4
3

Dealer Copy -- Not for Resale

Figure 20-20-26
2

1
P-94161

Install the piston (Item 1) and nut (Item 2) [Figure 20-20-

28] on the rod.
N-16894
Installation: Tighten to 102 - 108 N•m (75 - 80 ft-lb)
Install the O-ring (Item 1) [Figure 20-20-26] next to the torque.
back-up ring.
Apply assembly lube on the piston seal (Item 3) and on
the O-ring and back-up ring (Item 4) [Figure 20-20-28].

57 of 120 20-20-9 Grader Service Manual

LEVELING HYDRAULIC CYLINDER (CONT’D) Figure 20-20-31

Assembly (Cont’d)
1
Figure 20-20-29

N-17010

Hook the correct end of the retainer clip (Item 1) [Figure

20-20-31] into the cylinder head.
P12859

Figure 20-20-32
Apply assembly lube on the seal surface of the cylinder
case [Figure 20-20-29].
1

Dealer Copy -- Not for Resale

Figure 20-20-30

2
N-16873
1
Turn the spanner wrench clockwise to install the head
retainer ring (Item 1) [Figure 20-20-32].
P-94157

Install the rod assembly in the cylinder case.

Push the head into the case until the groove in the head
(Item 1) lines up with the slot in the case (Item 2) [Figure
20-20-30].

58 of 120 20-20-10 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER Figure 20-30-1

Removal And Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 1
P-88798

Remove the two hydraulic hoses (Item 1) [Figure 20-30-

IMPORTANT 1].

Installation: Connect hydraulic hoses and tighten. (See

Contain and dispose of any oil leakage in an HYDRAULIC CONNECTION SPECIFICATIONS on
environmentally safe manner. SPEC-40-1.)

Dealer Copy -- Not for Resale

I-2066-0395
Figure 20-30-2

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907 1
P-94155

Remove the two fittings (Item 1) [Figure 20-30-2].

Installation: Replace the O-rings on the fittings with new
O-rings. Install fittings.

59 of 120 20-30-1 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D)

Removal And Installation (Cont’d)

Figure 20-30-3

2
2

1
1

P-94155

Remove the two nuts, bolts (Item 1) [Figure 20-30-3].

Remove the two cylinder pins (Item 2) [Figure 20-30-3]

Dealer Copy -- Not for Resale

and remove the cylinder.
Repeat this procedure for the cylinder on the opposite
side of the grader.

Installation: Install cylinder, cylinder pins, bolts and nuts.

60 of 120 20-30-2 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D)

Parts Identification

1. Grease Fitting
2. Set Screw
3. Piston
4. Wear Ring
5. Seal
6. O-ring
7. Rod
8. Collar (with set screw)
9. Seal
10. Seal
11. Wear Ring
12. Back-up Ring
13. O-ring
14. Head
15. Nut
16. Case

Dealer Copy -- Not for Resale

2

16
3

5
15 14

11
4 9
6
13
12
10 7

8 1

P-94270

61 of 120 20-30-3 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D) Figure 20-30-4

Disassembly
2
NOTE: The photos may not show the cylinder exactly
as it appears, but the procedure is the correct.

The following tools will be needed to disassemble and

assemble the cylinder:

Spanner Wrench 1

Universal Seal Expander

Rod Seal Installation Tool

P-94272
Place the base end of the cylinder in a drain pan. Move
the rod slowly in and out to remove the fluid from the
cylinder. Loosen set screw (Item 1) [Figure 20-30-4].

Place the base end of the cylinder in a vise. Use a spanner wrench to turn the collar (Item 2) [Figure
20-30-4] counterclockwise. Remove the collar from the
cylinder case.

Dealer Copy -- Not for Resale

IMPORTANT Figure 20-30-5

When repairing hydrostatic and hydraulic systems,

1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 2
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

IMPORTANT
P-94425
Contain and dispose of any oil leakage in an
environmentally safe manner.
I-2066-0395 Remove the rod assembly (Item 1) from the cylinder case
(Item 2) [Figure 20-30-5].

Remove the cylinder case from the vise.

WARNING Place the rod end in the vise.

AVOID INJURY OR DEATH

Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

62 of 120 20-30-4 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D) Figure 20-30-8

Disassembly (Cont’d)
2
1
Figure 20-30-6

2
1

N-16894

Remove the O-ring (Item 1) and back-up ring (Item 2)

P12854 [Figure 20-30-8] from the head.

Figure 20-30-9
Remove the nut (Item 1) from the piston end of the rod
and slide the piston (Item 2) [Figure 20-30-6] off the rod.

Dealer Copy -- Not for Resale

Figure 20-30-7
1

1 2

N-16897

Remove the wiper seal (Item 1) [Figure 20-30-9] from

P12855 the head.

Remove the oil seal (Item 2) [Figure 20-30-9] from the

Remove the head (Item 1) [Figure 20-30-7] from the rod.
head.

63 of 120 20-30-5 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D) Figure 20-30-12

Disassembly (Cont’d)

Figure 20-30-10

1
P12858

Remove the O-ring (Item 1) [Figure 20-30-12] from the

P12856 piston.

Remove the O-ring (Item 1) [Figure 20-30-10] from the

piston.

Dealer Copy -- Not for Resale

Figure 20-30-11

P12857

Remove the piston seal (Item 1) [Figure 20-30-11] from

the piston.

64 of 120 20-30-6 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D) Allow the seal to stretch for 30 seconds before removing
it from the tool.
Assembly
Figure 20-30-15
Clean all parts in solvent and dry with compressed air.

While servicing the cylinder, do not damage the parts.

