100% found this document useful (7 votes)

2K views

Bobcat E85 Service Manual - 6990617

Bobcat E85 Service Manual

Uploaded by

Garreth Fitzsimon

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

100% found this document useful (7 votes)

2K views

Bobcat E85 Service Manual - 6990617

Bobcat E85 Service Manual

Uploaded by

Garreth Fitzsimon

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 918

Service Manual

E85 Excavator

Garreth Fitzsimon
Coonana
Ballinafagh Hill S/N B34T11001 & Above
Prosperous, Naas
Kildare S/N B34S11001 & Above
W91 TDX4

Dealer Copy -- Not for Resale

Ireland

Email address:
[email protected]

6990617enUS (07-16) (C) Printed in USA © Bobcat Company 2016. All rights reserved.
T4-Y S3B
1 of 918
2 of 918
Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

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

CORRECT CORRECT CORRECT

P-90216 B-19964 B-19959

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

Dealer Copy -- Not for Resale

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

WRONG WRONG WRONG

B-19962 B-19958 B-19798

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

1-1
3 of 918
4 of 918
1-2
Dealer Copy -- Not for Resale
CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-05

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

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

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

UPPERSTRUCTURE AND SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

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

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

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

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

Dealer Copy -- Not for Resale

5 of 918 1-3 E85 Service Manual

Dealer Copy -- Not for Resale

6 of 918 1-4 E85 Service Manual

FOREWORD

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

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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

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

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

the work lights. battery and cables.

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

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

function correctly and be in system.
good condition.

FW EXC DSN E85 EMEA-1015 SM

9 of 918 1-7 E85 Service Manual

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

18. Inspect for loose or broken 22. Inspect the attachment quick
parts or connections. coupler for wear or damage.
Repair or replace damaged
parts.

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

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

Dealer Copy -- Not for Resale

is returned to service.

FW EXC DSN E85 EMEA-1015 SM

10 of 918 1-8 E85 Service Manual

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

Dealer Copy -- Not for Resale

operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.

IMPORTANT • The AEM Safety Manual delivered with the machine

gives general safety information.

This notice identifies procedures which must be • The Service Manual and Parts Manual are available
followed to avoid damage to the machine. from your dealer for use by mechanics to do shop-
I-2019-0284 type service and repair work.

• The Compact Excavator Operator Training Course is

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

• The Bobcat compact excavator Safety Video is

WARNING available from your Bobcat dealer or at
www.training.bobcat.com or www.bobcat.com.

The signal word WARNING on the machine and in the

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI EXC-0913 SM

11 of 918 1-9 E85 Service Manual

SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner / operator review the

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

Cutting or drilling concrete containing sand or rock

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

Call Before You Dig

Dial 811 (USA Only)

Dealer Copy -- Not for Resale

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

SI EXC-0913 SM

12 of 918 1-10 E85 Service Manual

FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage

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

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

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

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

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

Dealer Copy -- Not for Resale

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

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

the emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
Check all electrical wiring and connections for damage. hot.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or Check the spark arrester exhaust system regularly to
frayed. make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
Battery gas can explode and cause serious injury. Use cleaning the spark arrester muffler (if equipped).
the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI EXC-0913 SM

13 of 918 1-11 E85 Service Manual

FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect

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

Have good ventilation when grinding or welding painted

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

Dust generated from repairing nonmetallic parts such as

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

Fire Extinguishers

Dealer Copy -- Not for Resale

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

SI EXC-0913 SM

14 of 918 1-12 E85 Service Manual

SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the excavator when Figure 2

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

Figure 1

P111018

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

on the top cover.

Dealer Copy -- Not for Resale

P111017

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

located on the swing frame on the front of the
upperstructure.

Explanation of Excavator Serial Number:

XXXX XXXXX

Module 2. - Production
Sequence (Series)

Module 1. - Model / Engine

Combination

1. The four digit Model / Engine Combination Module

number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies

the order which the excavator is produced.

15 of 918 1-13 E85 Service Manual

DELIVERY REPORT

Figure 3

B-16315

The delivery report [Figure 3] contains a list of items that

must be explained or shown to the owner or operator by
the dealer when the Bobcat excavator is delivered.

Dealer Copy -- Not for Resale

The delivery report must be reviewed and signed by the
owner or operator and the dealer.

16 of 918 1-14 E85 Service Manual

EXCAVATOR IDENTIFICATION

2
14 24
1
15 16
4

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

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

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

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

Raising And Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

CONTROL CONSOLE LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

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

20 of 918 10-02 E85 Service Manual

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

Dealer Copy -- Not for Resale

21 of 918 10-03 E85 Service Manual

Raise the blade fully. 2

1
Put all the control levers in neutral.

S37585
WARNING
S37586 P123127
AVOID INJURY OR DEATH
• Use a lifting fixture with sufficient capacity for
the weight of the excavator plus any added Fasten chains to the boom (Item 2) [Figure 10-20-1] and
attachments. [Figure 10-20-3] and up to a lifting device above the cab.
• Maintain center of gravity and balance when Place protective material between the chains and the cab
lifting. and the upperstructure to prevent damage.
• Do not swing boom or upperstructure.
• Never lift with operator on machine.
W-2434-0502

25 of 918 10-20-1 E85 Service Manual

LIFTING THE EXCAVATOR (CONT’D)

Procedure (Cont’d)

Figure 10-20-4

45°

Dealer Copy -- Not for Resale

B-23947A

The maximum angle between the front and rear chains

must not exceed 45° [Figure 10-20-4].

26 of 918 10-20-2 E85 Service Manual

OPERATOR CAB Cab Door

Description Figure 10-30-1

The Bobcat excavator has an operator cab (ROPS) as

standard equipment to provide protection if the excavator
is tipped over. The seat belt must be worn for ROPS 1
protection.

Check the ROPS cab, mounting, and hardware for

damage. Never modify the ROPS cab. Replace the cab
and hardware if damaged. See your dealer for parts.
2
ROPS - Roll Over Protective Structure per ISO 12117-2:
2008.

P111032

WARNING
The cab door can be locked (Item 1) [Figure 10-30-1]
Never modify operator cab by welding, grinding, with the same key as the starter switch.
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to The door can be held in the open position. Push the door

Dealer Copy -- Not for Resale

the cab can cause loss of operator protection from all the way open until the latch (Item 2) [Figure 10-30-1]
rollover and falling objects, and result in injury or engages to hold the door in the open position.
death.
W-2069-0200 Figure 10-30-2

2
1

P111029A

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

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

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

27 of 918 10-30-1 E85 Service Manual

OPERATOR CAB (CONT’D) Figure 10-30-5

Front Window

Opening The Front Window

Figure 10-30-3

P-86954

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

Dealer Copy -- Not for Resale

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

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

Using both window grab handles, pull the window forward

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

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

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

P-86322

Use both window grab handles to pull the top of the

window in [Figure 10-30-4].

Continue moving the window in and up over the

operator’s head until the window is fully raised.

28 of 918 10-30-2 E85 Service Manual

OPERATOR CAB (CONT’D) Window Washer Reservoir

Front Wiper Figure 10-30-8

Figure 10-30-6

P111031

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

Dealer Copy -- Not for Resale

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

1 2

P111022B

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

positions, OFF, intermittent wiper mode and full speed.

The window washer switch (Item 2) activates the front

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

29 of 918 10-30-3 E85 Service Manual

OPERATOR CAB (CONT’D)

Right Side Window

Opening The Right Front Window

Figure 10-30-9

P-86228

Dealer Copy -- Not for Resale

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

Closing The Right Front Window

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

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

30 of 918 10-30-4 E85 Service Manual

OPERATOR CAB (CONT’D) Figure 10-30-13

Heating, Ventilation And Air Conditioning Duct

Figure 10-30-10
1 2

P-97917

P111033
Use one of the three buttons (Item 1) located in the left
console to control which air ducts are active and two
Figure 10-30-11 buttons (Item 2) [Figure 10-30-13] that control fresh air
or recirculated air.

Operating Tip: To increase heating or cooling efficiency,

Dealer Copy -- Not for Resale

move the Recirculation / Fresh Air Control (Item 2)
[Figure 10-30-13] to the recirculation position. This will
allow the air to recirculate through the HVAC system and
improve temperature control. If left in the fresh air
position, the HVAC system will also need to heat or cool
1 the ambient air that is drawn in from the outside, slowing
and / or reducing the temperature change inside the cab.

P111034

Figure 10-30-12

P111035

The excavator is equipped with seven air vents (Item 1)

[Figure 10-30-10], [Figure 10-30-11] and [Figure 10-30-
12] that can be adjusted to deflect air flow to the desired
area of the cab.

31 of 918 10-30-5 E85 Service Manual

Dealer Copy -- Not for Resale

32 of 918 10-30-6 E85 Service Manual

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

When transporting the machine, observe the rules, motor

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

Secure the parking brakes and block the wheels of the

transport vehicle.

Align the ramps with the center of the transport vehicle.

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

Use metal loading ramps with a slip resistant surface.

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

Dealer Copy -- Not for Resale

36 of 918 10-50-2 E85 Service Manual

REAR COVER

Opening And Closing

The hydraulic tank breather / filter and hydraulic oil fill

cover is located under the rear cover.

Figure 10-60-1

P111079

Dealer Copy -- Not for Resale

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

Close and lock the rear cover when the service

procedure is completed.

37 of 918 10-60-1 E85 Service Manual

Dealer Copy -- Not for Resale

38 of 918 10-60-2 E85 Service Manual

CENTER COVER

Opening And Closing

The battery, circuit breaker, fusible links, some relays and

the swing motor are located under the center cover.
Figure 10-70-1

P111080

Dealer Copy -- Not for Resale

Use the start key (Item 1) [Figure 10-70-1] to unlock the
latch.

Pull the latch (Item 2) [Figure 10-70-1] and raise the

cover.

Close and lock the center cover when the service

procedure is completed.

39 of 918 10-70-1 E85 Service Manual

Dealer Copy -- Not for Resale

40 of 918 10-70-2 E85 Service Manual

SERVICE SCHEDULE

Maintenance Intervals
WARNING
Maintenance work must be done at regular intervals.
Failure to do so will result in excessive wear and early AVOID INJURY OR DEATH
failures. Instructions are necessary before operating or
servicing machine. Read and understand the
The service schedule is a guide for correct maintenance Operation & Maintenance Manual, Operator’s
of the Bobcat excavator. Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807

Every 10 Hours (Before Starting The Excavator)

• Engine Oil - Check level and add as needed.

• Engine Air Filters and Air System - Check display panel. Service only when required. Check for leaks and damaged
components.
• Engine Cooling System - Check coolant level COLD and add premixed coolant as needed.
• Fuel Filter - Check display panel. Remove the trapped water when required.

Dealer Copy -- Not for Resale

• Seat Belt, Seat Belt Retractors, Seat Belt Mounting hardware, Control Console Lockout - Check the condition
of seat belt and mounting hardware. Clean or replace seat belt retractors as needed. Check the control console
lockout lever for proper operation. Clean dirt and debris from moving parts.
• Motion Alarm - Check for proper function.
• Operator Cab - Check the cab condition and mounting hardware.
• Indicators and Lights - Check for correct operation of all indicators and lights.
• Safety Signs - Check for damaged signs (decals). Replace any signs that are damaged.
• Hydraulic Fluid - Check fluid level and add as needed.
• Track Tension - Check tension and adjust as needed.
• Swing Reduction Gearbox - Check fluid level and add as needed.
• Swing Bearing - Grease swing bearing every 10 hours when operating in water.
• Blade, Boom Swing, Boom Swing Cylinder and Bucket Pivot Points - Grease pivot points every 10 hours when
operating in water.
• Boom and Arm (Workgroup) Pivot Points - Grease pivot points every 10 hours when operating in water.

Every 50 Hours

• Hydraulic Hoses and Tubelines - Check for damage and leaks. Repair or replace as needed.
• Steering Levers and Joysticks - Check for correct operation. Repair as needed.
• Swing Bearing - Grease swing bearing.
• Blade, Boom Swing, Boom Swing Cylinder and Bucket Pivot Points - Grease pivot points.
• Battery - Check cables, connections, and electrolyte level; add distilled water as needed.
• Fuel Tank - Drain water and sediment from fuel tank.
• Drive Belts (Alternator, Air Conditioning, Water Pump) - Service at first 50 hours, then as scheduled. Check
condition. Replace as needed.
• Engine Oil and Filter - Service at first 50 hours, then as scheduled. Replace oil and filter.
• Fuel / Water Separator Screen - Service at first 50 hours, then as scheduled. Replace as needed.

Every 100 Hours

• Drive Belts (Alternator, air conditioning, water pump) - Check condition. Replace as needed.
• Belts and Idler - Service at first 100 hours, then as scheduled. Replace as necessary.
• Alternator and Starter - Service at first 100 hours, then as scheduled. Check connections.
• Travel Motors (Final Drive) - Service at first 100 hours, then as needed. Replace fluid.
• Swing Reduction Gearbox - Service at first 100 hours, then as needed. Replace fluid.
SS EXC E85-0616

41 of 918 10-80-1 E85 Service Manual

SERVICE SCHEDULE (CONT’D)

Maintenance Intervals (Cont’d)

Every 250 Hours Or Every 12 Months

• Boom and Arm (Workgroup) Pivot Points - Grease pivot points.

• Engine Oil and Filter - Replace oil and filter.
• Fuel / Water Separator Screen - Replace as needed.
• Travel Motors (Final Drive) - Check fluid level and add as needed.
• Hydraulic Suction Filter - Service at first 250 hours, then as scheduled. Clean the hydraulic suction filter, replace as
needed.
• Pilot Filter - Service at first 250 hours, then as scheduled. Replace pilot filter.

Every 500 Hours Or Every 12 Months

• Swing Pinion - Grease swing pinion.

• Cooling System - Clean debris from radiator, fuel cooler, hydraulic fluid cooler, air conditioning condenser (if
equipped), and front and rear grille.
• Fuel Filter - Replace filter element.
• Hydraulic Filter and Hydraulic Reservoir Breather Cap - Replace the charge filter and the reservoir breather cap.
• Belts and Idler - Check condition. Replace as necessary.
• Alternator and Starter - Check connections.
• Heater and Air Conditioning Filters - Clean or replace filters as needed.

Dealer Copy -- Not for Resale

Every 1000 Hours

• Engine Valves - Adjust the engine valve clearance.

Every 1000 Hours Or Every 12 Months

• Swing Reduction Gear - Grease swing reduction gear.

• Hydraulic Suction Filter - Clean the hydraulic suction filter, replace as needed.
• Travel Motors (Final Drive) - Replace fluid.
• Pilot Filter - Replace the pilot filter.
• Swing Reduction Gearbox - Replace fluid.

Every 1500 Hours

• Fuel Injectors - Check for proper operation.

• Exhaust Gas Recirculation (EGR) Cooler - Test the EGR cooler for leaks.
• Crankcase Ventilation Filter - Replace the crankcase ventilation filter.
• Positive Crankcase Ventilation (PCV) Valve - Check the PCV valve for free movement.

Every 2000 Hours Or Every 12 Months

• Hydraulic Reservoir - Replace the hydraulic fluid.

Every 3000 Hours

• Diesel Particulate Filter (DPF) - Disassemble, clean, and reassemble the DPF. Replace the DPF after two cleaning
events.
• Exhaust Gas Recirculation (EGR) System - Perform an EGR actuation test. Clean the gas and coolant passages.

Every 24 Months

• Coolant - Replace the coolant.

SS EXC E85-0616

42 of 918 10-80-2 E85 Service Manual

AIR CLEANER SERVICE The Check Air Cleaner Condition Icon (Item 1) will
appear in the top bar of the display panel when it is time
See the SERVICE SCHEDULE for the correct service to service the air filter. The pop up window can be
interval. (See SERVICE SCHEDULE on Page 10-80-1.) temporarily inactivated by pressing the MENU / ESC
button (Item 2) [Figure 10-90-1]. The pop up will
Daily Check
reappear each time the engine is started until the filter(s)
Figure 10-90-1 are serviced.

Dealer Copy -- Not for Resale

P-97888

43 of 918 10-90-1 E85 Service Manual

AIR CLEANER SERVICE (CONT’D) Install the cover (Item 2) and engage the three fasteners
(Item 1) [Figure 10-90-2].
Replacing The Filters
Make sure the dust evacuator cup (Item 3) [Figure 10-
Open the right side cover to access the air cleaner for 90-2] is in the down position as shown.
service. (See Opening And Closing on Page 10-50-1.)
Check the air intake hose and the air cleaner housing for
Figure 10-90-2
damage. Make sure all connections are tight.

Inner Filter
1
Only replace the inner filter under the following
conditions:

2 • Replace the inner filter every third time the outer filter
is replaced.
1
• After the outer filter has been replaced, start the
engine. If the air cleaner condition indicator icon (Item
1 1) [Figure 10-90-3] remains ON, replace the inner
3 filter.
P111083

Figure 10-90-4
Replace the inner filter every third time the outer filter is
replaced or as indicated.

Dealer Copy -- Not for Resale

Outer Filter

Pull out on the three fasteners (Item 1) and remove the

cover [Figure 10-90-2].

Clean the dust cup (Item 2) [Figure 10-90-2].

Figure 10-90-3
1

P111085

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

NOTE: Make sure all sealing surfaces are free of dirt

and debris. DO NOT use compressed air.

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

P111084 Install the outer filter and the air cleaner cover.

Pull the outer filter (Item 1) [Figure 10-90-3] from the air
cleaner housing.

Check the housing for damage.

Clean the housing and the seal surface. DO NOT use

compressed air.

Install a new filter.

44 of 918 10-90-2 E85 Service Manual

CAB FILTERS Figure 10-100-3

Cleaning And Maintenance

There are two cab air filters that must be cleaned

regularly. One filter is located below the operator seat.
The second one is located to the left side of the operator
seat. (See SERVICE SCHEDULE on Page 10-80-1.) 1

Below Seat Air Filter

Figure 10-100-1

P-87293

Installation: Install the filter with the arrows that indicate

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

1
2

Dealer Copy -- Not for Resale

P-86942

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

[Figure 10-100-1].

Figure 10-100-2

P-87294

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

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

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

45 of 918 10-100-1 E85 Service Manual

CAB FILTERS (CONT’D) Figure 10-100-6

Cleaning And Maintenance (Cont’d)

Left Side Of Seat Air Filter

1
Figure 10-100-4

1 2
1

P111102

Installation: Install the filter with the arrows that indicate

air flow direction (Item 1) [Figure 10-100-6] pointing
towards the outside of the cab.
P111104
Install the cover (Item 2) and the two bolts (Item 1)
[Figure 10-100-4].

Dealer Copy -- Not for Resale

Remove the two bolts (Item 1) and the cover (Item 2)
[Figure 10-100-4].

Figure 10-100-5

P111103

Pull up on and remove the filter (Item 1) [Figure 10-100-

5].

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

46 of 918 10-100-2 E85 Service Manual

ENGINE COOLING SYSTEM Open the right side cover.

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

Cleaning

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

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

FULL 1

LOW
1

P111100

Check the coolant level in the coolant recovery tank (Item

1) [Figure 10-110-2].

The coolant level must be between the LOW and FULL

Dealer Copy -- Not for Resale

marks on the coolant recovery tank (Item 1) [Figure 10-
P111098
110-2] when the engine is cold.
Use air pressure or water pressure to clean the radiator,
oil cooler, air conditioning condenser and the fuel cooler NOTE: The cooling system is factory filled with
(Item 1) [Figure 10-110-1]. Be careful not to damage fins ethylene glycol. DO NOT mix propylene glycol
when cleaning. with ethylene glycol.

NOTE: Allow the cooling system and engine to cool

before servicing or cleaning the cooling
system.
IMPORTANT
Checking Level
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

WARNING Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
AVOID BURNS damage.
Do not remove radiator cap when the engine is hot.
You can be seriously burned. Too little antifreeze reduces the additives which
W-2070-1203 protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

WARNING concentrated coolant can cause serious premature

engine damage.
I-2124-0497
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

47 of 918 10-110-1 E85 Service Manual

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

Removing And Replacing Coolant

See the SERVICE SCHEDULE for correct service

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

WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot. P111099

You can be seriously burned.

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

After all the coolant is removed, close the drain valves

(Item 1) [Figure 10-110-4].

Dealer Copy -- Not for Resale

Recycle or dispose of the used coolant in an
1 environmentally safe manner.

Mix the coolant in a separate container. (See Capacities

on Page SPEC-10-8.)

NOTE: The cooling system is factory filled with

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

P111101 The correct mixture of coolant to provide a -37°C (-34°F)

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

Add coolant to the recovery tank as needed.

Reinstall the lower engine access cover.

Close the right side cover.

48 of 918 10-110-2 E85 Service Manual

FUEL SYSTEM Biodiesel Blend Fuel

Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
Ultra low sulfur diesel fuel must be used in this machine.
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur • Biodiesel blend fuel is an excellent medium for
maximum. microbial growth and contamination that can cause
corrosion and plugging of fuel system components.
U.S. Standard (ASTM D975)
• Use of Biodiesel blend fuel may result in premature
Use only clean, high quality diesel fuel, Grade Number failure of fuel system components, such as: plugged
2-D or Grade Number 1-D. fuel filters and deteriorated fuel lines.

The following is one suggested blending guideline that • Shorter maintenance intervals may be required, such
should prevent fuel gelling during cold temperatures: as: cleaning the fuel system and replacing fuel filters
and fuel lines.
TEMPERATURE GRADE 2-D GRADE 1-D
• Using Biodiesel blended fuels containing more than
Above -9°C (+15°F) 100% 0% five percent Biodiesel can affect engine life and cause
Down to -21°C (-5°F) 50% 50% deterioration of hoses, tubelines, injectors, injector
Below -21°C (-5°F) 0% 100% pump, and seals.

Dealer Copy -- Not for Resale

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

49 of 918 10-120-1 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 10-120-2

Filling The Fuel Tank

1
WARNING
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807

Figure 10-120-1 P111087

NOTE: The fuel cap can be locked (Item 1) [Figure 10-

120-2] with the start key. The fuel cap does not
automatically lock when installed. The key
must be used to lock the cap.
1
NOTE: A paddle lock can also be used on the fuel cap

Dealer Copy -- Not for Resale

latch to secure the latch closed (covering the
fuel cap key lock) and not allow the start key
to unlock the fuel cap.

Figure 10-120-3

P111086

The fuel cap (Item 1) [Figure 10-120-1] is located behind

the left corner of the operator cab. 1

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

counterclockwise to remove.

P111088

Inspect the fuel strainer (Item 1) [Figure 10-120-3] for

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

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

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

Install and tighten the fuel fill cap. (Use the start key to
lock the cap, if desired.)

Clean up any spilled fuel.

50 of 918 10-120-2 E85 Service Manual

FUEL SYSTEM (CONT’D) Replacing Elements

Fuel Filters See the SERVICE SCHEDULE for the service interval
when to replace the fuel filter. (See SERVICE
Removing Water SCHEDULE on Page 10-80-1.)

Figure 10-120-5

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

See the SERVICE SCHEDULE for the service interval

when to remove water from the fuel water separator. (See P111090

SERVICE SCHEDULE on Page 10-80-1.)

Dealer Copy -- Not for Resale

Fuel Water Separator
Open the right side cover. (See Opening And Closing on
Page 10-50-1.) Turn the shut off valve (Item 1) [Figure 10-120-5]
clockwise to the closed position.
Figure 10-120-4
Remove the housing (Item 2) [Figure 10-120-5] and
replace the screen.

Clean the area around the filter housing. Put clean oil on
the seal of the new filter. Install the fuel filter and hand
tighten.
Turn the shut off valve (Item 1) [Figure 10-120-5]
counterclockwise to the open position.

1
P111089

Loosen the drain (Item 1) [Figure 10-120-4] at the

bottom of the filter (Item 2) [Figure 10-120-4] to drain
water from the filter into a container.

Clean up any spilled fuel.

51 of 918 10-120-3 E85 Service Manual

FUEL SYSTEM (CONT’D)

Replacing Elements (Cont’d)

Fuel Filter

Figure 10-120-6

P111092

Dealer Copy -- Not for Resale

Turn the shut off valve (Item 1) [Figure 10-120-5]
clockwise to the closed position.

Remove the filter (Item 1) [Figure 10-120-6].

Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-120-5.)

52 of 918 10-120-4 E85 Service Manual

FUEL SYSTEM (CONT’D)

Draining The Fuel Tank

See the SERVICE SCHEDULE for the correct service

WARNING
interval. (See SERVICE SCHEDULE on Page 10-80-1.)
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
Figure 10-120-7
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
1 1 not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Removing Air From The Fuel System

2
After replacing the fuel filter or when the fuel tank has run
out of fuel, air must be removed from the fuel system
before starting the engine.
1
1 P111091
Turn the start key to the ON position for 10 - 15 seconds.

Dealer Copy -- Not for Resale

The electric fuel pump will supply fuel under pressure
Remove four bolts / washers (Item 1) and remove the and force air from the system.
access cover (Item 2) [Figure 10-120-7] from below the
rear of the excavator.

Figure 10-120-8

P111093

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

10-120-8] at the bottom of the fuel tank. Route the hose
to a container.

Drain the fuel into a container. Tighten the drain valve

after the fuel has been removed.

Reuse, recycle or dispose of fuel in an environmentally

safe manner.

53 of 918 10-120-5 E85 Service Manual

Dealer Copy -- Not for Resale

54 of 918 10-120-6 E85 Service Manual

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

TEMPERATURE RANGE ANTICIPATED BEFORE

NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CJ-4 OR BETTER, OR ACEA
E9 OR BETTER)
P111094 [1] Bobcat Synthetic Oil – 5W-40
Bobcat engine oils are recommended for use in this
machine. If Bobcat engine oil is not available, use a good

Dealer Copy -- Not for Resale

Open the right side cover. (See Opening And Closing on
quality engine oil that meets API Service Classification of
Page 10-50-1.)
CJ-4 or better, or ACEA E9 or better [Figure 10-130-2].
Remove the dipstick (Item 1) [Figure 10-130-1].

Keep the oil level between the marks on the dipstick.

Reinstall the dipstick.

WARNING
Close the right side cover. (See Opening And Closing on AVOID INJURY OR DEATH
Page 10-50-1.) Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

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

55 of 918 10-130-1 E85 Service Manual

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

Removing And Replacing Oil And Filter

See the SERVICE SCHEDULE for the service interval for

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

Run the engine until it is at operating temperature. Rotate

the upperstructure 90° for access to the bottom engine
cover and the engine oil pan drain plug. Stop the engine. 1

Open the right side cover.

Figure 10-130-3
P111095
3 2
2 2
Remove the oil filter (Item 1) [Figure 10-130-5] and clean
the filter housing surface.

Use a genuine Bobcat replacement filter. Put clean oil on

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

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

Dealer Copy -- Not for Resale

Figure 10-130-6
1 2 1

P111138

From under the machine, loosen the two bolts (Item 1) 1

and remove four bolts / washers (Item 2) from the access
cover (Item 3) [Figure 10-130-3] from below the engine
area. Remove the access cover.

Figure 10-130-4

P-86268

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

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

Capacities on Page SPEC-10-8.)
1
Install the fill cap.

Start the engine and let it run for several minutes.

P111137
Stop the engine. Check for leaks at the oil filter. Check
the oil level.

Add oil as needed if it is not at the top mark on the

Remove the plug (Item 1) [Figure 10-130-4] from the dipstick.
engine oil pan. Drain the oil into a container.
Reinstall the access cover (Item 3) [Figure 10-130-3]
Recycle or dispose of used oil in an environmentally safe and tighten the bolts.
manner.

56 of 918 10-130-2 E85 Service Manual

HYDRAULIC SYSTEM Figure 10-140-2

Checking And Adding Fluid

Put the machine on a level surface. 3

Retract the arm and bucket cylinders, put the bucket on 3
the ground and lower the blade. Stop the engine.

Open the right side cover. (See Opening And Closing on 3 3

Page 10-50-1.)

Figure 10-140-1
1
2
3
3 P111113
2

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

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

Dealer Copy -- Not for Resale

bolts (Item 3) [Figure 10-140-2].

P111108 Clean the surface around the reservoir (breather) cap

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

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

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

57 of 918 10-140-1 E85 Service Manual

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

Hydraulic Fluid Chart Hydraulic Return Filter

RECOMMENDED ISO VISCOSITY GRADE (VG)

AND VISCOSITY INDEX (VI)

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

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-80-1.)

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

Dealer Copy -- Not for Resale

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

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

1 1
1
P111113

NOTE: When removing the cover (Item 2), there is

spring pressure under the cover. Push down
on the cover while removing the bolts (Item 1)
[Figure 10-140-4].

Clean the surface around the cover (Item 2) [Figure 10-

140-4] fully.

Press down on the cover (Item 2) and remove the six

bolts (Item 1) [Figure 10-140-4] and cover.

58 of 918 10-140-2 E85 Service Manual

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

Removing And Replacing Hydraulic Filters (Cont’d)

Hydraulic Return Filter (Cont’d)

Figure 10-140-5

1
1

P111110

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

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

P111115
Reinstall the valve (Item 1) [Figure 10-140-6].

Dealer Copy -- Not for Resale

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

Inspect the O-ring (Item 2) [Figure 10-140-5] for Reinstall the cover and align the bolt holes. Press down
damage. Replace if damaged. on the cover (Item 2) and install the six bolts (Item 1)
[Figure 10-140-4 on Page 10-140-2] and tighten the
Figure 10-140-6 bolts.

P111116

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

59 of 918 10-140-3 E85 Service Manual

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

Removing And Replacing Hydraulic Filters (Cont’d)

Hydraulic Suction Filter

See the SERVICE SCHEDULE for the correct service 1

interval. (See SERVICE SCHEDULE on Page 10-80-1.) 2

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

10-60-1.)

Figure 10-140-8

P111111
3
3
Remove the spring (Item 1) [Figure 10-140-9].
3 3
Lift up on the rod (Item 2) [Figure 10-140-9].

Figure 10-140-10

Dealer Copy -- Not for Resale

1
2 1
3
3 P111113
2

NOTE: When removing the cover (Item 2), there is

spring pressure under the cover. Push down
on the cover while removing the bolts (Item 3)
[Figure 10-140-8].

Clean the surface around the reservoir (breather) cap

(Item 1) and cover (Item 2) fully. Remove the six bolts
(Item 3) from the cover (Item 2) [Figure 10-140-8] and P111112
remove the cover.

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

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

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

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

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

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

60 of 918 10-140-4 E85 Service Manual

HYDRAULIC SYSTEM (CONT’D) Hydraulic Pilot Pressure Filter

Removing And Replacing Hydraulic Filters (Cont’d) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-80-1.)
Hydraulic Breather Filter
Figure 10-140-13
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-80-1.)
P
Open the rear cover. (See Opening And Closing on Page
10-60-1.)
1
Figure 10-140-11

Dealer Copy -- Not for Resale

P111113
If the Pilot Filter Icon (Item 1) [Figure 10-140-13] is
displayed on the instrument panel, the pilot filter will need
Clean the surface around the reservoir (breather) cap to be changed sooner than the recommended interval on
(Item 1) [Figure 10-140-11] and remove the cap by the Service Schedule.
turning counterclockwise.
Raise the operator cab. (See Raising And Lowering on
Figure 10-140-12 Page 10-210-1.)

Figure 10-140-14

1
P111114

P111153
Remove and replace the breather filter (Item 1) [Figure
10-140-12].
Clean the surface around the filter canister (Item 1)
Reinstall the cap (Item 1) [Figure 10-140-11]. [Figure 10-140-14] and remove the canister.

61 of 918 10-140-5 E85 Service Manual

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

Removing And Replacing Hydraulic Filters (Cont’d) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-80-1.)
Hydraulic Pilot Pressure Filter (Cont’d)

Figure 10-140-15

2
WARNING
1
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Retract the arm and bucket cylinders, lower the bucket to

3 P111152A
the ground. Lower the blade to the ground. Stop the
engine.

Dealer Copy -- Not for Resale

Remove the filter (Item 1) from the canister (Item 2) Figure 10-140-16
[Figure 10-140-15].

When installing the new filter, make sure the O-ring (Item
1 1
3) [Figure 10-140-15] is installed inside the filter. Apply
hydraulic oil to the O-ring before reinstalling the filter.

Install the filter (Item 1) inside the canister (Item 2)

[Figure 10-140-15].

Install the filter / canister (Item 1) [Figure 10-140-14].

1
Hand tighten the canister, then torque the canister to 22 - 2
34 N•m (17 - 25 ft-lb) torque.

P-86316

From below the rear of the excavator upperstructure,

remove three bolts (Item 1) and loosen the fourth bolt
(Item 2) [Figure 10-140-16] and rotate the cover plate to
the side to access the bottom of the hydraulic tank.

62 of 918 10-140-6 E85 Service Manual

HYDRAULIC SYSTEM (CONT’D) Figure 10-140-18

Removing And Replacing Hydraulic Fluid (Cont’d)

Figure 10-140-17

1
1

P111125

After the hydraulic fluid has been drained from the

P111117 excavator or after the hydraulic pump has been serviced,
the hydraulic pump must be flooded with hydraulic oil.
Allow sufficient time for the hydraulic fluid to gravity feed
Remove the drain plug (Item 1) [Figure 10-140-17] from into the hydraulic pump before starting the machine.
the bottom of the hydraulic tank.

Dealer Copy -- Not for Resale

Loosen the case drain hose (Item 1) [Figure 10-140-18]
Drain the fluid into a container. to see if hydraulic fluid is at the fitting. If oil is present the
pump has been flooded. Reinstall the hose.
Recycle or dispose of the fluid in an environmentally safe
manner. If fluid is not at the fitting, reinstall the hose (Item 1). Start
the engine and run at low idle for one minute. Remove
Reinstall the drain plug (Item 1) [Figure 10-140-17]. the hose (Item 1) [Figure 10-140-18] and verify fluid is at
the plug opening. Reinstall hose before operating.
Rotate the cover plate (Item 1) back to the original
location and install the three bolts (Item 2) [Figure 10- Recycle or dispose of the fluid in an environmentally safe
140-16]. Tighten the four bolts. manner.

Always replace the filters when changing the hydraulic Start the engine and operate the machine through the
oil. (See Removing And Replacing Hydraulic Filters on hydraulic functions. Stop the engine. Check the fluid level
Page 10-140-2.) and add as needed.

Install new Bobcat hydraulic fluid. (See Hydraulic Fluid

Chart on Page 10-140-2.)

63 of 918 10-140-7 E85 Service Manual

HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Swing Motor Gear Box
Fluid
Checking Swing Motor Gear Box Fluid Level
Figure 10-140-20
Figure 10-140-19
1

P111117
P111127

The swing motor carrier drain plug is located below the

Open the center cover to access the swing motor. (See engine area by the hydraulic tank drain plug.
Opening And Closing on Page 10-70-1.)
Rotate the cover to access the drain plug. (See

Dealer Copy -- Not for Resale

The swing motor gear box (Item 1) has a dipstick (Item 2) Removing And Replacing Hydraulic Fluid on Page 10-
[Figure 10-140-19] for checking the swing motor gear 140-6.)
box oil level. Remove the plug (Item 1) [Figure 10-140-20] and drain
the swing motor carrier. Reinstall the drain plug.
Keep the oil level between the marks on the dipstick.
Drain the fluid into a container.
Recycle or dispose of the fluid in an environmentally safe
manner.
Remove the dipstick (Item 2) [Figure 10-140-19] and add
gear lube (80W-90) until it is at the correct mark on the
dipstick. (See Capacities on Page SPEC-10-8.)

64 of 918 10-140-8 E85 Service Manual

LUBRICATING THE EXCAVATOR Figure 10-150-2

Lubrication Locations

Lubricate the excavator as specified in the SERVICE

SCHEDULE for the best performance of the machine.
(See SERVICE SCHEDULE on Page 10-80-1.)

Record the operating hours each time you lubricate the

excavator.

Always use a good quality lithium based multipurpose

grease when lubricating the machine. Apply the lubricant 4
until extra grease shows.

Figure 10-150-1 P111139

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

1
Figure 10-150-3
2

Dealer Copy -- Not for Resale

3
3

2
5

P111136
6

Ref Description (# of Fittings)

1. Blade Cylinder Rod End (1) P111141

2. Blade Cylinder Base End (1)

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

65 of 918 10-150-1 E85 Service Manual

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

Lubrication Locations (Cont’d)

Figure 10-150-4

9
7

P111142

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

P111140
Figure 10-150-7

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

Dealer Copy -- Not for Resale

Figure 10-150-5
11

8 P111145

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

P111143
11. Arm Cylinder Rod End (1)

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

66 of 918 10-150-2 E85 Service Manual

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

Lubrication Locations (Cont’d)

Figure 10-150-8

12
15

16 15

P-86304

15. Link Pivot Pin (2)

P111144
16. Arm (1) [Figure 10-150-10]

12. Bucket Cylinder Base End (1) [Figure 10-150-8] Figure 10-150-11

Dealer Copy -- Not for Resale

Figure 10-150-9
19 18
20
17
13

P-86905

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

18. Swing Motor Reduction Gear (1)

19. Slew Circle Bearing (1)

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

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

67 of 918 10-150-3 E85 Service Manual

LUBRICATING THE EXCAVATOR (CONT’D)

Lubrication Locations (Cont’d)

Articulated Boom (If Equipped)

Figure 10-150-12

23 24
22
P123133

Dealer Copy -- Not for Resale

21. Articulated Boom Cylinders Base End (2).

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

23. Articulated Boom Cylinders Rod End (2).

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

[Figure 10-150-12]

Figure 10-150-13

P123134

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

68 of 918 10-150-4 E85 Service Manual

PIVOT PINS Articulated Boom (If Equipped)

Inspection And Maintenance Figure 10-160-2

Figure 10-160-1

1 1

P123136
2

The articulated boom pivot has a large pin (Item 1)

[Figure 10-160-2] held in position with a bolt and two
nuts.

Dealer Copy -- Not for Resale

Check that all pivot bolts and nuts are securely tightened
and are not damaged. See your dealer for replacement
parts.

DIESEL PARTICULATE FILTER (DPF) SYSTEM A forced (stationary) regeneration cycle may be required
if too much soot is allowed to accumulate in the DPF. This
Description can occur in the following situations:

The engine exhaust system is equipped with a diesel 1. The excavator is often operated for brief periods (less
particulate filter (DPF). The DPF is an emissions than 30 minutes) that do not allow sufficient time for
reduction device that removes diesel particulate matter the DPF to complete an automatic regeneration cycle.
(soot) from the exhaust gases of the diesel engine. The
DPF will trap and collect the soot until it is burned off. The 2. The excavator is used with low load during extended
process of burning off the collected soot is called period of time.
regeneration.
3. When DPF inhibited / forced regeneration switch
Ash residue will remain after the regeneration process is (Item 1) is in the inhibited enabled position for an
complete. The ash must be periodically removed from the extended period of time. This will inhibit the DPF from
DPF. (See DPF Ash Cleaning on Page 10-180-4.) actively regenerating and burning off the collected
soot. The inhibited ICON (Item 2) will be ON when the
Forced (Stationary) Regeneration inhibited / forced switch (Item 1) [Figure 10-180-1] is
enabled.
Figure 10-180-1
When forced (stationary) regeneration is required, the
1
red Warning LED will flash ON and OFF in the instrument
panel (See Operation & Maintenance Manual for the
exact location) and the pop-up message “Forced
Regeneration Status” will appear.

Dealer Copy -- Not for Resale

NOTE: Failure to perform a forced (stationary)
regeneration when required can result in the
soot level exceeding the maximum allowable
level and the engine being derated. Continued
excavator operation will require exhaust
system service by your dealer.
P111022F

Ensure the excavator has enough fuel to operate for 30

minutes minimum.
2 3

WARNING
AVOID SERIOUS INJURY OR DEATH
Exhaust gas temperature and exhaust system
components are hot during regeneration. Keep
flammable material, explosive dust, and explosive
gases away from exhaust system.
W-2936-0412

P-97914

This excavator is equipped with a DPF inhibited / forced

regeneration switch (Item 1) [Figure 10-180-1] on the
right console.

73 of 918 10-180-1 E85 Service Manual

DIESEL PARTICULATE FILTER (DPF) SYSTEM 4. Move engine speed control to low idle and deactivate
(CONT’D) the auxiliary hydraulics.

Forced (Stationary) Regeneration (Cont’d) 5. Raise the left console to the locked out position. (See
Operation & Maintenance Manual for the correct
procedure.)
WARNING 6. When the ECU verifies the left console is raised to the
locked out position, the engine is at low idle, the
AVOID INJURY OR DEATH
coolant and DPF temperatures are at operating
When an engine is running in an enclosed area, fresh
temperatures; then the forced (stationary)
air must be added to avoid concentration of exhaust
regeneration cycle can be activated.
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
7. Press the DPF inhibited / forced regeneration switch
gases which can kill without warning.
W-2050-0807
(Item 1) to the inhibited position (Item 2) for
approximately 5 seconds. The pop-up message “DPF
Active Regeneration Inhibit Status” will appear. The
Figure 10-180-2 inhibited icon (Item 3) [Figure 10-180-2] will turn ON.
Press the inhibited / forced switch a second time to
1 turn the inhibited icon OFF.

8. Now press and hold the DPF inhibited / forced

regeneration switch (Item 1) to the regenerate
position (Item 4) for approximately 15 seconds (or

Dealer Copy -- Not for Resale

4 until the red Warning LED in the instrument panel is
flashing) to start regeneration. The DPF
Regeneration icon (Item 5) [Figure 10-180-2] will turn
ON (amber colored) and the pop-up message
2
“Regeneration Is Ready” will appear. The
regeneration process will start in a few seconds.
P111022C

9. Release the DPF inhibit / forced regeneration switch

5 (Item 1) [Figure 10-180-2] so it returns to the center
3
position.

P-97914

1. Park the machine on flat level ground and in an open

area with good ventilation. Lower the boom and blade
fully.
2. Run the engine until the coolant temperature is at a
minimum of 60°C (140°F).
3. Activate the auxiliary hydraulics with nothing
connected to the couplers and run the engine at high
idle for about 2 minutes. This will raise the DPF inlet
exhaust to the necessary temperature.

74 of 918 10-180-2 E85 Service Manual

DIESEL PARTICULATE FILTER (DPF) SYSTEM
(CONT’D)

Forced (Stationary) Regeneration (Cont’d)

After the regeneration cycle starts, the engine will idle

for a brief period. The engine speed will gradually
increase to approximately 1950 rpm.

The regeneration cycle will take approximately 30

minutes to complete. DO not stop this cycle unless
absolutely necessary.

If the regeneration cycle must be stopped, press the

DPF inhibited / forced regeneration switch (Item 2)
[Figure 10-180-2], or rotate the speed control knob
above the low idle position, or lower the lock lever or
turn the start key to the OFF position. Any of above
actions will cause the regeneration cycle to be
aborted.

NOTE: If the forced (stationary) regeneration cycle is

not completed for two consecutive times
(manually stopped), the engine check light

Dealer Copy -- Not for Resale

will turn ON and engine power will be
reduced. Error code P2463 “Service
Regeneration Required will be displayed in
the instrument panel.

IMPORTANT
Stopping the engine during the regeneration cycle
may cause severe damage to the DPF.
I-2352-0412

10. After the DPF regeneration is complete, the engine

will return to low idle and will continue to operate for a
cool down period. Once the DPF Icon (Item 5) [Figure
10-180-2] turns OFF, the regeneration cycle is
complete. The engine can now be stopped.

75 of 918 10-180-3 E85 Service Manual

DIESEL PARTICULATE FILTER (DPF) SYSTEM DPF Ash Cleaning
(CONT’D)
See the SERVICE SCHEDULE for the correct service
Service Regeneration interval. (See SERVICE SCHEDULE on Page 10-80-1.)

Your machine will indicate the need for service Figure 10-180-3
regeneration by displaying one of the following service
codes: 2 4

• [P1421] Forced (Stationary) Regeneration Required

• [P1424] or [P2463] Service Regeneration Required

• [P2458] Regeneration Defect (stationary

regeneration failure)

• [P2459] Regeneration Defect (stationary

regeneration not performed)
POP-UP
Service regeneration requires the use of specialized SCREEN
equipment. See your dealer for service regeneration.
1 MESSAGE
NOTE: The operator can perform a forced
(stationary) regeneration (Service Code

Dealer Copy -- Not for Resale

P1421) but if service regeneration is
requested, regeneration must be performed
by your dealer. (See Forced (Stationary)
Regeneration on Page 10-180-1.)

P-97888

Clean the DPF at the specified interval or when indicated

on the instrument panel.

A pop-up box (Item 1) will appear on the screen, the DPF

icon (Item 2) and the engine check light (Item 4) icons will
FLASH. Press the MENU / ESC button (Item 3) [Figure
10-180-3] until the display screen shows the service
codes. (See DIAGNOSTIC SERVICE CODES on Page
50-80-1.) Service code [P1420] (DPF Service Required)
will show in the display screen when DPF cleaning is
necessary.

The DPF is a critical component of the engine exhaust

system and must be properly maintained. Specialized
equipment is required to clean the ash from the DPF. See
your dealer for DPF cleaning.

76 of 918 10-180-4 E85 Service Manual

EMERGENCY EXITS Figure 10-190-3

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

Right Rear Side Window

Figure 10-190-1

P-86325
1

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

3].

Front Window
P111037
Figure 10-190-4

Dealer Copy -- Not for Resale

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

Figure 10-190-2

P-86322

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

NOTE: If the excavator has a Front Guard Kit

P-86218 installed, the front window is NOT an
emergency exit.

Remove the hammer from the storage position and strike

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

Use the hammer to remove broken glass from the edge

of the window before exiting.

77 of 918 10-190-1 E85 Service Manual

Dealer Copy -- Not for Resale

78 of 918 10-190-2 E85 Service Manual

SEAT BELT Figure 10-200-1

Inspection And Maintenance

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

Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly yearly or more

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

The seat belt system should be repaired or replaced if it

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

Dealer Copy -- Not for Resale

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

B-22283

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

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

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

2. Check the buckle and latch for correct operation.

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

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

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

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

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

79 of 918 10-200-1 E85 Service Manual

Dealer Copy -- Not for Resale

80 of 918 10-200-2 E85 Service Manual

CAB TILT PROCEDURE Figure 10-210-3

Raising And Lowering 1

Raising The Cab

1
Figure 10-210-1 1

5
2
1
4
3
2

P123143

Remove the four bolts (Item 1) and remove the cover

3 (Item 2) [Figure 10-210-3].

Remove the bolt (Item 3), loosen the bolt (Item 4) and
P123141
pivot the cover (Item 5) [Figure 10-210-3] down for
access to the cab tilt assembly.

Dealer Copy -- Not for Resale

Remove the two nuts and washers (Item 1) [Figure 10-
210-1] from the right and left rear corners of the cab. Figure 10-210-4

Remove the bolt (Item 2) and retaining ring (Item 3)

[Figure 10-210-1].

Figure 10-210-2

P123144

Install a wrench (Item 1) [Figure 10-210-4] and rotate the

cab tilt assembly clockwise to raise the cab.

P123142 NOTE: Do Not use any type of air or electrically

operated wrench. Only use a hand operated
Remove the bolt and washer (Item 1) [Figure 10-210-2]. wrench. Turning the tilt assembly at higher
speeds can damage the tilt assembly.

81 of 918 10-210-1 E85 Service Manual

CAB TILT PROCEDURE (CONT’D)

Raising And Lowering (Cont’d)

WARNING
Raising The Cab (Cont’d)
AVOID INJURY OR DEATH
Figure 10-210-5 Never work under the excavator cab without
installing an approved cab support device.
W-2435-0502

Lowering The Cab

Raise the cab slightly and rotate the cab support device
(Item 1) [Figure 10-210-6] to the storage position
[Figure 10-210-5].

2 Install the bolt (Item 1) [Figure 10-210-5].

1
Slowly lower the cab completely [Figure 10-210-4].

Install the two washers and nuts (item 1) [Figure 10-210-

P-97918 1] on the left and right side of the rear of the cab.

Remove the bolt (Item 1) from the cab support device Install the bolt and washer (Item 1) [Figure 10-210-2] at

Dealer Copy -- Not for Resale

(Item 2) [Figure 10-210-5]. the left rear corner of the cab. Install the retaining ring
(Item 3) and Tighten bolt (Item 2) [Figure 10-210-1].
Figure 10-210-6
Pivot the cover (Item 5) up and install the bolt (Item 3)
[Figure 10-210-3].

Tighten the bolts (Item 3 and 4) [Figure 10-210-3].

1 Install the cover (Item 2) and the four bolts (Item 1)

[Figure 10-210-3].

2
P-97919

Rotate the cab support device (Item 1) down to the

support post (Item 2) [Figure 10-210-6].

Slowly lower the cab until it is supported by the cab

support device.

82 of 918 10-210-2 E85 Service Manual

CONTROL CONSOLE LOCKOUT

Inspection And Maintenance

Figure 10-220-1

P-86321

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

hydraulic control levers (joysticks and traction system)

Dealer Copy -- Not for Resale

must not function.

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

Raise the left console.

Move the joystick control levers. There should be no

movement of the boom, arm, slew or bucket.

Move the travel control levers. There should be no

movement of the excavator.

Service the system if these controls do not deactivate

when the left control console is raised.

83 of 918 10-220-1 E85 Service Manual

Dealer Copy -- Not for Resale

84 of 918 10-220-2 E85 Service Manual

TOWING THE EXCAVATOR

Procedure

There is not a recommended towing procedure for the

excavators.

• The excavator can be lifted onto the transport vehicle.

• The excavator can be skidded a short distance for

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

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

the weight of the excavator. (See Capacities on Page
SPEC-10-8.)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

HYDRAULIC PILOT PRESSURE FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1

90 of 918 20-04 E85 Service Manual

HYDRAULIC/HYDROSTATIC SCHEMATIC
E85 (S/N B34T11001 AND ABOVE)
Printable Version Click Here

(PRINTED AUGUST 2015)

V-1559legend

1 HYDRAULIC RESERVOIR (PRESSURIZED) 17 PORT RELIEF / ANTI-CAVITATION VALVE – 32 RELIEF VALVE – Slew Motor Brake 48 MINIMUM PUMP DISPLACEMENT
Reservoir – 87 L (23 U.S. gal) (2nd Auxiliary – If Equipped) - (On Stroke Piston)
System – 127 L (39.1 U.S. gal) 31000 kPa (310 bar) (4496 psi) 33 SHUTTLE VALVE (Motion Alarm – If
Equipped)
2 18 3rd AUXILIARY QUICK COUPLERS – 49 TORQUE LIMITER 28000 kPa (280 bar) (4061 psi)
MAIN FILTER - 10 MICRON
With 250 kPa (2,5 bar) (36 psi) By-Pass Valve Male / Female (If Equipped) 34 SHUTTLE VALVE (Slew Motor Brake Valve)
50 SOLENOID ACTIVATED DIRECTIONAL
3 SUCTION FILTER - 150 MICRON 19 MANUAL DIRECTIONAL CONTROL 35 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (Regeneration)
VALVE (Bucket Cylinder – 3rd Auxiliary CONTROL VALVE (2nd Auxiliary)
Couplers) – (If Equipped) 51 HYDRAULIC FILL CAP With Breather Filter
4 CHECK VALVE – 259 kPa (2.5 bar) (36 psi) 36 PILOT ACTIVATED DIRECTIONAL
20 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (2) (2nd Auxiliary) 52 FILTER
5 CHECK VALVE – 300 kPa (3 bar) (44 psi) CONTROL VALVE (Load Holding valve) –
Boom 37 PORT RELIEF VALVE –(2nd Auxiliary –
If Equipped) 25000 kPa (250 bar) (3626 psi) 53 SOLENOID ACTIVATED DIRECTIONAL
6 OIL COOLER
21 RELIEF VALVE - (Load Holding valve) – CONTROL VALVE (2) (Boom Swing)
SOLENOID ACTIVATED DIRECTIONAL
38
Boom
7 LOAD CHECK Dealer Copy -- NotCONTROL VALVE (Two Speed)
for Resale 54 SOLENOID ACTIVATED DIRECTIONAL
22 CHECK VALVE With Restriction - (Load 39 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (2nd Auxiliary)
8 BACK-UP RELIEF VALVE: Holding valve) – Boom
34000 kPa (340 bar) (4931 psi) CONTROL VALVE - (Console Lockout / Pilot
Cut off) 55 2nd AUXILIARY QUICK COUPLERS –
23 NOT USED ON THIS MODEL
9 FLUSHING VALVE: 2500 kPa (25 bar) (362 psi) Male / Female (If Equipped)
40 FILTER - Pilot Witn By-Pass Valve
10 LOAD SENSE BLEED VALVE 170 kPa (1,7 bar) (25 psi)
24 AUXILIARY QUICK COUPLERS – Male / Female 56 ORIFICE – 0,8 mm (0.031 in)
11 LOAD SENSE RELIEF VALVE: 41 PRESSURE REDUCING VALVE -
25 BRAKE RELEASE VALVE – Travel Motor 57 ACCUMULATOR - Nitrogen 1020 kPa
28000 kPa (280 bar) (4060 psi) 630 kPa (6,3 bar) (91 psi) 3200 kPa (32 bar) (464 psi)
(10.2 bar) (148 psi) Precharged
12 PORT RELIEF / ANTI-CAVITATION VALVE (2) - 26 TWO SPEED SHIFT SPOOL – Travel Motor 42 CHECK VALVE: 50 kPa (0,5 bar) (7.25 psi)
(Boom Cylinder) - 31000 kPa (310 bar) (4496 psi)
27 CROSS PORT RELIEF VALVE (Travel Motor) 43 HYDRAULIC GEAR PUMP
13 PORT RELIEF / ANTI-CAVITATION VALVE (2) -
28000 kPa (280 bar) (4061 psi) 22 L/min (5.8 U.S. gpm) at High Idle
(Bucket Cylinder) - 31000 kPa (310 bar) (4496 psi)
28 COUNTERBALANCE SPOOL (Travel Motor) 44 HYDRAULIC PISTON PUMP
14 PORT RELIEF / ANTI-CAVITATION VALVE (2) - 144 L/min (38 U.S. gpm) at High Idle
(Arm Cylinder) - 31000 kPa (310 bar) (4496 psi)
29 BRAKE RELEASE VALVE - Slew Motor 45 TORQUE LIMITER SUPPLY SPOOL
15 PORT RELIEF / ANTI-CAVITATION VALVE - 1900 kPa (19 bar) (276 psi) 2000 kPa (20 bar) (290 psi)
(Continuous Flow / Auxiliary Hydraulics -
30 CROSS PORT RELIEF VALVE - Slew Motor 46 DESTROKE PISTON
31000 kPa (310 bar) (4496 psi)
22000 kPa (220 bar) (3190 psi)
16 ANTI-CAVITATION VALVE 31 ANTI-CAVITATION VALVE – Slew Motor 47 PUMP MARGIN SPOOL: NOTE: Unless otherwise specified
1500 kPa (15 bar) (218 psi) springs have NO significant
pressure value.

Printed in U.S.A. V-1559legend (9-1-15)

91 of 918
TRAVEL MOTOR (LH) TRAVEL MOTOR (RH) SWING MOTOR BOOM OFFSET CYLINDER
RED RED
D1 D2 D1 D2

REGENERATION BOOM BUCKET ARM BLADE P2 P3 P2 P3 S1

2nd AUXILIAYY HYDRAULICS
CYLINDERS
25 25
VALVE CYLINDER CYLINDER CYLINDER 26 26
SH (OPTIONAL)
(LH) (RH) P P
29 C D
25 F
PG
FEMALE
37
50 DB 55
27 27
28 28 MALE
E
31

32
36
23 P4 P3 P4 P3
LOAD HOLDING 23
(BACKWARD) A B (FORWARD) (FORWARD) A B (BACKWARD)
VALVE (BOOM)
C2
AUXILIARY C
M
21
E HYDRAUICS PA 30 PB
18
20
T
A(LH) B(RH)
V2
22 35
pb1
DIRECT TO
19

TANK VALVE 24 E B T P C F A CP T B
D A 2nd AUX
A VALVE
B P

BOOM BUCKET ARM BLADE TRAVEL(LH) TRAVEL(RH) SWING OFFSET

M pb1 pb2 pb3 pb4 pb5 pb6 pb7 pb8 pb9

P P2

Pressure Sensor
LS LS2

7 7 7 7 7 7 7 7 7

8 9 T B A T T B A T T B A T T B A T T B
10 11

T1 pa1 12 pa2
13
pa3
14
pa4 pa5 15 pa6 pa7 Dealer Copy -- Not for Resale
pa8 pa9
17 16

LOCKOUT / PILOT
P/T BLOCK
40

CONSOLE
2-SPEED
6
PILOT
FILTER
51
4 P 1/4 3/8
A2 A1
38 39 BLADE JOYSTICK
T
42
41 T P TRAVEL VALVE P
2 T P LEFT JOY STICK T P RIGHT JOY STICK

T1
45 UP DOWN

1 2 1

47 T PILOT PV 1 SWING 3 4 ARM 2 1 BUCKET 3 4 BOOM 2 1 L.TRAVEL 2 3 R.TRAVEL 4 pb4 pa4

SUPPLY LEFT RIGHT IN OUT IN DUMP UP DOWN BACKWARD BACKWARD
FORWARD FORWARD
X(LS)
VALVE
B1 pa2 pb2 pa9 pb9
57 56
46
B2 pb5 pa5
pb3 pa3
49
33 33 A(Open) B(Close) C(CW) D(CCW)
3
HYDRAULIC L1 A1 A3
33
Dr1
RESERVOIR 44 43 C1 D1 A1 B1
Dr2 pb8 pa8

56 L3 MOTION
ALARM
48 P
A2 B2
E
C2 D2
34 ISO 54 53
52
A1 A
HYDROSTATIC S1 L1 L S2 2 pb6 pa6 pb7 pa7
T EPPR VALVE
PUMP STD

R3
B1 S1 B2 MOTION ALARM
PRESSURE
R1
SH SWITCH
B3 B1
ISO / STD VALVE Printable Version Click Here
E85 (S/N B34T11001 AND ABOVE)
pa1 pb1

92 of 918
Printed In U.S.A. (PRINTED AUGUST 2015)
V-1559
HYDRAULIC/HYDROSTATIC SCHEMATIC
Without Articulated Boom
E85 (S/N B34S11001 AND ABOVE)
Printable Version Click Here

(PRINTED AUGUST 2015)

V-1559legend

1 HYDRAULIC RESERVOIR (PRESSURIZED) 17 PORT RELIEF / ANTI-CAVITATION VALVE – 32 RELIEF VALVE – Slew Motor Brake 48 MINIMUM PUMP DISPLACEMENT
Reservoir – 87 L (23 U.S. gal) (2nd Auxiliary – If Equipped) - (On Stroke Piston)
System – 127 L (39.1 U.S. gal) 31000 kPa (310 bar) (4496 psi) 33 SHUTTLE VALVE (Motion Alarm – If
Equipped)
2 18 3rd AUXILIARY QUICK COUPLERS – 49 TORQUE LIMITER 28000 kPa (280 bar) (4061 psi)
MAIN FILTER - 10 MICRON
With 250 kPa (2,5 bar) (36 psi) By-Pass Valve Male / Female (If Equipped) 34 SHUTTLE VALVE (Slew Motor Brake Valve)
50 SOLENOID ACTIVATED DIRECTIONAL
3 SUCTION FILTER - 150 MICRON 19 MANUAL DIRECTIONAL CONTROL 35 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (Regeneration)
VALVE (Bucket Cylinder – 3rd Auxiliary CONTROL VALVE (2nd Auxiliary)
Couplers) – (If Equipped) 51 HYDRAULIC FILL CAP With Breather Filter
4 CHECK VALVE – 259 kPa (2.5 bar) (36 psi) 36 PILOT ACTIVATED DIRECTIONAL
20 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (2) (2nd Auxiliary) 52 FILTER
5 CHECK VALVE – 300 kPa (3 bar) (44 psi) CONTROL VALVE (Load Holding valve) –
Boom 37 PORT RELIEF VALVE –(2nd Auxiliary –
If Equipped) 25000 kPa (250 bar) (3626 psi) 53 SOLENOID ACTIVATED DIRECTIONAL
6 OIL COOLER
21 RELIEF VALVE - (Load Holding valve) – CONTROL VALVE (2) (Boom Swing)
SOLENOID ACTIVATED DIRECTIONAL
38
Boom
7 LOAD CHECK Dealer Copy -- NotCONTROL VALVE (Two Speed)
for Resale 54 SOLENOID ACTIVATED DIRECTIONAL
22 CHECK VALVE With Restriction - (Load 39 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (2nd Auxiliary)
8 BACK-UP RELIEF VALVE: Holding valve) – Boom
34000 kPa (340 bar) (4931 psi) CONTROL VALVE - (Console Lockout / Pilot
Cut off) 55 2nd AUXILIARY QUICK COUPLERS –
23 LOCK VALVES – BLADE CYLINDER (2)
9 FLUSHING VALVE: 2500 kPa (25 bar) (362 psi) Male / Female
(If Equipped) 40 FILTER - Pilot Witn By-Pass Valve
10 LOAD SENSE BLEED VALVE 170 kPa (1,7 bar) (25 psi)
24 AUXILIARY QUICK COUPLERS – Male / Female 56 ORIFICE – 0,8 mm (0.031 in)
11 LOAD SENSE RELIEF VALVE: 41 PRESSURE REDUCING VALVE -
25 BRAKE RELEASE VALVE – Travel Motor 57 ACCUMULATOR - Nitrogen 1020 kPa
28000 kPa (280 bar) (4060 psi) 630 kPa (6,3 bar) (91 psi) 3200 kPa (32 bar) (464 psi)
(10.2 bar) (148 psi) Precharged
12 PORT RELIEF / ANTI-CAVITATION VALVE (2) - 26 TWO SPEED SHIFT SPOOL – Travel Motor 42 CHECK VALVE: 50 kPa (0,5 bar) (7.25 psi)
(Boom Cylinder) - 31000 kPa (310 bar) (4496 psi)
27 CROSS PORT RELIEF VALVE (Travel Motor) 43 HYDRAULIC GEAR PUMP
13 PORT RELIEF / ANTI-CAVITATION VALVE (2) -
28000 kPa (280 bar) (4061 psi) 22 L/min (5.8 U.S. gpm) at High Idle
(Bucket Cylinder) - 31000 kPa (310 bar) (4496 psi)
28 COUNTERBALANCE SPOOL (Travel Motor) 44 HYDRAULIC PISTON PUMP
14 PORT RELIEF / ANTI-CAVITATION VALVE (2) - 144 L/min (38 U.S. gpm) at High Idle
(Arm Cylinder) - 31000 kPa (310 bar) (4496 psi)
29 BRAKE RELEASE VALVE - Slew Motor 45 TORQUE LIMITER SUPPLY SPOOL
15 PORT RELIEF / ANTI-CAVITATION VALVE - 1900 kPa (19 bar) (276 psi) 2000 kPa (20 bar) (290 psi)
(Continuous Flow / Auxiliary Hydraulics -
30 CROSS PORT RELIEF VALVE - Slew Motor 46 DESTROKE PISTON
31000 kPa (310 bar) (4496 psi)
22000 kPa (220 bar) (3190 psi)
16 ANTI-CAVITATION VALVE 31 ANTI-CAVITATION VALVE – Slew Motor 47 PUMP MARGIN SPOOL: NOTE: Unless otherwise specified
1500 kPa (15 bar) (218 psi) springs have NO significant
pressure value.

Printed in U.S.A. V-1559legend (9-1-15)

93 of 918
TRAVEL MOTOR (LH) TRAVEL MOTOR (RH) SWING MOTOR BOOM OFFSET CYLINDER
RED RED
D1 D2 D1 D2

REGENERATION BOOM BUCKET ARM BLADE P2 P3 P2 P3 S1

2nd AUXILIAYY HYDRAULICS
CYLINDERS
25 25
VALVE CYLINDER CYLINDER CYLINDER 26 26
SH
(LH) (RH) P P
29 C D
25 F
BLADE LOCK PG
FEMALE
VALVE(OPTION) 37
50 DB 55
27 27
D B A C
28 28 MALE
E
C A B D
31

32
LOAD HOLDING 36
VALVE (ARM) 23 P4 P3 P4 P3
LOAD HOLDING 23
(OPTIONAL) (BACKWARD) A B (FORWARD) (FORWARD) A B (BACKWARD)
VALVE (BOOM)
C2 C2
AUXILIARY C
M M
21
E E
21 HYDRAUICS PA 30 PB
18
20
T 20 T V2
A(LH) B(RH)
V2
22 22 35
pb1 pa3
DIRECT TO
19

TANK VALVE 24 E B T P C F A CP T B
D A 2nd AUX
A VALVE
B P

BOOM BUCKET ARM BLADE TRAVEL(LH) TRAVEL(RH) SWING OFFSET

M pb1 pb2 pb3 pb4 pb5 pb6 pb7 pb8 pb9

P P2

Pressure Sensor
LS LS2

7 7 7 7 7 7 7 7 7

8 9 T B A T T B A T T B A T T B A T T B
10 11

T1 pa1 12 pa2
13
pa3
14
pa4 pa5 15 pa6 pa7
Dealer Copy -- Not for Resale
pa8 pa9
17 16

LOCKOUT / PILOT
P/T BLOCK
40

CONSOLE
2-SPEED
6
PILOT
FILTER
51
4 P 1/4 3/8
A2 A1
38 39 BLADE JOYSTICK
T
42
41 T P TRAVEL VALVE P
2 T P LEFT JOY STICK T P RIGHT JOY STICK

T1
45 UP DOWN

1 2 1

47 T PILOT PV 1 SWING 3 4 ARM 2 1 BUCKET 3 4 BOOM 2 1 L.TRAVEL 2 3 R.TRAVEL 4 pb4 pa4

SUPPLY LEFT RIGHT IN OUT IN DUMP UP DOWN BACKWARD BACKWARD
FORWARD FORWARD
X(LS)
VALVE
B1 pa3 pb3 pa2 pb2 pa9 pb9
57 56
46 pa1 pb1
B2 pb5 pa5

49
33 33 A(Open) B(Close) C(CW) D(CCW)
3
HYDRAULIC 33
Dr1
RESERVOIR 44 43 C1 D1 A1 B1
Dr2 pb8 pa8

56 MOTION
ALARM
48 P
A2 B2
E
C2 D2 54 53
34 52
A1 A
HYDROSTATIC S1 L1 L S2 2 pb6 pa6 pb7 pa7
T EPPR VALVE
PUMP

B1 S1 B2 MOTION ALARM
PRESSURE
SH SWITCH

(Without Articulated Boom)

E85 (S/N B34S11001 AND ABOVE)
Printed In U.S.A.
94 of 918 Printable Version Click Here (PRINTED AUGUST 2015)
V-1559
HYDRAULIC/HYDROSTATIC SCHEMATIC
With Articulated Boom
E85 (S/N B34S11001 AND ABOVE)
Printable Version Click Here

(PRINTED AUGUST 2015)

V-1559legend

1 HYDRAULIC RESERVOIR (PRESSURIZED) 17 PORT RELIEF / ANTI-CAVITATION VALVE – 32 RELIEF VALVE – Slew Motor Brake 48 MINIMUM PUMP DISPLACEMENT
Reservoir – 87 L (23 U.S. gal) (2nd Auxiliary – If Equipped) - (On Stroke Piston)
System – 127 L (39.1 U.S. gal) 31000 kPa (310 bar) (4496 psi) 33 SHUTTLE VALVE (Motion Alarm – If
Equipped)
2 18 3rd AUXILIARY QUICK COUPLERS – 49 TORQUE LIMITER 28000 kPa (280 bar) (4061 psi)
MAIN FILTER - 10 MICRON
With 250 kPa (2,5 bar) (36 psi) By-Pass Valve Male / Female (If Equipped) 34 SHUTTLE VALVE (Slew Motor Brake Valve)
50 SOLENOID ACTIVATED DIRECTIONAL
3 SUCTION FILTER - 150 MICRON 19 MANUAL DIRECTIONAL CONTROL 35 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (Regeneration)
VALVE (Bucket Cylinder – 3rd Auxiliary CONTROL VALVE (2nd Auxiliary)
Couplers) – (If Equipped) 51 HYDRAULIC FILL CAP With Breather Filter
4 CHECK VALVE – 259 kPa (2.5 bar) (36 psi) 36 PILOT ACTIVATED DIRECTIONAL
20 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (2) (2nd Auxiliary) 52 FILTER
5 CHECK VALVE – 300 kPa (3 bar) (44 psi) CONTROL VALVE (Load Holding valve) –
Boom 37 PORT RELIEF VALVE –(2nd Auxiliary –
If Equipped) 25000 kPa (250 bar) (3626 psi) 53 SOLENOID ACTIVATED DIRECTIONAL
6 OIL COOLER
21 RELIEF VALVE - (Load Holding valve) – CONTROL VALVE (2) (Boom Swing)
SOLENOID ACTIVATED DIRECTIONAL
38
Boom
7 LOAD CHECK Dealer Copy -- NotCONTROL VALVE (Two Speed)
for Resale 54 SOLENOID ACTIVATED DIRECTIONAL
22 CHECK VALVE With Restriction - (Load 39 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (2nd Auxiliary)
8 BACK-UP RELIEF VALVE: Holding valve) – Boom
34000 kPa (340 bar) (4931 psi) CONTROL VALVE - (Console Lockout / Pilot
Cut off) 55 2nd AUXILIARY QUICK COUPLERS –
23 LOCK VALVES – BLADE CYLINDER (2)
9 FLUSHING VALVE: 2500 kPa (25 bar) (362 psi) Male / Female
(If Equipped) 40 FILTER - Pilot Witn By-Pass Valve
10 LOAD SENSE BLEED VALVE 170 kPa (1,7 bar) (25 psi)
24 AUXILIARY QUICK COUPLERS – Male / Female 56 ORIFICE – 0,8 mm (0.031 in)
11 LOAD SENSE RELIEF VALVE: 41 PRESSURE REDUCING VALVE -
25 BRAKE RELEASE VALVE – Travel Motor 57 ACCUMULATOR - Nitrogen 1020 kPa
28000 kPa (280 bar) (4060 psi) 630 kPa (6,3 bar) (91 psi) 3200 kPa (32 bar) (464 psi)
(10.2 bar) (148 psi) Precharged
12 PORT RELIEF / ANTI-CAVITATION VALVE (2) - 26 TWO SPEED SHIFT SPOOL – Travel Motor 42 CHECK VALVE: 50 kPa (0,5 bar) (7.25 psi)
58 PORT RELIEF / ANTI-CAVITATION VALVE –
(Boom Cylinder) - 31000 kPa (310 bar) (4496 psi)
43 HYDRAULIC GEAR PUMP (Articulated Boom) - 31000 kPa (310 bar) (4496 psi)
13 PORT RELIEF / ANTI-CAVITATION VALVE (2) - 27 CROSS PORT RELIEF VALVE (Travel Motor)
28000 kPa (280 bar) (4061 psi) 22 L/min (5.8 U.S. gpm) at High Idle 59 PILOT ACTIVATED DIRECTIONAL
(Bucket Cylinder) - 31000 kPa (310 bar) (4496 psi) CONTROL VALVE (Load Holding valve) –
28 COUNTERBALANCE SPOOL (Travel Motor) 44 HYDRAULIC PISTON PUMP Articulated Boom
14 PORT RELIEF / ANTI-CAVITATION VALVE (2) - 144 L/min (38 U.S. gpm) at High Idle
(Arm Cylinder) - 31000 kPa (310 bar) (4496 psi) 60 RELIEF VALVE - (Load Holding valve) –
29 BRAKE RELEASE VALVE - Slew Motor 45 TORQUE LIMITER SUPPLY SPOOL Articulated Boom
15 PORT RELIEF / ANTI-CAVITATION VALVE - 1900 kPa (19 bar) (276 psi) 2000 kPa (20 bar) (290 psi)
(Continuous Flow / Auxiliary Hydraulics - 61 CHECK VALVE With Restriction - (Load
30 CROSS PORT RELIEF VALVE - Slew Motor 46 DESTROKE PISTON
31000 kPa (310 bar) (4496 psi) Holding valve) – Articulated Boom
22000 kPa (220 bar) (3190 psi)
16 ANTI-CAVITATION VALVE 31 ANTI-CAVITATION VALVE – Slew Motor 47 PUMP MARGIN SPOOL: NOTE: Unless otherwise specified
1500 kPa (15 bar) (218 psi) springs have NO significant
pressure value.

Printed in U.S.A. V-1559legend (9-1-15)

95 of 918
ARTICULATED
TRAVEL MOTOR (LH) TRAVEL MOTOR (RH) SWING MOTOR BOOM OFFSET CYLINDER
BOOM CYLINDER
RED RED
D1 D2 D1 D2
2nd AUXILIAYY
REGENERATION BOOM BUCKET ARM BLADE P2 P3 P2 P3 S1

CYLINDER CYLINDER CYLINDERS

25 25 HYDRAULICS
VALVE CYLINDER 26 26
SH
(LH) (RH) P P
29 C D
25 F
BLADE LOCK PG
FEMALE
VALVE(OPTION) 37
50 DB 55
27 27
D B A C
28 28 MALE
C2
E
C A B D M
31 60
E

32 ARTICULATED
LOAD HOLDING 59 LOCK VALVE 36
VALVE (ARM) 23 P4 P3 P4 P3 (OPTIONAL)
LOAD HOLDING
T V2
23
(OPTIONAL) (BACKWARD) A B (FORWARD) (FORWARD) A B (BACKWARD) 61
VALVE (BOOM) pb9
C2 C2
AUXILIARY C
M M
21
E E
21 HYDRAUICS PA 30 PB
18
20
T 20 T V2
A(LH) B(RH)
V2
22 22 35
pb1 pa3
DIRECT TO
19

TANK VALVE 24 E B T P C F A CP T B
D A 2nd AUX
A VALVE
B P

BOOM BUCKET ARM BLADE TRAVEL(LH) TRAVEL(RH) SWING ARTICULATED OFFSET

BOOM
M pb1 pb2 pb3 pb4 pb5 pb6 pb7 pb8 pb9 B9 A9 pb10 B10 A10

P P2

LS LS2

7 7 7 7 7 7 7 7 7 7

Pressure
Sensor
T
ATICULATED
8 T B A T T B A T T B A T T B A T T B T B T B
9 10 11 BOOM REMOTE
VALVE
Dealer Copy -- Not for Resale

H
T1 pa1 12 pa2 pa3 pa4 pa5 15 pa6 pa7 pa8 pa9 pa10
13 14 58 17 16

2 UP P T DOWN 1

pa9 pb9

LOCKOUT / PILOT
P/T BLOCK
40

CONSOLE
2-SPEED
6
PILOT
FILTER
51
4 P 1/4 3/8
A2 A1
38 39 BLADE JOYSTICK
T
42
41 T P TRAVEL VALVE P
2 T P LEFT JOY STICK T P RIGHT JOY STICK

T1
45 UP DOWN

1 2 1

47 T PILOT PV 1 SWING 3 4 ARM 2 1 BUCKET 3 4 BOOM 2 1 L.TRAVEL 2 3 R.TRAVEL 4 pb4 pa4

SUPPLY LEFT RIGHT IN OUT IN DUMP UP DOWN BACKWARD BACKWARD
FORWARD FORWARD
X(LS)
VALVE
B1 pa3 pb3 pa10 pb10
pa2 pb2 56
57
46 pa1 pb1
B2 pb5 pa5

49 A(Open) B(Close) C(CW) D(CCW)

33 33
3
HYDRAULIC 33
Dr1
RESERVOIR 44 43 C1 D1 A1 B1
Dr2 pb8 pa8

56 MOTION
ALARM P
48
E
A2 B2 54 53
C2 D2
52
34
A1 A
HYDROSTATIC S1 L1 L S2 2 pb6 pa6 pb7 pa7 T EPPR VALVE
PUMP

B1 S1 B2 MOTION ALARM
PRESSURE
SH SWITCH
(With Articulated Boom)
E85 (S/N B34S11001 AND ABOVE)
96 of 918 Printable Version Click Here (PRINTED AUGUST 2015)
Printed In U.S.A. V-1559A
HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols

Dealer Copy -- Not for Resale

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

97 of 918 20-10-1 E85 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

Dealer Copy -- Not for Resale

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

98 of 918 20-10-2 E85 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

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

Dealer Copy -- Not for Resale

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

104 of 918 20-10-8 E85 Service Manual

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

Description

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

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

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

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

The hydraulic control valve contains the boom, bucket,

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

Dealer Copy -- Not for Resale

P123146

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

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

The gear pump circuit supplies fluid to the manifold

assembly / accumulator.

105 of 918 20-10-9 E85 Service Manual

Dealer Copy -- Not for Resale

106 of 918 20-10-10 E85 Service Manual

CYLINDER (BOOM) Figure 20-20-3

Testing

Lower the boom / bucket and blade to the ground.

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

Remove both articulated boom cylinders. (See Removal

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

P-86898

Figure 20-20-4

1 Articulated Boom

Dealer Copy -- Not for Resale

P-87019

1
Figure 20-20-2
Articulated Boom
1 P122705

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

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

P122706

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

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

107 of 918 20-20-1 E85 Service Manual

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

Testing (Cont’d)

Figure 20-20-5

2 1

2
P-87000

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

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

Dealer Copy -- Not for Resale

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

S37541

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

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

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

or [Figure 20-20-6].

108 of 918 20-20-2 E85 Service Manual

CYLINDER (BOOM) (CONT’D)

Testing (Cont’d)

Figure 20-20-8

P-86896

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

Dealer Copy -- Not for Resale

Start the engine and move the hydraulic control lever to
the boom cylinder retract position.

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

109 of 918 20-20-3 E85 Service Manual

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

Removal And Installation

Lower the boom / bucket and blade to the ground.

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

Remove both articulated boom cylinders. (See Removal

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

P-86898

Figure 20-20-12
Articulated Boom
1

Dealer Copy -- Not for Resale

P-87019

Figure 20-20-10 1

Articulated Boom
P122705

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

P122706

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

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

110 of 918 20-20-4 E85 Service Manual

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

Removal And Installation (Cont’d)

2
Figure 20-20-13
3

1
P-86839

Figure 20-20-16
P-86896
Articulated Boom

Figure 20-20-14 2
3

Dealer Copy -- Not for Resale

1 1

S37541

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

P-86897 20-15].

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

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

111 of 918 20-20-5 E85 Service Manual

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

Removal And Installation (Cont’d)

Figure 20-20-17
2

1
1

P-87926

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

P-87000 20-19].

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

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

Dealer Copy -- Not for Resale

Figure 20-20-20

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

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

Figure 20-20-18

P-87008

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

P-87001

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

sides.

112 of 918 20-20-6 E85 Service Manual

CYLINDER (BOOM) (CONT’D)

Parts Identification

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

Dealer Copy -- Not for Resale

20. Housing 11
3
3
13
13

15
7
3
12

1 5
14
5

12
16
9

17
5
5
18
16 8
19

113 of 918 20-20-7 E85 Service Manual

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

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

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

Figure 20-20-21

P-87090

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

tubeline.
1
Figure 20-20-24

Dealer Copy -- Not for Resale

P-87085

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

washers and U-bolt. 1

Figure 20-20-22

P-87087
2

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

1 washers and U-bolt.

P-87086

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

[Figure 20-20-22].

114 of 918 20-20-8 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-25

1 1
P-86848

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

P-87088 27].

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

Dealer Copy -- Not for Resale

Figure 20-20-26

1
P-86849

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

P-87089

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

tubeline.

Clamp the base end of the cylinder in a vise.

115 of 918 20-20-9 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-29

P-86850

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

P-87077
Figure 20-20-32

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

from the cylinder housing.

Dealer Copy -- Not for Resale

1
Remove the cylinder housing from the vise.

Figure 20-20-30

P-86851

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

32].

Remove the nut.

P-86852

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

116 of 918 20-20-10 E85 Service Manual

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

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

P-87032

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

P-86853 the piston.

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

Dealer Copy -- Not for Resale

Figure 20-20-34

P-87031

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

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

piston.

117 of 918 20-20-11 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-37

P-87028

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

P-87030 piston.

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

Dealer Copy -- Not for Resale

Figure 20-20-38 1

P-86862

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

P-87029 piston.

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

the piston.

118 of 918 20-20-12 E85 Service Manual

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

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

P-86861

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

P-87011 rod.

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

Dealer Copy -- Not for Resale

Figure 20-20-42

1
1

P-86864

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

P-86860

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

the rod.

