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E20 Service Manual - B3BL11001&above

This service manual provides instructions and safety warnings for servicing a Bobcat compact excavator. The manual outlines proper lifting and support procedures for the excavator, and warns technicians to never modify equipment or add unauthorized attachments. Daily cleaning and maintenance is required. Proper ventilation and protective equipment is necessary when welding or grinding painted parts to avoid toxic dust and fumes.

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100% found this document useful (3 votes)

5K views

E20 Service Manual - B3BL11001&above

Uploaded by

Marco Gutiérrez

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

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 671

Service Manual

Compact Excavator
S/N AWRH11001 & Above
S/N B3BL11001 & Above

7255008enUS (04-18) (A) Printed in U.S.A. ©2018 Bobcat Company. All rights reserved.
T4
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

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

CORRECT CORRECT CORRECT

P-90216 B-19964 B-19959

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

B-19965 B-19960 B-19966

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

WRONG WRONG WRONG

B-19962 B-19958 B-19798

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

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CONTENTS

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

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

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

UPPERSTRUCTURE & SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

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

HEATING AND VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

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

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

1-3 E20 Service Manual

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FOREWORD

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

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

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

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

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

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

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

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

2. Check that ROPS/TOPS 10. Check for correct function of

mounting hardware is indicator lamps.
tightened and is Bobcat
approved.

3. The seat belt must be 11. Check all machine fluid

correctly installed, functional levels.
and in good condition.

4. Machine signs (decals) must 12. Inspect for fuel, oil or

be legible and in the correct hydraulic fluid leaks.
location.
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5. Travel levers, control levers 13. Lubricate the excavator.

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

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

the work lights. battery and cables.

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

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

function correctly and be in system.
good condition.

FW EXC-0617SM

1-7 E20 Service Manual

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

18. Inspect for loose or broken 22. Inspect the X-Change™ for
parts or connections. wear or damage. Repair or
replace damaged parts.

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

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

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CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.

FW EXC-0617SM

1-8 E20 Service Manual

SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
AVOID INJURY OR DEATH
Instructions are necessary before operating or • Machine signs (decals) instruct on the safe operation
servicing machine. Read and understand the and care of your Bobcat machine or attachment. The
Operation & Maintenance Manual, Operator’s signs and their locations are shown in the Operation
Handbook and signs (decals) on machine. Follow & Maintenance Manual. Replacement signs are
warnings and instructions in the manuals when available from your Bobcat dealer.
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or • An Operator’s Handbook fastened to the operator
service. Untrained operators and failure to follow cab. It’s brief instructions are convenient to the
instructions can cause injury or death. operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.

IMPORTANT • The AEM Safety Manual delivered with the machine

gives general safety information.

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

• The Compact Excavator Operator Training Course is

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

• The Bobcat compact excavator Safety Video is

WARNING available from your Bobcat dealer or at Bobcat.com/
training or Bobcat.com.

The signal word WARNING on the machine and in the

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

SI EXC-1016 SM

1-9 E20 Service Manual

SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner / operator review the

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

Cutting or drilling concrete containing sand or rock

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

Call Before You Dig

Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).

SI EXC1016 SM

1-10 E20 Service Manual

FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage

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

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

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

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

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
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cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs. These starting aids can cause explosion and
injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

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

1-11 E20 Service Manual

FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect

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

Have good ventilation when grinding or welding painted

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

Dust generated from repairing nonmetallic parts such as

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

Fire Extinguishers

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

SI EXC-1016 SM

1-12 E20 Service Manual

SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the excavator when Figure 3

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

Excavator Serial Number

Figure 1
P113547

P113543

The engine serial number is located on the top cover

(Item 1) or on the side of the engine block (Item 2)
P113376A [Figure 3] above the fuel pump.

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

located on the frame of the machine in the location

shown.

Figure 2

Module 2 - Production
Sequence (Series)

Module 1 - Model / Engine

Combination P-90175

Explanation of excavator Serial Number [Figure 2]:

1. The four digit Model / Engine Combination Module

number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies

the order which the excavator is produced.

1-13 E20 Service Manual

DELIVERY REPORT

Figure 4

B-16315

The delivery report [Figure 4] contains a list of items that

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

The delivery report must be reviewed and signed by the

owner or operator and the dealer.

1-14 E20 Service Manual

EXCAVATOR IDENTIFICATION

1 14
15
3 2
23
4

13
16
22
5
12
6 9 17
11

7 21
20
19
8 18 19 NA9346A
10 NA9347A

ITEM DESCRIPTION ITEM DESCRIPTION

1 Operator’s Handbook 15 Cab (ROPS / TOPS) [B]
2 Arm Cylinder 16 Rear Cover
3 Auxiliary Quick Couplers 17 Counterweight
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4 Boom 18 Tracks
5 Arm 19 Tie Downs (Both Sides)
6 Bucket Cylinder 20 Track Frames
7 Bucket Link 21 Blade
8 Bucket [A] 22 Right Side Cover
9 Boom Cylinder 23 Lift Point
10 Tie Downs / Lift Points
11 Blade Cylinder
12 Upperstructure
13 Control Levers (Joysticks)
14 Operator’s Seat with Seat Belt

[A] BUCKET - Several different buckets and other attachments are available for the Bobcat excavator.
[B] ROPS, TOPS - (Roll-Over Protective Structure / Tip-Over Protective Structure) as standard equipment. 
The ROPS / TOPS meets ISO 12117-2 AND ISO 12117.

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SAFETY & MAINTENANCE

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

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

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

OPERATOR CAB (ROPS / TOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Front Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Right Side Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Heating And Ventilation Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5

OPERATOR CANOPY (ROPS / TOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31-1

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

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
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Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Opening And Closing Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-2

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Replacing The Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

CAB FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3

10-01 E20 Service Manual

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-5

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

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

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing The Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing The Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3

LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

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SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . 10-210-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

10-02 E20 Service Manual

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1
Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

REMOTE START TOOL KIT - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230-3

REMOTE START TOOL (SERVICE TOOL) KIT - 7217666 . . . . . . . . . . . . . . . . . . . . . 10-231-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-231-1
Remote Start Tool (Service Tool) - 7022042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-231-2
Excavator Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-231-3
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-231-4
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10-03 E20 Service Manual

10-04
E20 Service Manual
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LIFTING AND BLOCKING THE EXCAVATOR Figure 10-10-2

Procedure

Always park the machine on a level surface.

WARNING
1
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
P113460
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or Raise one side of the machine (approximately 101,6 mm
service. Untrained operators and failure to follow (4 in)) using the boom and arm [Figure 10-10-1] and
instructions can cause injury or death. [Figure 10-10-2].
W-2003-0807

Raise the blade fully and install jackstands under the

blade and track frame (Item 1) [Figure 10-10-1] and
[Figure 10-10-2]. Raise the boom until all machine

WARNING weight is on the jackstands.

Repeat the procedure for the other side.

Put jackstands under the blade and rear corners of
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the undercarriage before working under the machine. Stop the engine.
Failure to block up the machine may allow it to move
or fall and result in injury or death.
W-2218-1195

Figure 10-10-1

P113459

10-10-1 E20 Service Manual

10-10-2
E20 Service Manual
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LIFTING THE EXCAVATOR Figure 10-20-2

Procedure

Figure 10-20-1
1
1

P113424

Figure 10-20-3
P113423

1
Fully extend the cylinders of the bucket, arm, and boom
so that the excavator is in the position as shown [Figure
10-20-1].

Raise the blade all the way.

Put all the control levers in NEUTRAL.

WARNING
P113425

AVOID INJURY OR DEATH

• Use chains and lifting equipment with sufficient Fasten chains to the ends of the blade (Item 1) [Figure
capacity for the weight of the excavator plus any 10-20-1] and [Figure 10-20-2] and up to a lifting fixture
added attachments. above the canopy / cab. The lifting fixture must extend
• Maintain center of gravity and balance when over the sides of the canopy / cab to prevent the chains
lifting. from hitting the ROPS / TOPS.
• Do not swing boom or upperstructure.
• Never lift with operator on machine. Fasten a chain (Item 1) [Figure 10-20-3] from the rod to
• Never lift with the blade angled (if equipped). the lift fixture.
W-2800-0709

NOTE: Depending on the type of chain hooks, it may

be necessary to install a clevis at the lift
points and then hook to the clevis.

10-20-1 E20 Service Manual

10-20-2
E20 Service Manual
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OPERATOR CAB (ROPS / TOPS)

Description

The Bobcat excavator has an optional operator cab

(ROPS / TOPS) as standard equipment to protect the
operator if the excavator is tipped over. The seat belt
must be worn for ROPS / TOPS protection.

Check the ROPS / TOPS cab, mounting, and hardware

for damage. Never modify the ROPS / TOPS cab.
Replace the cab and hardware if damaged. See your
dealer for parts.

ROPS / TOPS - Roll-Over Protective Structure per ISO

12117-2, and Tip-Over Protective Structure per ISO
12117.

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200
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10-30-1 E20 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D) Figure 10-30-3

Cab Door

Figure 10-30-1

1
1

P113389

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

(Item 1) [Figure 10-30-3] and close the door.

P113387
Figure 10-30-4

The cab door can be locked (Item 1) [Figure 10-30-1] 1

with the same key as the starter switch. Pull on the latch
to open the door.

Figure 10-30-2

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P113390

From inside the cab, push on the latch (Item 1) [Figure

10-30-4] and close the door.

1 2 Figure 10-30-5

P113388

Push the door all the way open until the latch post (Item
1) engages in the latch (Item 2) [Figure 10-30-2] to hold
the door in the open position.

P113391

From inside the cab, to open the door, pull on the latch
(Item 1) [Figure 10-30-5] and open the door.

10-30-2 E20 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D) Figure 10-30-8

Front Window

Opening The Front Window

Figure 10-30-6

2
1

1
P113394

When the window is fully raised, the latch (Item 1)

[Figure 10-30-8] (both sides) will close on the bracket in
the latched position.
P113392
Pull down and forward slightly on the window to make
sure it is fully latched.
Press the window latch button (Item 1) [Figure 10-30-6]
(both sides). Closing The Front Window

Figure 10-30-7 Use both window grab handles to support the window
while pressing the window latch button (Item 2) [Figure
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10-30-8] (both sides).

Use both window grab handles (Item 1) [Figure 10-30-7]

to pull the window down fully.

Press the top of the window in until the latch locks into
the latched position (both sides) [Figure 10-30-6].

Pull inward and upward slightly on the window to make

sure it is fully latched in the closed position.
1

P113393

Use both window grab handles (Item 1) [Figure 10-30-7]

to pull the top of the window in.

Continue moving the window in and up over the

operator’s head until the window is fully raised.

10-30-3 E20 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D) Window Washer Reservoir

Front Wiper Figure 10-30-10

Figure 10-30-9
1

P113396

P113395
The window washer reservoir (Item 1) [Figure 10-30-10]
is located on the right side cover.
The front window is equipped with a wiper (Item 1)
[Figure 10-30-9] and washer. NOTE: When temperatures are to reach below
freezing, use a washer fluid that is
recommended for use in cold temperatures to
avoid damage to the washer reservoir.

10-30-4 E20 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D) Heating And Ventilation Ducting

Right Side Window Figure 10-30-13

Opening The Right Front Window

Figure 10-30-11

P113397

Press down on the latch (Item 1) [Figure 10-30-11]

located at the front of the front window.
1
P113381
Figure 10-30-12

The heating and ventilation louvers (Item 1) [Figure 10-

30-13] can be positioned as needed to direct the air flow

to various areas in the cab.
1

P113398

Pull the latch (Item 1) [Figure 10-30-12] backward to

open the window until the desired stop. Release the latch
and latch the window in place.

Closing The Right Front Window

Press down on the latch (Item 1) [Figure 10-30-11] and

push the latch forward to close the window.

10-30-5 E20 Service Manual

10-30-6
E20 Service Manual
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OPERATOR CANOPY (ROPS / TOPS)

Description

The Bobcat excavator has an operator canopy (ROPS /

TOPS) as standard equipment to protect the operator if
the excavator is tipped over. The seat belt must be worn
for ROPS / TOPS protection.

Check the ROPS / TOPS canopy, mounting, and

hardware for damage. Never modify the ROPS / TOPS
canopy. Replace the canopy and hardware if damaged.
See your dealer for parts.

ROPS / TOPS - Roll-Over Protective Structure per ISO

12117-2, and Tip-Over Protective Structure per ISO
12117.

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200
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10-31-1 E20 Service Manual

10-31-2
E20 Service Manual
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TRANSPORTING THE EXCAVATOR ON A TRAILER Fastening

Loading And Unloading Figure 10-40-2

1
When transporting the machine, observe the rules, motor
vehicle laws, and vehicle limit ordinances. Use a
transport and towing vehicle of adequate length and
capacity.
1
Secure the parking brakes and block the wheels of the
transport vehicle.

Align the ramps with the center of the transport vehicle.

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

Use metal loading ramps with a slip resistant surface.

Use ramps that are the correct length and width and can P113429
support the weight of the machine.
Figure 10-40-3
The rear of the trailer must be blocked or supported when
loading or unloading the machine to prevent the front of
the transport vehicle from raising.

Determine the direction of the track movement before

moving the machine (blade forward). 1

Disengage the auto idle feature and move the two speed
travel to the low range position. 1
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Figure 10-40-1

P113428

Fasten chains to the front corners of the blade (Item 1)

[Figure 10-40-2] (or the front corner of the
upperstructure) and to the tie down loop at both sides of
the track frame (Item 1) [Figure 10-40-3] (or the tie down
on the rear of the upperstructure) to prevent it from
moving when going up or down slopes or during sudden
stops.
P113426
Use chain binders to tighten the chains and then safely tie
the chain binder levers to prevent loosening.
Move the machine forward onto the transport vehicle
[Figure 10-40-1].

Do not change direction of the machine while it is on the

WARNING
ramps.
AVOID SERIOUS INJURY OR DEATH
Lower the boom, arm, bucket, and blade to the transport Adequately designed ramps of sufficient strength are
vehicle. needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
Stop the engine and remove the key (if equipped).
break and cause personal injury.
W-2058-0807
Put blocks at the front and rear of the tracks.

10-40-1 E20 Service Manual

10-40-2
E20 Service Manual
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TAILGATE Figure 10-50-2

Opening And Closing

1
WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497

WARNING P113432

Keep the rear door closed when operating the To close the tailgate, lift up on the latch (Item 1) [Figure
machine. Failure to do so could seriously injure a 10-50-2] and slowly start to close the tailgate.
bystander.
W-2020-1285 Push firmly to close the tailgate.

Adjusting The Latch

Figure 10-50-1
Figure 10-50-3
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1 2

P113400

P113431

Press the button (Item 1) [Figure 10-50-1] and open the

tailgate. The tailgate latch (Item 1) can be adjusted by loosening
the two bolts (Item 2) [Figure 10-50-3], moving the latch,
Open the tailgate and rotate outward until it is held open and tightening the two bolts.
by the latch (Item 1) [Figure 10-50-2].
Close the tailgate before operating the excavator.

10-50-1 E20 Service Manual

TAILGATE (CONT’D)

Opening And Closing Right Side Cover

Right Side

Figure 10-50-4

P113433

Open the tailgate to access the right side cover latch

(Item 1) [Figure 10-50-4].

Pull out the lever (Item 1) [Figure 10-50-4] and open the
right side cover.

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Figure 10-50-5

P113434

Open the right side cover and rotate forward until it is

held open by the latch (Item 1) [Figure 10-50-5].

To close the tailgate, lift up on the latch (Item 1) [Figure

10-50-5] and slowly start to close the tailgate.

10-50-2 E20 Service Manual

SERVICE SCHEDULE

Maintenance Intervals

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early
failures. WARNING
The service schedule is a guide for correct maintenance
of the Bobcat excavator. AVOID INJURY OR DEATH
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

Every 10 Hours (Before Starting The Excavator)

• Engine Oil - Check level and add as needed.

• Engine Air Filters and Air System - Check air clearer condition indicator. Service only when required. Check for
leaks and damaged components.
• Engine Cooling System - Check coolant level COLD and add premixed coolant as needed.
• Fuel Filters- Check filters for moisture or contamination. Drain and replace as needed.
• Hydraulic Fluid - Check fluid level and add as needed.
• Fuel Filter- Check water from fuel filter.
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• Seat Belt, Seat Belt Retractors, Seat Belt Mounting hardware, Control Console Lockout - Check the condition
of seat belt and mounting hardware. Clean or replace seat belt retractors as needed. Check the control console
lockout lever for proper operation. Clean dirt and debris from moving parts.
• Motion Alarm - Check for proper function.
• Operator Cab - Check the cab condition and mounting hardware.
• Cab Heater Filters - Clean filters (if equipped).
• Indicators and Lights - Check for correct operation of all indicators and lights.
• Safety Signs - Check for damaged signs (decals). Replace any signs that are damaged.
• Console Lockout - Check console lockout for proper operation.
• Track Tension - Check tension and adjust as needed.
• Pivot Points - Grease all machinery pivot points. Grease track expansion. Grease clamp (if equipped).
• Attachment Coupler - Check for damage or loose parts (if equipped).

Every 50 Hours

• Swing Bearing - Grease swing bearing and swing pinion. Service every 10 hours when operating in water.
• Battery - Check cables, connections, and electrolyte level; add distilled water as needed.
• Fuel Tank - Drain water and sediment from fuel tank and fuel filter.

Every 100 Hours

• Spark Arrestor - Empty spark chamber.

10-60-1 E20 Service Manual

SERVICE SCHEDULE (CONT’D)

Maintenance Intervals (Cont’d)

Every 250 Hours Or Every 12 Months

• Fuel Filter - Replace fuel filter.

• Travel Motors (Final Drive) - Check fluid level and add as needed.
• Drive Belts (Alternator) - Check condition. Replace as needed. Service at first 50 hours, then as scheduled.

Every 500 Hours Or Every 12 Months

• Engine Oil and Filter - Service at first 50 hours, then as scheduled. Replace oil and filter.
• Cooling System - Clean debris from radiator / hydraulic fluid cooler.
• Hydraulic Filter and Hydraulic Reservoir Breather Cap - Replace the hydraulic filter and the reservoir breather cap.
Service at first 100 hours, then as scheduled.
• Alternator and Starter - Service at first 100 hours, then as scheduled. Check connections.
• Heater - Clean housing and coils (if equipped).

Every 1000 Hours Or Every 12 Months

• Hydraulic Fluid and Filters - Replace hydraulic fluid and filters.

• Engine Valves - Adjust the engine valve clearance.
• Travel Motors (Final Drive) - Service at first 100 hours, then as scheduled. Replace fluid.

Every 24 Months

• Coolant - Replace the coolant.

10-60-2 E20 Service Manual

AIR CLEANER SERVICE Replacing The Filter Elements

See the SERVICE SCHEDULE for the correct service Outer Filter
interval. (See SERVICE SCHEDULE on Page 10-60-1.)
Figure 10-70-2
Daily Check

The air cleaner is located in the engine compartment. 1

Open the tailgate to access the air cleaner for service.
(See TAILGATE on Page 10-50-1.)

Figure 10-70-1

1
2

P113438

Pull out on the latches (Item 1). Rotate the cover

counterclockwise and remove the dust cover (Item 2)
[Figure 10-70-2].

P113437
Figure 10-70-3

Check the condition indicator (Item 1) [Figure 10-70-1]. If

the red ring shows in the condition indicator, the filter
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needs to be replaced. 1

Replace the inner filter every third time the outer filter is
replaced or as indicated.

P113439

Slightly rotate the filter and pull the outer filter (Item 1)
[Figure 10-70-3] from the air cleaner housing.

Check the housing for damage.

Clean the housing and the seal surface. DO NOT use

compressed air.

Install a new filter.

10-70-1 E20 Service Manual

AIR CLEANER SERVICE (CONT’D) Inner Filter

Replacing The Filter Elements (Cont’d) Only replace the inner filter under the following
conditions:
Figure 10-70-4
• Replace the inner filter every third time the outer filter
is replaced.

2 • After the outer filter has been replaced, press the

button (Item 2) [Figure 10-70-1] on the condition
indicator and start the engine. Run at full rpm, then
reduce engine speed and stop the engine. If the red
ring shows in the condition indicator, replace the inner
filter.

1 Figure 10-70-5

P113438 1

Position the dust cover (Item 1) [Figure 10-70-4] to the

housing. Rotate the housing clockwise until the latch is at
the top as shown.

Secure the dust cover (Item 1) and by pushing in on the

latch (Item 2) [Figure 10-70-4].

Check the air intake hose and the air cleaner housing for

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damage. Make sure all connections are tight.
P113440

After the outer filter has been replaced, press the button
(Item 2) [Figure 10-70-1] on the end of the condition Remove the dust cover, outer filter and inner filter (Item 1)
indicator. [Figure 10-70-5].

Start the engine. Run at full rpm, then reduce engine NOTE: Make sure all sealing surfaces are free of dirt
speed and stop the engine. and debris.

If the red ring (Item 1) [Figure 10-70-1] shows in the Install the new inner filter.
condition indicator, replace the inner filter.
Install the outer filter and the dust cover.

Press the button on the condition indicator to reset the

red ring.

10-70-2 E20 Service Manual

CAB FILTER

Cleaning And Maintenance

Fresh Air Filter

The fresh air filter must be cleaned regularly. (See AIR

CLEANER SERVICE on Page 10-70-1.)

The fresh air filter is located on the right front corner of

the cab.

Figure 10-80-1

1
1

1 1

P113435
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Remove the four screws (Item 1) and remove the cover

(Item 2) [Figure 10-80-1].

Figure 10-80-2

P113436

Pull the filter (Item 1) [Figure 10-80-2] out of the housing.

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

Reinstall the cover (Item 2) and the four screws (Item 1)

[Figure 10-80-1].

10-80-1 E20 Service Manual

10-80-2
E20 Service Manual
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ENGINE COOLING SYSTEM

Check the cooling system every day to prevent

overheating, loss of performance or engine damage.
(See AIR CLEANER SERVICE on Page 10-70-1.)

Cleaning

NOTE: This excavator uses a pusher fan so flow

through the radiator / oil cooler will be from
inside the engine compartment to outside the
right cover. When cleaning the radiator, clean
both the inside and outside surfaces of the
radiator / oil cooler.

Open the tailgate. (See Opening And Closing on Page

10-50-1.)

Open the right side cover. (See Opening And Closing

Right Side Cover on Page 10-50-2.)

NOTE: Allow the cooling system and engine to cool

before servicing or cleaning the cooling
system.

Figure 10-90-1
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P113446

Use air pressure or water pressure to clean the radiator /

oil cooler (Item 1) [Figure 10-90-1] (both inside and
outside surfaces). Be careful not to damage fins when
cleaning.

Close the right side cover. (See Opening And Closing

Right Side Cover on Page 10-50-2.)

Close the tailgate. (See TAILGATE on Page 10-50-1.)

10-90-1 E20 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-2

Checking Level

WARNING 1

AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203

P113433

WARNING
Check the coolant level in the coolant recovery tank (Item
AVOID INJURY OR DEATH 1) [Figure 10-90-2].
Wear safety glasses to prevent eye injury when any
of the following conditions exist: The coolant level must be filled so it is within the MAX /
• When fluids are under pressure. MIN line marked on the on the coolant recovery tank.
• Flying debris or loose material is present.
• Engine is running. NOTE: The cooling system is factory filled with
• Tools are being used. propylene glycol (purple color). DO NOT mix
W-2019-0907 propylene glycol with ethylene glycol.

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IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.

Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

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

Open the tailgate. (See Opening And Closing on Page

10-50-1.)

10-90-2 E20 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-5

Removing And Replacing Coolant

See the service schedule for correct service intervals.

(See AIR CLEANER SERVICE on Page 10-70-1.) 1

Stop the engine. Open the right side cover. (See Opening
And Closing Right Side Cover on Page 10-50-2.)

WARNING
P113444
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned. Install a hose on the drain valve located at the engine
W-2070-1203 block by the end of the started. Open the drain valve
(Item 1) [Figure 10-90-5] and drain the coolant into a
Figure 10-90-3 container.

After all the coolant is removed, close both drain valves.

Recycle or dispose of the used coolant in an

1 environmentally safe manner.

Mix the coolant in a separate container. (See Capacities

on Page SPEC-10-6.)
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NOTE: The cooling system is factory filled with

propylene glycol (purple color). DO NOT mix
propylene glycol with ethylene glycol.
P113447
The correct mixture of coolant to provide a -37°C (-34°F)
freeze protection is 5 L propylene glycol mixed with 4,4 L
When the engine is cool, loosen and remove the coolant of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
fill cap (Item 1) [Figure 10-90-3]. of water.

Figure 10-90-4 Add premixed coolant, 47% water and 53% propylene
glycol, to the coolant tank until the coolant level reaches
the lower marker on the tank.

Use a refractometer to check the condition of propylene

glycol in your cooling system.

Add premixed coolant until the level is correct. Install the

1 coolant fill cap.

Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level when cool. Add
coolant as needed. Install the coolant fill cap.
P113446

Close the tailgate.

Install a hose on the drain valve at the bottom of the
radiator. Open the drain valve (Item 1) [Figure 10-90-4]
and drain the coolant into a container.

10-90-3 E20 Service Manual

10-90-4
E20 Service Manual
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FUEL SYSTEM Biodiesel Blend Fuel

Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Ultra low sulfur diesel fuel must be used in this machine.
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur • Cold weather conditions can lead to plugged fuel
maximum. system components and hard starting.

Use only clean, high quality diesel fuel, Grade Number • Biodiesel blend fuel is an excellent medium for
2-D or Grade Number 1-D. microbial growth and contamination that can cause
corrosion and plugging of fuel system components.
The following is one suggested blending guideline that
should prevent fuel gelling during cold temperatures: • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as: plugged
TEMPERATURE GRADE 2-D GRADE 1-D fuel filters and deteriorated fuel lines.

Above -9°C (+15°F) 100% 0% • Shorter maintenance intervals may be required, such
Down to -21°C (-5°F) 50% 50% as: cleaning the fuel system and replacing fuel filters
Below -21°C (-5°F) 0% 100% and fuel lines.

• Using biodiesel blended fuels containing more than

NOTE: Contact your local fuel supplier to receive
5% biodiesel can affect engine life and cause
specific recommendations for your region.
deterioration of hoses, tubelines, injectors, injector
pump, and seals.
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain
Apply the following guidelines if biodiesel blend fuel is
no more than 5% biodiesel mixed with ultra
used:
low sulfur petroleum based diesel. This
biodiesel blend fuel is commonly marketed as
• Ensure the fuel tank is as full as possible at all times
B5 blended diesel fuel. B5 blended diesel fuel
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to prevent moisture from collecting in the fuel tank.

must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
• Ensure that the fuel tank cap is securely tightened.

