Bobcat E85 Service Manual - 6990617
Bobcat E85 Service Manual - 6990617
E85 Excavator
Garreth Fitzsimon
Coonana
Ballinafagh Hill S/N B34T11001 & Above
Prosperous, Naas
Kildare S/N B34S11001 & Above
W91 TDX4
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.
1-1
3 of 918
4 of 918
1-2
Dealer Copy -- Not for Resale
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-05
UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2. Check that the cab mounting 10. Check for correct function of
hardware is tightened and is indicator lamps.
Bobcat approved.
7. Enclosure door latches must 15. Inspect the air cleaner for
open and close freely. damage or leaks. Check the
condition of the element.
18. Inspect for loose or broken 22. Inspect the attachment quick
parts or connections. coupler for wear or damage.
Repair or replace damaged
parts.
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.
SI EXC-0913 SM
SI EXC-0913 SM
Fire Extinguishers
SI EXC-0913 SM
Figure 1
P111018
Module 2. - Production
Sequence (Series)
Figure 3
B-16315
2
14 24
1
15 16
4
3 13
17 23
5
6 9 12
11 18
7
21
8 19 20 NA5962
10 22 NA5960
Procedure
WARNING
Figure 10-10-1
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903
WARNING
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
or fall and result in injury or death.
P-86926 W-2218-1195
1
1
P-86416
Procedure
Figure 10-20-1
2 1
1
S37585
1
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
Procedure (Cont’d)
Figure 10-20-4
45°
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
2
1
P111029A
From inside the cab, open the door using the handle
(Item 2) [Figure 10-30-2].
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.
Figure 10-30-4 Support the window while rotating both window latch pins
(Item 1) [Figure 10-30-5] to the unlocked position.
P-86322
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
1 2
1 2
P111022B
Figure 10-30-9
P-86228
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.
P111034
Figure 10-30-12
P111035
Use ramps that are the correct length and width and can P-87269
support the weight of the machine.
The rear of the trailer must be blocked or supported when Figure 10-40-3
loading or unloading the machine to prevent the front of
the transport vehicle from raising.
1
Determine the direction of the track movement before
moving the machine (blade forward).
P-97926
Figure 10-50-1
1 2
P111081
P111082
The right side cover latch (Item 1) [Figure 10-50-2] can
be adjusted.
Use the start key (Item 1) [Figure 10-50-1] to unlock the
latch. Loosen the bolts and nuts (Item 2) [Figure 10-50-2] and
Figure 10-60-1
P111079
P111080
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 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.
• 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
• 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
P-97888
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.
Figure 10-90-3
1
P111085
Remove the air cleaner cover, the outer filter and the
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.
Figure 10-100-1
P-87293
1
2
Figure 10-100-2
P-87294
Use low air pressure to clean the filter. Replace the filter
when very dirty.
1 2
1
P111102
Figure 10-100-5
P111103
Use low air pressure to clean the filter. Replace the filter
when very dirty.
Check the cooling system every day to prevent over- Figure 10-110-2
heating, loss of performance or engine damage.
Cleaning
FULL 1
LOW
1
P111100
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot. P111099
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.
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 10-120-3
P111086
P111088
Install and tighten the fuel fill cap. (Use the start key to
lock the cap, if desired.)
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
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
Fuel Filter
Figure 10-120-6
P111092
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.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-120-5.)
Figure 10-120-8
P111093
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
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.
P111138
Figure 10-130-4
P-86268
P111137
Stop the engine. Check for leaks at the oil filter. Check
the oil level.
Figure 10-140-1
1
2
3
3 P111113
2
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
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
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
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
Figure 10-140-5
1
1
P111110
2
Remove the return filter (Item 1) [Figure 10-140-7].
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
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
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
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.
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
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.
P-86316
Figure 10-140-17
1
1
P111125
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.
P111117
P111127
Lubrication Locations
2
5
P111136
6
Figure 10-150-4
9
7
P111142
10
8 P111145
Figure 10-150-8
12
15
16 15
P-86304
12. Bucket Cylinder Base End (1) [Figure 10-150-8] Figure 10-150-11
14
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)
Figure 10-150-12
21
23 24
22
P123133
Figure 10-150-13
25
P123134
Figure 10-160-1
1 1
P123136
2
P123135
The two nuts are used as jam nuts to hold the bolt without
tightening the bolt to the pin boss. After the nuts are
tightened together, the bolt should be free to spin.
Check that all pivot bolts and nuts are securely tightened
and are not damaged. See your dealer for replacement
parts.
Checking And Adding Oil For the correct service interval. (See SERVICE
SCHEDULE on Page 10-80-1.)
Figure 10-170-1
Park the excavator on a level surface with plugs (Item 1, 2
and 3) in the position shown. Remove plugs (Item 2 and
2
3) [Figure 10-170-1] and drain the lubricant into a
container.
WARNING
AVOID INJURY OR DEATH
3 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
P111133 explosion or fire.
W-2103-0508
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.
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
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.
P-97914
IMPORTANT
Stopping the engine during the regeneration cycle
may cause severe damage to the DPF.
I-2352-0412
Your machine will indicate the need for service Figure 10-180-3
regeneration by displaying one of the following service
codes: 2 4
P-97888
The door, the right side rear window and the front window
provide emergency exits.
Figure 10-190-1
P-86325
1
Front Window
P111037
Figure 10-190-4
Figure 10-190-2
P-86322
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
B-22283
5
2
1
4
3
2
P123143
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.
Figure 10-210-2
P123144
Raise the cab slightly and rotate the cab support device
(Item 1) [Figure 10-210-6] to the storage position
[Figure 10-210-5].
Remove the bolt (Item 1) from the cab support device Install the bolt and washer (Item 1) [Figure 10-210-2] at
2
P-97919
Figure 10-220-1
P-86321
Sit in the operator's seat, fasten the seat belt and start
the engine.
Procedure
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.
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
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
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
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.
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
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
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
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.
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
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
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
MS-1892-1
MC 2340 (6-2-98)
MS-1892-2
MC 2340-2 (6-2-98)
MS-1892-3
MC 2340-3 (6-2-98)
Description
IMPORTANT 1
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.
P123146
Testing
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
P-86898
Figure 20-20-4
1 Articulated Boom
1
Figure 20-20-2
Articulated Boom
1 P122705
P122706
Testing (Cont’d)
Figure 20-20-5
2 1
2
P-87000
S37541
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].
If there is any oil leakage from the base end fitting (Item
1) [Figure 20-20-8], remove the cylinder for repair or
replacement.
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
P-86898
Figure 20-20-12
Articulated Boom
1
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
1
P-86839
Figure 20-20-16
P-86896
Articulated Boom
Figure 20-20-14 2
3
S37541
Figure 20-20-17
2
1
1
P-87926
IMPORTANT 1
Figure 20-20-18
P-87008
P-87001
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
15
7
3
12
1 5
14
5
12
16
9
17
5
5
18
16 8
19
Disassembly
Figure 20-20-21
P-87090
Figure 20-20-22
P-87087
2
P-87086
Disassembly (Cont’d)
Figure 20-20-25
1 1
P-86848
Figure 20-20-28
Remove the four bolts (Item 1), lock washers and tubeline
(Item 2) [Figure 20-20-25].
1
1
P-86849
Disassembly (Cont’d)
Figure 20-20-29
P-86850
Figure 20-20-30
P-86851
Disassembly (Cont’d)
1
Figure 20-20-33
P-87032
Figure 20-20-36
Remove the piston (Item 1) [Figure 20-20-33].
1
P-87031
Disassembly (Cont’d)
Figure 20-20-37
P-87028
Figure 20-20-40
Remove O-ring (Item 1) [Figure 20-20-37] from the
piston.
P-86862
Disassembly (Cont’d)
1
Figure 20-20-41
P-86861
Figure 20-20-44
Remove the back-up ring (Item 1) [Figure 20-20-41] from
the piston.
1
1
P-86864
Disassembly (Cont’d)
Figure 20-20-45 1
P-86867
P-86868
P-86866
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].
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.
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.
Figure 20-20-53
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].
Assembly (Cont’d)
Figure 20-20-56
P-86866
Figure 20-20-59
Install the wiper seal (Item 1) [Figure 20-20-56] into the
head.
P-86865
Assembly (Cont’d)
Figure 20-20-60 1
1
P86860
Figure 20-20-63
Install the O-ring (Item 1) [Figure 20-20-60].
P-87011
Assembly (Cont’d)
Figure 20-20-64
1 P-87029
Figure 20-20-67
Install the O-ring (Item 1) [Figure 20-20-64] into the
piston.
P-87030
Figure 20-20-68
P-87028
P-87031
Assembly (Cont’d)
Figure 20-20-69 2
1
P-86853
2
P-86851
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.
Assembly (Cont’d)
Figure 20-20-73
1
P-87077
Figure 20-20-76
Install the set screw (Item 1) [Figure 20-20-73] into the
nut. 2
2
P-86849
Assembly (Cont’d)
Figure 20-20-77
P-87087
Figure 20-20-80
Install the O-ring (Item 1) [Figure 20-20-77] into the
tubeline.
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.
Assembly (Cont’d)
1
Figure 20-20-81 2
P-87014
Figure 20-20-84
Install the tubeline (Item 1), using the four bolts (Item 2)
[Figure 20-20-81] and lock washers.
P-36183
Testing 1
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
Figure 20-21-1
P-87020
1
Figure 20-21-4
Figure 20-21-2
Articulated Boom
1 3
P-87076
S37544 Start the engine and fully retract the cylinder rod.
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.
Figure 20-21-6
Articulated Boom
S37542
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
Figure 20-21-11
Figure 20-21-9
Articulated Boom
2
1 1
3
P-87076
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
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
2 3
P-87016
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].
Figure 20-21-17
1
P-87095
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
24
7
7
25
23 8
26
7 MS-2793S
Disassembly
Figure 20-21-18
P-87098
Figure 20-21-19
P-87096
1
1
P-87097
Disassembly (Cont’d)
Figure 20-21-22
1
P-86848
2
Figure 20-21-25
Remove the four bolts (Item 1), lock washers and hose
(Item 2) [Figure 20-21-22].
1
1
P-86849
Disassembly (Cont’d)
Figure 20-21-26
P-86850
Figure 20-21-27
P-86851
Disassembly (Cont’d)
Figure 20-21-30
1
P-87032
Figure 20-21-33
Remove the piston (Item 1) [Figure 20-21-30].