119 of 918 20-20-13 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-45 1

P-86867

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

P-86865 Figure 20-20-48

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

Dealer Copy -- Not for Resale

Figure 20-20-46

P-86868

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

P-86866

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

120 of 918 20-20-14 E85 Service Manual

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

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

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

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

Dealer Copy -- Not for Resale

Figure 20-20-50

1
2

P-87015

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

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

[Figure 20-20-50].

Remove the rod from the vise.

121 of 918 20-20-15 E85 Service Manual

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

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for nicks, scratches and other

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

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

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

Figure 20-20-53

Dealer Copy -- Not for Resale

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

122 of 918 20-20-16 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-56

P-86866

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

P-86868 head.

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

Dealer Copy -- Not for Resale

Figure 20-20-57

P-86865

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

P-86867 the head.

Install the snap ring (Item 1) [Figure 20-20-57] into the

head.

123 of 918 20-20-17 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-60 1

1
P86860

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

P-86864 the rod.

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

Dealer Copy -- Not for Resale

Figure 20-20-61

P-87011

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

the piston.

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

124 of 918 20-20-18 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-64

1 P-87029

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

P-86862 piston.

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

Dealer Copy -- Not for Resale

Figure 20-20-65

P-87030

Figure 20-20-68
P-87028

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

piston.

P-87031

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

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

125 of 918 20-20-19 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-69 2

1
P-86853

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

P-87032
Figure 20-20-72

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

piston.

Dealer Copy -- Not for Resale

Figure 20-20-70
1

2
P-86851

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

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

126 of 918 20-20-20 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-73

1
P-87077

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

P-86850 the cylinder housing.

Figure 20-20-76
Install the set screw (Item 1) [Figure 20-20-73] into the
nut. 2

Dealer Copy -- Not for Resale

Use a center punch to deform the threads of the set
screw bore.
1
Remove the rod end from the vise.
2
Figure 20-20-74

2
P-86849

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

[Figure 20-20-76].

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

torque.
1
P-87013

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

74].

127 of 918 20-20-21 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-77

P-87087

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

P-87089 20-20-79].

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

Dealer Copy -- Not for Resale

Figure 20-20-78
1

1
2

P-87090

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

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

128 of 918 20-20-22 E85 Service Manual

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

Assembly (Cont’d)
1
Figure 20-20-81 2

P-87014

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

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

S37544 Start the engine and fully retract the cylinder rod.

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

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

131 of 918 20-21-1 E85 Service Manual

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

Testing (Cont’d)

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

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

Start the engine and retract the cylinder.

1
If there is any leakage from the base end fitting, remove
the cylinder for repair or replacement.

Dealer Copy -- Not for Resale

P-86830

Figure 20-21-6
Articulated Boom

S37542

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

20-21-5] from the base end of the cylinder.

132 of 918 20-21-2 E85 Service Manual

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

Removal And Installation 1

Lower the boom / bucket and blade to the ground.

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

Figure 20-21-8

P-887020

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

Figure 20-21-11

Dealer Copy -- Not for Resale

P-87019

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

P-87076

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

21-11].

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

S37544

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

133 of 918 20-21-3 E85 Service Manual

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

Removal And Installation (Cont’d) 1

Figure 20-21-12

P-87078

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

Figure 20-21-15
Remove the hoses (Item 1) [Figure 20-21-12].
1

Dealer Copy -- Not for Resale

Figure 20-21-13

2 3

P-87016

P-87093 Figure 20-21-16

Articulated Boom
Remove the hose (Item 1) [Figure 20-21-13].
1
3

P123147

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

134 of 918 20-21-4 E85 Service Manual

CYLINDER (ARM) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-21-17

1
P-87095

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

Dealer Copy -- Not for Resale

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

135 of 918 20-21-5 E85 Service Manual

CYLINDER (ARM) (CONT’D)

Parts Identification

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

Dealer Copy -- Not for Resale

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

24
7
7
25
23 8
26

7 MS-2793S

136 of 918 20-21-6 E85 Service Manual

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

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

Hold the hydraulic cylinder over a drain pan and slowly 1

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

Figure 20-21-18

P-87098

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

tubeline.
1 Figure 20-21-21

Dealer Copy -- Not for Resale

P-87096

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

washers and U-bolt.

Figure 20-21-19

P-87096

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

2 washers and U-bolt.

1
1

P-87097

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

[Figure 20-21-19].

137 of 918 20-21-7 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-21-22

1
P-86848
2

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

1
P-87099 24].

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

Dealer Copy -- Not for Resale

Figure 20-21-23

1
P-86849

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

P-87100

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

tubeline.

Clamp the base end of the cylinder in a vise.

138 of 918 20-21-8 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-21-26

P-86850

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

P-87077
Figure 20-21-29

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

from the cylinder housing. 1

Dealer Copy -- Not for Resale

Remove the cylinder housing from the vise.

Figure 20-21-27

P-86851

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

29].

Remove the nut.

P-86852

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

Support the end of the rod with a block.

139 of 918 20-21-9 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-21-30
1

P-87032

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

P-86853 the piston.

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

Dealer Copy -- Not for Resale

Figure 20-21-31

1
1

P-87031

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

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

piston.

140 of 918 20-21-10 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-21-34

P-87028

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

P-87030 piston.

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

Dealer Copy -- Not for Resale

Figure 20-21-35 1

P-86862

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

P-87029 piston.

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

the piston.

141 of 918 20-21-11 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-21-38 1

P-86861

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

P-87011 rod.

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

Dealer Copy -- Not for Resale

Figure 20-21-39

1 1

P-86864

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

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

the rod.

142 of 918 20-21-12 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-21-42 1

P-86867

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

P-86865 Figure 20-21-45

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

Dealer Copy -- Not for Resale

Figure 20-21-43

1
P-86868

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

P-86866

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

143 of 918 20-21-13 E85 Service Manual

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

Disassembly (Cont’d) 2

Figure 20-21-46
1

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

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

Dealer Copy -- Not for Resale

Figure 20-21-47

1
2

P-87015

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

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

[Figure 20-21-47].

Remove the rod from the vise.

144 of 918 20-21-14 E85 Service Manual

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

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for nicks, scratches and other

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

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

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

Figure 20-21-50

Dealer Copy -- Not for Resale

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

145 of 918 20-21-15 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-21-53

P-86866

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

P-86868 head.

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

Dealer Copy -- Not for Resale

Figure 20-21-54

P-86865

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

P-86867 the head.

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

head.

146 of 918 20-21-16 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-21-57 1

1
P86860

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

P-86864 rod.

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

Dealer Copy -- Not for Resale

Figure 20-21-58 1

P-87011

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

the piston.

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

147 of 918 20-21-17 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-21-61

1 1

P-87029

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

P-86862 piston.

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

Dealer Copy -- Not for Resale

Figure 20-21-62

1
1

P-87030

Figure 20-21-65
P-87028

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

piston.

P-87031

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

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

148 of 918 20-21-18 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-21-66 2

1
1
P-86853

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

P-87032
Figure 20-21-69

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

piston.

Dealer Copy -- Not for Resale

Figure 20-21-67
1

1
P-86851

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

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

149 of 918 20-21-19 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-21-70

1 2

1
P-87077

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

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

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

Dealer Copy -- Not for Resale

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

2
P-86849

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

[Figure 20-21-73].

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

2
P-87013

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

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

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

71].

150 of 918 20-21-20 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-21-74

1
1

P-87098

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

P-86847 tubeline.

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

Dealer Copy -- Not for Resale

Figure 20-21-75

2 1

2
2

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

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

151 of 918 20-21-21 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-21-78
1
2

P-36183

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

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

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

21-78].

Dealer Copy -- Not for Resale

Figure 20-21-79

P-87014

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

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

152 of 918 20-21-22 E85 Service Manual

CYLINDER (BOOM SWING) Figure 20-22-3

Testing

Swing the boom to the right, fully extending the boom

offset cylinder.

Lower the boom / bucket to the ground.

Stop the engine.

Remove the left upperstructure side cover. (See Removal

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

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

cylinder and the excavator frame.
2
Tilt the cab. (See Raising And Lowering on Page 10-210-
1.)

Dealer Copy -- Not for Resale

Figure 20-22-4

P-87409
1

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

22-1].

Figure 20-22-2

P-87412

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

Install a plug on the hose.

Lower the cab.

Start the engine.

P-87410 Retract the cylinder.

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

153 of 918 20-22-1 E85 Service Manual

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

Removal And Installation

Swing the upperstructure 90° to the left or right.

Swing the boom to the right, fully extending the boom

offset cylinder.

Lower the boom / bucket to the ground.

Stop the engine.

1
Figure 20-22-5

P-87411

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

Figure 20-22-8

Dealer Copy -- Not for Resale

P-87409

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

22-5].

Figure 20-22-6 1

P-87417

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

[Figure 20-22-8].

Tilt the cab. (See Raising And Lowering on Page 10-210-

1.)

P-87410

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

154 of 918 20-22-2 E85 Service Manual

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

Removal And Installation (Cont’d)

2
Figure 20-22-9

1
1
1

P-87413

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

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

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

Dealer Copy -- Not for Resale

Figure 20-22-10

1
1

P-87415

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

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

device on the rod end of the cylinder.

155 of 918 20-22-3 E85 Service Manual

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

Removal And Installation (Cont’d)

Figure 20-22-13

1 1

P-89345

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

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

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

Dealer Copy -- Not for Resale

Remove the cable tie.

Figure 20-22-14

P-89347

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

Remove the cylinder.

P-89346

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

Remove the cable tie.

156 of 918 20-22-4 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D)

Parts Identification

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

Dealer Copy -- Not for Resale

5
8
9
10
9
9
11

1
12
13

15 1

16
1

MS-2795S

157 of 918 20-22-5 E85 Service Manual

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

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074- O-ring Seal Hook

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

1 P-87421

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

Figure 20-22-20

Dealer Copy -- Not for Resale

1
P-87419
1

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

cylinder in a vise.

Figure 20-22-18

1 P-87422

Insert the adjustable gland nut wrench into the notches

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

P-87420

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

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

158 of 918 20-22-6 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-22-21
2

1
1

P-87425

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

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

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

Dealer Copy -- Not for Resale

Remove the cylinder from the vise.

Figure 20-22-22

P-87390

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

P-87424

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

159 of 918 20-22-7 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-22-25

1 P-87429

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

P-87428
Figure 20-22-28

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

Dealer Copy -- Not for Resale

Figure 20-22-26

1
1

P-87430

Figure 20-22-42

P-87443

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

164 of 918 20-22-12 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-45

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander 1

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for nicks, scratches and other

damage. Replace any damaged parts.
P-87443
Always install new O-rings and seals during assembly.

Lubricate all O-ring and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-22-45] into the
installation. head.

Figure 20-22-44 Figure 20-22-46

Dealer Copy -- Not for Resale

P-87445 P-87442

Install the bushing (Item 1) and seal (Item 2) [Figure 20- Install the snap ring (Item 1) [Figure 20-22-46].
22-44]. (Both sides)

165 of 918 20-22-13 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-22-47
1

P-87439
2

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

P-87444
Figure 20-22-50

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

[Figure 20-22-47].

Dealer Copy -- Not for Resale

Figure 20-22-48
1

P-87438

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

P-87440 Figure 20-22-51

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

P-87437

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

166 of 918 20-22-14 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-22-52
1

P-87434

Install the O-ring (Item 1) [Figure 20-22-54] in the piston.

P-87436
Figure 20-22-55

Install the O-ring (Item 1) [Figure 20-22-52].

Dealer Copy -- Not for Resale

Clamp the rod end in a vise. Support the rod with a block.

Figure 20-22-53 1

P-87446

Install the seal (Item 1) [Figure 20-22-55].

1
P-87435

Install the head (Item 1) [Figure 20-22-53].

167 of 918 20-22-15 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-58

Assembly (Cont’d)

Figure 20-22-56

P-87431

Install the wear ring (Item 1) [Figure 20-22-58].

P-87433
Figure 20-22-59

Figure 20-22-57

Dealer Copy -- Not for Resale

1
1

P-87430

P-87439
Install the seal (Item 1) [Figure 20-22-59].

Install the O-ring (Item 1) [Figure 20-22-56] and seal

(Item 1) [Figure 20-22-57].

168 of 918 20-22-16 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-62

Assembly (Cont’d)

Figure 20-22-60

P-87428

1
Install the set screw (Item 1) [Figure 20-22-61].
P-87429
Use a center punch to deform the threads of the set
screw bore.
Install the piston (Item 1) [Figure 20-22-60].
Figure 20-22-63

Dealer Copy -- Not for Resale

Figure 20-22-61
1

1
P-87426
P-87427

Remove the rod end (Item 1) [Figure 20-22-63] from the

Install the nut (Item 1) [Figure 20-22-61]. vise.

Tighten the nut until the bore (Item 2) [Figure 20-22-61]

of the set screw is aligned with the groove (Item 2)
[Figure 20-22-60] of the rod.

169 of 918 20-22-17 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-66

Assembly (Cont’d)

Figure 20-22-64

2 1

P-87423

Install the rod assembly (Item 1) [Figure 20-22-66] into

P-87425 the housing.

Figure 20-22-67
Install the bushing (Item 1) and seal (Item 2) [Figure 20-
22-64] (both sides) into the rod end.

Dealer Copy -- Not for Resale

Figure 20-22-65 1

P-87422
1

Tighten the head (Item 1) [Figure 20-22-67].

P-87424

Install the fitting (Item 1) [Figure 20-22-65].

Clamp the base end of the cylinder housing in a vise.

170 of 918 20-22-18 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D)

Assembly (Cont’d)

Figure 20-22-68

P-87421

Bend the lock ring tab (Item 1) [Figure 20-22-68] into the
groove on the head.

Dealer Copy -- Not for Resale

Figure 20-22-69

P-87420

Remove the cylinder (Item 1) [Figure 20-22-69] from the

vise.

171 of 918 20-22-19 E85 Service Manual

Dealer Copy -- Not for Resale

172 of 918 20-22-20 E85 Service Manual

CYLINDER (BUCKET) Removal And Installation

Testing Fully retract the bucket cylinder.

Fully retract the bucket and arm cylinders. Lower the boom until the bucket is on the ground.

Lower the boom to the ground. Figure 20-23-3

With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.

Figure 20-23-1 1

1
P-87021

Dealer Copy -- Not for Resale

Support the arm with a chain hoist (Item 1) [Figure 20-
23-3].
P-86828
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
Remove the hydraulic hose (Item 1) [Figure 20-23-1]
from the base end of the bucket cylinder.

Figure 20-23-2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
1 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-86829

Install a plug (Item 1) [Figure 20-23-2] on the hose.

Start the engine and retract the bucket cylinder.

If there is any oil leakage from the base end fitting (Item
2) [Figure 20-23-2] on the bucket cylinder, remove the
cylinder for repair or replacement.

173 of 918 20-23-1 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-6

Removal And Installation (Cont’d)

2
Figure 20-23-4

2 1

P-86832

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

P-86828 23-6] from the base end pivot pin.

Figure 20-23-7
Remove the hose (Item 1) [Figure 20-23-4] from the
base end.

Dealer Copy -- Not for Resale

Remove the hose (Item 2) [Figure 20-23-4] from the rod
end. 2

Figure 20-23-5

P-86833

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

23-7] from the rod end pivot pin.

P-86834

Install a strap (Item 1) [Figure 20-23-5] and a lifting

device on the cylinder.

174 of 918 20-23-2 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-10

Removal And Installation (Cont’d)

Figure 20-23-8
1

1 P-86835

Remove the base end pivot pin (Item 1) [Figure 20-23-

P-86836 10] and the shims.

Figure 20-23-11
Remove the rod end pivot pin (Item 1) [Figure 20-23-8].

Dealer Copy -- Not for Resale

Figure 20-23-9

P-86838
1

P-86837 Remove the cylinder (Item 1) [Figure 20-23-11].

Remove the shims (Item 2) [Figure 20-23-11] (Both

Remove the shims (Item 1) [Figure 20-23-9] (Both sides).
sides).

175 of 918 20-23-3 E85 Service Manual

CYLINDER (BUCKET) (CONT’D)

Parts Identification

1. Bolt
2. Lockwasher 1
3. O-ring
4. Tubeline 2
5. Seal 4
6. Grease Fitting 3
8 3
7. Bushing
6
8. U-Bolt
9 1
9. Nut
10. Housing 2 2
11. Set Screw
7
12. Piston 4
13. Wear Ring
14. Seal Assembly 10
1
15. Back-up Ring 2 8
16. Cushion Ring 2 5
17 Snap Ring
18. Head
21
19. Wiper Seal
20. Rod
11

Dealer Copy -- Not for Resale

21. Spacer
3 13
3 13
15
16
3 9
17 12
5
1 14
5
3

3
15
7

18
5
5
19
17
6
20

7
5
MS-2794S

176 of 918 20-23-4 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-14

Disassembly

Use the following tools to disassemble the cylinder:

1
MEL1074 - O-ring Seal Hook

Hold the hydraulic cylinder over a drain pan and slowly

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

Figure 20-23-12

P-86843

Remove the O-ring (Item 1) [Figure 20-23-14] from the

spacer.

Figure 20-23-15
1

Dealer Copy -- Not for Resale

P-86839

Remove the two nuts (Item 1) [Figure 20-23-12], lock

washers and U-bolt.

Figure 20-23-13

P-86842

Remove the O-ring (Item 1) [Figure 20-23-15] from the

tubeline.

1 1

P-86840

Remove the four bolts (Item 1), tubeline (Item 2) [Figure

20-23-13] and spacer.

177 of 918 20-23-5 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-18

Disassembly (Cont’d)

Figure 20-23-16

1 1

P86847

2
Remove the O-ring (Item 1) [Figure 20-23-18] from the
P-86844 tubeline.

Clamp the base end of the cylinder in a vise.

Remove the two nuts (Item 1), lock washers and U-bolt
(Item 2) [Figure 20-23-16]. Figure 20-23-19

Dealer Copy -- Not for Resale

Figure 20-23-17

1
2
1

1
P-86848

P-86845
Support the cylinder with a block (Item 1) [Figure 20-23-
19].
Remove the four bolts (Item 1), lock washers and tubeline
(Item 2) [Figure 20-23-17].

178 of 918 20-23-6 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-22

Disassembly (Cont’d)
1
Figure 20-23-20

P-86852

1 Clamp the rod end (Item 1) [Figure 20-23-22] in a vise.

P-86849 Support the end of the rod with a block.

Figure 20-23-23
Remove the eight bolts (Item 1) [Figure 20-23-20].

Dealer Copy -- Not for Resale

Figure 20-23-21

P-86850
1

P-87077 Remove the set screw (Item 1) [Figure 20-23-23].

Remove the rod assembly (Item 1) [Figure 20-23-21]

from the cylinder housing.

Remove the cylinder housing from the vise.

179 of 918 20-23-7 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-26

Disassembly (Cont’d)

Figure 20-23-24
1

P-86542

Remove the seal (Item 1) [Figure 20-23-26] from the

P-86851 piston.

Figure 20-23-27
Apply moderate heat to the nut (Item 1) [Figure 20-23-
24].

Dealer Copy -- Not for Resale

Remove the nut. 1

Figure 20-23-25

P-87032

Remove the wear ring (Item 1) [Figure 20-23-27] from

the piston.

P-86853

Remove the piston (Item 1) [Figure 20-23-25].

180 of 918 20-23-8 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-30

Disassembly (Cont’d)

Figure 20-23-28

P-87029

Remove the wear ring (Item 1) [Figure 20-23-30] from

P-87031 the piston.

Figure 20-23-31
Remove the seal (Item 1) [Figure 20-23-28].

Dealer Copy -- Not for Resale

Figure 20-23-29

P-87028

P-87030 Remove the seal (Item 1) [Figure 20-23-31] from the

piston.

Remove the O-ring (Item 1) [Figure 20-23-29] from the

piston.

181 of 918 20-23-9 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-34

Disassembly (Cont’d)

Figure 20-23-32
1

P-86860

Remove the cushion ring (Item 1) [Figure 20-23-34] from

P-86862 the rod.

Figure 20-23-35
Remove the O-ring (Item 1) [Figure 20-23-32] from the
piston.

Dealer Copy -- Not for Resale

1
Figure 20-23-33

P-86861

Remove the head (Item 1) [Figure 20-23-35] from the

P-87011 rod.

Remove the back-up ring (Item 1) [Figure 20-23-33] from

the piston.

182 of 918 20-23-10 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-38

Disassembly (Cont’d)

Figure 20-23-36

P-86866

Remove the O-ring (Item 1) [Figure 20-23-38].

P-86864
Figure 20-23-39

Remove the O-ring (Item 1) [Figure 20-23-36].

Dealer Copy -- Not for Resale

Figure 20-23-37

P-86867

Remove the snap ring (Item 1) [Figure 20-23-39].

P-86865

Remove the back-up ring (Item 1) [Figure 20-23-37].

183 of 918 20-23-11 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-42

Disassembly (Cont’d)

Figure 20-23-40

1 1
2

P-86870

P-86868 Remove the snap ring (Item 1) and bushing (Item 2)

[Figure 20-23-42].

Remove the wiper seal (Item 1) [Figure 20-23-40]. Remove the rod from the vise.

Figure 20-23-41 Figure 20-23-43

Dealer Copy -- Not for Resale

1 1

2
1

P-87754 P-887014

Remove the two seals (Item 1) [Figure 20-23-41]. Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-23-43] from the rod end.

184 of 918 20-23-12 E85 Service Manual

CYLINDER (BUCKET) (CONT’D)

Disassembly (Cont’d)

Figure 20-23-44

2
1

P-87015

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

2) [Figure 20-23-44] from the base end.

Dealer Copy -- Not for Resale

185 of 918 20-23-13 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-46

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for nicks, scratches and other

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

Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-23-46] into the head.

Clamp the rod end in a vise. Figure 20-23-47

Figure 20-23-45

Dealer Copy -- Not for Resale

P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-23-47] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-23-45].

186 of 918 20-23-14 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-50

Assembly (Cont’d)

Figure 20-23-48

P-86866

Install the O-ring (Item 1) [Figure 20-23-50] onto the

P-86868 head.

Figure 20-23-51
Install the wiper seal (Item 1) [Figure 20-23-48] into the
head.

Dealer Copy -- Not for Resale

Figure 20-23-49

P-86865

Install the back-up ring (Item 1) [Figure 20-23-51] onto

P-86867 the head.

Install the snap ring (Item 1) [Figure 20-23-49] into the

head.

187 of 918 20-23-15 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-54

Assembly (Cont’d)

Figure 20-23-52 1

1
P86860

Install the cushion ring (Item 1) [Figure 20-23-54] on the

P-86864 rod.

Figure 20-23-55
Install the O-ring (Item 1) [Figure 20-23-52].

Dealer Copy -- Not for Resale

Figure 20-23-53

P-87011

P-86861 Install the back-up ring (Item 1) [Figure 20-23-55] in the

piston.

Install the head (Item 1) [Figure 20-23-53] onto the rod.

188 of 918 20-23-16 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-58

Assembly (Cont’d)

Figure 20-23-56

1
1

P-87029

Install the wear ring (Item 1) [Figure 20-23-58] onto the

P-86862 piston.

Figure 20-23-59
Install the O-ring (Item 1) [Figure 20-23-56] into the
piston.

Dealer Copy -- Not for Resale

Figure 20-23-57

P-87030

Figure 20-23-60
P-87028

Install the seal (Item 1) [Figure 20-23-57] onto the

piston.

P-87031

Install the O-ring (Item 1) [Figure 20-23-59] and seal

(Item 1) [Figure 20-23-60] onto the piston.

189 of 918 20-23-17 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-63

Assembly (Cont’d)
2
Figure 20-23-61

1
P-86853

Install the piston (Item 1) [Figure 20-23-63] onto the rod.

P-87032
Figure 20-23-64

Install the wear ring (Item 1) [Figure 20-23-61] onto the

piston.

Dealer Copy -- Not for Resale

Figure 20-23-62

1 1

P-86851

Install the nut (Item 1) [Figure 20-23-64].

P-87033 Tighten the nut until the bore (Item 2) [Figure 20-23-63]
of the set screw is aligned with the groove (Item 2)
[Figure 20-23-64] of the rod.
Install the seal (Item 1) [Figure 20-23-62] onto the
piston.

190 of 918 20-23-18 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-67

Assembly (Cont’d)

Figure 20-23-65

1
P-87077

Install the rod assembly (Item 1) [Figure 20-23-67] into

P-86850 the cylinder housing.

Figure 20-23-68
Install the set screw (Item 1) [Figure 20-23-65] into the
nut. 2

Dealer Copy -- Not for Resale

Use a center punch to deform the threads of the set
screw bore. 1

Remove the rod end from the vise.

2
Figure 20-23-66

2
P-86849

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

[Figure 20-23-68].

Tighten the bolts to 70 - 79 N•m (52 - 58 ft-lb) torque.

1
P-87013

Support the housing with a block (Item 1) [Figure 20-23-

66].

191 of 918 20-23-19 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-71

Assembly (Cont’d)

Figure 20-23-69
2

1
P-86844

1
Install the U-bolt (Item 1), lock washers and nuts (Item 2)
P-86847 [Figure 20-23-71].

Figure 20-23-72
Install the O-ring (Item 1) [Figure 20-23-69] into the
tubeline.

Dealer Copy -- Not for Resale

Figure 20-23-70

P-86842

2
Install the O-ring (Item 1) [Figure 20-23-72] into the
P-86845 tubeline.

Install the tubeline (Item 1), lock washers and bolts (Item
2) [Figure 20-23-70] onto the cylinder housing.

192 of 918 20-23-20 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-75

Assembly (Cont’d)

Figure 20-23-73

1
2
1

P-86839

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

P-86843 23-75].

Figure 20-23-76
Install the O-ring (Item 1) into the spacer (Item 2) [Figure
20-23-73].
1

Dealer Copy -- Not for Resale

Figure 20-23-74 2

3 3
P-87014

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

P-86840 23-76] (both sides) into the rod end of the cylinder.

Install the spacer (Item 1) and tubeline (Item 2) using the

four bolts (Item 3) [Figure 20-23-74] and lock washers.

193 of 918 20-23-21 E85 Service Manual

CYLINDER (BUCKET) (CONT’D)

Assembly (Cont’d)

Figure 20-23-77

1
2

P-36183

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

23-77] (both sides) into the base end of the cylinder.

Dealer Copy -- Not for Resale

194 of 918 20-23-22 E85 Service Manual

CYLINDER (BLADE)

Testing

Put the bucket on the ground.

Stop the engine.

With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.

Figure 20-24-1

Dealer Copy -- Not for Resale

P-86489

Remove the hydraulic hose (Item 1) [Figure 20-24-1]

from the base end of the blade cylinders.

Figure 20-24-2

P-86490

Install a plug (Item 1) [Figure 20-24-2] on the hose.

Start the engine and retract the blade cylinders.

If there is any oil leakage from the base end fitting (Item
2) [Figure 20-24-2] of the blade cylinders, remove the
cylinder for repair or replacement.

195 of 918 20-24-1 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-4

Removal And Installation

NOTE: The right blade cylinder is shown. The 2

procedure is the same for the left blade
cylinder.

Put the blade on the floor.

1
With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.

IMPORTANT P-86491

When repairing hydrostatic and hydraulic systems, Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-
clean the work area before disassembly and keep all 24-4] from the base end retaining pin.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-24-5
damage the system.
I-2003-0888

Dealer Copy -- Not for Resale

2
Figure 20-24-3

2
1

1
P-86492

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

24-5] from the rod end retaining pin.
P-86489

Remove the hose (Item 1) [Figure 20-24-3] from the

base end of the cylinder.

Remove the hose (Item 2) [Figure 20-24-3] from the rod

end of the cylinder.

196 of 918 20-24-2 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-8

Removal And Installation (Cont’d)

Figure 20-24-6

P-86496

Figure 20-24-9
P-86493

Figure 20-24-7

Dealer Copy -- Not for Resale

1 1

P-86495

Remove the retaining pins (Item 1) [Figure 20-24-8] and

P-86494 [Figure 20-24-9].

Install a sling (Item 1) [Figure 20-24-6] and [Figure 20-

24-7] on the rod end and base end of the cylinder.

197 of 918 20-24-3 E85 Service Manual

CYLINDER (BLADE) (CONT'D)

200 of 918 20-24-6 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-17

Disassembly (Cont’d)

Figure 20-24-15

P-86504

Remove the set screw (Item 1) [Figure 20-24-17].

P-86503
Figure 20-24-18

Remove the rod assembly (Item 1) [Figure 20-24-15]

from the housing.
1

Dealer Copy -- Not for Resale

Figure 20-24-16

P-86506

1
Apply moderate heat to the nut (Item 1) [Figure 20-24-
18].
P-86505
Remove the nut.

Clamp the rod end in a vise. Support the end of the rod
with a block (Item 1) [Figure 20-24-16].

201 of 918 20-24-7 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-21

Disassembly (Cont’d)

Figure 20-24-19

P-86541

Remove the wear ring (Item 1) [Figure 20-24-21].

P-86508
Figure 20-24-22

Remove the piston (Item 1) [Figure 20-24-19].

Dealer Copy -- Not for Resale

Figure 20-24-20

P-86548

Remove the back-up ring (Item 1) [Figure 20-24-22].

P-86542
NOTE: The slipper seal consists of four separate
pieces that are removed individually.
Remove the seal (Item 1) [Figure 20-24-20].

202 of 918 20-24-8 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-25

Disassembly (Cont’d)

Figure 20-24-23

P-86532

Remove the slipper seal (Item 1) [Figure 20-24-25].

P-86508
Figure 20-24-26

Remove the wear ring (Item 1) [Figure 20-24-23].

Dealer Copy -- Not for Resale

Figure 20-24-24

P-86531

Remove the seal (Item 1) [Figure 20-24-26].

P-86533

Remove the back-up ring (Item 1) [Figure 20-24-24].

203 of 918 20-24-9 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-29

Disassembly (Cont’d)

Figure 20-24-27 1

P-86517

Remove the back-up ring (Item 1) [Figure 20-24-29].

P-86515
Figure 20-24-30

Remove the back-up ring (Item 1) [Figure 20-24-27] from

the inside of the piston.
1

Dealer Copy -- Not for Resale

Figure 20-24-28

P-86518
1

Remove the head (Item 1) [Figure 20-24-30] from the

cylinder rod.
P-86516

Remove the O-ring (Item 1) [Figure 20-24-28].

204 of 918 20-24-10 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-33

Disassembly (Cont’d)

Figure 20-24-31

P-86524
1

Remove the O-ring (Item 1) [Figure 20-24-33].

P-86519
Figure 20-24-34

Remove the O-ring (Item 1) [Figure 20-24-31] from the

head.
1

Dealer Copy -- Not for Resale

Figure 20-24-32

P-86525

Remove the snap ring (Item 1) [Figure 20-24-34] from

the inside of the head.
P-86523

Remove the back-up ring (Item 1) [Figure 20-24-32].

205 of 918 20-24-11 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-37

Disassembly (Cont’d)

Figure 20-24-35

P-86529

Remove the seal (Item 1) [Figure 20-24-37].

P-86508
Figure 20-24-38

Remove the wiper seal (Item 1) [Figure 20-24-35].

Dealer Copy -- Not for Resale

Figure 20-24-36
2 1

1 P-86531

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

P-86527 [Figure 20-24-38].

Remove the seal (Item 1) [Figure 20-24-36].

206 of 918 20-24-12 E85 Service Manual

CYLINDER (BLADE) (CONT'D)

Disassembly (Cont’d)

Figure 20-24-39

P-86544

Remove the bushing (Item 1) [Figure 20-24-39] from the

rod.

Dealer Copy -- Not for Resale

Figure 20-24-40

P-86533

Remove the bushing (Item 1) [Figure 20-24-40] from the

base end.

207 of 918 20-24-13 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-42

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

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

Inspect the cylinder parts for nicks, scratches and other

damage. Replace any damaged parts.
P-86544
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-24-42] into the
assembly. rod.

Figure 20-24-41 Figure 20-24-43

Dealer Copy -- Not for Resale

2 1

P-86543 P-86530

Install the bushing (Item 1) [Figure 20-24-41] into the Install the bushing (Item 1) and snap ring (Item 2)
base end of the housing. [Figure 20-24-43] into the head.

208 of 918 20-24-14 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-46

Assembly (Cont’d)

Figure 20-24-44

1 1

P-86526

Install the wiper seal (Item 1) [Figure 20-24-46].

P-86529
Figure 20-24-47

Install the seal (Item 1) [Figure 20-24-44].

Dealer Copy -- Not for Resale

Figure 20-24-45

1
1

P-86525

Install the snap ring (Item 1) [Figure 20-24-47].

P-86527

Install the seal (Item 1) [Figure 20-24-45].

209 of 918 20-24-15 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-50

Assembly (Cont’d)

Figure 20-24-48

P-86519

Install the O-ring (Item 1) [Figure 20-24-50].

P-8624
Install the rod end in a vise.

Install the O-ring (Item 1) [Figure 20-24-48]. Figure 20-24-51

Dealer Copy -- Not for Resale

Figure 20-24-49

P-86518

P-86523
Install the head (Item 1) [Figure 20-24-51] onto the
cylinder rod.
Install the back-up ring (Item 1) [Figure 20-24-49].

210 of 918 20-24-16 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-54

Assembly (Cont’d)

Figure 20-24-52
1

P-86515

Install the back-up ring (Item 1) [Figure 20-24-54].

P-86517
Figure 20-24-55

Install the back-up ring (Item 1) [Figure 20-24-52].

Dealer Copy -- Not for Resale

Figure 20-24-53

1
1

P-86531

Install the seal (Item 1) [Figure 20-24-55].

P-86516

Install the O-ring (Item 1) [Figure 20-24-53].

211 of 918 20-24-17 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-58

Assembly (Cont’d)

Figure 20-24-56
1

P-86540

Install the wear ring (Item 1) [Figure 20-24-58].

P-86532
Figure 20-24-59

Install the slipper seal (Item 1) [Figure 20-24-56].

Dealer Copy -- Not for Resale

Figure 20-24-57

P-86548

Install the back-up ring (Item 1) [Figure 20-24-59].

P-86533

Install the back-up ring (Item 1) [Figure 20-24-57].

212 of 918 20-24-18 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-62

Assembly (Cont’d)

Figure 20-24-60

1
2

P-86507

Install the piston (Item 1) [Figure 20-24-62] onto the

P-86541 cylinder rod.

Figure 20-24-63
Install the wear ring (Item 1) [Figure 20-24-60].

Dealer Copy -- Not for Resale

Figure 20-24-61

P-86506

P-86542 Install the nut (Item 1) [Figure 20-24-63].

Tighten the nut until the bore of the set screw is aligned
Install the seal (Item 1) [Figure 20-24-61]. with the groove (Item 2) [Figure 20-24-62] of the rod.

213 of 918 20-24-19 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-66

Assembly (Cont’d)

Figure 20-24-64

P103657

Install the head (Item 1) [Figure 20-24-66] onto the

P-86504 housing.

Figure 20-24-67
Install the set screw (Item 1) [Figure 20-24-64].

Dealer Copy -- Not for Resale

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

Remove the rod assembly from the vise.

Clamp the base end of the cylinder housing in a vise.

Figure 20-24-65
1

P-86501
1

Bend the lock ring tab (Item 1) [Figure 20-24-67] into the
groove on the head.

P-86503

Install the rod assembly (Item 1) [Figure 20-24-65] into

the housing.

214 of 918 20-24-20 E85 Service Manual

CYLINDER (BLADE) (CONT'D)

Assembly (Cont’d)

Figure 20-24-68

P-86500

Install the fittings (Item 1) [Figure 20-24-68] into the

housing.

Dealer Copy -- Not for Resale

215 of 918 20-24-21 E85 Service Manual

Dealer Copy -- Not for Resale

216 of 918 20-24-22 E85 Service Manual

CYLINDER (ARTICULATED BOOM) Figure 20-25-3

Testing
2
NOTE: Both cylinders share the same rod end and
base end pivot pin. Removing either pivot pin
will loosen both cylinders from the articulated
boom.

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic 1
pressure.

Figure 20-25-1 S37546

Remove the stopper (Item 1), the shim and the rod end
1 pivot pin (Item 2) [Figure 20-25-3].

Figure 20-25-4

Dealer Copy -- Not for Resale

1
S37544 2

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

25-1].

Figure 20-25-2 S37547

Lower both cylinders (Item 1) [Figure 20-25-4]. Remove

3 the shims.

Start the engine and fully retract the cylinder rods (Item
1 2) [Figure 20-25-4].

Stop the engine. Relieve hydraulic pressure.

S37545

Install a sling (Item 1) [Figure 20-25-2] and lifting device

to the rod end of both cylinders.

Remove the nuts (Item 2) and bolt (Item 3) [Figure 20-

25-2].

217 of 918 20-25-1 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D)

Testing (Cont’d)

Figure 20-25-5

Dealer Copy -- Not for Resale

S37548

Remove the hose (Item 1) [Figure 20-25-5] from the

base end of both cylinders. Cap the hoses.

Start the engine and retract the cylinders.

If there is any oil leakage from the base end fittings (Item
1) [Figure 20-25-5], remove the cylinder for repair or
replacement.

218 of 918 20-25-2 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-8

Removal And Installation 1

NOTE: Both cylinders share the same rod end and 5
2
base end pivot pin. Removing either pivot pin
4
will loosen both cylinders from the articulated
boom.

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic 3
pressure.

Figure 20-25-6 S37650

Remove the hose (Item 1) [Figure 20-25-8] (both sides).

1
Remove the bolt (Item 2) [Figure 20-25-8] and washer
(both sides).

Remove the adapter (Item 3) from the fitting (Item 4)

Dealer Copy -- Not for Resale

[Figure 20-25-8] (both sides).

Remove the valve (Item 5) [Figure 20-25-8] from the

cylinder housing (both sides).

Remove the nuts (Item 2) and bolt (Item 3) [Figure 20-

S37544 25-7].

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

25-6].

Figure 20-25-7

S37545

Install a sling (Item 1) [Figure 20-25-7] and lifting device

to the rod end of both cylinders.

219 of 918 20-25-3 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-11

Removal And Installation (Cont’d)

1
3
Figure 20-25-9

2
4

2 5

S37653
1

Support both cylinders (Item 1) [Figure 20-25-11] so the

S37546 cylinders will not fall when the pivot pin is removed.

Remove the nuts (Item 2) and bolt (Item 3) [Figure 20-

Remove the stopper (Item 1), the shim and the rod end 25-11].
pivot pin (Item 2) [Figure 20-25-9].

Dealer Copy -- Not for Resale

Remove the stopper (Item 4), the shims and the base
Figure 20-25-10 end pivot pin (Item 5) to detach both cylinders (Item 1)
from the articulated boom at the same time [Figure 20-
25-11].

1
2

S37547

Lower both cylinders (Item 1) [Figure 20-25-10]. Remove

the shims.

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

220 of 918 20-25-4 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D)

Parts Identification

1. Bushing
2. Housing
3. Band
4. Bolt
5. Washer 4
6. Set Screw 3
7. Nut
8. Piston
9. Wear Ring 5
10. Seal
1
11. O-ring
12. Back-up Ring
13. Bushing 4
5
14. Head
15. Inner Seal 6
16. Wiper
17. Snap Ring 3
18. Rod

Dealer Copy -- Not for Resale

8
9
10
10
11
11
12
17
13
11

14
11
15
16
17

NA5527S

221 of 918 20-25-5 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-14

Disassembly

Use the following tools to disassemble the cylinder:

1
MEL1074 - O-ring Seal Hook

Hold the hydraulic cylinder over a drain pan and slowly

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

Figure 20-25-12

1
S37656

Straighten the lock ring tab (Item 1) [Figure 20-25-14].

Figure 20-25-15

Dealer Copy -- Not for Resale

S37654

Clamp the base end (Item 1) [Figure 20-25-12] of the

cylinder in a vise.

Figure 20-25-13

S37657

Remove the head (Item 1) [Figure 20-25-15] from the

housing.

1 Remove the rod assembly from the housing.

Remove the cylinder from the vise.

S37655

Support the cylinder with a block (Item 1) [Figure 20-25-

13].

222 of 918 20-25-6 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-18

Disassembly (Cont’d)

Figure 20-25-16

P-87390
1

Clamp the rod end in a vise. Support the rod with a block
P-87424 (Item 1) [Figure 20-25-18].

Figure 20-25-19
Remove the fitting (Item 1) [Figure 20-25-16].

Dealer Copy -- Not for Resale

Figure 20-25-17

1
1

S37688

P-87425 Remove the set screw (Item 1) [Figure 20-25-19].

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

2) [Figure 20-25-17].

223 of 918 20-25-7 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-22

Disassembly (Cont’d)

Figure 20-25-20

1
1

S37690

Remove the wear ring (Item 1) [Figure 20-25-22].

S37692
Figure 20-25-23

Apply moderate heat to the nut (Item 1) [Figure 20-25-

20]. Remove the nut.

Dealer Copy -- Not for Resale

Figure 20-25-21

S37689

1
Remove the seal (Item 1) [Figure 20-25-23].

S37687

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

224 of 918 20-25-8 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-26

Disassembly (Cont’d)

Figure 20-25-24

1
P-87435

Remove the head (Item 1) [Figure 20-25-26].

S37691
Figure 20-25-27

Remove the seal (Item 1) [Figure 20-25-24].

Dealer Copy -- Not for Resale

Figure 20-25-25
1

1
P-87436

Remove the O-ring (Item 1) [Figure 20-25-27].

P-87434

Remove the O-ring (Item 1) [Figure 20-25-25].

225 of 918 20-25-9 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-30

Disassembly (Cont’d)

Figure 20-25-28

P-87439

Remove the lock ring (Item 1) [Figure 20-25-30].

P-87437
Figure 20-25-31

Remove the back-up ring (Item 1) [Figure 20-25-28].

Dealer Copy -- Not for Resale

Figure 20-25-29
1

P-87440

Remove the snap ring (Item 1) [Figure 20-25-31].

P-87438

Remove the O-ring (Item 1) [Figure 20-25-29].

226 of 918 20-25-10 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-34

Disassembly (Cont’d)

Figure 20-25-32

1
2

P-87443
1

Remove the bushing (Item 1) [Figure 20-25-34].

P-87444
Figure 20-25-35

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

[Figure 20-25-32].

Dealer Copy -- Not for Resale

1
Figure 20-25-33

1
2

P-87445

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

2) [Figure 20-25-35].
P-87442

Remove the snap ring (Item 1) [Figure 20-25-33].

227 of 918 20-25-11 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-37

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander 1

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for nicks, scratches and other

damage. Replace any damaged parts.
P-87443
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-25-37] into the
assembly. head.

Figure 20-25-36 Figure 20-25-38

Dealer Copy -- Not for Resale

P-87445 P-87442

Install the bushing (Item 1) and seal (Item 2) [Figure 20- Install the snap ring (Item 1) [Figure 20-25-38].
25-36] (Both sides).

228 of 918 20-25-12 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-41

Assembly (Cont’d)

Figure 20-25-39
1

P-87439
1 2

Install the lock ring (Item 1) [Figure 20-25-41].

P-87444
Figure 20-25-42

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

[Figure 20-25-39].

Dealer Copy -- Not for Resale

Figure 20-25-40
1

P-87438

Install the O-ring (Item 1) [Figure 20-25-42].

P-87440 Figure 20-25-43

Install the snap ring (Item 1) [Figure 20-25-40].

P-87437

Install the back-up ring (Item 1) [Figure 20-25-43].

229 of 918 20-25-13 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-46

Assembly (Cont’d)

Figure 20-25-44
1

P-87434

Install the O-ring (Item 1) [Figure 20-25-46] in the piston.

P-87436
Figure 20-25-47

Install the O-ring (Item 1) [Figure 20-25-44].

Dealer Copy -- Not for Resale

Clamp the rod end in a vise. Support the rod with a block.

Figure 20-25-45 1

S37691

Install the seal (Item 1) [Figure 20-25-47].

1
P-87435

Install the head (Item 1) [Figure 20-25-45].

230 of 918 20-25-14 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-50

Assembly (Cont’d)

Figure 20-25-48 2

S37687

Install the piston (Item 1) [Figure 20-25-50].

S37689
Figure 20-25-51

Install the seal (Item 1) [Figure 20-25-48].

Dealer Copy -- Not for Resale

Figure 20-25-49
1

S37692

Install the nut (Item 1) [Figure 20-25-51].

S37690
Tighten the nut until the bore of the set screw is aligned
with the groove (Item 2) [Figure 20-25-50] of the rod.
Install the wear ring (Item 1) [Figure 20-25-49].

231 of 918 20-25-15 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-54

Assembly (Cont’d)

Figure 20-25-52
1

1
P-87425

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

S37688 25-54] into the rod end (Both sides).

Figure 20-25-55
Install the set screw (Item 1) [Figure 20-25-52].

Dealer Copy -- Not for Resale

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

Figure 20-25-53

P-87424

Install the fitting (Item 1) [Figure 20-25-55].

Clamp the cylinder housing in a vise. Support the

P-87426 cylinder with a block.

Install the rod assembly into the housing.

Remove the rod from the vise [Figure 20-25-53].

232 of 918 20-25-16 E85 Service Manual

CYLINDER (ARTICULATED BOOM) (CONT’D) Figure 20-25-58

Assembly (Cont’d)

Figure 20-25-56

S37655

Remove the cylinder from the vise [Figure 20-25-58].

S37656

Tighten the head (Item 1) [Figure 20-25-56].

Dealer Copy -- Not for Resale

Figure 20-25-57

S37657

Bend the lock ring tab (Item 1) [Figure 20-25-57] into the
groove on the head.

233 of 918 20-25-17 E85 Service Manual

Dealer Copy -- Not for Resale

234 of 918 20-25-18 E85 Service Manual

VALVES (RELIEF)

Description

Figure 20-30-1

P-86566

Figure 20-30-2

Dealer Copy -- Not for Resale

P123146

The piston pump circuit has one load sense relief valve
(Item 1) [Figure 20-30-1] and one back-up relief valve
(Item 1) [Figure 20-30-2] located on the hydraulic control
valve. The load sense relief valve (Item 1) [Figure 20-30-
1] is factory set at 28000 kPa (280 bar) (4060 psi).

The back-up relief valve (Item 1) [Figure 20-30-2] is set

at 34000 kPa (340 bar) (4931 psi), 3000 kPa (30 bar)
(435 psi) higher than the load sense relief.

The back-up relief valve and load sense relief valve are
tested and adjusted during the piston pump testing and
adjusting. (See Pump Testing on Page 20-50-6.)

235 of 918 20-30-1 E85 Service Manual

Dealer Copy -- Not for Resale

236 of 918 20-30-2 E85 Service Manual

VALVES (PORT RELIEF) Bucket Port Relief set at:
Rod End (Item 3) [Figure 20-31-1] 31000 kPa (310 bar)
Testing And Adjusting The Port Relief Valve Pressure (4495 psi)
Base End (Item 4) [Figure 20-31-1] 31000 kPa (310 bar)
(4495 psi)

IMPORTANT Arm Port Relief set at:

Rod End (Item 5) [Figure 20-31-1] 31000 kPa (310 bar)
(4495 psi)
When repairing hydrostatic and hydraulic systems, Base End (Item 6) [Figure 20-31-1] 31000 kPa (310 bar)
clean the work area before disassembly and keep all (4495 psi)
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Auxiliary Port Relief set at:
damage the system. Female Quick Coupler (Item 7) [Figure 20-31-1] 21000
I-2003-0888
kPa (210 bar) (3046 psi)
Male Quick Coupler (Item 8) [Figure 20-31-1] 21000 kPa
Tilt the cab. (See Raising And Lowering on Page 10-210- (210 bar) (3046 psi)
1.)
Figure 20-31-2
When testing the port relief valves with a hydraulic hand
pump, slowly pressurize the valve. If the hand pump is
pumped fast, the pressure will be altered by as much as 3
350 kPa (3,5 bar) (50 psi).
2

Dealer Copy -- Not for Resale

When testing the port relief valves with a hydraulic hand
pump, the valve crack pressure should be observed.

A portable hydraulic hand pump will be used to test the

work port relief valves. The hand pump must have clean
Bobcat hydraulic fluid.

Figure 20-31-1
1
P-86423

8 6
4 Install the hand pump (Item 1), hose (Item 2) and a
pressure gauge (Item 3) [Figure 20-31-2] (minimum of
2 34500 kPa (345 bar) (5000 psi) into the valve section
work port in which the port relief valve is located.
Pressurize this section with the hand pump until the port
relief valve opens. Record the pressure reading.
7 5
3
If the port relief pressure setting needs to be adjusted,
1 release the hand pump pressure valve.

P112577

Boom Port Relief set at:

Rod End (Item 1) [Figure 20-31-1] 31000 kPa (310
bar) (4495 psi)
Base End (Item 2) [Figure 20-31-1] 31000 kPa (310
bar) (4495 psi)

237 of 918 20-31-1 E85 Service Manual

VALVES (PORT RELIEF) (CONT'D)

Testing And Adjusting The Port Relief Valve Pressure

(Cont’d)

Figure 20-31-3

1
P-86411

Remove the protective cap (Item 1) [Figure 20-31-3].

Dealer Copy -- Not for Resale

Figure 20-31-4

2
P-86412

Loosen the lock nut (Item 1) [Figure 20-31-4].

Turn the adjusting screw (Item 2) [Figure 20-31-4]

clockwise to increase the pressure and counterclockwise
to reduce the pressure.

NOTE: One-quarter turn is approximately 6900 kPa

(69 bar) (1000 psi). When the correct pressure
setting is obtained, tighten the locknut while
holding the adjustment screw from turning.

Adjust the port relief valve until the correct setting is

obtained.

Install the protective cap.

238 of 918 20-31-2 E85 Service Manual

VALVE (PRESSURE REDUCING RELIEF) Figure 20-32-2

Testing And Adjusting The Pressure Reducing Valve

The pressure reducing valve supplies lower hydraulic

pressure to joysticks.

With the engine off, and the key in the run position, lower 1
the left console and move both joysticks to relieve
hydraulic pressure.

Tilt the cab. (See Raising And Lowering on Page 10-210-

1.)

P-86423
WARNING
Install the test fittings and 6900 kPa (69 bar) (1000 psi)
AVOID INJURY OR DEATH gauge (Item 1) [Figure 20-32-2] in between the A-1 port
Never work under the excavator cab without fitting and existing hose. Route the gauge to the outside
installing an approved cab support device. of the excavator.
W-2435-0502

Lower the cab. (See Raising And Lowering on Page 10-

Dealer Copy -- Not for Resale

Figure 20-32-1 210-1.)

Enter the cab, start the engine and warm up the hydraulic
fluid to operating temperature.
1
With the hydraulic fluid at operating temperature, run the
2 engine at full rpm.

The pressure at the gauge should be 3200 kPa (32 bar)

(464 psi).

Move the engine speed control to low idle speed.

Stop the engine.

P112468 With the engine off, and the key in the run position, lower
the left console and move both joysticks to relieve
hydraulic pressure.
The pressure reducing valve (Item 1) [Figure 20-32-1] is
located on the end of the manifold. If adjustment is needed, raise the cab. (See Raising And
Lowering on Page 10-210-1.)
Remove the hose (Item 2) [Figure 20-32-1] from the A-1
port.

239 of 918 20-32-1 E85 Service Manual

VALVE (PRESSURE REDUCING RELIEF) (CONT'D) Figure 20-32-4

Testing And Adjusting The Pressure Reducing Valve

(Cont'd)

Figure 20-32-3

P-86427

Inspect the O-rings and back-up rings on the pressure

reducing valve [Figure 20-32-4]. If O-rings and back-up
P112470 rings are worn or damaged, replace O-rings and back-up
rings. (See Disassembly And Assembly on Page 20-60-
2.)
Loosen the nut (Item 1) [Figure 20-32-3].

Dealer Copy -- Not for Resale

Reinstall the pressure reducing valve in the manifold
Turn the adjustment screw (Item 2) [Figure 20-32-3] assembly.
clockwise to increase the pressure or counterclockwise
to decrease the pressure. Repeat the pressure reducing valve test.

NOTE: 1/4 turn is approximately 340 kPa (3,4 bar) (50 If the O-rings and back-rings were not worn or damaged
psi). and the correct pressure could not be achieved, replace
the pressure reducing valve.
Tighten the nut (Item 1) [Figure 20-32-3].

Lower the cab and retest the pressure reducing valve

after adjustment.

If the pressure is still incorrect, relieve hydraulic pressure,

tilt the cab and remove the pressure reducing valve from
the manifold assembly for inspection or repair.

If the amount of oil pressure is at or over the service

limits, it is an indication of worn O-rings and back-up
rings on the pressure reducing valve, or a stuck pressure
reducing valve.

Inspect the port of the pressure reducing valve on the

manifold assembly to verify that there is no damage. If
damaged, replace the manifold assembly.

240 of 918 20-32-2 E85 Service Manual

HYDRAULIC CONTROL VALVE Figure 20-40-2

Description

The hydraulic control valve is located between the pump,

cylinders and motors on the oil pressure circuit. Each
component within the hydraulic control valve operates
and controls oil flowing from the main pump. Such control
changes operation, direction or speed of cylinders and
motors.

The hydraulic control valve has three main relief valves

that operate at 30000 kPa (300 bar) (4278 psi). The
bucket, boom 1, arm 1, boom 2 / auxiliary, articulated
boom (optional) and boom swing sections have 30999
kPa (310 bar) (4496 psi) work port relief valves. The P-87117
rotary section has a 25000 kPa (250 bar) (3626 psi) work
port relief valve.
Remove the pilot lines from the inboard side of the valve
Removal And Installation [Figure 20-40-2].

Remove the left upperstructure cover. (See Removal And Figure 20-40-3
Installation on Page 40-20-1.)

Dealer Copy -- Not for Resale

Tilt the cab. (See Raising And Lowering on Page 10-210-
1.)

Figure 20-40-1 Remove the pilot lines from the outboard side of the valve
[Figure 20-40-3].

P-87116

Mark and remove the hoses from the top of the valve
[Figure 20-40-1].

241 of 918 20-40-1 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-6

Removal And Installation (Cont’d)

Figure 20-40-4

1
1

P-87121

Remove the fitting (Item 1). Remove the bolt (Item 2)

P-87119 [Figure 20-40-6] and washer.

Figure 20-40-7
Remove the bolt (Item 1) [Figure 20-40-4] and washer.

Dealer Copy -- Not for Resale

Figure 20-40-5
2

1
1
1

P-87122

P-87120 Install lifting brackets (Item 1) on both ends of the valve.

Install a chain (Item 2) [Figure 20-40-7] and hoist on the
lifting brackets. Lift and remove the valve.
Remove the two bolts (Item 1) [Figure 20-40-5] and
washers.

242 of 918 20-40-2 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D)

Parts Identification

1. Inlet Valve Section

2. Boom Valve Section
3. Bucket Valve Section
4. Arm Valve Section
5. Blade Valve Section
6. Auxiliary Valve Section
7. Left Travel Valve Section
8. Right Travel Valve Section
9. Upperstructure Swing Valve Section
10. Boom Swing Valve Section
11. Articulated Boom Valve Section
12. Outlet Valve Section
13. Load Sense Relief Valve 28000 kPa (280 bar) (4060 psi)
14. Back-up Relief Valve 34000 kPa (340 bar) (4931 psi)
15. Boom Port Relief Valves 30999 kPa (310 bar) (4496 psi)
16. Bucket Port Relief Valves 30999 kPa (310 bar) (4496 psi)
17. Arm Port Relief Valves 30999 kPa (310 bar) (4496 psi)
18. Auxiliary Port Relief Valves 21001 kPa (210 bar) (3046 psi)
19. Boom Swing Port Relief Valve 30999 kPa (310 bar) (4496 psi)

Dealer Copy -- Not for Resale

20. Articulated Boom Port Relief Valves 30999 kPa (310 bar) (4496 psi)

13
15
16 2 1
17
3
18 4
5
6
7 14
8
20 9
10
11

15
16
17

19
20

NA9771

243 of 918 20-40-3 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-10

Disassembly And Assembly

Figure 20-40-8

1
1

P-87128

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

P-87126 10].

Figure 20-40-11
Remove the bolts (Item 1) [Figure 20-40-8], washers and
mounts.

Dealer Copy -- Not for Resale

1
Figure 20-40-9

1 1

P-87129

Remove the four O-rings (Item 1) [Figure 20-40-11].

1 P-87127

Remove the three nuts (Item 1) [Figure 20-40-9].

Installation: Tighten the nuts to 32 - 38 N•m (24 - 28 ft-

lb) torque.

244 of 918 20-40-4 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-14

Disassembly And Assembly (Cont’d)

Figure 20-40-12
1

P-87130

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

S37679 14].

Figure 20-40-15
Remove the articulated boom valve section (Item 1)
[Figure 20-40-12]. (If equipped.)

Dealer Copy -- Not for Resale

Figure 20-40-13 1

1 1

P-87131

1 1
Remove the four O-rings (Item 1) [Figure 20-40-15].
P-87131

Remove the four O-rings (Item 1) [Figure 20-40-13].

245 of 918 20-40-5 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-18

Disassembly And Assembly (Cont’d)

Figure 20-40-16

1
1

2
P-87134

Remove the four O-rings (Item 1). Remove the right hand
P-87132 travel valve section (Item 2) [Figure 20-40-18].

Figure 20-40-19
Remove the mid inlet (Item 1) [Figure 20-40-16] valve
section.

Dealer Copy -- Not for Resale

Figure 20-40-17
1

2
1 P-87135

Remove the four O-rings (Item 1). Remove the left hand
2 travel valve section (Item 2) [Figure 20-40-19].
P-87133

Remove the four O-rings (Item 1). Remove the boom

swing valve section (Item 2) [Figure 20-40-17].

246 of 918 20-40-6 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-22

Disassembly And Assembly (Cont’d)

Figure 20-40-20 1

2 1

P-87138
1
Remove the four O-rings (Item 1). Remove the arm valve
P-87136 section (Item 2) [Figure 20-40-22].

Figure 20-40-23
Remove the four O-rings (Item 1). Remove the auxiliary
valve section (Item 2) [Figure 20-40-20].

Dealer Copy -- Not for Resale

Figure 20-40-21 1

1
2

1
P-87139

2 Remove the four O-rings (Item 1). Remove the bucket

P-87137 valve section (Item 2) [Figure 20-40-23].

Remove the four O-rings (Item 1). Remove the blade

valve section (Item 2) [Figure 20-40-21].

247 of 918 20-40-7 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-40-24

P-87140

Remove the four O-rings (Item 1). Remove the boom

valve section (Item 2) [Figure 20-40-24] valve section.

Dealer Copy -- Not for Resale

Figure 20-40-25

2 1

P-87141

Remove the four O-rings (Item 1). Remove the tie rods
(Item 2) [Figure 20-40-25] from the inlet valve section.

248 of 918 20-40-8 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-28

Inlet Valve Section Disassembly And Assembly

Figure 20-40-26 1
1

1 2

P-87144
2

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

P-87142 [Figure 20-40-28] from the back-up relief valve.

Figure 20-40-29
Remove the load sense relief valve (Item 1) and back-up
relief valve (Item 2) [Figure 20-40-26].

Dealer Copy -- Not for Resale

Installation: Tighten the relief valves to 41 - 49 N•m (30 -
60 ft-lb) torque.

Figure 20-40-27
1

1 1

P-87145

Remove the load sense bleed cartridge (Item 1) [Figure

2 20-40-29].

Installation: Tighten the cartridge to 18 - 22 N•m (13 -

P-87143 17 ft-lb) torque.

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

[Figure 20-40-27] from the load sense relief valve.

249 of 918 20-40-9 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-32

Inlet Valve Section Disassembly And Assembly

1
(Cont’d)

Figure 20-40-30

P-35277

1
Remove the O-ring (Item 1) [Figure 20-40-32].

P-35275 Figure 20-40-33

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

Dealer Copy -- Not for Resale

from the flow regulator. Remove the filter (Item 3) [Figure
20-40-30] from the end of the cartridge. 1

Figure 20-40-31

P-87147

Remove the spring (Item 1) [Figure 20-40-33].

P-87146

Remove the plug (Item 1) [Figure 20-40-31].

250 of 918 20-40-10 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D)

Inlet Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-34

P-87148

Remove the spool (Item 1) [Figure 20-40-34].

Dealer Copy -- Not for Resale

Figure 20-40-35

P-87149

Remove the shims (Item 1) [Figure 20-40-35] from the

spool.

251 of 918 20-40-11 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-38

Boom, Arm And Bucket Valve Section Disassembly

And Assembly 1

Figure 20-40-36

1
1

P-87156

Remove the plug (Item 1) [Figure 20-40-38].

P-87155 Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-

lb) torque.

Remove the relief valves (Item 1) [Figure 20-40-36]. Figure 20-40-39

Dealer Copy -- Not for Resale

Installation: Tighten the valves to 70 N•m (52 ft-lb)
torque.
1
Figure 20-40-37

1
1

P-35253

2 Remove the O-ring (Item 1) [Figure 20-40-39].

P-35260

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

[Figure 20-40-37].

252 of 918 20-40-12 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-42

Boom, Arm And Bucket Valve Section Disassembly

And Assembly (Cont’d)

Figure 20-40-40

1
1

P-35279

Remove the O-ring (Item 1) [Figure 20-40-42] from both

covers.
P-87157
Figure 20-40-43

Remove the compensator (Item 1) [Figure 20-40-40].

Dealer Copy -- Not for Resale

Figure 20-40-41

1
1
1
2 2

2
P-35266

1
Remove the centering spring (Item 1) [Figure 20-40-43]
P-87158 from both ends.

Remove the spring seat (Item 2) [Figure 20-40-43] from

Remove the four screws (Item 1) [Figure 20-40-41] from both ends.
both ends of the valve.

Installation: Tighten the screws to 25 N•m (18 ft-lb)

torque.

Remove both covers (Item 2) [Figure 20-40-41].

253 of 918 20-40-13 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
Boom, Arm And Bucket Valve Section Disassembly damaged.
And Assembly (Cont’d)
Figure 20-40-46
Figure 20-40-44

P-87151
P-35267

Record the orientation of the spool (Item 1) [Figure 20- Apply moderate heat to the plug (Item 1) [Figure 20-40-
40-44]. 46] to melt the thread adhesive. Remove the plug from

Dealer Copy -- Not for Resale

both ends of the spool.
Remove the spool (Item 1) [Figure 20-40-44].
Installation: Apply thread adhesive (Loctite® 242) to the
NOTE: The spool is not symmetrical. Incorrect spool plug threads.
installation will cause poor hydraulic valve
performance. Figure 20-40-47

NOTE: The boom spool can be disassembled. Follow

the steps from [Figure 20-40-45] through
[Figure 20-40-48] to disassemble the spool. 1

Figure 20-40-45

Cut

0.5625 Dia
2.0 in

P-87152

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

1.500 in plugs.

0.750 in B-14674

To remove the plugs from the boom spool, a holding

fixture will have to be made from a 19 mm thick x 38 mm
wide x 50 mm long (0.750 in thick x 1.500 in wide x 2.0 in
long) piece of hardwood. Drill a 14 mm (0.5625 in) hole in
the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-45].

254 of 918 20-40-14 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-50

Boom, Arm And Bucket Valve Section Disassembly

And Assembly (Cont’d)

Figure 20-40-48

2 3
1

P-35269

3 1
Remove the poppet (Item 1) and spring (Item 2) from the
plug. Remove the O-ring (Item 3) [Figure 20-40-50] from
P-87154 the plug.

Remove the spring (Item 1), sleeve (Item 2) and poppet

Dealer Copy -- Not for Resale

(Item 3) [Figure 20-40-48] from both ends of the spool.

Figure 20-40-49

1
P-35268

Remove the check valves (Item 1) [Figure 20-40-49].

Installation: Tighten the check valves to 27 - 33 N•m (20

- 24 ft-lb) torque.

255 of 918 20-40-15 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-53

Left Travel, Right Travel And Blade Valve Section

Disassembly And Assembly

Figure 20-40-51

1 1

P-87165

Remove the plug (Item 1) [Figure 20-40-53].

P-87164 Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-

lb) torque.

Remove the plugs (Item 1) [Figure 20-40-51]. Figure 20-40-54

Dealer Copy -- Not for Resale

Installation: Tighten the plugs to 70 N•m (52 ft-lb)
torque.
1
Figure 20-40-52

P-35253
1
2
Remove the O-ring (Item 1) [Figure 20-40-54].

P-87160

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

[Figure 20-40-52].

256 of 918 20-40-16 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-57

Left Travel, Right Travel And Blade Valve Section

Disassembly And Assembly (Cont’d)

Figure 20-40-55

P-35279

Remove the O-ring (Item 1) [Figure 20-40-57].

P-87157 Figure 20-40-58

Remove the compensator (Item 1) [Figure 20-40-55].

Dealer Copy -- Not for Resale

Figure 20-40-56
1
2

1
2
2

1 P-35266

1 Remove the centering spring (Item 1) [Figure 20-40-58]

from both ends.
P-87158
Remove the spring seat (Item 2) [Figure 20-40-58] from
both ends.
Remove the four screws (Item 1) [Figure 20-40-56] from
both ends of the valve.

Installation: Tighten the screws to 25 N•m (18 ft-lb)

torque.

Remove both covers (Item 2) [Figure 20-40-56].

257 of 918 20-40-17 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-61

Left Travel, Right Travel And Blade Valve Section

Disassembly And Assembly (Cont’d)

Figure 20-40-59

1 2
1 3

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the

plug. Remove the O-ring (Item 3) [Figure 20-40-61] from
P-35267 the plug.

Figure 20-40-62
Remove the spool (Item 1) [Figure 20-40-59].

Dealer Copy -- Not for Resale

Figure 20-40-60

P-87167

P-35268 Remove the orifice (Item 1) [Figure 20-40-62].

NOTE: The right travel valve section is the only

Remove the check valves (Item 1) [Figure 20-40-60]. section equipped with an orifice.

Installation: Tighten the check valves to 27 - 33 N•m (20

- 24 ft-lb) torque.

258 of 918 20-40-18 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D)

Left Travel, Right Travel And Blade Valve Section

Disassembly And Assembly (Cont’d)

Figure 20-40-63

P-87168

Inspect the orifice (Item 1) [Figure 20-40-63] for damage

Dealer Copy -- Not for Resale

and plugging.

259 of 918 20-40-19 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-66

Auxiliary And Slew Valve Section Disassembly And

Assembly 1

Figure 20-40-64

P-87161

Remove the plug (Item 1) [Figure 20-40-66].

P-87159 Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-

lb) torque.

Remove the plugs (Item 1) [Figure 20-40-64]. Figure 20-40-67

Dealer Copy -- Not for Resale

Installation: Tighten the plug to 70 N•m (52 ft-lb) torque.

Figure 20-40-65 1

2 1

1 P-35253

Remove the O-ring (Item 1) [Figure 20-40-67].

P-87160

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

[Figure 20-40-65].

260 of 918 20-40-20 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-70

Auxiliary And Slew Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-68 2
1

P-35281

Hold the spool stroke limitation adjustment screw (Item 1)

to remove the fitting (Item 2) [Figure 20-40-70].
P-87157
Figure 20-40-71

Remove the compensator (Item 1) [Figure 20-40-68].

Dealer Copy -- Not for Resale

Figure 20-40-69 1

1 1

P-35283

Remove the O-ring (Item 1) [Figure 20-40-71].

P-87162

Remove the fittings (Item 1) [Figure 20-40-69] from both

ends of the valve section.

261 of 918 20-40-21 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-74

Auxiliary And Slew Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-72

P-35279

Remove the O-ring (Item 1) [Figure 20-40-74].

P-35280 Figure 20-40-75

Record the distance of the spool stroke limitation

Dealer Copy -- Not for Resale

adjustment screw (Item 1) [Figure 20-40-72] for correct
installation.

Figure 20-40-73 1

2
2

P-35266
1

1 Remove the centering spring (Item 1) [Figure 20-40-75].

Remove the spring seat (Item 2) [Figure 20-40-75] from

1 both ends.
2
P-87144

Remove the four screws (Item 1) [Figure 20-40-73] from

both ends of the value.

Installation: Tighten the screws to 25 N•m (18 ft-lb)

torque.

Remove both covers (Item 2) [Figure 20-40-73]

262 of 918 20-40-22 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-78

Auxiliary And Slew Valve Section Disassembly And

Assembly (Cont’d)
3
Figure 20-40-76 1 2

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the

plug. Remove the O-ring (Item 3) [Figure 20-40-78] from
P-35267 the plug.

Remove the spool (Item 1) [Figure 20-40-76].

Dealer Copy -- Not for Resale

Figure 20-40-77

1
P-35268

Remove the check valves (Item 1) [Figure 20-40-77].

Tighten the check valves to 27 - 33 N•m (20 - 24 ft-lb)

torque.

263 of 918 20-40-23 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-81

Boom Swing Valve Section Disassembly And

Assembly

Figure 20-40-79 1 2
4 3
1

1 1

P-87171

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

from the plug and the body. Remove the poppet (Item 3)
P-87169 and spring (Item 4) [Figure 20-40-81].

Figure 20-40-82
Remove the valves (Item 1) [Figure 20-40-79].

Dealer Copy -- Not for Resale

1
Installation: Tighten the valves to 70 N•m (52 ft-lb)
torque.

Figure 20-40-80

P-87156

Remove the plug (Item 1) [Figure 20-40-82].

Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-

P-87170 lb) torque.

Remove the plug (Item 1) [Figure 20-40-80] from the

body.

264 of 918 20-40-24 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-85

Boom Swing Valve Section Disassembly And 2

Assembly (Cont’d)

Figure 20-40-83

1
1
1

2 P-87166

Remove the four screws (Item 1) [Figure 20-40-85] from

both ends of the valve.
P-35253
Installation: Tighten the screws to 25 N•m (18 ft-lb)
torque.
Remove the O-ring (Item 1) [Figure 20-40-83].

Dealer Copy -- Not for Resale

Remove both covers (Item 2) [Figure 20-40-85].
Figure 20-40-84
Figure 20-40-86

P-87157

P-35279

Remove the compensator (Item 1) [Figure 20-40-84].

Remove the O-ring (Item 1) [Figure 20-40-86].

265 of 918 20-40-25 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-89

Boom Swing Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-87

1
2 P-35268

Remove the check valves (Item 1) [Figure 20-40-89].

P-35266 Installation: Tighten the check valves to 27 - 33 N•m (20

- 24 ft-lb) torque.

Remove the centering spring (Item 1) [Figure 20-40-87] Figure 20-40-90

Dealer Copy -- Not for Resale

from both ends.

Remove the spring seat (Item 2) [Figure 20-40-87] from

both ends.

Figure 20-40-88

1 2
1 3

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the

plug. Remove the O-ring (Item 3) [Figure 20-40-90] from
the plug.
P-35267

Remove the spool (Item 1) [Figure 20-40-88].

266 of 918 20-40-26 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-93

Articulated Boom Valve Section Disassembly And

Assembly 1

The articulated boom valve section (if equipped) controls

the hydraulic movement of the articulated boom cylinders
(optional).

Figure 20-40-91

1
P-87161

1 Remove the plug (Item 1) [Figure 20-40-93].

Installation: Tighten the plug to 54 - 66 N•m (40 - 48 ft-

lb) torque.

Figure 20-40-94

Dealer Copy -- Not for Resale

S37680

Remove the relief valves (Item 1) [Figure 20-40-91]. 1

Installation: Tighten the valves to 70 N•m (52 ft-lb)

torque.

Figure 20-40-92

1
1
P-35253

Remove the O-ring (Item 1) [Figure 20-40-94].

P-35260

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

[Figure 20-40-92].

267 of 918 20-40-27 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-97

Articulated Boom Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-95 2
1

P-35281

Hold the spool stroke limitation adjustment screw (Item 1)

to remove the fitting (Item 2) [Figure 20-40-97].
P-87157
Figure 20-40-98

Remove the compensator (Item 1) [Figure 20-40-95].

Dealer Copy -- Not for Resale

Figure 20-40-96 1

1 1

P-35283

Remove the O-ring (Item 1) [Figure 20-40-98].

P-87162

Remove the fittings (Item 1) [Figure 20-40-96] from both

ends of the valve section.

268 of 918 20-40-28 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-101

Articulated Boom Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-99

P-35279

Remove the O-ring (Item 1) [Figure 20-40-101].

P-35280 Figure 20-40-102

Record the distance of the spool stroke limitation

Dealer Copy -- Not for Resale

adjustment screw (Item 1) [Figure 20-40-99] for correct
installation.

Figure 20-40-100 1

2
2

P-35266
1

1 Remove the centering spring (Item 1) [Figure 20-40-

102].

1 Remove the spring seat (Item 2) [Figure 20-40-102] from

2
P-87144 both ends.

Remove the four screws (Item 1) [Figure 20-40-100]

from both ends of the valve.

Installation: Tighten the screws to 25 N•m (18 ft-lb)

torque.

Remove both covers (Item 2) [Figure 20-40-100]

269 of 918 20-40-29 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-105

Articulated Boom Valve Section Disassembly And

Assembly (Cont’d)
3
Figure 20-40-103 1 2

P-35269

Remove the poppet (Item 1) and spring (Item 2) from the

plug. Remove the O-ring (Item 3) [Figure 20-40-105]
P-35267 from the plug.

Remove the spool (Item 1) [Figure 20-40-103].

Dealer Copy -- Not for Resale

Figure 20-40-104

1
P-35268

Remove the check valves (Item 1) [Figure 20-40-104].

Tighten the check valves to 27 - 33 N•m (20 - 24 ft-lb)

torque.

270 of 918 20-40-30 E85 Service Manual

PUMP (HYDRAULIC PISTON)

Hydraulic Pump Work Sheet

Please review pump procedure as illustrated in Pump Testing on Page 20-50-6.

If any of the following adjustments are not obtainable, pump repair is required.

The outline listed below, gives the five adjustments for setting the hydraulic pump. The adjustments are listed in the order
in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page
location within the Service Manual for the complete adjustment procedure.

I. Torque Limiter Supply Pressure Adjustment on Page 20-50-6.

1. Bottom out pump margin spool (Approximately six turns in).

2. Remove the plug and install fitting and hose from the torque limit supply spool to a drain pan.

3. Install a 5000 kPa (50 bar) (725 psi) pressure gauge on the test port on the hydraulic control valve.

4. Warm hydraulic fluid to 50 - 60°C (122 - 144°F).

5. Run engine at high idle

Dealer Copy -- Not for Resale

6. Adjust as necessary to get 2000 ± 138 kPa (20 ± 1,38 bar) (290 ± 20 psi).

7. Record pressure

__________ TLS PRESSURE

8. Remove the hose and fitting from the torque limiter supply spool and plug the port

9. Reset pump margin spool (Approximately six turns out.)

II. Pump Margin Pressure Adjustment on Page 20-50-7.

10. Run engine at high idle

11. Adjust as necessary to get 1800 ± 138 kPa (18 ± 1,38 bar) (260 ± 20 psi).

12. Record pressure

__________ PM PRESSURE

13. Remove 5000 kPa (50 bar) (725 psi) pressure gauge.

III. Back-up Relief Valve Adjustment on Page 20-50-7.

14. Install 69000 kPa (690 bar) (10000 psi) gauge on the test port on the hydraulic control valve.

15. Turn the load sense relief valve in 1 turn.

16. Run engine at high idle and raise the blade until the blade cylinders are fully retracted and the relief valve opens.

17. Adjust back-up relief valve as necessary to get 34000 ± 345 kPa (340 ± 3,45 bar) (4931 ± 50 psi).

271 of 918 20-50-1 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Hydraulic Pump Work Sheet (Cont’d)

18. Record pressure

19. Reset load sense relief valve (one turn out)

__________ PRESSURE

IV. Load Sense Relief Valve Adjustment on Page 20-50-9.

20. Install 69000 kPa (690 bar) (10000 psi) gauge on the test port on the hydraulic control valve.

21. Run engine at high idle and raise the blade until the blade cylinders are fully retracted and the relief valve opens.

22. Adjust load sense relief valve as necessary to get 28000 ± 345 kPa (280 ± 3,45 bar) (4060 ± 50 psi).

23. Record pressure

__________ PRESSURE

24. Remove the 69000 kPa (690 bar) (10000 psi) gauge, from the diagnostic coupler at the hydraulic control valve.

Dealer Copy -- Not for Resale

V. Torque Limiter Adjustment on Page 20-50-10.

25. Remove the outlet hose from the pump, install a cap on the hose and install the inlet hose from the hydraulic tester,
to the outlet of the pump.

26. Route the outlet hose of the hydraulic tester to the tee fitting installed on the hydraulic reservoir adapter.

27. Bottom out the pump margin spool (approximately six turns in)

28. Run engine at high idle.

29. Free flow on the hydraulic tester is 144 L/min (38 U.S. gpm)

30. Adjust the hydraulic tester to 10300 kPa (103 bar) (1500 psi)

31. Adjust torque limiter to 129 - 136 L/min (34 - 36 U.S. gpm).

32. Record flow and engine rpm.

__________ FLOW

33. Adjust the hydraulic tester to 24100 kPa (241 bar) (3500 psi).

34. Adjust the torque limiter to obtain 57 - 64 L/min (15 - 17 U.S. gpm)

35. Record flow and engine rpm.

__________ FLOW

272 of 918 20-50-2 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Hydraulic Pump Work Sheet (Cont’d)

36. Remove the hydraulic tester

37. Install the pump outlet hose on the hydraulic control valve.

38. Reset pump margin spool to 1800 ± 138 kPa (18 ± 1,38 bar) (260 ± 20 psi).

ALL PUMP ADJUSTMENTS ARE NOW COMPLETED

Dealer Copy -- Not for Resale

273 of 918 20-50-3 E85 Service Manual

HYDRAULIC PISTON PUMP (CONT’D) Figure 20-50-1

Testing Information

The testing of the piston pump must be done in the

following order:

Torque limiter supply pressure

Pump margin pressure
Back-up Relief Valve
Load sense relief valve
Torque Limiter

All testing is done with the hydraulic oil at 50 - 60°C (122

- 140°F).
P103672
Check and adjust the engine high idle as needed before
any hydraulic testing.
Figure 20-50-2
The hydraulic hoses, tubelines and fittings on the E80
Excavator are BSPP fittings.

To test the piston pump, order the test kit:

Dealer Copy -- Not for Resale

MEL1713 - Hydraulic Test Kit

Use the gauge and hose assembly from test kit

MEL1173A.

P112286

[Figure 20-50-1] and [Figure 20-50-2] show the

components of MEL1713 Hydraulic Test Kit.

274 of 918 20-50-4 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Testing Information (Cont’d)

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-20-1.)

Figure 20-50-3

P-86558

Dealer Copy -- Not for Resale

Remove the plug (Item 1) [Figure 20-50-3] from the
hydraulic control valve.

Figure 20-50-4

P-86559

Install the test coupler (Item 1) [Figure 20-50-4].

275 of 918 20-50-5 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-7

Pump Testing

Torque Limiter Supply Pressure Adjustment 5

Figure 20-50-5 1
3
4
2

P112487

Install a fitting and drain hose (Item 1) [Figure 20-50-7].

Place the other end of the hose in a drain pan.

P-86560 NOTE: To adjust the Torque Limiter Supply Pressure,

the Pump Margin Spool must be temporarily
bottomed out.

Dealer Copy -- Not for Resale

Install a 50000 kPa (500 bar) (725 psi) pressure gauge
on the test coupler (Item 1) [Figure 20-50-5]. Loosen the nut (Item 2) [Figure 20-50-7].

Figure 20-50-6 Turn the pump margin spool (bottom spool) (Item 3)
[Figure 20-50-7] all the way in (approximately six turns).

Start the engine and run it at high idle.

Loosen the nut (Item 4) and adjust the torque limiter

supply pressure spool (Item 5) [Figure 20-50-7] until the
pressure gauge reads 2000 kPa (20 bar) (290 psi).

Turn the adjustment screw clockwise to increase

1 pressure and counterclockwise to decrease pressure.

NOTE: 1/4 turn is approximately 241 kPa (2,41 bar)

(35 psi).

P112288 Tighten the nut (Item 4) [Figure 20-50-7].

Stop the engine.

Remove the plug (Item 1) [Figure 20-50-6].
Repeat the procedure listed above until the pressure
is set.

Turn the pump margin spool (bottom spool) (Item 3)

[Figure 20-50-7] back to its original position
(approximately six turns).

Tighten the nut (Item 2) [Figure 20-50-7].

Remove the hose (Item 1) [Figure 20-50-7] and fitting.

Install the plug.