• Biodiesel blend fuel can damage painted surfaces,

remove all spilled fuel from painted surfaces
immediately.

• Drain all water from the fuel filter daily before

operating the machine.

• Do not exceed engine oil change interval. Extended

oil change intervals can cause engine damage.

• Before machine storage; drain the fuel tank, refill with

100% petroleum diesel fuel, add fuel stabilizer, and
operate the engine for at least 30 minutes.

NOTE: Biodiesel blend fuel does not have long-term

stability and should not be stored for more
than 3 months.

10-100-1 E20 Service Manual

FUEL SYSTEM (CONT’D)

Filling The Fuel Tank WARNING

Figure 10-100-1
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

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
P113441
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
The fuel cap uses the start key to unlock the fuel cap.

Remove the fuel fill cap (Item 1) [Figure 10-100-1].

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

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

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Install and tighten the fuel fill cap.

Clean up any spilled fuel.

See the service schedule for the service interval when to

remove water from or replace the fuel filter. (See AIR
CLEANER SERVICE on Page 10-70-1.)

NOTE: When filling the fuel tank, with the left console
raised, turn the start switch to the ON
position. As fuel is added to the tank, a buzzer
will beep and the closer the tank gets to full,
the quicker the beeps. When the tank is full,
the buzzer will sound continuously. Stop
fueling when buzzer sounds continuously.
Turn the start switch OFF.

10-100-2 E20 Service Manual

FUEL SYSTEM (CONT’D) Replacing Elements

Fuel Filter Remove and replace the fuel pre-filter (Item 3) [Figure
10-100-2].
Removing Water
Remove the filter (Item 2) [Figure 10-100-2].
Open the tailgate. (See Opening And Closing on Page
10-50-1.) Clean the area around the filter housing. Put clean oil on
Figure 10-100-2 the seal of the new filter. Install the fuel filter and hand
tighten.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-5.)
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.
3 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
P113543
from a physician familiar with this injury.
W-2072-0807
Loosen the drain (Item 1) [Figure 10-100-2] at the
bottom of the filter to drain water from the filter into a
container.
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Inspect the fuel pre-filter (Item 3) [Figure 10-100-2] daily

for moisture and contamination. Replace as necessary.

Clean up any spilled fuel.

10-100-3 E20 Service Manual

FUEL SYSTEM (CONT’D) Figure 10-100-4

Draining The Fuel Tank

1
See the service schedule for the correct service interval.
(See AIR CLEANER SERVICE on Page 10-70-1.)

The fuel tank can be drained in several ways. See below.

Figure 10-100-3 2

P113444

Second option for draining tank. Remove the fuel hose

(Item 1) at the fuel pump. Route the hose out of the
engine compartment and into a container. Squeeze the
primer bulb (Item 2) [Figure 10-100-4] to start a siphon
and drain the tank.
P113443

Reinstall the fuel hose (Item 1) [Figure 10-100-4].

Rotate the upperstructure so the fuel tank drain plug
(Item 1) is located between the rear tracks. Remove the
drain plug (Item 1) [Figure 10-100-3].

Drain the fuel into the container.

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Reuse, recycle or dispose of fuel in an environmentally
safe manner.

Reinstall the drain plug.

10-100-4 E20 Service Manual

FUEL SYSTEM (CONT’D)

Removing Air From The Fuel System WARNING

After replacing the fuel filter or when the fuel tank has run
out of fuel, air must be removed from the fuel system AVOID INJURY OR DEATH
before starting the engine. Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Open the tailgate. (See Opening And Closing on Page death. Fluid leaks under pressure may not be visible.
10-50-1.) Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
Figure 10-100-5 enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

P113438

Figure 10-100-6
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P113444

Open the fuel filter vent (Item 1) [Figure 10-100-5] and

operate the hand pump (priming bulb) (Item 1) [Figure
10-100-6] until the fuel flows from the vent (Item 1)
[Figure 10-100-5] with no air bubbles.

Close the vent (Item 1) [Figure 10-100-5].

Start the engine. It may be necessary to open the vent

(Item 2) [Figure 10-100-6] (at the fuel injection pump)
briefly until the engine runs smoothly.

10-100-5 E20 Service Manual

10-100-6
E20 Service Manual
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ENGINE LUBRICATION SYSTEM Engine Oil Chart

Checking And Adding Engine Oil Figure 10-110-2

Check the engine oil after every 8-10 hours of operation ENGINE OIL
and before starting the engine (See SERVICE RECOMMENDED SAE VISCOSITY NUMBER
SCHEDULE on Page 10-60-1.) (LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
Figure 10-110-1

P113445

TEMPERATURE RANGE ANTICIPATED BEFORE

Open the tailgate and remove the dipstick (Item 1) NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
[Figure 10-110-1]. CLASSIFICATION CI-4 OR BETTER)
[1] Synthetic Oil - Use recommendation from Synthetic
Keep the oil level between the marks on the dipstick. Oil Manufacturer.
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Use a good quality motor oil that meets the correct API Use good quality engine oil that meets API Service
Service Classification. Classification of CI-4 or better [Figure 10-110-2].

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

10-110-1 E20 Service Manual

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

Removing And Replacing Oil And Filter

See the service schedule for the service interval for 2

replacing the engine oil and filter. (See SERVICE
SCHEDULE on Page 10-60-1.)

Rotate upperstructure so that the oil drain plug is

between the rear tracks.

Run the engine until it is at operating temperature. Stop

the engine.

Open the tailgate. (See Opening And Closing on Page

10-50-1.) 1

Figure 10-110-3 P113445

Remove the oil filter (Item 1) [Figure 10-110-4] and clean

the filter housing surface.

1 Use a genuine Bobcat replacement filter. Put clean oil on

the filter gasket. Install the filter and hand tighten.

Install and tighten the drain plug (Item 1) [Figure 10-110-

3].

Remove the fill cap (Item 1) [Figure 10-110-4].

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Put oil in the engine. (See Checking And Adding Engine
Oil on Page 10-110-1.)
P113430

Install the fill cap (Item 1) [Figure 10-110-4].

Place a container under the oil pan. Remove the drain Start the engine and let it run for several minutes.
plug (Item 1) [Figure 10-110-3] from the bottom of the
engine oil pan. Stop the engine. Check for leaks at the oil filter. Check
the oil level.
Recycle or dispose of used oil in an environmentally safe
manner. Add oil as needed if it is not at the top mark on the
dipstick.

10-110-2 E20 Service Manual

HYDRAULIC SYSTEM

Checking And Adding Hydraulic Oil WARNING

Put the machine on a flat level surface.
AVOID INJURY OR DEATH
Retract the tracks fully. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Retract the arm and bucket cylinders, put the bucket on Failure to use care around combustibles can cause
the ground and lower the blade. Stop the engine. explosion or fire.
W-2103-0508
Open the tailgate. (See Opening And Closing on Page
10-50-1.) Figure 10-120-2

Figure 10-120-1
1

B
A
2 3
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P113456
1
B

A Remove screw (Item 1) [Figure 10-120-2] from the top of

the cover and remove the left side cover.

Clean the surface around the reservoir cap and remove

the cap from the reservoir (Item 2) [Figure 10-120-2].

Check the condition of the fill strainer screen (Item 3)

P113454A
P113455 [Figure 10-120-2]. Clean or replace as necessary.

Be sure the screen is installed before adding fluid.

Park the machine in the position shown [Figure 10-120-
1]. (The preferred method is to check the hydraulic oil Add the correct fluid to the reservoir until it is visible in the
when it is cold.) sight gauge.

Check the hydraulic oil level, it must be visible in the sight Check the cap and clean as necessary. Replace the cap
gauge (Item 1) [Figure 10-120-1]. The decal on the if damaged.
hydraulic tank shows the correct fill level.
Install the cap.
A - Correct Oil Level COLD (Preferred)
B - Correct Oil Level HOT (Optional) Close the right side cover and tailgate.

10-120-1 E20 Service Manual

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

Hydraulic / Hydrostatic Fluid Chart

Figure 10-120-3 WARNING

HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG) AVOID INJURY OR DEATH
AND VISCOSITY INDEX (VI) 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

Hydraulic Filter

See the service schedule for the correct service interval.

(See AIR CLEANER SERVICE on Page 10-70-1.)

Open the tailgate. (See Opening And Closing on Page

10-50-1.)
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE Figure 10-120-4
[1] VG 100; Minimum VI 130
[2] VG 46; Minimum VI 150
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid
(Unlike biodegradable fluids that are vegetable based,

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Bobcat biodegradable fluid is formulated to prevent
oxidation and thermal breakdown at operating
temperatures.)
1
Install the oil fill cap.

P113442

Remove the hydraulic filter (Item 1) [Figure 10-120-4].

Clean the housing where the filter gasket makes contact.

Put clean hydraulic oil on the gasket. Install the new filter
and hand tighten only. Use a genuine Bobcat
replacement filter.

10-120-2 E20 Service Manual

HYDRAULIC SYSTEM (CONT’D) Figure 10-120-6

Removing And Replacing The Hydraulic Oil

1
See the service schedule for the correct service interval.
(See AIR CLEANER SERVICE on Page 10-70-1.)

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 P113458

not use your bare hand. Wear safety goggles. If fluid

enters skin or eyes, get immediate medical attention
With the engine OFF, loosen the plug (Item 1) [Figure
from a physician familiar with this injury.
W-2072-0807
10-120-6] on the hydraulic pump. Tighten the plug after a
steady stream of hydraulic oil, free of any air bubbles,
drains from the plug. DO NOT RUN THE MACHINE
Retract the arm and bucket cylinders, lower the bucket to WITH THE PLUG OPEN. Tighten the plug to 30 -34 N•m
the ground. Stop the engine. (22 - 25 ft-lb) torque.

Open the tailgate. (See Opening And Closing on Page Figure 10-120-7
10-50-1.)

Figure 10-120-5
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1 P113448

There is also a port (Item 1) [Figure 10-120-7] on the

hydraulic cooler for bleeding air. Install a diagnostic
P113457 coupler and hose on this fitting to allow air to be bleed
from the hydraulic system after the hydraulic oil has been
The hydraulic oil drain plug (Item 1) [Figure 10-120-5] is replaced. Remove the hose and coupler before starting
located on the hydraulic pump inlet fitting. the engine.

Remove the plug (Item 1) [Figure 10-120-5]. Start the engine and operate the machine through the
hydraulic functions. Stop the engine. Check the fluid level
Drain the fluid into a container. and add as needed.

Recycle or dispose of the fluid in an environmentally safe

manner.

Install the plug (Item 1) [Figure 10-120-5].

Add fluid to the reservoir. (See Checking And Adding

Hydraulic Oil on Page 10-120-1.)

10-120-3 E20 Service Manual

10-120-4
E20 Service Manual
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LUBRICATING THE EXCAVATOR Figure 10-130-2

Lubrication Locations 4

Lubricate the excavator as specified in the SERVICE

SCHEDULE for the best performance of the machine.
(See SERVICE SCHEDULE on Page 10-60-1.)
5
Always use a good quality lithium based multipurpose
grease when lubricating the machine. Apply the lubricant
until extra grease shows.
5
Lubricate the following locations on the excavator EVERY
8 - 10 HOURS:

Figure 10-130-1 6 P113466

4. Boom Cylinder Rob End (1) [Figure 10-130-2]

1 5. Boom Swing Pivot (3) [Figure 10-130-2]

6. Boom Swing Cylinder Rod End (1) [Figure 10-130-2]

Figure 10-130-3
3
3
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2
P113465
7
7
Ref Description (# of Fittings)

1. Blade Cylinder Rod End (1) [Figure 10-130-1]

2. Blade Cylinder Base End (1) [Figure 10-130-1]

3. Blade Pivots (2) [Figure 10-130-1] P113467

7. Boom Pivot (2) [Figure 10-130-3]

10-130-1 E20 Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR Figure 10-130-6
(CONT’D)

Lubrication Locations (Cont’d)

Figure 10-130-4
12

P113470

12. Bucket Cylinder Base End (1) [Figure 10-130-6]

P113468 Figure 10-130-7

8. Boom Cylinder Base End (1) [Figure 10-130-4]

9. Arm Cylinder Base End (1) [Figure 10-130-4] 16

14
Figure 10-130-5

10 15

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13

P113471

13. Bucket Cylinder Rod End (1) [Figure 10-130-7]

11
14. Bucket Link Pin (1) [Figure 10-130-7]

P113472 15. Bucket Pivot (2) [Figure 10-130-7]

16. Bucket Link (2) [Figure 10-130-7]

10. Arm Cylinder Rod End (1) [Figure 10-130-5]

11. Arm Pivot (1) [Figure 10-130-5]

10-130-2 E20 Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR
(CONT’D)

Lubrication Locations (Cont’d)

Figure 10-130-8

P113474

17. Cab Door Hinges (3) [Figure 10-130-8] (If Equipped)

Figure 10-130-9

18
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P113473

18. Boom Swing Cylinder Base (1) [Figure 10-130-9]

Lubricate the following locations on the hydraulic

excavator EVERY 50 HOURS:

19. Slew Circle (1) [Figure 10-130-9]

20. Slew Pinion (1) [Figure 10-130-9]. (Install three to

four pumps of grease then rotate the upperstructure
90°. Install three to four pumps of grease and again
rotate the upperstructure 90°. Repeat this until the
slew pinion has been greased at four positions.)

10-130-3 E20 Service Manual

10-130-4
E20 Service Manual
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TRAVEL MOTOR Removing And Replacing Oil

Checking And Adding Oil See the service schedule for the correct service interval.
(See AIR CLEANER SERVICE on Page 10-70-1.)
Figure 10-140-1
Park the excavator on a level surface with plugs (Items 1
and 2) [Figure 10-140-1] in the position shown. Remove
both plugs and drain the lubricant into a container.

1
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
2 sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P113463

Install the bottom plug (Item 2) [Figure 10-140-1]. Add

Park the excavator on a level surface with the plugs fluid through the center plug hole until the fluid level is at
(Items 1 and 2) [Figure 10-140-1] in the position as the bottom edge of the hole.
shown.
Install the plug (Item 1) [Figure 10-140-1].
Remove the plug (Item 1) [Figure 10-140-1]. The fluid
level must be at the bottom edge of the hole.

Add lubricant (SAE 80W90) through the hole if the fluid

level is low.

10-140-1 E20 Service Manual

10-140-2
E20 Service Manual
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SPARK ARRESTER MUFFLER

Cleaning Procedure

See the SERVICE SCHEDULE for the correct service

IMPORTANT
interval. (See SERVICE SCHEDULE on Page 10-60-1.)
This machine is factory equipped with a U.S.D.A.
Forestry Service approved spark arrester exhaust
system.
WARNING The spark arrester muffler, if equipped, must be
cleaned to keep it in working condition. The spark
AVOID INJURY OR DEATH arrester muffler must be serviced by dumping the
When an engine is running in an enclosed area, fresh spark chamber every 100 hours of operation.
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust On some models, the turbocharger functions as the
outside. Exhaust fumes contain odorless, invisible spark arrester and must operate correctly for proper
gases which can kill without warning. spark arrester function.
W-2050-0807
If this machine is operated on flammable forest,
brush, or grass covered land, it must be equipped
with a spark arrester attached to the exhaust system
WARNING and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442.
PRC. Refer to local laws and regulations for spark
Stop engine and allow the muffler to cool before arrester requirements.
cleaning the spark chamber. Wear safety goggles. I-2284-0111
Failure to obey can cause serious injury.
W-2011-1285
Do not operate the excavator with a defective exhaust
system.
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Stop the engine. Open the tailgate. (See Opening And

WARNING Closing on Page 10-50-1.)

Remove the left side cover.

Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285

WARNING
When the engine is running during service, the
steering levers must be in neutral.

Failure to do so can cause injury or death.

W-2203-0595

10-150-1 E20 Service Manual

SPARK ARRESTER MUFFLER (CONT’D)

Cleaning Procedure (Cont’d)

Figure 10-150-1

P113458

Remove the plug (Item 1) [Figure 10-150-1] from the

bottom of the muffler.

Start the engine and run for about 10 seconds while a

second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler. The carbon deposits
will be forced out of the muffler plug hole (Item 1) [Figure
10-150-1].

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Stop the engine. Install and tighten the plug.

Close the tailgate.

10-150-2 E20 Service Manual

ALTERNATOR BELT Figure 10-160-2

Belt Adjustment
2
Stop the engine and open the tailgate. (See Opening And
Closing on Page 10-50-1.)

Figure 10-160-1

2
P113464

1
NOTE: The seat is shown removed for photo clarity.
The alternator adjusting bolts can be
accessed by removing the belt guard (Item 2)
[Figure 10-160-1] and reaching around the
P113431 engine.

If the belt tension is not correct, loosen the bolt and nut
Measure the belt (Item 1) [Figure 10-160-1] tension at (Item 1) and the bolt (Item 2) [Figure 10-160-2] until the
the middle of the belt span. alternator can be moved toward the engine.

If a belt tension tool is available, move the alternator until Adjust belt tension to correct specifications [Figure 10-
the belt has (new belt = 272 - 292 N [61 - 65 lbf] or used
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160-1].
belt = 233 - 252 N [53 - 57 lbf]) tension.
Tighten the mounting and adjustment bolts.
If a belt tension tool is not available, move the alternator
until the belt has 8,0 mm (5/16 in) movement at the Close the tailgate.
middle of the belt span with 66 N (15 lbf) of force.
Belt Replacement

Loosen the bolt and nut (Item 1) and the bolt (Item 2)
[Figure 10-160-2] until the alternator can be moved
toward the engine.

Remove the old belt and install a new belt.

Adjust belt tension to correct specifications [Figure 10-

160-1].

Tighten the mounting and adjustment bolts.

Reinstall the belt guard (Item 2) [Figure 10-160-1].

Close the tailgate.

10-160-1 E20 Service Manual

10-160-2
E20 Service Manual
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SEAT BELT Figure 10-170-1

Inspection And Maintenance

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

Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly yearly or more

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

The seat belt system should be repaired or replaced if it

shows cuts, fraying, extreme or unusual wear, significant
discolorations due to ultraviolet (UV) rays from the sun,
dusty / dirty conditions, abrasion to the seat belt webbing,
or damage to the buckle, latch plate, retractor (if
equipped), or hardware.

1. Check the seat belt webbing. If the system is

B-22283
equipped with a retractor, pull the webbing completely
out and inspect the full length of the webbing. Look for
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cuts, wear, fraying, dirt, and stiffness. The items below are referenced in [Figure 10-170-1].

2. Check the buckle and latch for proper function. Make

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

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

by extending the seat belt webbing to determine if it
extends and retracts the webbing correctly.

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

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

See your dealer for approved seat belt system

replacement parts for your machine.

10-170-1 E20 Service Manual

10-170-2
E20 Service Manual
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CONTROL CONSOLE LOCKOUTS

Inspection And Maintenance

Figure 10-180-1

P113427

When the left console is raised [Figure 10-180-1], the

hydraulic control levers (joysticks) and traction system
must not function.

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

Raise the left console [Figure 10-180-1].

Move the joystick control levers. There should be no

movement of the boom, arm, slew or bucket.

Move the steering control levers. There should be no

movement of the excavator tracks.

Service the system if these controls do not deactivate

when the left control console is raised. (See your dealer
for service.)

10-180-1 E20 Service Manual

10-180-2
E20 Service Manual
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PIVOT PINS

Inspection And Maintenance

Figure 10-190-1

3
2

1 2

P113469

The pivots and cylinders have a large pin (Item 1) held in

position with a bolt (Item 2) and double nuts (Item 3)
[Figure 10-190-1] securing the pin.

The two nuts (Item 3) are used as jam nuts to hold the
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bolt (Item 2) without tightening the bolt (Item 2) to the pin

boss. After the nuts (Item 3) are tightened together, the
bolt (Item 2) [Figure 10-190-1] should be free to spin.
See your dealer for replacement parts.

10-190-1 E20 Service Manual

10-190-2
E20 Service Manual
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EXCAVATOR STORAGE AND RETURN TO SERVICE Return To Service

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

necessary to follow a list of items to return the excavator
Sometimes it may be necessary to store your Bobcat to service.
Excavator for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the excavator including the engine
compartment. • Install a fully charged battery.

• Lubricate the excavator. • Remove grease from exposed cylinder rods.

• Replace worn or damaged parts. • Check all belt tensions.

• Drive the excavator onto planks in a dry protected • Be sure all shields and guards are in place.
shelter.
• Lubricate the excavator.
• Lower the boom fully with the bucket flat on the
ground. • Remove cover from exhaust pipe opening.

• Put grease on any exposed cylinder rods. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put fuel stabilizer in the fuel tank and run the engine correct operation.
a few minutes to circulate the stabilizer to the pump
and fuel injectors. • Drive the excavator off of the planks.

• Drain and flush the cooling system. Refill with • Operate machine, check for correct function.
premixed coolant.
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• Stop the engine and check for leaks. Repair as

• Replace all fluids and filters (engine, hydraulic). needed.

• Replace all filters (i.e.: air cleaner, heater, etc.).

• Put all controls in neutral position.

• Remove the battery. Be sure the electrolyte level is

correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.

• Cover the exhaust pipe opening.

• Tag the machine to indicate that it is in storage

condition.

10-200-1 E20 Service Manual

10-200-2
E20 Service Manual
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STOPPING THE ENGINE AND LEAVING THE Figure 10-210-3
EXCAVATOR
ON
Procedure STOP START

Figure 10-210-1

7186708A

P113422
Turn the switch to STOP [Figure 10-210-3].

Stop the machine on level ground. Lower the work Disconnect the seat belt. Remove the key from the switch
equipment and the blade to the ground [Figure 10-210- (If Equipped) to prevent operation of machine by
1]. unauthorized personnel. Raise the control console and
exit the machine.
NOTE: Tracks must be fully expanded for entering
and exiting the excavator.
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Figure 10-210-2

P113405

Move the engine speed control lever (Item 1) [Figure 10-

210-2] back to low idle.

Run the engine at idle speed for about 5 minutes to allow

it to cool.

10-210-1 E20 Service Manual

10-210-2
E20 Service Manual
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EMERGENCY EXIT Front Window

The door, the rear window, and the front window provide Figure 10-220-3
exits.

Rear Window

Figure 10-220-1

1 P113393

Open the front window and exit [Figure 10-220-3].

P113399 NOTE: If the excavator has a Special Applications Kit

installed, the front window is NOT an
emergency exit.
If emergency exit through the rear window is required,
use the supplied hammer (Item 1) [Figure 10-220-1]
located on the left rear side of the cab to break the
window.
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Figure 10-220-2

P-86218

Remove the hammer from the storage position and strike

the glass with the pointed end of the hammer [Figure 10-
220-2].

Use the hammer to remove broken glass from the edge

of the window before exiting.

10-220-1 E20 Service Manual

10-220-2
E20 Service Manual
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REMOTE START TOOL KIT - MEL1563 Figure 10-230-2

Remote Start Tool - MEL1563

Tools that will be needed to complete the following steps

are: 1

MEL1563 - Remote Start Tool

MEL1566 - Service Tool Harness Communicator
(Computer Interface)

Figure 10-230-1

1
P16117

The three function buttons (Item 1) [Figure 10-230-2] are

non-functional for excavators.

NOTE: Excavators can not be started by using the

Remote Start Tool.

Figure 10-230-3

P16114

1
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The Remote Start Tool (Item 1) [Figure 10-230-1] is

used for excavators.

The Remote Start Tool is required when the service

technician is checking the service codes.

Remote Start Tool is a link between the excavator and

the Service PC.

P16116

The 10-pin rectangular connector (Item 1) [Figure 10-

230-3] is not used for an excavator application.

10-230-1 E20 Service Manual

REMOTE START TOOL KIT - MEL1563 (CONT'D) Figure 10-230-5

Remote Start Tool - MEL1563 (Cont’d)

Figure 10-230-4

2
1
1

P117697

Remove the plug (Item 1) [Figure 10-230-5] from the

P16114 excavator harness connector.

Connect the Service Tool harness to the excavator

The Service Tool harness communicator (Item 1) [Figure harness.
10-230-4] is used to connect the Remote Start Tool to the
Service PC. Connect the Service Tool harness communicator
(MEL1566) to the designated serial port on the Service
Remove the Service Tool harness (Item 2) [Figure 10- PC.
230-4] from the cover.

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NOTE: Make all connections with the key or keyless
panel in the OFF position.

Open the right side cover.

10-230-2 E20 Service Manual

REMOTE START TOOL KIT - MEL1563 (CONT'D) Key Switch

Service Tool Harness Communicator - MEL1566 Figure 10-230-7

NOTE: To monitor, diagnose, or load new software

the Service PC must be connected to the
Remote Start Tool.

Figure 10-230-6

STOP
ON

START P113421

Turn the key (Item 1) [Figure 10-230-7] to the ON

position on the excavator.

P16119 NOTE: DO NOT start the excavator.

Figure 10-230-8
The Service Tool harness communicator (Item 1) [Figure
10-230-6] is required to connect the Service PC to the
Remote Start Tool.
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P-21334

Turn the key (Item 1) [Figure 10-230-8] to the RUN

position on the Remote Start Tool.

10-230-3 E20 Service Manual

REMOTE START TOOL KIT - MEL1563 (CONT'D)

Service Tool Harness Communicator - MEL1566

(Cont’d)

Keyless Start

Figure 10-230-9

ON 2
STOP START

P113420

Turn the start switch (Item 1) [Figure 10-230-9] to ON.

The indicator lights on the instrument panel will come ON
briefly and the Instrument Panel / monitoring system will
do a self test.

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Use the keypad (Item 2) [Figure 10-230-9] to enter the
password.

NOTE: DO NOT start the excavator.

Figure 10-230-10

P-21334

Turn the key (Item 1) [Figure 10-230-10] to the RUN

position on the remote start tool.

10-230-4 E20 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT -
7217666

Description

The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL1563 Remote Start Tool.

The Remote Start Tool (Service Tool) Kit, P/N 7217666,

can be used to service excavators using the supplied
harness P/N 6689747.