1
1
P-87031
Disassembly (Cont’d)
Figure 20-21-34
P-87028
Figure 20-21-37
Remove the O-ring (Item 1) [Figure 20-21-34] from the
piston.
P-86862
Disassembly (Cont’d)
Figure 20-21-38 1
P-86861
Figure 20-21-41
Remove the back-up ring (Item 1) [Figure 20-21-38].
1 1
P-86864
Disassembly (Cont’d)
Figure 20-21-42 1
P-86867
1
P-86868
P-86866
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].
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.
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.
Figure 20-21-50
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].
Assembly (Cont’d)
Figure 20-21-53
P-86866
Figure 20-21-56
Install the wiper seal (Item 1) [Figure 20-21-53] into the
head.
P-86865
Assembly (Cont’d)
Figure 20-21-57 1
1
P86860
Figure 20-21-60
Install the O-ring (Item 1) [Figure 20-21-57].
P-87011
Assembly (Cont’d)
Figure 20-21-61
1 1
P-87029
Figure 20-21-64
Install the O-ring (Item 1) [Figure 20-21-61] into the
piston.
1
1
P-87030
Figure 20-21-65
P-87028
P-87031
Assembly (Cont’d)
Figure 20-21-66 2
1
1
P-86853
1
P-86851
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.
Assembly (Cont’d)
Figure 20-21-70
1 2
1
P-87077
Figure 20-21-73
Install the set screw (Item 1) [Figure 20-21-70] into the
nut. 2
2
P-86849
Tighten the bolts to 123 - 149 N•m (91 - 110 ft-lb) torque.
2
P-87013
Assembly (Cont’d)
Figure 20-21-74
1
1
P-87098
Figure 20-21-77
Install the O-ring (Item 1) [Figure 20-21-74] into the
hose.
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.
Assembly (Cont’d)
Figure 20-21-78
1
2
P-36183
P-87014
Testing
P-87409
1
Figure 20-22-2
P-87412
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.
P-87411
1
Place a board (Item 1) [Figure 20-22-7] between the
2
cylinder and the excavator frame.
Figure 20-22-8
Figure 20-22-6 1
P-87417
P-87410
1
1
1
P-87413
Figure 20-22-12
Remove the hoses (Item 1) [Figure 20-22-9].
1
1
P-87415
Figure 20-22-13
1 1
P-89345
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.
Figure 20-22-14
P-89347
Continue sliding the cylinder out until the second cable tie
(Item 1) [Figure 20-22-14] can be removed.
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
1
12
13
14
15 1
16
1
MS-2795S
Disassembly
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
Figure 20-22-20
Figure 20-22-18
1 P-87422
P-87420
Disassembly (Cont’d)
Figure 20-22-21
2
1
1
P-87425
Figure 20-22-24
Remove the rod assembly (Item 1) [Figure 20-22-21]
from the housing.
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
Disassembly (Cont’d)
Figure 20-22-25
1 P-87429
1
1
P-87430
Disassembly (Cont’d)
Figure 20-22-29
P-87433
P-87446
Disassembly (Cont’d)
Figure 20-22-33
1
P-87436
P-87437
Disassembly (Cont’d)
Figure 20-22-37
1
P-87440
P-87444
Disassembly (Cont’d)
Figure 20-22-41 1
P-87445
P-87443
Assembly
Lubricate all O-ring and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-22-45] into the
installation. head.
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)
Assembly (Cont’d)
Figure 20-22-47
1
P-87439
2
P-87438
P-87437
Assembly (Cont’d)
Figure 20-22-52
1
P-87434
Figure 20-22-53 1
P-87446
1
P-87435
Assembly (Cont’d)
Figure 20-22-56
P-87431
Figure 20-22-57
P-87430
P-87439
Install the seal (Item 1) [Figure 20-22-59].
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
1
P-87426
P-87427
Assembly (Cont’d)
Figure 20-22-64
2 1
P-87423
Figure 20-22-67
Install the bushing (Item 1) and seal (Item 2) [Figure 20-
22-64] (both sides) into the rod end.
P-87422
1
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.
P-87420
Fully retract the bucket and arm cylinders. Lower the boom until the bucket is on the ground.
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
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
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.
2 1
P-86832
Figure 20-23-7
Remove the hose (Item 1) [Figure 20-23-4] from the
base end.
Figure 20-23-5
P-86833
P-86834
Figure 20-23-8
1
1 P-86835
Figure 20-23-11
Remove the rod end pivot pin (Item 1) [Figure 20-23-8].
P-86838
1
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
3
15
7
18
5
5
19
17
6
20
7
5
MS-2794S
Disassembly
Figure 20-23-12
P-86843
Figure 20-23-15
1
P-86839
Figure 20-23-13
P-86842
1 1
P-86840
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.
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].
Disassembly (Cont’d)
1
Figure 20-23-20
P-86852
Figure 20-23-23
Remove the eight bolts (Item 1) [Figure 20-23-20].
P-86850
1
Disassembly (Cont’d)
Figure 20-23-24
1
P-86542
Figure 20-23-27
Apply moderate heat to the nut (Item 1) [Figure 20-23-
24].
Figure 20-23-25
P-87032
P-86853
Disassembly (Cont’d)
Figure 20-23-28
P-87029
Figure 20-23-31
Remove the seal (Item 1) [Figure 20-23-28].
P-87028
Disassembly (Cont’d)
Figure 20-23-32
1
P-86860
Figure 20-23-35
Remove the O-ring (Item 1) [Figure 20-23-32] from the
piston.
P-86861
Disassembly (Cont’d)
Figure 20-23-36
P-86866
P-86867
P-86865
Disassembly (Cont’d)
Figure 20-23-40
1 1
2
P-86870
Remove the wiper seal (Item 1) [Figure 20-23-40]. Remove the rod from the vise.
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.
Disassembly (Cont’d)
Figure 20-23-44
2
1
P-87015
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.
Figure 20-23-45
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].
Assembly (Cont’d)
Figure 20-23-48
P-86866
Figure 20-23-51
Install the wiper seal (Item 1) [Figure 20-23-48] into the
head.
P-86865
Assembly (Cont’d)
Figure 20-23-52 1
1
P86860
Figure 20-23-55
Install the O-ring (Item 1) [Figure 20-23-52].
P-87011
Assembly (Cont’d)
Figure 20-23-56
1
1
P-87029
Figure 20-23-59
Install the O-ring (Item 1) [Figure 20-23-56] into the
piston.
P-87030
Figure 20-23-60
P-87028
P-87031
Assembly (Cont’d)
2
Figure 20-23-61
1
P-86853
1 1
P-86851
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.
Assembly (Cont’d)
Figure 20-23-65
1
P-87077
Figure 20-23-68
Install the set screw (Item 1) [Figure 20-23-65] into the
nut. 2
2
P-86849
1
P-87013
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.
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.
Assembly (Cont’d)
Figure 20-23-73
1
2
1
P-86839
Figure 20-23-76
Install the O-ring (Item 1) into the spacer (Item 2) [Figure
20-23-73].
1
3 3
P-87014
Assembly (Cont’d)
Figure 20-23-77
1
2
P-36183
Testing
With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.
Figure 20-24-1
Figure 20-24-2
P-86490
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.
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
2
1
1
P-86492
Figure 20-24-6
P-86496
Figure 20-24-9
P-86493
Figure 20-24-7
P-86495
Figure 20-24-10
P-86498
Figure 20-24-11
P-86497
Parts Identification
1. Grease Fitting
2. Bushing
3. Rod 1
4. Snap Ring
5. Wiper Seal 3
6. Seal
7. Head
8. O-ring 4 2
9. Back-up Ring 5
7
10. Snap Ring
6
11. Piston
12. Seal 8
13. Slipper Seal Assy 9
14. Wear Ring
15. Set Screw 2
10
16. Nut
8
17. Housing
9
11
12
16
17
MS-2796S
Disassembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-86501
Hold the cylinder over a drain pan and slowly move the
rod in and out to remove the oil from the cylinder.
Straighten the head lock ring (Item 1) [Figure 20-24-13].
Figure 20-24-12
Figure 20-24-14
2 P-86500
P103657
Disassembly (Cont’d)
Figure 20-24-15
P-86504
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].
Disassembly (Cont’d)
Figure 20-24-19
P-86541
P-86548
Disassembly (Cont’d)
Figure 20-24-23
P-86532
P-86531
Disassembly (Cont’d)
Figure 20-24-27 1
P-86517
P-86518
1
Disassembly (Cont’d)
Figure 20-24-31
P-86524
1
P-86525
Disassembly (Cont’d)
Figure 20-24-35
P-86529
1 P-86531
Disassembly (Cont’d)
Figure 20-24-39
P-86544
P-86533
Assembly
Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-24-42] into the
assembly. rod.
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.
Assembly (Cont’d)
Figure 20-24-44
1 1
P-86526
1
1
P-86525
Assembly (Cont’d)
Figure 20-24-48
P-86519
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].
Assembly (Cont’d)
Figure 20-24-52
1
P-86515
1
1
P-86531
Assembly (Cont’d)
Figure 20-24-56
1
P-86540
P-86548
Assembly (Cont’d)
Figure 20-24-60
1
2
P-86507
Figure 20-24-63
Install the wear ring (Item 1) [Figure 20-24-60].
P-86506
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.
Assembly (Cont’d)
Figure 20-24-64
P103657
Figure 20-24-67
Install the set screw (Item 1) [Figure 20-24-64].
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
Assembly (Cont’d)
Figure 20-24-68
P-86500
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.
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic 1
pressure.
Remove the stopper (Item 1), the shim and the rod end
1 pivot pin (Item 2) [Figure 20-25-3].
Figure 20-25-4
Start the engine and fully retract the cylinder rods (Item
1 2) [Figure 20-25-4].
S37545
Testing (Cont’d)
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-25-5
S37548
If there is any oil leakage from the base end fittings (Item
1) [Figure 20-25-5], remove the cylinder for repair or
replacement.
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic 3
pressure.
Figure 20-25-7
S37545
2
4
2 5
S37653
1
1
2
S37547
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
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
8
9
10
10
11
11
12
17
13
11
14
11
15
16
17
18
NA5527S
Disassembly
Figure 20-25-12
1
S37656
Figure 20-25-15
Figure 20-25-13
S37657
S37655
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].