Inspect for nicks, scratches or otherwise damaged or
bent parts before assembling the cylinder. Replace parts
that appear damaged in any way. The cylinder may not
function correctly if there is damage to any of the parts.

Destroy all the O-rings and seals and replace them

with NEW O-rings and seals.

Apply clean hydraulic fluid to all O-rings and seals before

installation.

Figure 20-30-13 1

P12857

Install the seal (Item 1) [Figure 20-30-15] on the piston.

Figure 20-30-16

Dealer Copy -- Not for Resale

1

P12858

Install the O-ring (Item 1) [Figure 20-30-13] on the

piston.

Figure 20-30-14 P12856

Install the O-ring (Item 1) [Figure 20-30-16] in the piston.

P7424

Install the seal on the tool and stretch the seal until it fits
the piston [Figure 20-30-14].

65 of 120 20-30-7 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D) Figure 20-30-19

Assembly (Cont’d)

Figure 20-30-17

P7425

Install the oil seal in the head [Figure 20-30-19].

N-22358
Figure 20-30-20

Use a ring compressor to compress the seal to the

correct size [Figure 20-30-17]. Leave the piston in the
piston ring compressor for three minutes.

Dealer Copy -- Not for Resale

NOTE: The O-ring side of the oil seal goes toward the 1
inside of the cylinder.

Figure 20-30-18

N-16896

Install the wiper seal (Item 1) [Figure 20-30-20] with the

lip toward the outside of the head.

P7427

Install the oil seal on the rod seal tool [Figure 20-30-18].

66 of 120 20-30-8 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D) Figure 20-30-23

Assembly (Cont’d)

Figure 20-30-21
1

P12855

Install the head (Item 1) [Figure 20-30-23] on the rod.

N-16895
Figure 20-30-24
Install the back-up ring (Item 1) [Figure 20-30-21] on the
head.

Dealer Copy -- Not for Resale

Figure 20-30-22
4
3
1
2

1
P12854

Install the piston (Item 1) and nut (Item 2) [Figure 20-30-

N-16894
24] on the rod.

Installation: Tighten to 102 - 108 N•m (75 - 80 ft-lb)

Install the O-ring (Item 1) [Figure 20-30-22] next to the torque.
back-up ring.
Apply assembly lube on the piston seal (Item 3) and on
the head O-ring and back-up ring (Item 4) [Figure 20-30-
24].

67 of 120 20-30-9 Grader Service Manual

TURNTABLE HYDRAULIC CYLINDER (CONT’D)

Assembly (Cont’d)

Figure 20-30-25

3 1
2

P-94425

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

(Item 2) [Figure 20-30-25].

Dealer Copy -- Not for Resale

Install the head (Item 3) [Figure 20-30-25] into the
cylinder case.

Figure 20-30-26

P-94272

NOTE: Apply assembly lube on the seal surface of

the collar and cylinder case before
installation.

Install the collar (Item 1) [Figure 20-30-26] onto the

case. Turn the collar clockwise and tighten using a
spanner wrench.

Tighten set screw (Item 2) [Figure 20-30-26].

68 of 120 20-30-10 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER Figure 20-40-1

Removal And Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 1
damage the system.
I-2003-0888
P-88801

Remove the two hydraulic hoses (Item 1) [Figure 20-40-

1].
IMPORTANT Installation: Connect hydraulic hoses and tighten. (See
Contain and dispose of any oil leakage in an HYDRAULIC CONNECTION SPECIFICATIONS on
environmentally safe manner. SPEC-40-1.)

Dealer Copy -- Not for Resale

I-2066-0395
Figure 20-40-2

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any 1 2
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

P-88804

Remove the snap ring (Item 1) and cylinder pin (Item 2)

[Figure 20-40-2] from the rod end of the cylinder.

Installation: Install cylinder, cylinder pin and snap rings.

69 of 120 20-40-1 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D)

Removal And Installation (Cont’d)

Figure 20-40-3

P-94156

Remove the snap ring (Item 1) and cylinder pin (Item 2)

[Figure 20-40-3] from the base end of the cylinder.

Dealer Copy -- Not for Resale

Remove the cylinder.

Installation: Install cylinder, cylinder pin and snap rings.

70 of 120 20-40-2 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D)

Parts Identification

1. Case
2. Plug
3. O-ring
4. Nut
5. Piston
6. O-ring
7. Seal
8. O-ring
9. Back-up Ring
10. Rod
11. O-ring
12. Seal
13. Seal
14. Head

8
7

Dealer Copy -- Not for Resale

6

2 3 10

11

12

13

14

TS-01147

71 of 120 20-40-3 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Put the base end of the hydraulic cylinder in a drain pan.
Move the rod in and out to remove the fluid from the
Disassembly cylinder. Move the rod slowly so the fluid will go directly
into the drain pan.
Use the following tools to disassemble and assemble the
hydraulic cylinder: Put the base end of the cylinder in a vise.

O-Ring Seal Hook Figure 20-40-4

Seal Installation Tool
Rod Seal Installation Tool
Spanner Wrench 1
Cylinder Wrench
Torque Multiplier (See your Bobcat dealer)

NOTE: The images may not show the cylinder exactly

as it appears, but the procedure is the correct.

WARNING P-94406

AVOID INJURY OR DEATH

Dealer Copy -- Not for Resale

Use a spanner wrench to loosen the head (Item 1)
Wear safety glasses to prevent eye injury when any
[Figure 20-40-4].
of the following conditions exist:
• When fluids are under pressure.
Figure 20-40-5
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly B-07001

damage the system.

I-2003-0888
Remove the rod assembly from the cylinder case [Figure
20-40-5].

Remove the cylinder case from the vise.