A computer can be connected to the Remote Start Tool

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the excavator harness.
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10-231-1 E20 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-231-2
7217666 (CONT’D)
2
Remote Start Tool (Service Tool) - 7022042

Tools that will be needed to complete the following steps 5 3

are:

Order from Bobcat Parts P/N: 7217666 - Remote Start 6 4

Tool (Service Tool) Kit

Kit Includes:
7022042 - Remote Start Tool (Service Tool)
1
6689747 - Excavator Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness P-76439

Figure 10-231-1
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-231-2] has five buttons.

The STOP button (Item 2) [Figure 10-231-2] is used to

stop the Remote Start Tool (Service Tool) from
communicating and stop the engine.

The RUN button (Item 3) [Figure 10-231-2] is used to

turn the Remote Start Tool (Service Tool) on and
activates the electrical system. The button will illuminate
1
to indicate the service tool is active.

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The START button (Item 4) [Figure 10-231-2] is used to
start the engine.
P-76678
The TRACTION LOCK button (Item 5) [Figure 10-231-2]
is not used in applications.
The Remote Start Tool (Item 1) [Figure 10-231-1] is
used for excavators. The AUXILIARY HYDRAULIC button (Item 6) [Figure 10-
231-2] is not used in applications.
The Remote Start Tool is required when the service
technician is checking the service codes.

Remote Start Tool is a link between the excavator and

the Service PC.

10-231-2 E20 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-231-5
7217666 (CONT’D)

Excavator Service Tool Harness - 6689747

2 1
Figure 10-231-3

3
P-76450
2

NOTE: The Remote Start Tool (Service Tool)

connection harness has two connectors (Item
P-76678 1) and (Item 2). The main connector (Item 1)
[Figure 10-231-5] is always used for
connection to the excavator harness.
The Service Tool harness control (Item 1) [Figure 10-
231-3] is used to connect the Remote Start Tool (Item 2) The second connector (Item 2) [Figure 10-231-
[Figure 10-231-3] to the electrical system on the 5] is not used for excavator applications. This
excavator. connector has a cap attached to it to prevent
damage or corrosion when not in use.
The Service Tool harness communicator (Item 3) [Figure
10-231-3] is used to connect the Remote Start Tool to the Connect the Remote Start Tool (Service Tool) connector
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Service PC. (Item 1) [Figure 10-231-5] to the excavator harness

connector.
NOTE: Make all connections with the key or keyless
panel in the OFF position.

Open the right side cover.

Figure 10-231-4

P117697

Remove the plug (Item 1) [Figure 10-231-4] from the

excavator harness connector.

10-231-3 E20 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-231-7
7217666 (CONT’D)

Computer Service Tool Harness - 6689746

NOTE: To monitor, diagnose, or load new software

the Service PC must be connected to the
Remote Start Tool.

Figure 10-231-6 1 2

P-76441

The gear icon with the left facing arrows (Item 1) [Figure
10-231-7] will illuminate and blink when the excavator key
is in the RUN position, excavator keyless panel is ON or
the Service Tool is in the RUN position and the excavator
is communicating with the Service Tool.
2
P-76450 NOTE: DO NOT start the excavator.

The computer icon with the right facing arrows (Item 2)

The computer service tool harness (Item 1) [Figure 10- [Figure 10-231-7] will illuminate and blink when the
231-6] is required to connect Remote Start Tool (Service Remote Start Tool (Service Tool) is transmitting data to
Tool) to the Service PC (Item 2) [Figure 10-231-6]. and from the computer.

10-231-4 E20 Service Manual

HYDRAULIC SYSTEM

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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Troubleshooting The Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Swing (Upperstructure Slew) Circuit . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-7

CYLINDER (BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8

CYLINDER (ARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-8

CYLINDER (BOOM SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
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Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-7

CYLINDER (BUCKET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7

CYLINDER (BLADE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-7

CYLINDER (TRACK FRAME EXPANSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-9

20-01 E20 Service Manual

VALVE (MAIN RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Testing And Adjusting Main Relief At Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Testing And Adjusting Main Relief at Hydraulic Control Valve . . . . . . . . . . . . . . . . . 20-30-5

VALVE (PORT RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Testing And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

VALVE (CROSS PORT RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-3

VALVE (PRESSURE REDUCING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33-1

Testing And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Right And Left Travel Valve Section Disassembly And Assembly . . . . . . . . . . . . . . 20-40-17
Arm And Bucket Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . 20-40-21
Boom Swing And Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . 20-40-23

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Boom Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Slew Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Blade Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing The Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Testing The Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Testing Auxiliary Hydraulic Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Gear Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-11
Gear Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-13
Piston Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-15
Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-25

MANIFOLD ASSEMBLY / ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4

ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

20-02 E20 Service Manual

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-10

SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Parts Identification (AWRH11419 & Above, B3BL11734 & Above) . . . . . . . . . . . . . 20-90-4
Parts Identification (AWRH11001 - AWRH11418, B3BL11001 - B3BL11733) . . . . . 20-90-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-8

SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-5
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-9
Brake Carrier Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-16

CONTROL LEVER (JOYSTICK) (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-13

CONTROL LEVER (JOYSTICK) (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-2
Joystick Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-11

HYDRAULIC FILTER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

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

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

20-03 E20 Service Manual

BLADE / TRACK EXPANSION SOLENOID BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-3
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-4

20-04 E20 Service Manual

E20 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N B3BL11001 AND ABOVE
Printable Version Click Here
(PRINTED MARCH 2018)
V-1590legend

LEGEND
1 HYDRAULIC RESERVOIR: Pressurized 17 SOLENOID ACTIVATED DIRECTIONAL 32 DRIVE MOTOR SHUTTLE – With
with Fill Strainer CONTROL VALVE – System By-Pass 0,8 mm (0.032 in) restrictors
Reservoir Capacity (at Site Gauge):
18 RELIEF VALVE: 23100 kPa
14.3 L (15.1 qt) 33 VALVE - Two Speed
(231 bar) (3350 psi)
System Capacity: 19.0 L (20.0 qt)
19 SOLENOID ACTIVATED DIRECTIONAL PISTON - Two Speed
34
2 PRESSURIZED BREATHER/FILL CAP CONTROL VALVE – Power Beyond
with FILTER:
600 kPa (0.4 bar) (6 psi) – Outlet 20 RELIEF VALVE: 20500 kPa RELIEF VALVE: 24000 kPa
35
60 kPa (0.04 bar) (0.6 psi) - Inlet (205 bar) (2973 psi) (240 bar) (3480 psi)
21 CHECK VALVE
3 HYDRAULIC FILTER ELEMENT 36 ANTI-CAVITATION VALVE (2)
15 Micron 22 ANTI-CAVITATION VALVE
4 FILTER BY-PASS: 340 kPa (3.4 bar) (50 psi) 37 CROSSPORT RELIEF VALVE:
23 CHECK VALVE (2) - With 13700 kPa (137 bar) (1987 psi)
5 PRESSURE DIFFERENTIAL SWITCH 0,58 mm (0.023 in) Orifice
38 ORIFICE: 1,5 mm (0.06 in)
6 HYDRAULIC PISTON PUMP (2) . . . . . . PORT RELIEF VALVE (With Anti-Cavitation
24
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15,0 Lpm (4.0 gpm) at High Engine RPM Valve) - (Boom Cylinder):
25000 kPa (250 bar) (3650 psi) 39 ORIFICE: 7,0 mm (0.276 in)
7 TORQUE LIMITER
PORT RELIEF VALVE (With Anti-Cavitation
25 40 ORIFICE: 7,5 mm (0.295 in)
8 HYDRAULIC GEAR PUMP . . . . . . Valve) - (Boom Cylinder):
11,3 Lpm (3.0 gpm) at High Engine RPM 21000 kPa (210 bar) (3046 psi)
41 RELIEF VALVE (Optional):
9 PORT RELIEF VALVE - (With Anti- 24000 kPa 1(240 bar) (4206 psi)
TEST PORT – Hydraulic Gear Pump P3 26
Cavitation Valve) - (Auxiliary Pressure Port:
18000 kPa (180 bar) (2610 psi) 42 SOLENOID ACTIVATED DIRECTIONAL
10 PRESSURE SENSOR – Auto Shift CONTROL VALVE – Track / Blade
(If Equipped) Expansion
PORT RELIEF VALVE (With Anti-Cavitation
27 Valve) - (BUCKET Cylinder):
11 ACCUMULATOR 43 AIR BLEED PORT
25000 kPa (250 bar) (3625 psi)

12 CHECK VALVE - Accumulator PORT RELIEF VALVE (With Anti-Cavitation

28
Valve) - (ARM Cylinder):
13 SOLENOID ACTIVATED DIRECTIONAL 25000 kPa (250 bar) (3625 psi)
CONTROL VALVE – Work Group Lockout
29 SOLENOID ACTIVATED DIRECTIONAL
14 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Boom Offset
CONTROL VALVE - Two Speed
SOLENOID ACTIVATED DIRECTIONAL
PRESSURE REDUCING VALVE: 30
15 CONTROL VALVE – Boom Offset
3200 kPa (32 bar) (464 psi) NOTE: Unless otherwise specified
springs have NO significant
31 CHECK VALVE – with 1500 kPa
16 TEST PORT – Pressure Reducing Valve pressure value.
(15 bar) (218 psi) spring

Printed in U.S.A. V-1590legend (3-7-18)

R.H. TRAVEL MOTOR L.H. TRAVEL MOTOR

34 34

FEMALE
MALE
BOOM SWING
CYLINDER BOOM CYLINDER ARM CYLINDER
BLADE CYLINDER
38 33 33

36 44
E F C D
TRACK EXPANSION LOCK VALVE LOCK VALVE
CYLINDER (OPTIONAL) (OPTIONAL)
37
35 35

32 32 46

45
46
CP
2ND AUX FUNCTION
AUXILIARY (OPTIONAL)
HYDRAULIC BUCKET CYLINDER
COUPLER
FEMALE
42 SWIVEL
JOINT

MALE
41

25 21 21

21
21

21 24 26 27 22 28
21 20

HYDRAULIC
CONTROL VALVE 23 29
23
30

9 9 10 11
ISO / STD SELECT
VALVE DRAIN
BLOCK
R.H. JOYSTICK
L.H. JOYSTICK
19 NOTE A
15 12
40
OIL COOLER

17 14 13 43

MANIFOLD BLOCK

16 Printable Version Click Here

NOTE A: Drain Line Changed
2
HYDRAULIC PUMP
S/N AWRH12186 & Above
S/N B3LB11020 & Above
HYDRAULIC SCHEMATIC
HYDRAULIC FILTER 4
E20 (S/N B3BL11001 AND ABOVE)
8 HYDRAULIC 1
RESERVOIR
(PRINTED MARCH 2018)
7 7249683 (E)
6 3

39 5 43
Printed in U.S.A.
E20 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N AWRH11001 AND ABOVE
(PRINTED MARCH 2018) Printable Version Click Here
V-1590legend

LEGEND
1 HYDRAULIC RESERVOIR: Pressurized 17 SOLENOID ACTIVATED DIRECTIONAL 32 DRIVE MOTOR SHUTTLE – With
with Fill Strainer CONTROL VALVE – System By-Pass 0,8 mm (0.032 in) restrictors
Reservoir Capacity (at Site Gauge):
18 RELIEF VALVE: 23100 kPa
14.3 L (15.1 qt) 33 VALVE - Two Speed
(231 bar) (3350 psi)
System Capacity: 19.0 L (20.0 qt)
19 SOLENOID ACTIVATED DIRECTIONAL PISTON - Two Speed
34
2 PRESSURIZED BREATHER/FILL CAP CONTROL VALVE – Power Beyond
with FILTER:
600 kPa (0.4 bar) (6 psi) – Outlet 20 RELIEF VALVE: 20500 kPa RELIEF VALVE: 24000 kPa
35
60 kPa (0.04 bar) (0.6 psi) - Inlet (205 bar) (2973 psi) (240 bar) (3480 psi)
21 CHECK VALVE
3 HYDRAULIC FILTER ELEMENT 36 ANTI-CAVITATION VALVE (2)
15 Micron 22 ANTI-CAVITATION VALVE
4 FILTER BY-PASS: 340 kPa (3.4 bar) (50 psi) 37 CROSSPORT RELIEF VALVE:
23 CHECK VALVE (2) - With 13700 kPa (137 bar) (1987 psi)
5 PRESSURE DIFFERENTIAL SWITCH 0,58 mm (0.023 in) Orifice
38 ORIFICE: 1,5 mm (0.06 in)
6 HYDRAULIC PISTON PUMP (2) . . . . . . PORT RELIEF VALVE (With Anti-Cavitation
24
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12 CHECK VALVE - Accumulator PORT RELIEF VALVE (With Anti-Cavitation

Printed in U.S.A. V-1590legend (3-7-18)

R.H. TRAVEL MOTOR L.H. TRAVEL MOTOR

34 34

FEMALE
MALE
BOOM SWING
CYLINDER BOOM CYLINDER ARM CYLINDER
BLADE CYLINDER
38 33 33

36 44
E F C D
TRACK EXPANSION LOCK VALVE LOCK VALVE
CYLINDER (OPTIONAL) (OPTIONAL)
37
35 35

32 32 46

45
46
CP
2ND AUX FUNCTION
AUXILIARY (OPTIONAL)
HYDRAULIC BUCKET CYLINDER
COUPLER
FEMALE
42 SWIVEL
JOINT

MALE
41

25 21 21

21
21

21 24 26 27 22 28
21 20

HYDRAULIC
CONTROL VALVE 23 29
23
30

9 9 10 11

DRAIN
BLOCK
R.H. JOYSTICK
L.H. JOYSTICK
19 NOTE A
15 12
40
OIL COOLER

17 14 13 43

MANIFOLD BLOCK

16
NOTE A: Drain Line Changed HYDRAULIC SCHEMATIC
2 S/N B3BL13712 and Above
HYDRAULIC PUMP S/N AWMM13132 & Above E20 (S/N AWRH11001 AND ABOVE)
HYDRAULIC FILTER 4 Printable Version Click Here
8 HYDRAULIC 1
RESERVOIR
(PRINTED MARCH 2018)
7 7249683 (E)
6 3

39 5 43
Printed in U.S.A.
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HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols

20-10-1
MS-1892-1

E20 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

20-10-2
MS-1892-2

E20 Service Manual

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Page 101 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

20-10-3
MS-1892-3

E20 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Hydraulic Circuit

TROUBLESHOOTING THE HYDRAULIC CIRCUIT

PROBLEM CAUSE CORRECTION
No hydraulic operation at 1 or more Hydraulic oil level low. Refill with correct oil.
circuits. Hydraulic pump drive coupling damaged. Replace.
Hydraulic pump defective. Check, repair or replace.
Main relief valve defective. Readjust or replace.
Hydraulic power insufficient to 1 or Main relief valve pressure setting incorrect. Readjust or replace.
more circuits.
Hydraulic speed too slow. Hydraulic oil level or viscosity incorrect. Refill or replace.
Engine rpm reduced. Readjust or replace.
Control valve linkage defective. Check, repair or replace
Hydraulic pump volume low. Check, repair or replace.

Oil temperature too high. Oil cooler or radiator fins plugged. Clean oil cooler external
surface.
Hydraulic oil level low. Refill or replace.
Non recommended hydraulic oil Replace.
Relief valve excessively activated. Use proper operating
procedures.
One or more relief valves not set correctly. Test, readjust or replace.
Extreme operating conditions. High ambient
temperature (IE: enclosed structure).
Alternator belt loose. Tighten alternator belt.

20-10-4 E20 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Cylinder Circuit

TROUBLESHOOTING THE CYLINDER CIRCUIT

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

Control valve internal leakage excessive. Repair or replace.

20-10-5 E20 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Swing (Upperstructure Slew) Circuit

TROUBLESHOOTING THE SWING (UPPERSTRUCTURE SLEW) CIRCUIT

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

20-10-6 E20 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Travel Circuit

TROUBLESHOOTING THE TRAVEL CIRCUIT

PROBLEM CAUSE CORRECTION
Travel system inoperable. Lever linkage incorrectly adjusted. Readjust.
Track tension too tight. Readjust.
Defective pump. Check, repair or replace.
Travel motor counterbalance spool sticking. Repair or replace.
Travel motor internal leakage excessive. Repair or replace.
Travel motor defective. Repair or replace.
Travel motor gears defective. Repair or replace.
Swivel joint defective. Repair or replace.
Main relief valve pressure too low. Readjust or replace.
Travel power. Track tension too tight. Readjust.
Main relief valve pressure too low. Readjust or replace.
Travel motor counterbalance spool sticking. Repair or replace.
Speed too slow. Lever linkage incorrectly adjusted. Readjust.
Swivel joint internal leakage excessive. Repair or replace.
Control valve internal leakage excessive. Repair or replace.
Low pump pressure. Check, repair or replace.
Travel motor internal leakage excessive. Repair or replace.
Machine not running straight. Lever linkage incorrectly adjusted. Readjust.
Track tension not equal. Readjust.
Pump output not equal. Repair or replace.
Travel motor internal leakage not equal. Repair or replace.
Travel motor counterbalance spool sticking. Repair or replace.
Main relief valve pressure set too low. Repair or replace.
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Swivel joint internal leakage excessive. Repair or replace.

Control valve internal leakage not equal. Repair or replace.
Machine will not hold on slope or Travel motor counterbalance valve leakage Repair or replace.
while digging. excessive.
Hose damage. Replace.
Blade drops while machine is Lever linkage misadjusted. Readjust.
moving. Cylinder internal leakage excessive. Repair or replace.
Control valve internal leakage excessive. Repair or replace.
Swivel joint internal leakage from travel motor Repair or replace.
pressure circuit into blade cylinder circuit.

20-10-7 E20 Service Manual

20-10-8
E20 Service Manual
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CYLINDER (BOOM) Figure 20-20-3

Testing

Lower the boom / bucket and blade to the ground.

Stop the engine. Raise the control console.

2
Figure 20-20-1
3
1

P117809

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

20-3] from the rod end pivot pin.

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

P117808 Lower control console and fasten the seat belt. Start the
engine and retract the boom cylinder.

Support the boom using a chain hoist [Figure 20-20-1]. With the key in the ON position and the engine stopped,
move the hydraulic controls to release the hydraulic
Figure 20-20-2 pressure. Raise the control console.
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Figure 20-20-4

P117810

S35275
Support the boom cylinder [Figure 20-20-2].

Disconnect the boom cylinder base end hose (Item 1)

[Figure 20-20-4] at the hose tubeline connection.

20-20-1 E20 Service Manual

CYLINDER (BOOM) (CONT’D)

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 20-20-5

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S35276

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

and tighten.

Lower control console and fasten seat belt. Start the

engine and retract the boom cylinder.

If there is any leakage from the base end fitting on the

cylinder, remove the cylinder for repair or replacement.

20-20-2 E20 Service Manual

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

Removal And Installation

Lower the boom / bucket and blade to the ground. Stop

the engine.

Figure 20-20-6

P117810

Support the boom cylinder [Figure 20-20-7].

Figure 20-20-8

P117808

Support the boom using a chain hoist [Figure 20-20-6].

1
With the key in the ON position, move the hydraulic
controls to release the hydraulic pressure. 4 3
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IMPORTANT 2
When repairing hydrostatic and hydraulic systems,
P117809
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 Disconnect the rod end hose (Item 1) [Figure 20-20-8].
damage the system.
I-2003-0888 Remove the nuts (Item 2) and bolts (Item 3) [Figure 20-
20-8] from the rod end pivot pin.

Remove the pivot pin (Item 4) [Figure 20-20-8].

20-20-3 E20 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-10

Removal And Installation (Cont’d)

Figure 20-20-9 1

1
S35277

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

S35275 20-10] from the boom cylinder base end pin.

Remove the boom cylinder base end pin (Item 3) [Figure

Disconnect the base end hose (Item 1) [Figure 20-20-9] 20-20-10].
from the cylinder.
Remove the boom cylinder.

IMPORTANT WARNING

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When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Hydraulic fluid escaping under pressure can have
parts clean. Always use caps and plugs on hoses, sufficient force to enter a person’s body by
tubelines and ports to keep dirt out. Dirt can quickly penetrating the skin. This can cause serious injury
damage the system. and possible death if proper medical treatment by a
I-2003-0888 physician familiar with this injury is not received
immediately.
W-2145-0290

20-20-4 E20 Service Manual

CYLINDER (BOOM) (CONT’D)

Parts Identification

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

1
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10
5 5

8
5
7

EM5184S

20-20-5 E20 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-12

Disassembly 3
Clean the outside of the cylinder before disassembly.
2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

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

Put the base end of the cylinder in a vise. S35804

Figure 20-20-11
Remove the nut (Item 1), piston (Item 2), and head (Item
3) [Figure 20-20-12].
1
Figure 20-20-13

2 1

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S35800

Use the adjustable gland nut wrench (Item 1) [Figure 20-

20-11] to loosen the head. S35805

Remove the head and the rod assembly from the

cylinder. Put the rod end in a vise. Remove the seal (Item 1) from the piston (Item 2) [Figure
20-20-13].

20-20-6 E20 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-16

Disassembly (Cont’d)

Figure 20-20-14 2 1

2
1

S35782

Remove the wiper seal (Item 1) and rod seal (Item 2)

S35806 [Figure 20-20-16] from the inside of the head.

Remove the O-ring (Item 1) from the piston (Item 2)

[Figure 20-20-13].

Figure 20-20-15

3 2 1
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S35807

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

[Figure 20-20-15] from the head.

Remove the O-ring (Item 3) [Figure 20-20-15].

20-20-7 E20 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-18

Assembly
2
1
Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S35806

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) on the piston (Item 2) [Figure
20-20-18].
Figure 20-20-17
Figure 20-20-19

2 1

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S35783
S35805

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-17]. Install the seal (Item 1) on the piston (Item 2) [Figure 20-
20-19].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

20-20-8 E20 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-22

Assembly (Cont’d)

Figure 20-20-20

S35785

Install the rod seal in the head [Figure 20-20-22].

S35774
Figure 20-20-23

Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about
1
three minutes [Figure 20-20-20].

Figure 20-20-21
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S35782

Install the wiper seal with the wiper (Item 1) [Figure 20-
20-23] toward the outside of the head.

S35784

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

NOTE: Install the spring side of the seal toward the

inside of the cylinder.

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

20-21].

20-20-9 E20 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-26

Assembly (Cont’d)
1
Figure 20-20-24

1 2
3

S35800

Use the adjustable gland nut wrench (Item 1) [Figure 20-

S35807 20-26] to tighten the head.

Tighten the head to 373 N•m (275 ft-lb) torque.

Install the O-ring (Item 1) [Figure 20-20-24].

Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-20-24].

Figure 20-20-25

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1

2
3

S35804

Install the head (Item 1) and the piston (Item 2) [Figure

20-20-25] on the rod.

Grease the piston where the nut contacts the piston. Do

not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.

Install the nut (Item 3) [Figure 20-20-25].

Tighten the nut to 1152 N•m (850 ft-lb) torque.

Put the base end of the hydraulic cylinder in a vise.

20-20-10 E20 Service Manual

CYLINDER (ARM)

Testing WARNING
Lower the boom / bucket and blade to the ground.
Hydraulic fluid escaping under pressure can have
Stop the engine. Raise the control console. sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
Figure 20-21-1 and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

Lower control console and fasten the seat belt. Start the
engine and retract the arm cylinder.

Stop the engine. With the key in the ON position, move

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

Figure 20-21-3

P117808

Support the boom using a chain hoist [Figure 20-21-1].

Figure 20-21-2
1
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3 4
1 S35279

Disconnect the arm cylinder base end hose (Item 1)

[Figure 20-21-3].

S35278

Support the arm cylinder (Item 1) [Figure 20-21-2].

Remove the bolt (Item 2) and nuts (Item 3) [Figure 20-

21-2].

Remove the pivot pin (Item 4) [Figure 20-21-2].

20-21-1 E20 Service Manual

CYLINDER (ARM) (CONT’D)

Testing (Cont’d)

Figure 20-21-4

S35280

Install a plug (Item 1) [Figure 20-21-4] on the tubeline

and tighten.

Lower control console and fasten the seat belt. Start the
engine and retract the arm cylinder.

If there is any leakage from the base end fitting on the

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cylinder, remove the cylinder for repair or replacement.

20-21-2 E20 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-6

Removal And Installation

Lower the boom / bucket and blade to the ground. Stop 1

the engine.

Figure 20-21-5

S35787

Remove the rod end hose (Item 1) [Figure 20-21-6] from

the arm cylinder.

P117808

Support the boom using a chain hoist [Figure 20-21-5].

With the key in the ON position, move the hydraulic

controls to release the hydraulic pressure.
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20-21-3 E20 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-8

Removal And Installation (Cont’d)

Figure 20-21-7 2

1 3
2 4
1
3

S35281

Disconnect the base end hose (Item 1) [Figure 20-21-8].

S35282
Remove the bolt (Item 2) and nuts (Item 3) [Figure 20-
21-8] from the base end pivot pin.
Remove the bolt (Item 1) and nuts (Item 2) [Figure 20-
21-5] from the rod end pivot pin. Remove the base end pin (Item 4) [Figure 20-21-8].

Remove the rod end pin (Item 3) [Figure 20-21-5]. Remove the cylinder from the arm.

WARNING

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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

20-21-4 E20 Service Manual

CYLINDER (ARM) (CONT’D)

Parts Identification

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

3
2

1
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9
8 11

5
7 5

EM5183S

20-21-5 E20 Service Manual

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

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

Use the following tools to disassemble the cylinder: 1

MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins

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

Put the base end of the cylinder in a vise. S35801

Figure 20-21-9
Remove the nut (Item 1), piston (Item 2), and head (Item
3) [Figure 20-21-10].

1 Figure 20-21-11

2 1

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S35800

Use the adjustable gland nut wrench (Item 1) [Figure 20-

21-9] to loosen the head. S35802

Remove the head and the rod assembly from the

cylinder. Put the rod end in a vise. Remove the seal (Item 1) from the piston (Item 2) [Figure
20-21-11].

20-21-6 E20 Service Manual

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

Disassembly (Cont’d)

Figure 20-21-12 2
1

2 1

S35782

Remove the wiper seal (Item 1) and rod seal (Item 2)

S35803 [Figure 20-21-14] from the inside of the head.

Remove the O-ring (Item 1) from the piston (Item 2)

[Figure 20-21-12].

Figure 20-21-13

1 2 3
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S35781

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

[Figure 20-21-13] from the head.

Remove the O-ring (Item 3) [Figure 20-21-13].