1
1
S37688
Disassembly (Cont’d)
Figure 20-25-20
1
1
S37690
S37689
1
Remove the seal (Item 1) [Figure 20-25-23].
S37687
Disassembly (Cont’d)
Figure 20-25-24
1
P-87435
1
P-87436
Disassembly (Cont’d)
Figure 20-25-28
P-87439
P-87440
Disassembly (Cont’d)
Figure 20-25-32
1
2
P-87443
1
1
2
P-87445
Assembly
Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-25-37] into the
assembly. head.
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).
Assembly (Cont’d)
Figure 20-25-39
1
P-87439
1 2
P-87438
P-87437
Assembly (Cont’d)
Figure 20-25-44
1
P-87434
Figure 20-25-45 1
S37691
1
P-87435
Assembly (Cont’d)
Figure 20-25-48 2
S37687
S37692
Assembly (Cont’d)
Figure 20-25-52
1
1
P-87425
Figure 20-25-55
Install the set screw (Item 1) [Figure 20-25-52].
Figure 20-25-53
P-87424
Assembly (Cont’d)
Figure 20-25-56
S37655
S37657
Bend the lock ring tab (Item 1) [Figure 20-25-57] into the
groove on the head.
Description
Figure 20-30-1
P-86566
Figure 20-30-2
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 and load sense relief valve are
tested and adjusted during the piston pump testing and
adjusting. (See Pump Testing on Page 20-50-6.)
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
Figure 20-31-3
1
P-86411
2
P-86412
With the engine off, and the key in the run position, lower 1
the left console and move both joysticks to relieve
hydraulic pressure.
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
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.
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.
Figure 20-32-3
P-86427
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].
Description
Remove the left upperstructure cover. (See Removal And Figure 20-40-3
Installation on Page 40-20-1.)
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 P-87118
Figure 20-40-1 Remove the pilot lines from the outboard side of the valve
[Figure 20-40-3].
P-87116
Mark and remove the hoses from the top of the valve
[Figure 20-40-1].
Figure 20-40-4
1
1
P-87121
Figure 20-40-7
Remove the bolt (Item 1) [Figure 20-40-4] and washer.
1
1
1
P-87122
Parts Identification
13
15
16 2 1
17
3
18 4
5
6
7 14
8
20 9
10
11
12
15
16
17
18
19
20
NA9771
Figure 20-40-8
1
1
P-87128
Figure 20-40-11
Remove the bolts (Item 1) [Figure 20-40-8], washers and
mounts.
1 1
P-87129
Figure 20-40-12
1
P-87130
Figure 20-40-15
Remove the articulated boom valve section (Item 1)
[Figure 20-40-12]. (If equipped.)
1 1
P-87131
1 1
Remove the four O-rings (Item 1) [Figure 20-40-15].
P-87131
Figure 20-40-16
1
1
1
1
2
P-87134
Remove the four O-rings (Item 1). Remove the right hand
P-87132 travel valve section (Item 2) [Figure 20-40-18].
Figure 20-40-19
Remove the mid inlet (Item 1) [Figure 20-40-16] valve
section.
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
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].
1
2
1
P-87139
Figure 20-40-24
P-87140
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.
Figure 20-40-26 1
1
1 2
P-87144
2
Figure 20-40-29
Remove the load sense relief valve (Item 1) and back-up
relief valve (Item 2) [Figure 20-40-26].
Figure 20-40-27
1
1 1
P-87145
Figure 20-40-30
P-35277
1
Remove the O-ring (Item 1) [Figure 20-40-32].
Figure 20-40-31
P-87147
P-87146
Figure 20-40-34
P-87148
P-87149
Figure 20-40-36
1
1
P-87156
1
1
P-35253
P-35260
Figure 20-40-40
1
1
P-35279
1
1
1
2 2
2
P-35266
1
Remove the centering spring (Item 1) [Figure 20-40-43]
P-87158 from both ends.
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
Figure 20-40-45
Cut
0.5625 Dia
2.0 in
P-87152
0.750 in B-14674
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.
Figure 20-40-49
1
P-35268
Figure 20-40-51
1 1
P-87165
P-35253
1
2
Remove the O-ring (Item 1) [Figure 20-40-54].
P-87160
Figure 20-40-55
P-35279
1
2
2
1 P-35266
Figure 20-40-59
1 2
1 3
P-35269
Figure 20-40-62
Remove the spool (Item 1) [Figure 20-40-59].
P-87167
Figure 20-40-63
P-87168
Figure 20-40-64
P-87161
Figure 20-40-65 1
2 1
1 P-35253
Figure 20-40-68 2
1
P-35281
1 1
P-35283
Figure 20-40-72
P-35279
Figure 20-40-73 1
2
2
P-35266
1
P-35269
1
P-35268
Figure 20-40-79 1 2
4 3
1
1 1
P-87171
Figure 20-40-82
Remove the valves (Item 1) [Figure 20-40-79].
Figure 20-40-80
P-87156
Figure 20-40-83
1
1
1
2 P-87166
P-87157
P-35279
Figure 20-40-87
1
2 P-35268
Figure 20-40-88
1 2
1 3
P-35269
Figure 20-40-91
1
P-87161
Figure 20-40-94
Figure 20-40-92
1
1
P-35253
P-35260
Figure 20-40-95 2
1
P-35281
1 1
P-35283
Figure 20-40-99
P-35279
Figure 20-40-100 1
2
2
P-35266
1
P-35269
1
P-35268
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.
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.
7. Record pressure
8. Remove the hose and fitting from the torque limiter supply spool and plug the port
11. Adjust as necessary to get 1800 ± 138 kPa (18 ± 1,38 bar) (260 ± 20 psi).
__________ PM PRESSURE
13. Remove 5000 kPa (50 bar) (725 psi) pressure gauge.
14. Install 69000 kPa (690 bar) (10000 psi) gauge on the test port on the hydraulic control valve.
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).
__________ PRESSURE
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).
__________ PRESSURE
24. Remove the 69000 kPa (690 bar) (10000 psi) gauge, from the diagnostic coupler at the hydraulic control valve.
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)
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).
__________ 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)
__________ FLOW
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).
Testing Information
P112286
Figure 20-50-3
P-86558
Figure 20-50-4
P-86559
Pump Testing
Figure 20-50-5 1
3
4
2
P112487
Figure 20-50-6 Turn the pump margin spool (bottom spool) (Item 3)
[Figure 20-50-7] all the way in (approximately six turns).
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
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.
Figure 20-50-11
1
2
P-86564
Figure 20-50-13
P-86560
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.
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.
Figure 20-50-14
P-86567
Move the engine speed control to the high idle position. Tighten the lock nut and lower the cab.
Tilt the cab. (See Raising And Lowering on Page 10-210- Retest the load sense relief valve.
1.)
Figure 20-50-16
1
1
1
P112291
Figure 20-50-17
1
3 P-86572
P112290
Install the adapter (Item 1), plate (Item 2) and bolts (Item
3) [Figure 20-50-17] on the hose.
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].
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].
Figure 20-50-24 Remove the hydraulic tester, fittings and adapter hose.
1 Figure 20-50-25
2
P112296
1
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
P-87476 1
2
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
Figure 20-50-30
P112396
Slide the pump away from the engine and remove the
P112395 pump [Figure 20-50-32].
P112392
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
14
13
12
10 11
9
2
3
3
4
MS-2790S
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
Figure 20-50-34
P-35330
Figure 20-50-35
1 1
2
N-23329
Figure 20-50-38
Remove the O-ring (Item 1) [Figure 20-50-35] from the
torque limiter valve.
Figure 20-50-36 1
P-35320
N-23328
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].
P-35322
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
Figure 20-50-44
P-35326
P-35324
Figure 20-50-47
1
4
P-35327
Figure 20-50-48
P-35328
Figure 20-50-49
P-35327
1
Install the O-ring washer (Item 1) on the adjustment
screw (Item 2) [Figure 20-50-50].
Figure 20-50-51
P-35328
P-35325
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].
Figure 20-50-53
2 1
2
1
P-35321
Figure 20-50-56
N-23328
1
Figure 20-50-59
Install the control spool assembly (Item 1) [Figure 20-50-
56] in the valve body.
Figure 20-50-57
N-23327
2
1
N-23329
Figure 20-50-60
1
P-35323
P-35322
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).
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.
Figure 20-50-66
P-87516
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
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
Figure 20-50-68
1 1
P-87517
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].
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].
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.
Figure 20-50-74
P-35338
P-35339
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].
1
1 2
P-35344
N-23379
Check the spool for scratches and make sure the orifices
(Items 1 and 2) [Figure 20-50-84] are not plugged.
Figure 20-50-83
P-35347
P-35348
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
25 5
27
21
17
20
8 6
29
22
5
24 26
23
B-23974
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
1
P-61054
Disassembly (Cont’d)
1
3
Figure 20-50-90
P-61070
2
1
1 1
N-23387
P-61055
Disassembly (Cont‘d)
Figure 20-50-94
2
1
P-61072
Figure 20-50-97
Remove the spring (Item 1) from the stroking piston (Item
2) [Figure 20-50-94].
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.
Disassembly (Cont’d)
1
Figure 20-50-98
3
P-35354
Figure 20-50-99
1 P-35355
P-35361
Disassembly (Cont’d)
1
Figure 20-50-102
2
4 4
3 2 3
1 2 3
4
N-15289
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].
4
1
2
1
2
3
N-15290
N-15288
Disassembly (Cont’d)
Figure 20-50-106
1
2 3
1 3
3 2
N-23395
N-15284
P-61075
Disassembly (Cont’d)
Figure 20-50-110
1
N-15277
Figure 20-50-113
Remove the snap ring (Item 1) [Figure 20-50-110] from
the housing.
1
1
N-15280
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].
N-23418
Remove the valve plate (Item 1) [Figure 20-50-115]. Remove the destroking piston (Item 2) [Figure 20-50-
117].
Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-61080
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and damage. Install the bearing race (Item 1) [Figure 20-50-119] in the
port block assembly.
Replace any worn or damaged parts.