276 of 918 20-50-6 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Back-up Relief Valve Adjustment

Pump Testing (Cont’d) Tilt the cab. (See Raising And Lowering on Page 10-210-
1.)
Pump Margin Pressure Adjustment
Figure 20-50-9
Start the engine and run at high idle.

Figure 20-50-8

P-86566

P112293 Remove the plastic cap (Item 1) [Figure 20-50-9].

Dealer Copy -- Not for Resale

Figure 20-50-10
Loosen the nut (Item 1) and adjust the pump margin
pressure adjustment spool (Item 2) [Figure 20-50-8] until
the pressure gauge reads 1800 kPa (18 bar) (260 psi).
1
Turn the adjustment screw clockwise to increase
pressure and counterclockwise to decrease pressure.

NOTE: 1/4 turn is 345 kPa (3,45 bar) (50 psi).

Tighten the nut (Item 1) [Figure 20-50-8].

Stop the engine.

Remove the gauge from the test coupler.

P-86567

WARNING Loosen the locknut and turn the load sense relief valve
adjustment screw (Item 1) [Figure 20-50-10] in 1.5 turn,
increasing the relief pressure approximately 8274 kPa
AVOID INJURY OR DEATH (83 bar) (1200 psi) to 36266 kPa (363 bar) (5260 psi).
Never work under the excavator cab without The load sense relief is now set to a higher pressure.
installing an approved cab support device.
W-2435-0502
Lower the cab.

277 of 918 20-50-7 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-12

Pump Testing (Cont’d)

Back-up Relief Valve Adjustment (Cont’d)

Figure 20-50-11

1
2

P-86564

Remove the plastic cap (Item 1) [Figure 20-50-12].

Figure 20-50-13
P-86560

Dealer Copy -- Not for Resale

Install a 69000 kPa (690 bar) (10000 psi) pressure gauge
on the test coupler (Item 1) [Figure 20-50-11].

Start the excavator and warm up the hydraulic oil to

operating temperature.
1
Move the engine speed control to the high speed
position.
2
Raise the blade until the blade cylinders are fully
retracted and the relief valve opens.
P-86565
Record the pressure.

The pressure at the gauge (Item 2) [Figure 20-50-11] Loosen the lock nut (Item 1) [Figure 20-50-13].
should be 34000 kPa (340 bar) (4931 psi).
Turn the adjustment screw (Item 2) [Figure 20-50-13]
Stop the engine. inwards to increase pressure and outwards to decrease
pressure.

NOTE: One quarter turn is approximately 1380 kPa

(13,8 bar) (200 psi).

Tighten the nut and retest the back-up relief valve.

Tilt the cab and turn the load sense relief valve
adjustment screw (Item 1) [Figure 20-50-10] one turn
outwards to the original setting.

Lower the cab.

278 of 918 20-50-8 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-15

Pump Testing (Cont’d)

Load Sense Relief Valve Adjustment 2

Figure 20-50-14

P-86567

Loosen the lock nut (Item 1) [Figure 20-50-15].

Turn the adjustment screw (Item 2) [Figure 20-50-15]

P-86560 inwards to increase pressure and outwards to decrease
pressure.

Dealer Copy -- Not for Resale

Install a 69000 kPa (690 bar) (10000 psi) pressure gauge NOTE: One quarter turn is approximately 1380 kPa
on the test coupler (Item 1) [Figure 20-50-14]. (13,8 bar) (200 psi).

Move the engine speed control to the high idle position. Tighten the lock nut and lower the cab.

Raise the blade until the blade cylinders are fully

retracted and the relief valve opens.

Record the pressure.

WARNING
The pressure at the gauge (Item 2) [Figure 20-50-14] AVOID INJURY OR DEATH
should be 28000 (280 bar) (4060 psi). Never work under the excavator cab without
installing an approved cab support device.
Stop the engine. W-2435-0502

Tilt the cab. (See Raising And Lowering on Page 10-210- Retest the load sense relief valve.
1.)

279 of 918 20-50-9 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-18

Pump Testing (Cont’d)

Torque Limiter Adjustment

Figure 20-50-16

1
1
1
P112291

Install the adapter (Item 1) on the pump using the existing

flanges (Item 2) [Figure 20-50-18] and bolts.

P112294 Figure 20-50-19

Dealer Copy -- Not for Resale

Remove the four bolts (Item 1) [Figure 20-50-16] and
flanges.

Remove the outlet hose (Item 2) [Figure 20-50-16] from 1

the pump.

Figure 20-50-17

1
3 P-86572

3 Connect the inlet hose (Item 1) [Figure 20-50-19] from

the tester to pump.

Connect the outlet hose (Item 2) [Figure 20-50-19] from

the tester to the hose.

P112290

Install the adapter (Item 1), plate (Item 2) and bolts (Item
3) [Figure 20-50-17] on the hose.

280 of 918 20-50-10 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-22

Pump Testing (Cont’d)

Torque Limiter Adjustment (Cont’d) 1

Figure 20-50-20

P-22253

The flow should be 144 L/m (38 U.S. gpm) on the flow
1
tester (Item 1) [Figure 20-50-22].

P-22253 Turn the hydraulic tester flow control (Item 2) clockwise

until the gauge (Item 3) [Figure 20-50-22] shows 10300
kPa (103 bar) (1500 psi).

Dealer Copy -- Not for Resale

Fully open the hydraulic tester flow control (Item 1)
[Figure 20-50-20]. The gauge (Item 1) [Figure 20-50-22] should show 129 -
136 L/min (34 - 36 U.S. gpm) which is flow at low
Figure 20-50-21 pressure.

Figure 20-50-23

1
P112293

P112295
Loosen the nut (Item 1) and turn the pump margin
adjustment screw (Item 2) [Figure 20-50-21] all the way
in (approximately six turns). Remove the dust cover (Item 1) [Figure 20-50-23].

Start the engine and run it at high idle.

281 of 918 20-50-11 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) NOTE: If adjustments were made to flow at high
pressure verify the flow at low pressure.
Pump Testing (Cont’d)
Install the protective cap on the hydraulic pump torque
Torque Limiter Adjustment (Cont’d) limiter.

Figure 20-50-24 Remove the hydraulic tester, fittings and adapter hose.

Install the outlet hose on the pump.

Install the return line on the reservoir.

1 Figure 20-50-25
2

P112296
1

Dealer Copy -- Not for Resale

Check that the 13 mm nut (Item 1) [Figure 20-50-24] is
locked in place.

Adjust the flow at the hydraulic pump torque limiter.

P112297
Loosen the 27 mm nut (Item 2) [Figure 20-50-24] and
adjust the flow at low pressure with an Allen wrench.
Adjust the pump margin spool (Item 1) [Figure 20-50-25]
When the proper flow is obtained, 129 - 136 L/min (34 - back to the original position (approximately six turns
36 U.S. gpm) at 10300 kPa (103 bar) (1500 psi), lock the outwards).
27 mm nut (Item 2) [Figure 20-50-24].
Retest and adjust the pump margin spool as needed.
NOTE: Changing the flow at low pressure (27 mm (See Pump Margin Pressure Adjustment on Page 20-50-
nut) will affect the flow at high pressure (13 7.)
mm nut).
ALL PUMP ADJUSTMENTS ARE NOW COMPLETED.
Turn the hydraulic tester flow control (Item 2) clockwise
until the gauge (Item 3) [Figure 20-50-22] reads 24100 Remove the test fitting from the valve. Install the left
kPa (241 bar) (3500 psi). upperstructure cover. (See Removal And Installation on
Page 40-20-1.)
NOTE: Do not exceed 33998 kPa (340 bar) (4931 psi)
with the hydraulic tester or the pump will be
damaged.

The gauge should show 57 - 64 L/min (15 - 17 U.S. gpm)

which is flow at high pressure.

Adjust the flow at the hydraulic pump torque limiter.

Loosen the 13 mm nut (Item 1) [Figure 20-50-24] and
adjust the flow at high pressure with an Allen wrench.

When the proper flow is obtained, 57 - 64 L/min (15 - 17

U.S. gpm) at 24100 kPa (241 bar) (3500 psi), lock the 13
mm nut (Item 1) [Figure 20-50-24].

282 of 918 20-50-12 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-28

Removal And Installation

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-140-6.)

Remove the air cleaner. (See Housing Removal And

Installation on Page 60-40-1.)
1
Remove the gear pump. (See Removal And Installation
on Page 20-51-3.)

Figure 20-50-26

P112317
1
1
Remove the top inlet flange bolts (Item 1) [Figure 20-50-
28].

1 Figure 20-50-29
1

Dealer Copy -- Not for Resale

2 2 3

P-87476 1
2

Remove the four bolts (Item 1) and remove the cover

(Item 2) [Figure 20-50-26].

Figure 20-50-27

P112394

Remove the load sense line (Item 1), high pressure lines
(Item 2) and case drain line (Item 3) [Figure 20-50-29].

P112316

Remove the bottom inlet flange bolts (Item 1) [Figure 20-

50-27].

283 of 918 20-50-13 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-32

Removal And Installation (Cont’d)

Figure 20-50-30

P112396

Slide the pump away from the engine and remove the
P112395 pump [Figure 20-50-32].

Install a sling (Item 1) [Figure 20-50-30] and hoist on the

pump.

Dealer Copy -- Not for Resale

Figure 20-50-31

P112392

Remove the bolts (Item 1) [Figure 20-50-31] and

washers.

284 of 918 20-50-14 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Parts Identification

1. Plug
2. O-ring
3. Spring 7
4. Spring Seat
5. Spool Assembly
6. Spool
7. Bolt
8. Housing 8
9. Body
10. Locknut
11. Washer
12. Screw
6
13. Nut
14. Cap
5

3 4
1 2

Dealer Copy -- Not for Resale

13
12
10 11

9
2

3
3
4

MS-2790S

285 of 918 20-50-15 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Removal And Installation

Clean the outside of the pump with clean solvent and dry
it with compressed air before removing any components
from the pump.

Figure 20-50-33

P-87516

Dealer Copy -- Not for Resale

Remove the tubeline (Item 1) [Figure 20-50-33] from the
pump control and torque limiter valve.

NOTE: Mark the tubeline for correct installation.

Loosen and remove the two mounting bolts (Item 2)

[Figure 20-50-33] from the torque limiter valve.

Installation: Tighten the mounting bolts to 9,5 - 10,5

N•m (7.0 - 7.5 ft-lb) torque.

Figure 20-50-34

P-35330

Remove the torque limiter (Item 1) [Figure 20-50-34]

from the pump.

286 of 918 20-50-16 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-37

Torque Limiter Valve Disassembly

Figure 20-50-35

1 1

2
N-23329

Remove the spring (Item 1) and spring seat (Item 2)

N-23327 [Figure 20-50-37].

Figure 20-50-38
Remove the O-ring (Item 1) [Figure 20-50-35] from the
torque limiter valve.

Dealer Copy -- Not for Resale

NOTE: Do not scratch or damage the mounting
surface on the valve body.

Remove the plug (Item 2) [Figure 20-50-35].

NOTE: The plug (Item 2) [Figure 20-50-35] is under

spring pressure.

Figure 20-50-36 1

P-35320

Remove the control spool assembly (Item 1) [Figure 20-

1 50-38].

NOTE: Do not scratch or damage the spool.

Scratches in the spool can cause internal
leakage.

N-23328

Remove the O-ring (Item 1) [Figure 20-50-36].

287 of 918 20-50-17 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-41

Torque Limiter Valve Disassembly (Cont’d)

Figure 20-50-39
2

N-23333
1
2
Remove the two springs (Items 1 and 2) [Figure 20-50-
P-35321 41].

Figure 20-50-42
Remove the metering spool (Item 1) from the control
spool (Item 2) [Figure 20-50-39].

Dealer Copy -- Not for Resale

Figure 20-50-40

P-35322

Remove the plug (Item 1) [Figure 20-50-42].

N-23332

Remove the spring retainer (Item 1) [Figure 20-50-40]

from the torque limiter valve.

288 of 918 20-50-18 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-45

Torque Limiter Valve Disassembly (Cont’d)

Figure 20-50-43

2
P-35325

1
Loosen the large nut (Item 1) [Figure 20-50-45].
P-35323
Turn the small nut (Item 2) [Figure 20-50-45] to remove
the adjustment body.
Remove the O-ring (Item 1) [Figure 20-50-43].
Figure 20-50-46

Dealer Copy -- Not for Resale

The following procedures are only used if the adjustment
assembly is removed.

NOTE: If the adjustment assembly is removed and /

or disassembled, the torque limiter must be
tested and adjusted after the pump assembly
1
is installed in the machine. (See Initial Torque
Limiter Valve Setting on Page 20-50-25.)

Figure 20-50-44

P-35326

Hold the adjustment bolt (Item 1) with an Allen wrench

and loosen the nut (Item 2) [Figure 20-50-46].

P-35324

Remove the dust cap (Item 1) [Figure 20-50-44].

289 of 918 20-50-19 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Disassembly (Cont’d)

Figure 20-50-47

1
4

P-35327

Remove the adjustment screw (Item 1), O-ring washer

(Item 2) and large nut (Item 3) from the adjustment body

Dealer Copy -- Not for Resale

(Item 4) [Figure 20-50-47].

Figure 20-50-48

P-35328

Remove the O-ring (Item 1) [Figure 20-50-48].

290 of 918 20-50-20 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-50

Torque Limiter Valve Assembly

3
Clean all the parts in solvent and dry with compressed
4
air.

Inspect seats and spools for wear. 1

2
Apply clean oil to new O-rings and spools.

The following procedures are only used if the adjustment

assembly is removed.

Figure 20-50-49
P-35327

1
Install the O-ring washer (Item 1) on the adjustment
screw (Item 2) [Figure 20-50-50].

Install the adjustment screw (Item 2) in the adjustment

body (Item 3) [Figure 20-50-50].

Dealer Copy -- Not for Resale

Install the nut (Item 4) [Figure 20-50-50] on the
adjustment body.

Figure 20-50-51

P-35328

Install the O-ring (Item 1) [Figure 20-50-49].

P-35325

Install the adjustment screw / adjustment body (Item 1)

[Figure 20-50-51] assembly into the valve body.

291 of 918 20-50-21 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-54

Torque Limiter Valve Assembly (Cont’d)

Figure 20-50-52

N-23332

1
Install the spring seat (Item 1) [Figure 20-50-54] in the
P-35324 valve body with the ball side facing the control spool.

Figure 20-50-55
Install the dust cap (Item 1) [Figure 20-50-52].

Dealer Copy -- Not for Resale

NOTE: After the pump assembly is installed in the
machine, the torque limiter must be tested
and adjusted. (See Initial Torque Limiter Valve
Setting on Page 20-50-25.)

Figure 20-50-53

2 1
2
1
P-35321

Put oil on the metering spool (Item 1) and install it in the

control spool (Item 2) [Figure 20-50-55].

NOTE: The end of the metering spool with the three

rings should enter the control spool first.
N-23333

Install the two springs (Items 1 and 2) [Figure 20-50-53]

in the valve body.

NOTE: Install the big spring first.

292 of 918 20-50-22 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-58

Torque Limiter Valve Assembly (Cont’d)

Figure 20-50-56

N-23328
1

Install the O-ring (Item 1) on the plug. Install the plug

P-35320 (Item 2) [Figure 20-50-58].

Figure 20-50-59
Install the control spool assembly (Item 1) [Figure 20-50-
56] in the valve body.

Dealer Copy -- Not for Resale

NOTE: Do not scratch or damage the spool (Item 1) 1
[Figure 20-50-56]. Scratches in the spool can
cause internal leakage.

Figure 20-50-57

N-23327
2

Install the O-ring (Item 1) [Figure 20-50-59].

1
N-23329

Install the spring seat (Item 1) [Figure 20-50-57] in the

valve body, with the smaller side facing the spring.

Install the spring (Item 2) [Figure 20-50-57] in the valve

body.

293 of 918 20-50-23 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Torque Limiter Valve Assembly (Cont’d)

Figure 20-50-60

1
P-35323

Install the O-ring (Item 1) [Figure 20-50-60] on the plug.

Dealer Copy -- Not for Resale

Figure 20-50-61

P-35322

Install the plug (Item 1) [Figure 20-50-61].

294 of 918 20-50-24 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-64

Initial Torque Limiter Valve Setting

The following procedures are only used if the adjustment

assembly is removed.

Figure 20-50-62

107 mm
(4.21 in)

P-40592

1
Measure from the plug to the top of the small adjusting
screw [Figure 20-50-64]. Set the small adjustment screw
to 106 mm (4.15 in).

N-23336 Figure 20-50-65

Dealer Copy -- Not for Resale

Remove the dust cap (Item 1) [Figure 20-50-62].

Figure 20-50-63

2 1

P-35330
96 mm
(3.78 in)
Align the linkage pin (Item 1) on the hydraulic piston
pump into the hole (Item 1) [Figure 20-50-65] in the
P-40592 torque limiter valve.

Turn the valve slightly to align the dowel pin (Item 2) on

Measure from the plug to the top of the large adjustment the hydraulic piston pump into the hole (Item 2) [Figure
screw. Set the large adjustment screw to 96 mm (3.78 in) 20-50-65] in the torque limiter valve.
[Figure 20-50-63].
NOTE: Before tightening the bolts, make sure the
dowel pin is aligned with the housing.

295 of 918 20-50-25 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Initial Torque Limiter Valve Setting (Cont’d)

Figure 20-50-66

P-87516

Tighten the bolts (Item 1) [Figure 20-50-66] to 9,5 - 10,5

N•m (7.0 - 7.5 ft-lb) torque.

Dealer Copy -- Not for Resale

Install the tubeline (Item 2) [Figure 20-50-66].

296 of 918 20-50-26 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Pump Control Parts Identification

1. Cap (If Equipped)

2. O-ring
3. Nut 1
4. Adjusting Screw
5. Adjustment Screw Body 1
6. Spring Seat 2
7. Spring
8. Spring 2
3
9. Spring Seat
10. Spool 3
11. Plug 2
12. Valve Body
2
13. Bolt
14. Fitting 4
15. Elbow
4

Dealer Copy -- Not for Resale

6
2

7 6

8
7
9 8

10 9

10
2 11
11
2

2 2

2
12
2
14
13

15 2
14 2
2

11 11

MS1540

297 of 918 20-50-27 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Pump Control Removal And Installation

Clean the outside of the pump with clean solvent and dry
it with compressed air before removing any components
from the pump.

Figure 20-50-67

P-87516

Dealer Copy -- Not for Resale

Mark the tubeline (Item 1) [Figure 20-50-67] for correct
assembly.

Remove the tubeline (Item 1) [Figure 20-50-67] from the

pump control and torque limiter valve.

Figure 20-50-68

1 1

P-87517

Remove the four bolts (Item 1) and remove the pump

control (Item 2) [Figure 20-50-68] from the hydraulic
piston pump.

Installation: Tighten the bolts to 13 N•m (10 ft-lb) torque.

298 of 918 20-50-28 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-71

Pump Control Disassembly And Assembly

Figure 20-50-69
4

3
1 2

1
P-35335

Remove the adjustment screw (Item 1), nut (Item 2), and
P-35332 O-ring washer (Item 3) from the adjustment assembly
(Item 4) [Figure 20-50-71].

Remove the three O-rings (Item 1) [Figure 20-50-69] Remove the adjustment assembly (Item 4) [Figure 20-
from the valve. 50-71].

Dealer Copy -- Not for Resale

Pump Margin Control Figure 20-50-72

Figure 20-50-70

3
2 3 1 4
1
P-35344

P-35333
Remove the adjustment seat (Item 1), large spring (Item
2), and the small spring (Item 3) [Figure 20-50-72] from
Before disassembling the pump margin control, remove the adjustment assembly.
the cap (Item 1) and O-ring washer (Item 2) [Figure 20-
50-70] from the adjustment assembly (If equipped.) Remove the O-ring (Item 4) [Figure 20-50-72].

Measure the adjustment screw (Item 3) [Figure 20-50-

70] thread length for the correct initial adjustment.

299 of 918 20-50-29 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-75

Pump Control Disassembly And Assembly (Cont’d)

Pump Margin Control (Cont’d)

Figure 20-50-73

N-23380

Check the spool for scratches and make sure the orifice
1 (Item 1) [Figure 20-50-75] is not plugged.

P-35336 Figure 20-50-76

Dealer Copy -- Not for Resale

Remove the spring seat (Item 1) [Figure 20-50-73].

Figure 20-50-74

P-35338

Remove the plug (Item 1) [Figure 20-50-76].

P-35337 Figure 20-50-77

Remove the spool (Item 1) [Figure 20-50-74].

P-35339

Remove the O-ring washer (Item 1) [Figure 20-50-77].

300 of 918 20-50-30 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-80

Pump Control Disassembly And Assembly (Cont’d)

Torque Limiter Supply Control

Figure 20-50-78 3
1

4
2
1
P-35343

3
2 Remove the adjustment screw (Item 1), nut (Item 2), and
O-ring washer (Item 3) from the adjustment assembly
(Item 4) [Figure 20-50-80].
P-35341
Remove the adjustment assembly (Item 4) [Figure 20-
50-80].

Dealer Copy -- Not for Resale

Before disassembling the pump torque limiter supply
control, remove the cap (Item 1) and O-ring washer (Item Figure 20-50-81
2) [Figure 20-50-78] from the adjustment assembly (If
equipped).

Measure the adjustment screw (Item 3) [Figure 20-50-

78] thread length for the correct initial adjustment. 4
3
Figure 20-50-79

1
1 2

P-35344

Remove the adjustment seat (Item 1), large spring (Item

2) [Figure 20-50-81], and small spring (Item 3) from the
adjustment assembly.

P-35342 Remove the O-ring (Item 4) [Figure 20-50-81].

Loosen the nut (Item 1) [Figure 20-50-79].

301 of 918 20-50-31 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-84

Pump Control Disassembly And Assembly (Cont’d)

Torque Limiter Supply Control (Cont’d)

2
Figure 20-50-82
1

N-23379

Check the spool for scratches and make sure the orifices
(Items 1 and 2) [Figure 20-50-84] are not plugged.

P-35345 Figure 20-50-85

Dealer Copy -- Not for Resale

Remove the spring seat (Item 1) [Figure 20-50-82].

Figure 20-50-83

P-35347

Remove the plug (Item 1) [Figure 20-50-85].

P-35346 Figure 20-50-86

Remove the spool (Item 1) [Figure 20-50-83].

P-35348

Remove the O-ring washer (Item 1) [Figure 20-50-86].

302 of 918 20-50-32 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D)

Parts Identification

1. Snap Ring
2. Seal
3. Housing
4. Plug
5. O-ring 7
6. Bearing
5 6
7. Shaft
8. Shim 3
9. Swash Plate
10. Rotating Group
11. Piston Assembly
12. Retaining Plate
13. Ball Guide
14. Cylinder Block 2
15. Pin 1
16. Thrust Washer 19
17. Spring
18. Snap Ring 18
19. Valve Plate 17
14 16
20. Piston

Dealer Copy -- Not for Resale

4 15
21. Piston Guide 10
22. Dowel Pin 12
13
23. Destroking Piston
24. Destroking Piston Guide 11
25. End Cap
26. Bolt 9
27. Coupler
28. Lock Washer 8
29. Gear Pump 26
28

25 5
27
21
17
20

8 6
29

22
5

24 26
23
B-23974

303 of 918 20-50-33 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-88

Disassembly

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

N-23355
Clean the outside of the hydraulic piston pump with
solvent and dry with compressed air.
Remove the pin assembly (Item 1) [Figure 20-50-88].
Remove the torque limiter valve. (See Torque Limiter
Valve Removal And Installation on Page 20-50-16.) Figure 20-50-89

Remove the pump control assembly. (See Pump Control

Removal And Installation on Page 20-50-28.)

Dealer Copy -- Not for Resale

Figure 20-50-87

1
P-61054

Remove the plug (Item 1) [Figure 20-50-89] from the

pump housing and drain the oil.
N-23354

Remove the screw (Item 1) [Figure 20-50-87] from the

pin assembly.

304 of 918 20-50-34 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-92

Disassembly (Cont’d)
1
3
Figure 20-50-90

P-61070

Remove the O-ring (Item 1) [Figure 20-50-92].

P-35349
Remove the destroking piston (Item 2) [Figure 20-50-
92].
Remove the O-ring (Item 1) [Figure 20-50-90] from the
plug. Remove the stroking piston / spring assembly (Item 3)

Dealer Copy -- Not for Resale

[Figure 20-50-92].
Mark the pump housing for proper installation.
Figure 20-50-93
Figure 20-50-91

2
1

1 1

N-23387
P-61055

Inspect the destroking piston (Item 1) [Figure 20-50-93]

Remove the four bolts (Item 1) [Figure 20-50-91]. for scratches and replace it if needed.

Remove the end cap (Item 2) [Figure 20-50-91] from the

pump.

305 of 918 20-50-35 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-96

Disassembly (Cont‘d)

Figure 20-50-94

2
1

P-61072

Remove the shim(s) (Item 1) [Figure 20-50-96] from the

N-23388 pump shaft.

Figure 20-50-97
Remove the spring (Item 1) from the stroking piston (Item
2) [Figure 20-50-94].

Dealer Copy -- Not for Resale

Figure 20-50-95

1
1

P-61073

Lay the pump assembly on its side and remove the rotary
P61071 group, swash plate, and shaft (Item 1) [Figure 20-50-97]
from the housing.

Remove the bearing (Item 1) [Figure 20-50-95].

306 of 918 20-50-36 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-100

Disassembly (Cont’d)
1
Figure 20-50-98

3
P-35354

Remove the retaining ball (Item 1) [Figure 20-50-100].

P-61074
Figure 20-50-101

Slide the rotary group (Item 1) and swash plate (Item 2)

from the shaft assembly (Item 3) [Figure 20-50-98]. 1

Dealer Copy -- Not for Resale

NOTE: It is NOT important that the pistons are
installed in their original positions.

NOTE: Check that there are no scratches or metal

deposits on the sliding surface. (Pistons must 1
be replaced in sets.) 1

Figure 20-50-99

1 P-35355

Inspect the three pins (Item 1) [Figure 20-50-101] for

wear and / or damage.

NOTE: The following procedure is only to

disassemble the rotating group for
inspection. The rotating group parts can not
be ordered separately and must be ordered as
an assembly.

P-35361

Remove the retainer plate and pistons (Item 1) [Figure

20-50-99].

307 of 918 20-50-37 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-104

Disassembly (Cont’d)
1
Figure 20-50-102
2

4 4

3 2 3
1 2 3
4

N-15289

Install the second trimmed washer (Item 1) over the

N-15299 threaded rod (Item 2) and install the nut (Item 3) [Figure
20-50-104].

To remove the spring from inside the cylinder block, use a NOTE: The modified washer (Item 1) must fit between
threaded rod (or bolt) (Item 1), two trimmed washers the three pins (Item 4) [Figure 20-50-104].

Dealer Copy -- Not for Resale

(Item 2), and two nuts (Item 3) [Figure 20-50-102].
Figure 20-50-105
Figure 20-50-103

4
1
2

1
2

3
N-15290
N-15288

Tighten the nut (Item 1) until the spring is compressed

Install the threaded rod and nut (Item 1) through the enough to remove the snap ring (Item 2) [Figure 20-50-
trimmed washer (Item 2) and through the block assembly 105].
(Item 3) [Figure 20-50-103].
Loosen the nut to release the tension on the spring and
NOTE: The modified washer (Item 2) must fit over the remove the bolts and washers.
spring, but must also fit inside the snap ring
(Item 4) [Figure 20-50-103].

308 of 918 20-50-38 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-108

Disassembly (Cont’d)

Figure 20-50-106

1
2 3
1 3
3 2

N-23395

Remove the bolt (Item 1) and remove the torque limiter

N-15291 plate (Item 2) [Figure 20-50-108].

NOTE: The caps (Item 3) [Figure 20-50-108] cannot be

Remove the spring (Item 1), washer (Item 2) and the replaced, order a new swash plate if
three pins (Item 3) [Figure 20-50-106] from the cylinder necessary.

Dealer Copy -- Not for Resale

block.
Figure 20-50-109
Figure 20-50-107

N-15284
P-61075

Press the bearing (Item 1) [Figure 20-50-109] off the

Remove the swash plate (Item 1) from the shaft (Item 2) shaft.
[Figure 20-50-107].

309 of 918 20-50-39 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-112

Disassembly (Cont’d)

Figure 20-50-110
1

N-15277

Remove the two brass bearings (Item 1) [Figure 20-50-

P-35356 112] from the housing.

Figure 20-50-113
Remove the snap ring (Item 1) [Figure 20-50-110] from
the housing.

Dealer Copy -- Not for Resale

Figure 20-50-111

1
1

N-15280

Remove the race (Item 1) [Figure 20-50-113] from the

P-35357 housing.

Remove the seal (Item 1) [Figure 20-50-111] from the

housing.

NOTE: The shaft seal can be removed without

disassembling the pump.

310 of 918 20-50-40 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-116

Disassembly (Cont’d)

Figure 20-50-114

1 1

1
1

P-61078

1
Remove the bearing race from the port block assembly
P-61076 with a bearing puller (Item 1) [Figure 20-50-116].

Figure 20-50-117
Remove the O-rings (Item 1) [Figure 20-50-114].

Dealer Copy -- Not for Resale

Figure 20-50-115
2

N-23418

P-61077 Remove the stroking piston (Item 1) [Figure 20-50-117].

(Spring Side)

Remove the valve plate (Item 1) [Figure 20-50-115]. Remove the destroking piston (Item 2) [Figure 20-50-
117].

311 of 918 20-50-41 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-119

Assembly

P-61080
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and damage. Install the bearing race (Item 1) [Figure 20-50-119] in the
port block assembly.
Replace any worn or damaged parts.

Figure 20-50-118

Dealer Copy -- Not for Resale

3
1

P-61079

Apply Loctite® 241 or equivalent on the threads and

install the destroking piston (Item 1) in the hole next to
the alignment pin (Item 2) [Figure 20-50-118].

Apply Loctite® 241 or equivalent on the threads and

install the stroking piston (Item 3) [Figure 20-50-118].

312 of 918 20-50-42 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-122

Assembly (Cont’d)

Figure 20-50-120

P-35356

Install the snap ring (Item 1) [Figure 20-50-122].

N-15296
Figure 20-50-123

Press the race into the housing [Figure 20-50-120].

Dealer Copy -- Not for Resale

Figure 20-50-121
2

1
1

N-15285

Press the bearing (Item 1) on the shaft (Item 2) [Figure

P-35357 20-50-123].

Install the shaft seal (Item 1) [Figure 20-50-121].

313 of 918 20-50-43 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-126

Assembly (Cont’d)
1
Figure 20-50-124 2

P-61083

Install the port block (Item 1) [Figure 20-50-126].

P-61081
Install the four bolts (Item 2) [Figure 20-50-126] and
tighten them to 119 N•m (88 ft-lb) torque.
To find the correct shim washer thickness for bearing end
play, the shaft / bearing assembly (Item 1) [Figure 20-50- Figure 20-50-127

Dealer Copy -- Not for Resale

124] must be installed in the housing.

Figure 20-50-125

P-35360

P-61082 Turn over the pump assembly [Figure 20-50-127].

Install the bearing (Item 1) [Figure 20-50-125] on the

shaft.

314 of 918 20-50-44 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-129

Assembly (Cont’d)

Figure 20-50-128

N-15277

Install the two brass bearings (Item 1) [Figure 20-50-

P-35359 129].

Figure 20-50-130
Install a dial indicator on the housing as shown [Figure
20-50-128] and set it to zero.

Dealer Copy -- Not for Resale

Pull the shaft up as far as it will go and record the reading
on the dial indicator. Repeat the procedure several times. 3
The reading must be the same each time.

Add the nominal preload of 0,025 mm (0.001 in) to the

reading found on the dial indicator [Figure 20-50-128].
The actual preload is 0,000 mm (0.000 in) to 0,050 mm
(0.002 in)
2 1
Example: (In Inches)

0.150 Measured movement of the shaft N-15283

0.001 Nominal Preload

Apply Loctite® 241 or equivalent and install the torque
= 0.151 ± thickness of the shim needed. (See Assembly limiter plate (Item 1) and bolt (Item 2) on the swash plate
on Page 20-50-42.) (Item 3) [Figure 20-50-130].

When the proper thickness of the shim washer is

determined, remove the dial indicator from the pump
housing.

Remove the two mounting bolts.

Remove the port block.

Remove the bearing and shaft from the pump housing.

315 of 918 20-50-45 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-133

Assembly (Cont’d)

Figure 20-50-131
3 2
1 2 3

1
2

N-15299

To compress the spring inside the cylinder block, use a

P-61075 threaded rod (or bolt) (Item 1), two trimmed washers
(Item 2), and two nuts (Item 3) [Figure 20-50-133].

Install the swash plate (Item 1) on the shaft (Item 2) Figure 20-50-134
[Figure 20-50-131].

Dealer Copy -- Not for Resale

Figure 20-50-132
2
1

3 3
2 1

N-15289

N-15291 Install the threaded rod and nut (Item 1) through the
modified washer (Item 2) and the block assembly (Item 3)
[Figure 20-50-134].
Apply clean grease to the three pins (Item 1) [Figure 20-
50-132] and install them in the appropriate groove.

Install the washer (Item 2) and the spring (Item 3)

[Figure 20-50-132].

NOTE: If the rotating group is damaged, the parts can

not be ordered separately and must be
ordered as an assembly.

316 of 918 20-50-46 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-137

Assembly (Cont’d)
1
Figure 20-50-135

2
1

3
P-35354

Install the retaining ball (Item 1) [Figure 20-50-137] on

N-15288 the three pins.

Figure 20-50-138
NOTE: The modified washer (Item 1) must fit over the
spring (Item 2), but must also fit inside the
1

Dealer Copy -- Not for Resale

snap ring (Item 3) [Figure 20-50-135].

Figure 20-50-136

2
1 P-35361

Install the retainer and piston assembly (Item 1) in the

cylinder block (Item 2) [Figure 20-50-138].
N-15290
NOTE: It is NOT important that the pistons are
installed in their original positions.
Tighten the nut (Item 1) until the spring is compressed
enough to install the snap ring (Item 2) [Figure 20-50-
136].

Remove the threaded rod / washer assembly.

317 of 918 20-50-47 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Set the pump housing in the up-right position.

Assembly (Cont’d) Figure 20-50-141

Figure 20-50-139

2
1
1

P-61072

P-61074
Install the shim (Item 1) [Figure 20-50-141].

Slide the rotary group assembly (Item 1) on the shaft Figure 20-50-142
(Item 2) [Figure 20-50-139].

Dealer Copy -- Not for Resale

Figure 20-50-140

2
1

P-61086

P-61073 Install the bearing (Item 1) [Figure 20-50-142] on the

shaft.

Lay the pump housing on its side and install the rotary Install the O-ring (Item 2) [Figure 20-50-142].
group assembly, swash plate and shaft in the housing
[Figure 20-50-140].

318 of 918 20-50-48 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-145

Assembly (Cont’d)
1
Figure 20-50-143

P-61089
1
3
Install the stroking piston assembly (Item 1) [Figure 20-
N-23399 50-145].

Figure 20-50-146
Install the valve plate (Item 1) on the port block assembly.
The valve plate can only be installed by aligning the

Dealer Copy -- Not for Resale

groove (Item 2) with the pin (Item 3) [Figure 20-50-143]. 1

Figure 20-50-144

3
1 2
2
3

1
1
P-61090

1
Install the end cap (Item 1) [Figure 20-50-146].

P-61087 NOTE: Align the stroking piston assembly (Item 2)

with the shaft (Item 3) [Figure 20-50-146].

Install the O-rings (Item 1) [Figure 20-50-144].

Grease the inside of the control piston (Item 2) [Figure

20-50-144].

Install the control piston (Item 2) on the control piston

shaft (Item 3) [Figure 20-50-144].

319 of 918 20-50-49 E85 Service Manual

PUMP (HYDRAULIC PISTON) (CONT’D) Figure 20-50-149

Assembly (Cont’d)

Figure 20-50-147

1
1 N-23354

Apply Loctite® 241 or equivalent on the bolt (Item 1)

P-61055 [Figure 20-50-149]. Tighten the bolt to 13 N•m (10 ft-lb)
torque.

Install the four bolts (Item 1) [Figure 20-50-147] and Install the torque limiter valve. (See Torque Limiter Valve
tighten to 119 N•m (88 ft-lb) torque. Removal And Installation on Page 20-50-16.)

Dealer Copy -- Not for Resale

Figure 20-50-148 Install the pump control assembly. (See Pump Control
Removal And Installation on Page 20-50-28.)

2
N-23355

Install the pin assembly (Item 1) [Figure 20-50-148].

The dowel pin (Item 2) must be fully seated in the hole

(Item 3) [Figure 20-50-148] on the swash plate.

320 of 918 20-50-50 E85 Service Manual

PUMP (GEAR) Pump Testing

Testing Information Figure 20-51-2

All testing is done with the hydraulic oil at 50 - 60°C (122

- 140°F).

Check and adjust the engine high idle as needed before

any hydraulic testing.

The hydraulic hoses, tubelines and fittings on the E80

Excavator are BSPP fittings. 1
Figure 20-51-1

P112298

Remove the hose (Item 1) [Figure 20-51-2] from the

2 gear pump.
1
Figure 20-51-3

Dealer Copy -- Not for Resale

P103673

To test the gear pump, use the following fittings from

MEL1713 Hydraulic Test Kit:

Item 1 [Figure 20-51-1]: MEL1713-1 Male-8 BSPP to 1

Male 8 NPTF.
2
Item 2 [Figure 20-51-1]: MEL1713-2 Female-8 to Male-8
NPTF. P112299

Connect the hydraulic tester inlet side (Item 1) [Figure

20-51-3] and adapter fitting to the gear pump.

Connect the hydraulic tester outlet side (Item 2) [Figure

20-51-3] and adapter fitting to the hose removed from the
gear pump.

321 of 918 20-51-1 E85 Service Manual

PUMP (GEAR) (CONT'D) NOTE: The high pressure flow must be at least 80%
of the free flow.
Pump Testing (Cont’d) HIGH PRESSURE FLOW (L/min [U.S. gpm])
%= X 100
Figure 20-51-4 FREE FLOW (L/min [U.S. gpm])

If the high pressure flow is less than 80% of the free flow,
remove the hydraulic pump for repair or replacement.

P-22253

Turn the hydraulic tester flow control (Item 1) [Figure 20-

51-4] counterclockwise until all restriction is removed.

Dealer Copy -- Not for Resale

NOTE: This is a direct pump test. There is no relief
valve in the system.

Start and run the engine at a low rpm. Make sure the
tester is connected correctly. If no flow is indicated at the
tester, the hoses are connected wrong.

Increase the engine speed to full rpm. Warm up the

hydraulic fluid to a temperature of 50 - 60°C (122 - 140°F)
by turning the restrictor valve until the gauge reads about
6900 kPa (69 bar) (1000 psi).

Fully open the restrictor valve when the temperature is

correct.

Record the pump free flow L/min (U.S. gpm).

Pump flow on a new pump is 21,9 L/min (5.8 U.S. gpm) at

2200 engine rpm.

Slowly close the flow control knob (Item 1) [Figure 20-

51-4] to 13400 kPa (134 bar) (1950 psi).

Record the pump high pressure flow L/min (U.S. gpm).

322 of 918 20-51-2 E85 Service Manual

PUMP (GEAR) (CONT'D) Figure 20-51-6

Removal And Installation

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-140-6.)

Mark the pump for correct installation.

1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P112300
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Installation: Install the O-ring (Item 1) [Figure 20-51-6]
I-2003-0888 in the O-ring groove of the flange.

Figure 20-51-5 Figure 20-51-7

Dealer Copy -- Not for Resale

1 1

P112298 P112301

Remove the four bolts (Item 1) [Figure 20-51-5], flange Remove the four bolts, flange (Item 1) [Figure 20-51-7]
and hose from the high pressure side of the pump. and hose from the suction side of the pump.

323 of 918 20-51-3 E85 Service Manual

PUMP (GEAR) (CONT'D) Figure 20-51-10

Removal And Installation (Cont’d)

Figure 20-51-8

2
1

P112304

Remove the O-ring (Item 1) and coupler (Item 2) [Figure

P112302 20-51-10].

Installation: Install the O-ring (Item 1) [Figure 20-51-8]

in the O-ring groove of the flange.

Dealer Copy -- Not for Resale

Figure 20-51-9

P112303

Remove the bolts (Item 1) [Figure 20-51-9] and the

pump.

324 of 918 20-51-4 E85 Service Manual

PUMP (GEAR) (CONT'D) Figure 20-51-13

Disassembly And Assembly

Figure 20-51-11
1

P-87379

Remove the end cap (Item 1) [Figure 20-51-13].

P-87377
Figure 20-51-14

Mark the pump (Item 1) [Figure 20-51-11] for correct

assembly.

Dealer Copy -- Not for Resale

1
Figure 20-51-12

1 1

1
1 P-87380

Remove the gear housing (Item 1) [Figure 20-51-14].

P-87378

Remove the four bolts (Item 1) [Figure 20-51-12].

Installation: Tighten the bolts to 61 N•m (45 ft-lb) torque.

325 of 918 20-51-5 E85 Service Manual

PUMP (GEAR) (CONT'D) Figure 20-51-17

Disassembly And Assembly (Cont’d)

Figure 20-51-15

P-87383

Remove the bearings (Item 1) [Figure 20-51-17].

P-87381
Figure 20-51-18

Remove the square cut seal (Item 1) [Figure 20-51-15]

from both sides of the gear housing.

Dealer Copy -- Not for Resale

1
Figure 20-51-16

P-87384

Separate the bearings and remove the dowel pin (Item 1)

[Figure 20-51-18].
P-87382

Remove the seal and back-up ring (Item 1) [Figure 20-

51-16].

326 of 918 20-51-6 E85 Service Manual

PUMP (GEAR) (CONT'D) Figure 20-51-21

Disassembly And Assembly (Cont’d)

1
Figure 20-51-19

P-87387

2 Remove the seal and back-up ring (Item 1) [Figure 20-

P-87385 51-21].

Figure 20-51-22
Remove the drive gear (Item 1). Remove the idler gear
(Item 2) [Figure 20-51-19].

Dealer Copy -- Not for Resale

Figure 20-51-20
1

P-87384

Separate the bearings and remove the dowel pin (Item 1)

P-87386 [Figure 20-51-22].

Remove the bearings (Item 1) [Figure 20-51-20].

327 of 918 20-51-7 E85 Service Manual

PUMP (GEAR) (CONT'D) Figure 20-51-25

Disassembly And Assembly (Cont’d)

Figure 20-51-23
1
1

P-87390

1 Remove the seal (Item 1) [Figure 20-51-25].

P-87388

Remove the dowel pins (Item 1) [Figure 20-51-23].

Dealer Copy -- Not for Resale

Figure 20-51-24

P-87138

Remove the snap ring (Item 1) [Figure 20-51-24].

328 of 918 20-51-8 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR Figure 20-60-2

Description

The accumulator provides short term reserve pressure 1

for joystick function with the engine off and the key in the
run position. 1

Removal And Installation

With the engine off and the key in the run position, move
the control levers to relieve hydraulic pressure.

Tilt the cab. (See Raising And Lowering on Page 10-210-

1.)
P112437
Figure 20-60-1

Mark and remove the hoses (Item 1) [Figure 20-60-2].

Figure 20-60-3

1
1 1

Dealer Copy -- Not for Resale

1
2

2
P112425

Mark and remove the hoses (Item 1) [Figure 20-60-1].

P112436

IMPORTANT Mark and disconnect the wire harness (Item 1) [Figure

20-60-3].

When repairing hydrostatic and hydraulic systems, Remove the bolts (Item 2) [Figure 20-60-3] and remove
clean the work area before disassembly and keep all the manifold.
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

329 of 918 20-60-1 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-6

Disassembly And Assembly

Figure 20-60-4

1 1 1

P112427

Remove the O-rings (Item 1) [Figure 20-60-6].

P112432
Figure 20-60-7

Remove the nuts (Item 1) [Figure 20-60-4] and remove

the coils. 1

Dealer Copy -- Not for Resale

Installation: Tighten the nuts to 4,8 - 5,2 N•m (3.5 - 3.8
ft-lb) torque.

Figure 20-60-5

P112428

Remove the pressure reducing valve (Item 1) [Figure 20-

60-7].

Installation: Tighten the valve to 37 - 39,4 N•m (28.8 -

29 ft-lb) torque.
P112431

Remove the spools (Item 1) [Figure 20-60-5].

Installation: Tighten the spools to 34 - 34,5 N•m (25 -

25.5 ft-lb) torque.

330 of 918 20-60-2 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-10

Disassembly And Assembly (Cont’d)

Figure 20-60-8 2

2 2

2
1

P112433
1 1

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

P-87111 [Figure 20-60-10].

Figure 20-60-11
Remove the back-up rings (Item 1) and O-rings (Item 2)
[Figure 20-60-8].

Dealer Copy -- Not for Resale

Figure 20-60-9

P112430

Remove the plug (Item 1) [Figure 20-60-11].

P112429
Installation: Tighten the plug to 24,3 - 24,7 N•m (17.9 -
18.2 ft-lb) torque.
Remove the check valve (Item 1) [Figure 20-60-9].

Installation: Tighten the check valve to 39 - 39,4 N•m

(28.8 - 29 ft-lb) torque.

331 of 918 20-60-3 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-14

Disassembly And Assembly (Cont’d)

Figure 20-60-12

P-87115
1

Remove the O-ring (Item 1) [Figure 20-60-14].

P112434

Remove the O-ring (Item 1) [Figure 20-60-12].

Dealer Copy -- Not for Resale

Figure 20-60-13

P112435

Remove the accumulator (Item 1) [Figure 20-60-13].

332 of 918 20-60-4 E85 Service Manual

TRAVEL MOTOR Figure 20-70-3

Removal And Installation

Remove the track. (See Track Removal And Installation

on Page 30-20-3.) or (See Track Removal And
Installation on Page 30-20-3.)

Remove the drive sprocket. (See Sprocket Removal And 2

Installation on Page 30-20-35.)

Figure 20-70-1 1

P-87914

Attach a lifting hook (Item 1) and chain (Item 2) [Figure

1
1 20-70-3] to the travel motor.
1
Remove the travel motor.

Dealer Copy -- Not for Resale

P-87909

Remove the bolts (Item 1) [Figure 20-70-1].

Remove the cover (Item 2) [Figure 20-70-1].

Figure 20-70-2

1 2
2
1 2

2
2
P-87910

Remove the hoses (Item 1) and bolts (Item 2) [Figure 20-

70-2].

Installation: Apply thread lock adhesive (Loctite® 242 or

equivalent) to the bolt threads. Tighten the bolts to 265
N•m (195 ft-lb) torque.

333 of 918 20-70-1 E85 Service Manual

TRAVEL MOTOR (CONT'D)

Parts Identification

1 Spring
2 Piston Assembly
3 Shoe 2 1
3
4 Pin
5 4
5 Pivot 6
6 Seal
7
7 Bearing
8 Shaft 8
9 Swash Plate 9
10 Piston
11 Retainer Plate 10
12 Thrust Ball
13 Washer 11
14 Pin
15 Cylinder 12
16 Snap Ring
17 Mating Plate
18 Friction Plate
13

Dealer Copy -- Not for Resale

19 O-ring
20 Timing Plate 14
21 Plug 15
22 Rear Flange 13 17
23 Retainer Spring 1 18
13
24 Filter 16 19
25 Ball 10
26 Valve 19
27 Spool 1
28 Bolt 21 21
19 20
29 Back-up Ring 1
30 Sleeve 22
23 19 7
31 Collar 21 19
32 Shim 1 26
33 Poppet
4
1 24
21 25
19 19 21
1 31 21 27
21 23
19 21
32 19 1 19
30 16 21
28 26 1
19
29 19
10
29 21
33 19
26
33 19
19
29 30
10 31
29 1
19
21
32

B-23945

334 of 918 20-70-2 E85 Service Manual

TRAVEL MOTOR (CONT'D)

Parts Identification Gear Reduction Hub

1 Bolt
2 Thrust Washer
3 Planetary Gear
4 Roller Bearing
5 Inner Ring
6 Collar
7 Nut
8 Ball Bearing
9 Hub
2 1
10 Seal 3
11 Spindle 4
12 Pin
5
13 O-ring 2
14 Plug
15 Snap Ring 7
16 Cover 8 6
17 Steel Ball
9
18 Sun Gear
19 Carrier

Dealer Copy -- Not for Resale

8
10
11

14
15 13
16
12 13
13
3 2 1 17

4
5
19
18

B-23946

335 of 918 20-70-3 E85 Service Manual

TRAVEL MOTOR (CONT'D) Recycle or dispose of used fluid in an environmentally
safe manner.
Disassembly
Figure 20-70-6
Clean the outside of the travel motor before disassembly.

Figure 20-70-4
P-89338

Remove the snap ring (Item 1) [Figure 20-70-6].

Figure 20-70-7

Dealer Copy -- Not for Resale

P-89004

1
Remove the plugs (Item 1) [Figure 20-70-4].

Remove and discard the O-rings from the plugs.

P-89085
Figure 20-70-5

Remove the cover (Item 1) [Figure 20-70-7].

Remove and discard the O-ring from the cover.

P-89005

Drain the fluid from the travel motor [Figure 20-70-5].

336 of 918 20-70-4 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-10

Disassembly (Cont’d)
1
Figure 20-70-8

2
1

P-89010

Remove the bolts, thrust washers, and planetary gears

P-89008 (Item 1) [Figure 20-70-10].

Remove the roller bearing and inner ring from the carrier.
Remove the sun gear (Item 1) [Figure 20-70-8].
NOTE: Do not reuse the bolts holding the planetary

Dealer Copy -- Not for Resale

Remove the steel ball (Item 2) [Figure 20-70-8] from the gears to the carrier.
sun gear.
Figure 20-70-11
Figure 20-70-9

1
2

P-89011
P-89009

Remove the snap ring (Item 1) and sun gear (Item 2)

Remove the carrier assembly (Item 1) [Figure 20-70-9] [Figure 20-70-11] from the carrier.
from the hub.

337 of 918 20-70-5 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-14

Disassembly (Cont’d)

Figure 20-70-12

1
1

2 P-89339

Remove the sleeve (Item 1) [Figure 20-70-14].

P-89012
Figure 20-70-15

Remove the bolts (Item 1) and thrust washers (Item 2)

[Figure 20-70-12].

Dealer Copy -- Not for Resale

Figure 20-70-13

2
P-89014

Remove the plug (Item 1) [Figure 20-70-15].

P-89013

Remove the planetary gears (Item 1), roller bearings and

inner rings (Item 2) [Figure 20-70-13].

Remove the thrust washers and thrust collars from the

spindle.

338 of 918 20-70-6 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-18

Disassembly (Cont’d)

Figure 20-70-16

P-89017

Remove the bolts from the rear flange [Figure 20-70-18].

P-89015
Figure 20-70-19

Remove the plug (Item 1) [Figure 20-70-16].

Dealer Copy -- Not for Resale

Figure 20-70-17

1
1

P-89018

Remove the rear flange (Item 1) [Figure 20-70-19].

P-89016

Remove the plug (Item 1) [Figure 20-70-17].

339 of 918 20-70-7 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-22

Disassembly (Cont’d)

Figure 20-70-20

P-89021

Remove the timing plate (Item 1) [Figure 20-70-22].

P-89019
Figure 20-70-23

Remove the pins (Item 1) [Figure 20-70-20].

Dealer Copy -- Not for Resale

Figure 20-70-21

P-89022

Remove the pin (Item 1) [Figure 20-70-23] from the rear

P-89020
flange.

Remove and discard the two O-rings (Item 1) [Figure 20-

70-21].

Remove the ten springs from the rear flange.

340 of 918 20-70-8 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-26

Disassembly (Cont’d)

Figure 20-70-24

1
1 2

P-89025

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

P-89023 [Figure 20-70-26] from the valve seat.

Discard the O-ring and back-up rings.

Remove the bearing (Item 1) [Figure 20-70-24].
Figure 20-70-27

Dealer Copy -- Not for Resale

Figure 20-70-25

P-89026
P-89024

Remove the O-ring (Item 1) [Figure 20-70-27] from the

Remove the sleeve (Item 1) [Figure 20-70-25]. sleeve.

Discard the O-ring.

341 of 918 20-70-9 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-30

Disassembly (Cont’d)

Figure 20-70-28

P-89029

1
Remove the O-ring (Item 1) [Figure 20-70-30] from the
P-89027 plug.

Figure 20-70-31
Remove the plug (Item 1) [Figure 20-70-28] from the
rear flange. (Both sides)

Dealer Copy -- Not for Resale

Remove the spring retainer and spring. (Both sides)

Figure 20-70-29

P-89030

Remove the plug (Item 1) [Figure 20-70-31].

1
P-89028

Remove the spool (Item 1) [Figure 20-70-29].

342 of 918 20-70-10 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-34

Disassembly (Cont’d)

Figure 20-70-32

1 P-89033

Remove the plug (Item 1) [Figure 20-70-34].

P-89031
Remove and discard the O-ring from the plug.

Remove the spring and valve (Item 1) [Figure 20-70-32]. Figure 20-70-35

Dealer Copy -- Not for Resale

Figure 20-70-33

P-89075
1
P-89032
Remove the spool (Item 1) [Figure 20-70-35] and spring.

Remove the O-ring (Item 1) [Figure 20-70-33] from the

plug.

Discard the O-ring.

343 of 918 20-70-11 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-38

Disassembly (Cont’d)

Figure 20-70-36

P-89037

Remove the cylinder block assembly (Item 1) [Figure 20-

P-89035 70-38].

Figure 20-70-39
Remove the piston by injecting low air pressure into the
access hole in the spindle [Figure 20-70-36].

Dealer Copy -- Not for Resale

Remove the O-ring from the piston.

Discard the O-ring.

Turn the motor on its side and drain the hydraulic fluid
into an approved container.

Figure 20-70-37
1 2

P-89038
1

Remove the piston assembly (Item 1) from the cylinder

block (Item 2) [Figure 20-70-39].

P-89036

Remove the mating plates and friction plates (Item 1)

[Figure 20-70-37].

344 of 918 20-70-12 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-42

Disassembly (Cont’d)

Figure 20-70-40
1

2
1
2 1

P-89041

1 Remove the washer and pins (Item 1) from the cylinder

P-89039 block (Item 2) [Figure 20-70-42].

Remove the pistons (Item 1) from the retainer plate (Item

2) [Figure 20-70-40].

Dealer Copy -- Not for Resale

Figure 20-70-41

P-89040

Remove the thrust ball (Item 1) from the cylinder block

(Item 2) [Figure 20-70-41].

345 of 918 20-70-13 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-45

Disassembly (Cont’d)

Figure 20-70-43
1

P-89045

Remove the swash plate (Item 1) [Figure 20-70-45].

P-89043
Figure 20-70-46

Place the cylinder block in a press [Figure 20-70-43].

Dealer Copy -- Not for Resale

Figure 20-70-44

3
P-89046

Remove the shaft (Item 1) [Figure 20-70-46].

P-89044

Remove the snap ring (Item 1), washer (Item 2), and
spring (Item 3) [Figure 20-70-43] and [Figure 20-70-44].

346 of 918 20-70-14 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-49

Disassembly (Cont’d)

Figure 20-70-47

1
2

P-89049

Remove the set screws (Item 1) [Figure 20-70-49].

P-89336
Figure 20-70-50

Place the shaft (Item 1) in a press and remove the

bearing (Item 2) [Figure 20-70-47].

Dealer Copy -- Not for Resale

Do not reuse the bearing.

Figure 20-70-48
1

P-89052

Remove the nut (Item 1) [Figure 20-70-50].

Do not reuse the nut.

P-89047

Remove the pivots and parallel pins (Item 1) [Figure 20-

70-48].

Remove the two-speed pistons and springs by applying

low air pressure to the oil passages.

347 of 918 20-70-15 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-53

Disassembly (Cont’d)

Figure 20-70-51

1 1

P-89055

2
Remove the bearing (Item 1) [Figure 20-70-53] from
P-89053 both sides of the hub.

Figure 20-70-54
Separate the spindle (Item 1) from the hub (Item 2)
[Figure 20-70-51].

Dealer Copy -- Not for Resale

Figure 20-70-52

1
1

P-89056

2
Remove the seal ring assembly (Item 1) [Figure 20-70-
P-89054 54] from the spindle.

Remove the seal ring assembly (Item 1) from the hub

(Item 2) [Figure 20-70-52].

NOTE: Do not reuse the seal.

348 of 918 20-70-16 E85 Service Manual

TRAVEL MOTOR (CONT'D)

Disassembly (Cont’d)

Figure 20-70-55

P-89057

Remove the oil seal (Item 1) from the spindle (Item 2)

[Figure 20-70-55].

Dealer Copy -- Not for Resale

349 of 918 20-70-17 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-57

Assembly
1
Clean all parts in solvent and dry with compressed air.
Inspect all parts and replace those that are damaged. If
any of the planetary gears are damaged, replace all the
planetary gears and the sun gear from that planetary.
2
One damaged gear can cause a microscopic fatigue
crack in the mating teeth and cause premature failure
after servicing.

Apply oil to all O-rings (as noted) and light grease to the
ball and roller bearings before installation.
P-46426
Position the hub in a press.

Figure 20-70-56 Install the O-ring (Item 1) on both seal rings (Item 2)
[Figure 20-70-57].

NOTE: Inspect the seal ring for burrs before installing

the O-ring. Make sure the O-ring is not twisted
when installing it. To remove any twists,

Dealer Copy -- Not for Resale

gently pull a section of the O-ring and let it
snap back.

Figure 20-70-58

P-89061

Install the bearing (Item 1) [Figure 20-70-56].

Use the same procedure to install the bearing on the

opposite side of the hub.

Apply a light film of grease onto the O-ring of the seal ring
assemblies. P-61811

Install the seal ring assembly (Item 1) [Figure 20-70-58].

Use firm even pressure to pop the O-ring into the

housing.

Apply a light film of oil to the metal seal ring.

350 of 918 20-70-18 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-61

Assembly (Cont’d)

Figure 20-70-59

P-87899

The seal assembly stand off height must be equal and

P-61812 the O-ring must not be twisted [Figure 20-70-61].

Figure 20-70-62
The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 20-70-59].

Dealer Copy -- Not for Resale

Figure 20-70-60

P-89053

Install the spindle onto the hub [Figure 20-70-62].

P-87900
Apply Loctite® 270 (or equivalent) to a new ring nut.

Install the seal ring assembly (Item 1) [Figure 20-70-60]. Install the ring nut with the chamfer towards the bearing.

Use firm even pressure to pop the O-ring into the

housing.

Apply a light film of oil to the metal seal ring.

351 of 918 20-70-19 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-65

Assembly (Cont’d)

Figure 20-70-63

P-89067

Install the oil seal (Item 1) [Figure 20-70-65] into the

P-89050 spindle.

Install the parallel pin / pivot assemblies.

Use a spanner wrench and tighten the nut to 533 - 644
N•m (393 - 475 ft-lb) torque [Figure 20-70-63]. Install the spring into the piston.

Dealer Copy -- Not for Resale

Figure 20-70-64 Figure 20-70-66

P-89049 P-89068

Install the set screws (Item 1) [Figure 20-70-64]. Install the piston assembly (Item 1) [Figure 20-70-66]
into the spindle.
Tighten the set screws to 8 - 11 N•m (6 - 8 ft-lb).

352 of 918 20-70-20 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-69

Assembly (Cont’d)

Figure 20-70-67 1

P-89045

Install the swash plate (Item 1) [Figure 20-70-69].

P-89069
NOTE: Make sure the pivots mounted on the spindle
enter the pivot holes of the swash plate.
Heat the bearing (Item 1) to 72 - 128°C (162 - 262°F) and
install the shaft (Item 2) [Figure 20-70-67]. Figure 20-70-70

Dealer Copy -- Not for Resale

Figure 20-70-68

2
5

3
1

P-89043

P-89070
Install the washer (Item 1), spring (Item 2), washer (Item
3) and snap ring (Item 4) into the cylinder block (Item 5)
Install the shaft (Item 1) [Figure 20-70-68] into the [Figure 20-70-70].
spindle.

353 of 918 20-70-21 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-73

Assembly (Cont’d)

Figure 20-70-71

1
1
1
2

1
P-89039

Install the pistons (Item 1) into the retainer plate (Item 2)

P-89041 [Figure 20-70-73].

Figure 20-70-74
Install the pins (Item 1) [Figure 20-70-71] into the
cylinder block.

Dealer Copy -- Not for Resale

1
Figure 20-70-72

P-61778

Install the piston assembly (Item 1) [Figure 20-70-74]

P-89040 into the cylinder block.

Install the washer and thrust ball (Item 1) [Figure 20-70-

72] onto the cylinder block.

354 of 918 20-70-22 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-77

Assembly (Cont’d)

Figure 20-70-75

1
1

P-89073

Install the friction plate (Item 1) [Figure 20-70-77]. Install

P-89036 the remaining mating plates and friction plates
alternately.

Install the cylinder block assembly (Item 1) [Figure 20- NOTE: Immerse the friction plates in hydraulic fluid
70-75] onto the shaft. prior to installation.

Dealer Copy -- Not for Resale

Figure 20-70-76 Figure 20-70-78

1
1

P-89072 P-89035

Install the mating plate (Item 1) [Figure 20-70-76]. Install the O-ring onto the piston. Install the piston (Item
1) [Figure 20-70-78] into the spindle.

355 of 918 20-70-23 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-81

Assembly (Cont’d)

Figure 20-70-79

1
P-89028

1 Install the spool (Item 1) [Figure 20-70-81].

P-89032
Figure 20-70-82

Install the O-ring (Item 1) [Figure 20-70-79] onto the

plug.

Dealer Copy -- Not for Resale

Install the valve and spring into the plug. 1

Figure 20-70-80

P-89029

Install the O-ring (Item 1) [Figure 20-70-82] onto the

1
plug.

P-89031

Install the plug assembly (Item 1) into the rear flange

(Item 2) [Figure 20-70-80].

Do not tighten it yet.

356 of 918 20-70-24 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-85

Assembly (Cont’d)

Figure 20-70-83

P-89025

Install the O-ring and back-up ring (Item 1) [Figure 20-

P-89027 70-85].

Figure 20-70-86
Install the spring retainer, spring and plug (both ends of
the spool) [Figure 20-70-83].

Dealer Copy -- Not for Resale

Figure 20-70-84

P-89074

1
Install the valve (Item 1) [Figure 20-70-86].
P-89026

Install the O-ring (Item 1) [Figure 20-70-84] onto the

valve.

357 of 918 20-70-25 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-89

Assembly (Cont’d)

Figure 20-70-87

1
1

P-89021

Install the timing plate (Item 1) [Figure 20-70-89].

P-89075
Figure 20-70-90

Install the spring (Item 1) and spool (Item 2) [Figure 20-

70-87].

Dealer Copy -- Not for Resale

Install the O-ring on the plug and install the plug.

Do not tighten it yet.

Figure 20-70-88
1

P-89340

1
Install the springs (Item 1) [Figure 20-70-90].

P-89023

Install the bearing (Item 1) [Figure 20-70-88].

Install the parallel pins.

358 of 918 20-70-26 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-93

Assembly (Cont’d)

Figure 20-70-91
1

1
P-89018

Install the rear flange (Item 1) onto the spindle (Item 2)

P-89020 [Figure 20-70-93]. Make sure the pins on the spindle
align with the holes in the rear flange.

Install the O-rings (Item 1) [Figure 20-70-91] into the Tighten the bolts to 85 - 118 N•m (63 - 87 ft-lb) torque.
groove of the spindle.

Dealer Copy -- Not for Resale

Figure 20-70-94
Figure 20-70-92

P-89015
P-89019

Tighten the plug (Item 1) [Figure 20-70-94] to 78 - 117

Install the parallel pins (Item 1) [Figure 20-70-92]. N•m (58 - 86 ft-lb) torque.

Add 1,2 L (1.3 qt) of hydraulic fluid to the spindle.

359 of 918 20-70-27 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-97

Assembly (Cont’d)

Figure 20-70-95 1

P-89016
1

Tighten the plug (Item 1) [Figure 20-70-97] to 74 - 117

P-89339 N•m (58 - 86 ft-lb) torque.

Figure 20-70-98
Tighten the valve (Item 1) [Figure 20-70-95] to 122 - 152
N•m (90 - 112 ft-lb) torque.

Dealer Copy -- Not for Resale

Figure 20-70-96

2 1

1 P-89011

Insert the sun gear (Item 1) into the carrier and install the
P-89014 snap ring (Item 2) [Figure 20-70-98].

Tighten the plug (Item 1) [Figure 20-70-96] to 313 - 392

N•m (231 - 289 ft-lb) torque.

360 of 918 20-70-28 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-101

Assembly (Cont’d)

Figure 20-70-99

P-89079

Install the thrust collar (Item 1) [Figure 20-70-101].

P-89010
Figure 20-70-102

Install the inner race, bearing and planetary gears (Item

1) [Figure 20-70-99] onto the carrier.

Dealer Copy -- Not for Resale

2
Figure 20-70-100

P-89080

Install the thrust washer (Item 1) onto the spindle shaft

(Item 2) [Figure 20-70-102].
P-89078

Install thrust washers and new bolts (Item 1) [Figure 20-

70-100].

Tighten the bolts to 28 - 39 N•m (21 - 29 ft-lb) torque

361 of 918 20-70-29 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-105

Assembly (Cont’d)

Figure 20-70-103
1

P-89083

Install the carrier assembly (Item 1) [Figure 20-70-105].

P-89013
Figure 20-70-106

Install the inner race, bearing and planetary gear (Item 1)

[Figure 20-70-103].

Dealer Copy -- Not for Resale

1
Figure 20-70-104

P-89084

Install the steel ball (Item 1) onto the sun gear (Item 2)
[Figure 20-70-106].
P-89082
Install the sun gear.

Install the thrust washers and new bolts (Item 1) [Figure Install the O-ring into the groove in the hub
20-70-104].

Tighten the bolts to 49 - 68 N•m (36 - 50 ft-lb) torque

362 of 918 20-70-30 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-109

Assembly (Cont’d)

Figure 20-70-107

1
P-89087

Install the plugs (Item 1) [Figure 20-70-109].

P-89085
Tighten the plugs to 49 - 68 N•m (36 - 50 ft-lb) torque.

Install the hub cover (Item 1) [Figure 20-70-107].

Dealer Copy -- Not for Resale

Figure 20-70-108

P-89338

Install the snap ring (Item 1) [Figure 20-70-108].

Install O-rings on the plugs.

363 of 918 20-70-31 E85 Service Manual

Dealer Copy -- Not for Resale

364 of 918 20-70-32 E85 Service Manual

SWIVEL JOINT Figure 20-80-2

Removal And Installation

P-89335A
Tilt the cab. (See Raising And Lowering on Page 10-210-
1.)
Attach a sling (Item 1) [Figure 20-80-2].
Remove the center cover. (See Removal And Installation
on Page 40-70-1.) Figure 20-80-3

Mark the hoses. 2

Dealer Copy -- Not for Resale

Figure 20-80-1
1 1
1
1
1

1
1

1 P-89311

1
1 Remove the bolts (Item 1) and bottom access plate (Item
2) [Figure 20-80-3].
P-89310

Mark the hoses for ease of installation.

Remove the hoses (Item 1) [Figure 20-80-1] from the top
of the swivel joint.

365 of 918 20-80-1 E85 Service Manual

SWIVEL JOINT (CONT'D) Figure 20-80-6

Removal And Installation (Cont’d)

1
Figure 20-80-4

P-89314

Remove the hoses (Item 1) [Figure 20-80-6].

P-89312
Figure 20-80-7

Remove the hoses (Item 1) [Figure 20-80-4].

Dealer Copy -- Not for Resale

Figure 20-80-5
1

P-89315

Remove the hoses (Item 1) [Figure 20-80-7].

P-89313

Remove the hoses (Item 1) [Figure 20-80-5].

366 of 918 20-80-2 E85 Service Manual

SWIVEL JOINT (CONT'D)

Removal And Installation (Cont’d)

Figure 20-80-8

P-89316

Remove the bolts (Item 1) [Figure 20-80-8].

Dealer Copy -- Not for Resale

Figure 20-80-9

P-89317

Remove the bolts (Item 1) [Figure 20-80-9].

367 of 918 20-80-3 E85 Service Manual

SWIVEL JOINT (CONT'D)

Parts Identification

1. Plug
2. Rotor
3. Dust Seal 1
4. O-ring
5. Seal 2
6. Housing
7. Shim 6
8. Spacer
9. Retainer
10. Cover
11. Washer
12. Bolt

Dealer Copy -- Not for Resale

3
8

4 9

5 10

MS2788

368 of 918 20-80-4 E85 Service Manual

SWIVEL JOINT (CONT'D) Figure 20-80-12

Disassembly 2
3
Figure 20-80-10 1

1 1
1

1 1 NA1242

2
Remove the seals (Item 1), O-ring (Item 2) and dust seal
NA1240 (Item 3) [Figure 20-80-12] from the housing.

Figure 20-80-13
Remove the bolts (Item 1) and cover (Item 2) [Figure 20-
80-10].

Dealer Copy -- Not for Resale

Remove the shim and O-ring from the cover.
1
Remove the snap ring, spacer and shim from the bottom
of the rotor. 1

Figure 20-80-11

1 1
1 NA1244

Remove the plugs (Item 1) [Figure 20-80-13].

NA1241

Remove the rotor (Item 1) from the housing (Item 2)

[Figure 20-80-11].

369 of 918 20-80-5 E85 Service Manual

SWIVEL JOINT (CONT'D) Figure 20-80-15

Assembly 2
3
Clean all components in solvent and dry with 1
compressed air.
1
NOTE: Be careful not to scratch the rotor surface as
damage to the finished surface could cause
1
internal leakage.

Check the components for wear and damage. 1

Always use new seals and O-rings.

Apply clean hydraulic oil to the components during NA1242

installation.

Wrap the plugs with teflon tape. Install the seals (Item 1), O-ring (Item 2) and dust seal
(Item 3) [Figure 20-80-15] in the housing.
Figure 20-80-14
Figure 20-80-16

Dealer Copy -- Not for Resale

1
1

1 NA1243

Install the plugs (Item 1) [Figure 20-80-14]. Tighten the 2

plugs to 58 - 69 N•m (43 - 51 ft-lb) torque.

Install the plugs (Item 2) [Figure 20-80-14]. Tighten the

plugs to 30 - 39 N•m (22 - 29 ft-lb) torque.

NA1245

Install the housing (Item 1) on the rotor (Item 2) [Figure

20-80-16].

370 of 918 20-80-6 E85 Service Manual

SWIVEL JOINT (CONT'D) Figure 20-80-18

Assembly (Cont’d)

Figure 20-80-17
1 1
4 5
2

1 1

3 6
NA1240
1

Install the bolts (Item 1) [Figure 20-80-18]. Tighten the

NA1246 bolts to 49 - 59 N•m (36 - 44 ft-lb) torque.

Install the shim (Item 1), spacer (Item 2) and snap ring
(Item 3) [Figure 20-80-17].

Dealer Copy -- Not for Resale

Install the O-ring (Item 4), shim (Item 5) and cover (Item
6) [Figure 20-80-17].

371 of 918 20-80-7 E85 Service Manual

Dealer Copy -- Not for Resale

372 of 918 20-80-8 E85 Service Manual

SWING MOTOR Figure 20-90-2

Removal And Installation

Remove the center cover. (See Removal And Installation

on Page 40-70-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-140-6.)

Tilt the cab. (See Raising And Lowering on Page 10-210-

1.) 1
1
Figure 20-90-1

P112449

Remove the hoses (Item 1) [Figure 20-90-2] from the PG

and SH ports.

Figure 20-90-3
1

Dealer Copy -- Not for Resale

P-87254

Remove the plug (Item 1) [Figure 20-90-1] and drain the

1
swing motor drive carrier.

IMPORTANT P112450

When repairing hydrostatic and hydraulic systems, Remove the hoses (Item 1) [Figure 20-90-3] from the A
clean the work area before disassembly and keep all and B ports.
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

NOTE: Mark all hoses before removal for ease of

installation.

373 of 918 20-90-1 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-6

Removal And Installation (Cont’d)

Figure 20-90-4

1
1
1
1
1

1 P112453

Remove the bolts (Item 1) [Figure 20-90-6].

P112451
Installation: Tighten the bolts to 101,7 ± 16 N•m (75 ±
12 ft-lb) torque.
Remove the hoses (Item 1) [Figure 20-90-4].
Figure 20-90-7

Dealer Copy -- Not for Resale

Figure 20-90-5

1
1

2
P11254
P112464

Install two bolts (Item 1) [Figure 20-90-7] (removed in

Mark the swing motor (Item 1) and swing motor drive previous step) in the threaded holes in the swing motor.
carrier (Item 2) [Figure 20-90-5] for proper installation. Tighten the bolts evenly to separate the swing motor from
the swing motor drive carrier.

Remove the swing motor.

374 of 918 20-90-2 E85 Service Manual

SWING MOTOR (CONT’D)

Parts Identification

1. Relief Valve
2. Bolt
3. Plug
4. O-ring
5. Spring 3
1
6. Anti-cavitation Valve
7. End Cap
8. Bearing 2
9. Valve Plate
10. Spring 6
11. Brake Piston 7 5
12. Separation Plate
13. Friction Plate 3
8
14. Snap Ring
15. Washer 4
9
16. Cylinder Block
17. Ball Guide 10
18. Piston Assembly 11
19. Piston Retainer
4
20. Thrust Plate 4

Dealer Copy -- Not for Resale

21. Pipe Plug 14
22. Dipstick Assembly 12
23. Brake Valve 15
13 10
15
16

15
17

19
2 20
21
23
22
8

NA-1044

375 of 918 20-90-3 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-10

Disassembly And Assembly

Figure 20-90-8

2
2

1 1

P-87586

Remove the springs (Item 1) and spools (Item 2) [Figure

P-87584 20-90-10].

Figure 20-90-11
Remove the three bolts and remove the brake valve (Item
1) [Figure 20-90-8].

Dealer Copy -- Not for Resale

Figure 20-90-9

1
1 1

P-87587

Remove the plug (Item 1) [Figure 20-90-11] from both

P-87585 sides of the end cap.

Installation: Tighten the plugs to 79 - 98 N•m (58 - 72 ft-

Remove the O-rings (Item 1) [Figure 20-90-9]. lb) torque.

376 of 918 20-90-4 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-14

Disassembly And Assembly (Cont’d)

Figure 20-90-12

1
1

P-87590

Remove the spool (Item 1) [Figure 20-90-14] from both

P-87588 sides of the end cap.

Figure 20-90-15
Remove the O-ring (Item 1) [Figure 20-90-12] from both
plugs.

Dealer Copy -- Not for Resale

Figure 20-90-13

1
1

P-87591

Remove the relief valves (Item 1) [Figure 20-90-15].

P-87589
Installation: Tighten the relief valves to 148 - 167 N•m
(109 - 123 ft-lb) torque.
Remove the spring (Item 1) [Figure 20-90-13] from both
sides of the end cap.

377 of 918 20-90-5 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-18

Disassembly And Assembly (Cont’d)

Figure 20-90-16
1

P-87594

Remove the valve plate (Item 1) [Figure 20-90-18] from

P-87592 the end cap.

Figure 20-90-19
Remove the O-ring (Item 1) [Figure 20-90-16] from both
relief valves.

Dealer Copy -- Not for Resale

Figure 20-90-17
1

1
1

P-87596
1

Installation: The hole (Item 1) in the valve plate must

P-87593 engage the pin (Item 2) [Figure 20-90-19] on the end
cap.

Remove the four bolts (Item 1) [Figure 20-90-17] and

remove the end cap.

Installation: Tighten the bolts to 85 - 118 N•m (63 - 87 ft-

lb) torque.

378 of 918 20-90-6 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-22

Disassembly And Assembly (Cont’d)

Figure 20-90-20
1

P-87598

Installation: Do not install springs in the spring bores

P-87595 with threaded holes (Item 1) [Figure 20-90-22].

Figure 20-90-23
Remove the bearing (Item 1) [Figure 20-90-20].

Dealer Copy -- Not for Resale

Figure 20-90-21

P-87599

P-87597 Install two screws (Item 1) [Figure 20-90-23] in the

threaded holes of the brake piston. Pull up on the screws
and remove the brake piston.
Remove the O-ring (Item 1). Remove the sixteen springs
(Item 2) [Figure 20-90-21].

379 of 918 20-90-7 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-26

Disassembly And Assembly (Cont’d)

1
Figure 20-90-24

P-87602

Remove the second friction plate (Item 1) [Figure 20-90-

P-87600 26].

Figure 20-90-27
Remove the friction plate (Item 1) [Figure 20-90-24].

Dealer Copy -- Not for Resale

Figure 20-90-25
1

1
1

P-86577

P-87601 Remove the O-rings (Item 1) [Figure 20-90-27].

Remove the separation plate (Item 1) [Figure 20-90-25].

380 of 918 20-90-8 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-30

Disassembly And Assembly (Cont’d)

Figure 20-90-28 1

1
P-87605

Remove the piston assemblies (Item 1) [Figure 20-90-

P-87603 30] from the retainer.

Figure 20-90-31
Tip the housing and remove the rotating group (Item 1)
[Figure 20-90-28].

Dealer Copy -- Not for Resale

1
Figure 20-90-29

P-87606

Remove the ball guide (Item 1) [Figure 20-90-31].

P-87604

Remove the piston assemblies / retainer (Item 1) [Figure

20-90-29] from the cylinder block.

NOTE: It is not important that the pistons are installed

in the original bores.

381 of 918 20-90-9 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-34

Disassembly And Assembly (Cont’d)

Figure 20-90-32

2
1

P-87615

Using a press and an appropriately sized spacer (Item 1),

P-87607 compress the spring in the cylinder block (Item 2) [Figure
20-90-34].

Remove the washer (Item 1) [Figure 20-90-32]. Figure 20-90-35

Dealer Copy -- Not for Resale

Figure 20-90-33

1
1
1

P-87616

P-87608
Remove the snap ring (Item 1) [Figure 20-90-35].
Remove the cylinder block from the press.
Remove the three pins (Item 1) [Figure 20-90-33].

382 of 918 20-90-10 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-38

Disassembly And Assembly (Cont’d)

Figure 20-90-36

1
3 2
1

P-87611

Remove the snap ring (Item 1) [Figure 20-90-38] from

P-87617 the shaft.

Figure 20-90-39
Remove the top washer (Item 1), spring (Item 2) and
bottom washer (Item 3) [Figure 20-90-36].

Dealer Copy -- Not for Resale

Figure 20-90-37
1

P-87612

Remove the shaft (Item 1) [Figure 20-90-39].

P-87609

Remove the thrust plate (Item 1) [Figure 20-90-37].

383 of 918 20-90-11 E85 Service Manual

SWING MOTOR (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-90-40

P-87613

Remove the bearing (Item 1) [Figure 20-90-40].

Dealer Copy -- Not for Resale

Figure 20-90-41

P-87614

Remove the seal (Item 1) [Figure 20-90-41].

Prior to assembly perform the following steps:

Clean all parts in solvent and dry with compressed air.

Check the components for wear and damage.

Always use new O-rings and seals.

Apply clean hydraulic oil to the components during

installation.

384 of 918 20-90-12 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) Figure 20-91-3

Removal And Installation

Remove the swing motor. (See Removal And Installation

on Page 20-90-1.)

Figure 20-91-1

P-87581

Install two bolts (Item 1) [Figure 20-91-3] (removed in

1
2 previous step) in the threaded holes in the swing motor
drive carrier. Tighten the bolts evenly to separate the
swing motor drive carrier from the frame.
P-87579
Figure 20-91-4

Dealer Copy -- Not for Resale

Remove the grease hose (Item 1) and the drain hose
(Item 2) [Figure 20-91-1]. 1

NOTE: Mark the swing motor drive carrier and frame

for proper installation.

Figure 20-91-2

P-87581

1 Install a sling (Item 1) [Figure 20-91-4] and hoisting

device to the swing motor drive carrier.
1 Remove the swing motor drive carrier.
1
P-87580

Remove the bolts (Item 1) [Figure 20-91-2].

385 of 918 20-91-1 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D)

Parts Identification

1. Snap Ring
2. Thrust Washer
3. Bearing Race
1
4. Needle Bearing 2
5. Planetary Gear
6. Sun Gear 3
7. Carrier 4
8. Screw 5
9. Thrust Plate 6
2
10. Collar 2
11. O-ring
12. Bearing 7
13. Seal
14. Housing
15. Plug
16. Dust Seal 6 2
17. Pinion Shaft
8
3
9 4

Dealer Copy -- Not for Resale

5
7
2

11
13

15
12

NA-1043

386 of 918 20-91-2 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-7

Disassembly And Assembly

1
Figure 20-91-5 2
3

1 4
5
7 6

NA-1114

Remove the snap ring (Item 1), thrust washer (Item 2),
NA-1110 planetary gear (Item 3), bearing (Item 4) bearing race
(Item 5) and thrust washer (Item 6) [Figure 20-91-7].