20-21-7 E20 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-16

Assembly
2 1
Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S35803

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) on the piston (Item 2) [Figure
20-21-16].
Figure 20-21-15
Figure 20-21-17

2 1

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S35783
S35802

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-21-15]. Install the seal (Item 1) on the piston (Item 2) [Figure 20-
21-17].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

20-21-8 E20 Service Manual

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

Assembly (Cont’d)

Figure 20-21-18

S35785

Install the rod seal in the head [Figure 20-21-20].

S35774
Figure 20-21-21

Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about
three minutes [Figure 20-21-18].
1
Figure 20-21-19
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S35782

Install the wiper seal with the wiper (Item 1) [Figure 20-
21-21] toward the outside of the head.

S35784

Install the rod seal on the rod seal tool [Figure 20-21-19].

NOTE: Install the spring side of the seal toward the

inside of the cylinder.

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

21-19].

20-21-9 E20 Service Manual

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

Assembly (Cont’d)

Figure 20-21-22 1

3 2 1

S35800

Use the adjustable gland nut wrench (Item 1) [Figure 20-

S35781 21-24] to tighten the head.

Tighten the head to 312 N•m (230 ft-lb) torque.

Install the O-ring (Item 1) [Figure 20-21-22].

Install the seal (Item 2) and O-ring (Item 3) [Figure 20-

21-22].

Figure 20-21-23

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1

S35801

Install the head (Item 1) and the piston (Item 2) [Figure

20-21-23] on the rod.

Grease the piston where the nut contacts the piston. Do

not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.

Install the nut (Item 3) [Figure 20-21-23].

Tighten the nut to 1152 N•m (850 ft-lb) torque.

Put the base end of the hydraulic cylinder in a vise.

20-21-10 E20 Service Manual

CYLINDER (BOOM SWING) Figure 20-22-3

Testing

Swing boom to the right side.

Lower the boom / bucket and blade to the ground.

1
Stop the engine. Raise the control console.

Figure 20-22-1

P117818

Remove the rod end hose (Item 1) [Figure 20-22-3].

2 1
Figure 20-22-4

P117817
2

Remove the nuts (Item 1) and bolt (Item 2) from the rod
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end pivot pin (Item 3) [Figure 20-22-1].

Remove the pivot pin.

Figure 20-22-2
1
P117819

Install a plug (Item 1) [Figure 20-22-4] on the hose and

tighten.

Lower control console and fasten the seat belt. Start the
engine and extend the cylinder.

If there is any leakage from the rod end fitting (Item 2)

[Figure 20-22-4] on the cylinder, remove the cylinder for
repair or replacement.

P117820

Lower the control console and fasten the seat belt. Start
the engine and extend the swing cylinder [Figure 20-22-
2].

Stop the engine. With the key in the ON position, move

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

20-22-1 E20 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-5

Removal And Installation

P117722

WARNING Swing the upperstructure [Figure 20-22-5] so the pin in

the base end of the cylinder is clear of the track frame.

Hydraulic fluid escaping under pressure can have Offset the boom slightly for additional working space.
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury Lower the boom / bucket and blade to the ground. Stop
and possible death if proper medical treatment by a the engine.
physician familiar with this injury is not received
immediately. Remove the floor mat and floor panels. (See Removal
W-2145-0290
And Installation on Page 40-140-1.)

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Figure 20-22-6

WARNING
3
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
1
2

P117817

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

22-6] from the pivot pin.

Remove the pivot pin (Item 3) [Figure 20-22-6].

Lower the control console and fasten the seat belt.

20-22-2 E20 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-9

Removal And Installation (Cont’d)

Figure 20-22-7

P117710

Remove the hose (Item 1) [Figure 20-22-9] from the rod

P117715 end of the cylinder.

Figure 20-22-10
Start the excavator and fully retract the cylinder [Figure
20-22-7].

Stop the engine.

2
Figure 20-22-8
1
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2
1

P117712

Remove the base end hydraulic hose (Item 1) [Figure

20-22-10].

P117704 Remove the grease hose (Item 2) [Figure 20-22-10].

Slide the cylinder out the front of the excavator frame.

Remove the base end pin bolt and nuts (Item 1) [Figure
20-22-8].

Remove the pivot pin (Item 2) [Figure 20-22-8].

Slide the boom swing cylinder forward.

20-22-3 E20 Service Manual

CYLINDER (BOOM SWING) (CONT’D)

Parts Identification

1. Grease Fitting
2. Rod
3. Wiper
4. Rod Seal
5. Head
6. O-ring
7. Back-up Ring
8. Piston Seal
6
9. Piston 7
10. Nut
6
11. Plug
12. Tube 5

4
3

2
1

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11
6

11 6

6
8
10

NA9365S

20-22-4 E20 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-13

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

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

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

Put the base end of the cylinder in a vise.

S35779

Figure 20-22-11
Remove the seal (Item 1) from the piston (Item 2) [Figure
20-22-13].
1
Figure 20-22-14

1
2
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P-22350

Use the adjustable gland nut wrench to loosen the head

(Item 1) [Figure 20-22-11].
S35780
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
Remove the O-ring (Item 1) from the piston (Item 2)
Figure 20-22-12 [Figure 20-22-14].

3
2
1

P-22365

Remove the nut (Item 1), piston (Item 2), and head (Item
3) [Figure 20-22-12].

20-22-5 E20 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-17

Disassembly (Cont’d)

Figure 20-22-15

3
2 2
1
1

P-22364

Remove plug (Item 1) and O-ring (Item 2) [Figure 20-22-

P-22356 17].

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

[Figure 20-22-15].

Remove the O-ring (Item 3) [Figure 20-22-15].

Figure 20-22-16

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3

2
1

P-22357

Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-22-16].

20-22-6 E20 Service Manual

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

Assembly
1
Use the following tools to assemble the cylinder:
2
MEL1396 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S35780

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) on the piston (Item 2) [Figure
20-22-19].
Figure 20-22-18
Figure 20-22-20

2 1
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P-7424
S35779

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-22-18]. Install the seal (Item 1) on the piston (Item 2) [Figure 20-
22-20].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

20-22-7 E20 Service Manual

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

Assembly (Cont’d)

Figure 20-22-21

P-7425

Install the rod seal in the head [Figure 20-22-23].

P-22358
Figure 20-22-24

Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about
three minutes [Figure 20-22-21].

Figure 20-22-22

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1

P-22359

Install the wiper seal with the wiper (Item 1) [Figure 20-
22-24] toward the outside of the head.

P-7427

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

NOTE: Install the spring side of the seal toward the

inside of the cylinder.

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

22-22].

20-22-8 E20 Service Manual

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

Assembly (Cont’d)

Figure 20-22-25

1
2 1
3
2

P-22364

Install O-ring (Item 1) and plug (Item 2) [Figure 20-22-

P-22356 27].

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

Install the O-ring (Item 1) [Figure 20-22-25].
Put the base end of the hydraulic cylinder in a vise.
Install the back-up ring (Item 2) and O-ring (Item 3)
[Figure 20-22-25]. Figure 20-22-28

Figure 20-22-26

1
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1
2
3

P-22350

P-22365
Use the adjustable gland nut wrench to tighten the head
(Item 1) [Figure 20-22-28].
Install the head (Item 1) and the piston (Item 2) [Figure
20-22-26] on the rod. Tighten the head to 312 N•m (230 ft-lb) torque.

Grease the piston where the nut contacts the piston. Do

not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.

Install the nut (Item 3) [Figure 20-22-26].

Tighten the nut to 407 N•m (300 ft-lb) torque.

20-22-9 E20 Service Manual

20-22-10
E20 Service Manual
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CYLINDER (BUCKET) Figure 20-23-3

Testing

Figure 20-23-1

S35286

Lower control console and fasten the seat belt. Start the
P117808 engine and retract the bucket cylinder [Figure 20-23-3].

Stop the engine. With the key in the ON position, move

Lower the boom / bucket and blade to the ground [Figure the hydraulic controls to release the hydraulic pressure.
20-23-1]. Raise the control console.

Stop the engine. Raise the control console.

Support the boom using a chain hoist [Figure 20-23-1]. WARNING

Figure 20-23-2
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.
1 W-2145-0290

S35285

Remove the retaining pin (Item 1) and washers (Item 2)

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

Remove the pivot pin (Item 3) [Figure 20-23-2].

20-23-1 E20 Service Manual

CYLINDER (BUCKET) (CONT’D)

Testing (Cont’d)

Figure 20-23-4

S35786

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

and install a plug on the hose fitting and tighten.

Lower control console and fasten the seat belt. Start the
engine and retract the bucket cylinder.

If there is any leakage from the base end fitting on the

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cylinder, remove the cylinder for repair or replacement.

20-23-2 E20 Service Manual

CYLINDER (BUCKET) (CONT’D) Remove the two snap rings (Item 1) and two washers
(Item 2) [Figure 20-23-6].
Removal And Installation
Remove the bucket link (Item 3) [Figure 20-23-6].
Lower the boom / bucket and blade to the ground. Stop
the engine. Remove the bucket link pins (Item 1) [Figure 20-23-6].

Support the boom using a chain hoist. Remove the cylinder.

With the key in the ON position, move the hydraulic

controls to release the hydraulic pressure.

Figure 20-23-5 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,
3 1 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
2 I-2003-0888

WARNING
Hydraulic fluid escaping under pressure can have
1 sufficient force to enter a person’s body by
S35287
penetrating the skin. This can cause serious injury
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and possible death if proper medical treatment by a

Remove the two hoses (Item 1) [Figure 20-23-5] from physician familiar with this injury is not received
the bucket cylinder. immediately.
W-2145-0290
Remove the hose clamp (Item 2) [Figure 20-23-5] on the
side of the cylinder.

Remove the bolt and nuts (Item 3) [Figure 20-23-5] from

the base end pin. WARNING
Remove the base end pin and lower the base end to the
floor. AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Figure 20-23-6 sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
1
2 W-2103-0508
1

S7901

20-23-3 E20 Service Manual

CYLINDER (BUCKET) (CONT’D)

Parts Identification

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

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10

11
9

8
5
5
7

EM5185SE

20-23-4 E20 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-8

Disassembly 3

Clean the outside of the cylinder before disassembly.

2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins

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

Put the base end of the cylinder in a vise. S35778

Figure 20-23-7
Remove the nut (Item 1), piston (Item 2), and head (Item
3) [Figure 20-23-8].

Figure 20-23-9

1 2 1
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S35777

Use the adjustable gland nut wrench (Item 1) [Figure 20-

23-7] to loosen the head. S35779

Remove the head and the rod assembly from the

cylinder. Put the rod end in a vise. Remove the seal (Item 1) from the piston (Item 2) [Figure
20-23-9].

20-23-5 E20 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-12

Disassembly (Cont’d)

Figure 20-23-10 2
1

2 1

S35782

Remove the wiper seal (Item 1) and rod seal (Item 2)

S35780 from the inside of the head [Figure 20-23-12].

Remove the O-ring (Item 1) from the piston (Item 2)

[Figure 20-23-10].

Figure 20-23-11

1 2 3

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S35781

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

[Figure 20-23-11] from the groove in the head.

Remove the O-ring (Item 3) [Figure 20-23-11].

20-23-6 E20 Service Manual

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

Assembly

Use the following tools to assemble the cylinder: 2 1

MEL1396 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S35780

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) on the piston (Item 2) [Figure
20-23-14].
Figure 20-23-13
Figure 20-23-15

2 1
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S35783
S35779

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-23-13]. Install the seal (Item 1) on the piston (Item 2) [Figure 20-
23-15].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

20-23-7 E20 Service Manual

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

Assembly (Cont’d)

Figure 20-23-16

S35785

Install the rod seal in the head [Figure 20-23-18].

S35774
Figure 20-23-19

Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about
three minutes [Figure 20-23-16].
1
Figure 20-23-17

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S35782

Install the wiper seal with the wiper (Item 1) [Figure 20-
23-19] toward the outside of the head.

S35784

Install the rod seal on the rod seal tool [Figure 20-23-17].

NOTE: Install the spring side of the seal toward the

inside of the cylinder.

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

23-17].

20-23-8 E20 Service Manual

CYLINDER (BUCKET) (CONT’D) Tighten the nut to 1152 N•m (850 ft-lb) torque.

Assembly (Cont’d) Put the base end of the hydraulic cylinder in a vise.

Figure 20-23-20 Be careful no to damage the cylinder tube.

Figure 20-23-22
2 1

S35781

S35777
Install the O-ring (Item 1) [Figure 20-23-20].

Install the back-up ring (Item 2) and O-ring (Item 3) Use the adjustable gland nut wrench (Item 1) [Figure 20-
[Figure 20-23-20]. 23-22] to tighten the head.

Figure 20-23-21 Tighten the nut to 271 N•m (200 ft-lb) torque.
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S35778

Install the head (Item 1) and the piston (Item 2) [Figure

20-23-21] on the rod.

Grease the piston where the nut contacts the piston. Do

not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.

Install the nut (Item 3) [Figure 20-23-21].

20-23-9 E20 Service Manual

20-23-10
E20 Service Manual
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CYLINDER (BLADE) Figure 20-24-2

Testing

Swing the upperstructure out of the way. Lower the boom

/ bucket to the ground. Raise the blade up until it stops.

Stop the engine.

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

1
the blade control to release the hydraulic pressure. Raise
the control console.

Figure 20-24-1

S35290
2

Remove the base end hose (Item 1) [Figure 20-24-2].

Figure 20-24-3
1

1
S35289
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2
Remove the two nuts (Item 1) [Figure 20-24-1] from the
shield.

Remove the blade cylinder shield (Item 2) [Figure 20-24-

1] from the blade cylinder. S35291

Install a plug (Item 1) [Figure 20-24-3] on the hose fitting

WARNING and tighten.

Lower control console. Start the engine and retract the

Hydraulic fluid escaping under pressure can have blade cylinder.
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury If there is any leakage from the base end fitting (Item 2)
and possible death if proper medical treatment by a [Figure 20-24-3] on the cylinder, remove the cylinder for
physician familiar with this injury is not received repair or replacement.
immediately.
W-2145-0290

20-24-1 E20 Service Manual

CYLINDER (BLADE) (CONT’D)

Removal And Installation

IMPORTANT
Lower the boom / bucket and blade to the ground. Stop
the engine. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Support the blade. With the key in the ON position, move parts clean. Always use caps and plugs on hoses,
the blade control to release the hydraulic pressure. Raise tubelines and ports to keep dirt out. Dirt can quickly
the control console. damage the system.
I-2003-0888
Figure 20-24-4
Figure 20-24-6

1
1

2
P117734

P117737

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Remove the two nuts (Item 1) [Figure 20-24-4] from the
shield. Remove the snap ring and washer (Item 1) [Figure 20-
24-6] (Both sides) from the base end pivot pin.
Remove the blade cylinder shield (Item 2) [Figure 20-24-
4] from the blade cylinder. Remove the base end pivot pin (Item 2) [Figure 20-24-6].

Figure 20-24-5

P117735

Remove the blade cylinder hoses (Item 1) [Figure 20-24-

5].

20-24-2 E20 Service Manual

CYLINDER (BLADE) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-24-7

P117736

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

24-7] (Both sides) from the cylinder rod end.

Remove the cylinder rod end pivot pin (Item 2) [Figure

20-24-7].

Remove the blade cylinder.

20-24-3 E20 Service Manual

CYLINDER (BLADE) (CONT’D)

Parts Identification

1. Rod
2. Wiper
3. Rod Seal
4. Head
5. O-ring
6. Back-up Ring
7. Piston Seal
8. Piston
9. Nut 5
10. Plug 6
11. Tube 5

3
2

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11
10
5
5

8 10

5
7

EM5186S

20-24-4 E20 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-9

Disassembly
3
Clean the outside of the cylinder before disassembly.
2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins

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

Put the base end of the cylinder in a vise. S35768

Figure 20-24-8
Remove the nut (Item 1), piston (Item 2), and head (Item
3) [Figure 20-24-9].

Figure 20-24-10
1
1
2
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S35767

Use the adjustable gland nut wrench (Item 1) [Figure 20-

24-8] to loosen the head. S35769

Remove the head and the rod assembly from the

cylinder. Put the rod end in a vise. Remove the seal (Item 1) from the piston (Item 2) [Figure
20-24-10].

20-24-5 E20 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-13

Disassembly (Cont’d)

Figure 20-24-11
2 1

1
2

S35772

Remove the wiper seal (Item 1) and rod seal (Item 2)

S35770
from the inside of the head [Figure 20-24-13].

Remove the O-ring (Item 1) from the piston (Item 2)

[Figure 20-24-11].

Figure 20-24-12

1 2 3

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S35771

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

[Figure 20-24-12] from the cylinder head.

Remove the O-ring (Item 3) [Figure 20-24-12].

20-24-6 E20 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-15

Assembly
1
2
Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S35770

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) on the piston (Item 2) [Figure
20-24-15].
Figure 20-24-14
Figure 20-24-16

1
2
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S35773
S35769

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-24-14]. Install the seal (Item 1) on the piston (Item 2) [Figure 20-
24-16].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

20-24-7 E20 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-19

Assembly (Cont’d)

Figure 20-24-17

S35776

Install the rod seal in the head [Figure 20-24-19].

S35774
Figure 20-24-20
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
three minutes [Figure 20-24-17].
1
Figure 20-24-18

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S35772

Install the wiper seal with the wiper (Item 1) [Figure 20-
24-20] toward the outside of the head.

S35775

Install the rod seal on the rod seal tool [Figure 20-24-18].

NOTE: Install the spring side of the seal toward the

inside of the cylinder.

Rotate the handles to collapse the rod seal.

20-24-8 E20 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-23

Assembly (Cont’d)

Figure 20-24-21
1
3 2 1

S35767

Use the adjustable gland nut wrench (Item 1) [Figure 20-

S35771
24-23] to tighten the head.

Tighten the head to 312 N•m (230 ft-lb) torque.

Install the O-ring (Item 1) [Figure 20-24-21].

Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-24-21].

Figure 20-24-22
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S35768

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

24-22] on the rod.

Grease the piston where the nut contacts the piston. Do

not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.

Install the nut (Item 3) [Figure 20-24-22].

Tighten the nut to 813 N•m (600 ft-lb) torque.

Put the base end of the hydraulic cylinder in a vise.

20-24-9 E20 Service Manual

20-24-10
E20 Service Manual
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CYLINDER (TRACK FRAME EXPANSION) Figure 20-25-3

Testing

Retract the track frame fully.

Figure 20-25-1

S35939

Remove the hose (Item 1) [Figure 20-25-3] from the

cylinder base end.

P117813

Place blocks under the excavator tracks. Lower the

WARNING
bucket and the blade to the ground [Figure 20-25-1].
Hydraulic fluid escaping under pressure can have
Stop the engine. Raise the control console. 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
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Figure 20-25-2
physician familiar with this injury is not received
immediately.
W-2145-0290

Figure 20-25-4

P118716

Remove the four bolts (Item 1) [Figure 20-25-2] and 1

remove the cover.
S6069

Install a plug (Item 1) [Figure 20-25-4] on the hose fitting

and tighten.

Lower control console and fasten the seat belt. Start the
engine and retract the expansion cylinder.

20-25-1 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-7

Testing (Cont’d)

If there is any leakage from the base end fitting on the

expansion cylinder, remove the cylinder for repair or
replacement.

Removal And Installation

Expand the track frame fully.

Figure 20-25-5 1

P118714

Remove the hose (Item 1) [Figure 20-25-7] from the rod

end.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
P117813
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,

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tubelines and ports to keep dirt out. Dirt can quickly
Place blocks under the excavator tracks for increased damage the system.
access to the expansion cylinder [Figure 20-25-5]. I-2003-0888

Figure 20-25-6

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

P118716

Remove the four bolts (Item 1) [Figure 20-25-6] and

remove the cover.

20-25-2 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-10

Removal And Installation (Cont’d)

1
Figure 20-25-8

S35940

Install a hose (Item 1) [Figure 20-25-10] on the cylinder

S6071 base end. Place the other end of the hose in a drain pan.

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

Figure 20-25-9

1
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S6074

Remove the three nuts (Item 1) [Figure 20-25-11] from

S35939 the rod end of the cylinder.

Installation: Tighten the nuts to 43 - 47 N•m (32 - 35 ft-

Remove the hose (Item 1) [Figure 20-25-9] from the lb) torque.
cylinder base end.

20-25-3 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-14

Removal And Installation (Cont’d)

Figure 20-25-12

1
S6079

Pull the cylinder out of the mount. Remove the two plates
S6075 (Item 1) [Figure 20-25-14] from the base end of the
cylinder.

Slightly compress the cylinder. Remove the two plates

(Item 1) [Figure 20-25-12] from the rod end of the
cylinder.

Figure 20-25-13

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1

1
S6078

Remove the three nuts (Item 1) [Figure 20-25-13] from

the base end of the cylinder.

Installation: Tighten the nuts to 43 - 47 N•m (32 - 35 ft-

lb) torque.

20-25-4 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D)

Removal And Installation (Cont’d)

Compress the cylinder.

Rotate the cylinder until the hose clamp is accessible.

Figure 20-25-15

P118715

Remove the bolt (Item 1) [Figure 20-25-15].

Remove the cylinder.

20-25-5 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D)

Parts Identification

1. Tube
2. Plug
3. O-ring
4. Nut
5. Piston
6. Piston Seal
7. Back-Up Ring 1
8. Head
9. Rod Seal
10. Wiper
11. Rod

4
5
3
3
6

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2

3
7
3

8
9
10

EM1920S

20-25-6 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-17

Disassembly
3
Clean the outside of the cylinder before disassembly. 2
1
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

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

Put the base end of the cylinder in a vise. N-22416

Figure 20-25-16
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-25-17].

Figure 20-25-18

2
1
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1
N-22440

Use the adjustable gland nut wrench to loosen the head

(Item 1) [Figure 20-25-16]. N-22418

Remove the head and the rod assembly from the

cylinder. Put the rod end in a vise. Remove the seal (Item 1) and O-ring (Item 2) from the
piston (Item 3) [Figure 20-25-18].

20-25-7 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-21

Disassembly (Cont’d)

Figure 20-25-19

3
2
1 2

N-22364

Remove plug (Item 1) and O-ring (Item 2) [Figure 20-25-

N-22356 21].

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

[Figure 20-25-19] from the head.

Remove the O-ring (Item 3) [Figure 20-25-19].

Figure 20-25-20

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3

2
1

N-22357

Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-25-20].

20-25-8 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-23

Assembly
3
Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander 1

MEL1033 - Rod Seal Installation Tool 2
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. N-22418

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-25-23].
Figure 20-25-22
Figure 20-25-24
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P-07424
N-22358

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-25-22]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it three minutes [Figure 20-25-24].
on the piston.

20-25-9 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-27

Assembly (Cont’d)

Figure 20-25-25

N-22359

Install the wiper seal with the wiper (Item 1) [Figure 20-
P-07427 25-27] toward the outside of the head.

Figure 20-25-28
Install the rod seal on the rod seal tool [Figure 20-25-25].

NOTE: Install the spring side of the seal toward the

inside of the cylinder.
1
Rotate the handles to collapse the rod seal.
3 2

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Figure 20-25-26

N-22356

Install the O-ring (Item 1) [Figure 20-25-28].

Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-25-28].

P-07425

Install the rod seal in the head [Figure 20-25-26].

20-25-10 E20 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-30

Assembly (Cont’d)

Figure 20-25-29

1
2
3
1

N-22364

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

N-22416 25-30].

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

Install the head (Item 1) and the piston (Item 2) [Figure
20-25-29] on the rod. Put the base end of the hydraulic cylinder in a vise.

Grease the piston where the nut contacts the piston. Do Figure 20-25-31
not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.
1
Install the nut (Item 3) [Figure 20-25-29].

Tighten the nut to 190 N•m (140 ft-lb) torque.

N-22440

Use the adjustable gland nut wrench to tighten the head

(Item 1) [Figure 20-25-31].

Tighten the plug to 183 N•m (135 ft-lb) torque.

20-25-11 E20 Service Manual

20-25-12
E20 Service Manual
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VALVE (MAIN RELIEF)

Description

Figure 20-30-1

3
P117701

There are three diagnostic couplers on the manifold. Port

PS1 (Item 1) is used to test pilot pressure. Port G (Item 2)
is used to test main relief valves. Port F (Item 3) [Figure
20-30-1] is used in the assembly of the machine.

There are two main reliefs used in the hydraulic system.

One main relief is located in the manifold and is set at

23097 kPa (230,9 bar) (3350 psi) with a range of 22601
kPa - 236601 kPa (227 - 237 bar) (3278 - 3423 psi).

One main relief is located on the hydraulic control valve

at the slew valve section and is set to 20594,6 kPa (206
bar) (2987 psi).

20-30-1 E20 Service Manual

VALVE (MAIN RELIEF) (CONT’D)

Description (Cont’d)

System Pressure At Gauge Port Specifications

   
SYSTEM CHECK FUNCTION TO CIRCUIT TEST TARGET ACCEPTABLE RANGE
ENGAGE PRESSURIZED PORT
JOYSTICK PILOT ANY JOYSTICK JOYSTICK PILOT PS1 3100 kPa 3000 - 3300 kPa
PRESSURE FUNCTION 31 bar 30 - 33 bar
450 psi 436 - 479 psi
SYSTEM BY - PASS NONE - CONSOLE UP DUMP TO TANK G 600 kPa MAX ALLOWABLE 1200
6 bar kPa
87 psi MAX ALLOWABLE 12 bar
MAX ALLOWABLE 168 psi
MAIN RELIEF ON BOOM P2 G 23100 kPa 22400 - 23800 kPa
MANIFOLD BLOCK 231 bar 224 - 238 bar
3350 psi 3248 - 3451 psi
MAIN RELIEF ON ARM P1 and P2 G 22600 kPa 21900 - 23300 kPa
MANIFOLD BLOCK 226 bar 219 - 233 bar
3277 psi 3176 - 3379 psi
MAIN RELIEF ON BLADE P3 G 20600 kPa 20100 - 21100 kPa
MANIFOLD BLOCK 206 bar 201 - 211 bar
2987 psi 2914 - 3060 psi
SWING MOTOR - CROSS SLEW RIGHT P3 G 16900 kPa 16200 - 17600 kPa
PORT RELIEF 169 bar 162 - 176 bar
2451 psi 2349 - 2552 psi

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SWING MOTOR - CROSS SLEW LEFT P3 G 16900 kPa 16200 - 17600 kPa
PORT RELIEF 169 bar 162 - 176 bar
2451 psi 2349 - 2552 psi

20-30-2 E20 Service Manual

VALVE (MAIN RELIEF) (CONT’D) Figure 20-30-2

Test Conditions

Turn the machine 90° counterclockwise to locate the

control valve between the tracks.