IMPORTANT Put the rod end in the vise.

Contain and dispose of any oil leakage in an

environmentally safe manner.
I-2066-0395

72 of 120 20-40-4 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Figure 20-40-8

Disassembly (Cont’d)

Figure 20-40-6

B-07004

If the head has a seal, remove the seal from the head
B-07002 [Figure 20-40-8].

Figure 20-40-9
Remove the nut from the piston end of the rod [Figure
20-40-6].

Dealer Copy -- Not for Resale

Figure 20-40-7

3 B-07199

2
Remove the O-ring and back-up ring from the head
B-7003 [Figure 20-40-9].

Pull the piston off the rod (Item 1). If the cylinder has a
cushion sleeve (Item 2), pull it off the rod. Pull the head
(Item 3) [Figure 20-40-7] off the rod.

73 of 120 20-40-5 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Figure 20-40-12

Disassembly (Cont’d)

Figure 20-40-10

B-03639

Remove the piston seal from the piston [Figure 20-40-

B-07005 12].

Figure 20-40-13
Remove the wiper seal [Figure 20-40-10].

Figure 20-40-11

Dealer Copy -- Not for Resale

B-03703

B-07006 Remove the O-ring from the piston [Figure 20-40-13].

Wash the cylinder parts in clean solvent and dry with
compressed air.
Remove the oil seal from the head [Figure 20-40-11].
NOTE: While servicing the cylinder do not damage
the parts. Inspect for nicks, scratches or
otherwise damaged or bent parts before
assembling the cylinder. Replace parts that
appear damaged in any way. The cylinder may
not function correctly if there is damage to
any of the parts.

Destroy all the O-rings and seals and replace them

with NEW O-rings and seals.

74 of 120 20-40-6 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Figure 20-40-16

Assembly

Clean all components in clean solvent and dry with

compressed air. Discard all the O-rings and back-up
rings and replace them with new O-rings and back-up
rings. Apply clean hydraulic fluid to all O-rings and back-
up rings before installation.

Figure 20-40-14

B-12813

Install the seal on the piston [Figure 20-40-16].

Figure 20-40-17

Dealer Copy -- Not for Resale

B-12812

Install the O-ring on the piston [Figure 20-40-14].

NOTE: Do not overstretch the seal.

Figure 20-40-15

B-12811

Use the ring compressor to compress the seal to the

correct size [Figure 20-40-17].

NOTE: Leave the piston in the ring compressor for

three minutes.

B-12809

Install the seal on the tool and stretch it until it fits the
piston [Figure 20-40-15].

Allow the seal to stretch for 30 seconds before removing

it from the tool.

75 of 120 20-40-7 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Figure 20-40-20

Assembly (Cont’d)

Figure 20-40-18

B-03682

Install the wiper seal with the lip toward the outside of the
B-03702 head [Figure 20-40-20].

Figure 20-40-21
Install the oil seal on the rod seal tool [Figure 20-40-18].

NOTE: The O-ring side of the oil seal goes toward the

Dealer Copy -- Not for Resale

inside of the cylinder.

Figure 20-40-19

B-07200

Install the back-up ring on the head [Figure 20-40-21].

B-03671

Install the oil seal in the head [Figure 20-40-19].

76 of 120 20-40-8 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Figure 20-40-24

Assembly (Cont’d)

Figure 20-40-22

B-07010

Use a ring compressor to compress the seal to the

B-07007 correct size [Figure 20-40-24]. Leave the tool over the
Teflon seal for five minutes.

Install the O-ring next to the back-up ring as shown Figure 20-40-25
[Figure 20-40-22].

Dealer Copy -- Not for Resale

If a seal was removed from the head, use the following
procedure to install a new seal.

Figure 20-40-23

B-07011

Install the head on the rod [Figure 20-40-25].

B-07009

Install the guide with a pilot and an adapter, if they are

required, on the head [Figure 20-40-23].

Install the seal on the head using the guide [Figure 20-
40-23].

NOTE: Do not turn (roll) the seal during installation.

Damage to the seal may result.

77 of 120 20-40-9 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Figure 20-40-28

Assembly (Cont’d)

Cylinders With Cushioned Piston

Figure 20-40-26

B-07002

Install and tighten nut to 203 - 251 N•m (150 - 185 ft-lb)
torque [Figure 20-40-28].

B-07198 Remove the rod from the vise.

Figure 20-40-29
Install the piston on the rod with the tapered end first

Dealer Copy -- Not for Resale

(toward the head) [Figure 20-40-26].

Figure 20-40-27

B-07013

Install the cylinder case in the vise.

B-03853
Put oil on the seal surface of the cylinder case [Figure
20-40-29].
Install the stop (if so equipped) and piston on the rod
[Figure 20-40-27].

78 of 120 20-40-10 Grader Service Manual

SIDE SHIFT HYDRAULIC CYLINDER (CONT’D) Figure 20-40-32

Assembly (Cont’d)

Figure 20-40-30

B-07014

Put oil on the seals on the head [Figure 20-40-32].

B-07012
Put oil on the threads of the head.

Put oil on the Teflon seal on the piston [Figure 20-40-30]. Figure 20-40-33

Figure 20-40-31
1

Dealer Copy -- Not for Resale

P-94406

B-07001
Use the spanner wrench to tighten the head (Item 1)
[Figure 20-40-33] until the head is flush with the case.
Install the rod assembly in the cylinder case [Figure 20-
40-31].