Figure 20-50-118
P-61079
Assembly (Cont’d)
Figure 20-50-120
P-35356
1
1
N-15285
Assembly (Cont’d)
1
Figure 20-50-124 2
P-61083
Figure 20-50-125
P-35360
Assembly (Cont’d)
Figure 20-50-128
N-15277
Figure 20-50-130
Install a dial indicator on the housing as shown [Figure
20-50-128] and set it to zero.
Assembly (Cont’d)
Figure 20-50-131
3 2
1 2 3
1
2
N-15299
Install the swash plate (Item 1) on the shaft (Item 2) Figure 20-50-134
[Figure 20-50-131].
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.
Assembly (Cont’d)
1
Figure 20-50-135
2
1
3
P-35354
Figure 20-50-138
NOTE: The modified washer (Item 1) must fit over the
spring (Item 2), but must also fit inside the
1
Figure 20-50-136
2
1 P-35361
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].
2
1
P-61086
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].
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
Figure 20-50-144
3
1 2
2
3
1
1
P-61090
1
Install the end cap (Item 1) [Figure 20-50-146].
Assembly (Cont’d)
Figure 20-50-147
1
1 N-23354
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.)
2
N-23355
P112298
If the high pressure flow is less than 80% of the free flow,
remove the hydraulic pump for repair or replacement.
P-22253
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.
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.
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.
Figure 20-51-8
2
1
P112304
P112303
Figure 20-51-11
1
P-87379
1 1
1
1 P-87380
P-87378
Figure 20-51-15
P-87383
P-87384
P-87387
Figure 20-51-22
Remove the drive gear (Item 1). Remove the idler gear
(Item 2) [Figure 20-51-19].
P-87384
Figure 20-51-23
1
1
P-87390
P-87138
Description
With the engine off and the key in the run position, move
the control levers to relieve hydraulic pressure.
Figure 20-60-3
1
1 1
2
P112425
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
Figure 20-60-4
1 1 1
P112427
Figure 20-60-5
P112428
Figure 20-60-8 2
2 2
2
1
P112433
1 1
Figure 20-60-11
Remove the back-up rings (Item 1) and O-rings (Item 2)
[Figure 20-60-8].
P112430
Figure 20-60-12
P-87115
1
P112435
Figure 20-70-1 1
P-87914
Figure 20-70-2
1 2
2
1 2
2
2
P-87910
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
B-23945
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
14
15 13
16
12 13
13
3 2 1 17
4
5
19
18
15
18
B-23946
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 20-70-4
P-89338
Figure 20-70-7
P-89004
1
Remove the plugs (Item 1) [Figure 20-70-4].
P-89005
Disassembly (Cont’d)
1
Figure 20-70-8
2
1
P-89010
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
1
2
P-89011
P-89009
Disassembly (Cont’d)
Figure 20-70-12
1
1
2 P-89339
2
P-89014
P-89013
Disassembly (Cont’d)
Figure 20-70-16
P-89017
1
1
P-89018
Disassembly (Cont’d)
Figure 20-70-20
P-89021
P-89022
Disassembly (Cont’d)
Figure 20-70-24
1
1 2
P-89025
P-89026
P-89024
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)
Figure 20-70-29
P-89030
Disassembly (Cont’d)
Figure 20-70-32
1 P-89033
Remove the spring and valve (Item 1) [Figure 20-70-32]. Figure 20-70-35
P-89075
1
P-89032
Remove the spool (Item 1) [Figure 20-70-35] and spring.
Disassembly (Cont’d)
Figure 20-70-36
P-89037
Figure 20-70-39
Remove the piston by injecting low air pressure into the
access hole in the spindle [Figure 20-70-36].
Turn the motor on its side and drain the hydraulic fluid
into an approved container.
Figure 20-70-37
1 2
P-89038
1
P-89036
Disassembly (Cont’d)
Figure 20-70-40
1
2
1
2 1
P-89041
P-89040
Disassembly (Cont’d)
Figure 20-70-43
1
P-89045
3
P-89046
Remove the snap ring (Item 1), washer (Item 2), and
spring (Item 3) [Figure 20-70-43] and [Figure 20-70-44].
Disassembly (Cont’d)
Figure 20-70-47
1
2
P-89049
Figure 20-70-48
1
P-89052
P-89047
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].
1
1
P-89056
2
Remove the seal ring assembly (Item 1) [Figure 20-70-
P-89054 54] from the spindle.
Disassembly (Cont’d)
Figure 20-70-55
P-89057
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].
Figure 20-70-58
P-89061
Apply a light film of grease onto the O-ring of the seal ring
assemblies. P-61811
Assembly (Cont’d)
Figure 20-70-59
P-87899
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].
P-89053
Install the seal ring assembly (Item 1) [Figure 20-70-60]. Install the ring nut with the chamfer towards the bearing.
Assembly (Cont’d)
Figure 20-70-63
P-89067
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).
Assembly (Cont’d)
Figure 20-70-67 1
P-89045
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.
Assembly (Cont’d)
Figure 20-70-71
1
1
1
2
1
P-89039
Figure 20-70-74
Install the pins (Item 1) [Figure 20-70-71] into the
cylinder block.
P-61778
Assembly (Cont’d)
Figure 20-70-75
1
1
P-89073
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.
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.
Assembly (Cont’d)
Figure 20-70-79
1
P-89028
Figure 20-70-80
P-89029
P-89031
Assembly (Cont’d)
Figure 20-70-83
P-89025
Figure 20-70-86
Install the spring retainer, spring and plug (both ends of
the spool) [Figure 20-70-83].
P-89074
1
Install the valve (Item 1) [Figure 20-70-86].
P-89026
Assembly (Cont’d)
Figure 20-70-87
1
1
P-89021
Figure 20-70-88
1
P-89340
1
Install the springs (Item 1) [Figure 20-70-90].
P-89023
Assembly (Cont’d)
Figure 20-70-91
1
1
P-89018
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.
P-89015
P-89019
Assembly (Cont’d)
Figure 20-70-95 1
P-89016
1
Figure 20-70-98
Tighten the valve (Item 1) [Figure 20-70-95] to 122 - 152
N•m (90 - 112 ft-lb) torque.
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].
Assembly (Cont’d)
Figure 20-70-99
P-89079
P-89080
Assembly (Cont’d)
Figure 20-70-103
1
P-89083
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].
Assembly (Cont’d)
Figure 20-70-107
1
P-89087
P-89338
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-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
1
1
1 P-89311
1
1 Remove the bolts (Item 1) and bottom access plate (Item
2) [Figure 20-80-3].
P-89310
P-89314
P-89315
Figure 20-80-8
P-89316
P-89317
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
4 9
5 10
11
12
MS2788
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].
Figure 20-80-11
1 1
1 NA1244
NA1241
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.
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
1
1
1 NA1243
NA1245
Assembly (Cont’d)
Figure 20-80-17
1 1
4 5
2
1 1
3 6
NA1240
1
Install the shim (Item 1), spacer (Item 2) and snap ring
(Item 3) [Figure 20-80-17].
P112449
Figure 20-90-3
1
P-87254
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
Figure 20-90-4
1
1
1
1
1
1 P112453
1
1
2
P11254
P112464
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
15
17
18
19
2 20
21
23
22
8
14
NA-1044
Figure 20-90-8
2
2
1 1
P-87586
Figure 20-90-11
Remove the three bolts and remove the brake valve (Item
1) [Figure 20-90-8].
1
1 1
P-87587
Figure 20-90-12
1
1
P-87590
Figure 20-90-15
Remove the O-ring (Item 1) [Figure 20-90-12] from both
plugs.
1
1
P-87591
Figure 20-90-16
1
P-87594
Figure 20-90-19
Remove the O-ring (Item 1) [Figure 20-90-16] from both
relief valves.
1
1
P-87596
1
Figure 20-90-20
1
P-87598
Figure 20-90-23
Remove the bearing (Item 1) [Figure 20-90-20].
P-87599
P-87602
Figure 20-90-27
Remove the friction plate (Item 1) [Figure 20-90-24].
1
1
P-86577
Figure 20-90-28 1
1
P-87605
Figure 20-90-31
Tip the housing and remove the rotating group (Item 1)
[Figure 20-90-28].
P-87606
Figure 20-90-32
2
1
P-87615
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].
Figure 20-90-36
1
3 2
1
P-87611
Figure 20-90-39
Remove the top washer (Item 1), spring (Item 2) and
bottom washer (Item 3) [Figure 20-90-36].
P-87612
Figure 20-90-40
P-87613
P-87614
Figure 20-91-1
P-87581
Figure 20-91-2
P-87581
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
10
12
11
13
14
15
12
16
17
NA-1043
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].
1
1
NA-1111
NA-1112
Figure 20-91-9 2
1 4
3
NA-1116
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.
1 NA-1119
NA-1120
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
P112471
Figure 20-100-3
2
1
P112475
1
Figure 20-100-6
Remove the snap ring (Item 1) [Figure 20-100-3].
1
1
P112476
2
P112474 Remove the set screw (Item 1) and handle (Item 2)
[Figure 20-100-6].
Figure 20-100-7
P112477
P112478
Testing
Figure 20-110-1
P-86421
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.)
P-86420
P-86683
P-86684
P-86682
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
190,5 mm
(7.50”)
P-86686
P-86663
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].
P-86688
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
15
15
2
21 22
5
23
8
24
MS-2789S
Figure 20-110-15 2
3 P-86692
Figure 20-110-18
Remove the lock (Item 1) [Figure 20-110-15] from the
connector body.
1 190,5 mm
(7.50”)
P-86686
Figure 20-110-19 1
P-86695
P-86696
Figure 20-110-23
P-86699
Figure 20-110-24
2 1
P-86701
P-21730
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].
1 1
P-86705
Testing
Figure 20-120-1
P-86421
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.)
P-86420
Figure 20-120-4
P-86769
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.
Figure 20-120-8
P-86685
190,5 mm
(7.50”)
P-86686
P-86772
Tilt the joystick (Item 1) towards the rear of the cab. Mark
and remove the hoses (Item 2) [Figure 20-120-12].
P-86762
P-86771
Parts Identification
1. Handle Assembly
2. Dust Boot
3. Connector Lock
4. Connector
5. Nut
6. Seal
7. Plug
8. O-ring
9. Push Rod
10. Spring Retainer
16
11. Spring Seat
12. Spring
13. Washer 6
14. Spool 6 17
7
15. Spring 7 8
16. Nut 8
17. Control Plate 9
18. Dust Boot 9 18
3 10
19. U-Joint 4 10
20. Plate 11
11
15
15
2
21 22
5
23
8
24
MS-2789S
Figure 20-120-13 2
1
3
P-86692
Figure 20-120-16
Remove the lock (Item 1) [Figure 20-120-13] from the
connector body.