Lower the boom / bucket and blade to the ground.

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-60-1.)
1
1. Engine High Idle Speed

2. Warm oil over relief function to minimum 66°C

(150°F). Cycle all functions during warm-up P117730
procedure. Warm oil until the pressure build-up valve
stabilizes near its target pressure.
Connect a 34,500 kPa (345 bar) (5000 psi) gauge (Item
3. Activate function until cylinder movement stops. Hold 1) [Figure 20-30-2] on the G diagnostic port.
over relief 5 - 10 Seconds.
Lower the control console and fasten the seat belt.
Testing And Adjusting Main Relief At Manifold
Start the engine and run at low rpm until hydraulic fluid is
All testing is done with the hydraulic fluid at operating at operating temperatures 66°C (150°F).
temperature and the engine at high idle speed. (See
Engine on Page SPEC-10-6. With the hydraulic fluid at operating temperature, run
engine at full rpm.
The following tools will be needed for the testing at the
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diagnostic coupler: Operate the following circuit over relief and record the
pressure.
MEL1355 - Test Kit includes the following:
MEL1355-3 - 34,500 kPa (345 bar) (5000 psi) Gauge The main relief valve pressure at “G” diagnostic port
MEL1355-12 Coupler [Figure 20-30-2] should be as follows:
MEL1355-9 Thermometer
Boom up:

22600 - 23600 kPa (226 - 236 bar) (3278 - 3423 psi).

20-30-3 E20 Service Manual

VALVE (MAIN RELIEF) (CONT’D)

Testing And Adjusting Main Relief at Manifold

(Cont’d)

Figure 20-30-3

P117728

If adjustment is needed, remove the protective cap (Item

1) [Figure 20-30-3].

Figure 20-30-4

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1

P117729

Loosen the nut (Item 1) and turn the adjustment bolt

(Item 2) [Figure 20-30-4] clockwise to increase the
pressure or counterclockwise to decrease the pressure.

Tighten the nut (Item 1) [Figure 20-30-4].

Retest the main relief valve after adjustment.

20-30-4 E20 Service Manual

VALVE (MAIN RELIEF) (CONT’D) Figure 20-30-6

Testing And Adjusting Main Relief at Hydraulic

Control Valve

Lower the control console and fasten the seat belt.

Start the engine and run at low rpm until hydraulic fluid is
2
at operating temperatures 66°C (150°F). 1

With the hydraulic fluid at operating temperature, run

engine at full rpm.

Operate the following circuit over relief and record the

pressure.
P118796
The main relief valve pressure at “G” diagnostic port
[Figure 20-30-2] should be as follows:
Turn the adjustment screw (Item 1) [Figure 20-30-6]
Blade up: clockwise to increase the pressure or counterclockwise
to decrease the pressure.
20100 - 21100 kPa (201 - 211 bar) (29141 - 3060 psi)
Tighten the nut (Item 2) [Figure 20-30-6].
Figure 20-30-5
Retest the main relief valve after adjustment.
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P118795

If adjustment is needed, loosen the nut (Item 1) [Figure

20-30-5].

20-30-5 E20 Service Manual

20-30-6
E20 Service Manual
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VALVE (PORT RELIEF) NOTE: The reliefs are located below the spool covers
on the valve sections.
Testing And Adjusting
A portable hydraulic hand pump will be used to test the
Turn the machine 90° counterclockwise to locate the work port relief valves. The hand pump must have clean
control valve between the tracks. Bobcat hydraulic fluid.

Lower boom / bucket and the blade to the ground. Turn the machine 90° counterclockwise to locate the
control valve between the tracks.
Remove the left upperstructure cover. (See Removal And
Installation on Page 40-60-1.) Lower the boom / bucket and blade to the ground.

Figure 20-31-1 Remove the upperstructure cover. (See Removal And

Installation on Page 40-60-1.)

6 4
1 Remove floor mats and floor panels. (See Removal And
Installation on Page 40-140-1.)

5 3 2 P118407
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Boom Port Relief set at:

Rod End (Item 1) [Figure 20-31-1] 25000 kPa

(250 bar)
(3625 psi)
Base End (Item 2) [Figure 20-31-1] 21001 kPa
(210 bar)
(3046 psi)

Bucket Port Relief set at:

Rod End (Item 3) [Figure 20-31-1] 25000 kPa
(250 bar)
(3625 psi)
Base End (Item 4) [Figure 20-31-1] 25000 kPa
(250 bar)
(3625 psi)

Arm Port Relief set at:

Rod End (Item 5) [Figure 20-31-1] 25000 kPa
(250 bar)
(3625 psi)
Base End (Item 6) [Figure 20-31-1] 25000 kPa
(250 bar)
(3625 psi)

20-31-1 E20 Service Manual

VALVE (PORT RELIEF) (CONT’D)

Testing And Adjusting (Cont’d)

Figure 20-31-2

P117745

Install the hand pump hose and a pressure gauge

(minimum of 34474 kPa (345 bar) (5000 psi), into the
valve section work port in which the port relief valve is
located [Figure 20-31-2]. Slowly pressurize this section
with the hand pump until the port relief valve opens and
make a note of the pressure reading.

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NOTE: Pumping the hand pump too fast will alter the
pressure readings up to 345 kPa (3,4 bar) (50
psi).

If the port relief pressure setting is incorrect, replace the

port relief valve.

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

20-31-2 E20 Service Manual

VALVE (CROSS PORT RELIEF)

Testing

The following tools will be needed for the testing at the

diagnostic coupler:

MEL1355 - Test Kit includes the following:

MEL1355-3 - 5000 psi Gauge
MEL1355-12 - Coupler
MEL1355-9 - Thermometer

TEST CONDITIONS

1. Engine High Idle Speed

2. Warm fluid over relief function to minimum 66°C

(150°F). Cycle all functions during warm-up
procedure. Warm fluid until the pressure build-up
valve stabilizes near its target pressure.

3. Activate function until cylinder movement stops. Hold

over relief for 5 - 10 seconds. Record pressure.

System Pressures At Gauge Port Specifications

FUNCTION TO CIRCUIT TEST TARGET ACCEPTABLE

SYSTEM CHECK ENGAGE PRESSURIZED PORT kPa (bar) RANGE kPa (bar)
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(psi) (psi)
SWING MOTOR - CROSS PORT SLEW RIGHT P3 G 16900 16200 - 17600
RELIEF (169) (162 - 176)
(2451) (2349 - 2552)
SWING MOTOR - CROSS PORT SLEW LEFT P3 G 16900 16200 - 17600
RELIEF (169) (162 - 176)
(2451) (2349 - 2552)

20-32-1 E20 Service Manual

VALVE (CROSS PORT RELIEF) (CONT’D) Figure 20-32-3

Testing (Cont’d)

Remove the left upperstructure cover panel. (See

Removal And Installation on Page 40-60-1.) 1

Figure 20-32-1

P118938

1
Install a plug and cap (Item 1) [Figure 20-32-3] on the
hose and the fitting.

Lower the control console and fasten the seat belt.

P117730
Start the engine and run at full rpm until hydraulic fluid is
at operating temperatures 66°C (150°F).
Connect the test gauge coupler and 34,5 MPa (345 bar)
(5000 psi) gauge to the diagnostic coupler (Item 1) Engage the upperstructure slew right function. 
[Figure 20-32-1] at the G port. Record the pressure on the gauge.

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Remove the floor mats and floor panels. (See Removal Engage the upperstructure slew left function. 
And Installation on Page 40-140-1.) Record the pressure on the gauge.

Figure 20-32-2 The crossport relief valve pressure should be as follows:

A target pressure of 16900 kPa (169 bar) (2451 psi) with

an acceptable range of 16200 - 17600 kPa (162 - 176
bar) (2349 - 2552 psi).

Stop the engine.

C118937

Disconnect the pilot hose for the swing brake (Item 1)

[Figure 20-32-2] to the swing motor.

NOTE: This will keep the swing brake disc engaged

when the swing function is activated.

20-32-2 E20 Service Manual

VALVE (CROSS PORT RELIEF) (CONT’D) Removal And Installation

Testing (Cont’d) Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Oil on Page 10-120-3.)
Figure 20-32-4
Remove the floor mat and floor panels. (See Removal
And Installation on Page 40-140-1.)

Figure 20-32-6
1

P118939

If the crossport relief valve (Item 1) [Figure 20-32-4]

does not meet specifications, remove, clean and inspect
P118800
the valve. Reinstall the valve and retest. If the valve still
does not meet specifications, adjust the crossport relief
valve. Mark and remove the crossport relief valves (Item 1)
[Figure 20-32-6].
Figure 20-32-5
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P118940

Loosen the jam nut (Item 1) and turn the adjusting screw
(Item 2) clockwise to increase pressure and
counterclockwise to reduce pressure.

1/4 turn equals 100 psi change in pressure.

20-32-3 E20 Service Manual

20-32-4
E20 Service Manual
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VALVE (PRESSURE REDUCING) Figure 20-33-2

Testing And Adjusting

The following tools will be needed for testing the pressure

reducing valve:

MEL1355 - Test Kit includes the following:

MEL1355-2 - 1000 psi Gauge 1
MEL1355-9 - Thermometer
2
Remove the left upperstructure cover. (See Removal And
Installation on Page 40-60-1.)

Figure 20-33-1
P118085
1

If adjustment is needed, loosen the nut (Item 1) [Figure

20-33-2].

Turn the adjustment screw (Item 2) [Figure 20-33-2]

clockwise to increase the pressure or counterclockwise
to decrease the pressure.

Tighten the nut (Item 1) [Figure 20-33-2].

Retest the pressure reducing valve after adjustment.

P117732

Locate the test port (PS1) on the manifold and install a

6895 kPa (69 bar) (1000 psi) gauge (Item 1) [Figure 20-
33-1] on the test port (PS1).

Lower control console and fasten seat belt.

Start the engine and warm the hydraulic fluid to operating

temperatures 66°C (150°F).

With the hydraulic fluid at operating temperature, run

engine at full rpm.

Operate the circuit over relief and record the pressure.

The pressure reducing valve pressure at the test port

(PS1) should be as follows:

3000 - 3300 kPa (30 - 33 bar) (436 - 479 psi)

Stop the engine.

20-33-1 E20 Service Manual

VALVE (PRESSURE REDUCING) (CONT’D)

Testing And Adjusting (Cont’d)

If pressure is still incorrect, remove the pressure reducing

valve from the manifold assembly and inspect.

Inspect the port of the pressure reducing valve on the

manifold assembly to verify no damage. If damaged
replace manifold assembly.

Figure 20-33-3

P117724

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Inspect the O-rings and back-up rings on the pressure
reducing valve (Item 1). If O-rings and back-up rings are
worn or damaged, replace O-rings and back-up rings
[Figure 20-33-3].

Install the pressure reducing valve in the manifold

assembly.

Repeat pressure reducing valve test.

If the O-rings and back-up rings were not worn or

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

20-33-2 E20 Service Manual

HYDRAULIC CONTROL VALVE

Description WARNING
The hydraulic control valve is a nine section open center
system and has 24994 kPa (250 bar) (3625 psi) work Hydraulic fluid escaping under pressure can have
port relief valves for the bucket, arm, and boom (rod end) sufficient force to enter a person’s body by
sections. The hydraulic control valve has 20995 kPa (210 penetrating the skin. This can cause serious injury
bar) (3045 psi) work port relief valve for the boom (base and possible death if proper medical treatment by a
end) section. physician familiar with this injury is not received
immediately.
Removal And Installation W-2145-0290

Turn the machine counterclockwise 90° for access to the

Figure 20-40-1
bottom of the valve.

Lower the boom / bucket and blade to the ground.

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

IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, P117726
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tubelines and ports to keep dirt out. Dirt can quickly

damage the system.
I-2003-0888 Remove the three bolts and the lower plate (Item 1)
[Figure 20-40-1] under the valve.
Remove the cab. (See Removal And Installation on Page
40-30-1.) Figure 20-40-2

Remove the left upperstructure covers. (See Removal

And Installation on Page 40-60-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Oil on Page 10-120-3.)

Remove the floor mat and floor panels. (See Removal 1

And Installation on Page 40-140-1.)

Remove the travel control assembly. (See Removal And

Installation on Page 40-110-1.)

2
P118068

Loosen the bolt (Item 1) and remove the bracket (Item 2)

[Figure 20-40-2].

20-40-1 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-5

Removal And Installation (Cont’d)

Figure 20-40-3
1

1
1

P118066

Remove the two cable ties (Item 1) [Figure 20-40-5].

P118070
Figure 20-40-6

Loosen the track extension cable nuts (Item 1) and

remove the pin (Item 2) [Figure 20-40-3].

Set cable to the side.

Figure 20-40-4

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1

1
1

P118071

Remove the horn wires (Item 1) and set harness to the

side [Figure 20-40-6].

P118069

Disconnect the wire harness (Item 1) [Figure 20-40-4].

20-40-2 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-9

Removal And Installation (Cont’d)

NOTE: Mark all hoses for aid in installation.

Figure 20-40-7

1
1

P118075

Remove the upper pilot hose (Item 1) [Figure 20-40-9].

Figure 20-40-10
P118067

Remove the hose (Item 1) [Figure 20-40-7] to the

hydraulic pump.

Figure 20-40-8
1
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P118076

Remove the two manifold pilot hoses (Item 1) [Figure 20-

40-10].

P118073

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

8].

20-40-3 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-13

Removal And Installation (Cont’d)

Figure 20-40-11

1 1
1
1

P118087

Remove the three pilot hoses (Item 1) [Figure 20-40-13].

P118084
Figure 20-40-14

Remove the four solenoid wire harness connectors (Item

1) [Figure 20-40-11].

Installation: The harness and the solenoids have color

coded tie straps for correct installation of the harness 1 2 3 4 5 6
connectors: 7 8 9

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- Yellow
- Green
- Orange
- None

If any tie straps are missing, mark the connectors for

ease of installation. P118086

Figure 20-40-12
Figure 20-40-15

1 2 3 4 5 6 7 8
9
1

P118085
P118088

Remove the two hydraulic pump hoses (Item 1) [Figure

20-40-12]. Remove the 18 hydraulic control valve hoses [Figure 20-
40-14] upper and [Figure 20-40-15] lower.

20-40-4 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-18

Removal And Installation (Cont’d)

1
Figure 20-40-16
1

2 1

1
1

P118093

Mark and disconnect the four solenoid wire connectors

(Item 1) [Figure 20-40-18].
P118092

Figure 20-40-19
Disconnect the two wire harness connectors (Item 1) and
remove the three pilot hoses (Item 2) [Figure 20-40-16].

Figure 20-40-17

1
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2
P118080

Remove the hydraulic line (Item 1) [Figure 20-40-19].

P118094
Figure 20-40-20

Remove the two manifold pilot hoses (Item 1) and

disconnect the switch harness (Item 2) [Figure 20-40-
17].

P118081

Support the assembly with a chain hoist [Figure 20-40-

20].

20-40-5 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-23

Removal And Installation (Cont’d)

1
Figure 20-40-21

1 1

P118082

Remove the two bolts at the front (Item 1) [Figure 20-40-

P118078 23].

Figure 20-40-24
Figure 20-40-22

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1

P118083
P118079

Slide the assembly back enough to clear the frame

Remove the two bolts (Item 1) [Figure 20-40-21] and [Figure 20-40-24].
[Figure 20-40-22] at the mounting bracket.
Remove the hydraulic control valve and manifold
assembly.

20-40-6 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Parts Identification

10 10

1 7 8
9

2
3 4 5 6
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P118407

1. RIGHT TRAVEL SECTION

2. ARM SECTION
3. BOOM SWING SECTION
4. BUCKET SECTION
5. AUXILIARY SECTION
6. BOOM SECTION
7. LEFT TRAVEL SECTION
8. SLEW SECTION
9. BLADE SECTION
10. LOAD CHECK VALVE

20-40-7 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-27

Disassembly

Clean the outside of the hydraulic control valve / manifold

assembly before disassembling.

NOTE: Mark all hoses, tubelines, and wire harness 1

connectors for correct installation.

Figure 20-40-25

1 P118455

Remove the two hoses (Item 1) [Figure 20-40-27].

Figure 20-40-28

1
2
P118168

Remove the two pilot hoses (Item 1) from the tee fitting

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and the 90° elbow hose (Item 2) [Figure 20-40-25].

Figure 20-40-26

P118170

Loosen the hose clamp (Item 1) [Figure 20-40-28] at the

manifold valve.
1

P118457

Remove the tubeline (Item 1) [Figure 20-40-26].

20-40-8 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Disassembly (Cont’d)
IMPORTANT
Figure 20-40-29
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

Figure 20-40-31

P118171

Figure 20-40-30
1
7 8 9
2 3 4 5 6

P118407
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1
Mark the valve section for aid in assembly [Figure 20-40-
31].

Figure 20-40-32

P118172

Remove the three control valve mounting bolts (Item 1)

[Figure 20-40-29] and [Figure 20-40-30].

Installation: Use Loctite® 242 on bolt threads.

1 1
Remove the hydraulic control valve from the mounting
plate.
1
P118290

Remove the three nuts (Item 1) [Figure 20-40-32].

20-40-9 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-35

Disassembly (Cont’d)

Figure 20-40-33
1 1

P118270

1
Remove the five O-rings (Item 1) [Figure 20-40-35].
P118261
Figure 20-40-36

Remove the right travel section (Item 1) [Figure 20-40-

33].

Figure 20-40-34

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1

P118263

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

36].
P118262

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

34].

20-40-10 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Disassembly (Cont’d)

Figure 20-40-37

P118273

Remove the five O-rings (Item 1) [Figure 20-40-37].

Figure 20-40-38
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P118264

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

38].

20-40-11 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-41

Disassembly (Cont’d)

Figure 20-40-39

1
1

1
P118275

1 Remove the seven O-rings (Item 1) [Figure 20-40-41].

P118274
Figure 20-40-42

Remove the seven O-rings (Item 1) [Figure 20-40-39].

Figure 20-40-40

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1

P118266

1
Remove the boom valve section (Item 1) [Figure 20-40-
P118265 42].

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

40-40].

NOTE: O-rings on both sides of auxiliary valve

section.

20-40-12 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-45

Disassembly (Cont’d)

Figure 20-40-43

1 1

1
P118268
1

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

P118276 45].

Figure 20-40-46
Remove the five O-rings (Item 1) [Figure 20-40-43].

Figure 20-40-44
1 1
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1 P118277

P118267 Remove the five O-rings (Item 1) [Figure 20-40-46].

Remove the left hand valve section (Item 1) [Figure 20-

40-44].

20-40-13 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-48

Assembly

2
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
P118281
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn Install the slew valve section (Item 1). Install the five O-
or damaged parts. rings (Item 2) [Figure 20-40-48].

Always install new seals and O-rings. Lubricate all seals Figure 20-40-49
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-47

1
1 1

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1
4

2
P118282

3 Install the left hand travel valve section (Item 1) [Figure

P118280
20-40-49].

Install the tie rods (Item 1) through the blade valve

section (Item 2). Place the valve (Item 2) on end and use
spacers (Item 3) to level the valve. Install the five O-rings
(Item 4) [Figure 20-40-47].

20-40-14 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-52

Assembly (Cont’d)
2
Figure 20-40-50

1
1

P118285

Install the bucket valve section (Item 1). Install the five O-
P118283 rings (Item 2) [Figure 20-40-52].

Figure 20-40-53
Install the boom valve section (Item 1). Install the O-rings
[Figure 20-40-50]. 2
Figure 20-40-51

2 1
1
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P118286

Install the boom swing valve section (Item 1) and five O-

P118284 rings (Item 2) [Figure 20-40-53].

Install the auxiliary valve section (Item 1). Install the

seven O-rings (Item 2) [Figure 20-40-51].

20-40-15 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-56

Assembly (Cont’d)
1
Figure 20-40-54

1
1

P118289

Install the three nuts (Item 1) [Figure 20-40-56].

P118287
Figure 20-40-57

Install the arm valve section (Item 1). Install the five O-
rings (Item 4) [Figure 20-40-54].

Figure 20-40-55

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1 1

1
P118290

Position the valve as shown and tighten the nuts (Item 1)

[Figure 20-40-57] to 19 N•m (14 ft-lb) torque.
P118288

Install the right hand travel valve section (Item 1) [Figure

20-40-55].

20-40-16 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-60

Right And Left Travel Valve Section Disassembly And

Assembly

Figure 20-40-58

1 P118298

Remove the cap (Item 1) [Figure 20-40-60].

P118296 Installation: Tighten the plug to 9 - 11 N•m (6 - 8 ft-lb)

torque.

Remove the plug (Item 1) [Figure 20-40-58]. Figure 20-40-61

Installation: Tighten the fitting to 28,5 - 30 N•m (21 - 22 1

ft-lb) torque.
2
Figure 20-40-59
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P118299

Remove the plug (Item 1) and remove the O-ring (Item 2)

[Figure 20-40-61] from the plug.
P118297

Remove the O-rings (Item 1) and the two bolts (Item 2)

[Figure 20-40-59].

20-40-17 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-64

Right And Left Travel Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-62

P118302
1

2 Remove the O-ring (Item 1) [Figure 20-40-64].

P118300 Figure 20-40-65

Remove the travel linkage cotter pin (Item 1) and lever

(Item 2) [Figure 20-40-62].

Figure 20-40-63

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1
2

P118303
1 1
Remove the spring retainer nut (Item 1) [Figure 20-40-
65].

P118301

Remove the two bolts (Item 1) for spool retainer (Item 2)

[Figure 20-40-63].

20-40-18 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-68

Right And Left Travel Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-66

2 1

P118306

Remove the O-ring (Item 1) [Figure 20-40-68].

1
P118304

Remove the spring assembly (Item 1) and O-ring (Item 2)

[Figure 20-40-66].

Figure 20-40-67
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P118305

Remove the switch (Item 1) [Figure 20-40-67].

20-40-19 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-71

Right And Left Travel Valve Section Disassembly And 1

Assembly (Cont’d)

Figure 20-40-69

1 1
2 P118309

Remove remaining four O-rings from fittings and plug

(Item 1) [Figure 20-40-71].
P118307

Figure 20-40-70

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P118308

Remove the washer (Item 1) and spool (Item 2). [Figure

20-40-69] and [Figure 20-40-70].

20-40-20 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-74

Arm And Bucket Valve Section Disassembly And

Assembly

Figure 20-40-72

2 2
1

P118312

4
3 3 Remove spring (Item 1) and retainer (Item 2) [Figure 20-
1 4
40-74].
P118310
Figure 20-40-75

Remove the five O-rings (Item 1) and remove the check

valve (Item 2) [Figure 20-40-72].

Remove the four screws (Item 3) [Figure 20-40-72] from

both end caps.
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Remove the end caps (Item 4) [Figure 20-40-72]

1
Installation: Tighten the screws to 7,5 N•m (5.5 ft-lb) 2
torque.
3
Figure 20-40-73

P118313

Remove the O-ring (Item 1) and washer (Item 2) from

both ends of the valve. Remove the spool (Item 3)
[Figure 20-40-75].

NOTE: The spool is not symmetrical. Incorrect spool

installation will cause poor hydraulic valve
1 performance.

P118311

Remove the O-ring (Item 1) [Figure 20-40-73].

20-40-21 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-78

Arm And Bucket Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-76

2 P118317

Remove the O-ring (Item 1) and inspect relief valve (Item

2) [Figure 20-40-78].
P118315
Installation: Tighten the relief valve to 69 - 79 N•m (51 -
58 ft-lb) torque.
Remove O-rings from fittings (Item 1) [Figure 20-40-76].

Figure 20-40-77

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1

P118316

Remove the relief valve (Item 1) [Figure 20-40-77] on

both sides.

20-40-22 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-81

Boom Swing And Auxiliary Valve Section

Disassembly And Assembly

Figure 20-40-79

1
1

P118320
1

Remove the O-ring (Item 1) [Figure 20-40-81].

P118318 Figure 20-40-82

Remove the five O-rings (Item 1) [Figure 20-40-79].

Figure 20-40-80
1
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P118321

1 Remove the three O-rings (Item 1) from end cap [Figure

1 20-40-82].
P118319

Remove the three screws (Item 1) from the valve body

[Figure 20-40-80].

Installation: Tighten the screws to 7,5 N•m (5.5 ft-lb)

torque.

20-40-23 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-85

Boom Swing And Auxiliary Valve Section

Disassembly And Assembly (Cont’d)

Figure 20-40-83

1
1
P118324
1

Remove O-ring on plug and fitting (Item 1) [Figure 20-

40-85].
1
P118322
Figure 20-40-86

Remove four solenoid screws (Item 1) [Figure 20-40-83].

Figure 20-40-84

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3
1
1
1
P118325

2
Remove the three cover screws (Item 1) and remove the
P118323 cover (Item 2) [Figure 20-40-86].

Mark and remove both solenoids (Item 1) and remove the

O-rings (Item 2) and inspect the screen (Item 3) [Figure
20-40-84].

20-40-24 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-89

Boom Swing And Auxiliary Valve Section

Disassembly And Assembly (Cont’d)

Figure 20-40-87

1
2 P118327

Remove the plug (Item 1) on both sides [Figure 20-40-

89].
P118326
Figure 20-40-90

Remove the O-ring (Item 1) and spool assembly (Item 2)

[Figure 20-40-87].

Figure 20-40-88

2
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1 2 1

P118328
4
3
Remove the O-ring (Item 1) from both plugs and remove
the check valve (Item 2) [Figure 20-40-90].
P118330
Installation: Tighten the plug to 69 - 78 N•m (51 - 58 ft-
lb) torque.
Remove bolt (Item 1), retainers (Item 2), spring (Item 3)
from spool (Item 4) [Figure 20-40-88].

20-40-25 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Boom Swing And Auxiliary Valve Section

Disassembly And Assembly (Cont’d)

Figure 20-40-91

1
P118329

Remove the O-ring (Item 1) and the O-rings on the

fittings (Item 2) [Figure 20-40-91].

20-40-26 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-94

Boom Valve Section Disassembly And Assembly

Figure 20-40-92

2 2

1 1

P118334

1
Remove the O-rings (Item 1) [Figure 20-40-94].
P118332
Figure 20-40-95

The boom valve section (Item 1) is the same as the arm

and bucket valve sections with the addition of the orifice
valves (Item 2) for the pilot hose connection [Figure 20-
40-92]. 2

Figure 20-40-93
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1 3

1 P118335

Remove the valve (Item 1), spring (Item 2), and retainer
(Item 3) [Figure 20-40-95].