Remove the sun gear (Item 1) [Figure 20-91-5]. Remove the sun gear thrust washer (Item 7) [Figure 20-
91-7].

Dealer Copy -- Not for Resale

Figure 20-91-6
Figure 20-91-8

1
1

NA-1111

NA-1112

Remove the carrier assembly (Item 1) [Figure 20-91-6].

Remove the sun gear (Item 1) [Figure 20-91-8].

387 of 918 20-91-3 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-11

Disassembly And Assembly (Cont’d) 1

Figure 20-91-9 2

1 4
3

NA-1116

Remove the thrust washer (Item 1), planetary gear (Item

NA-1113 2), bearing (Item 3), bearing race (Item 4) and thrust
washer (Item 5) [Figure 20-91-11].

Remove the carrier assembly (Item 1) [Figure 20-91-9]. Figure 20-91-12

Dealer Copy -- Not for Resale

Figure 20-91-10
1
1
1

NA-1117

NA-1115
Remove both halves of the collar (Item 1) [Figure 20-91-
12].
Heat the screws (Item 1) [Figure 20-91-10] to melt the
thread adhesive.

Remove the screws (Item 1) and remove the thrust plate

(Item 2) [Figure 20-91-10].

388 of 918 20-91-4 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-15

Disassembly And Assembly (Cont’d)

1
Figure 20-91-13

1 NA-1119

Remove the bearing (Item 1) [Figure 20-91-15].

NA-1118
Figure 20-91-16

Remove the pinion shaft (Item 1) [Figure 20-91-13].

Dealer Copy -- Not for Resale

Figure 20-91-14

NA-1120

Remove the seal (Item 1) [Figure 20-91-16].

NA-1130

Remove the bearing (Item 1) and dust seal (Item 2)

[Figure 20-91-14] from the pinion shaft.

389 of 918 20-91-5 E85 Service Manual

Dealer Copy -- Not for Resale

390 of 918 20-91-6 E85 Service Manual

CONTROL PATTERN SELECTOR VALVE Figure 20-100-2

Removal And Installation

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-20-1.)

Mark all hoses for proper installation.

IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P112472
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Remove the two bolts (Item 1) [Figure 20-100-2], lock
I-2003-0888 washers and flat washers.

Figure 20-100-1

Dealer Copy -- Not for Resale

P112471

Remove the eight hoses from the control pattern selector

valve (Item 1) [Figure 20-100-1].

391 of 918 20-100-1 E85 Service Manual

CONTROL PATTERN SELECTOR VALVE (CONT'D) Figure 20-100-5

Disassembly And Assembly

Figure 20-100-3

2
1

P112475
1

Remove the bolts (Item 1) and spring (Item 2) [Figure

P112473 20-100-5] from the spool.

Figure 20-100-6
Remove the snap ring (Item 1) [Figure 20-100-3].

Dealer Copy -- Not for Resale

Figure 20-100-4

1
1
P112476

2
P112474 Remove the set screw (Item 1) and handle (Item 2)
[Figure 20-100-6].

Remove the bushing (Item 1) push the spool (Item 2)

[Figure 20-100-4] on the front of the valve block.

392 of 918 20-100-2 E85 Service Manual

CONTROL PATTERN SELECTOR VALVE (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-100-7

P112477

Remove the bushing (Item 1) and O-ring (Item 2) [Figure

20-100-7].

Dealer Copy -- Not for Resale

Figure 20-100-8

P112478

Remove the O-ring (Item 1) [Figure 20-100-8] from the

valve block.

393 of 918 20-100-3 E85 Service Manual

Dealer Copy -- Not for Resale

394 of 918 20-100-4 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) Figure 20-110-3

Testing

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-20-1.) 1

Figure 20-110-1

P-86421

Install a 6900 kPa (69 bar) (1000 psi) gauge (Item 1)

[Figure 20-110-3] on the pilot line. Start the excavator
and warm up the hydraulic oil to operating temperature.
1

P-86419 Engage the circuit to be tested. Record the operating

pressure.

Dealer Copy -- Not for Resale

Cut and remove the cable ties (Item 1) [Figure 20-110- The operating pressure should be approximately 2800
1]. kPa (28 bar) (415 psi).

Find the pilot line of the control lever that is to be checked If the operating pressure is correct, check the valve
at the control valve assembly. section spool for proper operation. If the operating
pressure is incorrect, test the pressure reducing valve.
Figure 20-110-2 (See Testing And Adjusting The Pressure Reducing
Valve on Page 20-32-1.)

If the pressure reducing valve is incorrect, adjust the

pressure reducing valve. (See Testing And Adjusting The
Pressure Reducing Valve on Page 20-32-1.) Retest the
right control lever.

P-86420

Disconnect the hydraulic hose (Item 1) [Figure 20-110-2]

from the control valve.

395 of 918 20-110-1 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-6

Handle Removal And Installation

Remove the right console cover. (See Console Cover

Removal And Installation on Page 40-50-1.) 1
Figure 20-110-4

P-86683

Use a small flat blade screwdriver to depress the wire

terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-110-6].
1
P-86681 Installation: Use a small flat blade screwdriver to bend
the wire terminal tabs on each wire before installing the

Dealer Copy -- Not for Resale

individual wires in the connector bodies.
Disconnect the wire harness (Item 1) [Figure 20-110-4].
Figure 20-110-7
Figure 20-110-5

P-86684
P-86682

Pull the harness (Item 1) [Figure 20-110-7] out of the

Remove the lock (Item 1) [Figure 20-110-5] from the housing.
connector body.

Mark the wires to the connector bodies.

396 of 918 20-110-2 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Joystick Assembly Removal And Installation

Handle Removal And Installation (Cont’d) Remove the right console cover. (See Console Cover
Removal And Installation on Page 40-50-1.)
Figure 20-110-8
Figure 20-110-10

P-86685 1
P-86681

Loosen the nut (Item 1) [Figure 20-110-8] and unthread

the handle. Disconnect the wire harness (Item 1) [Figure 20-110-

Dealer Copy -- Not for Resale

10].
Figure 20-110-9
Figure 20-110-11

190,5 mm
(7.50”)

P-86686

P-86663

Installation: Install the cable tie (Item 1) [Figure 20-110-

9] at 190,5 mm (7.5 in) from the base of the handle. This Remove the bolts (Item 1) [Figure 20-110-11] and
provides the correct amount of slack in the handle wire washers from the blade control valve.
harness.
Reposition the blade control valve towards the rear of the
cab.

397 of 918 20-110-3 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-14

Joystick Assembly Removal And Installation (Cont’d)

Figure 20-110-12

2 1

1
P-86689
1

Tilt the joystick (Item 1) towards the rear of the cab. Mark
P-86687 and remove the hoses (Item 2) [Figure 20-110-14].

Remove the joystick.

Remove the bolts (Item 1) [Figure 20-110-12], flat
washers and lock washers from the front of the joystick.

Dealer Copy -- Not for Resale

Figure 20-110-13
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

P-86688

Remove the bolts (Item 1) [Figure 20-110-13], flat

washers and lock washers from the rear of the joystick.

398 of 918 20-110-4 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

Parts Identification

1. Handle Assembly
2. Dust Boot
3. Connector Lock
4. Connector
5. Nut
6. Seal
7. Plug
8. O-ring
9. Push Rod
10. Spring Retainer
16
11. Spring Seat
12. Spring
13. Washer 6
14. Spool 6 17
7
15. Spring 7 8
16. Nut 8
17. Control Plate 9
18. Dust Boot 9 18
3 10
19. U-Joint 4 10

Dealer Copy -- Not for Resale

20. Plate 11
11
21. Grommet
22. Body 19 12
12
23. Pipe Plug 13
24. Plug 1 13
20
14
14

15
15
2

21 22

5
23
8

MS-2789S

399 of 918 20-110-5 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-17

Disassembly And Assembly

Figure 20-110-15 2

3 P-86692

Loosen the nut (Item 1) and remove the handle (Item 2)

P-86690 and boot (Item 3) [Figure 20-110-17].

Figure 20-110-18
Remove the lock (Item 1) [Figure 20-110-15] from the
connector body.

Dealer Copy -- Not for Resale

Mark the wires to the connector body. 1
Figure 20-110-16

1 190,5 mm
(7.50”)

P-86686

Installation: Install the cable tie (Item 1) [Figure 20-110-

18] at 190,5 mm (7.5 in) from the base of the handle.
This provides the correct amount of slack in the handle
P-86691 wire harness.

Use a small flat blade screwdriver to depress the wire

terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-110-16].

Installation: Use a small flat blade screwdriver to bend

the wire terminal tabs on each wire before installing the
individual wires in the connector bodies.

400 of 918 20-110-6 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-21

Disassembly And Assembly (Cont’d)

Figure 20-110-19 1

P-86695

Remove the control plate (Item 1) [Figure 20-110-21].

P-86693
Figure 20-110-22

Remove the dust boot (Item 1) [Figure 20-110-19].

Dealer Copy -- Not for Resale

Figure 20-110-20
1

P-86696

Remove the U-joint (Item 1) [Figure 20-110-22].

P-86694

Remove the nut (Item 1) [Figure 20-110-20].

401 of 918 20-110-7 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-25

Disassembly And Assembly (Cont’d)

Figure 20-110-23

P-86699

Remove the push rod (Item 1) [Figure 20-110-25].

P-50872
Figure 20-110-26

Mark the plate (Item 1) [Figure 20-110-23] for correct

installation.

Dealer Copy -- Not for Resale

Remove the plate.

Figure 20-110-24

2 1

P-86701

1 Remove the O-ring (Item 1) from the O.D. of the plug.

Remove the seal (Item 2) [Figure 20-110-26] from the
I.D. of the plug.

P-21730

Remove the plug assemblies (Item 1) [Figure 20-110-

24].

402 of 918 20-110-8 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-29

Disassembly And Assembly (Cont’d)

Figure 20-110-27
2

3 1

1 P-86704

Remove the spring seat (Item 1), spring (Item 2), and
P-86702 washer (Item 3) [Figure 20-110-29] from the spool.

Figure 20-110-30
Remove the spool assemblies (Item 1) [Figure 20-110-
27].

Dealer Copy -- Not for Resale

Figure 20-110-28 1

1 1

P-86705

Remove the springs (Item 1) [Figure 20-110-30].

P-86703

Compress the spring and remove the spring retainers

(Item 1) [Figure 20-110-28].

403 of 918 20-110-9 E85 Service Manual

Dealer Copy -- Not for Resale

404 of 918 20-110-10 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) Figure 20-120-3

Testing

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-20-1.) 1

Figure 20-120-1

P-86421

Install a 6900 kPa (69 bar) (1000 psi) gauge (Item 1)

[Figure 20-120-3] on the pilot line. Start the excavator
and warm up the hydraulic oil to operating temperature.
1

P-86419 Engage the circuit to be tested. Record the operating

pressure.

Dealer Copy -- Not for Resale

Cut and remove the cable ties (Item 1) [Figure 20-120- The operating pressure should be approximately 2800
1]. kPa (28 bar) (415 psi).

Find the pilot line of the control lever that is to be checked If the operating pressure is correct, check the valve
at the control valve assembly. section spool for proper operation. If the operating
pressure is incorrect, test the pressure reducing valve.
Figure 20-120-2 (See Testing And Adjusting The Pressure Reducing
Valve on Page 20-32-1.)

If the pressure reducing valve is incorrect, adjust the

pressure reducing valve. (See Testing And Adjusting The
Pressure Reducing Valve on Page 20-32-1.) Retest the
right control lever.

P-86420

Disconnect the hydraulic hose (Item 1) [Figure 20-120-2]

from the control valve.

405 of 918 20-120-1 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-6

Handle Removal And Installation

Remove the upper left console cover. (See Upper 1

Console Cover Removal And Installation on Page 40-60-
2.)

Figure 20-120-4

P-86769

Use a small flat blade screwdriver to depress the wire

terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-120-6].

Installation: Use a small flat blade screwdriver to bend

P-86762 the wire terminal tabs on each wire before installing the

Dealer Copy -- Not for Resale

individual wires in the connector body.

Disconnect the wire harness (Item 1) [Figure 20-120-4]. Figure 20-120-7

Figure 20-120-5

P-86771

P-86768
Pull the harness (Item 1) [Figure 20-120-7] out of the
housing.
Remove the lock (Item 1) [Figure 20-120-5] from the
connector body.

Mark the wires to the connector bodies.

406 of 918 20-120-2 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT'D)

Handle Removal And Installation (Cont’d)

Figure 20-120-8

P-86685

Loosen the nut (Item 1) [Figure 20-120-8] and unthread

the handle.

Dealer Copy -- Not for Resale

Figure 20-120-9

190,5 mm
(7.50”)

P-86686

Installation: Install the cable tie (Item 1) [Figure 20-120-

9] at 190,5 mm (7.5 in) from the base of the handle. This
provides the correct amount of slack in the handle wire
harness.

407 of 918 20-120-3 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-12

Joystick Assembly Removal And Installation

Remove the upper left console cover. (See Upper

Console Cover Removal And Installation on Page 40-60-
2.) 2 1
Figure 20-120-10

P-86772

Tilt the joystick (Item 1) towards the rear of the cab. Mark
and remove the hoses (Item 2) [Figure 20-120-12].

Remove the joystick.

P-86762

Dealer Copy -- Not for Resale

Disconnect the wire harness (Item 1) [Figure 20-120-
IMPORTANT
10].
When repairing hydrostatic and hydraulic systems,
Figure 20-120-11 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-86771

Remove the four bolts (Item 1) [Figure 20-120-11], flat

washers and lock washers from the joystick.

408 of 918 20-120-4 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D)

Parts Identification

Dealer Copy -- Not for Resale

21. Grommet
22. Body 19 12
12
23. Pipe Plug 13
24. Plug 1 13
20
14
14

15
15
2

21 22

5
23
8

MS-2789S

409 of 918 20-120-5 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-15

Disassembly And Assembly

Figure 20-120-13 2

1
3

P-86692

Loosen the nut (Item 1) and remove the handle (Item 2)

P-86690 and boot (Item 3) [Figure 20-120-15].

Figure 20-120-16
Remove the lock (Item 1) [Figure 20-120-13] from the
connector body.

Dealer Copy -- Not for Resale

Mark the wires to the connector bodies. 1
Figure 20-120-14

1 190,5 mm
(7.50”)

P-86686

Installation: Install the cable tie (Item 1) [Figure 20-120-

16] at 190,5 mm (5.5 in) from the base of the handle.
This provides the correct amount of slack in the handle
P-86691 wire harness.

Use a small flat blade screwdriver to depress the wire

terminal tabs, and remove the individual wires from the
connector body (Item 1) [Figure 20-120-14].

Installation: Use a small flat blade screwdriver to bend

the wire terminal tabs on each wire before installing the
individual wires in the connector bodies.

410 of 918 20-120-6 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-19

Disassembly And Assembly (Cont’d)

Figure 20-120-17 1

P-86695

Remove the control plate (Item 1) [Figure 20-120-19].

P-86693
Figure 20-120-20

Remove the dust boot (Item 1) [Figure 20-120-17].

Dealer Copy -- Not for Resale

Figure 20-120-18
1

P-86696

Remove the U-joint (Item 1) [Figure 20-120-20].

P-86694

Remove the nut (Item 1) [Figure 20-120-18].

411 of 918 20-120-7 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-23

Disassembly And Assembly (Cont’d)

Figure 20-120-21

P-86699

Remove the push rod (Item 1) [Figure 20-120-23].

P-50872
Figure 20-120-24

Mark the plate (Item 1) [Figure 20-120-21] for correct

installation.

Dealer Copy -- Not for Resale

Remove the plate.

Figure 20-120-22

2 1

P-86701

1 Remove the O-ring (Item 1) from the O.D. of the plug.

Remove the seal (Item 2) [Figure 20-120-24] from the
I.D. of the plug.

P-21730

Remove the plug assemblies (Item 1) [Figure 20-120-

22].

412 of 918 20-120-8 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-120-27

Disassembly And Assembly (Cont’d)

Figure 20-120-25
2

3 1

1 P-86704

Remove the spring seat (Item 1), spring (Item 2), and
P-86702 washer (Item 3) [Figure 20-120-27] from the spool.

Figure 20-120-28
Remove the spool assemblies (Item 1) [Figure 20-120-
25].

Dealer Copy -- Not for Resale

Figure 20-120-26 1

1 1

P-86705

Remove the springs (Item 1) [Figure 20-120-28].

P-86703

Compress the spring and remove the spring retainers

(Item 1) [Figure 20-120-26].

413 of 918 20-120-9 E85 Service Manual

Dealer Copy -- Not for Resale

414 of 918 20-120-10 E85 Service Manual

BLADE CONTROL VALVE

Removal And Installation

IMPORTANT
Remove the right console cover. (See Console Cover
Removal And Installation on Page 40-50-1.) When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-130-1 parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
2 1 I-2003-0888

3
2

2
3

2
P112261

Dealer Copy -- Not for Resale

Disconnect the wire harness (Item 1). Remove the bolts
(Item 2) and plates (Item 3) [Figure 20-130-1].

Figure 20-130-2

P112262

Mark and remove the four hoses (Item 1) [Figure 20-130-

2]. Tilt the valve towards the rear of the cab and move the
two hoses on the bottom of the valve.

Remove the valve.

415 of 918 20-130-1 E85 Service Manual

BLADE CONTROL VALVE (CONT’D)

Parts Identification

1. Lever
2. Dust Boot
3. Nut
4. Guide
5. Bolt 1
6. Roll Pin
7. Pin
8. Cover
9. Detent Spring 10
10. Seal
11. Plug
12. Plunger 11
13. O-ring
14 Spring Keeper 12
15. Spring Seat
16. Spring 2
17. Spool 13
18. Plug
19. Body

Dealer Copy -- Not for Resale

16
3
13
4
17

3 16

5 18
5 6

7 13
8

NA5987S

416 of 918 20-130-2 E85 Service Manual

BLADE CONTROL VALVE (CONT’D) Figure 20-130-5

Disassembly And Assembly

1
Figure 20-130-3

2
P112266

Loosen the nut (Item 1) [Figure 20-130-5] and remove

P112263 the handle.

Figure 20-130-6
Remove the connector lock (Item 1) and remove the
connector (Item 2) [Figure 20-130-3] from the wire

Dealer Copy -- Not for Resale

harness.

Figure 20-130-4 1

2 1

P112267

Remove the roll pin (Item 1) [Figure 20-130-6].

P112264

Remove the four bolts (Item 1) and detent spring (Item 2)

[Figure 20-130-4].

417 of 918 20-130-3 E85 Service Manual

BLADE CONTROL VALVE (CONT’D) Figure 20-130-9

Disassembly And Assembly (Cont’d)

Figure 20-130-7
3

1 2

2 1

P112270

Remove the plunger (Item 1) from the plug (Item 2).

P112268 Remove the O-ring (Item 3) [Figure 20-130-9].

Figure 20-130-10
Remove the pin (Item 1) and guide (Item 2) [Figure 20-
130-7].

Dealer Copy -- Not for Resale

Figure 20-130-8

P112271

Remove the seal (Item 1) [Figure 20-130-10] from the

P112269 inside of the plug.

Remove the plunger / plug assemblies (Item 1) [Figure

20-130-8].

418 of 918 20-130-4 E85 Service Manual

BLADE CONTROL VALVE (CONT’D) Figure 20-130-13

Disassembly And Assembly (Cont’d)

Figure 20-130-11

4 3 2 1

P-86674

Remove the spring seat (Item 1), spring (Item 2), and
P112273 washer (Item 3) from the spool (Item 4) [Figure 20-130-
13].

Remove the spool assemblies (Item 1) [Figure 20-130- Figure 20-130-14

11].

Dealer Copy -- Not for Resale

Figure 20-130-12

P112274

P-86703 Remove the springs (Item 1) [Figure 20-130-14].

Compress the spring and remove the spring keepers

(Item 1) [Figure 20-130-12].

419 of 918 20-130-5 E85 Service Manual

BLADE CONTROL VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-130-15

P112275

Use a 10 mm hex wrench (Item 1) [Figure 20-130-15] to

remove the plugs.

Dealer Copy -- Not for Resale

Figure 20-130-16

P-86677

Remove the O-ring (Item 1) [Figure 20-130-16] from the

plug.

420 of 918 20-130-6 E85 Service Manual

HYDRAULIC RESERVOIR Figure 20-140-3

Removal And Installation

2
Remove the fuel tank. (See Removal And Installation on
Page 40-110-1.) 1

Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-140-6.) 3

Remove the suction filter. (See Removing And Replacing

Hydraulic Filters on Page 10-140-2.)

Figure 20-140-1

P-87212

Remove the fuel transfer line (Item 1) from the hose

restraint (Item 2) [Figure 20-140-3].
1
Remove the hoses (Item 3) [Figure 20-140-3].
2
Figure 20-140-4

Dealer Copy -- Not for Resale

P-87209 1

Remove the bolts (Item 1), washers and suction tube

(Item 2) [Figure 20-140-1].

Figure 20-140-2

1
1
P-87247
1

Remove the bolt (Item 1) [Figure 20-140-4].

P-87211

Remove the hydraulic return lines (Item 1) [Figure 20-

140-2] from the front of the tank.

NOTE: Mark the hydraulic hoses for ease of

installation.

421 of 918 20-140-1 E85 Service Manual

HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-7

Removal And Installation (Cont’d)

Figure 20-140-5

1
2

1 P-87216

Remove the bolt (Item 1) [Figure 20-140-7].

P-87246
Figure 20-140-8

Remove the bolts (Item 1) and shield (Item 2) [Figure 20-

140-5]. 2

Dealer Copy -- Not for Resale

Figure 20-140-6

1
1

P-87218

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

140-8].
P-87248

Remove the hydraulic hose (Item 1) [Figure 20-140-6].

422 of 918 20-140-2 E85 Service Manual

HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-11

Removal And Installation (Cont’d)

Figure 20-140-9

2 P-87251

Remove the bolt (Item 1) [Figure 20-140-11].

P-87249
Figure 20-140-12

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

140-9].

Dealer Copy -- Not for Resale

Figure 20-140-10

P-87237

Remove the bolt (Item 1) [Figure 20-140-12].

P-87217

Remove the P-clamp bolt (Item 1) [Figure 20-140-10]

and reposition the hose so that it will not interfere with the
removal of the tank.

423 of 918 20-140-3 E85 Service Manual

HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-15

Removal And Installation (Cont’d)

2
Figure 20-140-13
1

1
1
P-87238

Attach a chain (Item 1) and lifting device (Item 2) [Figure

P-87219 20-140-15].

Remove the bolts (Item 1) [Figure 20-140-13] from the

reservoir lifting points.

Dealer Copy -- Not for Resale

Figure 20-140-14

P-87252

Install lifting rings (Item 1) [Figure 20-140-14].

424 of 918 20-140-4 E85 Service Manual

HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-18

Removal And Installation (Cont’d)

Figure 20-140-16

1
1

P-86677

Inspect the mounting plate for shims (Item 1) [Figure 20-

P-86676 140-18]. Record the number and the locations of the
shims for ease of installation.

Remove the bolts (Item 1) [Figure 20-140-16] and

washers.

Dealer Copy -- Not for Resale

Figure 20-140-17

P-87583

Remove the bolts (Item 1) [Figure 20-140-17] and

washers.

Remove the hydraulic reservoir.

425 of 918 20-140-5 E85 Service Manual

Dealer Copy -- Not for Resale

426 of 918 20-140-6 E85 Service Manual

OIL COOLER

Removal And Installation

The oil cooler and radiator are removed from the

excavator as a unit. (See Radiator Removal And
Installation on Page 60-50-1.)

Dealer Copy -- Not for Resale

427 of 918 20-150-1 E85 Service Manual

Dealer Copy -- Not for Resale

428 of 918 20-150-2 E85 Service Manual

DIRECT TO TANK VALVE

Removal And Installation

Raise the cab.

Figure 20-160-1

P112415

Dealer Copy -- Not for Resale

Mark and remove the three hoses (Item 1) [Figure 20-
160-1].

Figure 20-160-2

P112416

Remove the bolts (Item 1) [Figure 20-160-2] and

washers. Remove the valve from the machine.

429 of 918 20-160-1 E85 Service Manual

DIRECT TO TANK VALVE (CONT’D) Figure 20-160-5

Disassembly And Assembly

Figure 20-160-3 1

P-86811

Remove the O-rings (Item 1) [Figure 20-160-5] from the

P-86809 spool.

Figure 20-160-6
Remove the snap ring (Item 1) [Figure 20-160-3].

Dealer Copy -- Not for Resale

Figure 20-160-4

P-86812

P-86810 Remove the O-rings (Item 1) [Figure 20-160-6] from the

inside bore of the valve.

Remove the spool (Item 1) [Figure 20-160-4].

430 of 918 20-160-2 E85 Service Manual

SWING MOTOR BRAKE RELEASE Figure 20-170-2

Description

When the left or right swing function is engaged, the

swing motor brake release directs pilot pressure to the
brake on the swing motor, releasing the brake.
1
Removal And Installation

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-20-1.)

Mark all hoses for proper installation.

IMPORTANT Remove the nut from both fittings (Item 1) [Figure 20-
170-2] and remove the valve.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly

Dealer Copy -- Not for Resale

damage the system.
I-2003-0888

Figure 20-170-1

Remove the five hoses (Item 1) [Figure 20-170-1].

431 of 918 20-170-1 E85 Service Manual

SWING MOTOR BRAKE RELEASE (CONT'D)

Parts Identification

1. Plug
2. O-ring
3. Back-up Ring
4. Ball
5. Valve Block

Dealer Copy -- Not for Resale

4
2
3
2

MS-2810S

432 of 918 20-170-2 E85 Service Manual

SWING MOTOR BRAKE RELEASE (CONT'D) Figure 20-170-5

Disassembly And Assembly

2
Figure 20-170-3

1
1

1 P-86440

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

P-86438 [Figure 20-170-5] from the plug.

Remove the plug (Item 1) [Figure 20-170-3].

Dealer Copy -- Not for Resale

Figure 20-170-4

P-86439

Remove the ball (Item 1) [Figure 20-170-4].

433 of 918 20-170-3 E85 Service Manual

Dealer Copy -- Not for Resale

434 of 918 20-170-4 E85 Service Manual

EPPR VALVE Figure 20-180-2

Description

The EPPR valve (Electro proportional pressure reducing

valve) is a solenoid operated valve that controls the pilot
pressure for the boom swing and auxiliary hydraulic
functions.

Removal And Installation

1 1
Tilt the cab. (See Raising And Lowering on Page 10-210-
1.)

WARNING P112447

Disconnect the wire harness (Item 1) [Figure 20-180-2].

AVOID INJURY OR DEATH
Never work under the excavator cab without Figure 20-180-3
installing an approved cab support device.
W-2435-0502

Dealer Copy -- Not for Resale

Figure 20-180-1
Remove the bolts (Item 1) [Figure 20-180-3] and remove
the valve.
1 1

P112438

Remove the hoses (Item 1) [Figure 20-180-1].

435 of 918 20-180-1 E85 Service Manual

EPPR VALVE (CONT'D)

Parts Identification

1. Valve Body
2. Filter Screen
3. Screw
4. Solenoid Valve

Dealer Copy -- Not for Resale

4
3

NA5989S

436 of 918 20-180-2 E85 Service Manual

EPPR VALVE (CONT'D) Figure 20-180-6

Disassembly And Assembly

Figure 20-180-4

1 2 1

1 P112442

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

P-112440 [Figure 20-180-6].

Figure 20-180-7
Remove the screws (Item 1) [Figure 20-180-4].

Dealer Copy -- Not for Resale

Installation: Tighten the screws to 1,5 N•m (8.8 in lb)

Figure 20-180-5

1
P112443

Repeat the procedure for the remaining solenoid valves

1 (Item 1) [Figure 20-180-7].
P112441

Remove the solenoid valve (Item 1) [Figure 20-180-5].

437 of 918 20-180-3 E85 Service Manual

EPPR VALVE (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-180-8

P112444

Remove the filter screen (Item 1) [Figure 20-180-8].

Dealer Copy -- Not for Resale

Installation: Tighten the filter screen to 27,1 N•m (20 ft-
lb) torque.

Figure 20-180-9

1 2

P112445

Remove the O-rings (Item 1). Inspect the screen (Item 2)

[Figure 20-180-9] for damage.

438 of 918 20-180-4 E85 Service Manual

FORCED REGENERATION VALVE

Removal And Installation

IMPORTANT
Figure 20-190-1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
2 I-2003-0888

Figure 20-190-3
1
1

P-112460

Disconnect the wire harness (Item 1) from the coil.

Remove the nut (Item 2) [Figure 20-190-1] from the coil.

Dealer Copy -- Not for Resale

Figure 20-190-2

P112457

Remove the hoses (Item 1) [Figure 20-190-3].

1
Figure 20-190-4

P112456

1
Remove the coil (Item 1) [Figure 20-190-2].

P112458

Remove the bolts (Item 1) [Figure 20-190-4] and remove

the valve.

439 of 918 20-190-1 E85 Service Manual

FORCED REGENERATION VALVE (CONT'D)

Disassembly And Assembly

Figure 20-190-5

P112465

Remove the solenoid (Item 1) [Figure 20-190-5] from the

valve body.

Dealer Copy -- Not for Resale

Installation: Tighten the solenoid to 20,5 - 25,5 N•m
(15.1 - 18.8 ft-lb) torque.

Figure 20-190-6

2 1

1 1

P-112459

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

[Figure 20-190-6] from the solenoid.

440 of 918 20-190-2 E85 Service Manual

ARTICULATED BOOM VALVE (OPTIONAL) Figure 20-200-2

Removal And Installation

Remove the floor mat. (See Removal And Installation on

Page 40-100-1.)
1
Tilt the cab. (See CAB TILT PROCEDURE on Page 10-
210-1.)

WARNING
2
AVOID INJURY OR DEATH
S37671
Never work under the excavator cab without
installing an approved cab support device.
W-2435-0502
Remove the two fittings (Item 1) [Figure 20-200-2].

Loosen the bottom fitting (Item 2) [Figure 20-200-2].

Figure 20-200-3
IMPORTANT

Dealer Copy -- Not for Resale

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

Figure 20-200-1
2
2
1

1 S37672

Disengage the pedal lock (Item 1) and remove the two

bolts (Item 2) [Figure 20-200-2].

1 Remove the valve.

P123148

Mark and remove the four hoses (Item 1) [Figure 20-200-

1].

441 of 918 20-200-1 E85 Service Manual

ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D)

Parts Identification

1. Bolt
2. Pin
3. Dust Boot
4. Bolt
5. Cover
6. Spring Retainer
7. Spring Seat
8. Spring
9. Spring
10. Washer
1
11. Spool
12. Body 20
13. O-ring
2
14. Plug
15. Plug 19
16. O-ring 3
17. Seal
18. Push rod 4
19. Screw

Dealer Copy -- Not for Resale

5 18
20. Cam
17

6 16
7
15

8
14
9

11
12

B-23950

442 of 918 20-200-2 E85 Service Manual

ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D) Figure 20-200-6

Disassembly And Assembly

Figure 20-200-4

1 1

P-86480

Loosen the screw (Item 1) [Figure 20-200-6].

P-86473
Figure 20-200-7

Remove the two bolts (Item 1) [Figure 20-200-4] and

washers. 2
1

Dealer Copy -- Not for Resale

Remove the pedal.

Figure 20-200-5

P-86481

Loosen the screw (Item 1) until the spring tension is

released from the cam (Item 2) [Figure 20-200-7].

Installation: Tighten the screw (Item 1) [Figure 20-200-

P-86474 7] until all free play is removed from the cam.

Remove the dust boot (Item 1) [Figure 20-200-5].

443 of 918 20-200-3 E85 Service Manual

ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D) Figure 20-200-10

Disassembly And Assembly (Cont’d)

Figure 20-200-8
1

3 1

P-86476
2

Remove the push rod / plug assemblies (Item 1) [Figure

P-86482 20-200-10].

Figure 20-200-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-200-8].

Dealer Copy -- Not for Resale

Figure 20-200-9

1
1
3
1
2

2 P-86477

Remove the push rod (Item 1) and O-ring (Item 2)

P-86475 [Figure 20-200-11] from the plug.

Remove the seal (Item 3) [Figure 20-200-11] from the

Loosen and remove the bolts (Item 1) evenly as the cover inside diameter of the plug.
(Item 2) [Figure 20-200-9] is under spring tension.

Remove the cover.

444 of 918 20-200-4 E85 Service Manual

ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D) Figure 20-200-14

Disassembly And Assembly (Cont’d)

Figure 20-200-12 2
4 3

P-86486

Remove the spring seat (Item 2), spring (Item 3) and

P-86478 washer (Item 4) [Figure 20-200-14] from the spool.

Figure 20-200-15
Remove the spool assemblies (Item 1) [Figure 20-200-
12].

Dealer Copy -- Not for Resale

Figure 20-200-13

1 P-86479

Remove the spring (Item 1) [Figure 20-200-15] from the

P-86485 bores.

Compress the spring (Item 1) [Figure 20-200-13] and

remove the spring keepers (Item 1) [Figure 20-200-14].

445 of 918 20-200-5 E85 Service Manual

ARTICULATED BOOM VALVE (OPTIONAL) (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 20-200-16

P-86487

Use a 10 mm hex wrench (Item 1) [Figure 20-200-16] to

remove the plug.

Dealer Copy -- Not for Resale

Figure 20-200-17

P-86488

Remove the O-ring (Item 1) [Figure 20-200-17] from the

plug.

446 of 918 20-200-6 E85 Service Manual

TRAVEL CONTROL VALVE Figure 20-210-2

Removal And Installation

Remove the floor mat. (See Removal And Installation on

Page 40-100-1.)

Tilt the cab. (See Raising And Lowering on Page 10-210- 1

1.)

2
WARNING
AVOID INJURY OR DEATH 1
P-86444
Never work under the excavator cab without
installing an approved cab support device.
W-2435-0502
Remove the three hoses (Item 1) from the side of the
valve. Remove the fittings (Item 2) [Figure 20-210-2].

Figure 20-210-3

IMPORTANT

Dealer Copy -- Not for Resale

1
Figure 20-210-1

P-86445

Remove the bolts (Item 1) [Figure 20-210-3] and

washers from the rear of the valve.

1 1

P-86443

Mark and remove the four hoses (Item 1) [Figure 20-210-

1] from the bottom of the valve.

447 of 918 20-210-1 E85 Service Manual

TRAVEL CONTROL VALVE (CONT'D)

Removal And Installation (Cont’d)

Figure 20-210-4

P-86446

Remove the bolts (Item 1) [Figure 20-210-4] from the

front of the valve.

Dealer Copy -- Not for Resale

Remove the valve / lever assembly from the cab.

448 of 918 20-210-2 E85 Service Manual

TRAVEL CONTROL VALVE (CONT'D)

Parts Identification

1. Dust Boot
2. Bolt 1 9
3. Set Screw
4. Cam Assembly 10
5. Pin
6. Bushing
7. Cover
8. Cover
9. Ball 11
10. Push Rod 2
12
11. Grease Cap
12 Dust Seal 4
13
13. Plug
14. O-ring 3 14
15. Piston
16. Spring 15
17. Spring Seat 7
18. Washer 5
19. Spool 16

Dealer Copy -- Not for Resale

6
20. Housing

3
17
6
18
5
18
16 8

14
19
14

20
16

3
13
14

14
13

NA5988S

449 of 918 20-210-3 E85 Service Manual

TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-7

Disassembly And Assembly

Figure 20-210-5 1
1
2

P-86450

Remove the dust boots (Item 1) [Figure 20-210-7].

P-86447
Figure 20-210-8

Remove the two bolts (Item 1) and washers. Remove the

left travel control lever / foot pedal (Item 2) [Figure 20-

Dealer Copy -- Not for Resale

210-5].

Figure 20-210-6
1

P-86451

Loosen and remove the bolts (Item 1) [Figure 20-210-8]

evenly, as the cover is under spring pressure.
2
P-86449

Remove the two bolts (Item 1) and washers. Remove the

right travel control lever / foot pedal (Item 2) [Figure 20-
210-6].

450 of 918 20-210-4 E85 Service Manual

TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-11

Disassembly And Assembly (Cont’d)

Figure 20-210-9

P-86454

Remove the cover / cam assembly (Item 1) [Figure 20-

P-86452 210-11].

Figure 20-210-12
Remove the cover / cam assembly (Item 1) [Figure 20-
210-9].

Dealer Copy -- Not for Resale

Figure 20-210-10
1

P-86455

Loosen the screw (Item 1) [Figure 20-210-12] on both

P-86453 cam assemblies.

NOTE: Heat the screw to melt the thread adhesive.

Loosen and remove the bolts (Item 1) [Figure 20-210-10]
evenly, as the cover is under spring pressure. Installation: Apply Loctite® 242 or equivalent to the
screw.

451 of 918 20-210-5 E85 Service Manual

TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-15

Disassembly And Assembly (Cont’d)

Figure 20-210-13

P-86458

1
Using a blunt tool, push the push rod (Item 1) [Figure 20-
P-86456 210-15] out of the plug.

Figure 20-210-16
Remove the pin (Item 1) from both cover / cam
assemblies. Remove the cam (Item 2) [Figure 20-210-

Dealer Copy -- Not for Resale

13] from the cover.
1
Figure 20-210-14

P-86459

Remove the plug (Item 1) [Figure 20-210-16] from the

bores.
P-86457

Remove the cover (Item 1) [Figure 20-210-14].

452 of 918 20-210-6 E85 Service Manual

TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-19

Disassembly And Assembly (Cont’d)

Figure 20-210-17

2
P-86462

Remove the dust seal (Item 1) [Figure 20-210-19] from

P-86460 the inside diameter of the plug.

Repeat the procedure for the three remaining plugs.

Remove the piston (Item 1) and spring (Item 2) [Figure
20-210-17]. Figure 20-210-20

Dealer Copy -- Not for Resale

Figure 20-210-18

2
1
P-86463

P-86461
Remove the O-rings (Item 1) [Figure 20-210-20].

Remove the O-ring (Item 1) and grease cap (Item 2)

[Figure 20-210-18] from the plug.

453 of 918 20-210-7 E85 Service Manual

TRAVEL CONTROL VALVE (CONT'D) Figure 20-210-23

Disassembly And Assembly (Cont’d)

Figure 20-210-21

P-86467
1

Compress the springs (Item 1) and remove the spring

P-86464 seat (Item 2) [Figure 20-210-23].

Figure 20-210-24
Remove the spool / spring assemblies (Item 1) [Figure
20-210-21].

Dealer Copy -- Not for Resale

Figure 20-210-22

1 3 2 1

P-86469

1
Remove the spring (Item 1) and washer (Item 2) from the
P-86465 spool (Item 3) [Figure 20-210-24].

Remove the springs (Item 1) [Figure 20-210-22].

454 of 918 20-210-8 E85 Service Manual

AUTO IDLE

Description

The auto Idle function is controlled by the ECU. The auto

the filter assembly.

457 of 918 20-230-1 E85 Service Manual

Dealer Copy -- Not for Resale

458 of 918 20-230-2 E85 Service Manual

UNDERCARRIAGE

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

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) . . . . . . . . . . . . . . . . . 30-20-1

Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-10
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-15
Track Tensioner Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-16
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-17
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-19
Lower Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-21
Lower Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-22
Lower Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-25

Dealer Copy -- Not for Resale

Upper Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-31
Upper Roller Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-32
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-35

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) . . . . . . . . . . . . . . . . . . 30-21-1

Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2
Track Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-3
Track Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-6
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-7
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-8
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-11
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-16
Track Tensioner Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-17
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-18
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-20
Guide Plate Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-22
Lower Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-23
Lower Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-24
Lower Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-27
Upper Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-33
Upper Roller Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-34
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-37

TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

459 of 918 30-01 E85 Service Manual

SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2

LOWER TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5

UPPER TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2

Dealer Copy -- Not for Resale

460 of 918 30-02 E85 Service Manual

BLADE Figure 30-10-3

Removal And Installation

1
Lower the blade the ground.

Remove the blade cylinders. (See Removal And

Installation on Page 20-24-2.)

Figure 30-10-1

2 P-87813

Install a chain hoist (Item 1) [Figure 30-10-3] in the

1 center of the blade crossmember.

Dealer Copy -- Not for Resale

P-87814

Figure 30-10-2

P-87810

Remove the right and left pivot pin retaining nuts (Item 1)
and bolt (Item 2) [Figure 30-10-1] and [Figure 30-10-2].

461 of 918 30-10-1 E85 Service Manual

BLADE (CONT’D)

Removal And Installation (Cont’d)

Figure 30-10-4

P-87811

Figure 30-10-5

Dealer Copy -- Not for Resale

P-87812

Remove the right and left pivot pin (Item 1) [Figure 30-
10-4] and [Figure 30-10-5] and shims.

Lift and remove the blade.

462 of 918 30-10-2 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK)

Track Lug Height

Rubber Track

The lug height of a new rubber track is 29,2 mm (1.15 in).

Figure 30-20-1

Straight Edge

Dealer Copy -- Not for Resale

B-14489

To find the percentage of wear on a excavator track,

measure the height of the lug by placing a straight edge
across the top of three lugs and measuring the distance
from the base of the track to the bottom of the straight
edge [Figure 30-20-1].

Divide this measurement by the new track height and

multiply by 100. This will give the percentage of track lug
left.

Example: lug height 23,4 mm (0.92 in)

0.92
1.15 x 100 = 80

80% of the track lug is remaining, with 20% wear on the

track lugs.

463 of 918 30-20-1 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Checking Tension WARNING

NOTE: The wear of the pins and bushings on the
undercarriage varies with the working AVOID INJURY
conditions and the types of soil. It is Keep fingers and hands out of pinch points when
necessary to inspect track tension to maintain checking the track tension.
W-2142-0903
the correct tension. See SERVICE SCHEDULE
for the correct service interval. (See SERVICE
SCHEDULE on Page 10-80-1.) Figure 30-20-4

Figure 30-20-2

10-15 mm
(0.39-0.59 in)

Dealer Copy -- Not for Resale

P-86332

P-49234
Figure 30-20-5

Raise the side of the machine (approximately 102 mm [4

in]) using the boom and arm [Figure 30-20-2]. Track Frame

Figure 30-20-3

10-15 mm
(0.39-0.59 in)

Track
Roller

Track
B-14067

1
1 Measure the clearance at the middle track roller. Do not
put your fingers into the pinch points between the track
P-86328A
and the track roller. Use a bolt or a dowel of the
appropriate size to check the gap between the contact
edge of the roller and the top edge of the track guide
Fully raise the blade and install jackstands (Item 1) [Figure 30-20-4] and [Figure 30-20-5].
[Figure 30-20-3] under the blade and track frame. Raise
the boom until all machine weight is on the jackstands. Track Clearance 10 - 15 mm
(0.39 - 0.59 in)
Stop the engine.

464 of 918 30-20-2 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Track Removal And Installation
TRACK) (CONT’D)
Lift and block both sides of the machine as follows:
Adjusting Tension
Fully raise the blade.
Figure 30-20-6
Figure 30-20-7
1 2

2 1

1
P-86333A

P-87901

NOTE: The track tension grease fitting (Item 1) is

Dealer Copy -- Not for Resale

installed into the end of the bleed fitting (Item Use the boom and arm to lift up the blade end of the
2). DO NOT loosen the grease fitting (Item 1), machine, and install jackstands (Item 1) [Figure 30-20-7]
loosen the bleed fitting (Item 2) [Figure 30-20- under the blade.
6] ONLY (maximum of 1-1/2 turns) when
releasing track pressure. Raise the boom.

Add grease to the fitting (Item 1) [Figure 30-20-6] until Figure 30-20-8
the track tension is correct.

To release track pressure, loosen the bleed fitting (Item 2)

[Figure 30-20-6] to release tension from the track.

NOTE: Do not loosen the grease fitting (Item 1)

[Figure 30-20-6].

Repeat the procedure for the other side.

WARNING 1

AVOID INJURY OR DEATH P-40662

• Do not loosen bleed fitting more than 1-1/2 turns.

• Do not loosen parts other than bleed fitting.
Grease is under high pressure. Swing the upperstructure 180° and use the boom and
W-2474-0104 arm to slowly lift the opposite end of the undercarriage,
and install jackstands (Item 1) [Figure 30-20-8] under the
undercarriage.

Raise the boom until the weight of the machine is

supported by the jackstands.

465 of 918 30-20-3 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-10
TRACK) (CONT’D)

Track Removal And Installation (Cont’d)

WARNING
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
or fall and result in injury or death.
W-2218-1195
P-40670
Stop the engine.
Insert a second steel rod or pipe (Item 1) [Figure 30-20-
Release track tension. (See Adjusting Tension on Page 10], at a distance of two lugs, between the track and the
30-20-3.) idler wheel. Continue to turn the track until the first pipe
contacts the track frame.

Stop the engine.

WARNING

Dealer Copy -- Not for Resale

AVOID INJURY OR DEATH
• Do not loosen bleed fitting more than 1-1/2 turns.
• Do not loosen parts other than bleed fitting.
Grease is under high pressure.
W-2474-0104

Start the engine.

Slowly turn the track in the forward direction.

Figure 30-20-9

P-40669

Insert a steel rod or pipe (Item 1) [Figure 30-20-9]

(Approximately 44,5 mm [1.750 in] diameter) between
the track and the idler wheel.

466 of 918 30-20-4 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Idler Removal And Installation
TRACK) (CONT’D)
Figure 30-20-12
Track Removal And Installation (Cont'd)

Figure 30-20-11

1
P-87929

P-40888 Remove the track. (See Track Removal And Installation

on Page 30-20-3.)

Insert a pry bar (Item 1) [Figure 30-20-11] between the Install a chain (Item 1) [Figure 30-20-12] and hoist to the

Dealer Copy -- Not for Resale

track and the idler wheel, and pry out on the track until idler and slide the idler towards the front of the track
the track slides off the idler wheel. frame.

Remove the track. Figure 30-20-13

To install the rubber track:

2
Put the track over the rear drive sprocket lugs.

Put the front of the track onto the front idler wheel. 1

See Adjustment for adding grease to the grease spring

and for checking track tension. (See Adjusting Tension on
Page 30-20-3.)

P-87930

Remove the four bolts (Item 1) and washers. Remove the

idler (Item 2) [Figure 30-20-13].

NOTE: The bolts may need to be heated to melt the

thread adhesive.

Installation: Apply thread adhesive (Loctite® 262 or

equivalent) to the bolt threads. Tight the bolts to 255 -
285 N•m (188 - 210 ft-lb) torque.

467 of 918 30-20-5 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Idler Parts Identification

1. Idler
2. Support 6
3. Shaft
4. Bushing
5. Floating Seal
6. Pin
7. O-ring 2
8. Plug 7
5
8 1
4

Dealer Copy -- Not for Resale

4
5

6
7

E80-2120S
MS-

468 of 918 30-20-6 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-16
TRACK) (CONT’D)

Idler Disassembly

Figure 30-20-14

P-89261

Figure 30-20-17

P-89259

Remove the roll pin (Item 1) [Figure 30-20-14].

Dealer Copy -- Not for Resale

Figure 30-20-15 1

P-89263

Remove the floating seal (Item 1) [Figure 30-20-16] and

[Figure 30-20-17] from the support and idler.

P-89260

Pull up on and remove the support (Item 1) [Figure 30-

20-15].

469 of 918 30-20-7 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-20
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-20-18

P-89267

Figure 30-20-21

P-89264

Remove the O-ring (Item 1) [Figure 30-20-18] from the 1

Dealer Copy -- Not for Resale

shaft.

Figure 30-20-19

P-89268

Remove the floating seal (Item 1) [Figure 30-20-20] and

[Figure 30-20-21] from the support and idler.

P-89266

Tip the idler over and remove the support / shaft

assembly (Item 1) [Figure 30-20-19].

470 of 918 30-20-8 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-24
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-20-22 1

P-89270

Remove the O-ring (Item 1) [Figure 30-20-24].

P-89262 Figure 30-20-25

Remove the O-ring (Item 1) [Figure 30-20-22] from all

Dealer Copy -- Not for Resale

four of the steel seals.
1
Figure 30-20-23

P-89271

Remove the bushings (Item 1) [Figure 30-20-25] from

2 both sides of the idler.

P-89269

Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-20-23] from the support.

471 of 918 30-20-9 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER NOTE: Inspect the seal ring for damage before
TRACK) (CONT’D) installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
Idler Assembly any twists, gently pull a section of the O-ring
and let it snap back.
Clean all parts in solvent and dry with compressed air.
Figure 30-20-28
The seal assemblies are a matched set and must be
replaced in pairs.
1
Figure 30-20-26

P-40754

Dealer Copy -- Not for Resale

Place the seal assembly in the installation tool (Item 1)
P-89271 [Figure 30-20-28].

The O-ring and seal ring assembly have to be lubricated

Install the bushings (Item 1) [Figure 30-20-26] on both with alcohol, so that the O-ring will slip past the housing
sides of the idler. retaining ring and seal uniformly in the housing radius.

Figure 30-20-27 Dip the seal assembly in a pan of alcohol.

Figure 30-20-29

1
1

P-89262

P-89276
Install the O-ring (Item 1) [Figure 30-20-27] on the seal
ring. Repeat this procedure on all four seal assemblies.
Shake off the excess alcohol and install the seal
The O-ring and seal ring must be clean and free of any assembly (Item 1) [Figure 30-20-29] in the idler.
dust, oil film and foreign matter.
Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Remove the installation tool.

472 of 918 30-20-10 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-32
TRACK) (CONT’D)

Idler Assembly (Cont’d) 1

Figure 30-20-30 2

P-89269

Install the shaft (Item 1) in the support. Install the roll pin
(Item 2) [Figure 30-20-32] through the shaft and support
P-89277 assembly.

Figure 30-20-33
The seal assembly stand off height must be equal and

Dealer Copy -- Not for Resale

the O-ring must not be twisted [Figure 30-20-30].
1
Figure 30-20-31

1
P-40754

Place the seal assembly (Item 1) [Figure 30-20-33] in

P-89270 the installation tool.

The O-ring and seal ring assembly have to be lubricated

Install the O-ring (Item 1) [Figure 30-20-31] onto the with alcohol, so that the O-ring will slip past the housing
shaft. retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

473 of 918 30-20-11 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-36
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-34 1

P-89264

Install the idler (Item 1) [Figure 30-20-36] on the shaft /

support assembly.
P-89274
Figure 30-20-37

Shake off the excess alcohol and install the seal

Dealer Copy -- Not for Resale

assembly (Item 1) [Figure 30-20-34] in the support.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Figure 30-20-35

P-40754

Place the seal assembly (Item 1) [Figure 30-20-37] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
P-89275 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-20-35].

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

474 of 918 30-20-12 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-40
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-38
1

P-89280

Install the O-ring (Item 1) [Figure 30-20-40] on the shaft.

P-89278 Figure 30-20-41

Shake off the excess alcohol and install the seal 1

Dealer Copy -- Not for Resale

assembly (Item 1) [Figure 30-20-38] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

Figure 30-20-39

P-40754

Place the seal assembly (Item 1) [Figure 30-20-41] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

P-89279

The seal assembly stand off height must be equal and

the O-ring (Item 1) [Figure 30-20-39] must not be
twisted.

475 of 918 30-20-13 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-44
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-42 1

P-89283

Install the support (Item 1) on the shaft. Press down on

the support and install the roll pin (Item 2) [Figure 30-20-
P-89281 44].

Figure 30-20-45
Shake off the excess alcohol and install the seal

Dealer Copy -- Not for Resale

assembly (Item 1) [Figure 30-20-42] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

1
Figure 30-20-43

89324

Remove the plug (Item 1) [Figure 30-20-45].

Add 0,101 - 0,139 L (3.4 - 4.7 U.S. fl oz) 30W oil to the
1
idler. Install the plug (Item 1) [Figure 30-20-45].

P-89282

The seal stand off height must be equal and the O-ring
(Item 1) [Figure 30-20-43] must not be twisted.

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

476 of 918 30-20-14 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Tensioner Removal And Installation WARNING

Figure 30-20-46

P-62574

AVOID INJURY OR DEATH

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly
W-2617-1004
P-89261

Install a sling (Item 1) [Figure 30-20-46] and hoist on the

Dealer Copy -- Not for Resale

grease cylinder.

Figure 30-20-47

P-87932

Guide the grease cylinder (Item 1) [Figure 30-20-47] out

of the track frame.

DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 1) [Figure 30-20-47].

477 of 918 30-20-15 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) (CONT’D)

Track Tensioner Parts Identification

1. Piston Rod
2. Piston 6
3. Piston Ring 5
4. Back-up Ring 4
5. Packing
6. Snap Ring 3
7. Dust Seal
8. Cylinder 2
9. Spring Assembly
10. Grease Fitting

Dealer Copy -- Not for Resale

EM7807

478 of 918 30-20-16 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly

WARNING
Figure 30-20-48

P-62574

AVOID INJURY OR DEATH

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly
W-2617-1004

P-87927
Figure 30-20-50

Remove the grease fitting and adapter (Item 1) [Figure

Dealer Copy -- Not for Resale

30-20-48].

Figure 30-20-49
2
1

P-87933

2 1
Use a 12 mm x 1,75 x 203 mm long bolt to thread the bolt
(Item 1) into the piston (Item 2) [Figure 30-20-50]. Pull
P-87928 the piston out of the cylinder.

Remove the piston rod (Item 1) [Figure 30-20-49] from

the cylinder.

DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 2) [Figure 30-20-49]

479 of 918 30-20-17 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-53
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly (Cont’d)

1
Figure 30-20-51

2 P-87935

Remove the two piston rings (Item 1) [Figure 30-20-53].

P-87937 Figure 30-20-54

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

Dealer Copy -- Not for Resale

[Figure 30-20-51].

Figure 30-20-52

1
1

P-87934

Remove the dust seal (Item 1) [Figure 30-20-54].

P-87936

Remove the back-up ring (Item 1) [Figure 30-20-52].

480 of 918 30-20-18 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-57
TRACK) (CONT’D)
2
Roller Removal And Installation

NOTE: The track does not have to be removed to 3

remove the top roller.

Figure 30-20-55

P-89268

Installation: Install the flat spot of the shaft (Item 1) to

1 the top of the mount. Tighten the bolt (Item 2) to 105 -
115 N•m (78 - 85 ft-lb) torque. Tighten the nut (Item 3)
1 [Figure 30-20-57] against the mount.

P-87911 Figure 30-20-58

Dealer Copy -- Not for Resale

Install blocks (Item 1) [Figure 30-20-55] between the
track frame and track. Loosen the track. (See Adjusting
Tension on Page 30-20-3.)
1
Figure 30-20-56

1
2 2

P-89285

NOTE: Remove the track to remove the bottom roller.

Place a jack under the bottom roller (Item 1). Remove the
four bolts (Item 2) [Figure 30-20-58].
P-87912
Installation: Apply thread adhesive (Loctite® 242 or
equivalent) to the bolt threads. Tighten the bolts to 160 -
Loosen the nut (Item 1) [Figure 30-20-56] and bolt. 180 N•m (118 - 113 ft-lb) torque.
Remove the top roller.

481 of 918 30-20-19 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Roller Removal And Installation (Cont’d)

Figure 30-20-59

P-89286

Lower the jack and remove the roller (Item 1) [Figure 30-

Dealer Copy -- Not for Resale

20-59].

482 of 918 30-20-20 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) (CONT’D)

Lower Roller Parts Identification

1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug

4
5
6

2
5

Dealer Copy -- Not for Resale

2
8 7

E80-2150S

483 of 918 30-20-21 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-62
TRACK) (CONT’D)

Lower Roller Disassembly

1
Figure 30-20-60

P-89289

Remove the seal assembly (Item 1) [Figure 30-20-62].

P-89287 Figure 30-20-63

Drive the pin (Item 1) towards the top of the collar (Item

Dealer Copy -- Not for Resale

2) [Figure 30-20-60].

NOTE: The pin bore in the collar is stepped.

Figure 30-20-61

1
1

P-89290

Remove the seal assembly (Item 1). Remove the O-ring

(Item 2) [Figure 30-20-63].

P-89288

Remove the collar (Item 1) [Figure 30-20-61].

484 of 918 30-20-22 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-66
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

Figure 30-20-64

P-89293

1
Remove the seal assembly (Item 1) [Figure 30-20-66]
from the collar.
P-89291
Figure 30-20-67

Remove the shaft assembly (Item 1) [Figure 30-20-64]

Dealer Copy -- Not for Resale

from the roller.

Figure 30-20-65 1

P-89262

Remove the O-ring (Item 1) [Figure 30-20-67] from all

four seal rings.
P-89292

Remove the seal assembly (Item 1) [Figure 30-20-65]

from the roller.

485 of 918 30-20-23 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-70
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

1
Figure 30-20-68

P-89296

1
Remove the O-ring (Item 1) [Figure 30-20-70].

P-87924 Figure 30-20-71

Remove the pin (Item 1) [Figure 30-20-68].

Dealer Copy -- Not for Resale

Figure 30-20-69
1

1
P-89297

Remove the bushing (Item 1) [Figure 30-20-71] from

both sides of the roller.
P-87925

Remove the shaft (Item 1) [Figure 30-20-69].

486 of 918 30-20-24 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-74
TRACK) (CONT’D)

Lower Roller Assembly

1
Clean all parts in solvent and dry with compressed air.

The seal assemblies are a matched set and must be

replaced in pairs.

Figure 30-20-72

1
P-89295

Install the shaft (Item 1) [Figure 30-20-74] in the collar.

Figure 30-20-75

Dealer Copy -- Not for Resale

P-89297

Install the bushing (Item 1) [Figure 30-20-72] on both

sides of the roller.

Figure 30-20-73

P-89294

Install the pin (Item 1) [Figure 30-20-75] in the collar and

through the shaft.

P-89296

Install the O-ring (Item 1) [Figure 30-20-73] on the shaft.

487 of 918 30-20-25 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Dip the seal assembly in a pan of alcohol.
TRACK) (CONT’D)
Figure 30-20-78
Lower Roller Assembly (Cont’d)

Figure 30-20-76

1
P-89298

P-89262 Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-20-78] in the collar.

Install the O-ring (Item 1) [Figure 30-20-76] on the seal Use firm, even pressure on the installation tool to pop the

Dealer Copy -- Not for Resale

ring. Repeat this procedure on all four seal assemblies. O-ring in to the collar.

The O-ring and seal ring must be clean and free of any Remove the installation tool.
dust, oil film and foreign matter.
Figure 30-20-79
NOTE: Inspect the seal ring for damage before
installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.

Figure 30-20-77

P-89299

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-79].

P-40754

Place the seal assembly in the installation tool (Item 1)

[Figure 30-20-77].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.

488 of 918 30-20-26 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-82
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-80

P-89301

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-82].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly (Item 1) [Figure 30-20-80] in NOTE: Do not get any oil on the rubber O-rings.

Dealer Copy -- Not for Resale

the installation tool.
Figure 30-20-83
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1
Dip the O-ring and seal assembly in a pan of alcohol.

Figure 30-20-81

P-89302

Install the roller (Item 1) [Figure 30-20-83] on the shaft.

P-89300

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-20-81] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

489 of 918 30-20-27 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-86
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-84

P-89304

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-86].
P-40754
Figure 30-20-87

Place the seal assembly in the installation tool (Item 1)

Dealer Copy -- Not for Resale

[Figure 30-20-84].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1
retaining ring and seal uniformly in the housing radius.

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-20-85

P-89305

Install the O-ring (Item 1) [Figure 30-20-87].

P-89303

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-20-85] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

490 of 918 30-20-28 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-90
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-88

P-89307

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-90].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.

Dealer Copy -- Not for Resale

[Figure 30-20-88].
Figure 30-20-91
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius. 1

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-20-89

P-89308

Install the collar (Item 1) on the shaft. Install the pin (Item
1 2) [Figure 30-20-91] in the collar.

P-89306

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-20-89] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

491 of 918 30-20-29 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-92

P-89309

Push down on the collar until the pin bore of the collar is

Dealer Copy -- Not for Resale

aligned with the pin bore of the shaft. Fully seat the pin
(Item 1) [Figure 30-20-92].

Remove the plug (Item 2) [Figure 30-20-92]. Add 0,121 -

0,160 L (4.1 - 5.4 U.S. fl oz) of 30W oil to the roller.

Install the plug.

492 of 918 30-20-30 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) (CONT’D)

Upper Roller Parts Identification

1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal 6
8. Shaft
9. Bolt
10. Nut
11. Mount
5

1
4

1 2

Dealer Copy -- Not for Resale

8
11

7
1

E80-2140S

493 of 918 30-20-31 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-95
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly

Figure 30-20-93
1

P-87918

Install a 50,8 mm (2.0 in) long 3,175 mm (1/8 in) NPT

pipe (Item 1) into the cover. Pull up on the pipe to remove
P-87915 the cover (Item 2) [Figure 30-20-95].

Figure 30-20-96
Remove the snap ring (Item 1) [Figure 30-20-93].

Dealer Copy -- Not for Resale

Figure 30-20-94

1
1

P-87919

P-87916 Remove the O-ring (Item 1) [Figure 30-20-96].

Remove the pipe plug (Item 1) [Figure 30-20-94].

494 of 918 30-20-32 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-99
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

1
Figure 30-20-97

1 P-87922

Remove the seal (Item 1) [Figure 30-20-99] from the

shaft.
P-87920
Figure 30-20-100

Remove the snap ring (Item 1) [Figure 30-20-97].

Dealer Copy -- Not for Resale

Turn the roller over and drain the oil.
1
Assembly: Add 0,133 - 0,169 L (4.5 - 5.7 U.S. fl oz) of
30W oil to the roller before installing the cover.

Figure 30-20-98

P-87923

1
Remove the seal (Item 1) [Figure 30-20-100] from the
roller.

P-87921

Remove the shaft (Item 1) [Figure 30-20-98] from the

roller.

495 of 918 30-20-33 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

Figure 30-20-101

P-87924

Remove the snap ring (Item 1) [Figure 30-20-101].

Dealer Copy -- Not for Resale

Figure 30-20-102

P-87925

Remove the bearings (Item 1) [Figure 30-20-102] from

both ends of the roller.

496 of 918 30-20-34 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Sprocket Removal And Installation

Figure 30-20-103

B-15022

Measure the clearance at the middle track roller. Do not

P-86926 get fingers into pinch points between the track and the
track roller. Check the gap between the bottom edge of
the track frame and the top surface of the track [Figure
Raise the side of the machine approximately 153 mm (6 30-21-3].
in) using the boom and arm [Figure 30-21-1].
TERRIAN TYPE DIMENSION A
Figure 30-21-2
Soil 140 - 150 mm
(5.51 - 5.91 in)
Gravel, Sand, Soft Soil 150 - 160 mm
(5.91 - 6.30 in)
Rock Bed 120 - 130 mm
(4.72 - 5.12 in)

1
1

P-86328B

Raise the blade fully and install jack stands (Item 1)

[Figure 30-21-2] under the blade and track frame. Raise
the boom until all machine weight is on the jack stands.

Stop the engine.

499 of 918 30-21-1 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Adjusting Tension

Figure 30-21-4

1 2

1 P-86333A

NOTE: The track tension grease fitting (Item 1) is

Dealer Copy -- Not for Resale

installed into the end of the bleed fitting (Item
2). DO NOT loosen the grease fitting (Item 1),
loosen the bleed fitting (Item 2) [Figure 30-21-
4] ONLY (maximum of 1.5 turns) when
releasing track pressure.

Add grease to the fitting (Item 1) [Figure 30-21-4] until

the track tension is correct.

To release track pressure, loosen the bleed fitting (Item 2)

[Figure 30-21-4] to release tension from the track.

NOTE: Do not loosen the grease fitting (Item 1)

[Figure 30-21-4].

Repeat the procedure for the other side.

WARNING
HIGH PRESSURE GREASE CAN
CAUSE SERIOUS INJURY
• Do not loosen grease fitting.
• Do not loosen bleed fitting more than 1 - 1/2
turns.
W-2781-0109

500 of 918 30-21-2 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Track Removal WARNING

Lift and block both sides of the machine as follows: Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Raise the blade fully. Failure to block up the machine may allow it to move
or fall and result in injury or death.
Figure 30-21-5 W-2218-1195

Stop the engine.

Release track tension (See Adjusting Tension on Page

30-21-2.)

With the excavator raised and the bleed fitting loosened,

start the excavator. (See Adjusting Tension on Page 30-
1 21-2.)

1 Slowly turn the track. This will force more grease out of
the grease spring.

Dealer Copy -- Not for Resale

P-87902

WARNING
Use the boom and arm to lift the blade end of the
machine up about 75 mm (3.0 in) and install jack stands AVOID INJURY OR DEATH
(Item 1) [Figure 30-21-5] under the blade. Keep fingers and hands out of pinch points when
removing the track.
Raise the boom. W-2173-0195

Figure 30-21-6

1 1

P-87903

Swing the upperstructure 180 degrees and use the boom

and arm to slowly lift the opposite end of the
undercarriage and install jack stands (Item 1) [Figure 30-
21-6] under the undercarriage.

Raise the boom until the weight of the machine is

supported by the jack stands.

501 of 918 30-21-3 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-9
TRACK) (CONT’D)

Track Removal (Cont’d)

Figure 30-21-7

1
1

P-87906

Remove the pin (Item 1) [Figure 30-21-9].

P-87904 Figure 30-21-10

Rotate the track until the master link and cotter pin (Item

Dealer Copy -- Not for Resale

1) [Figure 30-21-7] are at the bottom of the track frame,
between the drive motor and rear lower roller.

Stop the engine.

Remove the cotter pin (Item 1) [Figure 30-21-7].

Figure 30-21-8

P-87907

Start the excavator and run it at low idle. Slowly engage

the travel motor in the reverse direction. Continue to
engage the travel motor in the reverse direction until the
track has been driven off the track frame [Figure 30-21-
10].
1
Stop the engine.

P-87905

Drive the master pin (Item 1) [Figure 30-21-8] towards

the inside of the track frame.

502 of 918 30-21-4 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-12
TRACK) (CONT’D)

Track Installation

Figure 30-21-11

3
2 2
1
1
P-87906

1 Rotate the track until the track links (Item 1) are located
on the bottom of the track frame, between the drive motor
P-87907 and rear lower roller. Install the master pin (Item 2)
[Figure 30-21-12] from the inside of the track frame.

Place the steel track (Item 1) under the track frame and in Figure 30-21-13

Dealer Copy -- Not for Resale

line with the travel motor. Place the opposite end of the
track (Item 2) [Figure 30-21-11] over the drive sprocket.

WARNING
AVOID INJURY OR DEATH
Drive motor must be operated slowly to avoid any
sudden movements that could cause injury or death.
W-2174-0195
1

With the help of a second person, start the excavator.

Use the travel lever (on the side of the excavator the track
P-87904
in being installed) to slowly turn the drive motor in the
forward direction. Guide the track over the upper roller
(Item 3) [Figure 30-21-11] and on to the front idler. Install the cotter pin (Item 1) [Figure 30-21-13]

503 of 918 30-21-5 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT'D)

Idler Removal And Installation

Figure 30-21-14

P-87929

Remove the track. (See Track Removal on Page 30-21-

Dealer Copy -- Not for Resale

3.)

Install a chain (Item 1) [Figure 30-21-14] and hoist to the

idler and slide the idler towards the front of the track
frame.

Figure 30-21-15

P-87930

Remove the four bolts (Item 1) and washers. Remove the

idler (Item 2) [Figure 30-21-15].

NOTE: The bolts may need to be heated to melt the

thread adhesive.

Installation: Apply thread adhesive (Loctite® 262 or

equivalent) to the bolt threads. Tighten the bolts to 255 -
285 •m (188 - 210 ft-lb) torque.

504 of 918 30-21-6 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Idler Parts Identification

1. Idler
2. Support 6
3. Shaft
4. Bushing
5. Floating Seal
6. Pin
7. O-ring 2
8. Plug 7
5
8 1
4

Dealer Copy -- Not for Resale

4
5

6
7

E80-2120S
MS-

505 of 918 30-21-7 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-18
TRACK) (CONT’D)

Idler Disassembly

Figure 30-21-16

P-89261

Figure 30-21-19

P-89259

Remove the roll pin (Item 1) [Figure 30-21-16].

Dealer Copy -- Not for Resale

Figure 30-21-17 1

P-89263

Remove the floating seal (Item 1) [Figure 30-21-18] and

[Figure 30-21-19] from the support and idler.

P-89260

Pull up on and remove the support (Item 1) [Figure 30-

21-17].

506 of 918 30-21-8 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-22
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-21-20

P-89267

Figure 30-21-23

P-89264

Remove the O-ring (Item 1) [Figure 30-21-20] from the 1

Dealer Copy -- Not for Resale

shaft.

Figure 30-21-21

P-89268

Remove the floating seal (Item 1) [Figure 30-21-22] and

[Figure 30-21-23] from the support and idler.

P-89266

Tip the idler over and remove the support / shaft

assembly (Item 1) [Figure 30-21-21].

507 of 918 30-21-9 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-26
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-21-24 1

P-89270

Remove the O-ring (Item 1) [Figure 30-21-26].

P-89262 Figure 30-21-27

Remove the O-ring (Item 1) [Figure 30-21-24] from all

Dealer Copy -- Not for Resale

four of the steel seals.
1
Figure 30-21-25

P-89271

Remove the bushings (Item 1) [Figure 30-21-27] from

2 both sides of the idler.

P-89269

Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-21-25] from the support.

508 of 918 30-21-10 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL NOTE: Inspect the seal ring for damage before
TRACK) (CONT’D) installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
Idler Assembly any twists, gently pull a section of the O-ring
and let it snap back.
Clean all parts in solvent and dry with compressed air.
Figure 30-21-30
The seal assemblies are a matched set and must be
replaced in pairs.
1
Figure 30-21-28

P-40754

Dealer Copy -- Not for Resale

Place the seal assembly in the installation tool (Item 1)
P-89271 [Figure 30-21-30].

The O-ring and seal ring assembly have to be lubricated

Install the bushings (Item 1) [Figure 30-21-28] on both with alcohol, so that the O-ring will slip past the housing
sides of the idler. retaining ring and seal uniformly in the housing radius.

Figure 30-21-29 Dip the seal assembly in a pan of alcohol.

Figure 30-21-31

1
1

P-89262

P-89276
Install the O-ring (Item 1) [Figure 30-21-29] on the seal
ring. Repeat this procedure on all four seal assemblies.
Shake off the excess alcohol and install the seal
The O-ring and seal ring must be clean and free of any assembly (Item 1) [Figure 30-21-31] in the idler.
dust, oil film and foreign matter.
Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Remove the installation tool.

509 of 918 30-21-11 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-34
TRACK) (CONT’D)

Idler Assembly (Cont’d) 1

Figure 30-21-32 2

P-89269

Install the shaft (Item 1) in the support. Install the roll pin
(Item 2) [Figure 30-21-34] through the shaft and support
P-89277 assembly.

Figure 30-21-35
The seal assembly stand off height must be equal and

Dealer Copy -- Not for Resale

the O-ring must not be twisted [Figure 30-21-32].
1
Figure 30-21-33

1
P-40754

Place the seal assembly (Item 1) [Figure 30-21-35] in

P-89270 the installation tool.

The O-ring and seal ring assembly have to be lubricated

Install the O-ring (Item 1) [Figure 30-21-33] onto the with alcohol, so that the O-ring will slip past the housing
shaft. retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

510 of 918 30-21-12 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-38
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-21-36 1

P-89264

Install the idler (Item 1) [Figure 30-21-38] on the shaft /

support assembly.
P-89274
Figure 30-21-39

Shake off the excess alcohol and install the seal

Dealer Copy -- Not for Resale

assembly (Item 1) [Figure 30-21-36] in the support.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Figure 30-21-37

P-40754

Place the seal assembly (Item 1) [Figure 30-21-39] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
P-89275 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-21-37].

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

511 of 918 30-21-13 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-42
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-21-40
1

P-89280

Install the O-ring (Item 1) [Figure 30-21-42] on the shaft.

P-89278 Figure 30-21-43

Shake off the excess alcohol and install the seal 1

Dealer Copy -- Not for Resale

assembly (Item 1) [Figure 30-21-40] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

Figure 30-21-41

P-40754

Place the seal assembly (Item 1) [Figure 30-21-43] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

P-89279

The seal assembly stand off height must be equal and

the O-ring (Item 1) [Figure 30-21-41] must not be
twisted.

512 of 918 30-21-14 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-46
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-21-44 1

P-89283

Install the support (Item 1) on the shaft. Press down on

the support and install the roll pin (Item 2) [Figure 30-21-
P-89281 46].

Figure 30-21-47
Shake off the excess alcohol and install the seal

Dealer Copy -- Not for Resale

assembly (Item 1) [Figure 30-21-44] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

1
Figure 30-21-45

89324

Remove the plug (Item 1) [Figure 30-21-47].

Add 0,101 - 0,139 L (3.4 - 4.7 U.S. fl oz) 30W oil to the
1
idler. Install the plug (Item 1) [Figure 30-21-47].

P-89282

The seal stand off height must be equal and the O-ring
(Item 1) [Figure 30-21-45] must not be twisted.

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

513 of 918 30-21-15 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Track Tensioner Removal And Installation WARNING

Figure 30-21-48

P-62574

AVOID INJURY OR DEATH

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly
W-2617-1004
P-89261

Install a sling (Item 1) [Figure 30-21-48] and hoist on the

Dealer Copy -- Not for Resale

grease cylinder.

Figure 30-21-49

P-87932

Guide the grease cylinder (Item 1) [Figure 30-21-49] out

of the track frame.

DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 1) [Figure 30-21-49].

514 of 918 30-21-16 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Track Tensioner Parts Identification

1. Piston Rod
2. Piston 6
3. Piston Ring 5
4. Back-up Ring 4
5. Packing
6. Snap Ring 3
7. Dust Seal
8. Cylinder 2
9. Spring Assembly
10. Grease Fitting

Dealer Copy -- Not for Resale

EM7807

515 of 918 30-21-17 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly WARNING

Figure 30-21-50

P-62574

AVOID INJURY OR DEATH

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly
W-2617-1004

P-87927
Figure 30-21-52

Remove the grease fitting and adapter (Item 1) [Figure

Dealer Copy -- Not for Resale

30-21-50].

Figure 30-21-51
2
1

P-87933

2 1
Use a 12 mm x 1,75 x 203 mm long bolt to thread the bolt
(Item 1) into the piston (Item 2) [Figure 30-21-52]. Pull
P-87928 the piston out of the cylinder.

Remove the piston rod (Item 1) [Figure 30-21-51] from

the cylinder.

DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 2) [Figure 30-21-51]

516 of 918 30-21-18 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-55
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly (Cont’d)

1
Figure 30-21-53

2 P-87935

Remove the two piston rings (Item 1) [Figure 30-21-55].

P-87937 Figure 30-21-56

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

Dealer Copy -- Not for Resale

[Figure 30-21-53].

Figure 30-21-54

1
1

P-87934

Remove the dust seal (Item 1) [Figure 30-21-56].

P-87936

Remove the back-up ring (Item 1) [Figure 30-21-54].

517 of 918 30-21-19 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-59
TRACK) (CONT’D)
2
Roller Removal And Installation

NOTE: The track does not have to be removed to 3

remove the top roller.

Figure 30-21-57

P-89268

Installation: Install the flat spot of the shaft (Item 1) to

1 the top of the mount. Tighten the bolt (Item 2) to 105 -
115 N•m (78 - 85 ft-lb) torque. Tighten the nut (Item 3)
1 [Figure 30-21-59] against the mount.

P-87911 Figure 30-21-60

Dealer Copy -- Not for Resale

Install blocks (Item 1) [Figure 30-21-57] between the
track frame and track. Loosen the track. (See Adjusting
Tension on Page 30-21-2.)
1
Figure 30-21-58

1
2 2

P-89285

NOTE: Remove the track to remove the bottom roller.

Place a jack under the bottom roller (Item 1). Remove the
four bolts (Item 2) [Figure 30-21-60].
P-87912
Installation: Apply thread adhesive (Loctite® 242 or
equivalent) to the bolt threads. Tighten the bolts to 160 -
Loosen the nut (Item 1) [Figure 30-21-58] and bolt. 180 N•m (118 - 113 ft-lb) torque.
Remove the top roller.

518 of 918 30-21-20 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Roller Removal And Installation (Cont’d)

Figure 30-21-61

P-89286

Lower the jack and remove the roller (Item 1) [Figure 30-

Dealer Copy -- Not for Resale

21-61].

519 of 918 30-21-21 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Guide Plate Removal And Installation

Figure 30-21-62

1 1 1

2
P-89284

Remove the bolts (Item 1) and remove the four guide

Dealer Copy -- Not for Resale

plates (two per side) (Item 2) [Figure 30-21-62].

520 of 918 30-21-22 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Lower Roller Parts Identification

1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug

4
5
6

2
5

Dealer Copy -- Not for Resale

2
8 7

E802150S

521 of 918 30-21-23 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-65
TRACK) (CONT’D)

Lower Roller Disassembly

1
Figure 30-21-63

P-89289

Remove the seal assembly (Item 1) [Figure 30-21-65].

P-89287 Figure 30-21-66

Drive the pin (Item 1) towards the top of the collar (Item

Dealer Copy -- Not for Resale

2) [Figure 30-21-63].

NOTE: The pin bore in the collar is stepped.

Figure 30-21-64

1
1

P-89290

Remove the seal assembly (Item 1). Remove the O-ring

(Item 2) [Figure 30-21-66].

P-89288

Remove the collar (Item 1) [Figure 30-21-64].

522 of 918 30-21-24 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-69
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

Figure 30-21-67

P-89293

1
Remove the seal assembly (Item 1) [Figure 30-21-69]
from the collar.
P-89291
Figure 30-21-70

Remove the shaft assembly (Item 1) [Figure 30-21-67]

Dealer Copy -- Not for Resale

from the roller.

Figure 30-21-68 1

P-89262

Remove the O-ring (Item 1) [Figure 30-21-70] from all

four seal rings.
P-89292

Remove the seal assembly (Item 1) [Figure 30-21-68]

from the roller.

523 of 918 30-21-25 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-73
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

1
Figure 30-21-71

P-89296

1
Remove the O-ring (Item 1) [Figure 30-21-73].

P-87924 Figure 30-21-74

Remove the pin (Item 1) [Figure 30-21-71].

Dealer Copy -- Not for Resale

Figure 30-21-72
1

1
P-89297

Remove the bushing (Item 1) [Figure 30-21-74] from

both sides of the roller.
P-87925

Remove the shaft (Item 1) [Figure 30-21-72].

524 of 918 30-21-26 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-77
TRACK) (CONT’D)

Lower Roller Assembly

1
Clean all parts in solvent and dry with compressed air.

The seal assemblies are a matched set and must be

replaced in pairs.

Figure 30-21-75

1
P-89295

Install the shaft (Item 1) [Figure 30-21-77] in the collar.

Figure 30-21-78

Dealer Copy -- Not for Resale

P-89297

Install the bushing (Item 1) [Figure 30-21-75] on both

sides of the roller.

Figure 30-21-76

P-89294

Install the pin (Item 1) [Figure 30-21-78] in the collar and

through the shaft.

P-89296

Install the O-ring (Item 1) [Figure 30-21-76] on the shaft.

525 of 918 30-21-27 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Dip the seal assembly in a pan of alcohol.
TRACK) (CONT’D)
Figure 30-21-81
Lower Roller Assembly (Cont’d)

Figure 30-21-79

1
P-89298

P-89262 Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-21-81] in the collar.

Install the O-ring (Item 1) [Figure 30-21-79] on the seal Use firm, even pressure on the installation tool to pop the

Dealer Copy -- Not for Resale

ring. Repeat this procedure on all four seal assemblies. O-ring in to the collar.

The O-ring and seal ring must be clean and free of any Remove the installation tool.
dust, oil film and foreign matter.
Figure 30-21-82
NOTE: Inspect the seal ring for burrs before
installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.

Figure 30-21-80

P-89299

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-82].

P-40754

Place the seal assembly in the installation tool (Item 1)

[Figure 30-21-80].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.

526 of 918 30-21-28 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-85
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-83

P-89301

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-85].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly (Item 1) [Figure 30-21-83] in NOTE: Do not get any oil on the rubber O-rings.