79 of 120 20-40-11 Grader Service Manual

Dealer Copy -- Not for Resale

80 of 120 20-40-12 Grader Service Manual

MAIN FRAME

ACD (ATTACHMENT CONTROL DEVICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

BOLSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2

MOLDBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2

TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

WHEEL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4

81 of 120 30-01 Grader Service Manual

Dealer Copy -- Not for Resale

82 of 120 30-02 Grader Service Manual

ACD (ATTACHMENT CONTROL DEVICE) Figure 30-10-3

Removal And Installation

Figure 30-10-1

1
1

P-94099

While holding the ACD, remove the two bolts (Item 1)

P-88816 [Figure 30-10-3].

Installation: To install ACD, realign holes, tighten bolts to

To access the ACD, remove the bolts (Item 1) and specified torque listed on the ACD module.
remove the cover (Item 2) [Figure 30-10-1].

Dealer Copy -- Not for Resale

NOTE: Over torquing the bolts can damage the ACD
Installation: Install cover and tighten bolts. mounts.

Figure 30-10-2

P-94096

Remove the electrical wiring (Item 1) from the ACD (Item

2) [Figure 30-10-2].

Installation: Plug in the electrical wiring.

83 of 120 30-10-1 Grader Service Manual

Dealer Copy -- Not for Resale

84 of 120 30-10-2 Grader Service Manual

BOLSTER Figure 30-20-2

Removal And Installation

1
WARNING
AVOID INJURY OR DEATH 2
Securely block up the attachment before working
underneath.
W-2795-0409

P-88960

WARNING Remove the nut, bolt (Item 1) and remove bolster pin
(Item 2) [Figure 30-20-2].
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any Installation: Align the bolster, install the bolster pin, bolt
of the following conditions exist: and nut.
• When fluids are under pressure.

Dealer Copy -- Not for Resale

• Flying debris or loose material is present. Figure 30-20-3
• Engine is running.
• Tools are being used.
W-2019-0907
2
Remove casters. (See Removal And Installation on Page
30-30-1.)

Figure 30-20-1

P-88961

Slide the bolster (Item 1) out from the main frame (Item 2)
[Figure 30-20-3].

Installation: Slide bolster onto the main frame.

P-88826

Support the grader with chains [Figure 30-20-1].

NOTE: Use chains that are in good condition and of

adequate size to lift the attachment.

85 of 120 30-20-1 Grader Service Manual

Dealer Copy -- Not for Resale

86 of 120 30-20-2 Grader Service Manual

CASTER Figure 30-30-2

Removal And Installation

1 2

WARNING
AVOID INJURY OR DEATH
Securely block up the attachment before working
underneath.
W-2795-0409

P-88829

WARNING Remove the bolt (Item 1) and washer (Item 2) [Figure

30-30-2].
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any Installation: Install washer and bolt. Tighten to 410 N•m
of the following conditions exist: (300 ft-lb) torque.
• When fluids are under pressure.

Dealer Copy -- Not for Resale

• Flying debris or loose material is present. Figure 30-30-3
• Engine is running.
• Tools are being used.
W-2019-0907

Figure 30-30-1

P-88830

Remove the caster (Item 1) [Figure 30-30-3].

Installation: Install the caster.

P-88826

Support the grader with chains [Figure 30-30-1].

NOTE: Use chains that are in good condition and of

adequate size to lift the attachment.

87 of 120 30-30-1 Grader Service Manual

CASTER (CONT’D) Assembly

Disassembly Figure 30-30-5

Figure 30-30-4

P-88770

P-88831
Install the bushings (Item 1) [Figure 30-30-5] into the
bolster weldment using a press.
Remove the bushings (Item 1) [Figure 30-30-4] from the
bolster weldment. NOTE: Repeat this procedure on the other side.

Dealer Copy -- Not for Resale

NOTE: Repeat this procedure on the other side.

88 of 120 30-30-2 Grader Service Manual

MOLDBOARD Figure 30-40-2

Removal

WARNING
2
AVOID INJURY OR DEATH
Securely block up the attachment before working
underneath.
W-2795-0409

1
P-94501

WARNING
Attach a hand cable winch (Item 1) to the pin (Item 2)
AVOID INJURY OR DEATH [Figure 30-40-2], attach the other end of the hand cable
Wear safety glasses to prevent eye injury when any winch to a secure fixture.
of the following conditions exist:
• When fluids are under pressure. Figure 30-40-3
• Flying debris or loose material is present.

Dealer Copy -- Not for Resale

• Engine is running. 3 3
• Tools are being used.
W-2019-0907

Remove the side shift hydraulic cylinder. (See Removal

And Installation on Page 20-40-1.)

NOTE: A lifting device, a hand cable winch and a 2

minimum of two people are required for
removal or installation of the moldboard.
1
Figure 30-40-1
P-94506

NOTE: A lifting device and two chains must be

attached near the center of the moldboard.

1 NOTE: Use a lifting device and two chains that are in

2 good condition and of adequate size to lift the
moldboard.

Slide the moldboard (Item 1) partially off the hanger (Item

2) [Figure 30-40-3] using the hand cable winch.

When the center of the moldboard has slid far enough

P-94509 past the hanger, attach a lifting device and two chains
(Item 3) [Figure 30-40-3] near the center of the
moldboard. Continue to slide the moldboard off the
Install a pin (Item 1) into the moldboard cylinder mount
hanger. Remove the moldboard from the hanger.
(Item 2) [Figure 30-40-1].

89 of 120 30-40-1 Grader Service Manual

MOLDBOARD (CONT’D) Align the moldboard (Item 2) onto the hanger (Item 3).
Install a pin (Item 4) into the moldboard cylinder mount.
Installation Attach a hand cable winch (Item 5) [Figure 30-40-4] to
the pin.