P118333

Remove the valve assembly (Item 1) [Figure 20-40-93].

20-40-27 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-98

Slew Valve Section Disassembly And Assembly

Figure 20-40-96
2

2 3
1

P118338
1

Remove the spring seat (Item 1), spring (Item 2), and
P118336 spring seat (Item 3) [Figure 20-40-98].

Installation: Tighten the screws to 9 - 11 N•m (7 - 8 ft-lb)

Remove the four screws (Item 1) and end cap (Item 2) torque.
[Figure 20-40-96] on both sides.
Figure 20-40-99
Installation: Tighten the screws to 7,5 N•m (5.5 ft-lb)
torque.

Figure 20-40-97

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1
1

P118340

Remove the spool (Item 1) [Figure 20-40-99].

P118337
NOTE: The spool is not symmetrical. Incorrect spool
installation will cause poor hydraulic valve
Remove the O-ring (Item 1) [Figure 20-40-97]. performance.

20-40-28 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-102

Slew Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-100

1 P118343

Remove the plug (Item 1) [Figure 20-40-102].

P118341 Installation: Tighten the plug to 69 - 78 N•m (51 - 58 ft-

lb) torque.

Remove the relief valve (Item 1) [Figure 20-40-100]. Figure 20-40-103

Figure 20-40-101

1
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1
2
P118344

P118342
Remove the O-rings (Item 1) [Figure 20-40-103].

Remove the back-up ring (Item 1) and O-rings [Figure

20-40-101].

20-40-29 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Slew Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-104

1
1 1

P118345

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

40-104].

Installation: Tighten the fitting to 69 - 78 N•m (51 - 58 ft-

lb) torque.

20-40-30 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-107

Blade Valve Section Disassembly And Assembly

Figure 20-40-105

1 2

2
1

P118350

Remove the cover assembly (Item 1) and O-ring (Item 2)

P118349 [Figure 20-40-107].

Figure 20-40-108
Remove the bolt (Item 1) and linkage bracket (Item 2)
[Figure 20-40-105].

Figure 20-40-106

1
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1 1

2
P118351

1 Remove the two screws (Item 1) and cover (Item 2)

P118347 [Figure 20-40-108].

Remove the screws (Item 1) [Figure 20-40-106].

Installation: Use Loctite® 242 on threads. Tighten the

screws to 7,5 N•m (5.5 ft-lb) torque.

20-40-31 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-111

Blade Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-109

1 1

P118354

Remove the spring assembly (Item 1) [Figure 20-40-

111].
P118352
Figure 20-40-112

Hold the linkage end of spool (Item 1) [Figure 20-40-

109]. Remove the spring retainer nut (Item 1) [Figure 20-
40-110].
3
Figure 20-40-110

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3

2
1 1
2 P118355

Remove spool (Item 1), O-rings (Item 2), and washers

(Item 3) [Figure 20-40-112].

P118353

20-40-32 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-115

Blade Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-113

P118359

Remove the plug (Item 1) [Figure 20-40-115].

P118356 Installation: Tighten the plug to 28,5 - 30 N•m (21 - 22 ft-

lb) torque.

Remove the check valve (Item 1) [Figure 20-40-113]. Figure 20-40-116

Figure 20-40-114
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1 P118360

1 P118358
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-116] from the plug.
Remove the O-ring (Item 1) [Figure 20-40-114].

20-40-33 E20 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Blade Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-117

1 P118361

Remove the three O-rings (Item 1) [Figure 20-40-117].

20-40-34 E20 Service Manual

HYDRAULIC PUMP Torque Adjustment

Description Prior to making any torque adjustment, all piston and

gear pump tests must be completed and at rated
specifications. (See the following pages for pump tests.)
IMPORTANT Prior to making any torque adjustment, make sure the no
load engine rpm is correct.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Figure 20-50-2
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 20-50-1

1
2

P118259

2 3 The adjustment screw (Item 1) [Figure 20-50-2] is used

to match the maximum hydraulic horsepower of the pump
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to the maximum rated engine horsepower.

P117731
Remove any auxiliary hydraulic attachments from the
excavator.
Pump outlet one (Item 1) [Figure 20-50-1] provides
hydraulic fluid to the right hand travel and boom valve Start the engine and move the speed control to the high
sections. rpm position.

Pump outlet two (Item 2) [Figure 20-50-1] provides Engage the following hydraulic functions, and continue to
hydraulic fluid to the left hand travel section. engage the functions.

Hydraulic fluid from pump one and two combine to Engage the auxiliary hydraulics.
provide flow to the arm, boom swing, bucket, and Extend the bucket cylinder.
auxiliary valve sections. Extend the arm cylinder.
Extend the boom cylinder.
Pump outlet three (gear pump) (Item 3) [Figure 20-50-1] Extend the boom swing cylinder.
provides hydraulic fluid to the upperstructure swing and
blade valve sections. With all the above hydraulic functions engaged, the
engine speed must maintain 2500 rpm.

To adjust the hydraulic pump torque, loosen the lock nut

(Item 2) [Figure 20-50-2] and turn the adjustment screw
clockwise to increase pump torque or counterclockwise
to decrease pump torque.

20-50-1 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-4

Torque Adjustment (Cont'd)

Tighten the locknut and retest the pump.

Increase or decrease pump torque until correct engine

rpm is maintained.
2
Testing The Piston Pump
1
All pump testing is done with the hydraulic fluid at
operating temperature and with the engine at the high
rpm setting.

The following tool will be needed for the hydraulic pump P118424
test:

MEL10003 - Hydraulic Tester Connect the inlet (Item 1) [Figure 20-50-4] of the tester
to the pump.
Stop the engine.
Connect the outlet of the tester to the hose (Item 2)
Remove the left upperstructure cover. (See Removal And [Figure 20-50-4] that was removed from the pump.
Installation on Page 40-60-1.)

Figure 20-50-3

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P117731

Remove the outlet hose (Item 1) [Figure 20-50-3] from

the hydraulic pump being tested.

20-50-2 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-6

Testing The Piston Pump (Cont’d)

Figure 20-50-5

1
P-22253

Close the flow control knob (Item 1) [Figure 20-50-6]

1 slowly to 689 kPa (7 bar) (100 psi) below the relief valve
setting 22753 kPa (228 bar) (3300 psi).
P-22253
Record the pump high pressure flow L/min (U.S. gpm).
NOTE: Open the flow control knob (Item 1) [Figure
NOTE: The high pressure flow must be at least 80% of
20-50-5] fully to prevent pump damage. This is
free flow.
a direct pump test. There is no relief valve in
the system. HIGH PRESSURE FLOW (L/min [U.S. gpm])
%= x100
FREE FLOW (L/min [U.S. gpm])
Start the engine and run at low rpm. Make sure the tester
is connected correctly. If no flow is indicated at the tester, If the high pressure flow is less than 80% of free flow,
the hoses are connected wrong. remove the hydraulic pump for repair or replacement.
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Increase the engine speed to full rpm. Warm the Repeat the procedure for pump outlet two.
hydraulic fluid to 66°C (150°F) by turning the restrictor
valve until the gauge reads about 6895 kPa (69 bar) The pump flow must be equal between outlet one and
(1000 psi). Do not exceed system pressure. two.

After the temperature is correct, open the restrictor valve

fully.

Record the pump free flow L/min (U.S. gpm).

Pump flow on a new piston pump is 15,0 L/min (3.96 U.S.

gpm) @ 2500 rpm.

Repeat the procedure for pump outlet two.

The pump flow must be equal between outlet one and

two.

20-50-3 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-9

Testing The Gear Pump

All pump testing is done with the hydraulic fluid at

operating temperature and with the engine at the high
rpm setting.

Figure 20-50-7

1
1

P-22253

NOTE: Open the flow control knob (Item 1) [Figure

20-50-9] fully to prevent pump damage. This is
a direct pump test. There is no relief valve in
the system.

P117731 Start the engine and run at low rpm. Make sure the tester
is connected correctly. If no flow is indicated at the tester,
the hoses are connected wrong.
Remove the outlet hose (Item 1) [Figure 20-50-7] from
the gear pump section. Increase the engine speed to full rpm. Warm the
hydraulic fluid to 66°C (150°F) by turning the restrictor

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Figure 20-50-8 valve until the gauge reads about 6895 kPa (69 bar)
(1000 psi). Do not exceed system pressure.

After the temperature is correct, open the restrictor valve

fully.

2 1

P117733

Connect the inlet (Item 1) [Figure 20-50-8] of the tester

to the pump.

Connect the outlet of the tester to the hose (Item 2)

[Figure 20-50-8] that was removed from the pump.

20-50-4 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Testing Auxiliary Hydraulic Flow

Testing The Gear Pump (Cont’d) All testing is done with the hydraulic oil at operating
temperature and the engine high speed setting.
Record the pump free flow L/min (U.S. gpm).
The following tool will be needed for the auxiliary
Pump flow on a new gear pump is 11,0 L/min (3 U.S. hydraulic flow test:
gpm) @ 2500 rpm.
MEL10003 - Hydraulic Tester.
Figure 20-50-10
Stop the engine.

Figure 20-50-11

1
P-22253

Close the flow control knob (Item 1) [Figure 20-50-10]

S35839
slowly to 689 kPa (6,9 bar) (100 psi) below the relief valve
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setting 22753 kPa (228 bar) (3300 psi).

Connect the inlet side of the tester to the female coupler
Record the pump high pressure flow L/min (U.S. gpm). (Item 1). Connect the outlet side of the tester to the male
coupler (Item 2) [Figure 20-50-11].
NOTE: The high pressure flow must be at least 80% of
free flow.
HIGH PRESSURE FLOW (L/min [U.S. gpm])
%= x100
FREE FLOW (L/min [U.S. gpm])

If the high pressure flow is less than 80% of free flow,

remove the hydraulic pump for repair or replacement.

20-50-5 E20 Service Manual

HYDRAULIC PUMP (CONT’D)

Testing The Auxiliary Hydraulic Flow (Cont’d)

Figure 20-50-12

P-22253

NOTE: Open the flow control knob (Item 1) [Figure 20-

50-12] fully.

Start the engine, and run at low rpm. Engage the

auxiliary hydraulic circuit.

NOTE: When engaging the auxiliary hydraulic circuit,

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make sure the female coupler is pressure and
the male coupler is return.

Make sure the tester is connected correctly. If no flow is

indicated at the tester, the hoses are connected wrong.

Increase the engine speed to full rpm. Warm the

hydraulic fluid to 66°C (150°F) by turning the restrictor
valve until the gauge reads about 6895 kPa (69 bar)
(1000 psi). Do not exceed system pressure.

After the temperature is correct, open the restrictor valve

fully.

Record the auxiliary hydraulic free flow L/min (U.S. gpm).

20-50-6 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-14

Removal And Installation

Lower the boom / bucket and blade to the ground. 1

Relieve hydraulic pressure.

2
Drain the hydraulic reservoir. (See Removal And
Installation on Page 20-130-1.)

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-60-1.)

P117793

IMPORTANT Remove the hose (Item 1) and bolt (Item 2) [Figure 20-
50-14].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-50-15
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 20-50-13 1
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1 2

P117794

1 Remove the bolt (Item 1) [Figure 20-50-15].

Installation: Tighten bolts to 105 - 115 N•m (78 - 85 ft-lb)

P118259 torque.

Remove the pump from the excavator.

Mark and remove the hoses (Item 1) [Figure 20-50-13].

Move the clamp (Item 2) [Figure 20-50-13] back.

20-50-7 E20 Service Manual

HYDRAULIC PUMP (CONT’D)

Removal And Installation (Cont’d)

Figure 20-50-16

P113458

Installation: Remove the plug (Item 1) [Figure 20-50-

16] from the hydraulic pump. Install the plug after a
steady stream of hydraulic fluid free of any air drains from
the hydraulic pump. Tighten plug to 30 - 34 N•m (22 - 25
ft-lb) torque.

20-50-8 E20 Service Manual

HYDRAULIC PUMP (CONT’D)

Parts Identification

1. Screw
20. Pin
2. Washer 21. Spring Pin
3. Gear Pump 22. Bearing
4. Coupler 23. Port Plate
5. Collar 24. Snap Ring
6. O-ring 25. Washer
7. Nut 26. Spring
8. Seal Washer 27. Cylinder Block
9. Plug 28. Retainer
10. Bolt 29. Retainer Plate
11. Face Plate 30. Swash Plate
12. Spring Guide 31. Rod
13. Spring 32. Piston
14. Pin 33. Gasket
15. Spring Holder 34. Housing
16. Dish Washer 35. Plug
17. Stopper Pin B 36. Oil Seal
18. Ball 37. Shaft
19. Piston 38. Bearing
22 23 24 38

24
25
26 37
25 27
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36
21 24
28 29
30
35
19 32 16 6
31 16
20 33 35
7 34
1
8 11 6
9
9 18
12 17
9
10 16
16
13 14

6
12 3 14
9 9

4
5
6 6
15

P-62409

20-50-9 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-19

Disassembly And Assembly

Figure 20-50-17 1

1
S6120

Remove the O-rings (Item 1) [Figure 20-50-19].

P118468

Remove the bolts (Item 1) and remove the gear pump

(Item 2) [Figure 20-50-17] from the piston pump.

Figure 20-50-18

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2

1
S6107

Remove the coupler (Item 1) and collar (Item 2) [Figure

20-50-18] from the gear pump.

20-50-10 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-21

Gear Pump Disassembly

Mark the halves of the gear pump to aid in the assembly

process. Separate the two halves of the gear pump [Figure 20-50-
21].
Figure 20-50-20
Figure 20-50-22
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1
S6111
S6114

Remove the four bolts (Item 1) [Figure 20-50-20] from

the gear pump. Remove the seal (Item 1) [Figure 20-50-22].

NOTE: The seals for the gear pump are the only Figure 20-50-23
serviceable parts in the gear pump.

S6115

Remove the bearing (Item 1) [Figure 20-50-23].

20-50-11 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-26

Gear Pump Disassembly (Cont’d)

Figure 20-50-24

1 1
S6118

Remove the bearing (Item 1) [Figure 20-50-26].

S6116
Figure 20-50-27

Remove the seal (Item 1) [Figure 20-50-24].

Figure 20-50-25

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1
S6119

1
Remove the seal (Item 1) [Figure 20-50-27].
S6117
NOTE: The gear housing, two bearings, drive and
idler gears are not serviced separately. If any
Remove the drive and idler gears (Item 1) [Figure 20-50- part is damaged, the entire gear pump must
25]. be replaced.

20-50-12 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-30

Gear Pump Assembly

Figure 20-50-28

S6117

Install the drive and idler gears (Item 1) [Figure 20-50-

1 30].
S6119

Figure 20-50-31
Install the seal (Item 1) [Figure 20-50-28] on the bearing.

Figure 20-50-29
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S6116

1 Install the seal (Item 1) [Figure 20-50-31] on the bearing.

S6118

Install the bearing (Item 1) [Figure 20-50-29].

20-50-13 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-34

Gear Pump Assembly (Cont’d)

Figure 20-50-32

1
S6112

Assemble the two halves of the gear pump [Figure 20-

S6115 50-34].

Figure 20-50-35
Install the bearing (Item 1) [Figure 20-50-32].

Figure 20-50-33

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1
1
S6111

S6114 Install the four bolts (Item 1) [Figure 20-50-35] in the

gear pump.

Install the seal (Item 1) [Figure 20-50-33]. Tighten the bolts to 88,3 - 93,1 N•m (65.1 - 68.7 ft-lb)
torque.

20-50-14 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-38

Piston Pump Disassembly

Figure 20-50-36
Remove the plug (Item 1) [Figure 20-50-38] from the
pump block.

2 Figure 20-50-39

1
1
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P117669

Remove the two bolts (Item 1) and inlet fitting (Item 2)

[Figure 20-50-36].
P-59306

Figure 20-50-37
Remove the O-ring (Item 1) [Figure 20-50-39] from the
plug.

P-59304

Remove the O-ring (Item 1) [Figure 20-50-37].

20-50-15 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-42

Piston Pump Disassembly (Cont’d) 2

2
Figure 20-50-40

2
3 S6121

Remove the seal washer (Item 1) [Figure 20-50-42] from

1 S6153 the pump housing.

Remove the three bolts (Item 2) [Figure 20-50-42] from

Remove the pressure adjustment nut (Item 1) [Figure the pump housing.
20-50-40] from the pump housing.
Remove the two bolts (Item 3) [Figure 20-50-42] from
Figure 20-50-41 either side of the pressure adjusting spring in the pump
housing.

Figure 20-50-43

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S6122
1

Measure the outside length of the pressure adjustment

S6123
screw [Figure 20-50-41] for aid in adjustment after re-
assembly.
Remove the face plate (Item 1) [Figure 20-50-43].

20-50-16 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-46

Piston Pump Disassembly (Cont’d)

Figure 20-50-44

S6126

1 Remove the port plate (Item 1) [Figure 20-50-46].

S6124
Figure 20-50-47

Remove the gasket (Item 1) [Figure 20-50-44].

Figure 20-50-45

1
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S6127

Remove the spring guide (Item 1) [Figure 20-50-47].

S6125

Remove the O-ring (Item 1) [Figure 20-50-45].

20-50-17 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-50

Piston Pump Disassembly (Cont’d)

Figure 20-50-48

1
S6130

Remove the spring (Item 1) [Figure 20-50-50].

S6128
Figure 20-50-51

Remove the screw (Item 1) [Figure 20-50-48].

Figure 20-50-49

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1
S6131

Remove the spring seat (Item 1) [Figure 20-50-51].

S6129

Remove the O-ring (Item 1) [Figure 20-50-49].

20-50-18 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-54

Piston Pump Disassembly (Cont’d)

Figure 20-50-52

P-59745

Inspect the difference between the inner diameter of

S6132 cylinder block (D) and the outer diameter of piston (d)
[Figure 20-50-54]. The difference should be less than
0,05 mm (0.002 in).
Remove the cylinder block assembly (Item 1) [Figure 20-
50-52]. Figure 20-50-55

NOTE: The following procedure shown is to

disassemble the rotating group for inspection
only. The rotating group parts cannot be
ordered separately and must be ordered as an
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assembly.

Figure 20-50-53

1
P-59746

The clearance between the piston and shoe [Figure 20-

50-55] should be less than 0,2 mm (0.008 in).

S6133

Remove the retainer plate (Item 1) and pistons (Item 2)

[Figure 20-50-53] from the cylinder block.

20-50-19 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-58

Piston Pump Disassembly (Cont’d)

Figure 20-50-56

1
S6136

Remove the snap ring (Item 1) [Figure 20-50-58] in the

cylinder block.
S6134
Figure 20-50-59

Remove the retainer (Item 1) [Figure 20-50-56].

Figure 20-50-57

2 3
1

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1
1

1
S6137

Remove the retainer (Item 1), spring (Item 2), and

retainer (Item 3) [Figure 20-50-59].

S6135 Figure 20-50-60

Remove the three pins (Item 1) [Figure 20-50-57].

S6138

Remove the swash plate (Item 1) [Figure 20-50-60].

20-50-20 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-63

Piston Pump Disassembly (Cont’d)

Figure 20-50-61

S6141

Remove the rod (Item 1) [Figure 20-50-63].

S6139
Figure 20-50-64

Remove the balls (Item 1) [Figure 20-50-61].

Figure 20-50-62
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S6142

The step in the rod (Item 1) [Figure 20-50-64] must be

S6140 inserted into the pump housing first.

Visually inspect the balls for scratches, abnormal wear, or

damage [Figure 20-50-62].

20-50-21 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-67

Piston Pump Disassembly (Cont’d)

Figure 20-50-65

P-59644

Remove the piston B (Item 1) [Figure 20-50-67].

S6143
Figure 20-50-68

Remove the piston A (Item 1) [Figure 20-50-65].

Figure 20-50-66

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P-59744
1

P-59645
P-59744

1 Remove the two dish washers (Item 1) [Figure 20-50-

P-59643 68].

Remove the two dish washers (Item 1) [Figure 20-50-

66].

20-50-22 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-71

Piston Pump Disassembly (Cont’d)

Figure 20-50-69

S6147

Remove the snap ring (Item 1) [Figure 20-50-71].

S6145
Figure 20-50-72

Remove the pin (Item 1) [Figure 20-50-69].

Figure 20-50-70

1
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1 S6148

Remove the shaft and bearing assembly (Item 1) [Figure

S6146 20-50-72] from the pump housing by tapping the other
end of the shaft.

Remove the pin (Item 1) [Figure 20-50-70].

20-50-23 E20 Service Manual

HYDRAULIC PUMP (CONT’D)

Piston Pump Disassembly (Cont’d)

Figure 20-50-73

S6150

Remove the oil seal (Item 1) [Figure 20-50-73] from the

shaft.

Figure 20-50-74

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2

S6151

Remove the snap ring (Item 1) [Figure 20-50-74] from

the shaft.

Remove the bearing (Item 2) [Figure 20-50-74] from the

shaft.

20-50-24 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-77

Piston Pump Assembly

Clean all parts in solvent and dry with compressed air.

51,05 mm (2.01 in)

Do not use compressed air to dry the bearings.

30,99 mm
(1.22 in)
Inspect all parts for wear and damage. Replace all worn
and damaged parts.

Always install new seals and O-rings.

52,07 mm
Apply a thin coat of hydraulic fluid to all components (2.05 in)
before assembly.
70,1 mm (2.76 in)
Figure 20-50-75 P-59743

2 Manufacture the special tool [Figure 20-50-77] needed

to install the oil seal into the pump housing.

1 Figure 20-50-78
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S6151

Install the bearing (Item 1) [Figure 20-50-75] on the

shaft.

Install the snap ring (Item 2) [Figure 20-50-75] on the S6152

shaft.

Figure 20-50-76 Install the shaft, bearing, and oil seal assembly [Figure
20-50-78] into the pump housing by using the special
tool.

S6150

Install the oil seal (Item 1) [Figure 20-50-76] on the shaft.

20-50-25 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-81

Piston Pump Assembly (Cont’d)

Figure 20-50-79
1

S6145

1
Install the pin (Item 1) [Figure 20-50-81].
S6147
Figure 20-50-82

Install the snap ring (Item 1) [Figure 20-50-79].

Figure 20-50-80

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P-59744
1

P-59645
1

Install the two dish washers (Item 1) on the piston B (Item

S6146 2) [Figure 20-50-82].

Install the pin (Item 1) [Figure 20-50-80].

20-50-26 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-85

Piston Pump Assembly (Cont’d)

Figure 20-50-83

S6143

Install piston A and washers (Item 1) [Figure 20-50-85].

P-59644
Figure 20-50-86

Install piston B and washers (Item 1) [Figure 20-50-83].

Figure 20-50-84
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S6142

P-59744 2

1 The step in the rod (Item 1) [Figure 20-50-86] must be

P-59643 installed into the pump housing first.

Install the two dish washers (Item 1) on the piston A (Item

2) [Figure 20-50-84].

20-50-27 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-89

Piston Pump Assembly (Cont’d)

Figure 20-50-87

S6138

Install the swash plate (Item 1) [Figure 20-50-89].

S6141
Figure 20-50-90

Install the rod (Item 1) [Figure 20-50-87].

Figure 20-50-88

2 1

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3

1
S6137

Install the retainer (Item 1), spring (Item 2), and retainer
(Item 3) [Figure 20-50-90].
S6139

Install the balls (Item 1) [Figure 20-50-88].

20-50-28 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-93

Piston Pump Assembly (Cont’d)

Figure 20-50-91 1

S6134

1
S6136 Install the retainer (Item 1) [Figure 20-50-93].

Figure 20-50-94
Install the snap ring (Item 1) [Figure 20-50-91] in the
cylinder block.

Figure 20-50-92 2

1
1

1
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S6133

Install the retainer plate (Item 1) and piston assemblies

S6135 (Item 2) [Figure 20-50-94] into the cylinder block.

Install the three pins (Item 1) [Figure 20-50-92].

20-50-29 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-97

Piston Pump Assembly (Cont’d)

Figure 20-50-95

1
1
S6130

Install the spring (Item 1) [Figure 20-50-97].

S6132
Figure 20-50-98

Install the cylinder block assembly (Item 1) [Figure 20- 1

50-95].

Figure 20-50-96

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S6129

1 Install the O-ring (Item 1) [Figure 20-50-98].

S6131

Install the spring seat (Item 1) [Figure 20-50-96].

20-50-30 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-101

Piston Pump Assembly (Cont’d)

Figure 20-50-99

S6126

Install the port plate (Item 1) [Figure 20-50-101].

S6128
Figure 20-50-102

Install the screw (Item 1) [Figure 20-50-99] in the face

plate.

Figure 20-50-100
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S6125

Install the O-ring (Item 1) [Figure 20-50-102].

S6127

Install the spring guide (Item 1) [Figure 20-50-100].

20-50-31 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-105

Piston Pump Assembly (Cont’d) 2 2

Figure 20-50-103

2
1 S6121

1
Install the two bolts (Item 1) [Figure 20-50-105] on either
S6124 side of the pressure adjusting spring in the pump
housing. Alternate tightening each bolt until both pump
housings are assembled.
Install the gasket (Item 1) [Figure 20-50-103] in between
the pump housing and face plate. Install the remaining three bolts (Item 2) [Figure 20-50-
105] in the pump housing.
Figure 20-50-104
Installation: Tighten bolts to 54 - 63,7 N•m (39.8 - 47.0
ft-lb) torque.

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Install the seal washer (Item 3) [Figure 20-50-105] on
the pump housing.

Figure 20-50-106

1
S6123

Install the face plate (Item 1) [Figure 20-50-104].

S6122

Set the measurement of the outside length of the

pressure adjustment screw taken before disassembly.
Final adjustment may need to be made after installation
in excavator [Figure 20-50-106].

20-50-32 E20 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-109

Piston Pump Assembly (Cont’d)

Figure 20-50-107

1 P-59305

Install the plug (Item 1) [Figure 20-50-109] in the pump

S6153 block.

Install the pressure adjustment nut (Item 1) [Figure 20-

50-107] on the pump housing.

Installation: Tighten the nut to 14,8 - 19,7 N•m (10.9 -

14.5 ft-lb) torque.

Figure 20-50-108
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P-59306

Install the O-ring (Item 1) [Figure 20-50-108] on the plug.

20-50-33 E20 Service Manual

HYDRAULIC PUMP (CONT’D)

Piston Pump Assembly (Cont’d)

Figure 20-50-110

P-59304

Install the O-ring (Item 1) [Figure 20-50-110] on the

pump block.