Dealer Copy -- Not for Resale

the installation tool.
Figure 30-21-86
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1
Dip the O-ring and seal assembly in a pan of alcohol.

Figure 30-21-84

P-89302

Install the roller (Item 1) [Figure 30-21-86] on the shaft.

P-89300

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-21-84] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

527 of 918 30-21-29 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-89
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-87

P-89304

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-89].
P-40754
Figure 30-21-90

Place the seal assembly in the installation tool (Item 1)

Dealer Copy -- Not for Resale

[Figure 30-21-87].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1
retaining ring and seal uniformly in the housing radius.

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-21-88

P-89305

Install the O-ring (Item 1) [Figure 30-21-90].

P-89303

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-21-88] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

528 of 918 30-21-30 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-93
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-91

P-89307

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-93].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.

Dealer Copy -- Not for Resale

[Figure 30-21-91].
Figure 30-21-94
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius. 1

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-21-92

P-89308

Install the collar (Item 1) on the shaft. Install the pin (Item
1 2) [Figure 30-21-94] in the collar.

P-89306

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-21-92] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

529 of 918 30-21-31 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-95

P-89309

Push down on the collar until the pin bore of the collar is

Dealer Copy -- Not for Resale

aligned with the pin bore of the shaft. Fully seat the pin
(Item 1) [Figure 30-21-95].

Remove the plug (Item 2) [Figure 30-21-95]. Add 0,121 -

0,160 L (4.1 - 5.4 U.S. fl oz) of 30W oil to the roller.

Install the plug.

530 of 918 30-21-32 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Upper Roller Parts Identification

1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal 6
8. Shaft
9. Bolt
10. Nut
11. Mount
5

1
4

1 2

Dealer Copy -- Not for Resale

8
11

7
1

E80-2140S

531 of 918 30-21-33 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-98
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly

Figure 30-21-96
1

P-87918

Install a 50,8 mm (2.0 in) long 1/8 in NPT pipe (Item 1)

into the cover. Pull up on the pipe to remove the cover
P-87915 (Item 2) [Figure 30-21-98].

Figure 30-21-99
Remove the snap ring (Item 1) [Figure 30-21-96].

Dealer Copy -- Not for Resale

Figure 30-21-97

1
1

P-87919

P-87916 Remove the O-ring (Item 1) [Figure 30-21-99].

Remove the pipe plug (Item 1) [Figure 30-21-97].

532 of 918 30-21-34 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-102
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

1
Figure 30-21-100

1 P-87922

Remove the seal (Item 1) [Figure 30-21-102] from the

shaft.
P-87920
Figure 30-21-103

Remove the snap ring (Item 1) [Figure 30-21-100].

Dealer Copy -- Not for Resale

Turn the roller over and drain the oil.
1
Assembly: Add 0,133 - 0,169 L (4.5 - 5.7 U.S. fl oz) of
30W oil to the roller before installing the cover.

Figure 30-21-101

P-87923

1
Remove the seal (Item 1) [Figure 30-21-103] from the
roller.

P-87921

Remove the shaft (Item 1) [Figure 30-21-101] from the

roller.

533 of 918 30-21-35 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

Figure 30-21-104

P-87924

Remove the snap ring (Item 1) [Figure 30-21-104].

Dealer Copy -- Not for Resale

Figure 30-21-105

P-87925

Remove the bearings (Item 1) [Figure 30-21-105] from

both ends of the roller.

534 of 918 30-21-36 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Sprocket Removal And Installation

Figure 30-21-106

P-87908

Remove the drive sprocket bolts (Item 1) [Figure 30-21-

Dealer Copy -- Not for Resale

106].

Installation: Apply thread adhesive (Loctite® 242 or

equivalent) to the bolt threads. Tighten the bolts to 160 -
180 N•m (118 - 133 ft-lb) torque.

Remove the drive sprocket from the travel motor.

535 of 918 30-21-37 E85 Service Manual

Dealer Copy -- Not for Resale

536 of 918 30-21-38 E85 Service Manual

TRACK MAINTENANCE Causes of the damage:

Track Damage Identification When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
The following pages show photos and illustrations of of the embedded steel cords causes steel cords to be
track damage and their probable cause. These pages are cut:
intended to be used for identifying the reason for track
damage and how to avoid future track damage. Figure 30-30-3

Cutting Of Steel Cords

Figure 30-30-1

PI-13035

Dealer Copy -- Not for Resale

When the rubber track is detracting, the idler or sprocket
P-3864 rides on the projections of the embedded metal [Figure
30-30-3].

Figure 30-30-2 When the rubber track is detracted, projections of rubber

tracks get stuck between the frame of the undercarriage.

The rubber track is clogged with stones or foreign

obstacles.

When moisture invades through a cut on the lug side

rubber surface, the embedded steel cords will corrode.
The deterioration of the design strength may lead to the
breaking off of the steel cords.

Prevention:
Steel Cords
The following preventions should be taken to minimize
the risk of this damage:
PI-13034
Periodical checking of the recommended track
tension. (See Checking Tension on Page 30-20-2.)
Damage:
Avoiding quick turns on bumpy and rocky fields.
Embedded steel cords are cut off [Figure 30-30-1] and
[Figure 30-30-2]. Drive carefully to prevent stones and other articles
from clogging the rubber tracks.
Replacement:
Driving over sharp objects should be avoided. If this is
Replacement is required. impossible, do not make turns while driving over
sharp objects.

537 of 918 30-30-1 E85 Service Manual

TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d) Causes of the damage:

Abrasion Of Embedded Metals When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Figure 30-30-4 inevitable. The following cases sometimes accelerate
their abrasion:

Rubber tracks are driven with an extraordinary heavy

load on them.

Rubber tracks are used on sandy fields.

Prevention:

As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generates
a heavy load for rubber tracks, and when they are
P-3865 operated under a sandy field condition for a long time.

Dealer Copy -- Not for Resale

Damage:

In proportion to the service time, embedded metals will

gradually wear away by friction [Figure 30-30-4].

Figure 30-30-5

Abrasion

D D1 = 0.67D
PI-13037

Replacement:

Replacement is required when the width of the

embedded metals (D1) becomes 67% of the original
width (D) [Figure 30-30-5].

538 of 918 30-30-2 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Embedded metals are adhered between the steel cords
and the rubber body. The following cases generate
Separation Of Embedded Metals external forces greater than the adhesion strength,
causing separation of the embedded metals:
Figure 30-30-6
Figure 30-30-7

Idler

Rubber
Track

P-4379

PI-13039

Dealer Copy -- Not for Resale

Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded metals embedded metals, the embedded metals will eventually
cause their separation from the rubber track's body peel off [Figure 30-30-7].
[Figure 30-30-6].
Figure 30-30-8
Replacement:

Even a partial separation of embedded metals requires

replacement of the track.
Guide

PI-13040

When a rubber track is detracted, it becomes stuck

between the guide or the undercarriage frame, causing
the separation of embedded metals [Figure 30-30-8].

539 of 918 30-30-3 E85 Service Manual

TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Separation Of Embedded Metals (Cont’d)

Figure 30-30-9

Abrasion

PI-13041

Dealer Copy -- Not for Resale

Abnormally worn sprockets will pull embedded metals out
[Figure 30-30-9].

Prevention:

Similar to the prevention against the cutting of the steel

cords:

Track tension should be periodically checked. (See

Checking Tension on Page 30-20-2.)

Quick turns on bumpy and rocky fields should be

avoided.

If abnormal wear of sprockets is observed, they

should be replaced immediately.

540 of 918 30-30-4 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-11

Separation Of Embedded Metals Due To Corrosion Embedded metal Good

Figure 30-30-10

Separation of
bonded
rubber cover

PI-13043

Embedded metals are bonded to the rubber body. The

P-4378 following operating conditions cause embedded metals to
corrode, causing deterioration of the bonding, and finally
resulting in separation of the embedded metals from the

Dealer Copy -- Not for Resale

Damage: rubber body [Figure 30-30-11]:

Due to corrosion of embedded metals, the adhesion to Excessively salty fields, like the sea shore
the rubber body deteriorates, resulting in complete
separation [Figure 30-30-10]. Strong acidic or alkali soil conditions

Replacement: Compost spread grounds.

Even a partial separation of embedded metals requires a On tracks that are out of adjustment, the track rollers,
rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at the side of the track roller, causing exposure of
the embedded metals. Consequently the embedded
metals will corrode resulting in their separation from the
rubber body.

Prevention:

If rubber tracks are used under such field conditions as

described under (Causes of the damage). The tracks
should be washed with plenty of water. After being
completely dried, they should be stored correctly.

When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacing the
rubber track.

541 of 918 30-30-5 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-13

Cuts On The Lug Side Rubber

Figure 30-30-12 Cuts

PI-13045

When rubber tracks drive over projections or sharp

P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface

Dealer Copy -- Not for Resale

Damage: will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
Cuts on the lug side rubber are one of the most occurring steel cords' breakage due to their corrosion. It is highly
types of track damage [Figure 30-30-12]. recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 30-30-13].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately repaired Machine operators are requested to drive with great
with cold vulcanization rubber. attention to the ground's surface especially in terrains of
the following type:

Construction sites

Demolition sites

Paths covered with rocks and wood

Concrete ridges

Stumpy fields.

When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.

542 of 918 30-30-6 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue causes cracks, especially on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 30-30-14 even small external cracks. When operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.

Prevention:

Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. External
injuries on the lug side rubber sometimes cause more
chance of cracking. Machine operators should observe
soil conditions when driving, so as not to cause external
injuries to the lug side rubber. In order to minimize the
occurrence of ozone cracks, attention should be paid to
the following instructions for maintenance:

P-4382 Avoid exposing stored tracks to direct sun light.

Avoid exposing stored tracks to direct rain and snow

Dealer Copy -- Not for Resale

Figure 30-30-15 fall.

Store tracks in well ventilated warehouses.

Use the tracks at least once a month.

P-4380

Damage:

Small cracks around the root of the lug caused by

operation fatigue [Figure 30-30-14] and [Figure 30-30-
15].

Replacement:

When the cracks reach so deep that they expose the

steel cords, track replacement is required.

543 of 918 30-30-7 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Lug abrasion is inevitable. Even if lug abrasion is
proceeding, the rubber track can still be used. As the
Lug Abrasion traction performance deteriorates accordingly, it is highly
recommended to replace the abraded tracks with new
Figure 30-30-16 ones when the lug height becomes less than 5 mm
(0.197 in).

Prevention:

In order to prevent the rubber track from abnormal or

premature abrasion, following operating conditions
should be avoided:

Making quick and repeated turns on concrete and

asphalt roads.

Driving up and down hilly paths with slippage.

Making frequent turns on paths covered with rocks

P-4381 and wood.

Dealer Copy -- Not for Resale

Figure 30-30-17

Lug abrasion

PI-13049

Damage:

As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 30-30-16] and [Figure 30-
30-17].

Replacement:

No replacement is required.

544 of 918 30-30-8 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-19

Track Damage Identification (Cont’d)

Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 30-30-18
embedded metal rubber

PI-13051

Causes of the damage:

When rubber tracks drive over sharp projections,

PI-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals

Dealer Copy -- Not for Resale

Damage: [Figure 30-30-19].

Sometimes cracks and cuts on the lug side rubber at the Prevention:
edges of the embedded metals can be observed [Figure
30-30-18]. To avoid extensive stress applied to the lug root
where metals are embedded, machine operators are
Replacement: requested to avoid driving over stumps and ridges.

No replacement is required unless the cuts on the lug

side rubber are discovered all around the edges of the
embedded metals, as this will result in a complete cut off.

545 of 918 30-30-9 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-21

Track Damage Identification (Cont’d)

Abrasion Of The Track Roller Side Track roller

Figure 30-30-20 Abrasion

PI-13053

Causes of the damage:

The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against

Dealer Copy -- Not for Resale

Damage: the side of the rubber track causing the abrasion [Figure
30-30-21].
The rubber surface on which track rollers run is gradually
abraded. It will end in the exposure of the embedded The level of abrasion is highly dependent on terrain
metals [Figure 30-30-20]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers, increase the abrasion level.
It is recommended to replace the rubber track when more After an extended period of abrasion, it will be more likely
than half of the embedded metals are completely for exposed embedded metals to catch moisture through
exposed. the inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.

Prevention:

After operation in wet fields containing many small

stones, wash off the mud that is stuck on the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

546 of 918 30-30-10 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) This damage is caused by objects on the field or by
interference with the machine frame.
Cuts On The Edges Of Track Roller Side
Figure 30-30-24
Figure 30-30-22

PI-13056
P-4384

In case of damage by objects on the operating ground:

Dealer Copy -- Not for Resale

Figure 30-30-23
The edges of rubber track are often deformed, mainly
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. When a machine drives over
Edge Edge concrete ridges, this type of damage easily occurs
[Figure 30-30-24].

PI-13055

Damage:

Both edges of the rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 30-30-22] and
[Figure 30-30-23].

Replacement:

In such case, the rubber track does not have to be

replaced.

547 of 918 30-30-11 E85 Service Manual

TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Cuts On The Edges Of Track Roller Side (Cont’d)

Figure 30-30-25

Cut

Tear

PI-13057

Dealer Copy -- Not for Resale

In case of damage by interference with the machine
frame:

If a machine continues operating with rubber tracks

being detracted, the rubber tracks may get caught up
in the machine frame or undercarriage parts, resulting
in damage. When a machine travels along side
slopes, the rubber tracks are deformed so much that
they come into contact with the machine frame and
undercarriage parts, which causes cutting, gouging
and rubbing of rubber tracks in the end [Figure 30-30-
25].

Prevention:

When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracking.

548 of 918 30-30-12 E85 Service Manual

SWING CIRCLE GEAR

Swing Bearing Removal

Remove the upperstructure. (See Removal on Page 40-

10-1.)

Figure 30-40-1

P11599

Dealer Copy -- Not for Resale

Install a C-clamp (Item 1) [Figure 30-40-1] to prevent the
swing bearing from turning while being removed.

Figure 30-40-2

P-89381

Remove the twenty-four bolts and nuts that hold the

swing bearing on the track frame (Item 1) [Figure 30-40-
2].

Remove the swing bearing.

549 of 918 30-40-1 E85 Service Manual

SWING CIRCLE GEAR (CONT’D) Figure 30-40-5

Swing Bearing Installation

Figure 30-40-3

1
1

OUTER RACE
Soft zone is at
INNER RACE the Ball Bearing
Soft zone is filler plug
identified by a
letter “S”
stamped on ring
P-23504

Install the swing bearing bolts (Item 1) [Figure 30-40-5]

PI-13677 and lock nuts.

Tighten the bolts to 392 N•m (289 ft-lb) torque.

Figure 30-40-4
Put lubriplate grease or an equivalent on the swing

Dealer Copy -- Not for Resale

bearing gear.

P-89382

If reusing the existing swing bearing, use top, side and

edge aligning marks to put the swing bearing in the
correct location. If installing a new swing bearing find the
soft zone area (Item 1) [Figure 30-40-3] and [Figure 30-
40-4].

Install the swing bearing so the inside soft zone (Item 1)

[Figure 30-40-3] and [Figure 30-40-4] is at the right
hand side of the excavator.

NOTE: Do not put the soft zone to the front or rear of

the excavator.

550 of 918 30-40-2 E85 Service Manual

LOWER TRACK ROLLER

Parts Identification

1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug

4
5
6

2
5

Dealer Copy -- Not for Resale

2
8 7

E802150S

551 of 918 30-50-1 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Figure 30-50-3

Disassembly

NOTE: The procedure is shown on a steel track roller. 1

The procedure is the same for the rubber
track roller.

Figure 30-50-1

P-89289
2

Remove the seal assembly [Figure 30-50-3].

Figure 30-50-4

P-89287

Dealer Copy -- Not for Resale

Drive the pin (Item 1) towards the top of the collar (Item
2) [Figure 30-50-1].

NOTE: The pin bore in the collar is stepped.

2
Figure 30-50-2
1

P-89290
1

Remove the seal assembly (Item 1). Remove the O-ring

(Item 2) [Figure 30-50-4].

P-89288

Remove the collar (Item 1) [Figure 30-50-2].

552 of 918 30-50-2 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Figure 30-50-7

Disassembly (Cont’d)

Figure 30-50-5

P-89293
1

Remove the seal assembly (Item 1) [Figure 30-50-7]

P-89291 from the collar.

Figure 30-50-8
Remove the shaft assembly (Item 1) [Figure 30-50-5]
from the roller.

Dealer Copy -- Not for Resale

Figure 30-50-6
1

P-89262

Remove the O-ring (Item 1) [Figure 30-50-8] from all four

P-89292 seal rings.

Remove the seal assembly (Item 1) [Figure 30-50-6]

from the roller.

553 of 918 30-50-3 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Figure 30-50-11

Disassembly (Cont’d)
1
Figure 30-50-9

P-89296
1

Remove the O-ring (Item 1) [Figure 30-50-11].

P-87924
Figure 30-50-12

Remove the pin (Item 1) [Figure 30-50-9].

Dealer Copy -- Not for Resale

Figure 30-50-10
1

1
P-89297

Remove the bushing (Item 1) [Figure 30-50-12] from

P-87925 both sides of the roller.

Remove the shaft (Item 1) [Figure 30-50-10].

554 of 918 30-50-4 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Figure 30-50-15

Assembly

Clean all parts in solvent and dry them with compressed 1

air.

The seal assemblies are a matched set and must be

replaced in pairs.

Figure 30-50-13

1
P-89295

Install the shaft (Item 1) [Figure 30-50-15] in the collar.

Figure 30-50-16

Dealer Copy -- Not for Resale

P-89297

Install the bushing (Item 1) [Figure 30-50-13] on both

sides of the roller.

Figure 30-50-14

P-89294

Install the pin (Item 1) [Figure 30-50-16] in the collar and

through the shaft.

P-89296

Install the O-ring (Item 1) [Figure 30-50-14] on the shaft.

555 of 918 30-50-5 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Dip the seal assembly in a pan of alcohol.

Assembly (Cont’d) Figure 30-50-19

Figure 30-50-17

1
P-89298

P-89262
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-50-19] in the collar.
Install the O-ring (Item 1) [Figure 30-50-17] on the seal
ring. Repeat this procedure on all four seal assemblies. Use firm, even pressure on the installation tool to pop the

Dealer Copy -- Not for Resale

O-ring in to the collar.
The O-ring and seal ring must be clean and free of any
dust, oil film and foreign matter. Remove the installation tool.

NOTE: Inspect the seal ring for burrs before Figure 30-50-20
installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.

Figure 30-50-18

P-89299

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-50-20].

P-40754

Place the seal assembly in the installation tool (Item 1)

[Figure 30-50-18].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.

556 of 918 30-50-6 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Figure 30-50-23

Assembly (Cont’d)

Figure 30-50-21

P-89301

The seal assembly stand off height must be equal and

P-40754 the O-ring must not be twisted [Figure 30-50-23].

Apply a light film of oil to both metal seal rings.

Place the seal assembly (Item 1) [Figure 30-50-21] in
the installation tool. NOTE: Do not get any oil on the rubber O-rings.

Dealer Copy -- Not for Resale

The O-ring and seal ring assembly have to be lubricated Figure 30-50-24
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1
Dip the O-ring and seal assembly in a pan of alcohol.

Figure 30-50-22

P-89302

Install the roller (Item 1) [Figure 30-50-24] on the shaft.

P-89300

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-50-22] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

557 of 918 30-50-7 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Figure 30-50-27

Assembly (Cont’d)

Figure 30-50-25

P-89304

The seal assembly stand off height must be equal and

P-40754 the O-ring must not be twisted [Figure 30-50-27].

Figure 30-50-28
Place the seal assembly in the installation tool (Item 1)
[Figure 30-50-25].

Dealer Copy -- Not for Resale

The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius. 1

Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-50-26

P-89305

Install the O-ring (Item 1) [Figure 30-50-28].

P-89303

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-50-26] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

558 of 918 30-50-8 E85 Service Manual

LOWER TRACK ROLLER (CONT’D) Figure 30-50-31

Assembly (Cont’d)

Figure 30-50-29

P-89307

The seal assembly stand off height must be equal and

P-40754 the O-ring must not be twisted [Figure 30-50-31].

Apply a light film of oil to both metal seal rings.

Place the seal assembly in the installation tool (Item 1)
[Figure 30-50-29]. NOTE: Do not get any oil on the rubber O-rings.

UPPER TRACK ROLLER (CONT’D) Figure 30-60-3

Disassembly And Assembly

Figure 30-60-1

P-87918

Install a 50,8 mm (2.0 in) long 3,175 mm (1/8 in) NPT

P-87915 pipe (Item 1) into the cover. Pull up on the pipe to remove
the cover (Item 2) [Figure 30-60-3].

Remove the snap ring (Item 1) [Figure 30-60-1]. Figure 30-60-4

Dealer Copy -- Not for Resale

Figure 30-60-2

1 1

P-87919

P-87916
Remove the O-ring (Item 1) [Figure 30-60-4].

Remove the pipe plug (Item 1) [Figure 30-60-2].

562 of 918 30-60-2 E85 Service Manual

UPPER TRACK ROLLER (CONT’D) Figure 30-60-7

Disassembly And Assembly (Cont’d)

Figure 30-60-5 1

1
P-87922

Remove the seal (Item 1) [Figure 30-60-7] from the

P-87920 shaft.

Figure 30-60-8
Remove the snap ring (Item 1) [Figure 30-60-5].

Dealer Copy -- Not for Resale

Turn the roller over and drain the oil.
1
Assembly: Add 130 - 170 cc (4.5 - 5.7 oz) of 30W oil to
the roller before installing the cover.

Figure 30-60-6

P-87923

1
Remove the seal (Item 1) [Figure 30-60-8] from the
roller.

P-87921

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

roller.

563 of 918 30-60-3 E85 Service Manual

UPPER TRACK ROLLER (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 30-60-9

P-87924

Remove the snap ring (Item 1) [Figure 30-60-9].

Dealer Copy -- Not for Resale

Figure 30-60-10

P-87925

Remove the bearings (Item 1) [Figure 30-60-10] from

both ends of the roller.

564 of 918 30-60-4 E85 Service Manual

UPPERSTRUCTURE AND SWING SECTION

UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3

UPPERSTRUCTURE SIDE COVER (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

UPPERSTRUCTURE SIDE COVER (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-11
Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-12
Lower Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-13
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-14
Front Window Strut Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-19
Front Window Slide Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-20
Cab Tilt Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-21

Dealer Copy -- Not for Resale

Cab Tilt Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-22
Cab Tilt Assembly Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-23
Headliner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-24

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2

RIGHT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Lower Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Upper Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-2
Gas Strut Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-3
Lock Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-4
Lock Lever Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5
Console Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-6

CENTER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

CENTER ACCESS COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

565 of 918 40-01 E85 Service Manual

FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-5
Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-6

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-2

BOOM (ARTICULATED) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-141-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-141-1

Dealer Copy -- Not for Resale

ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-2
Bucket And Link Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-150-3

QUICK COUPLER (KLAC™ SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-7

QUICK COUPLER (LEHNHOFF® SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-1
Removal (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-2
Installation (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-3
Parts Identification (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-4
Disassembly And Assembly (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-5
Parts Identification (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-6
Disassembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-7
Assembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161-11

BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Side Cutting Edge Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-170-2

566 of 918 40-02 E85 Service Manual

RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-2

REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1

Dealer Copy -- Not for Resale

567 of 918 40-03 E85 Service Manual

Dealer Copy -- Not for Resale

568 of 918 40-04 E85 Service Manual

UPPERSTRUCTURE Figure 40-10-2

Removal

Drain the hydraulic reservoir. (See Removing And 3

Replacing Hydraulic Fluid on Page 10-140-6.)

Drain the fuel tank. (See Draining The Fuel Tank on Page
10-120-5.)
2
Remove the swing motor drive carrier. (See Removal And
Installation on Page 20-91-1.) 1

Remove the swivel joint. (See Removal And Installation

on Page 20-80-1.) 2
P-89379
Remove the boom. (See Removal And Installation on
Page 40-110-1.)
Install the boom pivot pin (Item 1), spacers (Item 2) and
Remove the cab. (See Removal And Installation on Page strap (Item 3) [Figure 40-10-2] on the pivot pin.
40-30-1.)
NOTE: The spacers are needed to prevent the strap
Remove the engine. (See Engine Removal And from sliding on the pivot pin causing the
Installation on Page 60-10-11.) upperstructure to tip side to side.

Dealer Copy -- Not for Resale

Remove the counterweight. (See Removal And
Installation on Page 40-90-1.)

Remove the hydraulic reservoir. (See Removal And

Installation on Page 20-140-1.)

Remove the fuel tank. (See Removal And Installation on

Page 40-110-1.)

Figure 40-10-1

P-89376

Mark the track frame to swing bearing (Item 1) [Figure

40-10-1].

569 of 918 40-10-1 E85 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-5

Removal (Cont’d)

Figure 40-10-3 1
1
1 1

P-89376

Remove the bolts (Item 1) [Figure 40-10-5].

P-89377
Rotate the upperstructure by hand and continue
removing the bolts.
Figure 40-10-4
NOTE: The upperstructure is mounted to the track

Dealer Copy -- Not for Resale

frame with twenty-four bolts.
1
Figure 40-10-6

P-89378

Install the rear lifting brackets (Item 1) [Figure 40-10-3]

and [Figure 40-10-4].
P-89379

Install chains and a hoist to the lifting brackets.

Raise the upperstructure. Make sure the upperstructure
NOTE: The chain hoist the lifting chains are attached is level as it is being raised [Figure 40-10-6].
to must have a swivel hook to allow the
upperstructure to be turned. Lower the upperstructure and adjust the lifting chains as
needed, to pull the upperstructure squarely off the track
Apply a small amount of lifting pressure to the frame.
upperstructure with the chain hoist.
Remove the upperstructure and position it on suitable
support stands or blocks.

570 of 918 40-10-2 E85 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-9

Installation

Figure 40-10-7

FRONT OF MACHINE

INNER RACE OUTER RACE

Soft zone is Soft zone is 1
identified by a at the
letter “S” ball bearing
stamped on filler plug
N-15781
ring

Use a 18 mm tap in the holes (Item 1) [Figure 40-10-9]

PI-13677 of the upperstructure to remove any dried thread lock
adhesive.

Figure 40-10-8 Figure 40-10-10

Dealer Copy -- Not for Resale

P-89380 B-13678

Rotate the swing bearing so the outside soft zone (Item Make three alignment pins by using M18 X 110 mm long
1) [Figure 40-10-7] and [Figure 40-10-8] is to the right bolts. Cut the head off these bolts at 90 mm (3.50 in),
hand side of the excavator. then taper the end of the bolts [Figure 40-10-10].

NOTE: The upperstructure can only be installed on

the swing bearing in one position. Match the
mount holes in the swing bearing to the
mount holes in the upperstructure.

571 of 918 40-10-3 E85 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-13

Installation (Cont’d)

Figure 40-10-11
1

1
1
N-15787

1 Remove the three, 90 mm (3.50 in) alignment pins (Item

N-15784 1) [Figure 40-10-13] from the upperstructure.

These headless pins can be removed from the bottom.

Install the pins (Item 1) [Figure 40-10-11] into the
upperstructure at approximately 120° apart. These will Apply thread adhesive (Loctite® 242 or equivalent) to the

Dealer Copy -- Not for Resale

act as alignment pins while lowering the upperstructure threads of the bolts. Install the bolts into all holes (except
onto the swing bearing. the three with the alignment bolts installed). Tighten
these bolts to 392 N•m (289 ft-lb) torque.
Install the upperstructure onto the swing bearing using
the alignment marks and the alignment pins. Remove the chains and lifting brackets.

Figure 40-10-12 Install the swing motor drive carrier. (See Removal And
Installation on Page 20-91-1.)

Check the backlash between the gears by moving the

frame back and forth at several points throughout 360° of
frame rotation. There must be some backlash present.

Install the swing motor. (See Removal And Installation on

Page 20-90-1.)

B-13693

Make sure the swivel joint is centered into the

upperstructure access hole [Figure 40-10-12].

572 of 918 40-10-4 E85 Service Manual

UPPERSTRUCTURE SIDE COVER (LEFT)

Removal And Installation

Figure 40-20-1

1
1

P-86415

Remove the four rubber plugs (Item 1) [Figure 40-20-1].

Dealer Copy -- Not for Resale

Figure 40-20-2

2
2 2

1
1
1 P-86416

Remove the three bottom bolts (Item 1), flat washers and
lock washers. Remove the four top bolts (Item 2) [Figure
40-20-2], flat washers and lock washers.

Remove the cover.

Note the number and position of the shims located

between the cover and upperstructure. Place the shims
in the correct position for installation.

573 of 918 40-20-1 E85 Service Manual

Dealer Copy -- Not for Resale

574 of 918 40-20-2 E85 Service Manual

UPPERSTRUCTURE SIDE COVER (RIGHT)

Removal And Installation

Figure 40-21-1

1 1

P-86824

Remove the three rubber plugs (Item 1) [Figure 40-21-

1].

Dealer Copy -- Not for Resale

Figure 40-21-2

2 2

1
1

P-86827

Remove the three bottom bolts (Item 1), flat washers and
lock washers. Remove the three top bolts (Item 2)
[Figure 40-21-2], flat washers and lock washers.

Remove the cover.

Note the number and position of the shims located

between the cover and upperstructure. Place the shims
in the correct position for installation.

575 of 918 40-21-1 E85 Service Manual

Dealer Copy -- Not for Resale

576 of 918 40-21-2 E85 Service Manual

CAB Figure 40-30-3

Removal And Installation

Remove the door. (See Door Removal And Installation on

Page 40-30-11.) 2

Remove the seat. (See Seat Removal And Installation on

Page 40-40-1.)

Remove the floor mat. (See Removal And Installation on 1

Page 40-100-1.) 1

Remove the instrument panel. (See Removal And

Installation on Page 50-100-1.)
P112309
Figure 40-30-1

Remove the screws (Item 1) and the right pocket cover

(Item 2) [Figure 40-30-3].

Figure 40-30-4

Dealer Copy -- Not for Resale

1 1

P-87715

Figure 40-30-2

P112161

Remove the cover (Item 1) [Figure 40-30-4].

P-87716

Remove the bolts (Item 1) [Figure 40-30-1] and [Figure

40-30-2] from the base of the right console. Reposition
the right console to create access to the side covers.

577 of 918 40-30-1 E85 Service Manual

CAB (CONT'D) Figure 40-30-7

Removal And Installation (Cont’d)

Figure 40-30-5
1

P112313

Remove the screw (Item 1) [Figure 40-30-7].

P112162
Figure 40-30-8

Remove the screw (Item 1) [Figure 40-30-5].

Dealer Copy -- Not for Resale

Figure 40-30-6

1
1

P112314

Remove the screws (Item 1) and remove the panel (Item

P112312 2) [Figure 40-30-8].

Remove the screw (Item 1) [Figure 40-30-6].

578 of 918 40-30-2 E85 Service Manual

CAB (CONT'D) Figure 40-30-11

Removal And Installation (Cont’d)

Figure 40-30-9

1 1

P112323

Remove the pad (Item 1) [Figure 40-30-11].

P112315
Figure 40-30-12

Remove the screws (Item 1) and right side cover (Item 2)

[Figure 40-30-9].

Dealer Copy -- Not for Resale

Figure 40-30-10

1
1 1
P112324

Remove the screw (Item 1) [Figure 40-30-12].

P112322

Remove the screws (Item 1) [Figure 40-30-10].

579 of 918 40-30-3 E85 Service Manual

CAB (CONT'D) Figure 40-30-15

Removal And Installation (Cont’d)

Figure 40-30-13

2 2 2

1 P112346

Remove the cover (Item 1) from the wiper motor. Remove

P112398 bolt (Item 2) [Figure 40-30-15] from the clamp.

Figure 40-30-16
Disconnect the wire harness and remove the switch
panel (Item 1) [Figure 40-30-13].

Dealer Copy -- Not for Resale

Remove the bolts (Item 2) [Figure 40-30-13] from the
wire harness clamps.

Figure 40-30-14 2

2 1

P-112349

Disconnect the washer hose (Item 1) and wire harness

1 (Item 2) [Figure 40-30-16].

P112318

Remove the screws (Item 1) and air duct (Item 2) [Figure

40-30-14].

580 of 918 40-30-4 E85 Service Manual

CAB (CONT'D) Figure 40-30-19

Removal And Installation (Cont’d)

Figure 40-30-17

1 1
1

1
P112350

Remove the screws (Item 1) [Figure 40-30-19] and rear

P112352 cover.

Figure 40-30-20
Disconnect the wire harness (Item 1) [Figure 40-30-17].

Dealer Copy -- Not for Resale

Figure 40-30-18

2
1 1

P112354

P112348 Disconnect the wire harness (Item 1) and remove the

screws (Item 2) [Figure 40-30-20].

Remove the screws (Item 1) and cover (Item 2) [Figure

40-30-18].

581 of 918 40-30-5 E85 Service Manual

CAB (CONT'D) Figure 40-30-23

Removal And Installation (Cont’d)

Figure 40-30-21

1 1

P112356

2 3
Remove the bolts (Item 1) [Figure 40-30-23] from the
P112353 wire harness clamps.

Figure 40-30-24
Remove the screws (Item 1). Remove the ducts (Item 2
and 3) [Figure 40-30-21].
3

Dealer Copy -- Not for Resale

Figure 40-30-22
1

1
1 1
P112357
2

Disconnect the wire harness (Item 1), remove the screws

P112355 and reposition the alarm (Item 2). Remove the bolts (Item
3) [Figure 40-30-24] from the wire harness clamps.

Remove the screws (Item 1) and remove the duct (Item

2) [Figure 40-30-22].

582 of 918 40-30-6 E85 Service Manual

CAB (CONT'D) Figure 40-30-27

Removal And Installation (Cont’d)

Figure 40-30-25 1

1 1 1

P112359

Remove the top screws (Item 1) [Figure 40-30-27] and

P112403 loosen the bottom screws. Reposition the controller.

Figure 40-30-28
Remove the relays (Item 1) [Figure 40-30-25].

Dealer Copy -- Not for Resale

Figure 40-30-26 1

1 1 1

P112360

P112364 Remove the bolt (Item 1) [Figure 40-30-28] from the wire
harness clamp.

Remove the screws (Item 1) [Figure 40-30-26] and

reposition the wire harness.

583 of 918 40-30-7 E85 Service Manual

CAB (CONT'D) Figure 40-30-31

Removal And Installation (Cont’d)

Figure 40-30-29
1
1

1 1

P-87775

Remove the bolts (Item 1) [Figure 40-30-31].

P-87774
Figure 40-30-32

Remove the bolts (Item 1) [Figure 40-30-29] from the

front of the cab.

Dealer Copy -- Not for Resale

Figure 40-30-30
1
1

1
1

P-87747

Install lifting hooks (Item 1) [Figure 40-30-32].

P-87776

Install the lifting hooks (Item 1) [Figure 40-30-30].

584 of 918 40-30-8 E85 Service Manual

CAB (CONT'D) Figure 40-30-35

Removal And Installation (Cont’d)

Figure 40-30-33

1 1

P-87791

Remove the right side bolt (Item 1) [Figure 40-30-35].

NA-1129
Figure 40-30-36

Attach lifting straps (Item 1) [Figure 40-30-33] to the

lifting hooks.

Dealer Copy -- Not for Resale

Attach a lifting device to the straps.
1
NOTE: The cab weighs approximately 480 kg (1058 lb)
1
Figure 40-30-34

P112361

Remove the right front bolts (Item 1) [Figure 40-30-36].

1
2

P112363

Remove the rear corner nuts (Item 1) and bolts (Item 2)

[Figure 40-30-34] (Both sides).

585 of 918 40-30-9 E85 Service Manual

CAB (CONT'D) Figure 40-30-39

Removal And Installation (Cont’d)

Figure 40-30-37

P-87795

1
Figure 40-30-40
P-87793

Remove the front center nuts (Item 1) [Figure 40-30-37].

Dealer Copy -- Not for Resale

Figure 40-30-38

1
P-87796

Remove the left side bolts (Item 1) [Figure 40-30-39] and

[Figure 40-30-40].

P-87794 Remove the cab.

Remove the left front bolts (Item 1) [Figure 40-30-38].

586 of 918 40-30-10 E85 Service Manual

CAB (CONT'D)

Door Removal And Installation

Figure 40-30-41

Dealer Copy -- Not for Resale

P-87666

Remove the hinge bolts (Item 1) [Figure 40-30-41].

Remove the door.

587 of 918 40-30-11 E85 Service Manual

CAB (CONT'D) Figure 40-30-44

Front Window Removal And Installation

1
Open the front window to the fully open and locked
position.

Figure 40-30-42
1

P-87668

With the help of a second person supporting the window,

release the window latches (Item 1) [Figure 40-30-44]
and partially lower the window.

P-87808 Figure 40-30-45

Dealer Copy -- Not for Resale

Figure 40-30-43

1
1

P-87669

P-87747 Tilt the front window and remove the roller (Item 1)
[Figure 40-30-45] (Both sides).

Remove the window slide bar bolts (Item 1) [Figure 40- Remove the window.
30-42] and [Figure 40-30-43].

588 of 918 40-30-12 E85 Service Manual

CAB (CONT'D)

Lower Front Window Removal And Installation

Open the front window.

Figure 40-30-46

P-87745

Dealer Copy -- Not for Resale

Grasp the lower window and pull it upwards until the
window is out of the channel [Figure 40-30-46].

Remove the window.

589 of 918 40-30-13 E85 Service Manual

CAB (CONT’D) Figure 40-30-48

Glass Installation

Top, Right Side, Left Side And Rear Glass

NOTE: See your dealer for the correct urethane

adhesive, combo primer, glass cleaner and
bumpers for correctly installing the new
glass.

Remove the majority of the old urethane adhesive from

the perimeter of the cab. 2

NOTE: Leave a thin film (0,79 mm (0.03 in) thick) of 1

the old urethane on the cab frame. Fresh NA1157
urethane will bond to the remaining film.

Prime and paint any bare metal or scratches. Install the damper (Item 1) on the frame (Item 2) [Figure
40-30-48].
Clean the metal surfaces with general purposes adhesive
cleaner. Clean the glass surface with glass cleaner. Shake the combo primer for one minute.

Figure 40-30-47 Apply one coat of the combo primer to the perimeter of

Dealer Copy -- Not for Resale

the cab and damper (Item 1) [Figure 40-30-48].

1 2
Shake the combo primer for one minute.
2
Allow the combo primer to dry for at least 15 minutes.
Excess primer can be removed from the glass using a
razor blade.

Cut the tip of the adhesive tube to the desired shape and
size to provide a bead with sufficient height to give good
contact with the glass around the entire perimeter.
1
2 Figure 40-30-49
1
2 1
NA1156
1
Install the damper (Item 1) on the glass (Item 2) [Figure
40-30-47].

MS1993

Apply a 6,4 X 9,5 mm (0.25 X 0.375 in) triangle shaped

bead of urethane adhesive (Item 1) [Figure 40-30-49] to
the perimeter of the cab.

590 of 918 40-30-14 E85 Service Manual

CAB (CONT’D) Figure 40-30-52

Glass Installation (Cont’d)

Top, Right Side, Left Side And Rear Glass (Cont’d)

Figure 40-30-50

1 1
2

P-61218

Cut and remove the old urethane adhesive (Item 1)

MS1994
leaving less than a 0,79 mm (0.03 in) thick layer (Item 2)
[Figure 40-30-52] for the new adhesive to bond to.
Install the glass and damper assembly (Item 1) [Figure
40-30-50]. Press the glass into the cab to make complete NOTE: Be careful not to scratch the paint on the
contact with the adhesive. Tape the glass in place. frame.

Dealer Copy -- Not for Resale

Allow the adhesive to cure for a minimum of twelve hours Figure 40-30-53
at 70° F and 20% relative humidity.

Remove the tape after the adhesive is cured.

Door And Front Window Glass

NOTE: The door and front windows are supplied as

1
kits that include the glass, urethane adhesive,
combo primer, glass cleaner and damper for
correctly installing the new glass.

Remove the front window or door that is to be repaired

from the excavator.

Figure 40-30-51 P-61219

Place the glass on a flat surface with the painted side of

the glass (Item 1) [Figure 40-30-53] facing up.

Thoroughly clean the entire glass with glass cleaner.

P-61216

Remove the broken glass (Item 1) [Figure 40-30-51].

591 of 918 40-30-15 E85 Service Manual

CAB (CONT’D) Figure 40-30-55

Glass Installation (Cont’d)

1
Door And Front Window Glass (Cont’d)

Figure 40-30-54

P-89351

Figure 40-30-56

P-61220

Apply one coat of combo primer (Item 1) [Figure 40-30-

Dealer Copy -- Not for Resale

54] on the painted edge of the glass. 1

Apply the combo primer to any scratches on the door /

front window frame in the area where the glass is
installed.

Allow the primer to dry for a minimum of 15 minutes.

Excess primer may be removed from the glass using a

P-89353
razor blade.

Install the dampers on the front window frame (Item 1)

[Figure 40-30-55] or on the door frame (Item 1) [Figure
40-30-56]. (The dampers are used to space the glass
away from the metal so there is no glass to metal
contact.)

592 of 918 40-30-16 E85 Service Manual

CAB (CONT’D)

Glass Installation (Cont’d)

Door And Front Window Glass (Cont’d) IMPORTANT

Figure 40-30-57 If the glass has direct contact with the metal frame,
the glass may break due to machine vibration.
I-2236-0105

P-61224

Apply a 6,4 X 9,5 mm (0.25 X 0.375 in) triangle shaped

Dealer Copy -- Not for Resale

bead of urethane adhesive (Item 1) [Figure 40-30-57]
around the front window / door frame.

Apply the adhesive directly on top of the old adhesive.

Figure 40-30-58

P-89350

Place the frame (Item 1) [Figure 40-30-58] on the glass.

The frame must be centered on the glass, and the glass
must not have direct contact with the front window / door
frame.

593 of 918 40-30-17 E85 Service Manual

CAB (CONT’D)

Glass Installation (Cont’d)

Door And Front Window Glass (Cont’d) IMPORTANT

Figure 40-30-59 If the glass has direct contact with the metal frame,
the glass may break due to machine vibration.
I-2236-0105

P-89352

Figure 40-30-60

Dealer Copy -- Not for Resale

P-89355

Clamp the frame and glass together [Figure 40-30-59]

and [Figure 40-30-60].

Place the clamps over the rubber bumpers on the frame.

Allow the adhesive to cure for a minimum of twelve hours

at 70° F and 20% relative humidity before removing the
clamps.

Install the front window / door on the excavator. (See the

correct Service Manual for installation procedure)

Install the wiper assembly on the front window. (See the

correct Service Manual for installation procedure)

594 of 918 40-30-18 E85 Service Manual

CAB (CONT’D)

Front Window Strut Removal And Installation

Remove the front window. (See Front Window Removal

And Installation on Page 40-30-12.)

Figure 40-30-61

P-87671

Dealer Copy -- Not for Resale

Remove the nut (Item 1) [Figure 40-30-61] from the
bottom of the strut.

Figure 40-30-62

P-87672

Remove the nut (Item 1) [Figure 40-30-62] from the top

of the strut.

Remove the strut.

595 of 918 40-30-19 E85 Service Manual

CAB (CONT’D) Figure 40-30-65

Front Window Slide Bar Removal And Installation

Remove the front window. (See Front Window Removal

And Installation on Page 40-30-12.) 1

Remove the front window strut. (See Front Window Strut

Removal And Installation on Page 40-30-19.)

Figure 40-30-63

1
P-87745

Remove the bushing (Item 1) [Figure 40-30-65] from the

side bar.

Dealer Copy -- Not for Resale

P-87673

Remove the C-clip (Item 1) [Figure 40-30-63].

Figure 40-30-64

P-87674

Remove the slide bar (Item 1) [Figure 40-30-64].

596 of 918 40-30-20 E85 Service Manual

CAB (CONT’D) Figure 40-30-68

Cab Tilt Assembly Removal And Installation

1
Remove the floor mat. (See Removal And Installation on
Page 40-100-1.)

Remove the left upperstructure side cover. (See Removal

And Installation on Page 40-20-1.)

Figure 40-30-66

1 P-89320

Remove the tilt assembly (Item 1) [Figure 40-30-68].

Dealer Copy -- Not for Resale

P-89319

Remove the bolts (Item 1) [Figure 40-30-66].

Figure 40-30-67

1 1 1

P-89320

Support the assembly and remove the bolts (Item 1)

[Figure 40-30-67].

Support the tilt assembly when removing the last bolt.

597 of 918 40-30-21 E85 Service Manual

CAB (CONT’D)

Cab Tilt Parts Identification

1. Clip
2. Washer
3. Shim
4. Link
5. Plate
6. Pin
7. Bracket
8. Bolt
9. Grease Fitting

Dealer Copy -- Not for Resale

1
2
3
4

5
1
2 4
3 3
2

8
7 6
2
3
2
9

E801340S

598 of 918 40-30-22 E85 Service Manual

CAB (CONT’D)

Cab Tilt Assembly Disassembly And Assembly

Figure 40-30-69

1 1

P-89322

Remove the clips (Item 1) [Figure 40-30-69] and

washers.

Dealer Copy -- Not for Resale

Figure 40-30-70

1
1 2

P-89320

Remove the pins (Item 1) [Figure 40-30-70] and

washers.

Remove the links (Item 2) [Figure 40-30-70].

599 of 918 40-30-23 E85 Service Manual

CAB (CONT’D) Figure 40-30-73

Headliner Removal And Installation

Figure 40-30-71

1
1
1

P-92416

2 Slide the radio (if equipped) out of the opening and

P-92413 disconnect the radio harness (Item 1) and antenna cable
(Item 2) [Figure 40-30-73].

Remove the screws (Item 1) and faceplate (Item 2) Figure 40-30-74

[Figure 40-30-71].

Dealer Copy -- Not for Resale

Figure 40-30-72 1

1
1

P-92763

P-92414 Remove the screws (Item 1) [Figure 40-30-74].

Remove the mounting screws for the radio (if equipped)

(Item 1) [Figure 40-30-72].

600 of 918 40-30-24 E85 Service Manual

CAB (CONT’D) Figure 40-30-77

Headliner Removal And Installation (Cont’d)

Figure 40-30-75

1
1

P-92768

Remove the speaker (if equipped) from the headliner and

P-92764 disconnect the wires (Item 1) [Figure 40-30-77].

Figure 40-30-78
Remove the speaker (if equipped) from the headliner and
disconnect the wires (Item 1) [Figure 40-30-75].

Dealer Copy -- Not for Resale

Figure 40-30-76

1 1

1 P-92770

Remove the front window bumpers (Item 1) [Figure 40-

P-92765 30-78].

Remove the screws (Item 1) [Figure 40-30-76].

601 of 918 40-30-25 E85 Service Manual

CAB (CONT’D) Figure 40-30-81

Headliner Removal And Installation (Cont’d)

Figure 40-30-79

1
1
1

1 1 1
1

P-92771

Remove the remaining screws (Item 1) [Figure 40-30-

P-92766 81].

Figure 40-30-82
Remove the screws (Item 1) [Figure 40-30-79].

Dealer Copy -- Not for Resale

Figure 40-30-80

1
1
1
1
P-92772

P-92767 Remove the dome light lens (Item 1) [Figure 40-30-82].

Remove the screws (Item 1) [Figure 40-30-80].

602 of 918 40-30-26 E85 Service Manual

CAB (CONT’D) Figure 40-30-85

Headliner Removal And Installation (Cont’d)

Figure 40-30-83

P-92774

1
Remove the headliner (Item 1) [Figure 40-30-85].
P-92775

Remove the screws (Item 1) [Figure 40-30-83].

Dealer Copy -- Not for Resale

Figure 40-30-84

P-92773

Remove the dome light and disconnect the electrical

connector (Item 1) [Figure 40-30-84].

603 of 918 40-30-27 E85 Service Manual

Dealer Copy -- Not for Resale

604 of 918 40-30-28 E85 Service Manual

SEAT Figure 40-40-2

Seat Removal And Installation

Open the upper front window. (See Front Window on

Page 10-30-2.)

Remove the lower front window. (See Lower Front

Window Removal And Installation on Page 40-30-13.)

Figure 40-40-1
1
2
1
2
P-87665

1 Figure 40-40-3

Dealer Copy -- Not for Resale

P-87713

Remove the bolts (Item 1) and travel control levers (Item

2) [Figure 40-40-1]. 1

P112305

Remove the bolts (Item 1) [Figure 40-40-2] and [Figure

40-40-3].

Remove the seat through the front of the cab.

605 of 918 40-40-1 E85 Service Manual

SEAT (CONT’D) Figure 40-40-6

Seat Mount Removal And Installation

Remove the seat. (See Seat Removal And Installation on

Page 40-40-1.)

Figure 40-40-4

P-87815

1
Remove the C-clip (Item 1) [Figure 40-40-6] from the left
console.

Figure 40-40-7
P-87715

Dealer Copy -- Not for Resale

Figure 40-40-5

1
P112308

Remove the bolts (Item 1) [Figure 40-40-7].

P-87716

Remove the bolts (Item 1) [Figure 40-40-4] and [Figure

40-40-5] from the right console.

Lay the console off to the side.

606 of 918 40-40-2 E85 Service Manual

SEAT (CONT’D) Figure 40-40-11

Seat Mount Removal And Installation (Cont’d)

Figure 40-40-8

P-87819

Figure 40-40-12
P-87717

Remove the nut (Item 1) and pin (Item 2) [Figure 40-40-

8].
Figure 40-40-9

Dealer Copy -- Not for Resale

1 P112417

Slide the seat mount forward and remove the bolts (Item
1) [Figure 40-40-11] and [Figure 40-40-12].
P-87820
Remove the seat mount.
Figure 40-40-10

P-87716

Slide the seat mount to the rear and remove the bolts
(Item 1) [Figure 40-40-9] and [Figure 40-40-10].

607 of 918 40-40-3 E85 Service Manual

Dealer Copy -- Not for Resale

608 of 918 40-40-4 E85 Service Manual

RIGHT CONSOLE Figure 40-50-3

Console Cover Removal And Installation

Figure 40-50-1

P112258

Remove the screw (Item 1) [Figure 40-50-3] from the

P112256 rear of the cover.

Figure 40-50-4
Pull the dust boot (Item 1) [Figure 40-50-1] towards the
rear of the cab.

Dealer Copy -- Not for Resale

Figure 40-50-2 2

3
1

P112259

Lift the cover (Item 1) up until the cover is free of the

P112257 joystick dust boot (Item 2) and blade lever dust boot (Item
3) [Figure 40-50-4].

Remove the screws (Item 1) [Figure 40-50-2].

609 of 918 40-50-1 E85 Service Manual

RIGHT CONSOLE (CONT’D)

Console Cover Removal And Installation (Cont’d)

Figure 40-50-5

P112260

Tilt the cover towards the rear of the cab and disconnect
the wire harness (Item 1) [Figure 40-50-5].

Dealer Copy -- Not for Resale

Remove the cover.

610 of 918 40-50-2 E85 Service Manual

LEFT CONSOLE Figure 40-60-3

Lower Console Cover Removal And Installation

Remove the upper console cover. (See Upper Console

Cover Removal And Installation on Page 40-60-2.) 1

Figure 40-60-1

P-86765

Raise the console and remove the two screws (Item 1)

[Figure 40-60-3] from the bottom of the cover.

Figure 40-60-4
P-86764

Dealer Copy -- Not for Resale

Remove the two screws (Item 1) [Figure 40-60-1] from
1
the front of the cover.

Figure 40-60-2

1 P-86766

Lower the console and remove the cover (Item 1) [Figure

40-60-4].

P-866763

Remove the two screws (Item 1) [Figure 40-60-2] from

the rear of the cover.

611 of 918 40-60-1 E85 Service Manual

LEFT CONSOLE (CONT’D) Figure 40-60-7

Upper Console Cover Removal And Installation

Figure 40-60-5

P-86758

Tilt the cover towards the rear of the cab and disconnect
P-86757 the wire harness (Item 1) [Figure 40-60-7].

Remove the cover.

Pull the dust boot towards the rear of the cab and remove
the two screws (Item 1) [Figure 40-60-5].

Dealer Copy -- Not for Resale

Figure 40-60-6

P-86756

Remove the two screws (Item 1) [Figure 40-60-6] from

the rear of the cover.

612 of 918 40-60-2 E85 Service Manual

LEFT CONSOLE (CONT’D) Figure 40-60-10

Gas Strut Removal And Installation 3

Remove the upper console cover. (See Upper Console

Cover Removal And Installation on Page 40-60-2.)

Remove the lower console cover. (See Lower Console 2

Cover Removal And Installation on Page 40-60-1.)
1
Figure 40-60-8

1 P120808

Remove the two bolts (Item 1), mount (Item 2) and

bushing (Item 3) [Figure 40-60-10].

NOTE: Loosen and remove the bolts evenly until the

gas strut is fully extended.

Dealer Copy -- Not for Resale

Figure 40-60-11
P-86779

Remove the nut (Item 1) [Figure 40-60-8].

1
Figure 40-60-9

1
P-86782
2

Support the console and remove the gas strut (Item 1)

[Figure 40-60-11].

P-86778

Remove the snap ring (Item 1) and washer. Remove the

nut (Item 2) [Figure 40-60-9].

613 of 918 40-60-3 E85 Service Manual

LEFT CONSOLE (CONT’D)

Lock Lever Removal And Installation

Remove the gas strut (See Gas Strut Removal And

Installation on Page 40-60-3.)

Figure 40-60-12

1 1

P-86785

Dealer Copy -- Not for Resale

Remove the bolts (Item 1) and lever (Item 2) [Figure 40-
60-12].

614 of 918 40-60-4 E85 Service Manual

LEFT CONSOLE (CONT’D) Figure 40-60-15

Lock Lever Disassembly And Assembly

Figure 40-60-13

1
1

P-86788

Remove the shims (Item 1) [Figure 40-60-15] from both

P-86786 sides of the lever.

Figure 40-60-16
Remove the snap ring (Item 1) [Figure 40-60-13].

Dealer Copy -- Not for Resale

Figure 40-60-14
1

P-86789

P-86787 Remove the bushing (Item 1) [Figure 40-60-16] from the

lever.

Remove the pin (Item 1) [Figure 40-60-14].

615 of 918 40-60-5 E85 Service Manual

LEFT CONSOLE (CONT’D)

Console Removal And Installation

Remove the left joystick. (See Joystick Assembly

Removal And Installation on Page 20-120-4.)

Remove the gas strut. (See Gas Strut Removal And

Installation on Page 40-60-3.)

Figure 40-60-17

Dealer Copy -- Not for Resale

P-86783

Remove the snap ring (Item 1) [Figure 40-60-17] and

washer.

Figure 40-60-18

P-86784

Remove the pin (Item 1) [Figure 40-60-18] and remove

the console.

616 of 918 40-60-6 E85 Service Manual

CENTER COVER

Removal And Installation

Figure 40-70-1

P-86417

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

[Figure 40-70-1].

Dealer Copy -- Not for Resale

617 of 918 40-70-1 E85 Service Manual

Dealer Copy -- Not for Resale

618 of 918 40-70-2 E85 Service Manual

CENTER ACCESS COVER

Removal And Installation

Open the cover.

Figure 40-80-1

3 3
2

P112191

Dealer Copy -- Not for Resale

Remove the clip (Item 1) and remove the prop rod (Item
2) from the bracket. Remove the bolts (Item 3) [Figure
40-80-1] and cover.

619 of 918 40-80-1 E85 Service Manual

Dealer Copy -- Not for Resale

620 of 918 40-80-2 E85 Service Manual

COUNTERWEIGHT Figure 40-90-3

Removal And Installation

Tilt the cab. (See Raising And Lowering on Page 10-210-

1.)
2
Remove the rear cover. (See Removal And Installation on
Page 40-190-1.)

Figure 40-90-1

P-93537

Figure 40-90-4

1 2

Dealer Copy -- Not for Resale

P-89560

Figure 40-90-2

P112252

Install lifting rings (Item 1) and chains (Item 2) [Figure

40-90-3] and [Figure 40-90-4].

P-89561

Remove the two plugs (Item 1) [Figure 40-90-1] and

[Figure 40-90-2].

621 of 918 40-90-1 E85 Service Manual

COUNTERWEIGHT (CONT’D) Figure 40-90-6

Removal And Installation (Cont’d)

Figure 40-90-5

P-89556

Figure 40-90-7
P-93486

Install a lifting device to the lifting chains [Figure 40-90-

5].

Dealer Copy -- Not for Resale

NOTE: The counterweight weighs 1274 kg (2806 lb).
Use a lifting device of sufficient capacity.
Raise the hoist until the weight of the
counterweight is supported by the hoist.

WARNING P-89558

AVOID INJURY OR DEATH Figure 40-90-8

• Use a lifting fixture with sufficient capacity for
the weight of the excavator plus any added
attachments.
• Maintain center of gravity and balance when
lifting.
• Do not swing boom or upperstructure. Engage
the upperstructure slew lock.
• Never lift with operator on machine.
W-2202-0607

P-89557

Remove the bolts (Item 1) [Figure 40-90-6], [Figure 40-

90-7] and [Figure 40-90-8].
Installation: Tighten the bolts to 1372 N•m (1010 ft-lb)
torque.
Remove the counterweight.

622 of 918 40-90-2 E85 Service Manual

FLOOR MAT

Removal And Installation

Figure 40-100-1

P111459

Figure 40-100-2
Articulated Boom

Dealer Copy -- Not for Resale

P123149

Pull up on and remove the floor mat (Item 1) [Figure 40-

100-1] or [Figure 40-100-2].

623 of 918 40-100-1 E85 Service Manual

Dealer Copy -- Not for Resale

624 of 918 40-100-2 E85 Service Manual

FUEL TANK Figure 40-110-3

Removal And Installation

Remove the rear cover. (See Removal And Installation on

Page 40-190-1.)
1
1
Drain the fuel tank.

Open the right side cover.

Figure 40-110-1

1 P-87223

Remove the bolts (Item 1) [Figure 40-110-3] and

reposition the wire harness.

Figure 40-110-4

Dealer Copy -- Not for Resale

P-87221 1

Disconnect the fuel sending unit wire harness (Item 1)

[Figure 40-110-1].

Figure 40-110-2

P-87224

Loosen the hose clamps (Item 1) and remove the hose

(Item 2) [Figure 40-110-4] from the top of the fuel tank.

P-87222

Remove the two bolts (Item 1) [Figure 40-110-2].

625 of 918 40-110-1 E85 Service Manual

FUEL TANK (CONT’D) Figure 40-110-7

Removal And Installation (Cont’d)

2
Figure 40-110-5

P-87229
2

Loosen the hose clamp (Item 1) and remove the fuel

P-87234 supply line (Item 2) [Figure 40-110-7].

Figure 40-110-8
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 40-110-5].

Dealer Copy -- Not for Resale

Figure 40-110-6

1 P-87225

Remove the bolts (Item 1) [Figure 40-110-8] from the

P-87235 tank lifting points.

Remove the bolt (Item 1) [Figure 40-110-6].

626 of 918 40-110-2 E85 Service Manual

FUEL TANK (CONT’D) Figure 40-110-11

Removal And Installation (Cont’d)

Figure 40-110-9

1 1

1 P-87242
1

Figure 40-110-12
P-87226

Install lifting hooks (Item 1) [Figure 40-110-9].

Dealer Copy -- Not for Resale

Figure 40-110-10 1

1
1

P-87241

Remove the tank mounting bolts (Item 1) [Figure 40-110-

11] and [Figure 40-110-12].

P-87243

Attach a chain (Item 1) and lifting device (Item 2) [Figure

40-110-10] to the lifting hooks.

627 of 918 40-110-3 E85 Service Manual

FUEL TANK (CONT’D)

Removal And Installation (Cont’d)

Figure 40-110-13

P-87226

Lift the tank high enough to access the bolt (Item 1)

[Figure 40-110-13] on the left side of the fuel tank.

Dealer Copy -- Not for Resale

Remove the bolt.

Remove the fuel tank.

Figure 40-110-14

P-87243

Record the number and location of the shims (Item 1)

[Figure 40-110-14].

628 of 918 40-110-4 E85 Service Manual

HORN

Removal And Installation

Remove the left upperstructure side cover. (See Removal

And Installation on Page 40-20-1.)

Figure 40-120-1

P-86441

Dealer Copy -- Not for Resale

Disconnect the wire harness (Item 1). Remove the bolt
(Item 2) [Figure 40-120-1] and washer.

Remove the horn.

629 of 918 40-120-1 E85 Service Manual

Dealer Copy -- Not for Resale

630 of 918 40-120-2 E85 Service Manual

SWING FRAME Figure 40-130-3

Removal And Installation

Rotate the upperstructure so that the blade is to the rear

of the excavator. 1
2
Remove the boom. (See Removal And Installation on
Page 40-140-1.)

Figure 40-130-1

P-87409

Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-

130-3].

Figure 40-130-4

Dealer Copy -- Not for Resale

1
P-87650

Measure the length of the hoses from the top of the

clamp to the end of each hose [Figure 40-130-1].

Figure 40-130-2

P-87410

Remove the pivot pin (Item 1) [Figure 40-130-4] from the

rod end of the swing cylinder.

1 2 1 1

P-87649

Remove the bolts (Item 1) and the clamp (Item 2) [Figure

40-130-2].

631 of 918 40-130-1 E85 Service Manual

SWING FRAME (CONT'D) Figure 40-130-7

Removal And Installation (Cont’d)

Figure 40-130-5

1
1

P-87655
2

Support the bottom pin [Figure 40-130-7].

P-87653
Figure 40-130-8

Remove the bolts (Item 1) and plate (Item 2) [Figure 40-

130-5].

Dealer Copy -- Not for Resale

Figure 40-130-6

1
2
P-87807
2
Install a porta-power between the top and bottom pins,
and press the top pin out [Figure 40-130-8].
P-87654

Install the boom pin (Item 1) using spacers (Item 2) to

position a lifting strap (Item 3) [Figure 40-130-6] on the
center of the boom pin.

NOTE: The spacers will prevent the strap from

sliding on the boom pin, causing the swing
frame to tip from side to side.

632 of 918 40-130-2 E85 Service Manual

SWING FRAME (CONT'D) Figure 40-130-11

Removal And Installation (Cont’d)

Figure 40-130-9

2 1

1
1 P-87657

Use a large punch (Item 1) [Figure 40-130-11] and drive

P-87374 the bottom swing frame pin out.

Figure 40-130-12
Remove the bolts (Item 1) and plate (Item 2) [Figure 40-
130-9].

Dealer Copy -- Not for Resale

Figure 40-130-10

1
1

P-87659

Remove the top spacer (Item 1) [Figure 40-130-12] from

P-87663 the swing frame.

Install a spacer tube (Item 1) [Figure 40-130-10] and

jack under the swing frame. The spacer tube must be
large enough to allow the pin to be driven into the center
of the spacer for pin removal.

633 of 918 40-130-3 E85 Service Manual

SWING FRAME (CONT'D)

Removal And Installation (Cont’d)

Figure 40-130-13

P-87660

Remove the bottom spacer (Item 1) [Figure 40-130-13]

from the swing frame.

Dealer Copy -- Not for Resale

Remove the swing frame.

634 of 918 40-130-4 E85 Service Manual

SWING FRAME (CONT’D) Figure 40-130-14

Bushing Removal 4
2

1
IMPORTANT
Do Not point (hammer) on the boom swing bracket.
Excess pressure can cause the casting to crack.
I-2095-1195
3

The following parts will be needed for removal and

installation of the swing frame bushings: 5
P-23570
1. Bolt - 19 x 153 mm or (3/4 x 6 in).

2. Nut - 19 mm or (3/4 in). Install the spacer (Item 1) and washer (Item 2) [Figure
40-130-14] over the flanged end of the bushing.
3. Washer - 22 mm I.D. x 102 mm O.D. x 10 mm thick or
(7/8 I.D. x 4-1/64 O.D. x 3/8 in thick). The spacer (Item 1) [Figure 40-130-14] must be
centered over the bushing to avoid contact between the
4. Washer - 22 mm I.D. x 119 mm O.D. x 10 mm thick or bushing and the spacer during removal.

Dealer Copy -- Not for Resale

(7/8 I.D. x 4-11/16 O.D. x 3/8 in thick).
Install the washer (Item 3) [Figure 40-130-14] onto the
5. Washer - 22 mm I.D. 146 mm O.D. x 13 mm thick or opposite end of the bushing. This washer must be
(7/8 I.D. x 5-3/4 O.D. x 1/2 in thick). centered on the bushing and must not contact the
casting.
6. Spacer - 119 mm I.D. x 140 mm O.D. x 38 mm thick
or (4-11/16 I.D. x 5-1/2 O.D. x 2 in thick). Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
130-14] through the washers and the spacer.

Tighten the bolt and nut to remove the bushing from the
casting.

635 of 918 40-130-5 E85 Service Manual

SWING FRAME (CONT’D) Figure 40-130-16

Bushing Installation

Apply a film of grease to the outer diameter of the

bushing and to the inner diameter of the casting.

Center the bushing on the casting hole.

NOTE: Make sure that the bushing is centered into

the casting hole and that it starts in the hole
evenly and square.

Figure 40-130-15

P-23573

Figure 40-130-17
4
1

Dealer Copy -- Not for Resale

2
3

5 P-23571

Put the washer (Item 1) [Figure 40-130-15] over the

flanged end of the bushing.
P-23572
Put the spacer (Item 2) and the washer (Item 3) [Figure
40-130-15] over the bushing hole casting. Center the
spacer and the washer over the bushing hole. The same procedure is used to remove and install the
bushings in the frame castings [Figure 40-130-16] and
Install the bolt (Item 4) through the washers, the spacer [Figure 40-130-17].
and the bushing. Install the nut (Item 5) [Figure 40-130-
15].

Tighten the bolt and nut until the bushing is seated in the
casting.

636 of 918 40-130-6 E85 Service Manual

BOOM

Removal And Installation

Remove the arm. (See Removal And Installation on Page

IMPORTANT
40-150-1.)
When repairing hydrostatic and hydraulic systems,
Remove the articulated boom (if equipped). (See clean the work area before disassembly and keep all
Removal And Installation on Page 40-141-1.) parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Remove the boom cylinder. (See Removal And damage the system.
I-2003-0888
Installation on Page 20-20-4.)

Figure 40-140-1 Figure 40-140-3

1
1

Dealer Copy -- Not for Resale

P-87003 P-87004

Figure 40-140-2 Figure 40-140-4

Articulated Boom Articulated Boom
1
1

1
1

P123150 P123151

Disconnect the wire harness (Item 1) [Figure 40-140-1] Mark and remove the hoses (Item 1) [Figure 40-140-3]
or [Figure 40-140-2]. or [Figure 40-140-4].

637 of 918 40-140-1 E85 Service Manual

BOOM (CONT’D) Bushing Removal And Installation

Removal And Installation (Cont’d) Figure 40-140-7

Figure 40-140-5

4
1 2 1

P-87084

P-87005
Remove the seals (Item 1) [Figure 40-140-7] from both
sides of the boom.
Remove the hose (Item 1) [Figure 40-140-5] (Both
sides). Remove the bushings from both sides of the boom.

Dealer Copy -- Not for Resale

Remove the nuts (Item 2), bolt (Item 3), and pivot pin Install new bushings in the boom.
(Item 4) [Figure 40-140-5].
Figure 40-140-8
Figure 40-140-6

1 5 mm (0.197 in)

TS-1614A
P-87006

Install the bushings until they are seated 5 mm (0.197 in)

Remove the boom (Item 1) [Figure 40-140-6]. in the pin boss [Figure 40-140-8].

Install new seals on both sides of the boom.

638 of 918 40-140-2 E85 Service Manual

BOOM (ARTICULATED) (OPTIONAL) Figure 40-141-3

Removal And Installation

3
Remove the arm. (See Removal And Installation on Page
40-150-1.)

Figure 40-141-1 1

2
2 1 4

S37808

Mark and remove the hoses (Item 1) [Figure 40-141-3]

(Both sides).

Remove the nuts (Item 2) and bolt (Item 3) [Figure 40-

S37686 141-3] (Both sides).

Dealer Copy -- Not for Resale

Remove the pivot pin (Item 4) [Figure 40-141-3].
Support the articulated boom with a chain hoist (Item 1)
in the articulated boom lifting point, and with a hoist at the Remove the articulated boom.
front of the articulated boom (Item 2) [Figure 40-141-1].

Remove the articulated boom cylinders. (See Removal

And Installation on Page 20-25-3.)
IMPORTANT
Figure 40-141-2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P123152

Disconnect the wire harness (Item 1) [Figure 40-141-2]

from the boom light (Both sides).

639 of 918 40-141-1 E85 Service Manual

BOOM (ARTICULATED) (OPTIONAL) (CONT’D)

Removal And Installation (Cont’d)

Figure 40-141-4

P-87084

Remove the seals (Item 1) [Figure 40-141-4] from both

sides of the articulated boom.

Dealer Copy -- Not for Resale

Remove the bushings from both sides of the articulated
boom.

Install new bushings in the articulated boom.

Figure 40-141-5

5 mm (0.197 in)

TS-1614A

Install the bushings until they are seated 5 mm (0.197 in)

in the pin boss [Figure 40-141-5].

Install new seals on both sides of the articulated boom.

640 of 918 40-141-2 E85 Service Manual

ARM Figure 40-150-3

Removal And Installation

Remove the bucket or attachment.

Remove the bucket cylinder. (See Removal And 1

Installation on Page 20-23-1.)

Remove the arm cylinder. (See Removal And Installation

on Page 20-21-3.)
2 3
Lower the boom / arm and blade to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic P-87025
pressure.

Figure 40-150-1 Remove the nuts (Item 2) and bolt (Item 3) [Figure 40-
150-3].
Articulated Boom
Figure 40-150-4

Dealer Copy -- Not for Resale

1 1

P-87019 S37686

Support the boom with a chain hoist (Item 1) [Figure 40- P-87024
150-1].

Figure 40-150-2 Remove the hydraulic lines (Item 1) on both sides of the
arm [Figure 40-150-3] and [Figure 40-150-4].

S37809

Support the arm with a chain hoist (Item 1) [Figure 40-

150-2].

641 of 918 40-150-1 E85 Service Manual

ARM (CONT’D) Arm To Boom Bushing Removal And Installation

Removal And Installation (Cont’d) Figure 40-150-7

Figure 40-150-5

2
1

P-87079

P-86891
Remove the seal (Item 1) and bushing (Item 2) [Figure
40-150-7] from both sides of the arm.
Remove the pivot pin (Item 1) [Figure 40-150-5].
Install the new bushings in the arm.

Dealer Copy -- Not for Resale

Figure 40-150-6
Figure 40-150-8

P-86893 5 mm (0.197 in)

TS-1614A

Remove the arm (Item 1) and shims (Item 2) [Figure 40-

150-6]. Install the bushings until they are seated 5 mm (0.197 in)
in the pin boss [Figure 40-150-8] (Both sides).

Install new seals on both sides of the arm.

642 of 918 40-150-2 E85 Service Manual

ARM (CONT’D) Figure 40-150-11

Bucket And Link Bushing Removal And Installation

Figure 40-150-9

5 mm (0.197 in)
TS-1614A

2
Install the bushings until they are seated 5 mm (0.197 in)
P-87081 in the pin boss [Figure 40-150-11] (Both sides).

Figure 40-150-10

Dealer Copy -- Not for Resale

P-87080

Remove the seals (Item 1) and bushings (Item 2) [Figure

40-150-9] and [Figure 40-150-10] from both sides of the
arm.

Install the new bushings in the arm.

643 of 918 40-150-3 E85 Service Manual

Dealer Copy -- Not for Resale

644 of 918 40-150-4 E85 Service Manual

QUICK COUPLER (KLAC™ SYSTEM)

Troubleshooting

PROBLEM CAUSE CORRECTION

Coupler does not seat properly on the Mud, dirt, stones or debris are lodged Remove mud, dirt, stones and debris
attachment mounting frame. between the coupler and the from between the coupler and the
attachment mounting frame. attachment mounting frame.
Worn locking mechanism. Repair or replace worn pins and
locking mechanisms.
Attachment mounting frame damaged. Repair or replace the attachment
mounting frame.

Daily Inspection

Figure 40-160-1

Dealer Copy -- Not for Resale

P-72274

Inspect the quick coupler for wear or damage. Inspect the

quick locking shaft (Item 1) and the hooks (Item 2)
[Figure 40-160-1] (on the attachment) for wear or
damage.

Repair or replace damaged parts.

645 of 918 40-160-1 E85 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-160-3

Removal And Installation

Figure 40-160-2
Unlatched Position Latched Position

P-72283

1
Install the tool (Item 1) [Figure 40-160-3] in the quick
P-72272 P-72272 coupler as shown. Push down on the tool until the latch
snaps closed.

Remove the attachment.

Dealer Copy -- Not for Resale

The quick coupler must be in the latched position (Item 1)
[Figure 40-160-2] for disassembly.

Inspect the quick coupler to make sure the latch is in the

latched position.

If the latch is in the unlatched position, see [Figure 40-

160-3] for additional information.

If the latch is in the latched position, proceed to [Figure

40-160-4].

WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
latching and unlatching the attachment quick
coupler.
W-2541-1106

646 of 918 40-160-2 E85 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-160-5

Removal And Installation (Cont’d)

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure. 1
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907 P-72269

Figure 40-160-4 Remove pins (Item 1) [Figure 40-160-5].

Figure 40-160-6
1

Dealer Copy -- Not for Resale

P-72270
1
P-72265
Remove the bolts (Item 1) [Figure 40-160-4] and nuts.

Installation: Align the holes of the connecting pins with Raise the arm and bucket link until the coupler is free
the holes in the coupler. Install the two bolts (Item 1) [Figure 40-160-6].
[Figure 40-160-4] and nuts. Tighten the nuts securely
against the couple. Installation: Align the arm and bucket link with the
coupler [Figure 40-160-6]. Lower the arm and bucket link
into the coupler.

NOTE: Place the coupler on the ground with the

mounting pin (Item 1) [Figure 40-160-6] facing
towards the excavator.

647 of 918 40-160-3 E85 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D)

Parts Identification

1. Coupler Body
2. Spring
3. Locking Plate
4. Tool

4
2

Dealer Copy -- Not for Resale

P-88398

648 of 918 40-160-4 E85 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-160-8

Disassembly
1

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present.
• Engine is running.
1
• Tools are being used.
W-2505-0604 P-72284

Figure 40-160-7 Remove the spring end hook (Item 1) [Figure 40-160-8]
from the quick coupler.
2 1 3
Figure 40-160-9

Dealer Copy -- Not for Resale

2
3 1

1
P-72285

The two springs (Item 1) [Figure 40-160-7] have different P-72294

style of end hooks.

The spring hook (Item 2) [Figure 40-160-7] are full circle Remove the opposite end of the two springs (Item 1)
hooks. [Figure 40-160-9].

The spring hook (Item 3) [Figure 40-160-7] are partial

circle hooks.

The spring ends must be positioned as shown when

assembled.

649 of 918 40-160-5 E85 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D)

Disassembly (Cont’d)

Figure 40-160-10

1 1

P-72295

Remove the two roll pins (Item 1) [Figure 40-160-10].

Drive the roll pins inwards to remove.

Dealer Copy -- Not for Resale

Figure 40-160-11

P-72296

Remove the latch (Item 1) [Figure 40-160-11].

650 of 918 40-160-6 E85 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-160-14

Assembly

Figure 40-160-12

P-72294
1

Install the partial circle hook end of the spring (Item 1)

P-72296 [Figure 40-160-14].

Figure 40-160-15
Install the latch (Item 1) [Figure 40-160-12].

Dealer Copy -- Not for Resale

Figure 40-160-13 1

1 1
1
P-72284

P-72295 Install the full circle end of the spring hook (Item 1)
[Figure 40-160-15] on the quick coupler.

Install the two roll pins (Item 1) [Figure 40-160-13]. Drive Do not lubricate the quick coupler. Lubrication will cause
the roll pins inwards until the roll pins are flush with the dirt to collect and interfere with proper movement of the
outside edge of the quick coupler. quick coupler.

651 of 918 40-160-7 E85 Service Manual

Dealer Copy -- Not for Resale

652 of 918 40-160-8 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM)

Troubleshooting

PROBLEM CAUSE CORRECTION

Daily Inspection

Figure 40-161-1

(MS03 & MS08)

Dealer Copy -- Not for Resale

P-88183

Inspect the quick coupler for wear or damage. Inspect the

hooks (Item 1) and coupler locking shaft (Item 2) [Figure
40-161-1] (on the attachment) for wear or damage.

Repair or replace damaged parts.

653 of 918 40-161-1 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-161-4

Removal (MS03 And MS08)

Raise the arm and bucket link until the quick coupler is
Figure 40-161-2 free [Figure 40-161-4].

2
2

Dealer Copy -- Not for Resale

1
1

P-88003

Remove the four nuts (Items 1). Remove the two bolts
(Item 2) [Figure 40-161-2].

Figure 40-161-3

1
P-88001

Remove the two connecting pins (Item 1) and O-rings

(Item 2) [Figure 40-161-3].

654 of 918 40-161-2 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-161-7

Installation (MS03 And MS08)

1
Figure 40-161-5 1

2
2

P-88003

1 Install the two bolts (Item 1) [Figure 40-161-7].

P-88000
Install nuts (Item 2) [Figure 40-161-7] just until contact is
made with the coupler.
Place the coupler on the ground with the hooks (Item 1)
[Figure 40-161-5] facing towards the excavator. NOTE: Do Not tighten nuts (Item 2) [Figure 40-161-7]
against the coupler. The retaining bolt must

Dealer Copy -- Not for Resale

Align the arm and bucket link with the coupler [Figure 40- rotate freely.
161-5].
Install and tighten nuts (Item 3) securely against the two
Figure 40-161-6 nuts (Item 2) [Figure 40-161-7]. The retaining bolts must
rotate freely.
2

3
P-88001

Install the O-rings (Item 1) [Figure 40-161-6] between

the coupler pivot point and the arm and bucket link when
lowering into position.

NOTE: The O-rings will prevent dirt and debris from

entering the pivot points of the coupler.

Align the holes of the connecting pins with the holes

(Item 2) [Figure 40-161-6] in the coupler.

Install the two pins (Item 3) [Figure 40-161-6] through

the coupler, arm and bucket link.

655 of 918 40-161-3 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)

Parts Identification (MS03)

1. Bolt
2. Lock Washer
3. Coupler Housing
4. Pressure Spring
5. Locking Mechanism 1

Dealer Copy -- Not for Resale

P-88114

656 of 918 40-161-4 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)

Disassembly And Assembly (MS03)

Figure 40-161-8

P-88004

Remove the two bolts (Item 1) [Figure 40-161-8] and

lock washers.

Dealer Copy -- Not for Resale

Figure 40-161-9

P-88005

Turn the threaded spindle (Item 1) counterclockwise until

the locking mechanism (Item 2) [Figure 40-161-9] is free
from the housing.

657 of 918 40-161-5 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)

Parts Identification (MS08)

1. Housing
2. Bushing
3. Bushing
4. O-ring
5. Cover
6. O-ring
7. O-ring 1
8. Reversing Lever
9. Threaded Pin
10. Pressure Spring 2
11. Pin
12. Pivoting Journal
13. Spring Washer
14. Bolt
15. Bearing Block 26 3
16. Locking Pin
4
17. Pressure Spring
18. Thrust Journal 3
19. Pin 25
20. O-ring 24
21. Driving Fork

Dealer Copy -- Not for Resale

22. Control Shaft
23. Bolt
24. Snap Ring 5
25. Bushing
6
26. Bushing
7
23
22
8
9

21 10 11
20
19
12
20 17
19 18

16
15 13

P-88115

658 of 918 40-161-6 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) NOTE: Do not scratch the mounting surface while
removing sealant.
Disassembly (MS08)
Figure 40-161-12

WARNING 1

AVOID INJURY OR DEATH

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

P-88010
Figure 40-161-10

Remove the two bolts (Item 1) [Figure 40-161-12].

2
Figure 40-161-13

Dealer Copy -- Not for Resale

P-88009

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

[Figure 40-161-10].
P-88011
Figure 40-161-11

Tilt the bearing block and pivoting journal (Item 1) up and

1
remove from the spring guide (Item 2) [Figure 40-161-
13].

P-88122

Remove all sealant (Item 1) [Figure 40-161-11] from the

housing and cover.

659 of 918 40-161-7 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-161-16

Disassembly (MS08) (Cont’d)

Figure 40-161-14

1
P-88013

Remove the snap ring (Item 1) [Figure 40-161-16].