1 190,5 mm
(7.50”)
P-86686
Figure 20-120-17 1
P-86695
P-86696
Figure 20-120-21
P-86699
Figure 20-120-22
2 1
P-86701
P-21730
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].
1 1
P-86705
3
2
2
3
2
P112261
Figure 20-130-2
P112262
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
15
16
3
13
4
17
3 16
5 18
5 6
7 13
8
19
NA5987S
2
P112266
Figure 20-130-6
Remove the connector lock (Item 1) and remove the
connector (Item 2) [Figure 20-130-3] from the wire
Figure 20-130-4 1
2 1
P112267
P112264
Figure 20-130-7
3
1 2
2 1
P112270
Figure 20-130-10
Remove the pin (Item 1) and guide (Item 2) [Figure 20-
130-7].
P112271
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].
P112274
Figure 20-130-15
P112275
P-86677
Figure 20-140-1
P-87212
P-87209 1
Figure 20-140-2
1
1
P-87247
1
P-87211
Figure 20-140-5
1
2
1 P-87216
1
1
P-87218
Figure 20-140-9
2 P-87251
P-87237
P-87217
1
1
P-87238
P-87252
Figure 20-140-16
1
1
P-86677
P-87583
Figure 20-160-1
P112415
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-160-2
P112416
Figure 20-160-3 1
P-86811
Figure 20-160-6
Remove the snap ring (Item 1) [Figure 20-160-3].
P-86812
Description
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
Figure 20-170-1
Parts Identification
1. Plug
2. O-ring
3. Back-up Ring
4. Ball
5. Valve Block
MS-2810S
1
1
1 P-86440
P-86439
Description
1 1
Tilt the cab. (See Raising And Lowering on Page 10-210-
1.)
WARNING P112447
Figure 20-180-1
Remove the bolts (Item 1) [Figure 20-180-3] and remove
the valve.
1 1
P112438
Parts Identification
1. Valve Body
2. Filter Screen
3. Screw
4. Solenoid Valve
4
3
NA5989S
Figure 20-180-4
1 2 1
1 P112442
Figure 20-180-7
Remove the screws (Item 1) [Figure 20-180-4].
Figure 20-180-5
1
P112443
Figure 20-180-8
P112444
Figure 20-180-9
1 2
P112445
Figure 20-190-3
1
1
P-112460
P112457
P112456
1
Remove the coil (Item 1) [Figure 20-190-2].
P112458
Figure 20-190-5
P112465
Figure 20-190-6
2 1
1 1
P-112459
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].
Figure 20-200-3
IMPORTANT
Figure 20-200-1
2
2
1
1 S37672
P123148
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
6 16
7
15
8
14
9
10
13
11
12
B-23950
Figure 20-200-4
1 1
P-86480
Figure 20-200-5
P-86481
Figure 20-200-8
1
3 1
P-86476
2
Figure 20-200-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-200-8].
1
1
3
1
2
2 P-86477
Figure 20-200-12 2
4 3
P-86486
Figure 20-200-15
Remove the spool assemblies (Item 1) [Figure 20-200-
12].
1 P-86479
Figure 20-200-16
P-86487
P-86488
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
1
Figure 20-210-1
P-86445
1 1
P-86443
Figure 20-210-4
P-86446
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
3
17
6
18
5
18
16 8
14
19
14
20
16
3
13
14
14
13
NA5988S
Figure 20-210-5 1
1
2
P-86450
Figure 20-210-6
1
P-86451
Figure 20-210-9
P-86454
Figure 20-210-12
Remove the cover / cam assembly (Item 1) [Figure 20-
210-9].
P-86455
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-
P-86459
Figure 20-210-17
2
P-86462
2
1
P-86463
P-86461
Remove the O-rings (Item 1) [Figure 20-210-20].
Figure 20-210-21
P-86467
1
Figure 20-210-24
Remove the spool / spring assemblies (Item 1) [Figure
20-210-21].
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].
Description
Figure 20-230-1
1 1
P112511
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
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Figure 30-10-1
2 P-87813
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].
Figure 30-10-4
P-87811
Figure 30-10-5
P-87812
Remove the right and left pivot pin (Item 1) [Figure 30-
10-4] and [Figure 30-10-5] and shims.
Rubber Track
Figure 30-20-1
Straight Edge
Figure 30-20-2
10-15 mm
(0.39-0.59 in)
P-49234
Figure 30-20-5
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.
2 1
1
P-86333A
P-87901
Add grease to the fitting (Item 1) [Figure 30-20-6] until Figure 30-20-8
the track tension is correct.
WARNING 1
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.
Figure 30-20-9
P-40669
Figure 30-20-11
1
P-87929
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
Put the front of the track onto the front idler wheel. 1
P-87930
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
4
5
6
7
E80-2120S
MS-
Idler Disassembly
Figure 30-20-14
P-89261
Figure 30-20-17
P-89259
P-89263
P-89260
Figure 30-20-18
P-89267
Figure 30-20-21
P-89264
Figure 30-20-19
P-89268
P-89266
Figure 30-20-22 1
P-89270
P-89271
P-89269
Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-20-23] from the support.
P-40754
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.
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
1
P-40754
Figure 30-20-34 1
P-89264
Figure 30-20-35
P-40754
Figure 30-20-38
1
P-89280
Figure 30-20-39
P-40754
Figure 30-20-42 1
P-89283
Figure 30-20-45
Shake off the excess alcohol and install the seal
89324
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.
P-62574
Figure 30-20-47
P-87932
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
10
EM7807
P-62574
P-87927
Figure 30-20-50
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.
2 P-87935
Figure 30-20-52
1
1
P-87934
P-87936
Figure 30-20-55
P-89268
1
2 2
P-89285
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.
Figure 30-20-59
P-89286
Lower the jack and remove the roller (Item 1) [Figure 30-
1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug
4
5
6
2
5
E80-2150S
P-89289
Drive the pin (Item 1) towards the top of the collar (Item
Figure 30-20-61
1
1
P-89290
P-89288
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
Figure 30-20-65 1
P-89262
P-89296
1
Remove the O-ring (Item 1) [Figure 30-20-70].
1
P-89297
Figure 30-20-72
1
P-89295
Figure 30-20-75
Figure 30-20-73
P-89294
P-89296
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
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
P-40754
Figure 30-20-80
P-89301
Place the seal assembly (Item 1) [Figure 30-20-80] in NOTE: Do not get any oil on the rubber O-rings.
Figure 30-20-81
P-89302
P-89300
Figure 30-20-84
P-89304
Figure 30-20-85
P-89305
P-89303
Figure 30-20-88
P-89307
Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.
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
Figure 30-20-92
P-89309
Push down on the collar until the pin bore of the collar is
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
8
11
7
1
E80-2140S
Figure 30-20-93
1
P-87918
Figure 30-20-96
Remove the snap ring (Item 1) [Figure 30-20-93].
1
1
P-87919
1 P-87922
Figure 30-20-98
P-87923
1
Remove the seal (Item 1) [Figure 30-20-100] from the
roller.
P-87921
Figure 30-20-101
P-87924
P-87925
Figure 30-20-103
P-87908
Track
A
1
1
P-86328B
Adjusting Tension
Figure 30-21-4
1 2
1 P-86333A
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
1 Slowly turn the track. This will force more grease out of
the grease spring.
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
Figure 30-21-7
1
1
P-87906
Rotate the track until the master link and cotter pin (Item
Figure 30-21-8
P-87907
P-87905
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
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
Figure 30-21-14
P-87929
Figure 30-21-15
P-87930
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
4
5
6
7
E80-2120S
MS-
Idler Disassembly
Figure 30-21-16
P-89261
Figure 30-21-19
P-89259
P-89263
P-89260
Figure 30-21-20
P-89267
Figure 30-21-23
P-89264
Figure 30-21-21
P-89268
P-89266
Figure 30-21-24 1
P-89270
P-89271
P-89269
Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-21-25] from the support.
P-40754
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.
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
1
P-40754
Figure 30-21-36 1
P-89264
Figure 30-21-37
P-40754
Figure 30-21-40
1
P-89280
Figure 30-21-41
P-40754
Figure 30-21-44 1
P-89283
Figure 30-21-47
Shake off the excess alcohol and install the seal
89324
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.
P-62574
Figure 30-21-49
P-87932
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
10
EM7807
P-62574
P-87927
Figure 30-21-52
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.
2 P-87935
Figure 30-21-54
1
1
P-87934
P-87936
Figure 30-21-57
P-89268
1
2 2
P-89285
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.
Figure 30-21-61
P-89286
Lower the jack and remove the roller (Item 1) [Figure 30-
Figure 30-21-62
1 1 1
2
P-89284
1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug
4
5
6
2
5
E802150S
P-89289
Drive the pin (Item 1) towards the top of the collar (Item
Figure 30-21-64
1
1
P-89290
P-89288
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
Figure 30-21-68 1
P-89262
P-89296
1
Remove the O-ring (Item 1) [Figure 30-21-73].
1
P-89297
Figure 30-21-75
1
P-89295
Figure 30-21-78
Figure 30-21-76
P-89294
P-89296
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
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
P-40754
Figure 30-21-83
P-89301
Place the seal assembly (Item 1) [Figure 30-21-83] in NOTE: Do not get any oil on the rubber O-rings.
Figure 30-21-84
P-89302
P-89300
Figure 30-21-87
P-89304
Figure 30-21-88
P-89305
P-89303
Figure 30-21-91
P-89307
Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.
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
Figure 30-21-95
P-89309
Push down on the collar until the pin bore of the collar is
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
8
11
7
1
E80-2140S
Figure 30-21-96
1
P-87918
Figure 30-21-99
Remove the snap ring (Item 1) [Figure 30-21-96].
1
1
P-87919
1 P-87922
Figure 30-21-101
P-87923
1
Remove the seal (Item 1) [Figure 30-21-103] from the
roller.
P-87921
Figure 30-21-104
P-87924
P-87925
Figure 30-21-106
P-87908
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
Figure 30-30-1
PI-13035
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.