Figure 20-50-111

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1

P117669

Install pump block (Item 1) and the two bolts (Item 2)

[Figure 20-50-111].

20-50-34 E20 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR Removal And Installation

Description Figure 20-60-1

The manifold body contains a two-speed solenoid valve,

a system bypass valve, a console (joystick) lockout
solenoid, a pressure reducing valve and a safety relief
valve.

The body is connected to the accumulator.

The manifold supplies 2999 kPa (30 bar) (435 psi) to the
joystick function with the engine OFF and the key in the
ON position.

The accumulator provides a short term reserve pressure

for joystick function with the engine OFF and the key in
ON position. P118368

Turn the machine counterclockwise 90° for access to the

bottom of the valve [Figure 20-60-1].

Lower the boom / bucket and blade to the ground.

With the engine OFF, turn the start key to the ON position
and move both hydraulic control levers to relieve the
hydraulic pressure.
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20-60-1 E20 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-4

Removal And Installation (Cont’d)

Mark the hoses and wire harness for correct installation.

Remove the left upperstructure covers. (See Removal

And Installation on Page 40-60-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Oil on Page 10-120-3.) 1

Figure 20-60-2

P118371

Remove the two hydraulic pump hoses (Item 1) [Figure

20-60-4].

Figure 20-60-5

1
P118369

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Remove the three bolts from the bottom plate (Item 1)
1
[Figure 20-60-2]. 1

Figure 20-60-3

P118373

1 Remove the four solenoid wire connectors (Item 1)

[Figure 20-60-5].

NOTE: The wires are marked with colored cable ties

1 to the solenoid it plugs into. If the cable ties
are missing, mark the connectors to match
1 them to the solenoids.

P118370

Remove the three pilot hoses (Item 1) [Figure 20-60-3].

20-60-2 E20 Service Manual

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

Removal and Installation (Cont’d)

Figure 20-60-6

1 1

P118377

Remove the two pilot hoses (Item 1) and disconnect wire

P118374 harness (Item 2) [Figure 20-60-8].

Figure 20-60-9
Loosen the hose clamp (Item 1) [Figure 20-60-6].

Figure 20-60-7

2
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1 1

P118373

P118375 Remove the two mounting bolts (Item 1) [Figure 20-60-

9].

Remove the three hoses (Item 1) and the hydraulic line Installation: Tighten the bolts to 43 N•m (32 ft-lb) torque.
(Item 2) [Figure 20-60-7].
Mounting bracket removed from the machine for photo
clarity.

Remove the manifold from the machine.

20-60-3 E20 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D)

Parts Identification

1. Accumulator 2 2 1
2. Nut
3. O-ring 3 3
4. Coil with yellow dot
5. Coil with green dot
6. Coil with orange dot 4 5
7. Coil with no marking
8. Solenoid Stem
9. Solenoid Stem
10. Check Valve
11. Pressure Reducing Valve 8
8
12. Plug
13. Main Relief Valve 2
14. Valve Body 2
15. Test Fitting 3 3
10 3 3
4 4

6 7

3
10 3 3
4
3
4

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9
10 9
3
10 4

3 3 3
4
4 4
10 3
4

10
3
4
15
3

15
3 3
11 4

15
4 3
3
13
3
12 14
NA10165S

20-60-4 E20 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR Figure 20-60-12

Disassembly And Assembly

Figure 20-60-10

P118175

Remove the accumulator (Item 1) [Figure 20-60-12].

1
P118174
Figure 20-60-13

Clean the outside of the manifold assembly / accumulator

before disassembly.

Remove the pressure reducing valve (Item 1) [Figure 20-

60-10].

Installation: Tighten the valve to 30 N•m (22 ft-lb) 1

torque.

Figure 20-60-11

2 P118513

Remove the O-ring (Item 1) [Figure 20-60-13] from the

accumulator.

Installation: Tighten the accumulator to 29 - 33 N•m (22

1 - 24 ft-lb) torque.

P118507

Remove the O-ring (Item 1) and the two seals (Item 2)

[Figure 20-60-11].

20-60-5 E20 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-16

Disassembly And Assembly (Cont’d)

Figure 20-60-14

1 1
1 1
1
1

P118519

Mark and remove the four solenoid stems (Item 1)

P118498 [Figure 20-60-16].

Figure 20-60-17
Mark and remove the four solenoids (Item 1) [Figure 20-
60-14].

Figure 20-60-15

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1 2
3
2 1
P118511

4
Remove the O-ring (Item 1) and the seal (Item 2) [Figure
P118512 20-60-17].

NOTE: The coil stems with the yellow and green

Remove the nut (Item 1), O-ring (Item 2), solenoid coil marks are longer and have two seals (Item 2)
(Item 3) and the O-ring (Item 4) [Figure 20-60-15]. [Figure 20-60-17] installed.

Installation: Tighten the nut for the coil to 3 N•m (2.2 ft-
lb) torque.

NOTE: The unmarked coil and the coil with the orange
mark are the only coils equipped with the
bottom O-ring (Item 4) [Figure 20-60-15].

20-60-6 E20 Service Manual

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

Disassembly And Assembly (Cont’d)

Figure 20-60-18

2
1

P118508

Remove the O-ring (Item 1) and the seal (Item 2) [Figure

1 20-60-20].
P118518

Figure 20-60-21
Remove the cap (Item 1) [Figure 20-60-18].

Figure 20-60-19
1
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P118503

1
P118504 Remove the check valve (Item 1) [Figure 20-60-21].

Installation: Tighten the check valve to 30 N•m (22 ft-lb)

Remove the main relief valve (Item 1) [Figure 20-60-19]. torque.

Installation: Tighten the relief valve to 30 N•m (22 ft-lb)

torque.

20-60-7 E20 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-24

Disassembly And Assembly (Cont’d)

Figure 20-60-22

2 1 P118509

Remove the O-ring (Item 1) [Figure 20-60-24].

P118510
Figure 20-60-25

Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

60-22].

Figure 20-60-23

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1
1
1 1 P118514

Remove the five check valves (Item 1) [Figure 20-60-25].

1
P118506 Installation: Tighten the check valve to 40 N•m (30 ft-lb)
torque.

Remove the switch (Item 1) [Figure 20-60-23].

Installation: Tighten the switch to 16 N•m (12 ft-lb)

torque.

20-60-8 E20 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D)

Disassembly and Assembly (Cont’d)

Figure 20-60-26

1
2

P118516

Remove the O-ring (Item 1) and the seal (Item 2) [Figure

20-60-26].

Clean all parts in solvent and dry with compressed air.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
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Inspect all parts for wear or damage. Repair any worn or

damaged parts.

20-60-9 E20 Service Manual

20-60-10
E20 Service Manual
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ACCUMULATOR Figure 20-70-1

Removal And Installation

Lower the boom / bucket and blade to the ground.

WARNING 1

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
P117863
immediately.
W-2145-0290

Remove the accumulator at the manifold (Item 1) [Figure

20-70-1].

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.
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I-2003-0888

From the operator's seat, drain the residual pressure

from the accumulator by stroking a function with the
engine off and the key in the RUN position.

Remove left side cover. (See Removal And Installation on

Page 40-60-1.)

20-70-1 E20 Service Manual

20-70-2
E20 Service Manual
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TRAVEL MOTOR Figure 20-80-2

Description
1
The travel motor is a hydraulic motor which receives
hydraulic fluid from the hydraulic pump through the 1
hydraulic control valve. The speed that the travel motor
rotates is related to the amount of hydraulic fluid it
receives.
2
Removal And Installation

Remove the track. (See Track Removal And Installation

on Page 30-20-5.)

P118946

IMPORTANT Remove the hoses (Item 1) [Figure 20-80-2] from the

travel motor.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Remove the travel motor mounting bolts (Item 2) [Figure
parts clean. Always use caps and plugs on hoses, 20-80-2].
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Installation: Tighten the bolts to 40 - 50 N•m (29 - 37 ft-
I-2003-0888 lb) torque.

Figure 20-80-1 Remove the travel motor.

The drive sprocket can be removed without removing the

travel motor.

If removing the sprocket from a travel motor that has

been removed from the track frame, clamp the motor in a
vise.

Figure 20-80-3
1
1
2

P118944

Remove the bolts (Item 1) [Figure 20-80-1] from the

track frame cover.

Installation: Tighten the bolts to 20 - 25 N•m (15 - 18 ft-

lb) torque.

Remove the cover. P118947

Mark the hoses for correct installation.

Remove the sprocket bolts (Item 1). Remove the sprocket
(Item 2) [Figure 20-80-3].

Installation: Tighten the bolts to 65 - 75 N•m (48 - 55 ft-

lb) torque.

20-80-1 E20 Service Manual

TRAVEL MOTOR (CONT’D)

Parts Identification

1. Housing 51. Snap Ring 59. Ball Bearing

2. Cover 52. Needle Bearing 60. Shim
3. Hub 53. Retaining Ring 61. Plug
4. Change Disposition Piston 54. Retaining Ring
5. Change Disposition Spring 55. Retaining Ring
6. Change Disposition Washer 56. Snap Ring
7. Distributor 57. O-ring
8. Swash Plate 58. O-ring
9. Motor Shaft
10. Plug 56 58
11. Spring 49 50
2 35
12. Washer 46 45
60
13. Needle Bearing 61 52
48
14. Sphere 47
15. Screw
44
16. Retaining Ring
17. Retaining Ring 53 42
18. O-ring 41
51 38
19. O-ring
20. O-ring 43
40
21. Seal 1 39
22. Washer
23. Pin 37
24. Pin 59
57

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25. Rotating Pump Assembly
26. Shockproof Valve 36 3
27. Ball Bearing 4
28. Counterbalance Valve 24
29. Cover
16 17
30. Change Displacement Valve 54 16
31. Fitting 55 9 14
32. Valve Piston 36
33. Plug 32
34. Spring 21
20 5 27
35. Gear
36. Bearing and Seal 6
37. Planetary Carrier
38. Planet Gear 25 13
7 22
39. Pin 19 29
40. Washer 15
8
41. Anti-Rotation Washer
42. Retaining Ring 26
43. Needle Bearing 28 23
44. Planetary Carrier 12
11
45. Planetary Gear 30
46. Sun Gear 33
10
47. Pin 18 30 30
48. Washer 30 32 34
49. Anti-Rotation Washer 31
50. Retaining Ring

P-62564

20-80-2 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-5

Disassembly

Clean the outside of the travel motor before disassembly.

Figure 20-80-6
Drain the lubricant from the travel motor.

Figure 20-80-4

2
1

1
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P-62503

P-62500 To remove the cover, lift the cover up using screwdrivers

in the upper groove [Figure 20-80-5] or install two
threaded pins in the drain holes and lift the cover off
Remove the drain plugs (Item 1) and snap ring (Item 2) [Figure 20-80-6].
[Figure 20-80-4] securing the reduction gear cover.

Drain the excess oil into a container.

20-80-3 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-9

Disassembly (Cont’d) 1
2
Figure 20-80-7
3

P-62506

Remove the retaining rings (Item 1), anti-rotation washer

1
P-62504 (Item 2), planetary gears (Item 3), needle bearings (Item
4), and thrust washer (Item 5) [Figure 20-80-9] from the
first stage planetary carrier assembly.
Remove the O-ring (Item 1) [Figure 20-80-7] from the
cover. Figure 20-80-10

Figure 20-80-8
1
1
2
3

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4

P-62507

P-62505
Remove the retaining ring (Item 1) from the second
reduction sun gear (Item 2) [Figure 20-80-10] and push
Remove the retaining ring (Item 1), shims (Item 2), and the gear down to remove from planetary carrier.
sun gear (Item 3) [Figure 20-80-8].

Remove the first stage planetary carrier (Item 4) [Figure

20-80-8] using your hands.

20-80-4 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-13

Disassembly (Cont’d)
1
Figure 20-80-11

P-62510

Remove the retaining ring (Item 1) [Figure 20-80-13]

P-62508 from the hub to free the two bearings, ring gear, and
motor.

Remove the second stage planetary carrier (Item 1) Figure 20-80-14

[Figure 20-80-11] using your hands.

Figure 20-80-12

1
1
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4 2

P-62511

P-62509 Remove the hub (Item 1) [Figure 20-80-14] from the ring
gear.

Remove the retaining rings (Item 1), anti-rotation washer

(Item 2), planetary gears (Item 3), needle bearings (Item
4), and thrust washer (Item 5) [Figure 20-80-12] from the
first stage planetary carrier assembly.

20-80-5 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-17

Disassembly (Cont’d)

Figure 20-80-15

3
1
4

P-62514

Remove the lapped bearing / front seal (Item 1) [Figure

P-62512 20-80-17].

NOTE: Be careful not to damage the bottom

Remove the O-ring (Item 1) from the ring gear (Item 2) polished / lapped surface of the bearing
and the retaining ring (Item 3) securing the bearing (Item [Figure 20-80-17].
4) [Figure 20-80-15].
NOTE: A commercial bearing extractor and
Figure 20-80-16 supporting cap, as shown, will be required for
bearing removal [Figure 20-80-17]. Be careful
not to damage the bottom polished / lapped

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1 surface of the bearing.

Figure 20-80-18

P-62513

Remove the ball bearing (Item 1) [Figure 20-80-16] by

pushing from underneath.
P-62515

Remove the front seal ring (Item 1) [Figure 20-80-18].

20-80-6 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-21

Disassembly (Cont’d)
1
2
Figure 20-80-19

3
3
1
2
1
4
3
1
2

P-62518

Remove the six screws and washers (Item 1) [Figure 20-

P-62516 80-21].

Remove the cover (Item 2) [Figure 20-80-21].

Remove the plugs (Item 1), springs (Item 2), washers
(Item 3), and counterbalance valve (Item 4) [Figure 20- NOTE: Removal of pin (Item 3) [Figure 20-80-21] is
80-19]. optional.

Figure 20-80-20 Figure 20-80-22

4 3 2
1
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4 3
1

5
2
5

P-62517 P-62519

Remove the plug (Item 1), springs (Item 2), piston valve Remove large O-ring (Item 1), small O-rings (Item 2), pin
(Item 3), and plug (Item 4) [Figure 20-80-20]. (Item 3), and needle bearing (Item 4) [Figure 20-80-22]
from the cover.
Remove the valves (Item 5) [Figure 20-80-20] from the
motor cover. NOTE: Removal of pin (Item 3) [Figure 20-80-22] is
optional.

20-80-7 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-25

Disassembly (Cont’d)
3 1
Figure 20-80-23
4 2

1 5

P-62522

Remove the swash plate (Item 1) [Figure 20-80-25].

P-62520
Remove the sphere (Item 2), pistons (Item 3), springs
(Item 4), and washers (Item 5) [Figure 20-80-25].
Remove the valve plate (Item 1) [Figure 20-80-23].
Figure 20-80-26
Figure 20-80-24

2 1

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1

P-62523
P-62521

Remove the retaining ring (Item 1) and bearing / drive

Remove the rotating pump assembly (Item 1) [Figure 20- shaft assembly (Item 2) [Figure 20-80-26].
80-24].
Remove the oil seal (Item 3) [Figure 20-80-26].

20-80-8 E20 Service Manual

TRAVEL MOTOR (CONT’D)

Disassembly (Cont’d)

Figure 20-80-27

2
1

3
P-62524

Remove the retaining ring (Item 1), ball bearing (Item 2),
and the second retaining ring (Item 3) [Figure 20-80-27].
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20-80-9 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-30

Assembly
2
Clean all parts in solvent and dry with compressed air.
Inspect all parts and replace any that are damaged. If
any of the planetary gears (first or second) are damaged,
replace the damaged planetary stage assembly (first or 1
second) complete with the sun gear that the damaged
gear is from. One damaged gear can cause microscopic
fatigue cracks in mating gear teeth and cause premature
failure after servicing. Apply oil to all O-rings and light
grease to the ball and roller bearings before installation.

Figure 20-80-28
P-62527
3

Install the bearing / drive shaft assembly (Item 1) [Figure

2 20-80-30].
1
Install the retaining ring (Item 2) [Figure 20-80-30].

Figure 20-80-31

4 5

3 1

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P-62525
2
Install the retaining ring (Item 1) [Figure 20-80-28] on the
drive shaft.

Install the ball bearing (Item 2) and the retaining ring

(Item 3) [Figure 20-80-28].

Figure 20-80-29 P-62528

1
Install the sphere (Item 1), washers (Item 2), springs
(Item 3), and pistons (Item 4) [Figure 20-80-31].

Install the swash plate (Item 5) [Figure 20-80-31].

P-62526

Install the oil seal (Item 1) [Figure 20-80-29] in the hub.

20-80-10 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-34

Assembly (Cont’d) 1 4 3

Figure 20-80-32
2

P-62531

Install the needle bearing (Item 1) [Figure 20-80-34] in

P-62529 the cover so the bearing edge extends from the face of
the cover 2,5 - 2,8 mm (0.98 - 0.110 in).

Install the rotating pump assembly (Item 1) [Figure 20- Install the large O-ring (Item 2), small O-rings (Item 3),
80-32]. and pin (Item 4) [Figure 20-80-34] in the cover.

Figure 20-80-33 Figure 20-80-35

1
1
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P-62530 P-62532

Install the valve plate (Item 1) [Figure 20-80-33]. Install the cover (Item 1) [Figure 20-80-35].

Install the six screws and washers (Item 2) [Figure 20-

80-35].

Tighten the screws in a crisscross manner to 40 - 50 N•m

(30 - 37 ft-lb) torque.

20-80-11 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-38

Assembly (Cont’d)
108,4 mm (4.3 in)
Figure 20-80-36
88,4 mm (3.5 in) 20 mm (0.79 in)
+0,05 mm (0.002 in)
-0,0
1 2

+0,1 mm (0.0004 in)

+0,2 mm (0.0008 in)

-0,2 mm (0.0008 in)
4

200 mm (7.9 in)

96 mm (3.8 in)
5

-0,0
3

146 mm (5.7 in)

144 mm (5.7 in)

P-62533

Install the plug (Item 1), piston valve (Item 2), springs
(Item 3), and plug (Item 4) [Figure 20-80-36]. 15 mm (0.6 in)

P-62563
Install the valves (Item 5) [Figure 20-80-36] in the motor
cover.

Figure 20-80-37 Figure 20-80-39

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2
3
4
1
1
2
4
3

P-62534 P-62535

Install the counterbalance valve (Item 1), washers (Item Install the ball bearing (Item 1) [Figure 20-80-39] using
2), springs (Item 3), and plugs (Item 4) [Figure 20-80- the bearing installation tool [Figure 20-80-38].
37].

20-80-12 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-42

Assembly (Cont’d)

Figure 20-80-40 2
1
2

P-62550

Install the O-ring (Item 1) [Figure 20-80-42] on the seal

P-62536 ring (Item 2) [Figure 20-80-42].

NOTE: Inspect the seal ring for burrs before

Install the retaining ring (Item 1) and O-ring (Item 2) installing the O-ring. Install the seal ring
[Figure 20-80-40]. making sure it is not twisted. To remove any
twists, gently pull a section of the O-ring and
Figure 20-80-41 let it snap back.

The O-ring, seal ring, and motor assembly must be clean

and free of any dust, oil film, or foreign matter.
1
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Figure 20-80-43

P-62537

Using the bearing installation tool [Figure 20-80-38],

install the second bearing (Item 1) [Figure 20-80-41]
keeping the lapped face up. Use extreme care not to
B-14594
damage the lapped face of the bearing.

Install the seal seating tool (MEL1468) on the seal ring

[Figure 20-80-43].

20-80-13 E20 Service Manual

TRAVEL MOTOR (CONT’D) Use firm even pressure on the installation tool
(MEL1468) to pop the O-ring into the motor housing
Assembly (Cont’d) [Figure 20-80-45].

Figure 20-80-44 Figure 20-80-46

1,00 mm 1,00 mm
(0.04 in) (0.04 in)

P-62555 P-62557A

The seal ring assembly [Figure 20-80-44] must be After the seal ring is installed, check the stand out height
lubricated with alcohol, so the O-ring will slip past the [Figure 20-80-46] in four places, 90° apart.
housing retaining ring and seal uniform in the motor
housing radius. The stand out height is 1,00 mm (0.04 in).

The O-ring [Figure 20-80-44] on the seal ring assembly NOTE: If the seal ring does not meet the height
must be lubricated with alcohol. specifications inspect the torque ring for

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twists or obvious bulges.
This will allow the O-ring to slide on the motor housing
sealing surface without twisting. Apply a light film of oil to the seal ring and lapped face of
the bearing.
Dip the O-ring [Figure 20-80-44] and seal ring assembly
in a pan of alcohol. NOTE: Do not get any oil on the O-ring.

Shake off the excess alcohol and install the seal ring Figure 20-80-47
assembly on the motor [Figure 20-80-44].

Figure 20-80-45

P-62539

B-14594 Press the reduction unit and motor assembly into the
seat of the bearings [Figure 20-80-47].

20-80-14 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-50

Assembly (Cont’d)

Figure 20-80-48 1

P-62542

Install the planetary assembly (Item 1) [Figure 20-80-

P-62540 50].

Figure 20-80-51
Install the external snap ring (Item 1) [Figure 20-80-48]
in the motor reduction unit.

Figure 20-80-49
2

5
4
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1 1

P-62543

Install the sun gear (Item 1) into the planetary carrier and
P-62541 lock with the retaining ring (Item 2) [Figure 20-80-51].

Install the thrust washers (Item 1), planetary gears (Item

2), needle bearing (Item 3), anti-rotation washers (Item
4), and external snap rings (Item 5) [Figure 20-80-49].

NOTE: Install the snap rings so the opening of the

snap ring is toward the outside.

20-80-15 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-54

Assembly (Cont’d) 3
2
1
Figure 20-80-52

5
4

P-62505

Install the sun gear (Item 1), shims (theoretical shimming

P-62544 0,5 mm (0.02 in) (Item 2), and retaining ring (Item 3)
[Figure 20-80-54].

Install the thrust washers (Item 1), planetary gears (Item Figure 20-80-55
2), needle bearings (Item 3), anti-rotation washers (Item
4), and external snap rings (Item 5) [Figure 20-80-52].

NOTE: Install the snap rings so the opening of the

snap ring is toward the outside.

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Figure 20-80-53

2
P-62504

Install the O-ring (Item 1) [Figure 20-80-55] on the cover.

P-62545

Install the outer planetary assembly (Item 1) [Figure 20-

80-53].

20-80-16 E20 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-80-58

Assembly (Cont’d)
1
Figure 20-80-56

P-62605

Add gear lube (SAE 80W90) to the top plug hole (Item 1)
P-62548 until the gear lube is at the bottom of the plug hole (Item
2) [Figure 20-80-58].

Install the cover (Item 1) [Figure 20-80-56] in the Install and tighten the two plugs (Item 2) [Figure 20-80-
housing. 57].

Figure 20-80-57

1
2
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P-62500

Install the snap ring (Item 1) [Figure 20-80-57] securing

the reduction gear cover.

20-80-17 E20 Service Manual

20-80-18
E20 Service Manual
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SWIVEL JOINT

Description
IMPORTANT
The swivel joint is located under the floor panels and
mounted to the upperstructure. The swivel joint directs When repairing hydrostatic and hydraulic systems,
hydraulic fluid to the undercarriage components while clean the work area before disassembly and keep all
allowing the upperstructure to rotate. parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Removal And Installation damage the system.
I-2003-0888
Expand the track frame fully.
Mark all hoses and tubelines for ease of assembly.
Figure 20-90-1
Figure 20-90-2

P118573
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P118574

Place blocks under the excavator tracks [Figure 20-90-

1]. Remove the two hoses (Item 1) [Figure 20-90-2] from
the swing motor.
Lower the boom / bucket and blade to the ground.
Figure 20-90-3
Relieve hydraulic pressure.

Remove the seat and seat mount. (See Removal And

Installation on Page 40-40-1.)

Remove the floor mat and floor panels. (See Removal

And Installation on Page 40-140-1.) 1

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Oil on Page 10-120-3.)

WARNING
Hydraulic fluid escaping under pressure can have P118575

sufficient force to enter a person’s body by

penetrating the skin. This can cause serious injury
Remove the hose (Item 1) [Figure 20-90-3] from the
and possible death if proper medical treatment by a
case drain manifold block.
physician familiar with this injury is not received
immediately.
W-2145-0290

20-90-1 E20 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-90-6

Removal And Installation (Cont’d)

Figure 20-90-4

1
2
2
3 1

P118716

Remove the bolts (Item 1) and the access plate (Item 2)

P118576 [Figure 20-90-6] from the bottom side of the excavator.

Remove the two pilot hoses (Item 1), the two blade / track
expansion valve hoses (Item 2), the two RH travel hoses
(Item 3) [Figure 20-90-4].

Figure 20-90-5

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2

P118577

Remove the two LH travel hoses (Item 1) and the blade

hose (Item 2) [Figure 20-90-5].

20-90-2 E20 Service Manual

SWIVEL JOINT (CONT’D)

Removal And Installation (Cont’d)

Figure 20-90-7

2
1

1
1

P118715

Remove the five hoses (Item 1) [Figure 20-90-7] from

the left side of the swivel joint.

Remove the five hoses (Item 2) [Figure 20-90-7] from

the right side of the swivel joint.

NOTE: Support the swivel joint on the bottom side of

the excavator to prevent the swivel joint from

falling when the three nuts are being
removed.

Figure 20-90-8

P118714

Remove the three nuts (Item 1) [Figure 20-90-8] and

slide the swivel joint out through the bottom of the
excavator.

20-90-3 E20 Service Manual

SWIVEL JOINT (CONT’D)

Parts Identification (AWRH11419 & Above, B3BL11734 & Above)

1. Rotor
2. Stop
3. Washer
4. Housing
5. Snap Ring
6. O-ring
7. Plug
8. Seal
9. Back-up Ring
10. Seal

1
8

10
2
9

9
10

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3

10
9

9
10

9
4
9

9
3

8
5

7
NA12011S

20-90-4 E20 Service Manual

SWIVEL JOINT (CONT’D)

Parts Identification (AWRH11001 - AWRH11418, B3BL11001 - B3BL11733)

1. Rotor
2. Stop
3. Washer
4. Housing
5. Snap Ring
6. O-ring
7. Plug
8. Seal
9. Back-up Ring
10. Seal

8
2

9
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3
9

9
10

9
4
9

9
3

8
5

7
NA8994S

20-90-5 E20 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-90-11

Disassembly

Figure 20-90-9

1
1

1
P-59178

Remove the snap ring (Item 1) [Figure 20-90-11] from

S6083 the bottom of the swivel joint.