Figure 30-40-5

WARNING
AVOID INJURY OR DEATH 1
Securely block up the attachment before working
underneath.
W-2795-0409

WARNING
AVOID INJURY OR DEATH
P-94508
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure. Attach the other end of the hand cable winch to the

Dealer Copy -- Not for Resale

• Flying debris or loose material is present. hanger cylinder mount (Item 1) [Figure 30-40-5].
• Engine is running.
• Tools are being used. Figure 30-40-6
W-2019-0907

4 4
NOTE: A lifting device and two chains must be
attached near the center of the moldboard.

NOTE: Use a lifting device and two chains that are in

good condition and of adequate size to lift the
moldboard.
2
Figure 30-40-4

1 1
3
1 P-94510

Slide the moldboard (Item 1) partially onto the hanger

4
(Item 2) using the hand cable winch (Item 3) [Figure 30-
40-6].
3
Remove the chains (Item 4) [Figure 30-40-6] when the
chains contact the hanger. Continue to slide the
5 moldboard onto the hanger.
2 P-94510
Install the side shift hydraulic cylinder. (See Removal And
Installation on Page 20-40-1.)
Attach a lifting device and two chains (Item 1) [Figure 30-
40-4] to the moldboard.

90 of 120 30-40-2 Grader Service Manual

TURNTABLE Figure 30-50-2

Removal And Installation

WARNING
AVOID INJURY OR DEATH
Securely block up the attachment before working
underneath.
W-2795-0409

1
P-88834

WARNING Support the grader with blocks and chains. Fasten chains
and lifting device to the drawbar (Item 1) [Figure 30-50-
AVOID INJURY OR DEATH 2].
Wear safety glasses to prevent eye injury when any
of the following conditions exist: NOTE: Use chains that are in good condition and of
• When fluids are under pressure. adequate size to lift the attachment.

Dealer Copy -- Not for Resale

• Flying debris or loose material is present.
• Engine is running. Figure 30-50-3
• Tools are being used.
W-2019-0907
4
Figure 30-50-1

2 3

3
2
1

P-88808
1

Remove the two bolts (Item 1), turntable clamp (Item 2),
clamp wear slide (Item 3) and spacers (Item 4) [Figure
P-88804
30-50-3].

Remove the hoses (Item 1) from the cylinder. Remove Installation: Install spacers, new wear slide and
the nut (Item 2) and remove the hose clamp (Item 3) turntable clamp. Tighten bolts to 408 - 459 N•m (301 -
[Figure 30-50-1]. 339 ft-lb) torque.

Remove the moldboard. (See MOLDBOARD on Page

30-40-1.)

Installation: Install hoses onto the cylinder and tighten

hoses. Install the hose clamp and nut onto the bolt and
tighten nut.

91 of 120 30-50-1 Grader Service Manual

TURNTABLE (CONT’D) Figure 30-50-6

Removal And Installation (Cont’d)

2
Figure 30-50-4

1
1

P-94277

Remove the nut (Item 1) remove the hose clamp (Item 2)

P-94236 [Figure 30-50-6].

Remove the turntable hydraulic cylinders. (See

Place jack stands (Item 1) [Figure 30-50-4] under the TURNTABLE HYDRAULIC CYLINDER on Page 20-30-
front of the hanger to prevent the hanger from falling. 1.)

Dealer Copy -- Not for Resale

Figure 30-50-5 Installation: Install hose clamp and nut.

1 1

P-88927

Remove the nuts, bolts (Item 1) remove the swaybar

(Item 2) [Figure 30-50-5].

Installation: Install swaybar, bolts and nuts. Tighten

bolts.

92 of 120 30-50-2 Grader Service Manual

TURNTABLE (CONT’D) Figure 30-50-9

Removal And Installation (Cont’d)

Figure 30-50-7

1
3
2

1
1
2
2 P-94223

Remove snap rings (Item 1) and pins (Item 2) [Figure

P-94222 30-50-9] from elevation cylinders. Swing cylinders out.

Raise the drawbar (Item 3) [Figure 30-50-9] upward with

Figure 30-50-8 lifting device.

Dealer Copy -- Not for Resale

Installation: Lower drawbar into position. Connect
elevation cylinders, install pins and snap rings.

Figure 30-50-10
1

1 3
3

2
P-94235

Remove the roll pin (Item 1) and nut (Item 2), [Figure 30-
50-7]. Remove the bolt (Item 1) [Figure 30-50-8].
P-94221
Installation: Install bolt, nut and roll pin. Tighten to 407
N•m (300 ft -lb) torque.
NOTE: Support the drawbar (Item 1) [Figure 30-50-10]
with blocks or chains and lifting device.

Remove the six bolts (Item 2) and remove the two

flanges (Item 3) [Figure 30-50-10]. Remove drawbar.

Installation: Apply grease to the ball before installing the

drawbar. Align the drawbar into position. Install flanges
and bolts. Tighten bolts.

93 of 120 30-50-3 Grader Service Manual

Dealer Copy -- Not for Resale

94 of 120 30-50-4 Grader Service Manual

WHEEL AXLE

Removal And Installation

Figure 30-60-1

P-88809

Remove the two bolts (Item 1) [Figure 30-60-1].

Dealer Copy -- Not for Resale

Installation: Insert the wheel into the caster weldment
and install the bolts. Tighten bolts to 240 N•m (175 ft-lb)
torque.

NOTE: Make sure the valve stem is facing the outside

of the attachment.

Figure 30-60-2

P-94162

Remove the five nuts (Item 1) [Figure 30-60-2] and

remove the wheel axle from the rim.

Installation: Insert the wheel axle into the rim and install
the five nuts. Tighten to 121,50 N•m (90 ft-lb) torque.