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:
Prevention:
Figure 30-30-5
Abrasion
D D1 = 0.67D
PI-13037
Replacement:
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
PI-13040
Figure 30-30-9
Abrasion
PI-13041
Prevention:
Figure 30-30-10
Separation of
bonded
rubber cover
PI-13043
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
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:
PI-13045
Construction sites
Demolition sites
Concrete ridges
Stumpy fields.
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:
P-4380
Damage:
Replacement:
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:
Lug abrasion
PI-13049
Damage:
Replacement:
No replacement is required.
PI-13051
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.
PI-13053
Prevention:
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
PI-13055
Damage:
Replacement:
Figure 30-30-25
Cut
Tear
PI-13057
Prevention:
Figure 30-40-1
P11599
Figure 30-40-2
P-89381
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
P-89382
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
E802150S
Disassembly
Figure 30-50-1
P-89289
2
Figure 30-50-4
P-89287
P-89290
1
P-89288
Disassembly (Cont’d)
Figure 30-50-5
P-89293
1
Figure 30-50-8
Remove the shaft assembly (Item 1) [Figure 30-50-5]
from the roller.
P-89262
Disassembly (Cont’d)
1
Figure 30-50-9
P-89296
1
1
P-89297
Assembly
Figure 30-50-13
1
P-89295
Figure 30-50-16
Figure 30-50-14
P-89294
P-89296
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
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
P-40754
Assembly (Cont’d)
Figure 30-50-21
P-89301
Figure 30-50-22
P-89302
P-89300
Assembly (Cont’d)
Figure 30-50-25
P-89304
Figure 30-50-28
Place the seal assembly in the installation tool (Item 1)
[Figure 30-50-25].
Figure 30-50-26
P-89305
P-89303
Assembly (Cont’d)
Figure 30-50-29
P-89307
Figure 30-50-30
P-89308
Install the collar (Item 1) on the shaft. Install the pin (Item
1
2) [Figure 30-50-32] in the collar.
P-89306
Assembly (Cont’d)
Figure 30-50-33
P-89309
Push down on the collar until the pin bore of the collar is
aligned with the pin bore of the shaft. Fully seat the pin
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
8
11
7
1
E802140S
Figure 30-60-1
P-87918
1 1
P-87919
P-87916
Remove the O-ring (Item 1) [Figure 30-60-4].
Figure 30-60-5 1
1
P-87922
Figure 30-60-8
Remove the snap ring (Item 1) [Figure 30-60-5].
Figure 30-60-6
P-87923
1
Remove the seal (Item 1) [Figure 30-60-8] from the
roller.
P-87921
Figure 30-60-9
P-87924
P-87925
UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3
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
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-2
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Side Cutting Edge Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-170-2
Removal
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
Figure 40-10-1
P-89376
Removal (Cont’d)
Figure 40-10-3 1
1
1 1
P-89376
P-89378
Installation
Figure 40-10-7
FRONT OF MACHINE
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].
Installation (Cont’d)
Figure 40-10-11
1
1
1
N-15787
Figure 40-10-12 Install the swing motor drive carrier. (See Removal And
Installation on Page 20-91-1.)
B-13693
Figure 40-20-1
1
1
P-86415
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.
Figure 40-21-1
1 1
P-86824
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.
Figure 40-30-4
P-87715
Figure 40-30-2
P112161
P-87716
Figure 40-30-5
1
P112313
1
1
P112314
Figure 40-30-9
1 1
P112323
1
1 1
P112324
P112322
Figure 40-30-13
2 2 2
1 P112346
Figure 40-30-16
Disconnect the wire harness and remove the switch
panel (Item 1) [Figure 40-30-13].
Figure 40-30-14 2
2 1
P-112349
P112318
Figure 40-30-17
1 1
1
1
P112350
Figure 40-30-20
Disconnect the wire harness (Item 1) [Figure 40-30-17].
2
1 1
P112354
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
1
1 1
P112357
2
Figure 40-30-25 1
1 1 1
P112359
Figure 40-30-28
Remove the relays (Item 1) [Figure 40-30-25].
1 1 1
P112360
P112364 Remove the bolt (Item 1) [Figure 40-30-28] from the wire
harness clamp.
Figure 40-30-29
1
1
1 1
P-87775
1
1
P-87747
P-87776
Figure 40-30-33
1 1
P-87791
P112361
P112363
Figure 40-30-37
P-87795
1
Figure 40-30-40
P-87793
1
P-87796
Figure 40-30-41
P-87666
Figure 40-30-42
1
P-87668
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].
Figure 40-30-46
P-87745
Glass Installation
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
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
Figure 40-30-50
1 1
2
P-61218
P-61216
Figure 40-30-54
P-89351
Figure 40-30-56
P-61220
P-61224
Figure 40-30-58
P-89350
P-89352
Figure 40-30-60
Figure 40-30-61
P-87671
Figure 40-30-62
P-87672
Figure 40-30-63
1
P-87745
Figure 40-30-64
P-87674
Figure 40-30-66
1 P-89320
Figure 40-30-67
1 1 1
P-89320
1. Clip
2. Washer
3. Shim
4. Link
5. Plate
6. Pin
7. Bracket
8. Bolt
9. Grease Fitting
5
1
2 4
3 3
2
8
7 6
2
3
2
9
E801340S
Figure 40-30-69
1 1
P-89322
1
1 2
P-89320
Figure 40-30-71
1
1
1
P-92416
1
1
P-92763
Figure 40-30-75
1
1
P-92768
Figure 40-30-78
Remove the speaker (if equipped) from the headliner and
disconnect the wires (Item 1) [Figure 40-30-75].
1 1
1 P-92770
Figure 40-30-79
1
1
1
1 1 1
1
P-92771
Figure 40-30-82
Remove the screws (Item 1) [Figure 40-30-79].
1
1
1
1
P-92772
Figure 40-30-83
P-92774
1
Remove the headliner (Item 1) [Figure 40-30-85].
P-92775
P-92773
Figure 40-40-1
1
2
1
2
P-87665
1 Figure 40-40-3
P112305
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
1
P112308
Figure 40-40-8
P-87819
Figure 40-40-12
P-87717
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].
Figure 40-50-1
P112258
Figure 40-50-4
Pull the dust boot (Item 1) [Figure 40-50-1] towards the
rear of the cab.
3
1
P112259
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].
Figure 40-60-1
P-86765
Figure 40-60-4
P-86764
Figure 40-60-2
1 P-86766
P-866763
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].
P-86756
1 P120808
1
P-86782
2
P-86778
Figure 40-60-12
1 1
P-86785
Figure 40-60-13
1
1
P-86788
Figure 40-60-16
Remove the snap ring (Item 1) [Figure 40-60-13].
P-86789
Figure 40-60-17
Figure 40-60-18
P-86784
Figure 40-70-1
P-86417
Figure 40-80-1
3 3
2
P112191
Figure 40-90-1
P-93537
Figure 40-90-4
1 2
Figure 40-90-2
P112252
P-89561
Figure 40-90-5
P-89556
Figure 40-90-7
P-93486
WARNING P-89558
P-89557
Figure 40-100-1
P111459
Figure 40-100-2
Articulated Boom
P123149
Figure 40-110-1
1 P-87223
Figure 40-110-4
Figure 40-110-2
P-87224
P-87222
P-87229
2
Figure 40-110-8
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 40-110-5].
1 P-87225
Figure 40-110-9
1 1
1 P-87242
1
Figure 40-110-12
P-87226
1
1
P-87241
P-87243
Figure 40-110-13
P-87226
Figure 40-110-14
P-87243
Figure 40-120-1
P-86441
Figure 40-130-1
P-87409
Figure 40-130-4
Figure 40-130-2
P-87410
1 2 1 1
P-87649
Figure 40-130-5
1
1
P-87655
2
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
Figure 40-130-9
2 1
1
1 P-87657
Figure 40-130-12
Remove the bolts (Item 1) and plate (Item 2) [Figure 40-
130-9].
1
1
P-87659
Figure 40-130-13
P-87660
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
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.
Tighten the bolt and nut to remove the bushing from the
casting.
Bushing Installation
Figure 40-130-15
P-23573
Figure 40-130-17
4
1
5 P-23571
Tighten the bolt and nut until the bushing is seated in the
casting.
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].
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.
1 5 mm (0.197 in)
TS-1614A
P-87006
Figure 40-141-1 1
2
2 1 4
S37808
P123152
Figure 40-141-4
P-87084
Figure 40-141-5
5 mm (0.197 in)
TS-1614A
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
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
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.
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
P-87080
Troubleshooting
Daily Inspection
Figure 40-160-1
P-72274
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.
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
latching and unlatching the attachment quick
coupler.
W-2541-1106
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 40-160-6
1
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.
Parts Identification
1. Coupler Body
2. Spring
3. Locking Plate
4. Tool
4
2
P-88398
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
1
P-72285
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].
Disassembly (Cont’d)
Figure 40-160-10
1 1
P-72295
P-72296
Assembly
Figure 40-160-12
P-72294
1
Figure 40-160-15
Install the latch (Item 1) [Figure 40-160-12].
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.
Troubleshooting
Daily Inspection
Figure 40-161-1
P-88183
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-88000
W-2019-0907
Raise the arm and bucket link until the quick coupler is
Figure 40-161-2 free [Figure 40-161-4].
2
2
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
2
2
P-88003
3
P-88001
1. Bolt
2. Lock Washer
3. Coupler Housing
4. Pressure Spring
5. Locking Mechanism 1
P-88114
Figure 40-161-8
P-88004
P-88005
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
21 10 11
20
19
12
20 17
19 18
16
15 13
14
P-88115
WARNING 1
P-88010
Figure 40-161-10
P-88009
P-88122
Figure 40-161-14
1
P-88013
2
1
P-88014
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].
Figure 40-161-19
P-88019
P-88016
Remove the locking pin assemblies [Figure 40-161-21].
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].
Figure 40-161-23
2 3
P-88022
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
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.
Figure 40-161-28
P-88023
Figure 40-161-31
Install the O-rings (Item 1) [Figure 40-161-28].
Figure 40-161-29
P-88024
P-88015 Install the control shaft through the spring guide driving
fork (Item 1) [Figure 40-161-31].