P-88012
Figure 40-161-17

Remove the pivoting journal (Item 1) [Figure 40-161-14]

from the bearing block.

Dealer Copy -- Not for Resale

Figure 40-161-15

2
1

P-88014

NOTE: Before removing the control shaft, note the

position of each of the components so that
P-88017 when the coupler is reassembled all
components are positioned correctly on the
control shaft [Figure 40-161-17].
Remove the pressure spring (Item 1) from the spring
guide (Item 2) [Figure 40-161-15].

660 of 918 40-161-8 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-161-20

Disassembly (MS08) (Cont’d)

4
Figure 40-161-18
1

1
3
2

P-88018

Remove the snap ring (Item 1) and pin (Item 2). Remove
P-88015 the spring guide (Item 3) from the driving fork (Item 4)
[Figure 40-161-20].

Remove the control shaft (Item 1) [Figure 40-161-18]. Figure 40-161-21

Figure 40-161-19

Dealer Copy -- Not for Resale

P-88019

P-88016
Remove the locking pin assemblies [Figure 40-161-21].

Remove O-rings (Item 1) [Figure 40-161-19].

661 of 918 40-161-9 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)

Disassembly (MS08) (Cont’d)

Figure 40-161-22

3
4 6

5
2 1

P-88021

Remove the snap ring (Item 1) and pin (Item 2). Remove
the driving fork (Item 3) [Figure 40-161-22].

Dealer Copy -- Not for Resale

Remove the snap ring (Item 4) and pin (Item 5). Remove
the reversing lever (Item 6) [Figure 40-161-22].

Repeat the procedure for the other locking pin.

Figure 40-161-23

2 3

P-88022

Remove the bushing (Item 1), O-ring (Item 2) and

bushing (Item 3) [Figure 40-161-23] from both locking
pin bores.

662 of 918 40-161-10 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-161-26

Assembly (MS08)

Figure 40-161-24

2 1

P-88019

3
Install the locking pin assemblies [Figure 40-161-26].
P-88022
NOTE: Position the locking levers with the flat side
down and away from the cover.
Install bushing (Item 1), O-ring (Item 2) and bushing (Item
3) [Figure 40-161-24] in both locking pin bores. Figure 40-161-27

Dealer Copy -- Not for Resale

Figure 40-161-25
1

4 3

3 1

4
2
2
5 6 P-88018

P-88021
Install the driving fork (Item 1), pin (Item 2) and snap ring
(Item 3) on the spring guide (Item 4) [Figure 40-161-27].
Install reversing lever (Item 1), pin (Item 2) and snap ring
(Item 3) [Figure 40-161-25] on the locking pin.

Install the driving fork (Item 4), pin (Item 5) and snap ring
(Item 6) [Figure 40-161-25] on the reversing lever.
Repeat the procedure for the other locking pin.

663 of 918 40-161-11 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-161-30

Assembly (MS08) (Cont’d)

Figure 40-161-28

P-88023

Install the control shaft through the first locking lever

P-88016 driving fork (Item 1) [Figure 40-161-30].

Figure 40-161-31
Install the O-rings (Item 1) [Figure 40-161-28].

Figure 40-161-29

Dealer Copy -- Not for Resale

P-88024

P-88015 Install the control shaft through the spring guide driving
fork (Item 1) [Figure 40-161-31].

Install the control shaft (Item 1) [Figure 40-161-29].

664 of 918 40-161-12 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-161-34

Assembly (MS08) (Cont’d)

Figure 40-161-32

1 P-88011

Install pressure spring (Item 1) on the spring guide. Tilt

P-88025 the bearing block and pivoting journal (Item 2) [Figure
40-161-34] down and install on the spring guide.

Install the control shaft through the second locking lever Figure 40-161-35
driving fork (Item 1) [Figure 40-161-32].

Dealer Copy -- Not for Resale

NOTE: Check proper alignment of all three driving
forks on the control shaft. If not aligned 1
properly, repeat the procedure.

Figure 40-161-33

P-88010

1
Install the two bolts (Item 1) [Figure 40-161-35].

P-88013

Install the snap ring (Item 1) [Figure 40-161-33].

665 of 918 40-161-13 E85 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)

Assembly (MS08) (Cont’d)

Figure 40-161-36

P-88026

Apply a bead of sealant around the cover mounting

surface (Item 1) [Figure 40-161-36].

Dealer Copy -- Not for Resale

Figure 40-161-37

P-88009

Install the cover (Item 1) [Figure 40-161-37].

Apply Loctite® 242 on the eight bolts.

Install the eight bolts (Item 2) [Figure 40-161-37].

666 of 918 40-161-14 E85 Service Manual

BUCKET Figure 40-170-2

Bucket Teeth Removal And Installation

WARNING 1

Wear safety glasses to prevent eye injury when any

of the following conditions exist:
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2505-0604 P-87320

Position the bucket at a 30° angle up from the ground so Use a punch and a hammer and drive the retainer pin
that the bucket teeth are easily accessible. Install a block (Item 1) down and out the bottom of the tooth (Item 2)
under the bucket. [Figure 40-170-2]. Remove the tooth from the shank.

Lower the boom until the bucket is fully on the ground Figure 40-170-3
and resting on the block.

Dealer Copy -- Not for Resale

Stop the engine and exit the excavator.
2
Figure 40-170-1
1

1
P-87316

Remove the rubber retainer (Item 1) from the shank (Item

3 2) [Figure 40-170-3].
P-87315
Installation: Install the rubber retainer (Item 1) into the
tooth shank (Item 2) [Figure 40-170-3].
The bucket tooth (Item 1) has a unique retaining pin (Item
2) and rubber retainer (Item 3). The retaining pin (Item 2) Position the new tooth point (Item 2) [Figure 40-170-2]
must be installed as shown, with the notch towards the on the shank (Item 2) [Figure 40-170-3].
rubber retainer (Item 3). The rubber retainer (Item 3)
[Figure 40-170-1] will be installed into the shank before Install the retainer pin (Item 1) [Figure 40-170-3] until it is
the tooth is installed on the shank. flush with the top of the tooth.

667 of 918 40-170-1 E85 Service Manual

BUCKET (CONT’D)

Bucket Side Cutting Edge Removal And Installation

Figure 40-170-4

P-87323

Remove the three nuts (Item 1) and bolts. Remove the

cutting edge (Item 2) [Figure 40-170-4].

Dealer Copy -- Not for Resale

668 of 918 40-170-2 E85 Service Manual

RIGHT SIDE COVER Figure 40-180-3

Removal And Installation

Remove the center access cover. (See Removal And

Installation on Page 40-80-1.)
1
Remove the center cover. (See Removal And Installation 2
on Page 40-70-1.)

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

Page 10-50-1.)

Figure 40-180-1

P111461

1 Figure 40-180-4

Dealer Copy -- Not for Resale

P111460

1
Figure 40-180-2

P111462

Remove the clip (Item 1) and washers (Item 2) [Figure

1 40-180-3] and [Figure 40-180-4] from the bottom of the
gas struts.

Support the cover and remove the gas struts.

2
Close the right side cover.

P111463

Remove the clip (Item 1) and washer (Item 2) [Figure 40-

180-1] and [Figure 40-180-2] from the top of the gas
struts.

669 of 918 40-180-1 E85 Service Manual

RIGHT SIDE COVER (CONT’D) Latch Adjustment

Removal And Installation (Cont’d) Figure 40-180-7

Figure 40-180-5

1 1

P111464

P112510
Loosen the two bolts (Item 1) and adjust the latch (Item
2) [Figure 40-180-7]. Tighten the nut after the
Remove the three bolts (Item 1) [Figure 40-180-5], adjustment is made.
washers and shims (if equipped).
Close the right side cover before operating the excavator.

Dealer Copy -- Not for Resale

Figure 40-180-6

1 1

P112507

Remove the three bolts (Item 1) [Figure 40-180-6],

washers and shims (if equipped).

Remove the cover.

670 of 918 40-180-2 E85 Service Manual

REAR COVER Figure 40-190-3

Removal And Installation

Remove the center access cover. (See Removal And

1
Installation on Page 40-80-1.)

Remove the center cover. (See Removal And Installation

on Page 40-70-1.)

Tilt the cab. (See Raising And Lowering on Page 10-210-

1.)

Figure 40-190-1

P-87207

Remove the bolt (Item 1) [Figure 40-190-3] from the

upper right side of the rear cover.

Figure 40-190-4

Dealer Copy -- Not for Resale

P-87205

Remove the bolt (Item 1) [Figure 40-190-1] from the

lower left side of the rear cover.
1
Figure 40-190-2

P-92769

Remove the bolt (Item 1) [Figure 40-190-4].

1
Remove the rear cover.

P-87206

Remove the bolt (Item 1) [Figure 40-190-2] from the

lower right side of the rear cover.

671 of 918 40-190-1 E85 Service Manual

Dealer Copy -- Not for Resale

672 of 918 40-190-2 E85 Service Manual

ELECTRICAL SYSTEM AND ANALYSIS

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Dealer Copy -- Not for Resale

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

CONSOLE LOCKOUT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Testing / Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2

FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Failure Mode Indicator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-7
Code Retrieval Through The Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-8

DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Setting The Operator Four Digit Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2

673 of 918 50-01 E85 Service Manual

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

RIGHT CONSOLE SWITCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Rocker Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-3
Speed Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-3
Auxiliary Power Outlet Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-4

WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

MOTION ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2

FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

AUTO IDLE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-2

VEHICLE CONTROL UNIT (VCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

674 of 918 50-02 E85 Service Manual

RED
BLK 55W

LCD WORK LIGHTS

GAUGE RED
PANEL
BLK 55W
DMB ANTENNA
RED/BLK
1
7 55W
FUEL SENDER ADDITIONAL WORKING RED/GRN
LAMP SWITCH CAB FRONT
LINE OUT R+ 21
YEL/RED LIGHT RELAY LIGHT RELAY WORKING LIGHT
LINE OUT L+ 13
VCU 40 0 BLK
YEL YEL 2 WHT/YEL 87a
47 87a WHT/RED 3 I
LINE OUT GND 22 30
YEL 30 WHT/YEL II BLU/BLK 55W
WHT/RED RE
11 6 87 87 RED/GRN RED/GRN
ORG/BLU D 0 CAB REAR
BLU 41 5 WHT/YEL
4 18 USB_PWR 12 I 86
JACK HYD TEMP. SENSOR 85 86 LGN/RED 85 BLK BLK WORKING LIGHT
BLU/GRN LGN/RED LGN/RED 6 II
ASS'Y 2 19 USB_D+ 20
BLU/BRN PILOT BUZZER BLK 7 8 WHT/RED
3 27 USB_D- 28
BLU/WHT - +
1 26 USB_GND
BLK/YEL BLU HORN RELAY
V+ 9V 16 12
WHT/RED 87a
V- 23 11 ORG HORN
ROTATING BEACON (OPTION) 30
RED/GRN
L_RX 5 Video Sig 24 17 87 GRN/RED
LGN/BLK
L_TX 6 Sig Gnd 25 33 BLK
ORG BLK/YEL 86 85 BLK
L_TX/S 9 BEACON SWITCH
YEL YEL 4 BLU +
J_GND 10 8 UART_RXD
CAN-H
0 1 ROTATING
4
PNK PNK 2
BEACON HORN SW
BLK YEL/BLK YEL/BLK 5
120ohm
54 SIG AUTO IDLE SENSOR YEL/RED
12 2 UART_TXD 10 CAN-L I 3 RED/YEL (ON JOYSTICK L.H)
SHIELD BLK/BLU 8
3 UART_GND 9 - 7 BLK
6 SHIELD WHT/RED BLK
7 TxD
OVER LOAD WARNING
8 RxD 2
PRESSURE SENSOR (OWD)

BLU
+
BRN/WHT
WHT 50 SIG
52 EPPR (+) BRN/BLK -
2WAY 51
R.H CLOSE WHT/BLK
53 EPPR (-)
WHT/BLU BLU LGN/BLK LGN/BLK LGN/BLK +
63 EPPR (+) BLU HIGH SPEED
2WAY -
R.H OPEN WHT/BLK PRESS SWITCH

DIODE
64 EPPR (-)
WHT/GRN BUZZER HEATED SEAT (OPTION)
ROTATING/ 3 EPPR (+) BRN/BLU
25
BOOM SWING BLU
QUICK COUPLER C2
WHT/BLK (UNLOCK) RED/BLU BLK
L.H CCW 16 EPPR (-)
WHT/RED
ROTATING/ 14 EPPR (+)
SEAT HEATER
BOOM SWING
WHT/BLK 32
LGN/RED TRAVEL ALARM (OPT)
L.H CW 15 EPPR (-) QUICK COUPLER C1
BLU
(LOCK)
E/G OIL PRESS BLK/YEL
SWITCH, 1 bar BLK BLK/YEL
27 DOME LIGHT
LGN/BLU AND SWITCH
31
INDICATOR BLK BLK/WHT BLU/RED B E BLK
28 SPEED CONTROL DIAL
10W
BLK GRN/WHT GRN/RED GRN/RED 1
WATER SEPARATOR 30 +5V 55 CW LOW
SIG GRN 2
56
BLK/RED 3 FUEL PUMP SW FUEL PUMP
GND 57 HIGH WINDOW WASHER 0 WIPER SWITCH
2 ORG
- + PUR BLU/RED BLU/RED + - BLK
GRN/RED 3 CW 2WAY 12V POWER SOCKET
P
PUR 3 I
BLK/RED 3
0
2
P
BLU/WHT 2 + - BLK 7 8 WHT/RED I ORG
SIG 58 (ON JOYSTICK R.H)
BLK PUR II
BLU/BLK 5
ECU GND 59 0 BLU/RED BLU/RED
DIODE WASHER SWITCH 5
I ORG

BLU/RED
GRN/RED BLK/WHT 6 II
3 CW ROTATING / FUEL FEED PUMP
D-3 RED BLK/YEL 7 8 WHT/RED

WHT/GRN
GRN/WHT 2 BLK

WHT/YEL
RED/BLU
YEL/RED

YEL/RED
5V 1-24 1-15 SIG 60
BOOM SWING ACC + -

BLU/BLK
DPF D-1 BLU C BLK
CAN LO 1-63 GRN/BLK 5 (ON JOYSTICK L.H) P

ORG
DIFF. D-2 GND 61
GRN

BL
PRESS. CAN HIGH 2-12 R2

U
18 B
D-6 BLK DIAGNOSTIC
SENSOR
Dealer Copy -- Not for Resale

BLK/YEL
GRD 1-77 CONNECTOR 0.85
20 1 2 3 4 5 6 7 8
R1
D-5 RED/WHT 06 ORG/BLU 3 7 ORG 10A 20A 20A 20A 20A 10A 20A 15A
DPF 1-81 10 WHT
INLET internal 05 BR STARTER
BLK
TEMP. CAN-H 1-75 YEL BREAKER SW 15 SWITCH
02 (ON JOYSTICK R.H) TWO SPEED SW
SENSOR 120ohm 1-53 YEL/BLK FUSE BOX
03 YEL RED/BLU RED/BLU
CAN-L ORG 19

BRN
DPF D-4 BRN UB3 1-90 01 RED/WHT
1-80 BLK 42 16
MID internal D_GND 1-65 04 ORG
BLK BLK/YEL WIPER MOTOR
TEMP. 24
20A 15A 30A 30A 30A 10A I
YEL
SENSOR WIPER TIMER
BOOM SWING / SECOND 9 10 11 12 13 14
C-1 BLU/WHT AUXILIARY HYDRAULICS
INJECTORS 2-33 DPF SWITCH
C-2 SWITCH (IF EQUIPPED) S BLU/WHT 4 1 ORG STARTER RELAY
I
RED

RED/GRN
2-16 7 8 WHT/RED 1 BLU/YEL

WHT/RED

BLU
BLK

BLU/RED
4
C-3 2 M STOP 5 2 BRN 85 87 YEL
WHT 3 BLK/RED
2-47 BLU/WHT 3 ON
C-4 BLU DPF REGSW 21 - RUN B
1 2-17 YEL 2 BLU 4 6 3 BLK/WHT 86 30
DPF INHSW 22 5 BRN/RED WHT
C-5 YEL/GRN 1 OFF 6 BLK
2-31 C
C-6 ORG BLK 9 10 WHT/RED E
2 2-1 8 7 BLK
C-7 B
GRN 0.5BrR
2-32 BLK
3 C-8 BRN BRN/RED 5B
2-2 34 0.5LR
GRN/WHT PILOT CUT OFF SW

AVX 5L
23 0.5BY
C-9 YEL LGN/YEL WHT/GRN
26 PILOT CUT OFF 0.5Br GLOW PLUG
HIGH C-10 YEL 87a GRN/WHT 2 1 86 30
0.5BG
PRESS. C-11 PNK
2-4
30 RED/GRN
S/V A
PUMP 2-5 RED/BLK RED/BLK 87 0.5RW
C-12 PNK 1 85 87

RED
BRN

BLK
43 85 86 RED/GRN STARTER BLK

WHT/RED
5V B1-1 LGN/YEL
RED PREHEAT RELAY FUSIBLE LINK 2 12V 2.3kW
EGR 1-45
CAN HIGH B1-2 YEL MAIN RELAY
PRESS. 1-85 DPF REGEN GRN/WHT
DIODE

5WR
SENSOR CAN LO B1-3 WHT S/V
1-39 BLU 45A FUSIBLE LINK 1
GRD B1-4 BLK
1-74 YEL/RED GRN
BLK
BLU/RED

RED/BLU RED
B1-5 PNK 27A
1-79 RED/BLK WHT/RED 22
AIR B1-6 BLK/WHT IGNSW CIRCUIT BREAKER
TEMP. 1-21 BLU/RED
1-88
SENSOR WHT WHT/RED A
BLK/YEL
1-35 COMPRESSOR RELAY RECEIVER DRIER B
B1-7 STARTSW
GRN 87a LOW PRESS HIGH PRESS BRN BRN/WHT BRN/WHT R
2-28 BRN/RED 30
WATER B1-8 BLU UB3 1-73 ORG/RED CUT OFF CUT OFF
TEMP. 2-29 BRN A/C CONTROL 87 BLK/WHT DIODE
STARTRLY1-28 BR
SENSOR BLK/GRN PANEL
AHRLY 1-70 86 85
BLU

BLU/WHT

DIODE
RED/GRN RED/GRN BLK
B2-5 RED VB 1-1
5V 1-23 REG/GRN BATTERY RELAY
B2-6 POWER 1-3 ACTUATOR A (RECYCLE) RED
INTAKE GRN
SIG 1-20 SUPPLY 1-5 REG.GRN YEL/GRN
THROTTLE B2-7 BRN OPEN P1 GRY/GRN 19 9
GRD 1-52 BLK AIR CONDTIONING UNIT
VALVE P-GND 1-2
B2-8 YEL EGR RELAY CLOSE P2 GRY/YEL 18
CAN HIGH 2-19 BLK M 6
B2-9 POWER 1-4 87a MASTER SWITCH
CAN LO
BLU/WHT THERMOSTAT COMPRESSOR
2-20 BLK 30 RED/GRN BLK 1 BLK
GROUND 1-6 ACTUATOR B (FACE) 2
ORG 87 YEL/RED 5
B1-11 RED/WHT OPEN P1 ORG/WHT 20 BLOWER RESISTOR
1-33 85 86

DIODE
EGR GAS internal BLU HOUR METER
BRN CLOSE P2 ORG/YEL 21
BLK 4
- +
- +

RED/WHT
TEMP. M 3
M RED/BLU 1 RED/WHT
SENSOR 12V 100AH
ACTUATOR C (FOOT) BLK 2 HOUR
RED 2Or 2Y BATTERY
B1-10 BLU ORG B2-1 FOOT P1 ORG/YEL 2 1 3 WHT
INTAKE 2-59 EGR BLU BLU BLK
internal BRN PNK B2-2 VALVE DEF. P2 ORG/WHT
MANIFOL

YEL
M

ORG
RED
1-54

WHT
D TEMP. BLU B2-3
SENSOR 1-76 86 30 86 30 86 30
BLK B2-4 ACTUATOR D (REAR) BLU
W B(BATT)
B3-1 RED STARTER SWITCH CONNECTION
RAIL 5V 2-7 BLU OPEN P1 GRN 7
26 IG
PRESS. 1-68 BLK BLOWER TML B
s B3-2 GRN
2-26 CLOSE P2 GRN/WHT 6 PST BR R1 R2 C ACC
SENSOR M RELAYS OFF
- B3-3 BLK/WHT
2-25 ON
WIRE COLOR LEGEND 85 87 87a 85 87 87a 85 87 87a START
+ B3-4 RED/WHT B+

BLU
2-8

BLU
CAM

BLU
POSITION s B3-5 BLU
2-37
WATER VALVE ASS'Y REG.
SENSOR B3-6 BLK/BLU
2-52 RED RED L
GRD
4 LGN/WHT BLU/BLK (HI)
CRANK + B3-7 PNK
SHIELD BLACK BLK WARM
14 3
2-39 COOL 6 LGN/BLK BLU/YEL (MID)
POSITION - B3-8 M 15 5
SENSOR
ORG
2-54 WHITE WHT 3 YEL/RED
2 8
BLU/WHT (LOW)
B3-9 BLK
2-38 1 YEL/WHT E
GRD BROWN BRN 2 BLK
16 ALTERNATOR (80A) BLK
B3-10 1
EXH
TEMP. internal
YEL
1-56 ORANGE ORG
BRN/WHT
SENSOR YEL
YELLOW LED

B3-11 BLU
PURPLE PUR WHT/RED 11
FUEL 2-11 ENGINE EMERGENCY RED/BLU
TEMP. GRD B3-12 BRN/WHT BRN/WHT
2-51
STOP SWITCH PINK PNK 13
SENSOR UB3 1
RED GRAY GRY
2-50
1-32
PNK 3
TAN TAN
Printable Version Click Here
LIGHT BLUE LBU
DARK BLUE DBU
E85 (S/N B34S11001 - B34S12286)
LIGHT GREEN
DARK GREEN
GRN
DGN
E85 (S/N B34T11001 - B34T12286)
675 of 918
(PRINTED AUGUST 20135)
Printed In U.S.A. V-1558 (0)
RED
BLK 55W

LCD WORK LIGHTS

GAUGE RED
PANEL
BLK 55W
DMB ANTENNA
RED/BLK
1
7 55W
FUEL SENDER ADDITIONAL WORKING RED/GRN
LAMP SWITCH CAB FRONT
LINE OUT R+ 21
YEL/RED LIGHT RELAY LIGHT RELAY WORKING LIGHT
LINE OUT L+ 13
VCU 40 0 BLK
YEL YEL 2 WHT/YEL 87a
47 87a WHT/RED 3 I
LINE OUT GND 22 30
YEL 30 II BLU/BLK 55W
WHT/RED WHT/YEL
11 6 87 87 RED/GRN RED/GRN
ORG/BLU RED 0 CAB REAR
BLU/RED 41 5 WHT/YEL
4 18 USB_PWR 12 I 86
JACK HYD TEMP. SENSOR 85 86 LGN/RED 85 BLK BLK WORKING LIGHT
BLU/GRN LGN/RED LGN/RED 6 II
ASS'Y 2 19 USB_D+ 20
BLU/BRN PILOT BUZZER BLK 7 8 WHT/RED
3 27 USB_D- 28
BLU/WHT - +
1 26 USB_GND
BLK/YEL BLU HORN RELAY
V+ 9V 16 12
WHT/RED 87a
V- 23 11 ORG HORN
ROTATING BEACON (OPTION) 30
RED/GRN
L_RX 5 Video Sig 24 17 87 GRN/RED
LGN/BLK
L_TX 6 Sig Gnd 25 33 BLK
BLU ORG BLK/YEL 86 85 BLK
L_TX/S 9 36
BEACON SWITCH
YEL YEL 4 BLU +
J_GND 10 8 UART_RXD
CAN-H
0 1 ROTATING
4
PNK PNK 2
BEACON HORN SW
BLK YEL/BLK YEL/BLK 5
120ohm
54 SIG AUTO IDLE SENSOR YEL/RED
12 2 UART_TXD 10 CAN-L I 3 RED/YEL (ON JOYSTICK L.H)
SHIELD BLK/BLU 8
3 UART_GND 9 - 7 BLK
6 SHIELD WHT/RED BLK
7 TxD
OVER LOAD WARNING
8 RxD 2
PRESSURE SENSOR (OWD)

BLU
+
BRN/WHT
WHT 50 SIG
52 EPPR (+) BRN/BLK -
2WAY 51
R.H CLOSE WHT/BLK
53 EPPR (-)
WHT/BLU BLU LGN/BLK LGN/BLK LGN/BLK +
63 EPPR (+) BLU HIGH SPEED
2WAY -
R.H OPEN WHT/BLK PRESS SWITCH

BLU/RED
GRN/RED BLK/WHT 6 II
3 CW ROTATING / FUEL FEED PUMP
D-3 RED BLK/YEL 7 8 WHT/RED

WHT/GRN
GRN/WHT 2 BLK

WHT/YEL
RED/BLU
YEL/RED

YEL/RED
DPF 5V 1-24 1-15 SIG 60
BOOM SWING ACC + -

BLU/BLK
DIFF. D-1 BLU C BLK
CAN LO 1-63 GRN/BLK 5 (ON JOYSTICK L.H) P

ORG
GND 61

BLU
PRESS. D-2 GRN
TEMP. CAN HIGH 2-12 B R2
D-6 DIAGNOSTIC 18
SENSOR BLK

BLK/YEL
GRD 1-77 CONNECTOR 0.85
20 1 2 3 4 5 6 7 8
R1
D-5 06 ORG/BLU ORG
DPF
INLET
TEMP.
SENSOR
internal
RED/WHT
BLK
1-81
CAN-H
120ohm
1-75 YEL
05
02
10
3

BREAKER SW
(ON JOYSTICK R.H)
7

TWO SPEED SW
10A 20A 20A 20A 20A 10A 20A 15A

FUSE BOX
15 Dealer Copy -- Not for Resale
WHT
BR STARTER
SWITCH
1-53 YEL/BLK RED/BLU RED/BLU
03 YEL
CAN-L ORG 19

RED/GRN
2-16 7 8 WHT/RED 1 BLU/YEL

WHT/RED

BLU
BLK

BLU/RED
4
C-3 2 M STOP 5 2 BRN 85 87 YEL
WHT 3 BLK/RED
2-47 BLU/WHT 3 ON
C-4 BLU DPF REGSW 21 - RUN B
1 2-17 YEL 2 BLU 4 6 3 BLK/WHT 86 30
DPF INHSW 22 5 BRN/RED WHT
C-5 YEL/GRN 1 OFF 6 BLK
2-31 C
C-6 ORG BLK 9 10 WHT/RED E
2 2-1 8 7 BLK
C-7 B
GRN BRN/RED
2-32 BRN/RED BLK
C-8 BRN 34 5B
3 GRN/WHT PILOT CUT OFF SW BLU/RED
2-2 23

AVX 5L
87a WHT/GRN BLK/YEL
C-9 YEL PILOT CUT OFF
30 LGN/YEL GRN/WHT 1 BRN GLOW PLUG
2
HIGH C-10 YEL 87 S/V 86 30
BLK/GRN
PRESS. C-11 PNK
2-4 A

RED
PUMP 2-5 LGN/YEL 85 86 RED/GRN RED/WHT
C-12 PNK 26 85 87

BLK
LGN/YEL STARTER BLK
MAIN RELAY

WHT/RED
5V B1-1 RED PREHEAT RELAY FUSIBLE LINK 2
1-45 87a 12V 2.3kW
EGR CAN HIGH B1-2
DPF REGEN GRN/WHT
YEL 30 RED/GRN S/V
PRESS. 1-85 WHT/RED
B1-3 RED/BLK RED/BLK 87
SENSOR CAN LO WHT 1 BLU FUSIBLE LINK 1
1-39 45A
GRD B1-4 BLK BRN
1-74 43 85 86 RED/GRN BLK YEL/RED GRN

RED/BLU RED
B1-5 PNK DIODE
1-79 BLU/RED RED/BLK MAIN RELAY WHT/RED 22 27A
AIR B1-6 BLK/WHT IGNSW CIRCUIT BREAKER
TEMP. 1-21 BLU/RED
1-88
SENSOR WHT WHT/RED B A
BLK/YEL
1-35 COMPRESSOR RELAY RECEIVER DRIER
B1-7 STARTSW
GRN 87a LOW PRESS HIGH PRESS BRN BRN/WHT BRN/WHT R
2-28 BRN/RED 30
WATER B1-8 BLU UB3 1-73 ORG/RED CUT OFF CUT OFF
TEMP. 2-29 BRN A/C CONTROL 87 BLK/WHT DIODE
STARTRLY1-28 BR
SENSOR BLK/GRN PANEL

RED
AHRLY 1-70 86 85
BLU

DIODE
RED/GRN RED/GRN BLK
B2-5 RED VB 1-1

BLU/WHT
5V 1-23 REG/GRN BATTERY RELAY
B2-6 POWER 1-3 ACTUATOR A (RECYCLE)
INTAKE GRN
SIG 1-20 SUPPLY 1-5 REG.GRN YEL/GRN
THROTTLE B2-7 BRN OPEN P1 GRY/GRN 19 9
GRD 1-52 BLK AIR CONDTIONING UNIT
VALVE P-GND 1-2
B2-8 YEL EGR RELAY CLOSE P2 GRY/YEL 18
CAN HIGH 2-19 BLK M 6 MASTER SWITCH
B2-9 POWER 1-4 87a
CAN LO
BLU/WHT THERMOSTAT COMPRESSOR
2-20 BLK 30 RED/GRN 1 2
GROUND 1-6 ACTUATOR B (FACE)
ORG 87 YEL/RED 5 RED/WHT
B1-11 RED/WHT OPEN P1 ORG/WHT 20 BLOWER RESISTOR RED
1-33 85 86

DIODE
EGR GAS BLU HOUR METER

RED
internal BRN CLOSE P2 ORG/YEL 21
BLK 4 BLK
- +

RED/WHT
TEMP. M 3
M RED/BLU 1 RED/WHT
SENSOR
ACTUATOR C (FOOT) BLK 2 HOUR
RED 2Or 2Y
B1-10 BLU/YEL ORG B2-1 FOOT P1 ORG/YEL 2 1 3 WHT WHT - +
INTAKE 2-59 EGR BLU BLU BLK
internal BRN PNK B2-2 VALVE DEF. P2 ORG/WHT 12V 100AH
MANIFOLD

YEL
M

ORG
RED
1-54

WHT
TEMP. BLU B2-3 BATTERY
SENSOR 1-76 86 30 86 30 86 30
BLK B2-4 ACTUATOR D (REAR) BLU
W B(BATT)
B3-1 RED STARTER SWITCH CONNECTION
RAIL 5V 2-7 BLU OPEN P1 GRN 7
26 IG
PRESS. 1-68 BLK BLOWER TML B
s B3-2 GRN
2-26 CLOSE P2 GRN/WHT 6 PST BR R1 R2 C ACC
SENSOR M RELAYS OFF
- B3-3 BLK/WHT
2-25 ON
WIRE COLOR LEGEND 85 87 87a 85 87 87a 85 87 87a START
+ B3-4 RED/WHT B+

BLU
2-8

BLU
CAM

B3-11 BLU
PURPLE PUR WHT/RED 11
FUEL 2-11 ENGINE EMERGENCY RED/BLU
TEMP. GRD B3-12 BRN/WHT BRN/WHT
2-51
STOP SWITCH PINK PNK 13
SENSOR UB3 1
GRAY GRY
2-50
1-32
RED
PNK 3
TAN TAN
Printable Version Click Here
LIGHT BLUE
DARK BLUE
LBU
DBU
E85 (S/N B34S12287 AND ABOVE)
LIGHT GREEN GRN E85 (S/N B34T12287 AND ABOVE)
DARK GREEN DGN

676 of 918 (PRINTED AUGUST 2015)

Printed In U.S.A. V-1558(A)
ELECTRICAL SYSTEM INFORMATION

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting the most common AVOID INJURY OR DEATH
problems. Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807

PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

677 of 918 50-10-1 E85 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Location / Identification

Description A decal is on the cover to show location and amp ratings.

Figure 50-10-1 Remove the cover to check or replace the fuses.

Figure 50-10-2

1 2 3 4 5 6 7 8

1
9 10 11 12 13 14

P111119A

B-23955
The excavator has a 12 volt, negative ground electrical
system. The electrical system is protected by fuses

Dealer Copy -- Not for Resale

located below the left rear side of the operator’s seat The fuse location and sizes are shown [Figure 50-10-2]
(Item 1) [Figure 50-10-1]. The fuses will protect the and in the below chart.
electrical system when there is an electrical overload.
The reason for the overload must be found before AM
starting the engine again. REF DESCRIPTION
P
1 Beacon / Strobe Light (Optional) 10
The battery cables must be clean and tight. Check the
2 Horn, Wiper, Washer 20
electrolyte level in the battery. Add distilled water as
needed. Remove acid or corrosion from the battery and 3 Heated Seat (Optional), HVAC Panel 20
cables with a sodium bicarbonate and water solution. 4 Stereo 20
5 12 Power Port, HVAC Unit 20
Put Battery Saver P/N 6664458 or grease on the battery 6 Pilot Cutoff 10
terminals and cable ends to prevent corrosion. 7 Work Lights 20
8 Cab Lights 15
9 Interior Lights, Fuel Pump 20
10 Start Switch 15

WARNING 11
12
Instrument Panel, VCU, ECU
A/C Compressor
30
30
13 Spare Fuse 30
AVOID INJURY OR DEATH 14 Spare Fuse 10
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

678 of 918 50-10-2 E85 Service Manual

ELECTRICAL SYSTEM (CONT’D)

Fuse And Relay Location / Identification (Cont’d) REF DESCRIPTION

1 Horn
Figure 50-10-3
2 Blower (1) (Lo)
3 Blower (2) (Med)
4 Blower (3) (High)
12 5 Compressor
6 Additional Lights (Cab Work Lights)
7 Lights
11
1 8 EGR
9 Main Controller
10 Controller
11 Preheat
2 12 Starter

3 NOTE: Relays (Item 11 and 12) [Figure 50-10-3] are

located under the center cover.
P123130

A 60 amp circuit breaker (Item 1) and two fusible links Master Disconnect Switch
(Item 2) 27 amp and (Item 3) 45 amp [Figure 50-10-3]

Dealer Copy -- Not for Resale

are located under the front center cover. Figure 50-10-5

The 27 amp fusible link (Item 2) is for the start circuit and
the 45 amp fusible link (Item 3) [Figure 50-10-3] is for the
preheat circuit.

Figure 50-10-4
1

3 4 5 6
10 2 7
1 8
9

P123130

The excavator has a master disconnect switch (Item 1)

[Figure 50-10-5] located under the center cover. The
switch will disconnect the positive circuit between the
P111109 battery and the electric / electronic devices.

The relays are shown in [Figure 50-10-4] and in the

below chart. The relays are located behind the access
panel that is located behind the operator’s seat.

679 of 918 50-10-3 E85 Service Manual

Dealer Copy -- Not for Resale

680 of 918 50-10-4 E85 Service Manual

BATTERY Figure 50-20-2

Battery Maintenance

Open the center cover. (See Opening And Closing on

Page 10-70-1.)

Figure 50-20-1

1
P9589 P9590

The battery cables must be clean and tight [Figure 50-

20-2]. Remove acid or corrosion from the battery and
cables using a sodium bicarbonate and water solution.
Cover the battery terminals and cable ends with battery
P123130 saver grease to prevent corrosion.

Dealer Copy -- Not for Resale

Check for broken or loose connections.
The battery (Item 1) [Figure 50-20-1] is located under
the center cover. If the battery cables are removed for any reason,
disconnect the negative (-) cable first. When installing the
battery cables, make the last connection the negative (-)
cable to the battery.

IMPORTANT The original equipment battery is maintenance free. If a

replacement battery is installed, check the electrolyte
AVOID ELECTRICAL COMPONENT DAMAGE level in the battery.
Disconnecting the battery while the engine is
running can cause damage to electrical components. If the electrolyte level is lower than 13 mm (0.50 in) above
Disconnect battery only when the engine is turned the plates, add distilled water only.
OFF.
I-2374-0513

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

681 of 918 50-20-1 E85 Service Manual

BATTERY (CONT’D)

Using A Booster Battery (Jump Starting)

IMPORTANT
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the Damage to the alternator can occur if:
operator's seat and one person to connect and • Engine is operated with battery cables
disconnect the battery cables. disconnected.
• Battery cables are connected when using a fast
Be sure the key switch is OFF. The booster battery must
be 12 volt. charger or when welding on the excavator.
(Remove both cables from the battery.)
Open the center cover. (See Opening And Closing on • Extra battery cables (booster cables) are
Page 10-70-1.) connected wrong.
I-2223-0903
Figure 50-20-3

1 WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
2 rubber gloves to keep acid off body.

Dealer Copy -- Not for Resale

In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
P123131
minutes.

If electrolyte is taken internally drink large quantities

Connect one end of the first cable to the positive (+) of water or milk! DO NOT induce vomiting. Get
terminal of the booster battery. Connect the other end of prompt medical attention.
the same cable to the positive (+) terminal (Item 1) W-2065-0807
[Figure 50-20-3] of the excavator battery.

Connect one end of the second cable to the negative (-)

terminal of the booster battery. Connect the other end of
the same cable to a frame ground (Item 2) [Figure 50-20-
3] (not at the battery negative (-) post).

Start the engine. After the engine has started, remove

the ground (-) cable first (Item 2) [Figure 50-20-3].

Remove the positive (+) cable (Item 1) [Figure 50-20-3]

and the other cables.

NOTE: (See Cold Temperature Starting in the

Operation And Maintenance Manual.)

682 of 918 50-20-2 E85 Service Manual

BATTERY (CONT’D) Always clean the terminals and the cable ends, even
when installing a new battery.
Removing And Installing Battery
Install the battery. Install the hold down clamp, washers
Open the center cover. (See Opening And Closing on and tighten the nuts.
Page 10-70-1.)
Connect the battery cables. Connect the negative (-)
Figure 50-20-4 cable (Item 1) [Figure 50-20-5] last to prevent sparks.

Rotate the master disconnect switch (Item 1) [Figure 50-

20-4] clockwise to the ON position.

Close the center cover. (See Opening And Closing on

Page 10-70-1.)
1

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
P123130
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

Dealer Copy -- Not for Resale

Rotate the master disconnect switch (Item 1) [Figure 50- In case of acid contact, wash immediately with water.
20-4] counterclockwise to the OFF position. In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
Figure 50-20-5 minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
1 prompt medical attention.
3 2 W-2065-0807

3
P123132

Disconnect the negative (-) cable (Item 1) [Figure 50-20-

5] first.

Disconnect the positive (+) cable (Item 2) [Figure 50-20-

5].

Remove the two nuts and washers (Item 3) and remove

the hold down clamp (Item 4) [Figure 50-20-5].

Remove the battery.

683 of 918 50-20-3 E85 Service Manual

Dealer Copy -- Not for Resale

684 of 918 50-20-4 E85 Service Manual

ALTERNATOR Belt Replacement

Belt Adjustment Figure 50-30-3

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-80-1.) 2

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

Page 10-50-1.)

NOTE: The following photos show the engine

removed for photo clarity.

Figure 50-30-1

1
2

P-97915

Loosen the alternator mounting nut (item 1) and the

adjusting strap mounting bolt (Item 2) [Figure 50-30-3].

Remove the old belt and install a new belt.

Dealer Copy -- Not for Resale

1 When belt tension is correct, tighten the alternator
adjusting strap mounting bolt (Item 2) and the nut (item 1)
[Figure 50-30-3].
P97915

Loosen the alternator mounting nut (item 1) and the

adjusting strap mounting bolt (Item 2) [Figure 50-30-1].
WARNING
Figure 50-30-2 AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
screens, shields or rubber deflectors.
• Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
W-2528-0406

P-97916

Press down on the belt midway between the fan pulley

and the alternator pulley. The correct tension should
allow the belt to deflect 10 mm (0.375 in) [Figure 50-30-
2].

When belt tension is correct, tighten the alternator bolts.

685 of 918 50-30-1 E85 Service Manual

ALTERNATOR (CONT’D) Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
Charging System Inspection corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive

WARNING terminal.

BATTERY GAS CAN EXPLODE AND CAUSE

SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
WARNING
make final connection (negative) at machine frame. AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
Do not jump start or charge a frozen or damaged contact. Wear goggles, protective clothing and
battery. Warm battery to 16°C (60°F) before rubber gloves to keep acid off body.
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never In case of acid contact, wash immediately with water.
lean over battery while boosting, testing or charging. In case of eye contact get prompt medical attention
W-2066-0910
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

Dealer Copy -- Not for Resale

of water or milk! DO NOT induce vomiting. Get
IMPORTANT prompt medical attention.
W-2065-0807

Damage to the alternator can occur if:

• Engine is operated with battery cables Figure 50-30-4
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2223-0903 1

If the charging system malfunctions, check the following:

Check the condition and tension of the alternator belt. If

the belt is worn or deteriorated, replace the belt. (See
Belt Replacement on Page 50-30-1.)

Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.

Check the electrolyte level in the battery. Add distilled

water as needed. (Does not apply to maintenance free
batteries.) P-97914

Verify the charge of the battery. Make sure battery is fully

charged. With the key in the run position and the engine off, the
icon (Item 1) [Figure 50-30-4] must be illuminated.

686 of 918 50-30-2 E85 Service Manual

ALTERNATOR (CONT’D) Figure 50-30-7

Charging System Inspection (Cont’d)

Figure 50-30-5

1 1

P112524

Start the engine. At low idle, the icon must be off. If the
P112070 icon is on, inspect the alternator belt (Item 1) [Figure 50-
30-7] for correct tension.

If the icon does not illuminate, disconnect the harness Figure 50-30-8
(Item 1) [Figure 50-30-5] from the alternator.

Dealer Copy -- Not for Resale

Figure 50-30-6 1

1
P111022

P112526 Increase engine speed to approximately 1500 rpm. Turn

the boom work light (Item 1) [Figure 50-30-8] to the on
position.
Ground the terminal (Item 1) [Figure 50-30-6].

If the icon still does not illuminate, replace the indicator.

If the icon is illuminated, inspect the rotor assembly and

brushes for wear or damage.

687 of 918 50-30-3 E85 Service Manual

ALTERNATOR (CONT’D) Alternator Voltage Testing

Charging System Inspection (Cont’d) Figure 50-30-10

Figure 50-30-9

2 1
P123132

P123132
Run the engine at rated speed. Check to make sure that
all accessories are turned OFF. Connect the positive lead
If the icon is illuminated, measure the voltage at the of the voltmeter to the positive terminal (Item 1) of the
battery (Item 1) [Figure 50-30-9]. battery. Connect the negative lead of the volt meter to the

Dealer Copy -- Not for Resale

negative terminal (Item 2) [Figure 50-30-10]. If the
Battery voltage should be between 13 and 15 volts. reading on the voltmeter is less than 13 volts or more
than 15.5 volts, replace the alternator.
If the voltage is less than 13 volts or over 15.5 volts,
replace the alternator.

688 of 918 50-30-4 E85 Service Manual

ALTERNATOR (CONT’D) Figure 50-30-13

Removal And Installation

Open the right side cover. (See Opening And Closing on 1

Page 10-50-1.) 2

Figure 50-30-11 3

2
P112530
3

Disconnect the wire harness (Item 1). Remove the nut

and washer. Remove the wire (Item 2) [Figure 50-30-13].

Remove the bolt (Item 3) [Figure 50-30-13] and remove

P112525 the ground wire from the alternator case.

Dealer Copy -- Not for Resale

Figure 50-30-14
Remove the bolt (Item 1) and stand off (Item 2) [Figure
50-30-11]. Reposition the heater hoses as needed.

Remove the bolt (Item 3) [Figure 50-30-11]. 1

Figure 50-30-12

3 2

1
P-97915

Loosen the top bolt (Item 1), bottom bolt (Item 2) [Figure
50-30-14] and nut.

P112527 Remove the belt (Item 3) [Figure 50-30-14].

NOTE: Engine is shown removed for photo clarity.

Loosen the bolt (Item 1) and rotate the bracket (Item 2)
[Figure 50-30-12] towards the rear of the engine.

689 of 918 50-30-5 E85 Service Manual

ALTERNATOR (CONT’D) Figure 50-30-17

Removal And Installation (Cont’d)

Figure 50-30-15

P112531

Remove the bottom bolt (Item 1) [Figure 50-30-17], nut,

P112528 washer and spacer.

Remove the alternator from the machine.

Remove the bolt (Item 1) [Figure 50-30-15] from the
alternator.

Dealer Copy -- Not for Resale

Figure 50-30-16

P112529

Remove the bolt (Item 1) [Figure 50-30-16] from the

alternator bracket. Remove the bracket.

690 of 918 50-30-6 E85 Service Manual

STARTER Figure 50-40-2

Testing

Figure 50-40-1 Bat

S
M

Bat
S
M Cranking
Motor

Cranking
Motor
A-1991

Connect a jumper wire (of at least 4 gauge in size)

A-1992 between the M terminal and the BAT terminal [Figure 50-
40-2].

The key switch must be in the OFF position. If the starter turns, the defect is in the solenoid.

Dealer Copy -- Not for Resale

The battery must be at full charge. If the starter does not turn, the starter is defective.

The cable connections on the battery must be clean and

tight.

Connect a jumper wire between S terminal and BAT

terminal [Figure 50-40-1].

If the starter turns but does not turn the engine, the
starter drive has a defect.

691 of 918 50-40-1 E85 Service Manual

STARTER (CONT'D) Figure 50-40-5

Removal And Installation

2
Open the right side cover.
1
Disconnect the negative cable from the battery. (See 1
Removing And Installing Battery on Page 50-20-3.)

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

Figure 50-40-3

P112532

Remove the bolts (Item 1) and cover (Item 2) [Figure 50-

40-5].

Figure 50-40-6
1

Dealer Copy -- Not for Resale

P112534 1

Figure 50-40-4

2 1
1 4

P112536

Disconnect the wire harness (Item 1) [Figure 50-40-6]

from the starter.

P112533

Loosen the air intake hose clamps (Item 1) [Figure 50-

40-3] and [Figure 50-40-4]

Remove the bolts (Item 2). Remove the elbow (Item 3)

and hose (Item 4) [Figure 50-40-4].

692 of 918 50-40-2 E85 Service Manual

STARTER (CONT'D)

Removal And Installation (Cont’d)

Figure 50-40-7

P112535

Remove the bolts (Item 1) [Figure 50-40-7] and remove

the starter.

Dealer Copy -- Not for Resale

693 of 918 50-40-3 E85 Service Manual

STARTER (CONT'D)

Parts Identification

1. Rubber cover
2. Solenoid
3. Shims
4. Plunger
5. Torsion Spring 1
6. Shift Lever 2
7. Gear Housing
8. Bolt 3
9. Retaining Ring
10. Pinion Stop 5
11. Spring 6
12. Clutch Assembly
13. Bearing Retainer
14. Pinion Shaft 7
15. Rear Cover 4
16. O-ring
17. Brush Holder
18. Field Coil Assembly 10
19. Armature Assembly 11
12

Dealer Copy -- Not for Resale

13
8
18 9
14 18
15 18

E80025S

694 of 918 50-40-4 E85 Service Manual

STARTER RELAY Figure 50-41-3

Removal And Installation

Open the center cover.

Figure 50-41-1
1 2

1
2
1
P1125113

Remove the nuts (Item 1). Remove the wires (Item 2)

[Figure 50-41-3] from the relay.

P123130 Figure 50-41-4

Dealer Copy -- Not for Resale

The starter relay (Item 1) [Figure 50-41-1] is located
below the ECU, beside the battery.
2 2
Figure 50-41-2

1 P112514

1 Disconnect the wire harness (Item 1). Remove the bolts

(Item 2) [Figure 50-41-4] and remove the relay.

P112512

Pull the ends of the wire harness (Item 1) [Figure 50-41-

2] back.

695 of 918 50-41-1 E85 Service Manual

STARTER RELAY (CONT'D

Removal And Installation (Cont'd)

Figure 50-41-5

P112516

Mark and remove the wire harness (Item 1) [Figure 50-

41-5] from the relay.

Dealer Copy -- Not for Resale

696 of 918 50-41-2 E85 Service Manual

LIGHTS Boom Light Bulb Replacement

Boom Light Removal And Installation Figure 50-50-3

Figure 50-50-1

2
1
1

P111470

P111468
Remove the screws (Item 1) and bezel (Item 2). Pull the
lens (Item 3) [Figure 50-50-3] out of the housing.
Disconnect the wire harness (Item 1) [Figure 50-50-1].
Figure 50-50-4

Dealer Copy -- Not for Resale

Figure 50-50-2

1
1

P111471
P111469

Squeeze the retainer (Item 1) [Figure 50-50-4] together

Remove the nut (Item 1) and washers. Remove the light and remove the bulb from the lens.
(Item 2) [Figure 50-50-2] from the boom.

697 of 918 50-50-1 E85 Service Manual

LIGHTS (CONT’D)

Boom Light Bulb Replacement (Cont’d)

Figure 50-50-5

P111472

Disconnect the wire harness (Item 1) [Figure 50-50-5]

and remove the harness / bulb assembly.

Dealer Copy -- Not for Resale

NOTE: Do not touch the glass of the halogen bulb
with your fingers or allow the bulb to come in
contact with oils. If contaminated, the bulb
must be cleaned with mild alcohol and a clean
cloth [Figure 50-50-5].

698 of 918 50-50-2 E85 Service Manual

CONSOLE LOCKOUT SWITCH Figure 50-60-3

Testing / Adjustment

Remove the upper left console cover. (See Upper

Console Cover Removal And Installation on Page 40-60-
2.)

Figure 50-60-1

P-86775
1

There must be continuity when the console is in the down

and locked position [Figure 50-60-3].

Figure 50-60-4

P-86773

Dealer Copy -- Not for Resale

Disconnect the wire harness (Item 1) [Figure 50-60-1].
2
Connect a multimeter to the switch wire harness.

Figure 50-60-2
1

P-86776

Loosen the nut (Item 1) and turn the stop (Item 2)

[Figure 50-60-4] out to raise the stop, or in to lower the
stop.

Tighten the nut (Item 1) [Figure 50-60-4] after adjusting

the stop height.
P-86654

There must be no continuity when the console is in the

raised position [Figure 50-60-2].

699 of 918 50-60-1 E85 Service Manual

CONSOLE LOCKOUT SWITCH (CONT’D)

Removal And Installation

Remove the upper console cover. (See Upper Console

Cover Removal And Installation on Page 40-60-2.)

Remove the lower console cover. (See Lower Console

Cover Removal And Installation on Page 40-60-1.)

Figure 50-60-5

Dealer Copy -- Not for Resale

P-86773

Disconnect the wire harness (Item 1) [Figure 50-60-5].

Figure 50-60-6

P-86777

Loosen the nut (Item 1) [Figure 50-60-6] and remove the

switch.

700 of 918 50-60-2 E85 Service Manual

FUEL LEVEL SENDER Figure 50-70-3

Removal And Installation

1
Disconnect the negative battery cable. (See Removing
And Installing Battery on Page 50-20-3.)

Remove the rear cover. (See Removal And Installation on

Page 40-190-1.)

Figure 50-70-1

P-89565

Remove the sender (Item 1) [Figure 50-70-3].

Figure 50-70-4

Dealer Copy -- Not for Resale

P-89563
1

Disconnect the harness (Item 1) [Figure 50-70-1].

Figure 50-70-2

1
P-89570

Installation: Install the sender with the arrow (Item 1)

[Figure 50-70-4] pointing up.

1
1

P-89564

Remove the screws (Item 1) [Figure 50-70-2].

701 of 918 50-70-1 E85 Service Manual

Dealer Copy -- Not for Resale

702 of 918 50-70-2 E85 Service Manual

DIAGNOSTIC SERVICE CODES The error codes will be displayed on the instrument panel
(Item 1) [Figure 50-80-1] under the “Real Time Failure
Service Codes List Information” screen.

Figure 50-80-1 Enter the display panel REAL TIME FAILURE

INFORMATION screen.

1 See the following chart for the codes.

Use the following procedure to access the Real Time

Failure Codes.

Figure 50-80-2 1

2
P120809

1 Scroll down through the menu to Real Time Failure info

(Item 1) and press 7 (Item 2) [Figure 50-80-4]. The

Dealer Copy -- Not for Resale

P117654
codes will be displayed

With the engine OFF and the key switch in the ON

position, press 3 (Item 1) [Figure 50-80-2].

Figure 50-80-3

1 3

P117655

Use 2 or 6 (Item 1) to select vehicle state (Item 2). Press

7 (Item 3) [Figure 50-80-3].

710 of 918 50-80-8 E85 Service Manual

DIAGNOSTIC SERVICE CODES (CONT’D)

Code Retrieval Through The Dash (Cont’d)

Failure Information

Use the following procedure to access the Failure

Information (stored codes).

Figure 50-80-5

Dealer Copy -- Not for Resale

P117609

With the engine OFF and the key switch in the ON

position, press and hold 3 (Item 1) for five seconds
[Figure 50-80-5].

Figure 50-80-6

P117613

The main menu will open. Scroll down to Failure

Information (Item 1) and press 7 (Item 2) [Figure 50-80-
6] The codes will be displayed.

711 of 918 50-80-9 E85 Service Manual

Dealer Copy -- Not for Resale

712 of 918 50-80-10 E85 Service Manual

DIAGNOSTIC TOOL Figure 50-90-3

Installation

Figure 50-90-1

1 1
1

P120823

Connect the diagnostic cable (Item 1) [Figure 50-90-3] to

P-95320 the CAN checker connector.

Figure 50-90-4
Tilt the seat back forward and remove the four screws
(Item 1). Remove the cover (Item 2) [Figure 50-90-1].

Dealer Copy -- Not for Resale

Figure 50-90-2

1
P120824

Connect the opposite end of the cable to the diagnosis

P120822 interface box [Figure 50-90-4].

Locate the CAN checker connector (Item 1) [Figure 50-

90-2].

713 of 918 50-90-1 E85 Service Manual

DIAGNOSTIC TOOL (CONT'D) Figure 50-90-7

Installation (Cont’d)

Figure 50-90-5

1
1

P120826

When connected correctly the lights (Item 1) [Figure 50-

P120825 90-7] on the interface box will be illuminated.

Follow the instructions provided on the

Connect the USB cable (Item 1) [Figure 50-90-5] to the www.BobcatDealerNet.com (for dealers in Europe, go to
diagnosis interface box. Connect the opposite end of the dealers.bobcat.eu) to download, register and use Yanmar

Dealer Copy -- Not for Resale

cable to the Service PC. SA-D (SmartAssist-Direct) Software.

Turn the Service PC on.

Figure 50-90-6

P120827

With the engine off, turn the key (Item 1) [Figure 50-90-
6] to the run position.

714 of 918 50-90-2 E85 Service Manual

INSTRUMENT PANEL Figure 50-100-3

Removal And Installation

Figure 50-100-1

1
1

P112128
1
Disconnect the two wire harness connectors (Item 1)
P112126 [Figure 50-100-3].

Figure 50-100-4
Pull out and remove the hourmeter (Item 1) [Figure 50-
100-1].

Dealer Copy -- Not for Resale

2
Figure 50-100-2
1

1
1

1
P112129

Remove the four screws (Item 1) and bracket (Item 2)

P112127 [Figure 50-100-4].

Remove the four screws (Item 1) [Figure 50-100-2].

715 of 918 50-100-1 E85 Service Manual

INSTRUMENT PANEL (CONT’D)

Setting The Operator Four Digit Password

Figure 50-100-5 Figure 50-100-7

1 3

P117654 P117656

With the engine OFF and the key in the ON position, Press 6 (Item 1) and select password setting (Item 2).
press 3 (Item 1) [Figure 50-100-5]. Press 7 (Item 3) [Figure 50-100-7].

Dealer Copy -- Not for Resale

Figure 50-100-6 Figure 50-100-8

3 1
1
P117655 P117657

Press 6 (Item 1) and select the GP Configuration (Item Press 0 (Item 1) [Figure 50-100-8] four times.
2). Press 7 (Item 3) [Figure 50-100-6].

716 of 918 50-100-2 E85 Service Manual

INSTRUMENT PANEL (CONT’D)

Setting The Operator Four Digit Password (Cont’d)

Figure 50-100-9 Figure 50-100-11

1 2

1 3

P117658 P117623

Press 6 or 2 (Item 1) and select password change (Item Enter the new password using the number pad (Item 1) a
2). Press 7 (Item 3) [Figure 50-100-9]. second time. Press 7 (Item 2) [Figure 50-100-11].

Dealer Copy -- Not for Resale

Figure 50-100-10 Figure 50-100-12

1 3

P117659 P117661

Enter the new password using the number pad (Item 1) Press 6 or 2 (Item 1) and select confirm (Item 2). Press 7
[Figure 50-100-10]. (Item 3) [Figure 50-100-12].

717 of 918 50-100-3 E85 Service Manual

INSTRUMENT PANEL (CONT’D)

Setting The Operator Four Digit Password (Cont’d)

Figure 50-100-13

1 3

P117663

Press 6 or 2 (Item 1) and select a time (Item 2) for

password use. Press 7 (Item 3) [Figure 50-100-13].

Dealer Copy -- Not for Resale

By selecting NOT USE, the password is disabled.

By selecting ALWAYS, the password must be entered

every time to start the engine.

By selecting 1 min or 5 min, the engine can be started

within one minute or five minutes of shutdown without
reentering the password.

Cycle the key switch and the new operator password is

installed.

718 of 918 50-100-4 E85 Service Manual

KEY SWITCH Figure 50-110-3

Removal And Installation

Remove the right console cover. (See Console Cover

Removal And Installation on Page 40-50-1.)

Figure 50-110-1

1
P-86680

Remove the switch assembly (Item 1) [Figure 50-110-3]

1 from the back of the console cover.

P-86678

Dealer Copy -- Not for Resale

Remove the nut (Item 1) [Figure 50-110-1].

Figure 50-110-2

P-86679

Remove the flat washer (Item 1) and wave washer (Item

2) [Figure 50-110-2].

719 of 918 50-110-1 E85 Service Manual

Dealer Copy -- Not for Resale

720 of 918 50-110-2 E85 Service Manual

RIGHT CONSOLE SWITCH COVER Figure 50-120-3

Removal And Installation

Remove the instrument panel (See Removal And

Installation on Page 50-100-1.) 2

Figure 50-120-1

1 1

P112178

1 Remove the screws (Item 1) and panel (Item 2) [Figure

50-120-3].

Figure 50-120-4
P112161

Dealer Copy -- Not for Resale

1
Remove the cover (Item 1) [Figure 50-120-1].

Figure 50-120-2
2
1

1
1 1
1 P112177

Remove the screws (Item 1) and plate (Item 2) [Figure

50-120-4].

P112179

Remove the screws (Item 1) [Figure 50-120-2].

721 of 918 50-120-1 E85 Service Manual

RIGHT CONSOLE SWITCH COVER (CONT’D) Figure 50-120-7

Removal And Installation (Cont’d)

Figure 50-120-5
1

2 P112159

Remove the cover (Item 1) [Figure 50-120-7].

P112180
Figure 50-120-8

Pull the panel (Item 1) away from the side of the cab.
Remove the bolt (Item 2) [Figure 50-120-5].

Dealer Copy -- Not for Resale

Figure 50-120-6 1

P112160

1
Remove the screw (Item 1) [Figure 50-120-8].

P112176 Tilt the cover towards the operator seat.

Remove the bolt (Item 1) [Figure 50-120-6].

722 of 918 50-120-2 E85 Service Manual

RIGHT CONSOLE SWITCH COVER (CONT’D) Speed Control Removal And Installation

Rocker Switch Removal And Installation Figure 50-120-11

NOTE: The removal of the two-speed switch is

shown, all rocker switch removal is the same.

Figure 50-120-9 1

P-87698

Disconnect the wire harness (Item 1) [Figure 50-120-

11].
P-87696
Figure 50-120-12

Dealer Copy -- Not for Resale

Disconnect the wire harness (Item 1) [Figure 50-120-9]
from the switch.

Figure 50-120-10

P-87699

Remove the two screws (Item 1) [Figure 50-120-12] and

the speed control.
P-87697

Depress the tabs on both sides of the switch and remove

the switch (Item 1) [Figure 50-120-10] from the cover.

723 of 918 50-120-3 E85 Service Manual

RIGHT CONSOLE SWITCH COVER (CONT’D) Figure 50-120-15

Auxiliary Power Outlet Removal And Installation

Figure 50-120-13 1

P-87704

Remove the collar (Item 1) and slide the housing (Item 2)

P-87702 [Figure 50-120-15] out of the cover.

Disconnect the wire harness (Item 1) [Figure 50-120-

13].

Dealer Copy -- Not for Resale

Figure 50-120-14

P-87703

Remove the nut (Item 1) [Figure 50-120-14].

724 of 918 50-120-4 E85 Service Manual

WIPER MOTOR Figure 50-130-3

Removal And Installation

2
Figure 50-130-1

1
P-87706

Remove the nut (Item 1) and remove the upper arm (Item
P-87705 2) [Figure 50-130-3].

Figure 50-130-4
Disconnect the washer hose (Item 1) [Figure 50-130-1]
inside the cab.

Dealer Copy -- Not for Resale

Figure 50-130-2
1

P-87708

Remove the wiper motor cover (Item 1) [Figure 50-130-

P-87707 4].

Tilt the cover (Item 1) [Figure 50-130-2] on the wiper arm

to the open position.

725 of 918 50-130-1 E85 Service Manual

WIPER MOTOR (CONT’D) Figure 50-130-7

Removal And Installation (Cont’d)

Figure 50-130-5

1
1

1
P-87711

Remove the top and bottom nut (Item 1) [Figure 50-130-

P-87709 7] and remove the wiper motor.

Disconnect the wire harness connectors (Item 1) [Figure

50-130-5].

Dealer Copy -- Not for Resale

Figure 50-130-6

P-87710

Remove the plastic nut (Item 1) and castle nut (Item 2)

[Figure 50-130-6].

726 of 918 50-130-2 E85 Service Manual

MOTION ALARM SYSTEM Move the travel control levers (one lever at a time) in the
forward direction. The motion alarm must sound. Move
Description
the travel control levers (one lever at a time) in the
reverse direction. The motion alarm must sound.
This excavator is equipped with a motion alarm system.
The motion alarm will sound when the operator moves
Return both levers to neutral and turn excavator key to
the travel control levers in the either the forward or
OFF position. Exit the excavator. (See Operation &
reverse direction. Slight movement of the steering levers
Maintenance Manual for the correct procedure.)
in either the forward or reverse direction is required with
hydraulic components before the motion alarm will
The motion alarm is located inside the lower part of the
sound.
engine compartment.
Inspecting
Figure 50-140-2
Figure 50-140-1

2
1
2
1

Dealer Copy -- Not for Resale

P111077

Inspect for damaged or missing motion alarm decal (Item

1) [Figure 50-140-1]. Replace if required.

NOTE: The excavator will need to be moved slightly P111078

in both the forward and reverse direction to
test the motion alarm. Keep all bystanders
away from machine during test. Inspect the motion alarm electrical connector (Item 1)
and wire harness (Item 2) [Figure 50-140-2] for damage.
Make sure there are no bystanders in the area. Repair or replace any damaged components.

If the motion alarm sensor requires adjustment, see the

following information.
WARNING
AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807

Sit in the operator’s seat. Perform the PRE-STARTING

PROCEDURE. (See PRE-STARTING PROCEDURE in
the Operation and Maintenance Manual). Start the
engine.

727 of 918 50-140-1 E85 Service Manual

MOTION ALARM SYSTEM (CONT’D)

Adjusting Switch Position

Stop the engine. Raise the operator cab. (See Service

Manual for correct procedure.)
Figure 50-140-3

P-86551

Dealer Copy -- Not for Resale

The motion alarm sensor (Item 1) [Figure 50-140-3] is
hydraulic pressure activated and located under the
operator cab in the motion alarm valve.

The sensor (Item 1) [Figure 50-140-3] is non-adjustable.

It must be fully installed into the valve housings and
tightened.

Inspect the motion alarm system for proper function if

sensor is replaced.

WARNING
This machine is equipped with a motion alarm.
ALARM MUST SOUND!
when operating forward or backward.

Failure to maintain a clear view in the direction of

travel could result in serious injury or death.

The operator is responsible for the safe operation of

this machine.
W-2786-0309

728 of 918 50-140-2 E85 Service Manual

FUEL TRANSFER PUMP Figure 50-150-3

Removal And Installation

Figure 50-150-1 2

1 2 1

P-92652

Loosen the clamps (Item 1) and remove the hoses (Item

P-92644 2) [Figure 50-150-3].

Figure 50-150-4
Remove the tie strap (Item 1) [Figure 50-150-1].

Dealer Copy -- Not for Resale

Figure 50-150-2

1 1

P-92642

P-92643 Remove the upper bolts (Item 1) [Figure 50-150-4] and

lower bolts.

Disconnect the wires (Item 1) [Figure 50-150-2]. Remove the pump.

729 of 918 50-150-1 E85 Service Manual

FUEL TRANSFER PUMP (CONT’D)

Removal And Installation (Cont’d)

Figure 50-150-5

P-92639

Remove the fittings (Item 1) [Figure 50-150-5].

Dealer Copy -- Not for Resale

730 of 918 50-150-2 E85 Service Manual

AUTO IDLE PRESSURE SWITCH

Removal And Installation

Tilt the cab. (See CAB TILT PROCEDURE on Page 10-

210-1.)

Figure 50-160-1

P112508

Dealer Copy -- Not for Resale

Disconnect the wire harness (Item 1) [Figure 50-160-1].

Figure 50-160-2

P112509

Remove the switch (Item 1) [Figure 50-160-2] from the

hydraulic control valve.

731 of 918 50-160-1 E85 Service Manual

Dealer Copy -- Not for Resale

732 of 918 50-160-2 E85 Service Manual

ENGINE CONTROL UNIT (ECU)

Description

The engine ECU controls the amount, timing, mixture

IMPORTANT
and pressure of fuel that is injected. The engine ECU
operates each kind of control based on the signals from Avoid damage to the Engine Control Unit (ECU).
each type of sensor. Water entering ECU atmospheric pressure sensor
will damage the ECU. Do not use high water pressure
The actuator for controlling the amount, timing and around the ECU when cleaning the engine
mixture of fuel injection is the injector, while the actuator compartment.
I-2357-0512
for controlling fuel pressure is the supply pump.

The amount of fuel to be injected is determined using a

basic injection amount, which is calculated based on the
state of the engine and driving conditions, with
corrections added for parameters such as water
temperature, fuel temperature, intake pressure, etc.

The ECU controls the timing for starting to energize the

injectors, first determining the timing for the main
injection and then the timing of other injections, such as
pilot injections.

Dealer Copy -- Not for Resale

By conducting a pilot injection, the initial fuel mixture is
kept to a minimum, mitigating the explosive initial
combustion and reducing NOx and noise.

The ECU calculates the set fuel injection pressure based

on the engine load (last injection amount and engine
RPM) and controls the amount the supply pump supplies
and the fuel pressure inside the rail.

The ECU monitors the diesel particulate filter (DPF) and

determines when regeneration and level of regeneration
should occur.

Figure 50-170-1

P123130

The ECU is located under the center cover (Item 1)

[Figure 50-170-1].

733 of 918 50-170-1 E85 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D) Figure 50-170-3

Removal And Installation

Clean the ECU and connectors before disconnecting the

2
wire harness.

NOTE: Do not use high pressure water to clean the

ECU.

IMPORTANT
Avoid damaging the Engine Control Unit (ECU) and P112523

electrical connectors. Use care when removing or

installing the ECU connectors. Lift the lever (Item 1) and push fully forward to remove the
I-2356-0512
connector (Item 2) [Figure 50-170-3].

NOTE: The wire harness connector is shown removed Figure 50-170-4

from the ECU to show wire harness connector
operation.

Dealer Copy -- Not for Resale

Figure 50-170-2

P112518

Pull the connector (Item 1) [Figure 50-170-4] straight out

to avoid damage.
P112521

Slide the lock (Item 1) [Figure 50-170-2] forward.

734 of 918 50-170-2 E85 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D)

Removal And Installation (Cont’d)

Figure 50-170-5

2 2

1
P123153

Remove the connectors (Item 1) [Figure 50-170-5] from

the bottom of the ECU.

Dealer Copy -- Not for Resale

Remove the four mounting bolts (Item 2) and remove the
ECU [Figure 50-170-5].

735 of 918 50-170-3 E85 Service Manual

Dealer Copy -- Not for Resale

736 of 918 50-170-4 E85 Service Manual

VEHICLE CONTROL UNIT (VCU) Figure 50-180-3

Removal And Installation

1
Disconnect the battery. (See Master Disconnect Switch
on Page 50-10-3.)

Figure 50-180-1
1
1

1
1 P120804

Remove the screws (Item 1) [Figure 50-180-3].

2 Figure 50-180-4

P120801

Dealer Copy -- Not for Resale

Remove the fasteners (Item 1) and remove the cover
(Item 2) [Figure 50-180-1]. 2

Figure 50-180-2

2 1
1

P120802

1 Remove the screws (Item 1) and remove the cover (Item

2) [Figure 50-180-4].

P120803

Remove the bolts (Item 1) and reposition the door latch

(Item 2) [Figure 50-180-2].

737 of 918 50-180-1 E85 Service Manual

VEHICLE CONTROL UNIT (VCU) (CONT’D)

Removal And Installation (Cont’d)

Figure 50-180-5

P120805

Disconnect the wire harness (Item 1) [Figure 50-180-5]

from the VCU.

Dealer Copy -- Not for Resale

Figure 50-180-6

1 P120806

Remove the three screws (Item 1) [Figure 50-180-6] and

remove the VCU.

738 of 918 50-180-2 E85 Service Manual

ENGINE SERVICE

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
Compression - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-18

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

DIESEL PARTICULATE FILTER (DPF) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by the engine. The
speed of the fan is determined by the engine rpm.

741 of 918 60-10-1 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications

Cylinder Head

Cylinder Head Surface Distortion 0,05 mm (0.0020 in) or less

Cylinder Had Surface Distortion Allowable Limit 0,15 mm (0.0059 in)
Compression 3330 - 3540 kPa (33,3 - 35,4 Bar) (483 - 513 psi)
Compression Allowable Limit 2650 - 2860 kPa (26,5 - 28,6 Bar) (384 - 414 psi)
Allowable Difference Between Cylinders 200 - 290 kPa (2,0 - 2,9 Bar) (29 - 43 psi)

Valves

Valve Seat Width

Intake Valve Stem O.D 6,945 - 6,960 mm (0.2734 - 0.2740 in)
Intake Valve Stem O.D. Allowable Limit 6,9 mm (0.2717 in)
Intake Valve Guide I.D. 7,0 - 7,015 mm (0.2756 - 0.2762 in)
Intake Valve Guide I.D. Allowable Limit 7,08 mm (0.2787 in)
Intake Valve Stem Bend 0,04 - 0,07 mm (0.0016 - 0.0028 in)
Intake Valve Stem Bend Allowable Limit 0,17 mm (0.0067 in)
Exhaust Valve Stem O.D. 6,940 - 6,955 mm (0.2732 - 0.2738 in)

Dealer Copy -- Not for Resale

Exhaust Valve Stem O.D. Allowable Limit 6,90 mm (0.2717 in)
Exhaust Valve Guide I.D. 7,0 - 7,015 mm (0.2756 - 0.2762 in)
Exhaust Valve Guide I.D. Allowable Limit 7,08 mm (0.2787 in)
Exhaust Valve Stem Bend 0,045 - 0,075 mm (0.0018 - 0.0030 in)
Exhaust Valve Stem Bend Allowable Limit 0,17 mm (0.0067 in)
Valve Guide Projection From Cylinder Head 14,71 - 15,00 mm (0.5791 - 0.5905 in)
Valve Guide Projection From Cylinder Head (4 Valves) 18,7 - 19,0 mm (0.736 - 0.748 in)
Intake Valve Recession 0,36 - 0,56 mm (0.0142 - 0.0220 in)
Intake Valve Recession Allowable Limit 0,8 mm (0.0318 in)
Exhaust Valve Recession 0,35 - 0,55 mm (0.0138 - 0.0217 in)
Exhaust Valve Recession Allowable Limit 0,8 mm (0.0315 in)
Valve Clearance 0,15 - 0,25 mm (0.006 - 0.010 in)
Valve Seat Angle (Int.) 120°
Valve Seat Angle (Exh.) 90°
Valve Seat Correction Angle 40°, 150°

742 of 918 60-10-2 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Valve Springs

Free Length 47,5 mm (1.8701 in)

Allowable Limit 47,0 mm (1.8504 in)
Inclination Allowable Limit 1,2 mm (0.0472 in)

Rocker Arm And Shaft

O.D. Of Rocker Arm Shaft 18,470 - 18,490 mm (0.7272 - 0.7280 in)

O.D. Of Rocker Arm Shaft Allowable Limit 18,44 mm (0.7260 in)
I.D. Of Rocker Arm 18,5 - 18,52 mm (0.7283 - 0.7291 in)
I.D. of Rocker Arm Allowable Limit 18,57 mm (0.7311 in)
Clearance Between Rocker Arm And Shaft 0,01 - 0,05 mm (0.0004 - 0.0020 in)
Clearance Between Rocker Arm & Shaft Allowable Limit 0,13 mm (0.0051 in)

Camshaft

Dealer Copy -- Not for Resale

Endplay 0,05 - 0,20 mm (0.0020 - 0.0079 in)
Endplay Allowable Limit 0,030 mm (0.0118 in)
Alignment (1/2 dial gauge reading) 0,0 - 0,02 mm (0.0 - 0.0008 in)
Alignment Allowable Limit 0,05 mm (0.0020 in)
Cam Lobe Height 42,435 - 42,565 mm (1.6707- 1.6758 in)
Cam Lob Height Allowable Limit 42,185mm (1.6608 in)
Gear End Bushing I.D. 49,99 - 50,055 mm (1.9681 - 1.9707 in)
Gear End Bushing I.D. Allowable Limit 50,13 mm (1.9736 in)
Gear End Camshaft O.D. 49,925 - 49,950 mm (1.9655 - 1.9665 in)
Gear End Camshaft O.D. Allowable Limit 49,890 mm (1.9642 in)
Gear End Oil Clearance 0,04 - 0,130 mm (0.0016 - 0.0051 in)
Gear End Oil Clearance Allowable Limit 0,240 mm (0.0094 in)
Intermediate Bore I.D. 50,0 - 50,025 mm (1.9685 - 1.9695 in)
Intermediate Bore I.D. Allowable Limit 50,1 mm (1.9724 in)
Intermediate Camshaft O.D. 49,91 - 49,935 mm (1.9650 - 1.9659 in)
Intermediate Camshaft O.D. Allowable Limit 49,875 mm (1.9636 in)
Intermediate Camshaft Oil Clearance 0,065 - 0,115 mm (0.0026 - 0.0045 in)
Intermediate Camshaft Oil Clearance Allowable Limit 0,225 mm (0.0089 in)
Flywheel End Inside Bore 50,0 - 50,025 mm (1.9685 - 1.9695 in)
Flywheel End Inside Bore Allowable Limit 50,1 mm (1.9724 in)
Flywheel End Camshaft O.D. 49,925 - 49,950 mm (1.9655 - 1.9665 in)
Flywheel End Camshaft O.D. Allowable Limit 49,890 mm (1.9642 in)
Flywheel End Oil Clearance 0,050 - 0,10 mm (0.0020 - 0.0039 in)
Flywheel End Oil Clearance Allowable Limit 0,210 mm (0.0083 in)

743 of 918 60-10-3 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Tappet

Tappet Bore I.D. 12,0 - 12,018 mm (0.4724 - 0.4731 in)

Tappet Bore I.D. Allowable Limit 12,038 mm (0.4739 in)
Tappet Stem O.D. 11,975 - 11,990 mm (0.4715 - 0.4720 in)
Tappet Stem O.D. Allowable Limit 11,955 mm (0.4707 in)
Oil Clearance 0,010 - 0,043 mm (0.0004 - 0.0017 in)
Oil Clearance Allowable Limit 0,083 mm (0.0033 in)

Push Rod

Push Rod Bend Allowable Limit 0,03 mm (0.0012 in)

Cylinders

Cylinder Bore I.D. 98,000 - 98,030 mm (3.8583 - 3.8594 in)

Crankshaft End Play 0,13 - 0,23 mm (0.0051 - 0.0091 in)

Crankshaft End Play Allowable Limit 0,28 mm (0.0110 in)

Timing Gear Backlash

Crank Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)

Crank Gear Allowable Limit 0,16 mm (0.0063 in)
Cam Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
Cam Gear Allowable Limit 0,16 mm (0.0063 in)
Idler Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
Idler Gear Allowable Limit 0,16 mm (0.0063 in)
Fuel Injection Pump Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
Fuel Injection Pump Gear Allowable Limit 0,16 mm (0.0063 in)
PTO Gear 0,08 - 0,14 mm (0.0031 - 0.0055 in)
PTO Gear Allowable Limit 0,16 mm (0.0063 in)

746 of 918 60-10-6 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Idler Gear Shaft And Bushing

Shaft O.D. 45,950 - 45,975 mm (1.8091 - 1.8100 in)

Shaft O.D. Allowable Limit 45,900 mm (1.8071 in)
Bushing I.D. 46,0 - 46,025 mm (1.8110 - 1.8120 in)
Busing I.D. Allowable Limit 46,075 mm (1.8140 in)
Oil Clearance 0,025 - 0,075 mm (0.0010 - 0.0030 in)
Oil Clearance Allowable Limit 0,175 mm (0.0069 in)
Torque Values (* Lightly oiled threads)

N•m ft-lb
*Cylinder Head Bolt 101,1 - 112,9 76 - 83
*Connecting rod Bolt 53,9 - 58,8 40 - 43
*Flywheel Bolt 186,2 - 205,8 137 - 152
*Main Bearing Cap Bolt 108,1 - 117,9 80 - 87
*Crankshaft Pulley Bolt 107,9 - 127,5 80 - 94

Dealer Copy -- Not for Resale

Fuel Injector Bolt 22,6 - 28,4 17 - 21
Supply Pump Drive Gear Nut 75 - 85 55 - 63
High Pressure Fuel Lines Nuts 29,4 - 34,3 21.7 - 25.3
(Common Rail, Injector, Supply Pump)
Speed Sensor Flywheel 6,0 - 10,0 4.4 - 7.4
Speed Sensor Camshaft 7,5 - 8,5 5.5 - 6.3
Pipe, EGR Valve 58,7 - 63,7 43.3 - 47.0
Sensor, Fresh Air Temp. (M6 x 1.0) 5,6 - 8,4 4.1 - 6.2
Sensor, Fresh Air Temp. (M14 x 1.5) 11,0 - 17,0 8.1 - 12.5
Sensor, DPF Temp. 25,0 - 40,0 18.4 - 29.5
Sensor, Differential Press 6,6 - 8,4 4.9 - 6.2
Sensor, Differential Press DPF 45,0 - 55,0 33.2 - 40.5
Nut, Valve Cover 12,0 - 15,0 8.9 - 11.0
Glow Plug 15,0 - 20,0 11 - 14.8
Glow Connector Nut 1,0 - 1,5 0.7 - 1.1

(* Lightly oiled threads)

747 of 918 60-10-7 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Sensor Location

Figure 60-10-2

1. EGR Valve
2. Pressure Sensor
3. Water Temperature Sensor
4. Cam Speed Sensor
5. Pump Discharge Control Valve
6. Fuel Temperature Sensor
7. Fuel Rail Pressure Sensor
8. New Air Temperature Sensor
9. Crank Rotation Sensor
10. Intake Air Throttles
11. Differential Pressure Sensor
12. Fuel Injectors

Dealer Copy -- Not for Resale

11 1

9
4
8
5
7
6

NA5994

748 of 918 60-10-8 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Sensor Location (Cont’d)

Figure 60-10-3

1. MPROP
2. Fuel Temperature Sensor

Dealer Copy -- Not for Resale

NA5995

749 of 918 60-10-9 E85 Service Manual

ENGINE INFORMATION (CONT'D)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common.

PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53

Dealer Copy -- Not for Resale

Start and stop 9, 10, 11

KEY TO CORRECT THE CAUSE

1. Battery capacity low 28. Worn valves and seat
2. Bad electrical connections 29. Broken or worn piston rings
3. Faulty starter motor 30. Worn valve stems or guides
4. Incorrect grade of oil 31. Worn or damaged bearings
5. Low cranking speed 32. Not enough oil in the oil pan
6. Fuel tank empty 33. Switch is defective
7. Faulty stop control operation 34. Oil pump worn
8. Plugged fuel line 35. Relief valve is stuck open
9. Plugged fuel filter 36. Relief valve is stuck closed
10. Restriction in the air cleaner 37. Broken relief valve spring
11. Air in the fuel system 38. Faulty suction pipe
12. Faulty fuel injection pump 39. Plugged oil filter
13. Faulty fuel injectors 40. Piston seizure
14. Broken injection pump drive 41. Incorrect piston height
15. Incorrect injection pump timing 42. Faulty engine mounting
16. Incorrect valve timing 43. Incorrect alignment of flywheel
17. Poor compression 44. Faulty thermostat
18. Plugged fuel tank vent 45. Restriction in water jacket
19. Incorrect grade of fuel 46. Loose alternator belt
20. Exhaust pipe restriction 47. Plugged radiator
21. Cylinder head gasket leaking 48. Plugged breather pipe
22. Over heating 49. Plugged breather pipe
23. Cold running 50. Damaged valve stem oil deflectors
24. Incorrect tappet adjustment 51. Coolant level too low
25. Sticking valves 52. Plugged oil pump pipe strainer
26. Incorrect high pressure fuel lines 53. Broken valve spring
27. Worn cylinder bores

750 of 918 60-10-10 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-5

Engine Removal And Installation

1
Disconnect the battery. (See Removing And Installing
Battery on Page 50-20-3.)

Remove the right side upperstructure cover. (See

Removal And Installation on Page 40-21-1.) 2
Remove the right side cover. (See Removal And
Installation on Page 40-180-1.)
1
Remove the hydraulic piston pump. (See Removal And
Installation on Page 20-50-13.) 1
P112062
Drain the radiator. (See Removing And Replacing
Coolant on Page 10-110-2.)
Loosen the clamps (Item 1) and remove the lower
Remove the muffler. (See Removal And Installation on radiator hose (Item 2) [Figure 60-10-5].
Page 60-30-2.)
Figure 60-10-6
Remove the fan. (See Fan Removal And Installation on
Page 60-50-7.).

Dealer Copy -- Not for Resale

Remove the air cleaner. (See Housing Removal And
Installation on Page 60-40-1.)

Figure 60-10-4

3
2

1
2

P112061

Loosen the clamps (Item 1) and remove the upper

1
radiator hose (Item 2) [Figure 60-10-4].

P112063

Loosen the hose clamps (Item 1) and remove the heater

hoses (Item 2). Remove the bolt (Item 3) [Figure 60-10-
6] from the clamp. Reposition the hoses.

751 of 918 60-10-11 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-9

Engine Removal And Installation (Cont’d)

Figure 60-10-7 2

1 1
3

1 2

P112066

Loosen the nut (Item 1). Loosen the adjustment bolt (Item
P112064 2) and remove the belt (Item 3) [Figure 60-10-9] from the
A/C compressor pulley.

Loosen the hose clamps (Item 1) and remove the fuel Figure 60-10-10
lines (Item 2) [Figure 60-10-7].

Dealer Copy -- Not for Resale

Figure 60-10-8
1

1
2

3 1

P112067

P112065 Remove the three bolts (Item 1) [Figure 60-10-10].

Remove the bolts (Item 1) and washers. Remove the belt

shield (Item 2) [Figure 60-10-8].

Remove the bolt (Item 3) [Figure 60-10-8] and reposition

the fuel lines.

752 of 918 60-10-12 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-13

Engine Removal And Installation (Cont’d) 1

Figure 60-10-11

P112070
1

Disconnect the wire harness (Item 1). Remove the nut

P112069 and wire harness (Item 2) [Figure 60-10-13] from the
alternator.

Remove the bolt (Item 1) [Figure 60-10-11] and lower Remove the nut (Item 3) [Figure 60-10-13] and wire
the compressor to the excavator frame. harness clamp from the stud.

Dealer Copy -- Not for Resale

Figure 60-10-12 Figure 60-10-14

1 1
2

P112068 P112073

Disconnect the wire harness (Item 1) [Figure 60-10-12] Remove the bolt (Item 1) [Figure 60-10-14] and wire
from the compressor. harness clamp.

Remove the bolt and ground wire (Item 2) [Figure 60-10-

14] from the back of the alternator.

753 of 918 60-10-13 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-17

Engine Removal And Installation (Cont’d)

Figure 60-10-15

2
1

1
P112075

Remove the bolts (Item 1) and clamps (Item 2) [Figure

P112071 60-10-17].

Figure 60-10-18
Remove the nuts and disconnect the wire harness (Item
1) [Figure 60-10-17] from the starter.

Dealer Copy -- Not for Resale

Figure 60-10-16
1

1 P112076

Slide the wire harness connector locks (Item 1) [Figure

P112072 60-10-18] back.

Remove the bolt (Item 1) [Figure 60-10-18] and ground

strap.

754 of 918 60-10-14 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-21

Engine Removal And Installation (Cont’d)

Figure 60-10-19

P112133

2 Remove the nut (Item 1) [Figure 60-10-21] and remove

P112077 the wire harness from the glow plug.

Figure 60-10-22
Depress the tabs (Item 1) [Figure 60-10-19] and
disconnect the wire harness (Item 2).

Dealer Copy -- Not for Resale

2
Figure 60-10-20
1

P112132
1

Disconnect the wire harness (Item 1) and (Item 2)

P112131 [Figure 60-10-22].

Repeat the procedure for the bottom wire harness

connectors (Item 1) [Figure 60-10-20].

755 of 918 60-10-15 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-25

Engine Removal And Installation (Cont’d)

Figure 60-10-23

1
1

P112135

1 Remove the two rear bolts (Item 1) [Figure 60-10-25],

P112134 washers and top half of the mount.

Remove the bolts (Item 1) [Figure 60-10-23] and

reposition the fuel filter.

Dealer Copy -- Not for Resale

Figure 60-10-24

P112139

Install a lifting hoist and chain on the engine lifting points

[Figure 60-10-24].

756 of 918 60-10-16 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-28

Engine Removal And Installation (Cont’d)

Figure 60-10-26

1 P112138

Raise the hoist and remove the engine [Figure 60-10-

P112137 28].

Figure 60-10-27

Dealer Copy -- Not for Resale

P112136

Remove the front two bolts (Item 1) [Figure 60-10-26]

and [Figure 60-10-27] nuts, washers and top half of the
mount

757 of 918 60-10-17 E85 Service Manual

ENGINE INFORMATION (CONT’D) NOTE: The following photo shows the engine
removed for photo clarity.
Compression - Testing
Figure 60-10-30
The tools listed will be needed to do the following
procedure:

MEL10630B - Engine Compression Kit

MEL1743 - Compression Adapter

NOTE: Compression testing is best done using SA-D

diagnostic tool software. (See DIAGNOSTIC
TOOL on Page 50-90-1.)

Run the engine until it reaches operating temperature.

Stop the engine.

1
Remove the glow plugs (See Removal And Installation on P-97916
Page 60-120-2.)

If SA-D diagnostic tool software is not available, Disconnect the camshaft speed sensor (Item 1) [Figure
disconnect the crankshaft position speed sensor and the 60-10-30].
camshaft speed sensor to prevent the engine from

Dealer Copy -- Not for Resale

starting:

Figure 60-10-29

P120462

Disconnect the crankshaft position speed sensor (Item 1)

[Figure 60-10-29].

758 of 918 60-10-18 E85 Service Manual

ENGINE INFORMATION (CONT’D) Crank the engine with the starter at 250 rpm.

Compression - Testing (Cont’d) Compression pressure at 3330 - 3540 kPa

250 rpm (33,3 - 35,4 bar)
Figure 60-10-31 (483 - 513 psi)
Allowable Limit 2650 - 2860 kPa
(26,5 - 28,6 bar)
(384 - 414 psi)

1 Variance among cylinders 200 - 300 kPa

(2 - 3 bar)
(29 - 43 psi)

P120460

Install the compression adapter (Item 1) [Figure 60-10-

31].

Dealer Copy -- Not for Resale

Figure 60-10-32

P120461

Install the gauge (Item 1) [Figure 60-10-32] on the

adapter.

759 of 918 60-10-19 E85 Service Manual

Dealer Copy -- Not for Resale

760 of 918 60-10-20 E85 Service Manual

ENGINE SPEED CONTROL

Adjustment

Figure 60-20-1

1 Engine Control
Dial
2 ECU (Engine
Control Unit)

2 1

EM7804

Dealer Copy -- Not for Resale

When the engine control dial is moved, the output voltage
changes according to the dial position [Figure 60-20-1].

761 of 918 60-20-1 E85 Service Manual

ENGINE SPEED CONTROL (CONT’D)

Adjustment (Cont’d)

Figure 60-20-2

Dealer Copy -- Not for Resale

S9597

The engine control dial has a built-in potentiometer (Item

1). When the control knob (Item 2) is moved, the output
voltage (through 2 and 3 terminals) will vary from the 5V
supplied from the engine throttle controller, as shown in
the graph (Item 3) [Figure 60-20-2].

762 of 918 60-20-2 E85 Service Manual

DIESEL PARTICULATE FILTER (DPF) SYSTEM

Description

The engine exhaust system is equipped with a diesel

particulate filter (DPF). The DPF is an emissions
reduction device that removes diesel particulate matter
(soot) from the exhaust gases of the diesel engine. The
DPF will trap and collect the soot until it is burned off. The
process of burning off the collected soot is called
regeneration.

Ash residue will remain after the regeneration process is

complete. The ash must be periodically removed from the
DPF.

Figure 60-30-1

1
3

Dealer Copy -- Not for Resale

P109420

The DPF muffler full assembly serial number (Item 1) is

located on the side of the DPF (Item 2) and on the
differential pressure sensor (Item 3) [Figure 60-30-1].

763 of 918 60-30-1 E85 Service Manual

DIESEL PARTICULATE FILTER (DPF) SYSTEM Figure 60-30-3
(CONT’D)

Removal And Installation

WARNING
HOT SURFACES CAN CAUSE SERIOUS INJURY
• Do not touch.
• Allow to cool before servicing.
W-2533-1012

P112390
NOTE: Use care during removal and installation
since the DPF cannot be reused if dropped or
given a shock, even if there is no outward Mark the location of the three sensor connectors (Item 1)
damage, replace with a new one. [Figure 60-30-3] and disconnect.

Before removing the DPF, connect the Figure 60-30-4

diagnostic tool, check the failure history and
save the project.

Dealer Copy -- Not for Resale

Open the right side cover. (See Opening And Closing on
1
Page 10-50-1.)

Figure 60-30-2

1 2

P112391
2
Remove the four nuts (Item 1) from exhaust manifold to
the DPF. After removal of the DPF, remove and discard
the gasket (Item 2) [Figure 60-30-4].

P112418 Installation: Tighten the nuts to 49 - 55 N•m (37 - 41 ft-

lb) torque.

Loosen the clamp (Item 1) and remove the drain hose

(Item 2) [Figure 60-30-2].

764 of 918 60-30-2 E85 Service Manual

DIESEL PARTICULATE FILTER (DPF) SYSTEM
(CONT’D)

Removal And Installation (Cont’d)

Figure 60-30-5

P112393

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

Dealer Copy -- Not for Resale

the DPF assembly.

765 of 918 60-30-3 E85 Service Manual

Dealer Copy -- Not for Resale

766 of 918 60-30-4 E85 Service Manual

AIR CLEANER

Housing Removal And Installation

Open the right side cover.

Figure 60-40-1

P112306

Dealer Copy -- Not for Resale

Loosen the hose clamps (Item 1) and remove the hoses
from the air cleaner housing. Disconnect the wire
harness (Item 2) [Figure 60-40-1].

Figure 60-40-2

1 1

P112307

Remove the two bolts (Item 1) [Figure 60-40-2] and

washers.

Remove the air cleaner housing.

NOTE: Plug the intake to keep contamination out of

the engine.

767 of 918 60-40-1 E85 Service Manual

Dealer Copy -- Not for Resale

768 of 918 60-40-2 E85 Service Manual

ENGINE COOLING SYSTEM Figure 60-50-2

Radiator Removal And Installation

Drain the hydraulic reservoir. (See Removing And 2

Replacing Hydraulic Fluid on Page 10-140-6.)
1
Drain the radiator. (See Removing And Replacing
Coolant on Page 10-110-2.)

Remove the right side cover. (See Removal And

Installation on Page 40-180-1.)
1
Remove the right upperstructure side cover. (See
Removal And Installation on Page 40-21-1.)
P112505
Remove the fan. (See Fan Removal And Installation on
Page 60-50-7.)
Loosen the clamps (Item 1) and top radiator hose (Item
Figure 60-50-1 2) [Figure 60-50-2].
Figure 60-50-3
1

Dealer Copy -- Not for Resale

2
P112506

P112504

Remove the top oil cooler hose (Item 1) [Figure 60-50-

1]. Figure 60-50-4

IMPORTANT 1

When repairing hydrostatic and hydraulic systems, 3

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
damage the system.
I-2003-0888
3

P112503

Loosen the clamps (Item 1) and remove the hose (Item 2)

[Figure 60-50-3] and [Figure 60-50-4].
Remove the bolt (Item 3) [Figure 60-50-4] and clamp.

769 of 918 60-50-1 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-7

Radiator Removal And Installation (Cont’d)

Figure 60-50-5 1

1 2
1

P112501

P112502 Remove the bolts (Item 1) [Figure 60-50-7] and

reposition the hoses.

Remove the two top bolts (Item 1), three bottom bolts, Figure 60-50-8
and fan shield (Item 2) [Figure 60-50-5].

Dealer Copy -- Not for Resale

Figure 60-50-6

1 1
1 1

3
1

1
1
P112500
2
P112499
Remove the bolts (Item 1) [Figure 60-50-8] and remove
the plates.
Loosen the hose clamp (Item 1) and remove the lower
radiator hose (Item 2) [Figure 60-50-6].

Remove the radiator drain hose (Item 3) [Figure 60-50-

6].

770 of 918 60-50-2 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-11

Radiator Removal And Installation (Cont’d)

1
Figure 60-50-9

2
1

3 P112494

Remove the top bolt (Item 1), and loosen the bottom bolt
P112498 (Item 2) and pivot the brace (Item 3) [Figure 60-50-11]
towards the front of the excavator.

Remove the bolts (Item 1) [Figure 60-50-9] and Figure 60-50-12

reposition the fuel cooler.

Dealer Copy -- Not for Resale

Figure 60-50-10

1
1

P112495

P112497 Remove the two shroud bolts and install lifting eyes,
chain and hoist [Figure 60-50-12].

Remove the bolts (Item 1) [Figure 60-50-10] and

reposition the air conditioning condenser.

771 of 918 60-50-3 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-15

Radiator Removal And Installation (Cont’d)

Figure 60-50-13

P112492
2
1 Remove the radiator from the excavator [Figure 60-50-
P112493 15].

Figure 60-50-16
Pull the foam insulation bar (Item 1) back, and remove
the two bolts (Item 2) [Figure 60-50-13].

Dealer Copy -- Not for Resale

Figure 60-50-14

1
1

1 P112491
1

Remove the shims (Item 1) [Figure 60-50-16] (if

P112496 equipped).

Remove the bolts (Item 1) [Figure 60-50-14].

772 of 918 60-50-4 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-19

Radiator Disassembly And Assembly

Figure 60-50-17

1 1 1 1
1

1
2
1

P112487
1

Remove the bolts (Item 1) [Figure 60-50-19].

P112486
Figure 60-50-20

Figure 60-50-18
1

Dealer Copy -- Not for Resale

2
1

1
P112489

P112488
Remove the radiator (Item 1) [Figure 60-50-20].

Remove the bolts (Item 1) and top cover (Item 2) [Figure

60-50-17] and [Figure 60-50-18].

773 of 918 60-50-5 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Radiator Disassembly And Assembly (Cont’d)

Figure 60-50-21

P112490

Remove the oil cooler (Item 1) [Figure 60-50-21].

Dealer Copy -- Not for Resale

774 of 918 60-50-6 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-50-24

Fan Removal And Installation

Figure 60-50-22 1

P112058

Remove the bolt (Item 1) [Figure 60-50-24].

P112054
Figure 60-50-25

Pull up on and remove the coolant reservoir (Item 1)

[Figure 60-50-22].
1

Dealer Copy -- Not for Resale

Figure 60-50-23
2

1 1

112057

P112066
Remove the two bolts (Item 1) and remove the fan guard
(Item 2) [Figure 60-50-25].
Remove the two bolts (Item 1) [Figure 60-50-23] and
remove the reservoir bracket.

775 of 918 60-50-7 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Fuel Cooler Removal And Installation

Fan Removal And Installation (Cont’d) Figure 60-50-28

Figure 60-50-26

1
1

P112052

P112059
Loosen the hose clamps (Item 1) [Figure 60-50-28] and
remove the hoses.
Remove the four bolts (Item 1) [Figure 60-50-26] from
the fan. Figure 60-50-29

Dealer Copy -- Not for Resale

Figure 60-50-27

1 1

1
2
P112053

P112060
Remove the bolts (Item 1) and remove the cooler (Item 2)
[Figure 60-50-29].
Slide the fan towards the radiator and remove the spacer
(Item 1) [Figure 60-50-27].

Remove the fan.

776 of 918 60-50-8 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Water Pump Removal And Installation

NOTE: Replace the engine coolant pump as an

assembly only. Do not attempt to repair the
engine coolant pump or replace individual
components.

Remove the alternator belt. (See Belt Replacement on

Page 50-30-1.)

Figure 60-50-30

1
2

Dealer Copy -- Not for Resale

S9605

Remove the fan (Item 1), spacer (Item 2) and pulley (Item
3) [Figure 60-50-30].

Disconnect the coolant hoses and the temperature switch

lead wire from the engine coolant pump.

Remove the engine coolant pump (Item 4) [Figure 60-

50-30].

Installation: Install a new O-ring between the engine

coolant pump and the joint.

NOTE: The correct O-ring must be used. The O-ring

dimensions are the same as a commercially
available O-ring, the material is different.

777 of 918 60-50-9 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Water Pump Parts Identification

1. Thermostat Cover
2. Gasket
3. Thermostat
4. O-ring
5. O-ring
6. Water Pump
7. Temperature Switch
8. Gasket
9. Gasket
10. Belt
11. Pulley
12. Spacer
14
13. Fan
14. Bolt
15. Water Temperature Sensor 1

Dealer Copy -- Not for Resale

5 4
15

8
6
7

9 14

NA5991S

778 of 918 60-50-10 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Temperature Switch - Testing

Thermostat Removal And Installation Figure 60-50-32

Figure 60-50-31 3

1
1

3 2
2

6 4

5
S9607

Connect a continuity light or ohmmeter to the

temperature switch. Connect one lead to the terminal of
the switch (Item 1) and the other lead to the metal portion
of the switch (Item 2) [Figure 60-50-32].

Dealer Copy -- Not for Resale

Install the temperature switch and an accurate
thermometer (Item 3) [Figure 60-50-32] in engine
coolant.

S9606 Slowly increase the temperature of the fluid.

The temperature switch is working properly if the

Remove the thermostat cover (Item 1) and the thermostat
continuity light or ohmmeter indicates continuity when the
(Item 2) [Figure 60-50-31].
fluid reaches 107 - 113°C (225 - 235°F).
Installation: Use a new gasket (Item 3) and O-ring (Item
4) [Figure 60-50-31].

Remove the temperature switch (Item 5) [Figure 60-50-

31].

Installation: Use a new gasket (Item 6) [Figure 60-50-

31].

779 of 918 60-50-11 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Thermostat - Testing

Temperature Sensor - Testing Figure 60-50-34

Figure 60-50-33
2

2
1
1

S9609

S9608
Install the thermostat (Item 1) and an accurate
thermometer (Item 2) [Figure 60-50-34] in hot water.
Connect an electric resistor to the coupler of the water
temperature sensor (Item 1) [Figure 60-50-33]. Slowly increase the temperature of the fluid.

Dealer Copy -- Not for Resale

Install the temperature switch and an accurate The thermostat is operating properly if it starts to open at
thermometer (Item 2) [Figure 60-50-33] in engine the temperature value stamped on the flange of the
coolant. thermostat, and fully opens as the temperature of the
water is increased.
Slowly increase the temperature of the fluid and measure
the electric resistance value. Figure 60-50-35

If the resistance value at each of the following

temperatures is within the permissible range specified,
the water temperature sensor is operating properly.

RESISTANCE
WATER TEMPERATURE (K OHM)
20°C (68°F) 2.45 (+/- 0.13)
80°C (176°F) 0.318 (+/- 0.008)
100°C (212°F) 0.1836
1

S9610

Install the radiator cap (Item 1) [Figure 60-50-35] on a

cooling system tester.

Apply 75 - 105 kPa (0,75 - 1,05 bar) (10.8 - 14.8 psi) to

the radiator cap. The radiator cap relief valve must open
within the specified range.

780 of 918 60-50-12 E85 Service Manual

LUBRICATION SYSTEM Figure 60-60-2

Oil Pan Removal And Installation

Figure 60-60-1

3
2

1
2

1
NA1084

Dealer Copy -- Not for Resale

NA1090

Remove the bolts (Item 1) and remove the oil pan (Item
2) [Figure 60-60-1]. Remove the bolts (Item 1), oil pickup tube (Item 2) and O-
ring (Item 3) [Figure 60-60-2].
Installation: Apply a continuous bead of liquid gasket to
the mounting surface of the oil pan (Item 2). Installation: Install the oil pickup tube (Item 2) using a
new O-ring (Item 3) [Figure 60-60-2].
NOTE: Be sure to circle each bolt hole.

Reinstall the oil pan and tighten the bolts.

781 of 918 60-60-1 E85 Service Manual

LUBRICATION SYSTEM (CONT’D) Figure 60-60-4

Oil Pump Removal And Installation

NOTE: If the oil pump must be replaced, replace it as

an assembly only. Do not replace individual
components.

Remove the engine cooling fan (See Fan Removal And

Installation on Page 60-50-7.).

The oil pump is located in the front gear case and is 1

driven by the same gear train that drives the camshaft
and fuel injection pump. Remove crankshaft pulley and
the front gear case cover to gain access to the oil pump
(See Timing Gear Case Cover Removal And Installation 2 S9387
on Page 60-100-1.).

Figure 60-60-3 Remove the oil pump assembly bolts. Remove the oil
pump assembly (Item 1) from the gear case housing
(Item 2) [Figure 60-60-4].

Figure 60-60-5
1

Dealer Copy -- Not for Resale

5
1

4
S9385

Gear Case Housing (Item 1)

Outer Rotor (Item 2) 2 S9393
Inner Rotor (Item 3)
Cover Plate (Item 4)
Drive Gear (Item 5) [Figure 60-60-3] Remove the outer rotor (Item 1) [Figure 60-60-5] from
the gear case housing.
Remove the crankshaft pulley and the gear case cover.
Installation: Lubricate the outer rotor and pump bore in
the gear case with clean engine oil. The punch mark
(Item 2) [Figure 60-60-5] on the end of the outer rotor
must face away from the gear case housing

782 of 918 60-60-2 E85 Service Manual

LUBRICATION SYSTEM (CONT’D) Figure 60-60-7

Oil Pump Inspection

Wash the oil pump, oil pressure regulator and oil pump
cavity with clean solvent. Inspect for wear or damage. 1
Replace if necessary. 2

NOTE: If any oil pump component clearance exceeds

its limit, the oil pump must be replaced as an
assembly.

Figure 60-60-6

1
S9389
2

Measure the clearance between the lobes of the inner

rotor (Item 1) and outer rotor (Item 2) [Figure 60-60-7].

Allowable Limit 0,16 mm (0.0063 in)

Figure 60-60-8

Dealer Copy -- Not for Resale

S9388

Measure the clearance between the outer rotor (Item 1)

and pump body (Item 2) [Figure 60-60-6].

0,1 - 0,155 mm
Clearance 1
(0.0039 - 0.0061 in)
Allowable Limit 0,25 mm (0.0098 in) 2

S9390

Determine the side clearance of the outer rotor (Item 1)

across the pump cavity (Item 2) [Figure 60-60-8].
Measure the side clearance using a depth micrometer.

0,05 - 0,10 mm
Side Clearance
(0.002 - 0.0039 in)
Allowable Limit 0,15 mm (0.0059 in)

783 of 918 60-60-3 E85 Service Manual

LUBRICATION SYSTEM (CONT’D) Engine Oil Pressure - Testing

Oil Pump Inspection (Cont’d) Perform an engine oil pressure check if there is any
indication of low oil pressure such as the oil pressure
Figure 60-60-9 indicator is on or the oil pressure gauge indicates low oil
pressure.

Figure 60-60-10
1

FUEL SYSTEM

Electronic Fuel Injection Schematic - Components

Figure 60-70-1

Electronic Fuel Injection System - Control Schematic 2

Dealer Copy -- Not for Resale

4
3

P109444

Supply Pump (Item 1) [Figure 60-70-1]- The fuel Crank Speed Sensor (Item 4) and Gear Speed Sensor
passes the pre-filter and is pressure-fed by a fuel feed (Item 5) [Figure 60-70-1] - The crank speed sensor is
pump to the main filter, then it arrives at the supply pump. equipped on the flywheel side and the gear speed sensor
The ECU controls the opening of the intake metering is equipped on the gear side. Based on these 2 sensor
valve and adjusts the fuel intake volume so that the rail outputs, the ECU recognizes the engine speed and each
pressure is at the target value. The fuel pressurized in the piston position.
supply pump is fed to the rail.
Electronic Control Unit (ECU) (Item 6) [Figure 60-70-
Rail (Item 2) [Figure 60-70-1] - A pressure of up to 160 1] - Based on the information from each sensor, ECU
MPa is accumulated in the rail. The rail is equipped with a determines optimum injection volume, injection timing
rail pressure sensor and it sends information to the ECU. and rail pressure, and controls the intake metering valve
In the case of an abnormal increase in the rail pressure, of the supply pump and injector. It also monitors the
the mechanical relief valve opens to prevent the pressure occurrence of system abnormality at all times. If an
increase. abnormality is detected, it notifies the operator and
controls the safe running condition of the system.
Injector (Item 3) [Figure 60-70-1] - The ECU controls
the injector to maintain optimum injection volume and
injection timing and injects the high pressure fuel
accumulated in the rail into the cylinder.

787 of 918 60-70-1 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-70-3

Fuel Supply Pump Removal And Installation

Remove the air cleaner. (See Housing Removal And

Installation on Page 60-40-1.) 1

Remove the DPF. (See Removal And Installation on Page

60-30-2.)

NOTE: Allow five minutes after the engine is shut

down for the fuel pressure to bleed down.

WARNING P112598

AVOID INJURY OR DEATH Figure 60-70-4

Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
2
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid

Dealer Copy -- Not for Resale

enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Figure 60-70-2
1

P112599

P112597
Pull up on and reposition the coolant overflow tank (Item
1) [Figure 60-70-2].
Remove the bolts (Item 1) [Figure 60-70-3] and [Figure
60-70-4].

Reposition the fan guard (Item 2) [Figure 60-70-4].

788 of 918 60-70-2 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-70-7

Fuel Supply Pump Removal And Installation (Cont’d)

Figure 60-70-5

P112595.

Figure 60-70-8
P112593

Remove the nut (Item 1) [Figure 60-70-5] bolt, washer

and top engine mount.
1

Dealer Copy -- Not for Resale

Figure 60-70-6

P112596

1
Loosen the remaining three engine mount bolts (Item 1)
[Figure 60-70-6], [Figure 60-70-7] and [Figure 60-70-
8].

P112594...

789 of 918 60-70-3 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-70-11

Fuel Supply Pump Removal And Installation (Cont’d)

Figure 60-70-9 1

P1125990

Remove the six bolts (Item 1) [Figure 60-70-11] and

lower the mount to the excavator frame.
P112592
Figure 60-70-12
Install a hoist (Item 1) [Figure 60-70-9] on the front
engine lifting bracket.

Dealer Copy -- Not for Resale

Figure 60-70-10
1

1
1

P112688

Remove the fuel lines (Item 1) [Figure 60-70-12].

Figure 60-70-13
P112591

Raise the hoist enough to remove the bottom engine

mount (Item 1) [Figure 60-70-10].

1
1

P112586

Disconnect the wire harness (Item 1) [Figure 60-70-13].

790 of 918 60-70-4 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-70-16

Fuel Supply Pump Removal And Installation (Cont’d)

Figure 60-70-14

1 P112583

Remove the nut (Item 1) [Figure 60-70-16] and lock

P112585 washer.

Installation: Tighten the nut to 75 - 85 N•m (55 - 63 ft-lb)

Remove the fuel line (Item 1) [Figure 60-70-24] from the torque.
supply pump to the fuel rail.

Dealer Copy -- Not for Resale

Figure 60-70-17
Installation: Tighten the fuel line to 29,4 - 34,3 N•m
(21.7 - 25.3 ft-lb) torque.

Figure 60-70-15

1 2

2 1

P112584

1
Install the nut (Item 1) on the shaft three turns. Do not
P112587 contact the face of the gear with the face of the nut. Make
an alignment mark (Item 2) [Figure 60-70-17] between
the supply pump gear and the idler gear.
Remove the bolts (Item 1) and plate (Item 2) [Figure 60-
70-15].

Installation: Apply a thin continuous bead of silicone

sealant around the outer edge of the plate. Tighten the
bolts to 22,6 - 28,4 N•m (16.6 - 20.9 ft-lb) torque.

791 of 918 60-70-5 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-70-20

Fuel Supply Pump Removal And Installation (Cont’d)

Figure 60-70-18

P112580

Remove the three bolts (Item 1) [Figure 60-70-20] and

P112581 remove the pump.

Installation: Tighten the bolts to 22,6 - 28,4 N•m (16.6 -

Install the puller on the gear [Figure 60-70-18]. 20.9 ft-lb) torque.

Dealer Copy -- Not for Resale

Remove the gear from the pump shaft. Figure 60-70-21

NOTE: The gear will stay in the timing case after it is

removed from the pump shaft.

Figure 60-70-19

1
1
P112578

Remove the O-ring (Item 1) [Figure 60-70-21].

P112582

Remove the puller and remove the nut (Item 1) [Figure

60-70-19].

792 of 918 60-70-6 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-70-23

Fuel Rail Assembly Removal And Installation

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
P109440 / P109438
from a physician familiar with this injury.
W-2072-0807

Disconnect the injector fuel return line assembly (Item 1)

NOTE: Allow 5 minutes after the engine is shut down [Figure 60-70-23] from the injectors.
for the fuel pressure to bleed down.
Figure 60-70-24
Remove the EGR valve. (See Removal And Installation
on Page 60-110-2.)

Dealer Copy -- Not for Resale

Remove the air cleaner flange, intake throttle valve and 1
intake air heater from the engine. (See Housing Removal 2
And Installation on Page 60-40-1.)

Figure 60-70-22

P109460

Disconnect the fuel pressure sensor (Item 1) and the fuel

pressure relief line (Item 2) [Figure 60-70-24].

P109438

Disconnect the injector wires (Item 1) [Figure 60-70-22].

793 of 918 60-70-7 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-70-26

Fuel Rail Assembly Removal And Installation (Cont’d)

Figure 60-70-25 1
2

P109460

1 Remove the fuel rail assembly bolts (Item 1) and the fuel
P109443 rail assembly (Item 2) [Figure 60-70-26].

Installation: Tighten the bolts to 22,6 - 28,4 N•m (16.7 -

Clean around the high pressure fuel fittings (Item 1) 21.0 ft-lb) torque.
[Figure 60-70-25] and remove the fuel lines from the

Dealer Copy -- Not for Resale

common rail and injectors. Install caps and plugs. NOTE: When removing the fuel rail assembly do not
Installation: Tighten the high pressure fuel line nuts: hold it by the fuel rail pressure limiter or fuel
(Injector Side) to 26,5 - 31,4 N•m (19.5 - 23.1 ft-lb) torque rail pressure sensor.
and (Fuel Rail Side) to 29,4 - 34,3 N•m (21.7 - 25.3 ft-lb)
torque. Cap and store the fuel rail assembly and injector pipes to
protect against dust and other contaminants.

Figure 60-70-27

IMPORTANT
3
Do not bend the high pressure fuel injection tubes 2 1
when removing or installing them.
I-2029-0289

P107515

Do not disassemble the fuel rail assembly. The fuel rail

pressure sensor (Item 1), fuel rail pressure relief (Item 2)
and the fuel rail (Item 3) [Figure 60-70-27] are not
serviceable parts. Fuel rail assembly must be replaced
as a single unit.

794 of 918 60-70-8 E85 Service Manual

FUEL SYSTEM (CONT'D) Figure 60-70-29

Fuel Injector Removal And Installation

WARNING
1
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention 1
from a physician familiar with this injury. P109443

W-2072-0807

Remove the high pressure fuel lines (Item 1) from the

NOTE: Allow 5 minutes after the engine is shut down common rail and injectors [Figure 60-70-29]. Install caps
for the fuel pressure to bleed down. and plugs.

Remove the EGR valve. (See Removal And Installation Installation: Tighten the high pressure fuel line nuts
on Page 60-110-2.) (Injector Side) to 26,5 - 31,4 N•m (19.5 - 23.1 ft-lb) torque

Dealer Copy -- Not for Resale

and (Fuel Rail Side) to 29,4 - 34,3 N•m (21.7 - 25.3 ft-lb)
Remove the air cleaner flange, intake throttle valve and torque.
intake air heater from the engine. (See Housing Removal
And Installation on Page 60-40-1.)

Figure 60-70-28 IMPORTANT

1 Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

P109438

Disconnect the injector wires (Item 1) [Figure 60-70-28].

795 of 918 60-70-9 E85 Service Manual

FUEL SYSTEM (CONT'D) Figure 60-70-31

Fuel Injector Removal And Installation (Cont’d) 1

Figure 60-70-30
2

2
3

P107496A
1
Remove and replace the injection nozzle assembly O-
P109463 rings (Item 1) and nozzle gasket (Item 2) [Figure 60-70-
31] before installation.

Remove the glow plug strip (Item 1) for access to the

injection nozzle bolts. Remove the injector bolts (Item 2)

Dealer Copy -- Not for Resale

and clamps (Item 3) [Figure 60-70-30].

Remove the injector nozzle assembly and gasket (Item 3)

[Figure 60-70-30].

Installation: Tighten the injection nozzle assembly bolt

to 24,4 - 28,4 N•m (18 - 21 ft-lb) torque.

NOTE: Do not disassemble the injector. Do not

remove or damage the injector QR code tag.
Do not get the injectors out of order. If the
injectors get out of order or need replacing, it
is necessary to perform injector correction.
(See Fuel Injector Removal And Installation
on Page 60-70-9.)

796 of 918 60-70-10 E85 Service Manual

CYLINDER HEAD

Valve Clearance Adjustment

NOTE: Valve clearance must be inspected and Rotate the crankshaft clockwise as seen from the coolant
adjusted when engine is cold. pump end, to bring No. 1 piston to top dead center (TDC)
on the compression stroke while watching the rocker arm
Remove the valve cover. motion and the timing grid on the flywheel. (Position
where both the intake and exhaust valves are closed.)
Installation: Install the valve cover and tighten the nuts
to 12 - 15 N•m (8.9 - 11 ft-lb) torque. With the number 1 cylinder (flywheel end) at TDC, adjust
the following valves.

Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 Cylinder at
X X X X
TDC Compression

Rotate the crankshaft until the number 4 cylinder (radiator end) is at TDC. Adjust the following valves.

Cylinder No. 1 2 3 4

Dealer Copy -- Not for Resale

Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No. 4 Cylinder at
X X X X
TDC Compression

797 of 918 60-80-1 E85 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-80-3

Valve Clearance Adjustment (Cont’d)

2
Figure 60-80-1

3 1

P109429

Insert a feeler gauge of the correct thickness (Item 1)

P109429 (See table below) between the rocker arm and valve cap.
Turn the valve adjustment screw (Item 2) [Figure 60-80-3]
to adjust the valve clearance so there is a slight drag on
Insert a feeler gauge (Item 1) between the rocker arm the feeler gauge when sliding it between the rocker arm
and valve cap (Item 2) [Figure 60-80-1], and record the and the valve cap.

Dealer Copy -- Not for Resale

measured valve clearance. (Use the data for estimating
the wear.) Hold the adjusting screw while tightening the valve
adjusting screw lock nut (Item 3) [Figure 60-80-3].
If adjustment is required, proceed to the next step. If no
adjustment is required, inspect the rest of the valves and Valve Factory spec. 0,15 - 0,25 mm
adjust as required. clearance (0.006 - 0.010 in)

Figure 60-80-2

P109430

Loosen the valve adjusting screw lock nut (Item 1)

[Figure 60-80-2] and valve adjusting screw (Item 2) on
the rocker arm and check the valve for inclination of the
valve cap, entrance of dirt, or wear.

798 of 918 60-80-2 E85 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-80-5

Cylinder Head Removal And Installation 6 5

7
Drain the coolant from the engine into a suitable
4
container. (See Removing And Replacing Coolant on
Page 10-110-2.)
3
Remove the diesel particulate filter from the engine. (See 2
Removal And Installation on Page 60-30-2.)

Remove the coolant pump. (See Water Pump Removal

And Installation on Page 60-50-9.)

Remove the high-pressure fuel lines and injectors from 1

the cylinder head. (See Fuel Injector Removal And P109422
Installation on Page 60-70-9.)

Remove the fuel rail and return fuel lines from the Remove the intake manifold bolts (Item 1). Remove the
cylinder head. (See Fuel Rail Assembly Removal And intake manifold (Item 2). Discard the intake manifold
Installation on Page 60-70-7.) gasket (Item 3). Remove the exhaust manifold bolts (Item
4) and nuts (Item 5). Remove the exhaust manifold (Item
Figure 60-80-4 6) and the exhaust manifold gasket (Item 7) [Figure 60-
80-5]. Discard and replace of the original gaskets with

Dealer Copy -- Not for Resale

new gaskets.

Figure 60-80-6

2
1

P109421

Disconnect the electrical wires from the glow plug,

injector, intake throttle, EGR valve and sensors (Item 1) P109423
[Figure 60-80-4].

Remove the glow plug harness (Item 1) from each glow

plug (Item 2) [Figure 60-80-6]. Remove the glow plug
from the cylinder head.

NOTE: Remove the glow plugs in advance to avoid

damaging to the tips protruding below the
cylinder head combustion chamber surface.

Installation: Install the glow plugs and tighten to 15 - 20

N•m (133 - 177 in-lb) torque. Install the harness and
tighten the nuts to 1,0 - 1,5 N•m (9 - 13 in-lb) torque.

799 of 918 60-80-3 E85 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-80-9

Cylinder Head Removal And Installation (Cont’d) 7

6 4
Figure 60-80-7
5
1 2
3 1

2
3

P109426

4
Remove the rocker arm shaft alignment stud (Item 1)
P109424 from support (Item 2) [Figure 60-80-9].

NOTE: Clamp the support in a padded vise. Twist and

Remove the valve cover bolts (Item 1) and O-rings (Item pull out on the rocker arm shaft to remove.
2). Remove the valve cover (Item 3) and valve cover

Dealer Copy -- Not for Resale

gasket (Item 4) [Figure 60-80-7]. Slide the rocker arm shaft (Item 3) out of the rocker arm
supports (Item 2), springs (Item 4), and rocker arms (Item
Installation: Install the valve cover and tighten the nuts 5). Remove the valve adjusting screw (Item 6) and the
to 12 - 15 N•m (8.9 - 11 ft-lb) torque. lock nut (Item 7) [Figure 60-80-9] from the rocker arms.

Figure 60-80-8 Figure 60-80-10

1 2
1

1
P109425 P109451

Remove the bolts (Item 1) that retain the rocker arm shaft Installation: The lubrication holes (Item 1) in the rocker
supports. Remove the rocker arm shaft assembly from arm shaft must be oriented correctly with respect to the
the cylinder head. Remove the push rods (not shown) rocker arms (Item 2) [Figure 60-80-10]. Align the push
[Figure 60-80-8]. rods with their respective rocker arms. Adjust the valve
clearance.
NOTE: Mark the push rods and rocker arms so the
parts are reinstalled in their original positions.

800 of 918 60-80-4 E85 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly

Cylinder Head Removal And Installation (Cont’d) Figure 60-80-13

Figure 60-80-11
1

7 16 14 6
1 9 18 12 4
A
3 11 17 10 2
5 13 15 8

NA1048

Loosen the cylinder head bolts in the sequence shown P109428

[Figure 60-80-11].
Place the cylinder head on a work bench with the
NOTE: A is the cooling fan end.
combustion side down. Remove the valve cap (Item 1)
[Figure 60-80-13].
Figure 60-80-12

Dealer Copy -- Not for Resale

1 NOTE: If the valves are to be reused, identify the
valves and the caps so they can be reinstalled
in their original locations.

Figure 60-80-14
2

3
P109427

Remove the bolts (Item 1). Remove the cylinder head

(Item 2) and remove and discard the gasket (Item 3)
[Figure 60-80-12].
P109447
NOTE: Place the cylinder head on a flat surface to
avoid damage to the combustion surface.
Use a valve spring compressor tool (Item 1) [Figure 60-
Installation: Apply a light film of oil to the bolt threads. 80-14] to compress the valve spring.
Tighten the bolts in the correct sequence of #18 to #1, to
103 - 113 N•m (76 - 83 ft-lb) torque [Figure 60-80-11].

801 of 918 60-80-5 E85 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-80-17

Cylinder Head Disassembly And Assembly (Cont’d)

1
Figure 60-80-15
1
3

NA1052

4
Use the valve guide tool or other appropriate tool to drive
P109428 the valve guides (Item 1) [Figure 60-80-17] out of the
head.

Remove the valve keepers (Item 1). Slowly release the NOTE: Do not remove the valve guides until the
tension on the valve spring (Item 2). Remove the spring inspection and measurement procedures

Dealer Copy -- Not for Resale

retainer (Item 3) [Figure 60-80-15] and valve spring. have been performed (See Valve Guide -
Repeat the procedure with the remaining valves. Inspection on Page 60-80-8.).

Turn the cylinder head so the exhaust port side faces Installation: The valve guides have a tight press fit.
down. Remove the valves (Item 4) [Figure 60-80-15] and Before installing, place the valve guides in a freezer for at
the valve stem seals (Item 5). least twenty minutes. Immediately after removing the
valve guides from the freezer, insert the valve guides
Figure 60-80-16 (Item 1) [Figure 60-80-17] in their proper positions.
Valve Guide Removal Tool
Figure 60-80-18
75,0 mm
Valve Guide Installation Tool
(2.953 in)
65,0 mm
20,0 mm
(2.559 in)
(0.787 in)
14,0 mm 15,0 mm
(0.551 in) (0.591 in)

11,0 mm
(0.433 in) 20,0 mm
7,5 mm
1 (0,787 in)
(0,295 in)
P109453

1
P109465
The tool (Item 1) [Figure 60-80-16] above is not
provided. The tool is used for removing the valve guides.
Use the dimensions shown to make this tool. The tool (Item 1) [Figure 60-80-18] above is not
provided. The tool is used for installing the valve guides.
Use the dimensions shown to make this tool.

802 of 918 60-80-6 E85 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-80-21

Cylinder Head Disassembly And Assembly (Cont’d)

Figure 60-80-19
3

3
2

4
2
P109450

1 Install new valve stem seals (Item 1) [Figure 60-80-21] in

the correct locations.
P109449
NOTE: The exhaust and intake valve stem seals are
different and can be identified by either paint
Finish installing the valve guides (Item 1) into the cylinder marks on the outside of the seals or by the
head to the proper height (Item 2) using the valve guide seal spring (Item 2) [Figure 60-80-21] color.

Dealer Copy -- Not for Resale

installation tool (Item 3) [Figure 60-80-19].
Apply oil to the lip of the valve stem seal (Item 1). Use the
Figure 60-80-20 valve stem seal installation tool (Item 3), to install a new
valve stem seal on each of the valve guides (Item 4)
Valve Stem Seal Installation Tool [Figure 60-80-21].
65,0 mm Figure 60-80-22
(2.559 in)
16,2 mm 5 4
(0.638 in) 18,8 mm 3
(0.740 in)
2
22,0 mm
(0,866 in)

65,0 mm
1
(2.559 in)

P109428
4,0 mm
13,5 mm (0.157 in) Turn the cylinder head so the exhaust port side faces
(0.531 in) down. Install all the valves (Item 1) [Figure 60-80-22] in
their proper location in the cylinder head.
16,2 mm
(0.638 in) 18,8 mm Turn the cylinder head so the combustion side faces
(0.740 in) down. Install the valve spring (Item 2) and spring retainer
22,0 mm
(Item 3) [Figure 60-80-22].
(0,866 in)
P109506
Using the valve spring compressor tool, compress the
valve spring. Insert the valve keepers (Item 4) and slowly
The tool (Item 1) [Figure 60-80-20] above is not release the tension in the valve spring. Install the valve
provided. The tool is used for installing the valve stem cap (Item 5) [Figure 60-80-22]. Repeat the procedure on
seals. Use the dimensions shown to make this tool. all the remaining valves.

803 of 918 60-80-7 E85 Service Manual

CYLINDER HEAD (CONT’D) Valve Guide - Inspection

Cylinder Head - Servicing Clean the valve seat and combustion chamber.

Thoroughly clean the surface of the cylinder head and all Figure 60-80-25
components using a non-metallic brush and an
appropriate solvent. Each part must be free of carbon,
metal filings and other debris.
1
Figure 60-80-23

P-87490

2 Install the valve into the guide in their original locations.

Measure the valve recessing with a depth gauge (Item 1)

Dealer Copy -- Not for Resale

NA1057 [Figure 60-80-25].

Put a straight edge (Item 1) [Figure 60-80-23] on the Figure 60-80-26

cylinder head. 2
NOTE: Do not put the straight edge across
combustion chambers.

Put a feeler gauge (Item 2) [Figure 60-80-23] between

the straight edge and the surface of the cylinder head. 1
Figure 60-80-24

1. Cylinder Head
Surface
2. Recessing
PI-9990

If the measurement exceeds the allowable limit, replace

the valve or cylinder head [Figure 60-80-26].

Recessing (Intake) 0,36 - 0,56 mm

(0.0142 - 0.0220 in)
Recessing (Exhaust) 0,35 - 0,55 mm
PI-9988 (0.0138 - 0.0217 in)
Allowable Limit 0,8 mm
Put the straight edge on the cylinder head’s four sides (Intake, Exhaust) (0.0315 in)
and on the two diagonals as shown [Figure 60-80-24].

The maximum distortion of the head surface is ± 0,15

mm (± 0.0059 in). If the measurement exceeds the
specification, replace the cylinder head.

804 of 918 60-80-8 E85 Service Manual

CYLINDER HEAD (CONT’D) Intake And Exhaust Valve - Inspection

Valve Guide - Inspection (Cont’d) Inspect the intake and exhaust valves. Replace any
valves that are obviously discolored, heavily pitted or
Inspect the valve guides for wear or other damage and otherwise damaged.
replace as required.
Figure 60-80-28
Figure 60-80-27

1 1

NA1058
NA1056

Dealer Copy -- Not for Resale

Measure the valve stem diameter (Item 1) [Figure 60-80-
Measure the valve guide I.D. at three different depths and 28] where shown.
90° apart [Figure 60-80-27].
Intake Valve Stem O.D. 6,945 - 6,960 mm
NOTE: Measure the valve guides while they are still (0.2734 - 0.2740 in)
installed in the cylinder head.
Allowable Limit 6,90 mm
(Intake, Exhaust) (0.2717 in)
Valve Guide I.D. 7,0 - 7,015 mm
(0.2756 - 0.2762 in)
Allowable Limit 7,08 mm
Exhaust Valve Stem O.D. 6,940 - 6,955 mm
(0.2787 in)
(0.2732 - 0.2738 in)
Valve Guide Projection 14,7 - 15,0 mm
Allowable Limit 6,90 mm
From Cylinder Head (0.5791 - 0.5905 in)
(Intake, Exhaust) (0.2717 in)

805 of 918 60-80-9 E85 Service Manual

CYLINDER HEAD (CONT’D) Valve Face And Seat

Valve Stem Bend - Inspection Inspect the seating surfaces of each valve and valve seat
for wear, damage or evidence of overheating. Severely
Figure 60-80-29 worn or damaged components will require replacement.

Figure 60-80-30
1

NA-1059

NA1062
Place the valve stem on an inspection block. Roll the
valve until a gap can be observed between a portion of

Dealer Copy -- Not for Resale

the valve stem and the surface of the block or bed. Use a Coat the valve seat with a thin coat of bluing compound.
feeler gauge (Item 1) [Figure 60-80-29] to measure the Install the valve and rotate to distribute bluing onto the
gap. valve face. The contact pattern on the valve face (Item 1)
[Figure 60-80-30] should be approximately centered and
Intake Valve Stem Bend 0,040 - 0,070 mm even in width.
(0.0016 - 0.0028 in)
Exhaust Valve Stem Bend 0,045 - 0,075 mm Figure 60-80-31
(0.0018 - 0.0030 in)
Allowable Limit 0,17 mm
(0.0067 in) 150°
1
40°

NA1063

The valve seat diameter (Item 1) [Figure 60-80-31] can

be adjusted by top grinding with a 150° stone to make the
seat diameter smaller, and bottom grinding using a 40°
stone to make the seat diameter larger.

Seat Angle Intake 120°

Exhaust 90°

806 of 918 60-80-10 E85 Service Manual

CYLINDER HEAD (CONT’D) Push Rod - Inspection

Valve Spring - Inspection Figure 60-80-34

Inspect the valve springs. If damage or corrosion is seen,

or if measurements exceed the specified limits, replace
the springs. 1

Figure 60-80-32

NA1053

Place the push rod on an inspection block. Roll the push

rods until a gap can be observed between a portion of
the push rod and the surface of the block. Use a feeler
NA1065 gauge (Item 1) [Figure 60-80-34] to measure the gap.

Dealer Copy -- Not for Resale

Push Rod Bend Less than 0,03 mm
Measure the valve spring free length [Figure 60-80-32]. (0.0012 in)
Allowable Limit 0,03 mm
Free Length 47,5 mm
(0.0012 in)
(1.8701 in)
Allowable Limit 47,0 mm
(1.8504 in)

Figure 60-80-33

NA1064

Use a flat surface and square to check the springs for

squareness [Figure 60-80-33].

Squareness Allowable 1,2 mm

Limit (0.0472 in)

807 of 918 60-80-11 E85 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-80-36

Rocker Arm - Inspection

Figure 60-80-35
2

1
1
1
NA1055

Measure the outside diameter (O.D.) of the rocker arm

shaft at two points 90° apart (Item 1) and (Item 2) [Figure
NA1054
60-80-36].

Calculate the oil clearance (difference) between the shaft

Inspect the rocker arm contact areas (Item 1) [Figure 60- O.D. and rocker arm bore I.D.
80-35] for wear or damage and replace as required.
Measure the inside diameter (I.D.) of the rocker arm bore. Rocker Arm Bore I.D. 18,5 - 18,52 mm

Dealer Copy -- Not for Resale

(0.7283 - 0.7291 in)
Allowable Limit 18,57 mm
(0.7311 in)
Shaft O.D. 18,47 - 18,49 mm
(0.7272 - 0.7280 in)
Allowable Limit 18,44 mm
(0.7260 in)
Oil Clearance 0,010 - 0,050 mm
(0.004 - 0.0020 in)
Allowable Limit 0,13 mm
(0.0051 in)

808 of 918 60-80-12 E85 Service Manual

CRANKSHAFT AND PISTONS Figure 60-90-2

Piston And Connecting Rod Removal And

Installation
1
Remove the oil pan. (See Oil Pan Removal And
Installation on Page 60-60-1.)

Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 60-80-3.)

NOTE: Keep the piston pin parts, piston assemblies,

and connecting rod assemblies together to be
returned to the location and same position
during the reassembly process. Mark the
parts using an appropriate method. P109454

NOTE: Remove the top ridge from the cylinder bore

with a ridge reamer before removing the Place a piece of PLASTIGAGE (Item 1) [Figure 60-90-2]
pistons. along the full width of the bearing insert.

Figure 60-90-1 NOTE: Do not rotate the crankshaft when using the
PLASTIGAGE. A false reading may result.

Dealer Copy -- Not for Resale

Reinstall bearing cap and tighten to specification.
Remove bearing cap.

Figure 60-90-3

NA1091

Using a feeler gauge, measure the connecting rod side

clearance [Figure 60-90-1]. If the measurement is out of
specification, replace the crankshaft, connecting rod, or
both. P109455

Connecting Rod Side 0,20 - 0,40 mm

Clearance (0.0079 - 0.0157 in) Compare the width of the flattened PLASTIGAGE to the
graduation marks on the package (Item 1) [Figure 60-90-
Remove the bearing cap to measure the bearing oil 3]. The mark that most closely matches the width of the
clearance. Do this before removing the pistons and flattened PLASTIGAGE will indicate the oil clearance.
connecting rods to determine the extent of bearing wear.
Oil Clearance 0,025 - 0,051 mm
NOTE: Do not remove the bearing inserts at this time. (0.0010 - 0.0020 in)
Wipe oil from the bearing insert and crankshaft journal Oil Clearance Allowable Limit 0,109 mm (0.0043 in)
surfaces.

809 of 918 60-90-1 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-5

Piston And Connecting Rod Removal And 6

Installation (Cont’d)
3 9
To remove the cylinders, use a wooden dowel against the 8
connecting rod and tap the piston / connecting rod
7
assembly out of the cylinder.
2 4
NOTE: To avoid damage to the bearing journal, do 1
3
NOT allow the connecting rod to contact the 1
crankshaft journal.

NOTE: Mark the cylinder number on the piston and 5

connecting rod for reassembly.
P-37210
Figure 60-90-4
Connecting Rod Bushing Removal / Installation Remove the compression rings (Item 1), oil ring (Item 2),
circlips (Item 3) and wrist pin (Item 4) from the piston
100,0 mm (Item 5) [Figure 60-90-5].
(3.937 in)
20,0 mm Remove the connecting rod (Item 6) and bearing (Item 7)
(0.787 in) [Figure 60-90-5].

Dealer Copy -- Not for Resale

30,0 mm 33,0 mm NOTE: When using the existing crank bearings, put
(1,181 in) (1.299 in) marks on the crank pin bearing and the
connecting rod in order to keep their position.

Repeat the procedure until all pistons are removed and

1 disassembled.
P109505
Installation: When installing the piston pin, immerse the
piston in 80° C (176° F) oil for 10 to 15 minutes and insert
The tool (Item 1) [Figure 60-90-4] above is not provided. the piston pin to the piston.
The tool is used for removing and installing the
connecting rod bushings. Use the dimensions shown to Assemble the piston to the connecting rod with the ↑
make this tool. mark (Item 8) and the connecting rod numbering mark
(Item 9) [Figure 60-90-5] facing same side.

810 of 918 60-90-2 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-8

Piston And Connecting Rod Removal And

Installation (Cont’d)

Figure 60-90-6
1

P-37161

When installing the ring, assemble the rings so that the

manufacturer's mark (Item 1) [Figure 60-90-8] near the
2 gap faces the top of the piston.
P-37211A

Figure 60-90-9
Be sure the crank pin bearing and the connecting rod are Top Ring Gap

Dealer Copy -- Not for Resale

the same I.D. colors (Items 1 and 2) [Figure 60-90-6].

NOTE: The connecting rod is drilled for oil passage to

pin bushing. Make sure to line up pin bushing Second Ring
to avoid oil starvation to piston pin. Gap
Oil Ring Gap
Figure 60-90-7

Piston
Pin Hole

1 P109459

2
The piston ring gaps must be located a 120° intervals
[Figure 60-90-9].

NOTE: Do not position the top piston ring end gap in

line with the piston pin holes.

P-37160
Before installing the piston into the cylinder, apply engine
oil to the cylinder to aid in reassembly and initial startup.
When installing the oil ring onto the piston, place the
expander joint (Item 1) on the opposite side of the oil ring NOTE: Locate each piston and cylinder combination
gap (Item 2) [Figure 60-90-7]. by the markings made earlier.

811 of 918 60-90-3 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Piston And Connecting Rod Removal And

Installation (Cont’d)

Figure 60-90-10

P-37208

Install the pistons using a piston ring compressor (Item 1)

Dealer Copy -- Not for Resale

[Figure 60-90-10].

812 of 918 60-90-4 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-12

Piston And Connecting Rod - Servicing

Figure 60-90-11

P47273

Measure the O.D. of the piston pin where it contacts the

P-37233A bushing with an outside micrometer [Figure 60-90-12].

Measure the I.D. of the piston pin bushing at the

When installing the piston into the cylinder, face the connecting rod small end with a cylinder gauge [Figure
marks (Item 1) [Figure 60-90-11] on the connecting rod 60-90-12].

Dealer Copy -- Not for Resale

and top of piston toward the injection pump side of the
engine. If the clearance (difference) exceeds the allowable limit,
replace the bushing. If it still exceeds the allowable limit,
Install the bearing inserts in the connecting rod and cap. replace the piston pin.
Apply a liberal coat of clean engine oil to the bearing
inserts and crankshaft journal. Oil clearance Factory 0,025 - 0,51 mm
between piston spec. (0.0010 - 0.0020 in)
Apply engine oil to the connecting rod bolts and lightly pin and small
thread in by hand, then tighten to the specified torque. Allowable 0,109 mm
end bushing limit (0.0043 in)
If the connecting rod bolts do not thread together
smoothly, clean the threads. If the connecting rod bolt is
still hard to thread in, replace it. Piston pin O.D. Factory 29,987 - 30,0 mm
spec. (1.1806 - 1.1811 in)
Tightening Connecting 53,9 - 58,8 N•m Small end Factory 30,025 - 30,038 mm
torque rod bolt (40 - 43 ft-lb) bushing I.D. spec. (1.1821 - 1.1826 in)

813 of 918 60-90-5 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-15

Piston And Connecting Rod - Servicing (Cont’d)

Figure 60-90-13

22 mm
(0.8661 in)
NA1085

1 Measure 22 mm (0.8661 in) upwards from the bottom of

2
the piston skirt at 90° from the wrist pin bore [Figure 60-
P-37179 90-15].

Press out the used bushing using a small end bushing Piston OD 97,940 - 97,950 mm
replacing tool (Item 1) [Figure 60-90-13]. (3.8559 - 3.8563 in)

Dealer Copy -- Not for Resale

Allowable Limit 97,905 mm
Clean a replacement small end bushing and connecting (3.8545 in)
rod bore, and apply engine oil to aid in assembly.
If the measurement is below the allowable limit, replace
Figure 60-90-14
the piston.

Figure 60-90-16

P-37142A

Place the bushing onto the tool and press-fit it with a P-47272

press (Item 2) [Figure 60-90-13] so that the seam (Item

1) [Figure 60-90-14] of the bushing is flush with the Measure the piston pin bore I.D. in both the horizontal
connecting rod. and vertical directions with a cylinder gauge [Figure 60-
90-16].

If the pin bore measurement exceeds the allowable limit,

replace the piston.
Wrist Pin Bore ID 30,0 - 30,009 mm
(1.1811 - 1.1815 in)
Allowable Limit 30,039 mm
(1.1826 in)

814 of 918 60-90-6 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) If the gap exceeds the allowable limit, replace the ring.

Piston And Connecting Rod - Servicing (Cont’d) Top Ring End Gap 0,250 - 0,450 mm
(0.0098 - 0.0177 in)
Figure 60-90-17
Allowable Limit 0,540 mm
(0.0213 in)
Second Ring End Gap 0,450 - 0,650 mm
(0.017 - 0.0256 in)
Allowable Limit 0,730 mm
(0.0287 in)
Oil Ring End Gap 0,250 - 0,450 mm
(0.0098 - 0.0177 in)
Allowable Limit 0,550 mm
(0.0217 in)

PI-10017

Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler

Dealer Copy -- Not for Resale

gauge [Figure 60-90-17].

If the clearance exceeds the allowable limit, replace the

ring. If the clearance still exceeds the allowable limit,
replace the piston.
Top Ring Side Clearance 0,08 - 0,12 mm
(0.0031 - 0.0047 in)
Second Ring Side 0,09 - 0,125 mm
Clearance (0.0035 - 0.0049 in)
Oil Ring Side Clearance 0,025 - 0,060 mm
(0.0010 - 0.0024 in)
Figure 60-90-18

B3622

Install a piston ring into the lower part of the cylinder

bore. Measure the ring gap with a feeler gauge [Figure
60-90-18].

815 of 918 60-90-7 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-90-20

Cylinder Bore - Inspection

The oil passages must be clear and unobstructed. 20 mm (.75 in)

Inspect for discoloration or evidence of cracks. If a crack
is suspected, use the color check method or the
Magnaflux method to determine if the cylinder block is
cracked.

Figure 60-90-19

20 mm (.75 in)

P109456

To find the maximum wear, check the inside diameter in

six different locations [Figure 60-90-20].

If the cylinder bore is not within specifications, bore and

hone the cylinder for an oversize piston. Replace the
piston and piston rings with oversize (0,5 mm) ones.

Dealer Copy -- Not for Resale

B-4066 Cylinder ID 98,0 - 98,03 mm
(3.8583 - 3.8594 in)

Use a gauge to measure the inside of the cylinder bore Allowable Limit 98,13 mm (3.8634 in)
[Figure 60-90-19]. Cylinder Bore Taper - Roundness 0,01 mm (0.0004 in)
Allowable Limit 0,03 mm (0.0012 in)

NOTE: When the oversize cylinder is worn beyond

the allowable limit, replace the cylinder block
with a new one.

816 of 918 60-90-8 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings Removal And Installation

Crankshaft End Play Figure 60-90-22

Figure 60-90-21 1 2
3
4
5

NA1095

NA1096
Remove the bolts (Item 1) and flywheel (Item 2) [Figure
60-90-22].
Install a dial indicator on the cylinder block with the tip on
the end of the crankshaft [Figure 60-90-21]. Measure the Installation: Tighten the bolts to 186 - 206 N•m (137 -

Dealer Copy -- Not for Resale

end play by moving the crankshaft to the front and rear. 152 ft-lb) torque.

Crankshaft End Play 0,13 - 0,23 mm Remove the oil seal retainer bolts (Item 3), oil seal
(0.0051 - 0.0091 in) retainer (Item 4) and seal (Item 5) [Figure 60-90-22].
Allowable Limit 0,28 mm
(0.0110 in) NOTE: Before removing the main bearing caps,
measure the crankshaft end play. (See
Crankshaft End Play on Page 60-90-9.)
If the measurement exceeds the allowable limit, replace
the thrust bearings.
Figure 60-90-23

NA1098

Mark for assembly and remove the rod bearing caps, rod
bearings, bearing caps and main bearings [Figure 60-
90-23].

NOTE: The arrows on the main bearing caps point to

the flywheel end of the engine.

Remove the crankshaft from the block.

817 of 918 60-90-9 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings - Servicing

Crankshaft And Bearings Removal And Installation Use the color check method or Magnaflux® to inspect the
(Cont’d) crankshaft for cracks. Replace the crankshaft if evidence
of cracks are found.
Figure 60-90-24
Figure 60-90-25

3
2

NA1099

A2763

Do not remove the crankshaft gear (Item 1), key (Item 2)

Dealer Copy -- Not for Resale

and parallel pin (Item 3) [Figure 60-90-24] unless worn Put the crankshaft end journals on V-blocks. Install a dial
or damaged. indicator on the center journal [Figure 60-90-25].

NOTE: If it is necessary remove the crankshaft gear Turn the crankshaft at a slow rate to obtain the
using a gear puller, use care not to damage misalignment (one half of the alignment measurement).
the threads in the end of the crankshaft.
If the misalignment exceeds the allowable limit, replace
the crankshaft.

Alignment 0,02 mm
(0.0008 in)

818 of 918 60-90-10 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Crankshaft And Bearings - Servicing (Cont’d)

Figure 60-90-26

A2716

Measure the main bearing journals and connecting rod

journals [Figure 60-90-26].

Dealer Copy -- Not for Resale

Connecting Journal OD 57,952 - 57,962 mm
Rod Journal (2.2816 - 2.2827 in)
Allowable Limit 57,902 mm
(2.2796 in)
Bearing ID 58,0 - 58,026 mm
(2.2835 - 2.2845 in)
Bearing Insert 1,492 - 1,50 mm
Thickness (0.0587 - 0.0591 in)
Oil Clearance 0,038 - 0,074 mm
(0.0015 - 0.0029 in)
Allowable Limit 0,150 mm
(0.0059 in)
Main Bearing Journal OD 64,952 - 64,962 mm
Journal (2.5572 - 2.5576 in)
Allowable Limit 64,902 mm
(2.5552 in)
Bearing ID 65,0 - 65,020 mm
(2.559 - 2.5598 in)
Bearing Insert 1,995 - 2,010 mm
Thickness (0.0785 - 0.0791in)
Oil Clearance 0,038 - 0,068 mm
(0.0015 - 0.0027 in)
Allowable Limit 0,150 mm
(0.0059 in)

819 of 918 60-90-11 E85 Service Manual

Dealer Copy -- Not for Resale

820 of 918 60-90-12 E85 Service Manual

CAMSHAFT AND TIMING GEARS Figure 60-100-2

Timing Gear Case Cover Removal And Installation 4

Remove the bolt and washer from the crankshaft pulley.

Remove the crankshaft pulley using a gear puller.

NOTE: Use care not to damage the threads in the end

of the crankshaft when removing the
crankshaft pulley.
1
Installation: Apply engine oil to the bolt threads and
tighten the crankshaft pulley bolt to 108 - 128 N•m (80 - 2
94 ft-lb) torque. 5
3 P109418
NOTE: Clean the crankshaft bolt and the drive pulley
sleeve surface thoroughly.
Remove the timing gear case bolts mounting to the
Figure 60-100-1 cylinder block (Item 1) and oil pan (Item 2). Remove the
oil pump and mounting bolt (Item 3) (See Oil Pump
1 Removal And Installation on Page 60-60-2.). Remove the
3 gear case and gasket (Item 4). Clean all of the old
sealant off the cylinder block and timing gear case.

Dealer Copy -- Not for Resale

Remove and discard the O-rings (Item 5) [Figure 60-
100-2].

Installation: Confirm that the liquid gasket coating

surface is free of water, dust and oil in order to maintain
sealing effect.

NOTE: Apply a liquid gasket evenly to the gearcase

cover. Assemble the adhesive-applied parts
2
within the manufacture’s specified cure time.
P109417
Figure 60-100-3

Remove the gear case cover bolts mounting to the gear

case (Item 1) and oil pan (Item 2) [Figure 60-100-4].
Remove the gear case covers (Item 3).
1

P109435

Remove the oil pump (See Oil Pump Removal And

Installation on Page 60-60-2.). Remove the oil pump
drive gear (Item 1) [Figure 60-100-3] using a puller.

821 of 918 60-100-1 E85 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-5

Timing Gear Backlash - Inspection

Before removing the timing gears, measure the gear

backlash and determine the gear wear.

Figure 60-100-4
1 2 4
3

NA1081

Install a dial indicator and rotate the idler gear back and
forth to check the idler gear to crankshaft backlash
5 [Figure 60-100-5]. Check the remainder of the gears
using the above procedure.
6
P109433
NOTE: Do not allow the gear being checked to move

Dealer Copy -- Not for Resale

axially as excess end play could cause a false
(Item 1) Fuel injection pump drive gear reading.
(Item 2) Idler gear (B)
(Item 3) Idler gear (A)
(Item 4) Camshaft drive gear
(Item 5) Crankshaft drive gear
(Item 6) [Figure 60-100-4] Oil pump drive gear.

Fuel Injection Pump Gear 0,08 - 0,14 mm

(0.0031 - 0.0055 in)
Idler Gear (B) 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Idler Gear (A) 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Camshaft Gear 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Crank Shaft Gear 0,08 - 0,14 mm
(0.0031 - 0.0055 in)
Allowable Limit 0,16 mm
(0.0063 in)
Oil Pump Gear 0,09 - 0,15 mm
(0.0035 - 0.0059 in)
Allowable Limit 0,17 mm
(0.0067 in)

822 of 918 60-100-2 E85 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-8

Idler Gear And Camshaft Removal And Installation

Figure 60-100-6
Camshaft Bushing Removal Tool

70,0 mm
(2.756 in)

50,0 mm 18,0 mm
(1.968 in) (0.709 in)

53,0 mm
(2,087
P109436

Install a dial indicator on the cylinder block. Move the

1 camshaft back and forth to measure end play [Figure 60-
P109507 100-8].

The tool (Item 1) [Figure 60-100-6] above is not Camshaft End Play 0,05 - 0,20 mm
provided. The tool is used for removing the camshaft (0.0020 - 0.0079 in)
bushings. Use the dimensions shown to make this tool.

Dealer Copy -- Not for Resale

Allowable Limit 0,030 mm
Figure 60-100-7 (0.0118 in)

3 Figure 60-100-9
2

4
1
5 P109434
1

Remove the bolts from the idler gear shafts (Item 1). P-87490

Remove the idler gear ‘B’ (Item 2), shaft and bushing
(Item 3). Remove the idler gear ‘A’ (Item 4), shaft, Remove the two bolts (Item 1) from the retaining plate
bushing and plate (Item 5) [Figure 60-100-7]. (Item 2). Rotate the engine on the engine stand so that
gravity causes the tappets (Item 3) [Figure 60-100-9] to
Do not remove the crankshaft gear unless it requires drop away from the camshaft lobes.
replacement. If it must be removed, use a gear puller.
NOTE: If the engine is not installed on an engine
Do not remove the camshaft gear unless it or the stand, stand the engine upright on the
camshaft requires replacement. To remove the camshaft flywheel end mounting flange. Rotate the
gear, remove the camshaft from the engine, heat to 356° camshaft at least two turns to bump the
- 392°F (180° - 200°C) and use a knife-edge puller and a tappets out of the way.
press.
NOTE: Use care to not damage the front camshaft
NOTE: Before removing the camshaft, check the bearing.
camshaft end play.
Mark and remove the tappets (Item 3) [Figure 60-100-9].

823 of 918 60-100-3 E85 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-12

Valve Tappet - Servicing

Figure 60-100-10

1 2

P-37174

Measure the I.D. of the tappet bore with a cylinder gauge,

and calculate the oil clearance [Figure 60-100-12].
P109457

Tappet O.D. Factory 11,975 - 11,990 mm

Inspect the tappet contact surfaces for abnormal wear spec. (0.4715 - 0.4720 in)
(Item 1). Normal wear will be even as shown in (Item 2) Allowable 11,955 mm
[Figure 60-100-10]. Slight surface defects can be

Dealer Copy -- Not for Resale

limit (0.4707 in)
corrected using an oilstone.
Tappet Factory 12,000 - 12,018 mm
Figure 60-100-11 spec. (0.4724 - 0.4731 in)
Bore I.D. Allowable 12,038 mm
limit (0.4739 in)

Oil clearance Factory 0,010 - 0,043 mm

between tappet spec. (0.0004 - 0.0017 in)
and guide Allowable 0,083 mm
limit (0.0033 in)

If the oil clearance exceeds the allowable limit or the

tappet is damaged, replace the tappet.

Before installing the tappets, apply engine oil to aid in

P109458
assembly and initial startup.

Measure the tappet O.D. with an outside micrometer NOTE: Use the cylinder number markings on the
[Figure 60-100-11]. tappets to prevent interchanging.

824 of 918 60-100-4 E85 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-100-14

Camshaft - Servicing

Figure 60-100-13

B-5001

Measure the cam lobes at their highest point [Figure 60-

A-2760 100-14].

If the measurement is less than the allowable limit,

Put the camshaft in V-blocks. Install a dial indicator replace the camshaft.
[Figure 60-100-13].

Dealer Copy -- Not for Resale

Cam Lobe Height 42,435 - 42,565 mm
Turn the camshaft at a slow rate. If the misalignment (1.6707 - 1.6758 in)
exceeds the allowable limit, replace the camshaft.
Allowable Limit 42,185 mm
(1.6608 in)
Camshaft Alignment 0,02 mm
(0.0008 in)
Allowable Limit 0,05 mm
(0.002 in)

825 of 918 60-100-5 E85 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Flywheel And Bore ID 50,0 - 50,025 mm
Journal (1.9685 - 1.9695 in)
Camshaft - Servicing (Cont’d)
Allowable Limit 50,1 mm
Figure 60-100-15 (1.9724 in)
Camshaft OD 49,925 - 49,95 mm
(1.9655 - 1.9665 in)
Allowable Limit 49,89 mm
(1.7673 in)
Oil Clearance 0,05 - 0,1 mm
(0.0020 - 0.0039 in)
Allowable Limit 0,210 mm
(0.0083 in)

Idler Gear And Shaft - Servicing

Figure 60-100-16
A-2761
2

Measure the camshaft journal [Figure 60-100-15].

Dealer Copy -- Not for Resale

Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the camshaft.

Gear End Bushing ID 49,99 - 50,06 mm

Journal (1.9681 - 1.9707 in)
Allowable Limit 50,130 mm
(1.9736 in) 2

Camshaft OD 49,925 - 49,950 mm

(1.9655 - 1.9665 in) 1
P109434
Allowable Limit 49,89 mm
(1.9642 in)
Oil Clearance 0,04 - 0,13 mm Measure the OD of the idler gear shafts (Item 1) and the
(0.0016 - 0.0051 in) ID of the bushing (Item 2) [Figure 60-100-16] and
calculate the oil clearance.
Allowable Limit 0,240 mm
(0.0094 in)
Shaft OD 45,95 - 45,975 mm
Intermediate Bore ID 50,0 - 50,025 mm (1.8091 - 1.8100 in)
Journal (1.9685 - 1.9695 in)
Allowable Limit 45,9 mm
Allowable Limit 50,1 mm (1.8071 in)
(1.9724 in)
Bushing ID 46,0 - 46,025 mm
Camshaft OD 49,91 - 49,935 mm (1.8110 - 1.8120 in)
(1.9650 - 1.9659 in)
Allowable Limit 46,075 mm
Allowable Limit 49,875 mm (1.8140 in)
(1.9636 in)
Oil Clearance 0,025 - 0,075 mm
Oil Clearance 0,065 - 0,115 mm (0.001 - 0.003 in)
(0.0026 - 0.0045 in)
Allowable Limit 0,175 mm
Allowable Limit 0,225 mm (0.0069 in)
(0.0089 in)
If the oil clearance exceeds the allowable limit, replace
the bushing.

826 of 918 60-100-6 E85 Service Manual

EXHAUST GAS RECIRCULATION (EGR) VALVE

Description

Figure 60-110-1

P109547

The EGR valve (Item 1) [Figure 60-110-1] controls the

exhaust gas recirculation flow rate depending on the

Dealer Copy -- Not for Resale

engine speed / load signals from the E-ECU.

Figure 60-110-2

4
2 1
3
P109548

The EGR valve (Item 1) is connected to the EGR cooler

(Item 2) with an EGR pipe (Item 3) and on top of the
intake manifold (Item 4) [Figure 60-110-2].

827 of 918 60-110-1 E85 Service Manual

EXHAUST GAS RECIRCULATION (EGR) VALVE Figure 60-110-3
(CONT’D)

Removal And Installation 1

WARNING
AVOID INJURY OR DEATH
When the engine is running during service, the
steering levers or joysticks must be in neutral and
2
the parking brake engaged. 1
W-2717-0208

P109549

WARNING Remove the EGR valve electrical connectors for the three
temperature sensors (Item 1) and the one motor control
(Item 2) [Figure 60-110-3].
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Figure 60-110-4
Put jackstands under the front and rear of the
machine before running engine for service.

Dealer Copy -- Not for Resale

W-2718-0208

WARNING
5
AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust 4
outside. Exhaust fumes contain odorless, invisible 1 3 2
gases which can kill without warning. P109548
W-2050-0807

Remove the nuts (Item 1) in the coupling flanges of the

EGR cooler and the EGR pipe. Remove the bolts (Item 2)
in the coupling flanges of the EGR pipe and EGR valve,
WARNING and remove the EGR pipe (Item 3). Remove the four
EGR mounting bolts (Item 4) and the EGR valve and
motor assembly (Item 5) [Figure 60-110-4].
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation NOTE: The EGR system uses steel gaskets at the
system can be hot. Use caution when conducting joints between its components / parts. These
diagnostic tests. steel gaskets are specific to the respective
joints. When you remove the system's
Allow the engine to cool before servicing. components / parts and reinstall them,
W-2716-0208 replace the steel gaskets between them with
new correct ones.
Remove the battery cable from the negative (-) battery
terminal.

828 of 918 60-110-2 E85 Service Manual

EXHAUST GAS RECIRCULATION (EGR) VALVE Lead (Reed) Valve Cleaning
(CONT’D)
Figure 60-110-5
EGR Valve Testing And Cleaning

When the key is first turned to the run position, the ECU
checks valve operation by opening and shutting the
valve. 1

The EGR valves and pipes must be cleaned every 3,000

hours to prevent deterioration of the EGR ratio. To
remove deposited carbon, use compressed air (0.19
MPa, [1,9 bar] [27 psi] or lower). If the valves are heavily
fouled, use carbon cleaner, kerosene, or some other
liquid capable of removing carbon as well as a soft brush
to clean the valves, taking care not to damage their parts.

NOTE: When cleaning the valves, take extreme care

P109547
to prevent water, solvent, cleaner, and other
liquid from entering into the motor and
coupler terminals or failure may result. The reed valve (Item 1) [Figure 60-110-5] located
between the EGR valve and the intake manifold prevents
If the EGR valve continues to operate poorly, replace the fresh air from flowing into the EGR system.
valve.

Dealer Copy -- Not for Resale

To remove deposited carbon inside the lead valves,
NOTE: When it is necessary to replace an EGR valve, disassemble and clean them. Use carbon cleaner,
be sure to replace the entire EGR valve kerosene, or some other liquid capable of removing
assembly. Do NOT attempt to disassemble carbon as well as a soft brush to clean the valves, taking
and repair the EGR valve, or replace its care not to damage their parts. Make sure that the case,
individual components. valve and stopper are free of foreign matter and liquids
and then reinstall.

Installation

Figure 60-110-6

3
1

P109550

Install the valve and stopper (Item 1) so that they are

located on the left-hand side of the valve and evenly
positioned inside the case window (Item 2) [Figure 60-
110-6].

Tighten the screws (Item 3) [Figure 60-110-6] to 1.4 N•m

(12.4 in-lb) torque. After tightening, mark the screw.

829 of 918 60-110-3 E85 Service Manual

EXHAUST GAS RECIRCULATION (EGR) VALVE
(CONT’D)

EGR Cooler Cleaning

Drain the radiator. (See Removing And Replacing

Coolant on Page 10-110-2.)

Figure 60-110-7

P109551

Dealer Copy -- Not for Resale

Remove the EGR cooler (Item 1) [Figure 60-110-1]. To
remove deposited carbon inside the exhaust section of
the cooler, disassemble and clean using carbon cleaner
or kerosene. Rinse the coolant section with a descaler
solution.

830 of 918 60-110-4 E85 Service Manual

EXHAUST GAS RECIRCULATION (EGR) VALVE Figure 60-110-9
(CONT’D)

Intake Throttle

Figure 60-110-8

P109552

The intake throttle valve [Figure 60-110-9] is motor

driven. The ECU controls the appropriate degree of
P109547 opening of the throttle depending on the engine speed
and load conditions.

The intake throttle (Item 1) [Figure 60-110-8] controls the Intake Throttle Handling Precautions:

Dealer Copy -- Not for Resale

amount of the engine air intake. The intake throttle is
used for the combustion of soot collected inside the DPF. • To avoid injury, do not touch the throttle valve when
the throttle is energized.

• To avoid damage, do not operate the valve with the

installation surface pointing down, as the valve
protrudes below the installation surface.

• Do not apply excessive impact or load to the throttle.

Replace a throttle if it has been dropped, due to
possible internal damage.

• Prevent any foreign matter including oil, dust, and

water droplets from entering the air passage and the
connector.

• Prevent static electric charge of the human body

when handling the throttle. Do not touch the sensor
cover terminal directly.

• Do not remove the sensor cover installation rivet.

• Do not adjust the stop screw.

831 of 918 60-110-5 E85 Service Manual

Dealer Copy -- Not for Resale

832 of 918 60-110-6 E85 Service Manual

GLOW PLUGS

Testing

Figure 60-120-1

P112552

Connect a test meter to the end of the glow plug.

Connect the second lead of the meter to the glow plug

Dealer Copy -- Not for Resale

body [Figure 60-120-1].