95 of 120 30-60-1 Grader Service Manual

WHEEL AXLE (CONT’D)

Parts Identification

1. Tube Caster Bearing

2. Axle Caster
3. Bearing Insert
4. Nut Wheel
5. Bolt Wheel

Dealer Copy -- Not for Resale

2 1

3
2

P-94230

96 of 120 30-60-2 Grader Service Manual

WHEEL AXLE (CONT’D) Figure 30-60-5

Disassembly

Figure 30-60-3
1

P-94165

Remove the bearing (Item 1) [Figure 30-60-5].

P-94163
Figure 30-60-6

Clamp the wheel axle in a vise and loosen the two set
screws (Item 1) [Figure 30-60-3] on the lock collar.

Dealer Copy -- Not for Resale

Remove the lock collar.

Figure 30-60-4

1
P-94166

Remove the bearing (Item 1) [Figure 30-60-6] from the

other side of the hub.

P-94164

Slide the shaft (Item 1) out from the hub (Item 2) [Figure
30-60-4].

97 of 120 30-60-3 Grader Service Manual

WHEEL AXLE (CONT’D) Figure 30-60-9

Assembly

Figure 30-60-7 1

P-94164

Clamp the hub in the vise and slide the shaft (Item 1)
P-94165 [Figure 30-60-9] into the hub.

NOTE: Adjust the shaft so there is equal amount of

Figure 30-60-8 shaft at both ends.

Dealer Copy -- Not for Resale

Figure 30-60-10

1
1
P-94166

P-94163
Install the two new bearings (Item 1) [Figure 30-60-7] &
[Figure 30-60-8].
Install the lock collar (Item 1) and tighten the two set
NOTE: Apply clean oil to the bearings before screws (Item 2) [Figure 30-60-10].
installation.

98 of 120 30-60-4 Grader Service Manual

SPECIFICATIONS

SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Electrical Schematic (S/N ACW900242 & Below, AJ2E00215 & Below) . . . . . . .SPEC-10-2
Electrical Schematic (S/N ACW900243 & Above, AJ2E00216 & Above) . . . . . . .SPEC-10-3

GRADER ATTACHMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-5

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-40-1

Dealer Copy -- Not for Resale

Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2

99 of 120 SPEC-01 Grader Service Manual

Dealer Copy -- Not for Resale

100 of 120 SPEC-02 Grader Service Manual

101 of 120
SCHEMATICS

Left Angle Right Angle

Grader 96, 108

Cylinder Cylinder
Hydraulic Schematic

Left Elevation Right Elevation Side Shift

Cylinder Cylinder Cylinder

SPEC-10-1
Ø0.020

Ø0.020

P-88600

Grader Service Manual

Dealer Copy -- Not for Resale
SCHEMATICS (CONT’D)

Electrical Schematic (S/N ACW900242 & Below, AJ2E00215 & Below)

Grader 96, 108

Dealer Copy -- Not for Resale

P-88601

SPEC-10-2 Grader Service Manual

102 of 120
SCHEMATICS (CONT’D)

Electrical Schematic (S/N ACW900243 & Above, AJ2E00216 & Above)

Grader 96, 108

Dealer Copy -- Not for Resale

P102306

SPEC-10-3 Grader Service Manual

103 of 120
Dealer Copy -- Not for Resale

SPEC-10-4 Grader Service Manual

104 of 120
GRADER ATTACHMENT SPECIFICATIONS

Dimensions

• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.

• Where applicable, specifications conform to SAE and ISO standards and are subject to change without notice.

Dealer Copy -- Not for Resale

C

G
D

P-94217

DESCRIPTION Grader 96 Grader 108

Length (A) 2642 mm (104 in) 2642 mm (104 in)
Frame Length (B) 2565 mm (101 in) 2565 mm (101 in)
Frame Height (C) 1311 mm (51.6 in) 1311 mm (51.6 in)
Lift Height (D) 173 mm (6.8 in) 173 mm (6.8 in)
Depth of Cut (E) 188 mm (7.4 in) 188 mm (7.4 in)
Blade (Base) (F) 1212 mm (47.7 in) 1212 mm (47.7 in)
Blade Height (G) 432 mm (17 in) 432 mm (17 in)

105 of 120 SPEC-20-1 Grader Service Manual

GRADER ATTACHMENT SPECIFICATIONS (CONT’D)

Dimensions (Cont’d)

• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.

• Where applicable, specifications conform to SAE and ISO standards and are subject to change without notice.

F
A

Dealer Copy -- Not for Resale

B

D
E

P-94218

DESCRIPTION Grader 96 Grader 108

Height (A) 1522 mm (59.9 in) 1522 mm (59.9 in)
Wheel Base (Center) (B) 1252 mm (49.3 in) 1252 mm (49.3 in)
Wheel Base (Outside) (C) 1468 mm (57.8 in) 1468 mm (57.8 in)
Width (D) 2438 mm (96 in) 2743 mm (108 in)
Blade Side Shift (E) ± 330 mm (±13 in) ± 330 mm (±13 in)
Bolster Oscillation (F) ±12 º
±12º

106 of 120 SPEC-20-2 Grader Service Manual

GRADER ATTACHMENT SPECIFICATIONS (CONT’D)

Dimensions (Cont’d)

• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.

• Where applicable, specifications conform to SAE and ISO standards and are subject to change without notice.