Figure 40-161-32
1 P-88011
Install the control shaft through the second locking lever Figure 40-161-35
driving fork (Item 1) [Figure 40-161-32].
Figure 40-161-33
P-88010
1
Install the two bolts (Item 1) [Figure 40-161-35].
P-88013
Figure 40-161-36
P-88026
P-88009
WARNING 1
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.
1
P-87316
Figure 40-170-4
P-87323
Figure 40-180-1
P111461
1 Figure 40-180-4
P111460
1
Figure 40-180-2
P111462
P111463
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.
1 1
P112507
Figure 40-190-1
P-87207
Figure 40-190-4
P-87205
P-92769
P-87206
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
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
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
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
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
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 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
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
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
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
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
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.
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]
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
Battery Maintenance
Figure 50-20-1
1
P9589 P9590
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.
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.
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.
3
P123132
Figure 50-30-1
1
2
P-97915
P-97916
WARNING terminal.
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.
1
P111022
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
Figure 50-30-11 3
2
P112530
3
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.
Figure 50-30-15
P112531
P112529
Testing
Bat
S
M Cranking
Motor
Cranking
Motor
A-1991
The key switch must be in the OFF position. If the starter turns, the defect is in the solenoid.
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 50-40-3
P112532
Figure 50-40-6
1
Figure 50-40-4
2 1
1 4
P112536
P112533
Figure 50-40-7
P112535
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
16
17
18
19
E80025S
Figure 50-41-1
1 2
1
2
1
P1125113
1 P112514
P112512
Figure 50-41-5
P112516
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
1
1
P111471
P111469
Figure 50-50-5
P111472
Testing / Adjustment
Figure 50-60-1
P-86775
1
Figure 50-60-4
P-86773
Figure 50-60-2
1
P-86776
Figure 50-60-5
Figure 50-60-6
P-86777
Figure 50-70-1
P-89565
Figure 50-70-4
Figure 50-70-2
1
P-89570
1
1
P-89564
P111024
Figure 50-80-2 1
2
P120809
Figure 50-80-3
1 3
P117655
Failure Information
Figure 50-80-5
Figure 50-80-6
P117613
Installation
Figure 50-90-1
1 1
1
P120823
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].
1
P120824
Installation (Cont’d)
Figure 50-90-5
1
1
P120826
Figure 50-90-6
P120827
With the engine off, turn the key (Item 1) [Figure 50-90-
6] to the run position.
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].
1
1
1
P112129
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].
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].
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].
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].
Figure 50-100-13
1 3
P117663
Figure 50-110-1
1
P-86680
P-86678
Figure 50-110-2
P-86679
Figure 50-120-1
1 1
P112178
Figure 50-120-4
P112161
Figure 50-120-2
2
1
1
1 1
1 P112177
P112179
Figure 50-120-5
1
2 P112159
Pull the panel (Item 1) away from the side of the cab.
Remove the bolt (Item 2) [Figure 50-120-5].
P112160
1
Remove the screw (Item 1) [Figure 50-120-8].
Figure 50-120-9 1
P-87698
Figure 50-120-10
P-87699
Figure 50-120-13 1
P-87704
P-87703
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.
P-87708
Figure 50-130-5
1
1
1
P-87711
P-87710
2
1
2
1
P-86551
WARNING
This machine is equipped with a motion alarm.
ALARM MUST SOUND!
when operating forward or backward.
Figure 50-150-1 2
1 2 1
P-92652
Figure 50-150-4
Remove the tie strap (Item 1) [Figure 50-150-1].
1 1
P-92642
Figure 50-150-5
P-92639
Figure 50-160-1
P112508
Figure 50-160-2
P112509
Description
Figure 50-170-1
P123130
IMPORTANT
Avoid damaging the Engine Control Unit (ECU) and P112523
P112518
Figure 50-170-5
2 2
1
P123153
Figure 50-180-1
1
1
1
1 P120804
2 Figure 50-180-4
P120801
Figure 50-180-2
2 1
1
P120802
P120803
Figure 50-180-5
P120805
1 P120806
Specifications
Cylinder Head
Valves
Specifications (Cont’d)
Valve Springs
Camshaft
Specifications (Cont’d)
Tappet
Push Rod
Cylinders
Piston Rings
Specifications (Cont’d)
Pistons
Connecting Rods
Oil Pump
Oil Pressure @ Rated rpm 290 - 390 kPa (2,9 - 3,9 Bar) (42 - 57 psi)
Idle Speed Allowable Limit 60 kPa (0,6 Bar) (9 psi)
Outer Rotor Outside Clearance 0,100 - 0,155 mm (0.0039 - 0.0061 in)
Outer Rotor Outside Clearance Limit 0,25 mm (0.0098 in)
Outer Rotor Side Clearance 0,05 - 0,10 mm (0.0020 - 0.0039 in)
Outer Rotor Side Clearance Limit 0,15 mm (0.0059 in)
Outer Rotor To Inner Rotor Tip Clearance 0,16 mm (0.0063 in)
Gear Case Bearing Inside Diameter 12,980 - 13,020 mm (0.5110 - 0.5126 in)
Gear Case Bearing Inside Diameter Allowable Limit 13,050 mm (0.5138 in)
Rotor Shaft Outside Diameter 12,955 - 12,965 mm (0.5100 - 0.5104 in)
Rotor Shaft Outside Diameter Allowable Limit 12,945 mm (0.5096 in)
Rotor Clearance 0,0006 - 0,0026 mm (0.015 - 0.065 in)
Rotor Clearance Allowable Limit 0,105 mm (0.0041 in)
Specifications (Cont’d)
Crankshaft
Crankshaft Alignment Allowable Limit (1/2 Dial Gauge 0,02 mm (0.0008 in)
Reading)
Connecting Rod Journal O.D. 57,952 - 57,962 mm (2.2816 - 2.2820 in)
Connecting Rod Journal O.D. Allowable Limit 57,902 mm (2.2796 in)
Connecting Rod Bearing I.D. 58,0 - 58,026 mm (2.2835 - 2.2845 in)
Connecting Rod Bearing Thickness 1,492 - 1,5 mm (0.0587 - 0.0591 in)
Oil Clearance Between Connecting Rod Journal And 0,038 - 0,074 mm (0.0015 - 0.0029 in)
Bearing
Oil Clearance Between Connecting Rod Journal And 0,150 mm (0.0059 in)
Bearing Allowable Limit
Main Bearing Journal O.D. 64,952 - 64,962 mm (2.5572 - 2.5576 in)
Main Bearing Journal O.D. Allowable Limit 64,902 mm (2.5552 in)
Main Bearing I.D. 65,0 - 65,020 mm (2.5590 - 2.5598 in)
Main Bearing Thickness 1,995 - 2,010 mm (0.0785 - 0.0791 in)
Thrust Bearing
Specifications (Cont’d)
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
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
12
10
9
4
8
5
7
6
NA5994
Figure 60-10-3
1. MPROP
2. Fuel Temperature Sensor
NA5995
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
Figure 60-10-4
3
2
1
2
P112061
P112063
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].
1
2
3 1
P112067
Figure 60-10-11
P112070
1
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.
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.
Figure 60-10-15
2
1
1
P112075
Figure 60-10-18
Remove the nuts and disconnect the wire harness (Item
1) [Figure 60-10-17] from the starter.
1 P112076
Figure 60-10-19
P112133
Figure 60-10-22
Depress the tabs (Item 1) [Figure 60-10-19] and
disconnect the wire harness (Item 2).
P112132
1
Figure 60-10-23
1
1
P112135
P112139
Figure 60-10-26
1 P112138
Figure 60-10-27
P112136
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
Figure 60-10-29
P120462
P120460
P120461
Adjustment
Figure 60-20-1
1 Engine Control
Dial
2 ECU (Engine
Control Unit)
2 1
EM7804
Adjustment (Cont’d)
Figure 60-20-2
S9597
Description
Figure 60-30-1
1
3
P109420
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.
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].
Figure 60-30-5
P112393
Figure 60-40-1
P112306
Figure 60-40-2
1 1
P112307
2
P112506
P112504
IMPORTANT 1
P112503
Figure 60-50-5 1
1 2
1
P112501
Remove the two top bolts (Item 1), three bottom bolts, Figure 60-50-8
and fan shield (Item 2) [Figure 60-50-5].
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].
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.
1
1
P112495
P112497 Remove the two shroud bolts and install lifting eyes,
chain and hoist [Figure 60-50-12].
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].
1
1
1 P112491
1
Figure 60-50-17
1 1 1 1
1
1
2
1
P112487
1
Figure 60-50-18
1
1
P112489
P112488
Remove the radiator (Item 1) [Figure 60-50-20].
Figure 60-50-21
P112490
Figure 60-50-22 1
P112058
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.
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
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].
Figure 60-50-30
1
2
S9605
Remove the fan (Item 1), spacer (Item 2) and pulley (Item
3) [Figure 60-50-30].
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
8
6
7
9 14
12
10
11
14
13
NA5991S
Figure 60-50-31 3
1
1
3 2
2
6 4
5
S9607
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.
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
Figure 60-60-1
3
2
1
2
1
NA1084
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.
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
5
1
4
S9385
Wash the oil pump, oil pressure regulator and oil pump
cavity with clean solvent. Inspect for wear or damage. 1
Replace if necessary. 2
Figure 60-60-6
1
S9389
2
Figure 60-60-8
0,1 - 0,155 mm
Clearance 1
(0.0039 - 0.0061 in)
Allowable Limit 0,25 mm (0.0098 in) 2
S9390
0,05 - 0,10 mm
Side Clearance
(0.002 - 0.0039 in)
Allowable Limit 0,15 mm (0.0059 in)
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
S9391 1
Figure 60-60-11
1
2
3
4
P109448
Figure 60-70-1
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.
WARNING P112598
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].
Figure 60-70-5
P112595.
Figure 60-70-8
P112593
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...
Figure 60-70-9 1
P1125990
1
1
P112688
Figure 60-70-13
P112591
1
1
P112586
Figure 60-70-14
1 P112583
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].
Figure 60-70-18
P112580
Figure 60-70-19
1
1
P112578
P112582
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
Figure 60-70-22
P109460
P109438
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].
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
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 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
P109438
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.
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
3 1
P109429
Figure 60-80-2
P109430
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
Figure 60-80-6
2
1
P109421
2
3
P109426
4
Remove the rocker arm shaft alignment stud (Item 1)
P109424 from support (Item 2) [Figure 60-80-9].