The reading should be approximately 0.5 ohm. If the

resistance is infinite or zero, the glow plug is defective
and must be replaced.

833 of 918 60-120-1 E85 Service Manual

GLOW PLUGS (CONT’D) Figure 60-120-4

Removal And Installation

Figure 60-120-2
1

P112551

Remove the glow plugs (Item 1) [Figure 60-120-4].

P112549
Installation: Tighten the glow plug to 15 - 20 N•m (133 -
177 in-lb)
Remove the nut (Item 1) [Figure 60-120-2] and wire from
the glow plug.

Dealer Copy -- Not for Resale

Figure 60-120-3

1
2

P112550

Loosen the nuts (Item 1) on the three glow plugs and

reposition the glow plug strap (Item 2) [Figure 60-120-3].

834 of 918 60-120-2 E85 Service Manual

ENGINE FLYWHEEL Figure 60-130-3

Hydraulic Pump Coupler Removal And Installation

Remove the hydraulic piston pump. (See Removal And

Installation on Page 20-50-13.)

Figure 60-130-1

1
1
P-87488

Remove the snap ring (Item 1) [Figure 60-130-3].

Figure 60-130-4
2
P-87483

Dealer Copy -- Not for Resale

Remove the twelve bolts (Item 1) and plate (Item 2)
[Figure 60-130-1].

Installation: Apply thread adhesive (Loctite® 242) to the

bolt threads before installation.

Tighten the bolts to 61 N•m (45 ft-lb) torque.

Figure 60-130-2

P-87489

1
1 Turn the coupler over and remove the center of the
coupler [Figure 60-130-4].

1
2

P112051

Remove the bolts (Item 1) and coupler (Item 2) [Figure

60-130-2].

NOTE: The bolts may need to be heated to melt the

thread adhesive before removal.

Installation: Apply thread adhesive (Loctite® 271) to the

bolt threads before assembly.

835 of 918 60-130-1 E85 Service Manual

ENGINE FLYWHEEL (CONT’D) Flywheel Ring Gear Removal And Installation

Flywheel Removal And Installation

Figure 60-130-5
WARNING
AVOID INJURY OR DEATH
1 Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
1
• Engine is running.
• Tools are being used.
W-2019-0907

1
The ring gear on the flywheel is an interference fit. Heat
the ring gear enough to expand it and hit it with a
P-87490
hammer evenly to remove it.

Clean the outer surface of the flywheel to give a smooth

Remove the six bolts (Item 1) [Figure 60-130-5] from the fit.
flywheel.

Dealer Copy -- Not for Resale

Clean the new ring gear and heat it to a temperature of
Installation: Tighten the bolts 186 - 206 N•m (137 - 152 232 - 260°C (450 - 500°F)
ft-lb) torque.
Fit the ring gear over the flywheel. Make sure the gear is
Remove the flywheel. seated correctly.

836 of 918 60-130-2 E85 Service Manual

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 70-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 70-30-1
The Compressor Operates Improperly Or Not At All . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Dealer Copy -- Not for Resale

Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-2
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-4
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-5
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-6

SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 70-40-1
Charging With A Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-4

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4

CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

837 of 918 70-01 E85 Service Manual

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

HVAC CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Dealer Copy -- Not for Resale

838 of 918 70-02 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW

Description

In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.

The compressor (Item 1) (See Chart on Page 70-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 70-10-2.).

Ambient air passing through the condenser removes the heat from the refrigerant, resulting in a physical state change in
the refrigerant from a gas to a liquid.

The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 70-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) Page (See Chart on Page 70-10-2.).

The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 70-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) (See Chart on Page 70-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and

Dealer Copy -- Not for Resale

drips into the drain pan, which directs the water out of the cab.

The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

839 of 918 70-10-1 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

Chart

Thermostat
Cold Air
Evaporator

5
Evaporator
4 Expansion Valve

Blower 6

Dealer Copy -- Not for Resale

1 Compressor

2 Condenser
Pressure
Switch
Sight
Glass

Fan
Desiccant

3 Receiver Drier

High Pressure Gas Low Pressure Liquid

High Pressure Liquid
Low Pressure Gas

840 of 918 70-10-2 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-3

Components

Figure 70-10-1 1

P112052

1 Condenser: The condenser (Item 1) [Figure 70-10-3] is

P-86815 the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
Compressor: The compressor (Item 1) [Figure 70-10-1]
is the pump that circulates the refrigerant through the Figure 70-10-4

Dealer Copy -- Not for Resale

system. It raises the pressure of the refrigerant for heat
transfer through the condenser and evaporator.

NOTE: The A/C system (Compressor) is 2

recommended to be turned on for at least five
minutes weekly through the year to lubricate
the internal components.

Figure 70-10-2
1

P112520

Receiver / Drier: The receiver / drier (Item 1) [Figure 70-

10-4] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
1 from the system. It also serves as a storage tank for the
extra liquid refrigerant until it is needed by the evaporator.

P-86889 Pressure Switch: The pressure switch (Item 2) [Figure

70-10-4] will disengage the compressor clutch at high
pressure readings on the high side, or at very low
Compressor Diode: The compressor diode is located pressure on the high side, which indicates loss of
under the compressor [Figure 70-10-2]. refrigerant.

841 of 918 70-10-3 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-7

Components (Cont’d) 3 2

Figure 70-10-5

P-87074
1

Thermostat: The thermostat (Item 1) [Figure 70-10-7]

P-86942 controls the temperature of the evaporator coil.

Heater Coil: The heater coil (Item 2) [Figure 70-10-7]

Evaporator / Heater Unit: The evaporator / heater unit supplies the warm air into the cab by passing air through
(Item 1) [Figure 70-10-5] is located under the operator the coil.

Dealer Copy -- Not for Resale

seat in the excavator cab. The unit delivers cold air for the
A/C and warm air for heat into the cab. The unit contains Evaporator Coil: The evaporator coil (Item 3) [Figure 70-
the blower, heater coil, evaporator coil, thermostat, and 10-7] cools and dehumidifies the air before it enters the
expansion valve. cab.

Figure 70-10-6 Figure 70-10-8

1 1

P-87067 P-87068

Expansion Valve: The expansion valve (Item 1) [Figure Heater / Evaporator Blower: The blower (Item 1) [Figure
70-10-6] controls the amount of refrigerant entering the 70-10-8] pushes air through the heater and evaporator
evaporator coil. coils and into the cab.

842 of 918 70-10-4 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-10

Components (Cont’d)

Figure 70-10-9

3 5 5
6
1

2 4
P112538

Heater Valve: The heater valve (Item 1) [Figure 70-10-

P111020 10] is used to control the amount of engine coolant that
flows to the heater coil.

Control Panel: The panel (Item 1) [Figure 70-10-9] has

three separate components.

Dealer Copy -- Not for Resale

Fan Switch: This is a three position switch (Item 2)
[Figure 70-10-9]. When the fan switch is in the off
position the A/C will not engage.

A/C Switch: The switch (Item 3) [Figure 70-10-9] will be

illuminated when the A/C is engaged.

Temperature Control: The temperature control (Item 4)

[Figure 70-10-9] controls the cooling / heating air
temperature.

Directional Switches: The switches (Item 5) [Figure 70-

10-9] control the direction of the air flow.

Off Switch: The off switch (Item 6) [Figure 70-10-9] shuts

the HVAC system off.

843 of 918 70-10-5 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-12

Safety Equipment

In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.

Figure 70-10-11

P-16399

R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8°C (21.6°F)
“INSTANTLY”.

If it spills on your skin or in your eyes you should flood the

Dealer Copy -- Not for Resale

P-16398 area with cool water and SEEK MEDICAL ATTENTION
FAST! It is a good idea to wear gloves to prevent frost
bite if you should get refrigerant on your hands [Figure
In addition to exercising caution in your work, DO WEAR 70-10-12].
SAFETY GLASSES OR A FACE SHIELD when you are
using R-134a or a leak detector, adjusting service valves
or the manifold gage set connectors. Safety glasses or a
transparent face shield are practical safety items and one
or the other is absolutely required [Figure 70-10-11].
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
WARNING blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
In the event of a leak, wear safety goggles. Escaping when it contacts open flame or very hot
refrigerant can cause severe injuries to eyes. In substances.
contact with a flame, R-134a refrigerant gives a toxic • NEVER SMOKE when there is the possibility of
gas. even small amounts of R-134a in the air.
W-2371-0611 Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611

844 of 918 70-10-6 E85 Service Manual

REGULAR MAINTENANCE Figure 70-20-3

Filters

Remove the Heat / A/C filter. (See Cleaning And

Maintenance on Page 10-100-1.)

Clean the filter by shaking it or using low air pressure. 2

Belt Adjustment

See the SERVICE SCHEDULE for the correct service 1

interval. (See SERVICE SCHEDULE on Page 10-80-1.)

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

Page 10-50-1.)
P111134
Figure 70-20-1

Press down on the belt midway between the crankshaft

pulley and the compressor pulley. The correct tension
1 should allow the belt to deflect 10 mm (0.375 in) [Figure
70-20-3].

Loosen the lock nut (Item 1) and adjust the bolt (Item 2)

Dealer Copy -- Not for Resale

[Figure 70-20-3] until the belt tension is correct.

When the belt tension is correct, tighten the lock nut (Item
1) [Figure 70-20-3].

Tighten the belt idler mounting bolt (Item 1) [Figure 70-

20-2].
P111130

Reinstall the shield (Item 2) and the two bolts and

The air conditioning belt will be adjusted by using the bolt washers (Item 1) [Figure 70-20-1].
(Item 1) [Figure 70-20-1].

Figure 70-20-2
WARNING
AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
screens, shields or rubber deflectors.
1 • Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
W-2528-0406

P111135

NOTE: The belt shield is removed for photo clarity in

the following two photos.

Loosen the belt idler mounting bolt (Item 1) [Figure 70-

20-2].

845 of 918 70-20-1 E85 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 70-20-6

Belt Replacement

Figure 70-20-4

2
1

P111134

Loosen the lock nut (Item 1) and the bolt (Item 2) [Figure
P111130 70-20-6] until the belt can be removed.

Install a new belt.

Remove the two bolts and washers (Item 1) and remove
the shield (Item 2) [Figure 70-20-4]. Adjust the bolt (Item 2) until the belt tension is correct.

Dealer Copy -- Not for Resale

Tighten the lock nut (Item 1) [Figure 70-20-6].
Figure 70-20-5
Tighten the belt idler mounting bolt (Item 1) [Figure 70-
20-5].

Reinstall the shield (Item 2) and the two bolts and

washers (Item 1) [Figure 70-20-4].

1
WARNING
AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
screens, shields or rubber deflectors.
P111135
• Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
Loosen the belt idler nut (Item 1) [Figure 70-20-5]. W-2528-0406

846 of 918 70-20-2 E85 Service Manual

REGULAR MAINTENANCE (CONT’D)

Condenser

Open the right side cover.

Figure 70-20-7

P112052

Check the condenser (Item 1) [Figure 70-20-7] for mud

Dealer Copy -- Not for Resale

or dirt.

The condenser can be cleaned with low water or air

pressure.

847 of 918 70-20-3 E85 Service Manual

REGULAR MAINTENANCE (CONT’D)

Air Conditioning Service Chart

Service Company Name / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:

Pre Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure:
Low Side Pressure:
Ambient Humidity:
Observations:

Dealer Copy -- Not for Resale

Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure:
Low Side Pressure:
Ambient Humidity:
Observations:

848 of 918 70-20-4 E85 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 70-20-10

Evaporator / Heater Coil 1

NOTE: The following procedure is shown for

cleaning the evaporator / heater coil. The unit
is not serviceable separately.

Remove the evaporator / heater unit. (See Removal And

Installation on Page 70-80-1.)

Remove the blower fan. (See Removal And Installation

on Page 70-110-1.)

Figure 70-20-8
P-87074

1. Loose drive belt The belt is vibrating or oscillating Adjust tension
2. Internal compressor
The compressor is locked up and the belt slips Replace compressor
malfunction
MAGNETIC CLUTCH RELATED
3. Low battery voltage Clutch slips Recharge the battery
4. Faulty coil Clutch slips Replace the magnetic clutch
5. Oil on the clutch surface Clutch slips Replace or clean the clutch surface
Clutch does not engage and there is not reading
6. Open oil when a circuit tester is connected between the coil Replace clutch
and terminals
7. Broken wiring or poor Clutch will not engage. Inspect the ground and
Repair
ground connections.
8. Wiring harness Test the conductance of the pressure switch,
Check operation
components thermostat, relay, etc.

851 of 918 70-30-1 E85 Service Manual

TROUBLESHOOTING (CONT'D)

Gauge Pressure Related Troubleshooting

Figure 70-30-1 Install the gauge set on the low pressure port (Item 1)
and the high pressure port (Item 2) [Figure 70-30-1].

Open all windows and doors.

Start the engine and run at 1800 - 2000 rpm.

2
Check the high / low pressure of refrigerant.

1
P-86825

High Pressure 790 - 980 kPa (7,9 - 9,8 bar) (114 - 142 psi)
Low Pressure 90 kPa (0,9 bar) (14 psi)

Dealer Copy -- Not for Resale

POSSIBLE CAUSE INSPECTION SOLUTION
Inspect connections for traces of refrigerant oil Reassemble fittings
Low refrigerant level Use leak detection device to check for leakage at Repair / replace leaking
all major components and connections component

High Pressure Over 2260 kPa (22,6 bar) (327 psi)

Low Pressure Approximately 240 -290 kPa (2,4 - 2,9 bar) (35 - 42 psi)

POSSIBLE CAUSE INSPECTION SOLUTION

Recover refrigerant and
Overcharge, frost on condenser High system pressure
recharge to correct pressure
Condenser tube and / or fin Inspect condenser for damaged tubes or cooling
Repair / replace condenser
damage fins.

High Pressure 1970 - 2450 kPa (19,7 - 24,5 bar) (285 - 355 psi)
Low Pressure 240 - 340 kPa (2,4 - 3,4 bar) (35 - 50 psi)

High Pressure Over 2120 - 2260 kPa (21,2 - 22,6 bar) (313 - 327 psi)
Low Pressure 250 kPa (2,5 bar) (36 psi)

POSSIBLE CAUSE INSPECTION SOLUTION

Refrigerant pressure problem due Install temperature sensor
Inspect whether the temperature sensor is installed
to defective expansion valve or correctly, replace expansion
correctly
temperature sensor valve.

High Pressure over 690 - 1080 kPa (6,9 - 10,8 bar) (100 - 156 psi)
Low Pressure 390 - 590 kPa (3,9 - 5,9 bar) (57 - 85 psi)

POSSIBLE CAUSE SOLUTION

Low pressure due to poor compressor performance Inspect and replace compressor if necessary

853 of 918 70-30-3 E85 Service Manual

TROUBLESHOOTING (CONT'D)

Temperature / Pressure Chart

NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP C (F) kPag (barg) (psig) TEMP C (F) kPag (barg) (psig)
-9 (16) 108 (1,08) (15.69) 34 (93) 760 (7,60) (110.20)
-8 (18) 118 (1,18) (17.04) 34 (94) 773 (7,73) (112.10)
-7 (20) 127 (1,27) (18.43) 35 (95) 787 (7,87) (114.10)
-6 (22) 137 (1,37) (19.87) 38 (100) 857 (8,57) (124.30)
-4 (24) 147 (1,47) (21.35) 39 (102) 886 (8,86) (128.50)
-3 (26) 158 (1,58) (22.88) 40 (104) 916 (9,16) (132.90)
-2 (28) 169 (1,69) (24.47) 41 (106) 947 (9,47) (137.30)
-1 (30) 179 (1,79) (26.10) 42 (108) 978 (9,78) (141.90)
0 (32) 192 (1,92) (27.79) 43 (110) 1010 (10,10) (146.50)
1 (34) 204 (2,04) (29.52) 44 (112) 1043 (10,43) (151.30)
2 (36) 216 (2,16) (31.32) 46 (114) 1076 (10,76) (156.10)
3 (38) 229 (2,29) (33.17) 47 (116) 1111 (11,11) (161.10)
4 (40) 242 (2,42) (35.07) 48 (118) 1145 (11,45) (166.10)
6 (42) 255 (2,55) (37.03) 49 (120) 1181 (11,81) (171.30)
7 (44) 269 (2,69) (39.05) 50 (122) 1218 (12,18) (176.60)
7 (45) 276 (2,76) (40.09) 51 (124) 1255 (12,55) (182.00)
10 (50) 314 (3,14) (45.48) 52 (126) 1293 (12,93) (187.50)
13 (55) 353 (3,53) (51.27) 53 (128) 1331 (13,31) (193.10)

Dealer Copy -- Not for Resale

16 (60) 396 (3,96) (57.47) 54 (130) 1371 (13,71) (198.90)
18 (65) 442 (4,42) (64.10) 57 (135) 1473 (14,73) (213.70)
21 (70) 491 (4,91) (71.19) 60 (140) 1582 (15,82) (229.40)
24 (75) 543 (5,43) (78.75) 63 (145) 1695 (16,95) (245.80)
27 (80) 598 (5,98) (86.80) 66 (150) 1813 (18,13) (263.00)
29 (85) 658 (6,58) (95.40) 68 (155) 1938 (19,38) (281.10)
32 (90) 720 (7,20) (104.40) 71 (160) 2069 (20,69) (300.10)
33 (91) 733 (7,33) (106.30) 74 (165) 2207 (22,07) (320.10)
33 (92) 746 (7,46) (108.20) 77 (170) 2350 (23,50) (340.80)

Evaporator

Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add -12.5 ± -0.5°C (9 ± 1°F) to the temperature on the chart.

Condenser

Temperatures are not ambient temperatures but condensing temperatures. Add 4°C (40°F) to the ambient temperature to
get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.

Example: Ambient Temperature = 32°C (90°F)

32°C (90°F)
+ 4°C (40°F)
54°C (130°F) condenser temperature = 1379 kPa (14 bar) (200 psig)

Conditions and pressures will vary from system to system.

854 of 918 70-30-4 E85 Service Manual

TROUBLESHOOTING (CONT'D) Figure 70-30-4

Poor A/C Performance

1
Start the excavator. Engage the A/C system with the
blower fan on high. Run the excavator at full rpm for
approximately 15 minutes, with the cab door closed.

Figure 70-30-2 1

1
1
P111035

Figure 70-30-5

P111033

Dealer Copy -- Not for Resale

Figure 70-30-3

N-22411

Check the temperature at the louvers (Item 1) [Figure

70-30-2], [Figure 70-30-3] and [Figure 70-30-4] with a
thermometer [Figure 70-30-5].

The louver temperature should be between 2,2 - 11,6° C

1 (36 - 53° F) depending on the amount of humidity in the
air.

If louver temperature is too high see the System

Troubleshooting Chart. (See Gauge Pressure Related
P111034
Troubleshooting on Page 70-30-2.)

Check the fan for proper operation or noise, and replace

if necessary. (See Removal And Installation on Page 70-
110-1.)

Check the air conditioning belt tension. (See Belt

Adjustment on Page 70-20-1.)

Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Evaporator / Heater Coil on Page 70-20-
5.)

Inspect the sight glass located on the receiver / drier for

air bubbles. (See Insufficient Cooling Although Air Flow
And Compressor Operation Are Normal on Page 70-30-
1.)

855 of 918 70-30-5 E85 Service Manual

TROUBLESHOOTING (CONT'D)

HVAC Repair And Leaks

Figure 70-30-6

P112520

Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /
drier (Item 1) [Figure 70-30-6] must be changed.

Dealer Copy -- Not for Resale

Never leave hose fittings, compressor fittings or
components uncapped while working on the A/C system.

856 of 918 70-30-6 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION Figure 70-40-2

Reclamation And Charging With Recovery / Charging

Unit 1

Figure 70-40-1

N-23024

NOTE: Before reclaiming a refrigeration system, it is

1
recommended to identify the type of
P-86815 refrigerant that is in the A/C system and
whether it is pure enough to use or not. The
tool MEL1592, Refrigerant Identifier (Item 1)
Open the right side cover and locate the low pressure [Figure 70-40-2] will determine the kind of

Dealer Copy -- Not for Resale

port (Item 1) and high pressure port (Item 2) [Figure 70- refrigerant and any possible harmful or
40-1]. dangerous substances that may be present in
the system. Thus preventing mixing of
dangerous material with your reclaimed R-
134a in your reclaimer, and further
WARNING contamination to other A/C systems that are
reclaimed and charged from your MEL1581
Recovery / Recycling / Recharging Machine.
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

NOTE: This procedure is run with the excavator

engine OFF, and the A/C switch in the OFF
position.

857 of 918 70-40-1 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D)

Reclamation And Charging With Recovery / Charging

Unit (Cont’d) WARNING
Figure 70-40-3 HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
1 equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611
P-86819

Figure 70-40-4
Remove the protective cap and connect the Refrigerant

Dealer Copy -- Not for Resale

Identifier to the low pressure hose (Item 1) [Figure 70-
40-3].

Connect the refrigerant identifier to a power source.

Follow the steps displayed on the refrigerant identifier

screen.

Allow two minutes for the refrigerant identifier to display

the type of refrigerant and air content. If potentially
flammable hydrocarbons are present an alarm will sound
and the visual display will indicate it.

Disconnect the refrigerant identifier from the excavator A/ N-22291

C.
Use an approved recover / charging unit [Figure 70-40-4]
If the refrigerant is dangerous or flammable, it must be
to evacuate the system.
evacuated from the A/C system into a separate container
and properly and safely disposed of.
Connect the reclaimer to the excavator A/C charge ports.
If R-134a is found, evacuate the system.

858 of 918 70-40-2 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-7

Reclamation And Charging With Recovery / Charging

Unit (Cont’d)

Figure 70-40-5

N-22381

NOTE: The reclaimer unit has a complete step by

step set of instructions [Figure 70-40-7] to
2 follow for reclamation and recharging of the
P-86825
A/C system. A trained technician should
follow these instructions as they may very
Connect the Red hose (Item 1) [Figure 70-40-5] to the slightly depend on the model and brand of

Dealer Copy -- Not for Resale

high pressure port and open the valve. reclaimer used.

Connect the Blue hose (Item 2) [Figure 70-40-5] to the

low pressure port and open the valve.

Figure 70-40-6

N-22292

Turn the reclaimer unit to the ON position and follow the

on screen instructions [Figure 70-40-6].

859 of 918 70-40-3 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-9

Charging With A Manifold Gauge Set

Open the right side cover.

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
P-52658

Figure 70-40-8
Connect the Yellow hose (Item 1) [Figure 70-40-9] to the
vacuum pump.

Dealer Copy -- Not for Resale

2
1

3
P-87052

Check to see that the hand valves (Item 1) [Figure 70-

40-8] are closed on the manifold gauge set.

If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure.
(See Reclamation And Charging With Recovery /
Charging Unit on Page 70-40-1.)

Connect the gauge to the excavator A/C charge ports.

Connect the Red hose (Item 2) [Figure 70-40-8] to the

high pressure port and open the valve.

Connect the Blue hose (Item 3) [Figure 70-40-8] to the

low pressure port and open the valve.

860 of 918 70-40-4 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-12

Charging With A Manifold Gauge Set (Cont’d)

Figure 70-40-10

P-87051

A thermistor vacuum gauge (Item 1) [Figure 70-40-12]

1 can be used to determine the critical vacuum level during
P-87050
evacuation. It is a solid state instrument that constantly
monitors and visually indicates the vacuum level.
Start the vacuum pump and open the ISO-valve (Item 1)
[Figure 70-40-10] on the vacuum pump. The thermistor vacuum gauge is used with the vacuum

Dealer Copy -- Not for Resale

pump [Figure 70-40-12].
Run the vacuum pump for at least 5 - 10 minutes to make
sure that a vacuum has been pulled on the system. Start the vacuum pump and open the ISO-valve on the
vacuum pump.
Close the ISO-valve (Item 1) [Figure 70-40-10] (which
isolates the vacuum pump from the A/C system) and turn Make sure that both hand valves, and both charge port
OFF the vacuum pump. valves are open.

Figure 70-40-11 Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.

Stop the vacuum pump and close the ISO-valve on the

1 vacuum pump.

Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.

Remove the vacuum pump and thermistor vacuum

gauge.

P-87052

Note the vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 70-40-11]. Let stand for 5-
10 minutes and recheck the pressure for changes.

If the pressure drops, this may be an indication of a leak

in the A/C system.

Determine the problem with the A/C system and repair it.

861 of 918 70-40-5 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-15

Charging With A Manifold Gauge Set (Cont’d)

Figure 70-40-13
1

3
1 3 4
2

P111020

Press the A/C (Item 1) [Figure 70-40-15] switch to ON

2 position.
P-87053

Press the fan switch (Item 2) [Figure 70-40-15] to HIGH

Place a refrigerant container with R-134a (Item 1) on a position.
charging scale (Item 2) [Figure 70-40-13] and zero out

Dealer Copy -- Not for Resale

the scale. Press the cool switch (Item 3) until all the indicator lights
(Item 4) [Figure 70-40-15] are green.
Connect the yellow hose (Item 3) [Figure 70-40-13] from
the manifold gauge set to the valve on the refrigerant Start the engine, with the left console in the raised
tank. position, and run at medium speed.

Figure 70-40-14 Watch the scale and run the system until the
predetermined amount of refrigerant is added to the A/C
system.

The A/C system holds 0,63 - 0,67 kg (1.38 - 1.48 lb) of

refrigerant.

Turn OFF the valve on the refrigerant container, and the

1 hand valves on the manifold gauge set.
2
Turn OFF the engine, and remove the A/C charging
equipment from the excavator.

P-87054

Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure
70-40-14] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.

862 of 918 70-40-6 E85 Service Manual

COMPRESSOR Figure 70-50-3

Removal And Installation

Open the right side cover.

Remove the right upperstructure side cover. (See

Removal And Installation on Page 40-21-1.)

Evacuate the A/C system. (See SYSTEM CHARGING 1

AND RECLAMATION on Page 70-40-1.)

Figure 70-50-1

P111134

1
Remove the belt (Item 1) [Figure 70-50-3].

Figure 70-50-4
2 1

Dealer Copy -- Not for Resale

P111130

Remove the three bolts (Item 1) and washers. Remove

the belt shield (Item 2) [Figure 70-50-1].
1
Figure 70-50-2

3 P-86877
2

Remove the bolt (Item 1) [Figure 70-50-4] and the hoses

from the compressor.
1

P111135

Loosen the nut (Item 1) on the pulley. Loosen the lock nut
(Item 2) and adjustment bolt (Item 3) [Figure 70-50-2].

863 of 918 70-50-1 E85 Service Manual

COMPRESSOR (CONT'D) Figure 70-50-7

Removal And Installation (Cont'd)

Figure 70-50-5

1
1

2
P-86873

1
Remove the three screws (Item 1) and remove the dust
P-86871 cover (Item 2) [Figure 70-50-7].

Figure 70-50-8
Remove the seal washers (Item 1) [Figure 70-50-5] from
the tubelines.

Dealer Copy -- Not for Resale

Figure 70-50-6

1 P-86875

Disconnect the wire harness (Item 1) [Figure 70-50-8].

P-86872

Remove the rear bolt (Item 1) [Figure 70-50-6] and

washer.

864 of 918 70-50-2 E85 Service Manual

COMPRESSOR (CONT'D) Oil

Removal And Installation (Cont'd) Figure 70-50-11

Figure 70-50-9
1

P-86877

1 P-86874
The compressor (Item 1) [Figure 70-50-11] is factory
filled with 0,266 L (9.0 U.S. fl oz) of PAG oil.
Remove the three bolts (Item 1) [Figure 70-50-9] and the
compressor from the excavator. It is necessary to check, replenish or replace the

Dealer Copy -- Not for Resale

compressor oil in the following cases:
Figure 70-50-10
1. When the evaporator, condenser or receiver-drier is
replaced.

2. When refrigerant has leaked from the system.

2
3. When refrigerant is suddenly released from the
1 cooling cycle.

4. When any oil related problems occur in the cooling

cycle.
1
When one of the components (the evaporator, condenser
or receiver-drier) is replaced, 0,029 L (1.0 U.S. fl oz) of
PAG oil should be added for each component replaced.
P-86876

If the A/C compressor is changed, no oil should be added

to the system, the compressor comes factory filled with
Remove the two bolts (Item 1) and washers. Remove the
oil.
bracket (Item 2) [Figure 70-50-10].
NOTE: Only PAG oil should be used. Never mix R-12
and R-134a Oils.

865 of 918 70-50-3 E85 Service Manual

COMPRESSOR (CONT'D) Figure 70-50-12

Oil Check

The compressor oil should be checked as follows when

1
oil is being added to an in service excavator.

There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. When checking the amount of
oil in the system or replacing any system component, the
compressor must be run in advance to insure return of oil
to the compressor.

If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND P-86878
RECLAMATION on Page 70-40-1.)

Open the cab door and windows. Figure 70-50-13

Run the blower at maximum speed.

Run the compressor for at least 20 minutes at 800 - 1200

rpm.

Dealer Copy -- Not for Resale

Remove the compressor from the excavator. (See
Removal And Installation on Page 70-50-1.)

P-16534A

Remove the oil drain plug (Item 1) [Figure 70-50-12] and

drain the oil through the connectors and the oil drain hole
[Figure 70-50-13].

Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4

- 10.8 ft-lb) torque.

866 of 918 70-50-4 E85 Service Manual

COMPRESSOR (CONT'D) Figure 70-50-15

Oil Check (Cont'd)

Figure 70-50-14

P-86878

1
Add new compressor oil through the suction side
N-22246 connector (Item 1) [Figure 70-50-15].

Installation: Add 0,266 L (9.0 U.S. fl oz) of PAG oil.

NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil NOTE: The suction port on the compressor is marked

Dealer Copy -- Not for Resale

through the discharge-side connector by with an S and is the larger port on the
rotating the drive pulley (Item 1) [Figure 70-50- compressor.
14] several times by hand.

Measure the drained oil in a measuring cylinder.

Check the oil for contamination, dirt, metal shavings, or

varnish color. Discard the oil if contaminated.

NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

867 of 918 70-50-5 E85 Service Manual

Dealer Copy -- Not for Resale

868 of 918 70-50-6 E85 Service Manual

CONDENSER

Removal And Installation

WARNING
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 70-40-1.) In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
Figure 70-60-1 contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

1 Remove the bolts (Item 2) [Figure 70-60-2] and remove

the condenser from the evacuator.
2

P112539

Dealer Copy -- Not for Resale

Remove the bolts (Item 1) and reposition the fuel cooler
(Item 2) [Figure 70-60-1].

Figure 70-60-2

2 2

1 1

2
2

P112540

Remove the hoses (Item 1) [Figure 70-60-2] from the

condenser.

869 of 918 70-60-1 E85 Service Manual

Dealer Copy -- Not for Resale

870 of 918 70-60-2 E85 Service Manual

RECEIVER / DRIER Note the flow direction on the drier for proper installation.

Receiver / Drier Removal And Installation

Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 70-40-1.)
WARNING
Open the center cover. (See Opening And Closing on In the event of a leak, wear safety goggles. Escaping
Page 10-70-1.) refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
Figure 70-70-1 gas.
W-2371-0611

Remove the two bolts (Item 2) [Figure 70-70-2] and

1 remove the receiver / drier from the excavator.

NOTE: When replacing a receiver / drier, 0,029 L (1.0

U.S. fl oz) of PAG oil must be added to the
system when recharging.

Dealer Copy -- Not for Resale

P112519

Disconnect the wire harness (Item 1) [Figure 70-70-1].

Figure 70-70-2

P112520

Remove the A/C hoses (Item 1) [Figure 70-70-2] from

the receiver / drier.

Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.

871 of 918 70-70-1 E85 Service Manual

RECEIVER / DRIER (CONT’D)

Pressure Switch Removal And Installation

WARNING
Open the center cover.
In the event of a leak, wear safety goggles. Escaping
Figure 70-70-3 refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
1

P-86888

Dealer Copy -- Not for Resale

The pressure switch (Item 1) [Figure 70-70-3] is located
on the receiver / drier.

Figure 70-70-4

P112519

Disconnect the wire harness (Item 1) [Figure 70-70-4]

from the pressure switch.

NOTE: The pressure switch can be changed without

evacuating the A/C system.

Remove the pressure switch from the receiver / drier.

872 of 918 70-70-2 E85 Service Manual

EVAPORATOR / HEATER UNIT Figure 70-80-2

Removal And Installation

1
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 70-40-1.)

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611 P-87059

Tilt the cab. (See Raising And Lowering on Page 10-210- Remove the two bolts (Item 1) [Figure 70-80-2] and
1.) washers.

Drain the radiator. (See Removing And Replacing Figure 70-80-3

Coolant on Page 10-110-2.)
2

Dealer Copy -- Not for Resale

Figure 70-80-1

P-87060

P-87058 Remove the wire harness (Item 1) from the mount.

Support the housing and remove the two bolts (Item 2)
[Figure 70-80-3] and washers.
Disconnect the A/C lines (Item 1). Loosen the hose
clamps and remove the heater hoses (Item 2) [Figure Lower the housing.
70-80-1].

NOTE: Mark the hoses before removal for correct

installation.

873 of 918 70-80-1 E85 Service Manual

EVAPORATOR / HEATER UNIT (CONT’D)

Removal And Installation (Cont’d)

Figure 70-80-4

P-87061

Disconnect the wire harness (Item 1) [Figure 70-80-4].

Dealer Copy -- Not for Resale

Remove the unit from the machine.

874 of 918 70-80-2 E85 Service Manual

THERMOSTAT Figure 70-90-3

Inspection
2
NOTE: The thermostat is not serviceable separately.
The procedure shown is for inspection
purposes.

Remove the blower fan. (See Removal And Installation

on Page 70-110-1.)

Figure 70-90-1
1

1
P-87074

1 Inspect the thermostat (Item 1) for damage. Inspect the

1 thermostat probe (Item 2) [Figure 70-90-3] for correct
placement.

Dealer Copy -- Not for Resale

P-87072

Remove the five screws (Item 1) [Figure 70-90-1].

Figure 70-90-2

P-87073

Remove the cover (Item 1) [Figure 70-90-2].

875 of 918 70-90-1 E85 Service Manual

Dealer Copy -- Not for Resale

876 of 918 70-90-2 E85 Service Manual

EXPANSION VALVE Figure 70-100-3

Removal And Installation

NOTE: The expansion valve is not serviceable 1

separately. The procedure shown is for
inspection purposes.

Remove the evaporator / heater unit. (See Removal And

Installation on Page 70-80-1.)

Figure 70-100-1

P-87064
2

1 Remove the bottom cover (Item 1) [Figure 70-100-3].

Figure 70-100-4

Dealer Copy -- Not for Resale

P-87062

Loosen the clamps (Item 1) and remove the fittings (Item

2) [Figure 70-100-1].

Figure 70-100-2
1

P-87065
1

Remove the bolts (Item 1) [Figure 70-100-4] and

1 washers from both sides.

P-87063

Remove the two bolts (Item 1) [Figure 70-100-2] and

washers from both sides.

877 of 918 70-100-1 E85 Service Manual

EXPANSION VALVE (CONT’D) Figure 70-100-7

Removal And Installation (Cont’d)

Figure 70-100-5 1 2

1 2

P-87075

Remove the tubelines (Item 1). Loosen the tubeline nuts

P-87066 (Item 2) and remove the expansion valve (Item 3) [Figure
70-100-7].

Remove the heater core / evaporator (Item 1) [Figure 70-

100-5] from the top cover.

Dealer Copy -- Not for Resale

Figure 70-100-6

1
P-87070

Remove the tape (Item 1) [Figure 70-100-6].

878 of 918 70-100-2 E85 Service Manual

BLOWER FAN Figure 70-110-3

Removal And Installation

1
Remove the evaporator / heater unit. (See Removal And
Installation on Page 70-80-1.)

Figure 70-110-1

P-87064
1

Remove the bottom cover (Item 1) [Figure 70-110-3].

Figure 70-110-4

P-87062

Dealer Copy -- Not for Resale

Loosen the clamps (Item 1) and remove the fittings (Item
2) [Figure 70-110-1].

Figure 70-110-2

1
1

1 P-87065

Remove the two bolts (Item 1) [Figure 70-110-4] and

washers from both sides.

P-87063

Remove the two bolts (Item 1) [Figure 70-110-2] and

washers from both sides.

879 of 918 70-110-1 E85 Service Manual

BLOWER FAN (CONT’D) Figure 70-110-7

Removal And Installation (Cont’d)

Figure 70-110-5
1
1

P-87071

Remove the motor / fan assembly (Item 1) [Figure 70-

P-87066 110-7].

Figure 70-110-8
Remove the heater core / evaporator (Item 1) [Figure 70-
110-5] from the top cover.

Dealer Copy -- Not for Resale

Figure 70-110-6
1 1 1 1 2

3
2

1 1

P-87068

Disconnect the wire harness (Item 1) [Figure 70-110-8].

P-87068
Remove the two screws (Item 2) [Figure 70-110-8].

Remove the eight screws (Item 1) [Figure 70-110-6]. Remove the resistor block (Item 3) [Figure 70-110-8].

880 of 918 70-110-2 E85 Service Manual

HEATER VALVE

Removal And Installation

Drain the radiator. (See Removing And Replacing

Coolant on Page 10-110-2.)

Tilt the cab. (See Raising And Lowering on Page 10-210-

1.)

Figure 70-120-1

2
1 1

Dealer Copy -- Not for Resale

P112532

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

[Figure 70-120-1].

Figure 70-120-2

2
3

P112537

Disconnect the wire harness (Item 1), loosen the clamps

and remove the top (Item 2) [Figure 70-120-2] and
bottom hose.

Remove the bolts (Item 3) [Figure 70-120-2]. Remove

the valve assembly from the machine.

881 of 918 70-120-1 E85 Service Manual

Dealer Copy -- Not for Resale

882 of 918 70-120-2 E85 Service Manual

HVAC CONTROLLER Figure 70-130-3

Removal And Installation

Remove the upper left console cover. (See Upper

Console Cover Removal And Installation on Page 40-60-
2.)
1
Figure 70-130-1

P-86761

Remove the controller (Item 1) [Figure 70-130-3] from

1 the upper console cover.

P-86759

Dealer Copy -- Not for Resale

Remove the screws (Item 1) [Figure 70-130-1].

Figure 70-130-2

P-86760

Remove the screws (Item 1) [Figure 70-130-2].

883 of 918 70-130-1 E85 Service Manual

Dealer Copy -- Not for Resale

884 of 918 70-130-2 E85 Service Manual

SPECIFICATIONS

EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Dimensions - Standard Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Dimensions - Long Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Dimensions - Articulated Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Slew System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9

Dealer Copy -- Not for Resale

TECHNICAL SERVICE GUIDE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Excavator Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

O-Ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-Ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-3

HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1

885 of 918 SPEC-01 E85 Service Manual

SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-4
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-6
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-6

Certain specification(s) are based on engineering calculations and are not actual measurements. Specification(s)
are provided for comparison purposes only and are subject to change without notice. Specification(s) for your
individual Bobcat equipment will vary based on normal variations in design, manufacturing, operating conditions,
and other factors.

Dealer Copy -- Not for Resale

886 of 918 SPEC-02 E85 Service Manual

EXCAVATOR SPECIFICATIONS

Dimensions

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

70°

55°

Dealer Copy -- Not for Resale

STD. ARM LONG ARM
2265 mm 6165 mm 6265 mm
(89.0 in) (242.7 in) (246.6 in)
STD. ARM LONG ARM
1370 mm 4785 mm 4890 mm
1030 mm (54.0 in) (188.3 in) (192.5 in)
(40.6 in)
925 mm 1300 mm
(36.4 in) (51.2 in)
408 mm
(16.0 in)

2640 mm 735 mm
STD. ARM
(104.0 in) (28.9 in)
2085 mm
(82.1 in)

LONG ARM
670 mm 304 mm
450 mm 2410 mm
(26.4 in) (12.0 in)
(17.7 in) (94.9 in)
1910 mm
1850 mm 362 mm (75.0 in)
(72.8 in) (14.2 in) 2200 mm
(87.0 in)
2300 mm
(91.0 in) 2825 mm
(111.0 in)
3280 mm
(129.0 in)
NA5969

887 of 918 SPEC-10-1 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Dimensions (Cont’d)

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

70°

55°

Dealer Copy -- Not for Resale

2265 mm 5891 mm
(89.0 in) (231.9 in)

1370 mm 4521 mm
1030 mm (54.0 in) (178 in)
(40.6 in)
925 mm 1300 mm
(36.4 in) (51.2 in)

2640 mm 735 mm 2737 mm

(104.0 in) (28.9 in) (107.8 in)

670 mm 304 mm 408 mm

450 mm
(26.4 in) (12.0 in) (16.0 in)
(17.7 in)
1910 mm 304 mm
1850 mm 362 mm (75.0 in) (12 in)
(72.8 in) (14.2 in) 2200 mm
(87.0 in)
2300 mm
(91.0 in) 2825 mm
(111.0 in)
3280 mm
(129.0 in)
NA5969

888 of 918 SPEC-10-2 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Dimensions - Standard Arm

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

2550 mm
(100.4 in)

6630 mm
(261.0 in)

5655 mm
(222.6 in)

4645 mm

Dealer Copy -- Not for Resale

(182.9 in)

3245 mm
580 mm (127.8 in)
(22.8 in)
3815 mm
(150.2 in)

4175 mm
(164.4 in)

1510 mm
(59.4 in)
4730 mm
(186.2 in)

6765 mm
(266.3 in)

6915 mm
(272.2 in)

MS2792A

889 of 918 SPEC-10-3 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Dimensions - Long Arm

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

2635 mm
(103.7 in)

6980 mm
(274.8 in)

6005 mm
(236.4 in)

4995 mm

Dealer Copy -- Not for Resale

(196.7 in)

3755 mm
55 mm (147.8 in)
(2.2 in)
4420 mm
(174.0 in)

4725 mm
(186.0 in)

1480 mm
(58.3 in)
4905 mm
(193.1 in)

7295 mm
(287.2 in)

7430 mm
(292.5 in)

MS2792A

890 of 918 SPEC-10-4 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Dimensions - Articulated Boom

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

2655 mm
(104.5 in)

7380 mm
(290.6 in)

6373 mm
(250.9 in)

5365 mm

Dealer Copy -- Not for Resale

(211.2 in)

3550 mm
490 mm (139.8 in)
(19.3 in)
3925 mm
(154.5 in)

4100 mm
(161.4 in)

1405 mm
(55.3 in)
4530 mm
(178.3 in)

7035 mm
(277 in)

7180 mm
(282.7 in)

NA9774

891 of 918 SPEC-10-5 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Performance
Operating Weight w/ Cab. HVAC, Rubber Tracks 8600 kg (18960 lb)
and 610 mm (24 in) Bucket
If Equipped with Steel Tracks (Optional) add: 30 kg (66 lb)
If Equipped with Long Arm (Optional) add: 60 kg (132 lb)
If Equipped with Articulated Boom (Optional) add: 495 kg (1091 lb)
Travel Speed Low Range 2,7 km/h (1.7 mph)
High Range 4,7 km/h (2.9 mph)
Digging Force (Per ISO 6015)
Arm (Standard) 43800 N (9847 lbf)
Arm (Long Arm) (Optional) 36500 N (8206 lbf)
Arm (Articulated Boom) (Optional) 43800 N (9847 lbf)
Bucket (Standard and Long Arm) 65600 N (14747 lbf)
Bucket (Articulated Boom) 58500 N (13151 lbf)
Boom Swing (Offset) Left 70° Right 55°

Controls
Steering Two hand levers or foot pedals.
Hydraulics Two hand operated levers (joysticks) control boom, bucket, arm and

Dealer Copy -- Not for Resale

upperstructure slew. Blade is controlled by a separate lever. Left
pedal controls articulated boom (optional).
Auxiliary Hydraulics Thumb swatches in joystick control auxiliary hydraulics
and boom swing.
Auxiliary Pressure Release Electric switches in joystick
Engine Engine speed control dial with auto-idle feature,
key type start switch
Starting Aid Air Intake Heater - activated by key switch
Brakes
Travel Hydraulic lock in motor
Service & Parking Hydraulic lock in motor
Swing
Service Hydraulic lock in motor
Holding Automatically applied slew brake integrated in slew motor

Engine
Make / Model E85 w/ S/N B34T11001 & Above Yanmar 4TNV98C Tier 4 Final / Stage IIIB
E85 w/ S/N B34S11001 & Above Yanmar 4TNV98C Stage IIIB
Fuel / Cooling Diesel / Liquid (Antifreeze mixture)
Horsepower (SAE Gross) 44,3 kW (59.4 hp) @ 2100 rpm
Torque 241 N•m (179.8 ft-lb) @ 1365 rpm
Number Of Cylinders 4
Displacement 3,3 L (203 in3)
Bore / Stroke 98 x 110 mm (3.85 x 4.33 in)
Lubrication Pressure System with Filter
Crankcase Ventilation Closed Breather
Air Cleaner Dual dry replaceable paper cartridges
Ignition Diesel Compression
Low Idle 1050 rpm
High Idle 2150 rpm
Engine Coolant Ethylene Glycol / water mixture (50% EG / 50% water)

892 of 918 SPEC-10-6 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic System
Pump Type Engine driven, variable displacement piston pump with pressure
compensating, load sensing and torque limiter controls and gear pump.
Piston Pump Capacity 151 Lpm (39,8 U.S. gpm)
Gear Pump Capacity 23,1 Lpm (6.1 U.S. gpm)
Auxiliary Hydraulics (Continuous Flow,
Auxiliary Hydraulic Flow and Secondary 95 Lpm (25.1 U.S. gpm)
Auxiliary Flow)
Auxiliary Hydraulics (Secondary
Auxiliary Flow) 50 Lpm (13.2 U.S. gpm)
Control Valve 12 spool closed centre
Fluid Type Bobcat Fluid, Hydraulic / Hydrostatic
6903117 - (2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
System Relief Pressure
Travel Circuits 27503 kPa (275 bar) (3989 psi)
Slew Circuit 21601 kPa (216 bar) (3133 psi)

Dealer Copy -- Not for Resale

Boom, Arm, Bucket, Boom Swing,
Blade, Auxiliary Hydraulics 29503 kPa (295 bar) (4279 psi)
Joystick Control Pressure 3200 kPa (32 bar) (464 psi)
Arm Port Relief, Base And Rod End 30999 kPa (310 bar) (4496 psi)
Boom Port Relief, Base End 30999 kPa (310 bar) (4496 psi)
And Rod End
Articulated Boom Port Relief, Base End 30999 kPa (310 bar) (4496 psi)
And Rod End (Optional)
Bucket Port Relief, Base End 30999 kPa (310 bar) (4496 psi)
Rod End
Primary Auxiliary Port Relief 21001 kPa (210 bar) (3046 psi)
Secondary Auxiliary Port Relief 25000 kPa (250 bar) (3626 psi)
(If Equipped)
Swing Motor Cross Port Relief Valves 21994 kPa (220 bar) (3190 psi)
Hydraulic Filter Bypass 250 kPa (2,5 bar) (36 psi)
Hydraulic Pilot Filter Bypass 145 kPa (1,5 bar) (21 psi)

Hydraulic Cylinders
Cylinder Bore Rod Stroke
Boom (Cushion Up) 115 mm (4.52 in) 75 mm (2.95 in) 775 mm (30.51 in)
Articulated Boom (Cushion 100 mm (3.94 in) 55 mm (2.17 in) 370 mm (14.57 in)
Extend / Retract) (Optional)
Arm 100 mm (3.94 in) 65 mm (2.56 in) 866 mm (34.88 in)
Bucket (Cushion Extend / 85 mm (3.35 in) 55 mm (2.17 in) 690 mm (27.17 in)
Retract)
Boom Swing (Cushion Left/ 110 mm (4.33 in) 60 mm (2.36 in) 738 mm (29.05 in)
Right)
Blade 100 mm (3.94 in) 60 mm (2.36 in) 149 mm (5.87 in)

893 of 918 SPEC-10-7 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic Cycle Times

Boom Raise 3.2 Seconds Lower 3.0 Seconds
Articulated Boom (Optional) Raise 5.9 Seconds Lower 5.5 Seconds
Arm Retract 3.8 Seconds Extend 2.9 Seconds
Bucket Curl 3.3 Seconds Dump 2.1 Seconds
Blade Raise 2.4 Seconds Lower 2.9 Seconds
Boom Swing Left 6.9 Seconds Right 8.6 Seconds

Electrical
Starting Aid Glow Plugs (automatic)
Alternator 12 volt, 80 Amp open frame w/ internal regulator
Battery 12 volt - 900 CCA @ -18°C (0°F)
Starter 12 volt gear reduction 3.0 kW (4.0 hp)
Instrumentation Fuel gauge with low fuel indicator, Engine temperature gauge with audible alarm, Engine oil
pressure light with audible alarm, Engine check light, Air filter restriction indicator, Auto idle
indicator, Auxiliary flow mode indicator, Clock - day and time, Engine preheat indicator, Two
speed travel indicator, DPF status indicator and Hourmeter

Dealer Copy -- Not for Resale

Drive System
Final Drive Each track is independently driven by an axial piston motor
Type of Reduction Three-stage planetary gear reduction

Slew System
Slew Motor Axial Piston Motor
Slew Circle Single row shear type ball bearing with internal gear
Slew Speed 9.5 rpm

Excavator Torques

Travel Motor To Frame Bolt 265 N•m (195 ft-lb)

Sprocket To Travel Motor 160 - 180 N•m (118 - 133 ft-lb)
Swing Bearing To Frame Bolt 392 N•m (289 ft-lb)
Swing Bearing To Upperstructure Bolt 392 N•m (289 ft-lb)
Swing Motor Mounting Bolts 85,7 - 117,7 N•m (63 - 87 ft-lb)

897 of 918 SPEC-20-1 E85 Service Manual

Dealer Copy -- Not for Resale

898 of 918 SPEC-20-2 E85 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS

Torque For General SAE Bolts

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

THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9,0 - 10,2 12,4 - 13,6
N•m (80 - 90) (110 - 120)
(ft-lb) 0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
0.375 34 - 38 47 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
N•m 0.750 300 - 330 410 - 450
(ft-lb) (220 - 245) (300 - 330)

Dealer Copy -- Not for Resale

0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 5830 - 6500
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

899 of 918 SPEC-30-1 E85 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric Bolts

THREAD SIZE MATERIAL

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

Dealer Copy -- Not for Resale

900 of 918 SPEC-30-2 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-2
O-ring Face Seal Tightening Torque
O-Ring Face Seal Connection
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)

IMPORTANT 1/4”
3/8”
9/16” - 18
11/16” - 16
18 (13)
30 (22)
When repairing hydrostatic and hydraulic systems, 1/2” 13/16” - 16 54 (40)
clean the work area before disassembly and keep all 5/8” 1” - 14 81 (60)
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 3/4” 1-3/16” - 12 114 (84)
damage the system. 7/8” 1-3/16” - 12 133 (98)
I-2003-0888
1” 1-7/16” - 12 160 (118)
1-1/4” 1-11/16” - 12 209 (154)
Figure SPEC-40-1
1-1/2” 2” - 12 221 (163)

Dealer Copy -- Not for Resale

B-7575

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

901 of 918 SPEC-40-1 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONT’D)
Figure SPEC-40-4
Straight Thread O-Ring Fitting

Figure SPEC-40-3
1

Nut Nut

Washer
Washer
O-ring

O-ring
TS-1619A

A-1852 Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts

Dealer Copy -- Not for Resale

the jam nut and install the fitting. Tighten the jam nut until of the connection (Item 1) [Figure SPEC-40-4].
the washer is tight against the surface [Figure SPEC-40-
3]. Figure SPEC-40-5

Tubelines And Hoses Flare Fitting Tightening Torque

Tubeline x TORQUE
Replace any tubelines that are bent or flattened. They will Outside x N•m
restrict flow, which will slow hydraulic action and cause Diameter Thread Size (ft-lb)
heat. 1/4” 7/16” - 20 18 (13)

Replace hoses which show signs of wear, damage or 5/16” 1/2” - 20 23 (17)
weather cracked rubber. 3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
Always use two wrenches when loosening and tightening
hose or tubeline fittings. 5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)

Use the chart [Figure SPEC-40-5] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.

902 of 918 SPEC-40-2 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-7
(CONT’D)
Port Seal and O-ring Boss
Port Seal Fitting Tightening Torque
x TORQUE
Figure SPEC-40-6 x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
Nut Seals 1-3/16” - 12 133 (98)
To Fitting 1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
Nut Seals 1-5/8” - 12 221 (163)
To Port
Use the chart [Figure SPEC-40-7] to tighten the port
seal fitting.

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

Dealer Copy -- Not for Resale

Secondary O-ring Seal P-13008
fittings use the same tightening torque valve chart.

The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-6].

The hex portion of the nut does not contact the surface of
the component when the nut is tight.

903 of 918 SPEC-40-3 E85 Service Manual

Dealer Copy -- Not for Resale

904 of 918 SPEC-40-4 E85 Service Manual

HYDRAULIC FLUID SPECIFICATIONS

Specifications

Use only Bobcat hydraulic fluid.

WARNING
During cold weather (0°C [32°F] and below), do not
DO NOT use automatic transmission fluids in the
operate machine until the engine has run for at least
excavator or permanent damage to the hydraulic system
5 minutes at less than half throttle. This warm-up
will result.
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
Bobcat hydraulic fluid is available in:
period.
• 9.5 L (2.5 U.S. gal) qty 2 (P/N 6903117)
When temperatures are below -30°C (-20°F), the
hydrostatic oil must be heated or kept warm. The
• 18.9 L (5 U.S. gal) (P/N 6903118)
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
• 208 L (55 U.S. gal) (P/N 6903119)
temperature will be above -18°C (0°F) if possible.
W-2027-0311

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can

Dealer Copy -- Not for Resale

penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

When temperatures below -18°C (0°F) are common, the

excavator must be kept in a warm building. Extra warm-
up time must be used each time the excavator is started
during cold temperature conditions. Cold fluid will not flow
easily and it makes action of the hydraulic function
slower. Loss of fluid flow to the hydraulic system
(Indicated by hydraulic temp / pressure lights on) can
cause system damage in less than 60 seconds.

905 of 918 SPEC-50-1 E85 Service Manual

Dealer Copy -- Not for Resale

906 of 918 SPEC-50-2 E85 Service Manual

CONVERSIONS

Decimal And Millimeter Equivalent Chart

Dealer Copy -- Not for Resale

U.S. To Metric Conversion Chart

907 of 918 SPEC-60-1 E85 Service Manual

Dealer Copy -- Not for Resale

908 of 918 SPEC-60-2 E85 Service Manual

SERVICE TOOLS REQUIRED

The following is a list of service tools required for servicing excavators.

Remote Start Tools

TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool E20 - E55 This tool has been replaced by
the new remote start tool
7003031, see below. MEL1563
includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness Used with MEL1563 to connect
remote start tool to machine

MEL1566 Service Tool Harness Used with MEL1563 to connect

Communicator remote start tool to PC

7217666 Remote Start Tool Kit E20 - E55 This tool replaced the original

Dealer Copy -- Not for Resale

remote start tool kit MEL1563
(Was 7003031) and 7003031. Kit 7217666
includes: 7022042, 6689747,
(Was 6689779) 6689746 and 6689745.

7022042 Remote Start Tool This tool replaces remote start

tool 6689778 and 7003030.
(Was 7003030)

(Was 6689778)
6689747 Remote Start Tool Used with 7003030 to connect
Harness remote start tool to excavator.

6689746 Remote Start Tool Used with 7003030 to connect

Harness Service PC to remote start tool.

See www.BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools
Catalogue and Doosan Shop for parts ordering information.)

ST EXC-0516

909 of 918 SPEC-70-1 E85 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1744 Hydraulic Tester E08 - E85 Hydraulic tester MEL1744, MEL10003
(Flow Meter) or TWX-RFIK200-S-6 can be used for
hydraulic testing.

MEL10003 Hydraulic Tester MEL10003 and TWX-RFIK22-S-6 are

(Flow Meter) no longer available, order MEL1744.

TWX-RFIK200- Hydraulic Tester

S-6 (Flow Meter)

MEL1074 O-Ring Seal Hook

Dealer Copy -- Not for Resale

MEL1075 Adjustable Gland Nut Includes MEL1075-1 and MEL1075-2
Wrench

MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075-1 for disassembling
various cylinders
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075-1 for disassembling
various cylinders
MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2

MEL1396-2 Piston Ring

Compressor

MEL1418 Cylinder Hone =

2.00 in
OEM6275 Cylinder Hone =
2.75 - 3.00 in
OEM6270 Cylinder Hone =
3.00 - 3.50 in
OEM6271 Cylinder Hone =
3.50 - 4.00 in

See www.BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools
Catalogue and Doosan Shop for parts ordering information.)

ST EXC-0516

910 of 918 SPEC-70-2 E85 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1033 Rod Seal Installation E08 - E85
Tool

MEL1355 Hydraulic Test Kit This test kit includes various gauges,
adapters, couplers and hoses that are
used when testing hydraulic functions.
MEL1355 Includes: MEL1355-1 thru
MEL1355-12

MEL1355-2 1000 psi gauge

MEL1355-3 5000 psi gauge

MEL1355-12 Coupler

Dealer Copy -- Not for Resale

MEL1412 Seal Installation Tool E32, E35 Used for installing Travel Motor Seal

Test Kit MEL1489, MEL1546, MEL1551,
MEL1594, MEL1594,
MEL10630-1 - MEL10630-11 and
MEL10630-14

MEL1352 Compression E26, Used in glow plug port for testing

Adapter E42 - E55 compression - Included with
MEL10630
MEL1631 Compression E32, E35 Used in glow plug port for testing

Dealer Copy -- Not for Resale

Adapter compression, NOT included with
MEL10630
MEL1743 Compression E63, E85 Used in glow plug port for testing
Adapter compression, NOT included with
MEL10630
MEL1237 Fuel Line Adapter E25 - E55 Adapter used to test delivery valve at
the injection pump (Used with
pressure gauge MEL1173-1)

MEL1173-1 Pressure Gauge

10000 psi

4200 Injector Nozzle

Tester

7268212 Valve Lash Adjusting All Bobcat

Wrench Engine
Models

7255632 Valve Stem Seal Tool

See www.BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools
Catalogue and Doosan Shop for parts ordering information.)

ST EXC-0516

913 of 918 SPEC-70-5 E85 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Electrical Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7292829 Injector Signal Tester Excavators Used to test injector signal on
equipped with Bobcat 1.8L and 2.4L engines.
Bobcat
engines

HVAC Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1581 HVAC Recover, E25 - E85 MEL1581 is no longer available,
Recycling, order MEL1735 or MEL1736
Recharging Machine

Dealer Copy -- Not for Resale

MEL1735 Deluxe HVAC
Recover, Recycling,
Recharging Machine

MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine

MEL1592 HVAC Refrigerant

Identification Tool

MEL1595 AC Compressor
Pulley Puller

See www.BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools
Catalogue and Doosan Shop for parts ordering information.)

ST EXC-0516

914 of 918 SPEC-70-6 E85 Service Manual

ALPHABETICAL INDEX

AIR CLEANER SERVICE . . . . . . . . . . . 10-90-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14

AIR CLEANER . . . . . . . . . . . . . . . . . . . 60-40-1 DIAGNOSTIC SERVICE CODES . . . . .50-80-1
AIR CONDITIONING SYSTEM FLOW DIAGNOSTIC TOOL . . . . . . . . . . . . . . .50-90-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 DIESEL PARTICULATE FILTER (DPF)
ALTERNATOR . . . . . . . . . . . . . . . . . . . 50-30-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .10-180-1
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 DIESEL PARTICULATE FILTER (DPF)
ARTICULATED BOOM VALVE (OPTIONAL) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1 DIRECT TO TANK VALVE . . . . . . . . .20-160-1
AUTO IDLE PRESSURE SWITCH . . . 50-160-1 ELECTRICAL SYSTEM INFORMATION
AUTO IDLE . . . . . . . . . . . . . . . . . . . . . 20-220-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 EMERGENCY EXITS . . . . . . . . . . . . .10-190-1
BLADE CONTROL VALVE . . . . . . . . . 20-130-1 ENGINE CONTROL UNIT (ECU) . . . .50-170-1
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 ENGINE COOLING SYSTEM . . . . . .10-110-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 70-110-1 ENGINE COOLING SYSTEM . . . . . . .60-50-1
BOOM (ARTICULATED) (OPTIONAL) ENGINE FLYWHEEL . . . . . . . . . . . . .60-130-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-141-1 ENGINE INFORMATION . . . . . . . . . . .60-10-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1 ENGINE LUBRICATION SYSTEM . . .10-130-1

Dealer Copy -- Not for Resale

BUCKET . . . . . . . . . . . . . . . . . . . . . . . 40-170-1 ENGINE SPEED CONTROL . . . . . . . .60-20-1
CAB FILTERS . . . . . . . . . . . . . . . . . . . 10-100-1 EPPR VALVE . . . . . . . . . . . . . . . . . . .20-180-1
CAB TILT PROCEDURE . . . . . . . . . . 10-210-1 EVAPORATOR / HEATER UNIT . . . . . .70-80-1
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 EXCAVATOR IDENTIFICATION . . . . . . . . 1-15
CAMSHAFT AND TIMING GEARS EXCAVATOR SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
CENTER ACCESS COVER . . . . . . . . . 40-80-1 EXHAUST GAS RECIRCULATION (EGR)
CENTER COVER . . . . . . . . . . . . . . . . . 10-70-1 VALVE . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
CENTER COVER . . . . . . . . . . . . . . . . . 40-70-1 EXPANSION VALVE . . . . . . . . . . . . . .70-100-1
COMPRESSOR . . . . . . . . . . . . . . . . . . 70-50-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11
CONDENSER . . . . . . . . . . . . . . . . . . . 70-60-1 FLOOR MAT . . . . . . . . . . . . . . . . . . . .40-100-1
CONSOLE LOCKOUT SWITCH . . . . . 50-60-1 FORCED REGENERATION VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-190-1
CONTROL CONSOLE LOCKOUT . . . 10-220-1
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CONTROL PATTERN SELECTOR VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1 FUEL LEVEL SENDER . . . . . . . . . . . .50-70-1
CONVERSIONS . . . . . . . . . . . . . . . SPEC-60-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-120-1
COUNTERWEIGHT . . . . . . . . . . . . . . . 40-90-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .60-70-1
CRANKSHAFT AND PISTONS . . . . . . 60-90-1 FUEL TANK . . . . . . . . . . . . . . . . . . . .40-110-1
CYLINDER (ARM) . . . . . . . . . . . . . . . . 20-21-1 FUEL TRANSFER PUMP . . . . . . . . . .50-150-1
CYLINDER (ARTICULATED BOOM) GLOW PLUGS . . . . . . . . . . . . . . . . . .60-120-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1 HEATER VALVE . . . . . . . . . . . . . . . . .70-120-1
CYLINDER (BLADE) . . . . . . . . . . . . . . 20-24-1 HORN . . . . . . . . . . . . . . . . . . . . . . . . .40-120-1
CYLINDER (BOOM SWING) . . . . . . . . 20-22-1 HVAC CONTROLLER . . . . . . . . . . . . .70-130-1
CYLINDER (BOOM) . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC CONNECTION
CYLINDER (BUCKET) . . . . . . . . . . . . . 20-23-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-40-1
CYLINDER HEAD . . . . . . . . . . . . . . . . 60-80-1 HYDRAULIC CONTROL VALVE . . . . . .20-40-1

915 of 918 INDEX-01 E85 Service Manual

HYDRAULIC FLUID SPECIFICATIONS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
HYDRAULIC PILOT PRESSURE FILTER SERVICE SCHEDULE . . . . . . . . . . . . 10-80-1
ASSEMBLY . . . . . . . . . . . . . . . . . . . . .20-230-1
SERVICE TOOLS REQUIRED . . . .SPEC-70-1
HYDRAULIC RESERVOIR . . . . . . . . .20-140-1
STARTER RELAY . . . . . . . . . . . . . . . . 50-41-1
HYDRAULIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 50-40-1
HYDRAULIC SYSTEM . . . . . . . . . . . .10-140-1 SWING CIRCLE GEAR . . . . . . . . . . . 30-40-1
INSTRUMENT PANEL . . . . . . . . . . . .50-100-1 SWING FRAME . . . . . . . . . . . . . . . . 40-130-1
KEY SWITCH . . . . . . . . . . . . . . . . . . .50-110-1 SWING MOTOR (DRIVE CARRIER)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1
LEFT CONSOLE . . . . . . . . . . . . . . . . .40-60-1
SWING MOTOR BRAKE RELEASE
LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-1
SWING MOTOR . . . . . . . . . . . . . . . . . 20-90-1
LIFTING AND BLOCKING THE EXCAVATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 SWIVEL JOINT . . . . . . . . . . . . . . . . . . 20-80-1
LIFTING THE EXCAVATOR . . . . . . . . .10-20-1 SYSTEM CHARGING AND RECLAMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .50-50-1
TECHNICAL SERVICE GUIDE
LOWER TRACK ROLLER . . . . . . . . . .30-50-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-20-1
LUBRICATING THE EXCAVATOR . . .10-150-1 THERMOSTAT . . . . . . . . . . . . . . . . . . 70-90-1

Dealer Copy -- Not for Resale

LUBRICATION SYSTEM . . . . . . . . . . .60-60-1 TORQUE SPECIFICATIONS FOR BOLTS
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
MANIFOLD ASSEMBLY / ACCUMULATOR TOWING THE EXCAVATOR . . . . . . . 10-230-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1 TRACK MAINTENANCE . . . . . . . . . . 30-30-1
MOTION ALARM SYSTEM . . . . . . . .50-140-1 TRACK UNDERCARRIAGE COMPONENTS
OIL COOLER . . . . . . . . . . . . . . . . . . .20-150-1 (RUBBER TRACK) . . . . . . . . . . . . . . . 30-20-1
OPERATOR CAB . . . . . . . . . . . . . . . . .10-30-1 TRACK UNDERCARRIAGE COMPONENTS
PIVOT PINS . . . . . . . . . . . . . . . . . . . .10-160-1 (STEEL TRACK) . . . . . . . . . . . . . . . . . 30-21-1
PUMP (GEAR) . . . . . . . . . . . . . . . . . . .20-51-1 TRANSPORTING THE EXCAVATOR ON A
TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
PUMP (HYDRAULIC PISTON) . . . . . . .20-50-1
TRAVEL CONTROL VALVE . . . . . . . 20-210-1
QUICK COUPLER (KLAC™ SYSTEM)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-160-1 TRAVEL MOTOR . . . . . . . . . . . . . . . 10-170-1
QUICK COUPLER (LEHNHOFF® SYSTEM) TRAVEL MOTOR . . . . . . . . . . . . . . . . 20-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-161-1 TROUBLESHOOTING . . . . . . . . . . . . 70-30-1
REAR COVER . . . . . . . . . . . . . . . . . . .10-60-1 UPPER TRACK ROLLER . . . . . . . . . . 30-60-1
REAR COVER . . . . . . . . . . . . . . . . . .40-190-1 UPPERSTRUCTURE SIDE COVER (LEFT)
RECEIVER / DRIER . . . . . . . . . . . . . . .70-70-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
REGULAR MAINTENANCE . . . . . . . . .70-20-1 UPPERSTRUCTURE SIDE COVER (RIGHT)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
RIGHT CONSOLE SWITCH COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-120-1 UPPERSTRUCTURE . . . . . . . . . . . . . 40-10-1
RIGHT CONSOLE . . . . . . . . . . . . . . . .40-50-1 VALVE (PRESSURE REDUCING RELIEF)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1
RIGHT CONTROL LEVER (JOYSTICK)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1 VALVES (PORT RELIEF) . . . . . . . . . . 20-31-1
RIGHT SIDE COVER . . . . . . . . . . . . . .10-50-1 VALVES (RELIEF) . . . . . . . . . . . . . . . 20-30-1
RIGHT SIDE COVER . . . . . . . . . . . . .40-180-1 VEHICLE CONTROL UNIT (VCU)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
WIPER MOTOR . . . . . . . . . . . . . . . . 50-130-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . .10-200-1

916 of 918 INDEX-02 E85 Service Manual

917 of 918
Dealer Copy -- Not for Resale
Dealer Copy -- Not for Resale

Bobcat®, the Bobcat logo and the colors of the Bobcat machine are registered trademarks of
Bobcat Company in the United States and various other countries.
918 of 918

SL4640 SL4840 SL5640 SL6640 Skid Loader PDF
100% (10)
SL4640 SL4840 SL5640 SL6640 Skid Loader PDF
232 pages
Bobcat 442 Mini Excavator Service Manual
96% (26)
Bobcat 442 Mini Excavator Service Manual
1,257 pages
Bobcat Excavators 325 328 6901138 Service Manual 2 06-21416B320070
83% (12)
Bobcat Excavators 325 328 6901138 Service Manual 2 06-21416B320070
798 pages
BobCat E35 Service Manual
83% (6)
BobCat E35 Service Manual
1,020 pages
Www. Bobcat-: Service Manual T190 Compact Track Loader
No ratings yet
Www. Bobcat-: Service Manual T190 Compact Track Loader
888 pages
E20 Service Manual - B3BL11001&above
100% (4)
E20 Service Manual - B3BL11001&above
671 pages
Bobcat E35 Date Back2013-2014
58% (24)
Bobcat E35 Date Back2013-2014
992 pages
Service Manual TL150 Ct7e002 PDF
100% (2)
Service Manual TL150 Ct7e002 PDF
828 pages
E20 7255008 enUS SM PDF
100% (3)
E20 7255008 enUS SM PDF
671 pages
BOBCAT T190 COMPACT TRACK LOADER Service Repair Manual SN 527811001 & Above PDF
0% (1)
BOBCAT T190 COMPACT TRACK LOADER Service Repair Manual SN 527811001 & Above PDF
15 pages
SM 20130101
100% (7)
SM 20130101
1,046 pages
Bobcat 322 322D 322G Excavator Operation Maintenance Manual
No ratings yet
Bobcat 322 322D 322G Excavator Operation Maintenance Manual
317 pages
Gehl V270 V330 Skid-Steer Loaders Service Repair Manual
25% (4)
Gehl V270 V330 Skid-Steer Loaders Service Repair Manual
6 pages
Bobcat - 435 6902331 SM 4 08
100% (2)
Bobcat - 435 6902331 SM 4 08
1,426 pages
t190 6987043 SM 8-09 PDF
86% (7)
t190 6987043 SM 8-09 PDF
888 pages
Manual Service Bobcat x331 Compact Excavator Safety Maintenance Systems Componentes Engine Specifications
100% (1)
Manual Service Bobcat x331 Compact Excavator Safety Maintenance Systems Componentes Engine Specifications
525 pages
Service Manual S70 Skid-Steer Loader: S/N A3W611001 & Above S/N A3W711001 & Above
71% (7)
Service Manual S70 Skid-Steer Loader: S/N A3W611001 & Above S/N A3W711001 & Above
420 pages
T770 7252384 enUS SM 12-16 - Decrypted
0% (1)
T770 7252384 enUS SM 12-16 - Decrypted
6 pages
Takeuchi TL Series
100% (4)
Takeuchi TL Series
196 pages
Bobcat T750 Compact Track Loader Service Repair Manual Download S N Atf611001 Above-1
100% (6)
Bobcat T750 Compact Track Loader Service Repair Manual Download S N Atf611001 Above-1
1,084 pages
142809-Bobcat 331 331E 334 PDF
100% (4)
142809-Bobcat 331 331E 334 PDF
953 pages
463 6903711 SM 8-07 PDF
75% (8)
463 6903711 SM 8-07 PDF
372 pages
Takeuchi TB175 Operator's Manual PDF
0% (1)
Takeuchi TB175 Operator's Manual PDF
231 pages
v723 6986675 SM 4-10 (Full Permission) - Unprotected
No ratings yet
v723 6986675 SM 4-10 (Full Permission) - Unprotected
913 pages
BOBCAT E45 6989437 enUS SM
No ratings yet
BOBCAT E45 6989437 enUS SM
1,101 pages
142809-Bobcat 331 331E 334 SN-232511001 Plus SN-232711001 Plus SN-232611001 Plus
100% (1)
142809-Bobcat 331 331E 334 SN-232511001 Plus SN-232711001 Plus SN-232611001 Plus
865 pages
E85 Service Manual - B48411001&Above
No ratings yet
E85 Service Manual - B48411001&Above
891 pages
Electrical Bobcat 442 Mini Excavator Service Manual
No ratings yet
Electrical Bobcat 442 Mini Excavator Service Manual
91 pages
Service Manual E80 Excavator: S/N AETB11001 & Above S/N AET311001 & Above
100% (3)
Service Manual E80 Excavator: S/N AETB11001 & Above S/N AET311001 & Above
879 pages
Service Manual E55 Compact Excavator: S/N ARWM11001 & Above S/N ASW311001 & Above
No ratings yet
Service Manual E55 Compact Excavator: S/N ARWM11001 & Above S/N ASW311001 & Above
6 pages
325-328 6986940 SM 10-09
No ratings yet
325-328 6986940 SM 10-09
762 pages
TacheuchiTB1140 S51400007 - Service
100% (3)
TacheuchiTB1140 S51400007 - Service
652 pages
429 - E50 6989441 enUS SM
100% (3)
429 - E50 6989441 enUS SM
1,038 pages
19537106-Bobcat T550 Compact Track Loader 2019 Service Repair Manual SN Ajzv11001 Above P NB 6990689enus 02-19 G
100% (1)
19537106-Bobcat T550 Compact Track Loader 2019 Service Repair Manual SN Ajzv11001 Above P NB 6990689enus 02-19 G
1,258 pages
435 - E80 6987194 enUS SM
100% (6)
435 - E80 6987194 enUS SM
893 pages
Gradall Service Manual
No ratings yet
Gradall Service Manual
1,102 pages
Operation & Maintenance Manual T870 Compact Track Loader: S/N B3BZ11001 & Above
No ratings yet
Operation & Maintenance Manual T870 Compact Track Loader: S/N B3BZ11001 & Above
230 pages
Bobcat S250 OM
100% (1)
Bobcat S250 OM
127 pages
Parts Manual: S/N 5230 11001 & Above S/N 5231 11001 & Above
100% (1)
Parts Manual: S/N 5230 11001 & Above S/N 5231 11001 & Above
361 pages
TB 250 PDF
100% (1)
TB 250 PDF
352 pages
Complete Hire Sydney Clarke Bobcat Track Loader T630 Operation Manual
50% (2)
Complete Hire Sydney Clarke Bobcat Track Loader T630 Operation Manual
242 pages
Service Manual Grader: (Grader 96) S/N ACW900101 & Above (Grader 108) S/N AJ2E00101 & Above
No ratings yet
Service Manual Grader: (Grader 96) S/N ACW900101 & Above (Grader 108) S/N AJ2E00101 & Above
120 pages
T590 6989682 enUS Om 04-14 - LM
No ratings yet
T590 6989682 enUS Om 04-14 - LM
236 pages
Service Manual: 6566694 (11-95) Printed in U.S.A. Melroe Company 1995
67% (3)
Service Manual: 6566694 (11-95) Printed in U.S.A. Melroe Company 1995
340 pages
Bobcat T250
100% (3)
Bobcat T250
964 pages
T630 7277035 enUS Om (OPERACIÓN Y MANTENIMIENTO) PDF
No ratings yet
T630 7277035 enUS Om (OPERACIÓN Y MANTENIMIENTO) PDF
246 pages
BOBCAT 175,185 Service
100% (9)
BOBCAT 175,185 Service
943 pages
SM-s250-s300 6901926 SM 3-06 Bobcat S250 Service Manual
No ratings yet
SM-s250-s300 6901926 SM 3-06 Bobcat S250 Service Manual
1,030 pages
Takeuchi Tl250 Bu3z004-1 Crawler Loader Parts Manual
100% (1)
Takeuchi Tl250 Bu3z004-1 Crawler Loader Parts Manual
515 pages
Vio27 35-2 (Us) (New Cabin) SVM
100% (3)
Vio27 35-2 (Us) (New Cabin) SVM
584 pages
tb125 PDF
100% (2)
tb125 PDF
267 pages
Downloaded From Manuals Search Engine: 1BAAACDAP2310
No ratings yet
Downloaded From Manuals Search Engine: 1BAAACDAP2310
98 pages
s130 6903151 SM 2-06 PDF
50% (2)
s130 6903151 SM 2-06 PDF
612 pages
Bobcat Manual PDF
100% (2)
Bobcat Manual PDF
292 pages
Manual Bobcat S250-S300
100% (1)
Manual Bobcat S250-S300
936 pages
Manu 450
No ratings yet
Manu 450
236 pages
220 6720503 SM 6-90 PDF
No ratings yet
220 6720503 SM 6-90 PDF
305 pages
Operation & Maintenance Manual: S/N 531711001 & Above
No ratings yet
Operation & Maintenance Manual: S/N 531711001 & Above
147 pages
PT 30
100% (1)
PT 30
116 pages
Manual de Serviço E45
No ratings yet
Manual de Serviço E45
904 pages
Name of Researcher
No ratings yet
Name of Researcher
1 page
Transcript Request
No ratings yet
Transcript Request
1 page
TRAINING AND DEVELOPMENT Notes
No ratings yet
TRAINING AND DEVELOPMENT Notes
28 pages
Safety in Molten Salt Bath Operations: Address: 12890 Westwood St. Revised: February 26, 2016
No ratings yet
Safety in Molten Salt Bath Operations: Address: 12890 Westwood St. Revised: February 26, 2016
18 pages
standardizationnews20230910-dl
No ratings yet
standardizationnews20230910-dl
68 pages
Grade 9 Reviewer MAPEH
No ratings yet
Grade 9 Reviewer MAPEH
6 pages
Status of Provincial Initiatives Under RRP - Provinces
No ratings yet
Status of Provincial Initiatives Under RRP - Provinces
20 pages
cs604 Quiz
No ratings yet
cs604 Quiz
4 pages
Data Ownership and Data Access Rights
No ratings yet
Data Ownership and Data Access Rights
24 pages
Sanju An County History
No ratings yet
Sanju An County History
434 pages
Natural Language Processing
No ratings yet
Natural Language Processing
20 pages
Najjar Ayat
No ratings yet
Najjar Ayat
16 pages
(FREE PDF Sample) The Brothel of Pompeii: Sex, Class, and Gender at The Margins of Roman Society Sarah Levin-Richardson Ebooks
100% (1)
(FREE PDF Sample) The Brothel of Pompeii: Sex, Class, and Gender at The Margins of Roman Society Sarah Levin-Richardson Ebooks
53 pages
Owner'S Manual: Guitar Effects Processor/Preamp
No ratings yet
Owner'S Manual: Guitar Effects Processor/Preamp
18 pages
Microbes As Bio Fertilizer: Name:-Deep Gaikwad STD:-XII (Science) Subject:-Biology
No ratings yet
Microbes As Bio Fertilizer: Name:-Deep Gaikwad STD:-XII (Science) Subject:-Biology
12 pages
Fusion Applications Extend Applications With ADF D67777GC10 - 28 - US
No ratings yet
Fusion Applications Extend Applications With ADF D67777GC10 - 28 - US
3 pages
cns4 1
No ratings yet
cns4 1
12 pages
Quiz 2 PDF
0% (1)
Quiz 2 PDF
7 pages
ABT, FGMO and OA in System Operation
No ratings yet
ABT, FGMO and OA in System Operation
57 pages
Lumen Method Lighting Calculation
100% (2)
Lumen Method Lighting Calculation
9 pages
Real Estate Advertising Guidelines
No ratings yet
Real Estate Advertising Guidelines
26 pages
Semantic Field: Definition and Usage History Semantic Shifts Anthropological Discourse See Also References
No ratings yet
Semantic Field: Definition and Usage History Semantic Shifts Anthropological Discourse See Also References
3 pages
MUGShots Sem 2
No ratings yet
MUGShots Sem 2
38 pages
Dissertation Epq
No ratings yet
Dissertation Epq
7 pages
Yash C++ Project
No ratings yet
Yash C++ Project
28 pages
Project Report On: "Engine Control Unit
No ratings yet
Project Report On: "Engine Control Unit
9 pages
Fisher, R A - Statistical Methods For Research Workers
100% (1)
Fisher, R A - Statistical Methods For Research Workers
111 pages
RCOM AR 2007-2008 Abriged
No ratings yet
RCOM AR 2007-2008 Abriged
88 pages
Developing Your PMO Roadmap
No ratings yet
Developing Your PMO Roadmap
7 pages
Assignment Supply Chain Chopra
No ratings yet
Assignment Supply Chain Chopra
4 pages