Dealer Copy -- Not for Resale

A

P-94219

DESCRIPTION Grader 96 Grader 108

Blade Width (Fully Angled) (A) 2116 mm (83.3 in) 2380 mm (93.7 in)
Blade Angle (B) ± 30 º ± 30º

107 of 120 SPEC-20-3 Grader Service Manual

GRADER ATTACHMENT SPECIFICATIONS (CONT’D)

Performance

DESCRIPTION Grader 96 Grader 108

Grader Weight 1265 kg (2788 lb) 1298 kg (2861 lb)
Maximum Hydraulic Operating Pressure 24,1 MPa (241,3 bar) (3500 psi) 24,1 MPa (241,3 bar) (3500 psi)

Hydraulic System

DESCRIPTION CYLINDERS
Elevation Cylinder (2) Angle Cylinder (2) Side Shift Cylinder (1)
Bore 63,5 mm (2.50 in) 76,2 mm (3.00 in) 50,8 mm (2.00 in)
Rod 38,1 mm (1.50 in) 38,1 mm (1.50 in) 25,4 mm (1.00 in)
Stroke 431,8 mm (17.00 in) 444,5 mm (17.50 in) 660,4 mm (26.00 in)

Tires

Size 23 x 8.5 - 12 Ply

Dealer Copy -- Not for Resale

Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO
NOT mix brands of tires used on the attachment.

108 of 120 SPEC-20-4 Grader Service Manual

GRADER ATTACHMENT SPECIFICATIONS (CONT’D)

Controls

GCR Receiver

Input Voltage Machine power 9v - 30v DC

Current Draw @ 12 V DC Less than 500 mA excluding valve current. Up to 8 A (measured at the bulkhead
connector) depending on valve drive requirements.
Operating & Storage Temperature -28 - 70°C (-20 - 160°F)
Humidity 90% non-condensing
Displays >2000 mcd LED’s Long life and visible in sunlight.
Calibration Control Panel Environmentally seal to IP 65 Life>1,000,000 cycles.
Housing Die Cast Aluminum.
Height 24,2 cm (9.51 in)
Width 11,3 cm (4.44 in)
Depth 13,2 cm (5.19 in)
Weight <1,00 kg (2.21 lb)
Laser Detection Angle 360° with laser >7,62 m (25 ft) from unit.
Transmitter Types Supported 300 to 1200 rpm transmitters IR beam power >0.4 mW HeNe beam power >1.3 mW.

Dealer Copy -- Not for Resale

Laser Detection Height (nominal) 21,3 cm (8.4 in or 0.7 ft)
On-Grade Deadband 0.03 ± 0.01 ft

BLR2 Receiver

Input Voltage Machine power 9v - 16v DC

Current Draw @ 12 V DC <500 mA.
Operating & Storage Temperature -28 - 70°C (-20 - 160°F)
Humidity 90% non-condensing
Displays >2000 mcd LED’s Long life and visible in sunlight.
Housing High Impact Plastic.
Height 24,2 cm (9.51 in)
Width 11,3 cm (4.44 in)
Depth 7,51 cm (2.96 in) (w/o mounting hook)
13,2 cm (5.19 in) (with mounting hook)
Weight <1,00 kg (2.21 lb)
Laser Detection Angle 360°
Transmitter Types Supported 300 to 1200 rpm transmitters IR beam power >0.4 mW HeNe beam power >1.3 mW.
Laser Detection Height (nominal) 200 mm (7.87 in)
On-Grade Deadband 3,0 mm (0.12 in)

109 of 120 SPEC-20-5 Grader Service Manual

GRADER ATTACHMENT SPECIFICATIONS (CONT’D)

Controls (Cont’d)

Laser Beacon

See the Laser Beacon owners manual for specifications.

Laser Detector

Capture Height 48 mm (1 7/8 in)

Acceptance Angle ±45°
LCD Readout Front and back
On Grade Sensitivity Ultra-Fine: 0,0 mm (0.0 in)
Fine: 2 mm (1/16 in)
Medium: 4 mm (1/8 in)
Coarse: 6,4 mm (1/4 in)
Power Source Two 1.5-V batteries (type LR6/AA)
Battery Life Alkaline: >74 hour
@ 68° F (20°C) Ni-Cd: >48 hour
Battery Indicator LCD battery symbol

Dealer Copy -- Not for Resale

Automatic Shutoff 30 minutes after last laser detection or push button actuation
Spectral Sensitivity Operates with red visible and infrared lasers rotating between 300 and 600 rpm
Marking Notch 50 mm (2 in) below top of receiver
Volume Control High/Low/Off
LCD Backlighting Two-button actuation
Operating Temperature -20 - + 50°C (-4 - +122°F)
Storage Temperature -40 - +70°C (-40 - +158°F)
Weight 0,27 kg (9 1/2 oz)
Dimensions (T x W x L) 2,6 x 7,4 x 16,3 cm (1 x 2 7/8 x 6 3/8 in)

110 of 120 SPEC-20-6 Grader Service Manual

TORQUE SPECIFICATIONS FOR BOLTS

Torque For General SAE Bolts

The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.

Thread
SAE Grade 5 SAE Grade 8
Size
N•m 0.250 9,0 - 10,2 12,4 - 13,6
(in-lb) (80 - 90) (110 - 120)
0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
N•m 0.375 34 - 38 47 - 54
(ft-lb) (25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)

Dealer Copy -- Not for Resale

0.625 170 - 190 240 - 260
(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)

111 of 120 SPEC-30-1 Grader Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric Bolts

THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M 14 x 1.25 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

Dealer Copy -- Not for Resale

112 of 120 SPEC-30-2 Grader Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting

O-ring Face Seal Connection Figure SPEC-40-2

IMPORTANT
Nut Nut
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, Washer
tubelines and ports to keep dirt out. Dirt can quickly O-ring
damage the system.
I-2003-0888 O-ring

Figure SPEC-40-1
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-
2].

Dealer Copy -- Not for Resale

Tubelines And Hoses

Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.