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.
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
Figure 60-80-14
2
3
P109427
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
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.
Figure 60-80-19
3
3
2
4
2
P109450
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.
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
1. Cylinder Head
Surface
2. Recessing
PI-9990
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
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
NA1063
Figure 60-80-32
NA1053
Figure 60-80-33
NA1064
Figure 60-80-35
2
1
1
1
NA1055
Figure 60-90-1 NOTE: Do not rotate the crankshaft when using the
PLASTIGAGE. A false reading may result.
Figure 60-90-3
NA1091
Figure 60-90-6
1
P-37161
Figure 60-90-9
Be sure the crank pin bearing and the connecting rod are Top Ring Gap
Piston
Pin Hole
1 P109459
2
The piston ring gaps must be located a 120° intervals
[Figure 60-90-9].
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.
Figure 60-90-10
P-37208
Figure 60-90-11
P47273
Figure 60-90-13
22 mm
(0.8661 in)
NA1085
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)
Figure 60-90-16
P-37142A
Place the bushing onto the tool and press-fit it with a P-47272
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
B3622
Figure 60-90-19
20 mm (.75 in)
P109456
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)
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 -
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].
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
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)
Figure 60-90-26
A2716
P109435
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
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
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.
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].
Figure 60-100-10
1 2
P-37174
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.
Camshaft - Servicing
Figure 60-100-13
B-5001
Figure 60-100-16
A-2761
2
Description
Figure 60-110-1
P109547
Figure 60-110-2
4
2 1
3
P109548
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.
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
When the key is first turned to the run position, the ECU
checks valve operation by opening and shutting the
valve. 1
Installation
Figure 60-110-6
3
1
P109550
Figure 60-110-7
P109551
Intake Throttle
Figure 60-110-8
P109552
The intake throttle (Item 1) [Figure 60-110-8] controls the Intake Throttle Handling Precautions:
Testing
Figure 60-120-1
P112552
Figure 60-120-2
1
P112551
1
2
P112550
Figure 60-130-1
1
1
P-87488
Figure 60-130-4
2
P-87483
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
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.
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
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
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
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
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4 Expansion Valve
Blower 6
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Components
Figure 70-10-1 1
P112052
Figure 70-10-2
1
P112520
Components (Cont’d) 3 2
Figure 70-10-5
P-87074
1
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.
Components (Cont’d)
Figure 70-10-9
3 5 5
6
1
2 4
P112538
Safety Equipment
Figure 70-10-11
P-16399
Filters
Belt Adjustment
Loosen the lock nut (Item 1) and adjust the bolt (Item 2)
When the belt tension is correct, tighten the lock nut (Item
1) [Figure 70-20-3].
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
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.
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
Condenser
Figure 70-20-7
P112052
Figure 70-20-8
P-87074
Figure 70-20-9
P-87073
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].
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)
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)
Turn on air conditioning, set blower switch to high, turn air conditioner OFF and wait 10 minutes. Recheck High / Low
pressure readings.
High Pressure 1280 - 1860 kPa (12,8 - 18,6 bar) (185 - 270 psi)
Low Pressure 140 - 320 kPa (1,4 - 3,2 bar) (21 - 47 psi)
High Pressure 590 - 1770 kPa (5,9 - 17,7 bar) (85 - 256 psi)
Low Pressure 500 mm Hg (19.7 in Hg) (Negative Pressure)
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)
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.
32°C (90°F)
+ 4°C (40°F)
54°C (130°F) condenser temperature = 1379 kPa (14 bar) (200 psig)
Figure 70-30-2 1
1
1
P111035
Figure 70-30-5
P111033
N-22411
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Evaporator / Heater Coil on Page 70-20-
5.)
Figure 70-30-6
P112520
Figure 70-40-1
N-23024
Figure 70-40-4
Remove the protective cap and connect the Refrigerant
Figure 70-40-5
N-22381
Figure 70-40-6
N-22292
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.
3
P-87052
Figure 70-40-10
P-87051
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.
P-87052
Determine the problem with the A/C system and repair it.
Figure 70-40-13
1
3
1 3 4
2
P111020
Figure 70-40-14 Watch the scale and run the system until the
predetermined amount of refrigerant is added to the A/C
system.
P-87054
Figure 70-50-1
P111134
1
Remove the belt (Item 1) [Figure 70-50-3].
Figure 70-50-4
2 1
3 P-86877
2
P111135
Loosen the nut (Item 1) on the pulley. Loosen the lock nut
(Item 2) and adjustment bolt (Item 3) [Figure 70-50-2].
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.
1 P-86875
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
Oil Check
P-16534A
Figure 70-50-14
P-86878
1
Add new compressor oil through the suction side
N-22246 connector (Item 1) [Figure 70-50-15].
P112539
Figure 70-60-2
2 2
1 1
2
2
P112540
Figure 70-70-2
P112520
Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
P-86888
Figure 70-70-4
P112519
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.
P-87060
Figure 70-80-4
P-87061
Inspection
2
NOTE: The thermostat is not serviceable separately.
The procedure shown is for inspection
purposes.
Figure 70-90-1
1
1
P-87074
Figure 70-90-2
P-87073
Figure 70-100-1
P-87064
2
Figure 70-100-4
Figure 70-100-2
1
P-87065
1
P-87063
Figure 70-100-5 1 2
1 2
P-87075
1
P-87070
Figure 70-110-1
P-87064
1
Figure 70-110-4
P-87062
Figure 70-110-2
1
1
1 P-87065
P-87063
Figure 70-110-5
1
1
P-87071
Figure 70-110-8
Remove the heater core / evaporator (Item 1) [Figure 70-
110-5] from the top cover.
3
2
1 1
P-87068
Remove the eight screws (Item 1) [Figure 70-110-6]. Remove the resistor block (Item 3) [Figure 70-110-8].
Figure 70-120-1
2
1 1
Figure 70-120-2
2
3
P112537
P-86761
P-86759
Figure 70-130-2
P-86760
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
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.
Dimensions
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
70°
55°
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
Dimensions (Cont’d)
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
70°
55°
1370 mm 4521 mm
1030 mm (54.0 in) (178 in)
(40.6 in)
925 mm 1300 mm
(36.4 in) (51.2 in)
• 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
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
• 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
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
• 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
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
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
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)
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)
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)
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
Slew System
Slew Motor Axial Piston Motor
Slew Circle Single row shear type ball bearing with internal gear
Slew Speed 9.5 rpm
Undercarriage
Crawler Track Design Sealed track rollers with boxed section track, Roller frame, Grease type track
adjuster
Capacities
Fuel Tank 110 L (29.1 U.S. gal)
Hydraulic Reservoir Only (Centre of
Sight Glass) 87 L (23.0 U.S. gal)
Hydraulic System (With Reservoir) 148 L (39.1 U.S. gal)
Cooling System 10,0 L (10.6 qt)
Engine Oil And Filter 10,8 L (10.2 qt)
Final Drive (Each) 1,5 L (1.6 qt) 80W90 gear lube
Swing Motor Reduction Drive 1,5 L (16 qt) 80W90 gear lube
Track
Type Rubber Steel
Width 450 mm (17.7 in) 450 mm (17.7 in)
Number Of Shoes Single Assembly 39
Number of Track Rollers (Per Side) 5 5
Ground Pressure
Ground Pressure
Rubber Tracks 38,3 kPa (0,383 bar) (5.5 psi)
Steel Tracks 38,3 kPa (0,383 bar) (5.5 psi)
Engine
Allowable Engine Oil Pressure at Low Idle 60 kPa (0,6 bar) (9 psi)
Engine Oil Pressure at High Idle 290 - 390 kPa (2,9 - 3,9 bar) (42 - 57 psi)
Location of Number 1 Cylinder Closest to water pump
Crankshaft Rotation (Facing Crankshaft
Clockwise
Pulley)
Valve Clearance (Cold) Intake 0,15 - 0,25 mm (.006 - 010 in)
Valve Clearance (Cold) Exhaust 0,15 - 0,25 mm (.006 - 010 in)
Engine Torques
Fuel Injection Tubeline Nuts (Fuel Rail) 29,4 - 34, 3 N•m (21.7 - 25.3 ft-lb)
Fuel Injection Tubeline Nuts (Injector 26,5 - 31,4 N•m (19.5 - 23.1 ft-lb)
Glow Plugs 15 - 20 N•m (11 - 14.8 ft-lb)
Injection Pump Mounting Bolts 22,6 - 28,4 N•m (16.6 - 20.9 ft-lb)
Valve Cover Nut 12 - 15 N•m (8.9 - 11 ft-lb)
Head Bolts 101,1 - 112,9 N•m (76 - 83 ft-lb)
Cooling System
Coolant Type and Mix 50% Water and 50% Ethylene Glycol
Radiator Cap Pressure 75 - 105 kPa (0,75 - 1,05 bar) (10.8 - 14.8 psi)
NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 60-50-1.)
Excavator Torques
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.
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)
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].
Figure SPEC-40-3
1
Nut Nut
Washer
Washer
O-ring
O-ring
TS-1619A
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
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)
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Specifications
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
7217666 Remote Start Tool Kit E20 - E55 This tool replaced the original
(Was 6689778)
6689747 Remote Start Tool Used with 7003030 to connect
Harness remote start tool to excavator.
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
Hydraulic Tools
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
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
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
MEL1355-12 Coupler
MEL1413 Seal Installation Tool E26 Used for installing Travel Motor Seal
6675936 Grease Spring Tool E08 - E55 Machines with two track tension
(MEL1560) (Grease Release) fittings.
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
MEL1713 Hydraulic Fitting Kit E60, E63, This test kit includes various adapters
E80, E85 and couplers that are used when
testing hydraulic functions. MEL1713
Includes: MEL1713-1 thru MEL1713-
12
MEL1727 Spanner Wrench E60, E63 Used for removing and installing
bearing nut used in the Travel Motor
MEL1728 Seal Installation Tool E60, E63 Used for installing Travel Motor Seal
7031370 Rear Main Seal T4 Bobcat Used for installing rear main seal
Installer Engine
Applications
7031369 Front Seal Installer T4 Bobcat Used for installing front seal
Engine
Applications
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
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
Electrical Tools
HVAC Tools
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
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.
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