B-7575 Replace hoses which show signs of wear, damage or

weather cracked rubber.

When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use petroleum jelly to hold the O-ring in
position until the fittings are assembled [Figure SPEC-
40-1].

O-ring Face Seal Tightening Torque

xTubeline xx TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 9/16” - 18 18 (13)
3/8” 11/16” - 16 30 (22)
1/2” 13/16” - 16 54 (40)
5/8” 1” - 14 81 (60)
3/4” 1-3/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-7/16” - 12 160 (118)
1-1/4” 1-11/16” - 12 209 (154)
1-1/2” 2” - 12 221 (163)

113 of 120 SPEC-40-1 Grader Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Port Seal Fitting
(CONT’D)
Figure SPEC-40-4
Flare Fitting

Figure SPEC-40-3

1
Nut Seals
To Fitting

Nut Seals
2 To Port

P-79498

Secondary O-ring Seal P-13008

Use the following procedure to tighten the flare fitting:

Dealer Copy -- Not for Resale

Tighten the nut until it makes contact with the seat. Make The nut is the primary seal, the O-ring is the secondary
a mark across the flats of both the male and female parts seal and helps absorb vibration and pressure pulses at
of the connection (Item 1) [Figure SPEC-40-3] the connection [Figure SPEC-40-4].

Use the chart (below) to find the correct tightness needed The hex portion of the nut does not contact the surface of
(Item 2) [Figure SPEC-40-3]. If the fitting leaks after the component when the nut is tight.
tightening, disconnect it and inspect the seat area for
damage. Port Seal and O-ring Boss
Tightening Torque
Flare Fitting Tightening Torque x TORQUE
Tubeline x TORQUE x N•m
Outside x N•m Thread Size (ft-lb)
Diameter Thread Size (ft-lb) 7/16” - 20 18 (13)
1/4” 7/16” - 20 18 (13) 9/16” - 18 30 (22)
5/16” 1/2” - 20 23 (17) 3/4” -1 6 54 (40)
3/8” 9/16” - 18 30 (22) 7/8” - 14 81 (60)
1/2” 3/4” - 16 54 (40) 1-1/16” - 12 114 (84)
5/8” 7/8” - 14 81 (60) 1-3/16” - 12 133 (98)
3/4” 1-1/16” - 12 114 (84) 1-5/16” - 12 160 (118)
7/8” 1-3/16” - 12 133 (98) 1-7/16” - 12 209 (154)
1” 1-5/16” - 12 160 (118) 1-5/8” - 12 221 (163)
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)

114 of 120 SPEC-40-2 Grader Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)

Port Seal Fitting (Cont’d)

Use the following procedure to tighten the port seal

fitting:

Port seal and nut, washer and O-ring (O-ring Boss)

fittings use the same tightening torque valve chart.

If a torque wrench cannot be used, use the following

method.

Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.

Tighten the nut with a wrench no more than one hex flat
maximum.

Do not over tighten the port seal fitting.

NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate

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guideline.

NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.

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116 of 120 SPEC-40-4 Grader Service Manual

ALPHABETICAL INDEX

ACD (ATTACHMENT CONTROL DEVICE)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
ATTACHMENT IDENTIFICATION . . . . . . . 1-8
ATTACHMENT STORAGE AND RETURN TO
SERVICE . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
BOLSTER . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
CASTER . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
DAILY INSPECTION . . . . . . . . . . . . . . 10-20-1
DELIVERY REPORT . . . . . . . . . . . . . . . . . 1-7
GRADER ATTACHMENT SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
HYDRAULIC CONNECTION
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1
HYDRAULIC CONTROL VALVE . . . . . 20-10-1
LEVELING HYDRAULIC CYLINDER . . 20-20-1
LUBRICATING THE ATTACHMENT . . 10-30-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1

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MOLDBOARD . . . . . . . . . . . . . . . . . . . 30-40-1
REGULAR MAINTENANCE ITEMS . . . 10-40-1
REMOVAL AND INSTALLATION OF CUTTING
EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
REMOVAL AND INSTALLATION OF
TURNTABLE CLAMP . . . . . . . . . . . . . . 10-51-1
REMOVAL AND INSTALLATION OF
TURNTABLE WEAR SLIDE . . . . . . . . . 10-52-1
SCHEMATICS . . . . . . . . . . . . . . . . SPEC-10-1
SERIAL NUMBER LOCATION . . . . . . . . . . 1-7
SERVICE MANUAL REVISION . . . . . . SMR-1
SIDE SHIFT HYDRAULIC CYLINDER . 20-40-1
TORQUE SPECIFICATIONS FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TROUBLESHOOTING . . . . . . . . . . . . . 10-10-1
TURNTABLE HYDRAULIC CYLINDER 20-30-1
TURNTABLE . . . . . . . . . . . . . . . . . . . . 30-50-1
WHEEL AXLE . . . . . . . . . . . . . . . . . . . 30-60-1

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118 of 120 INDEX-02 Grader Service Manual

ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: Grader - 1

Date: 15 November 2010
Product: Attachments
Model: Grader
Manual No: 6987469 (11-10)

Dealer Copy -- Not for Resale

The following Sections are a revision to the above Service Manual.

Above replaces Grader SM 6987469 (8-09).

Cover.
Foreword.
Section 10-10.
Section 20-10.
Section 20-20.
Section 20-30.
Section 20-40.
Section 30-TOC.
Section 30-60.
Section SPEC-TOC.
Section SPEC-10.
Section SPEC-20.
Section ALPHA INDEX.
Section SMR.

119 of 120 SMR-1 Grader Service Manual

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120 of 120 SMR-2 Grader Service Manual