Figure 20-90-12
Mark fitting orientation. Remove the fittings (Item 1)
[Figure 20-90-9].

Figure 20-90-10

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1

1 1

P-59179

Remove the nylon washer (Item 1) [Figure 20-90-12].

S6084

Remove the three bolts (Item 1). Remove the mount

(Item 2) [Figure 20-90-10].

20-90-6 E20 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-90-15

Disassembly (Cont’d)
1 1 1 1
1
Figure 20-90-13

P-59184

1
Remove the seals, back-up seals and O-rings (Item 1)
P-59180 [Figure 20-90-15].

Figure 20-90-16
Tap the end of the rotor (Item 1) [Figure 20-90-13] with a
rubber mallet to drive the rotor out of the housing.
1
Figure 20-90-14

1
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2
P-59184

Remove the outer and inner seals (Item 1). Remove the
P-59181 nylon washer (Item 2) [Figure 20-90-16].

Remove the outer and inner seals (Item 1) [Figure 20-

90-14].

20-90-7 E20 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-90-19

Assembly
1 1 1 1
1
Clean all parts in solvent and dry with compressed air.

Inspect the rotor and housing for scratches or wear that

could cause internal leakage. Always install new seals
and back-up seals. Lubricate all seals and back-up seals
with clean hydraulic fluid before installation.

Figure 20-90-17

P-62345
P-59184

Install the O-rings under the seals (Item 1) [Figure 20-

90-19].

Heat the seals in hydraulic fluid for three minutes at 54°C

(130°F).

Install the seals and back-up seals (Item 1) [Figure 20-

1 90-19].
P-59184
NOTE: The seal and O-ring are serviceable as one
part number.

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Install the nylon washer (Item 1) [Figure 20-90-17].
Figure 20-90-20
Figure 20-90-18
1
1

P-62346 P-59181
P-62345 P-59184

Heat the seals in hydraulic fluid for three minutes at 54°C

Heat the seals in hydraulic fluid for three minutes at 54°C (130°F).
(130°F).
Install the inner and outer seals (Item 1) [Figure 20-90-
Install the inner and outer seals (Item 1) [Figure 20-90- 20].
18].
NOTE: The inner and outer seal are serviceable as
NOTE: The inner and outer seal are serviceable as one part number.
one part number.

20-90-8 E20 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-90-23

Assembly (Cont’d)

Figure 20-90-21

P-59179

Install the nylon washer (Item 1) [Figure 20-90-23].

P-59185
Figure 20-90-24

NOTE: A ring compressor (Item 1) [Figure 20-90-21]

may be used to fit the seals into the seal
grove. Compress the seals for three minutes.

Figure 20-90-22
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1
P-59178

Install the snap ring (Item 1) [Figure 20-90-24].

1
P-59180

Apply hydraulic fluid to the rotor. Install the rotor (Item 1)

[Figure 20-90-22] in the housing.

20-90-9 E20 Service Manual

SWIVEL JOINT (CONT’D)

Assembly (Cont’d)

Figure 20-90-25

2
2

S6084

Install the mount (Item 1) [Figure 20-90-25] on the swivel

joint.

Apply Loctite® 242 to each bolt (Item 2) [Figure 20-90-

25].

Install the bolts (Item 2) [Figure 20-90-25]. Tighten the

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bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.

Figure 20-90-26

1
1

S6083

Install the fittings (Item 1) [Figure 20-90-26] and

orientate accordingly.

20-90-10 E20 Service Manual

SWING MOTOR Figure 20-100-1

Description

The swing motor is a hydraulic motor that receives 2 1

hydraulic fluid from the gear pump through the control
valve to swing the upperstructure left or right. The speed
that the swing motor rotates is related to the amount of
hydraulic fluid it receives.

The swing motor is equipped with an internal brake that is

spring applied and releases with hydraulic pressure.

Removal And Installation

P120260

IMPORTANT Remove the hose (Item 1) from the drain manifold. Cut
and remove the cable tie (Item 2) [Figure 20-100-1].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Remove the hoses from the swing motor [Figure 20-100-
parts clean. Always use caps and plugs on hoses, 1].
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Figure 20-100-2
I-2003-0888

Remove the floor panel. (See Removal And Installation

1
on Page 40-140-1.)
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Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Oil on Page 10-120-3.)

Remove the battery. (See Removal And Installation on

Page 50-20-2.)
1
Remove the travel controls. (See Removal And
Installation on Page 40-110-1.)

P120261

Remove the four bolts (Item 1) [Figure 20-100-2] (front

two shown).

20-100-1 E20 Service Manual

SWING MOTOR (CONT’D)

Removal And Installation (Cont’d)

Figure 20-100-3

P120262

The right rear bolt is accessible through the right side of

the excavator upperstructure [Figure 20-100-3].

Figure 20-100-4

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P120263

Remove the swing motor [Figure 20-100-4].

Installation: Apply thread adhesive (Loctite® 271) to the

bolt threads. Tighten the bolts to 115 N•m (85 ft-lb)
torque.

20-100-2 E20 Service Manual

SWING MOTOR (CONT’D)

Parts Identification

1. Plug
2. Shaft
14
3. Retaining Ring
4. Bearing
5. Seal
6. O-ring 1
1
7. Housing
17
8. Steel Disc
16 1
9. Fiber Disc 6
10. Drive 16
18 5 15
11. Geroler® 5
12. Valve Plate 4
17
13. Valve 13
14. Bolt 6 1
12 6
15. Ball 1
16. Spring 6
17. Crossport Relief Valve
10
18. Pin 6
11
19. Plate
19

10 6
6
14

4
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16 3
6
6

13
6
9
5
8
7
6

6
3
5
4
3
1
2

NA10146S

20-100-3 E20 Service Manual

SWING MOTOR (CONT’D)

Disassembly And Assembly

Clean the outside of the swing motor before disassembly.

Figure 20-100-5

P117890

Remove the bolts (Item 1) [Figure 20-100-5].

Installation: Apply thread adhesive Loctite® 242 to the

bolt threads. Tighten the bolts 34,3 N•m (46.5 ft-lb)
torque.

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Figure 20-100-6

P117903

Remove the springs (Item 1) and O-ring (Item 2) [Figure

20-100-6] from the motor.

20-100-4 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-9

Motor Disassembly
1
Mark the outside of the swing motor for ease of assembly.

Figure 20-100-7

2 2

1
1
S6416

Remove the O-ring (Item 1) [Figure 20-100-9] from the

plug.

P117904 Figure 20-100-10

Remove the crossport relief valves (Item 1). Remove the

plugs (Item 2) [Figure 20-100-7].

Figure 20-100-8 1
2
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1
1

P117905

Remove the springs (Item 1) and balls (Item 2) [Figure

20-100-10].

S6414

Remove the O-rings (Item 1) [Figure 20-100-8] from the

crossport relief valves.

20-100-5 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-13

Motor Disassembly (Cont’d)

Figure 20-100-11 1

2
1

1 1

1 1
P117907

Remove the O-rings (Item 1) [Figure 20-100-13].

P117906
Figure 20-100-14

Remove the bolts (Item 1) [Figure 20-100-11].

1
Figure 20-100-12

1
1
2

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2

3
P117908

Remove the balance ring (Item 1) [Figure 20-100-14].

S6419 Figure 20-100-15

Remove the top of the motor (Item 2) [Figure 20-100-11]

by lifting straight up. If done carefully, the springs (Item 2
1), pins (Item 2), and balance ring assembly (Item 3) 1
[Figure 20-100-12] will remain on the valve for easy
removal.

Remove the springs (Item 1) and pins (Item 2) [Figure

20-100-12].

S6423

Remove the inner seal (Item 1) and outer seal (Item 2)

[Figure 20-100-15].

20-100-6 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-18

Motor Disassembly (Cont’d)

1
Figure 20-100-16

P117911

Remove the valve plate (Item 1) [Figure 20-100-18].

P117909
Figure 20-100-19

Remove the valve (Item 1) [Figure 20-100-16].

Figure 20-100-17 1

1 1
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P117912

Remove the O-rings (Item 1) [Figure 20-100-19] from the

P117910 valve plate.

Remove the drive (Item 1) [Figure 20-100-17].

20-100-7 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-22

Motor Disassembly (Cont’d)

Figure 20-100-20 1

P117915

Turn the housing over and remove the snap ring (Item 1)
P117913 [Figure 20-100-22].

Figure 20-100-23
Remove the Geroler® (Item 1) [Figure 20-100-20].
1
NOTE: Do not disassemble the Geroler®.

Figure 20-100-21 2

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2

P117916

Remove the bearing (Item 1) and remove the seal (Item

2) [Figure 20-100-23].
P117914

Remove the O-rings (Item 1) [Figure 20-100-21].

Remove the drive (Item 2) [Figure 20-100-21].

20-100-8 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-26

Motor Assembly

Clean all parts in solvent and dry with compressed air. 2

Inspect all parts for wear or damage. Replace any worn

or damaged parts. 1

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 20-100-24 1

2
P118035

1
Turn the housing over and install the O-rings (Item 1)
[Figure 20-100-26].

Install the drive (Item 2) [Figure 20-100-26].

P117916
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Install the seal (Item 1) and bearing (Item 2) [Figure 20-

100-24] in the housing.

Figure 20-100-25

P117915

Install the snap ring (Item 1) [Figure 20-100-25].

20-100-9 E20 Service Manual

SWING MOTOR (CONT’D)

Motor Assembly (Cont’d)

Figure 20-100-27

P118036

Install the Geroler® (Item 1) [Figure 20-100-27].

Figure 20-100-28

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1

P117912

Install the O-rings (Item 1) [Figure 20-100-28] on the

valve plate.

20-100-10 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-31

Motor Assembly (Cont’d)

Motor Timing 1

The direction that the output shaft rotates is determined

by timing. Time the motor as follows:

Figure 20-100-29

P118038

Install the drive (Item 1) [Figure 20-100-31].

1 Figure 20-100-32

P118036

Locate the largest open pocket in the Geroler® (Item 1)

[Figure 20-100-29].
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Figure 20-100-30 1

P118039

Align one of the side openings (Item 1) [Figure 20-100-

32] in the valve with the valve plate slot that is over the
1 largest open Geroler® pocket.

Engage the valve with the valve drive by rotating it

clockwise until the spline teeth mesh.

P118037

Install the valve plate and locate the open slot (Item 1)
[Figure 20-100-30] that is over the largest open Geroler®
pocket.

20-100-11 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-35

Motor Assembly (Cont’d)

Figure 20-100-33 2
1

2
2

S6423

Figure 20-100-36
P118040

Install the O-rings (Item 1) [Figure 20-100-33].

3
Apply assembly lube to the springs, and install the 1
2
springs (Item 2) [Figure 20-100-33].

Figure 20-100-34

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Balance Ring

1 B-13495A

1
Install the inner (Item 1) and outer (Item 2) [Figure 20-
100-35] and [Figure 20-100-36] face seals on the
balance ring as shown.

P118041

Install the pins (Item 1) [Figure 20-100-34].

20-100-12 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-39

Motor Assembly (Cont’d)

Figure 20-100-37 1

1
2

S6440

Install the housing (Item 1) [Figure 20-100-39] on the

P118042 motor.

Remove the screwdriver (Item 2) [Figure 20-100-39].

Install the balance ring (Item 1) [Figure 20-100-37]. The
pins must engage the pin notches (Item 3) [Figure 20- Figure 20-100-40
100-36] in the balance ring.

Figure 20-100-38
1
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P118043

S6439 Apply thread sealant to the bolt threads (Item 1) [Figure

20-100-40].

Insert a small screw driver through the port in the

housing. Apply pressure to the side of the balance ring
assembly until the valve housing is in place [Figure 20-
100-38].

20-100-13 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-43

Motor Assembly (Cont’d) 1

Figure 20-100-41

1 1

1 1
S6416

Install the O-ring (Item 1) [Figure 20-100-43] on the

P117906 plugs.

Figure 20-100-44
Install the bolts (Item 1) [Figure 20-100-41]. Tighten the
bolts to 50 N•m (37 ft-lb) torque in a crisscross pattern.

Figure 20-100-42
1
1

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1
2

S6414

Install the O-rings (Item 1) [Figure 20-100-44] on the

P117905 crossport relief valves.

Install the balls (Item 1) and springs (Item 2) [Figure 20-

100-42].

20-100-14 E20 Service Manual

SWING MOTOR (CONT’D)

Motor Assembly (Cont’d)

Figure 20-100-45

1 1

2
2

P117904

Install the plugs (Item 1) [Figure 20-100-45]. Tighten the

plugs to 59 N•m (43.5 ft-lb) torque.

Install the relief valves (Item 2) [Figure 20-100-45].

Tighten the valves to 98 N•m (72 ft-lb) torque.

Clamp the motor in a vise.

Figure 20-100-46

1
P117889

Turn the shaft (Item 1) [Figure 20-100-46] in a clockwise

direction.

If the motor is correctly timed, there will be suction at the

top port (Item 2) [Figure 20-100-46].

20-100-15 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-49

Brake Carrier Disassembly And Assembly

Figure 20-100-47 1

P117894

Remove the ring (Item 1) [Figure 20-100-49].

P117892
Figure 20-100-50

Remove the brake piston (Item 1) [Figure 20-100-47].

1
Figure 20-100-48

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1

P117895

Remove the inner and outer O-ring (Item 1) [Figure 20-

P117893 100-50].

Remove the O-ring (Item 1) [Figure 20-100-48].

20-100-16 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-53

Brake Carrier Disassembly And Assembly (Cont’d)

Figure 20-100-51
1

P117898

Turn the housing over and remove the snap ring (Item 1)
P117896 [Figure 20-100-53].

Figure 20-100-54
Remove the plate (Item 1) [Figure 20-100-51].

Figure 20-100-52
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P117899

P117897 Tap the shaft assembly (Item 1) [Figure 20-100-54] out

of the bottom of the housing.

Remove the friction disk (Item 1) [Figure 20-100-52].

Continue to remove the plates and friction disks.

20-100-17 E20 Service Manual

SWING MOTOR (CONT’D) Figure 20-100-57

Brake Carrier Disassembly And Assembly (Cont’d)

Figure 20-100-55

1
P117902

Press the collar (Item 1) and bearing (Item 2) [Figure 20-

P117900 100-57] off the shaft.

Remove the seal (Item 1) [Figure 20-100-55] from the

housing.

Figure 20-100-56

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1

P117901

Remove the snap ring (Item 1) [Figure 20-100-56].

20-100-18 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) Figure 20-110-2

Testing

Check the pressure reducing valve for the correct

pressure. (See Testing And Adjusting on Page 20-33-1.)

The following tools will be needed to do the procedure:

1
MEL1355 - Hydraulic Test Kit

Lower the boom / bucket and blade to the ground.

Stop the engine.

Relieve hydraulic pressure. P118633

Remove the floor mat and floorplate (See Removal And

Installation on Page 40-140-1.) At the control valve assembly (Item 1) [Figure 20-110-2]
find the pilot line of the control lever (joystick) that is to be
checked (boom, arm, slew, bucket).

IMPORTANT Disconnect the hose from the control 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
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damage the system.

I-2003-0888

Figure 20-110-1

1 2
1

P118632

Remove the nuts (Item 1) and floorplate (Item 2) [Figure

20-110-1].

20-110-1 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Handle Removal And Installation

Testing (Cont’d) Figure 20-110-4

Figure 20-110-3

P118627

P118634
Open the right side cover and disconnect the joystick wire
harness (Item 1) [Figure 20-110-4].
From the test kit, install a 3447 kPa (35 bar) (500 psi)
gauge (Item 1)[Figure 20-110-3] on the pilot line. Start Figure 20-110-5
the excavator, and warm the hydraulic oil to operating
temperature.

Engage the circuit to be tested. Record the operating

pressure. 1

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The operating pressure should be approximately 3000 -
3303 kPa (30 - 33 bar) (435 - 479 psi).

If the operating pressure is correct, check the valve

section spool for proper operation. If the operating
pressure is incorrect, remove the pilot pressure relief
valve, clean, install and retest. (See Testing And
Adjusting on Page 20-33-1.)
P118628
If the pressure is still incorrect, replace the pilot pressure
relief valve. (See Testing And Adjusting on Page 20-33-
1.) Remove the lock (Item 1) [Figure 20-110-5] from the wire
harness.

20-110-2 E20 Service Manual

CONTROL LEVER (CONT’D) Figure 20-110-7

Handle Removal And Installation (Cont’d)

Figure 20-110-6

1
2

P-21668

Installation: The wires [Figure 20-110-7] must be

P-21671A installed in the proper locations in the wire connector,
listed below.

With a small piece of wire (Item 1), depress the wire A Yellow
terminal tabs (Item 2) [Figure 20-110-6].
B Black
Carefully remove the individual wires from the back of the C Black
electrical connector. D Red

Installation: Use a small piece of wire and re-bend the E Brown

tab (Item 1) [Figure 20-110-6] on each wire before

installing the electrical connector.

20-110-3 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-10

Handle Removal And Installation (Cont’d)

Figure 20-110-8

2
2
1

P-32521
1

Installation: Align the top of the dust boot (Item 1) with

P118630 the groove (Item 2) [Figure 20-110-10].

Pull the boot (Item 1) down and pull the wire harness
(Item 2) [Figure 20-110-8] out of the housing.

Figure 20-110-9

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1

P118631

Pull the boot down. Loosen the nut (Item 1) [Figure 20-
110-9] and remove the handle.

20-110-4 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D)

Removal And Installation

WARNING
AVOID INJURY OR DEATH
WARNING Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any In case of acid contact, wash immediately with water.
of the following conditions exist: In case of eye contact get prompt medical attention
• When fluids are under pressure. and wash eye with clean, cool water for at least 15
• Flying debris or loose material is present. minutes.
• Engine is running.
• Tools are being used. If electrolyte is taken internally drink large quantities
W-2019-0907 of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
Figure 20-110-11 W-2065-0807

Remove the right side cover. (See Removal And

Installation on Page 40-250-1.)

Remove the radiator / oil cooler. (See Radiator / Oil

Cooler Removal And Installation on Page 60-40-1.)

Figure 20-110-12
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1 1

P113449

2
Disconnect the negative (-) cable (Item 1) [Figure 20-
110-10] from the battery. 1

P118211

Remove the three bolts (Item 1) from the bracket (Item 2)

[Figure 20-110-12].

20-110-5 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-15

Removal And Installation (Cont’d)

Figure 20-110-13

1 1
1
2
2

P118232

Cut the cable tie (Item 1) from the wire harness (Item 2)
P118230 [Figure 20-110-15].

Figure 20-110-16
Remove the two bolts (Item 1) from the fuse relay center
(Item 2) [Figure 20-110-13] and place fuse center out of
the way.

Figure 20-110-14

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1
2
1

P118233

Disconnect wires (Item 1) [Figure 20-110-16] from the

ignition switch.
P118231

Remove the two bolts (Item 1) from the ECU (Item 2)

[Figure 20-110-14].

20-110-6 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-19

Removal And Installation (Cont’d)

Figure 20-110-17
1

P118236

Mark (Item 1) [Figure 20-110-19] and remove the hoses.

P118234

Disconnect the joystick wires (Item 1) [Figure 20-110-

17]. IMPORTANT
Figure 20-110-18
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
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1 damage the system.

I-2003-0888

P118235

Remove the three mounting bolts (Item 1) [Figure 20-

110-19].

20-110-7 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D)

Parts Identification

1. Handle
2. Dust Boot
3. Coupler
4. Actuator Control Plate
5. U-Joint
6. Plate 1
7. Intermediate Plate
8. Bottom Plate
9. Plunger Assembly
10. Spool
11. Spring
12. Housing

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4

7 9

8
11

NA8317S

20-110-8 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-22

Disassembly

Remove the left handle. (See Handle Removal And

Installation on Page 20-110-2.)
2
Clean the outside of the control lever before disassembly.

Figure 20-110-20
1

2
P-32576

Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-110-22].

Figure 20-110-23

1
P118681

2
Remove the boot (Item 1) from the control lever (joystick)
(Item 2) [Figure 20-110-20].
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Figure 20-110-21
3

2
3

P118683

1
Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-110-23] for correct installation.

Remove the coupler from the control plate.

P118682

Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-110-21] for correct assembly.

20-110-9 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-26

Disassembly (Cont'd)

Figure 20-110-24

P118686

Remove the plate (Item 1) [Figure 20-110-26].

P118684
Figure 20-110-27

Remove the control plate (Item 1) from the U-Joint (Item

2) [Figure 20-110-24].

Figure 20-110-25
1

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1

P118687

Remove the intermediate plate (Item 1) [Figure 20-110-

27].
P118685

Mark the plate and housing for correct installation.

Remove the U-joint (Item 1) [Figure 20-110-25].

NOTE: The plate (Item 2) [Figure 20-110-25] is spring

loaded and will come up as the U-Joint is
removed.

20-110-10 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-30

Disassembly (Cont'd)
1
Figure 20-110-28 2
3

P-32587

Remove the O-ring (Item 1) and plunger (Item 2) from the

P118688 bushing (Item 3) [Figure 20-110-30].

NOTE: Mark the spool assemblies for installation in

Remove the bottom plate (Item 1) [Figure 20-110-28]. their original location.

Figure 20-110-29 Figure 20-110-31

1
1
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P118689 P118690

Remove the plunger assemblies (Item 1) [Figure 20-110- Remove the spool assemblies (Item 1) [Figure 20-110-
29]. 31].

20-110-11 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-34

Disassembly (Cont'd)

Figure 20-110-32

P118691

2
Remove the springs (Item 1) [Figure 20-110-34] from the
P-32591 housing.

Figure 20-110-35
Compress the spring (Item 1) and remove the seat (Item
2) [Figure 20-110-32].
2
Figure 20-110-33

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2 1
1

P-32594

Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

P-32590 110-35].

Remove the spring (Item 1) and shim (Item 2) from the

spool (Item 3) [Figure 20-110-33].

20-110-12 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-38

Assembly

Clean all parts in solvent and dry with compressed air. 2

Inspect all parts for wear or damage. Replace any worn

or damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. 1

Figure 20-110-36

P-32591
1

Compress the spring (Item 1) and install the spring seat

(Item 2) [Figure 20-110-38].

Figure 20-110-39

P118691
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Install the springs (Item 1) [Figure 20-110-36].

Figure 20-110-37

3
P118690
1
2
Install the spool assemblies (Item 1) [Figure 20-110-39]
into the housing.

P-32590

Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-110-37].

20-110-13 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-42

Assembly (Cont'd)

Figure 20-110-40 1

1
2

P118689

Install the plunger assemblies (Item 1) [Figure 20-110-

P-32586 42] into the housing.

Figure 20-110-43
Install the plunger (Item 1) into the bushing (Item 2)
[Figure 20-110-40].

Figure 20-110-41
1

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P118688

Install the bottom plate (Item 1) [Figure 20-110-43].

P-32584

Install the O-ring (Item 1) [Figure 20-110-41] on the

bushing.

20-110-14 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D) Figure 20-110-46

Assembly (Cont'd)
2
Figure 20-110-44

1
1

P118685

Press down on the plates (Item 1) to seat the plunger

P118687 assemblies. Install the U-Joint (Item 2) [Figure 20-110-
46].

Install the intermediate plate (Item 1) [Figure 20-110-44]. Figure 20-110-47

Figure 20-110-45

1
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P118684

P118686
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-110-
Install the top plate (Item 1) [Figure 20-110-45]. 47].

20-110-15 E20 Service Manual

CONTROL LEVER (JOYSTICK) (RIGHT) (CONT’D)

Assembly (Cont'd)

Figure 20-110-48

4
1
5

3
P118683

Align the coupler (Item 1) with the control plate (Item 2)

and plate (Item 3) [Figure 20-110-48]. Tighten the
coupler.

Install the connector (Item 4) [Figure 20-110-48].

Align the connector with the coupler (Item 1) and tighten

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the nut (Item 5) [Figure 20-110-48].

Figure 20-110-49

P-32560

Install the tabs of the boot (Item 1) in between the joystick

flange and mounting plate (Item 2) [Figure 20-110-49].

Install the handle. (See Handle Removal And Installation

on Page 20-110-2.)

20-110-16 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) Figure 20-111-2

Testing

Check the pressure reducing valve for the correct

pressure. (See Testing And Adjusting on Page 20-33-1.)

The following tools will be needed to do the procedure:

1
MEL1355 - Hydraulic Test Kit

Lower the boom / bucket and blade to the ground.

Stop the engine.

Relieve hydraulic pressure. P118633

Remove the floor mat and floorplate. (See Removal And

Installation on Page 40-140-1.) At the control valve assembly (Item 1) [Figure 20-111-2]
find the pilot line of the control lever (joystick) that is to be
checked (boom, arm, slew, bucket).

IMPORTANT Disconnect the hose from the control 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
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damage the system.

I-2003-0888

Figure 20-111-1

1 2
1

P118632

Remove the nuts (Item 1) and floorplate (Item 2) [Figure

20-111-1].

20-111-1 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Handle Removal And Installation

Testing (Cont’d) Remove the left console cover. (See Removal And
Installation on Page 40-60-1.)
Figure 20-111-3
Figure 20-111-4

P118634

P118635

From the test kit, install a 3447 kPa (35 bar) (500 psi)
gauge (Item 1)[Figure 20-111-3] on the pilot line. Start Disconnect the wire harness (Item 1) [Figure 20-111-4].
the excavator, and warm the hydraulic oil to operating
temperature. Figure 20-111-5

Engage the circuit to be tested. Record the operating

pressure.

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The operating pressure should be approximately 3000 -
3303 kPa (30 - 33 bar) (435 - 479 psi).

If the operating pressure is correct, check the valve

section spool for proper operation. If the operating
pressure is incorrect, remove the pilot pressure relief
valve, clean, install and retest. (See Testing And
Adjusting on Page 20-33-1.) 1

If the pressure is still incorrect, replace the pilot pressure

relief valve. (See Testing And Adjusting on Page 20-33- P118636
1.)

Remove the lock (Item 1) [Figure 20-111-5] from the

electrical connector.

20-111-2 E20 Service Manual

CONTROL LEVER (JOYSTICK) LEFT (CONT’D)

Handle Removal And Installation (Cont’d)

Figure 20-111-6

P-32914

Using a small piece of wire, depress the wire terminal

tabs (Item 1) [Figure 20-111-6].

Carefully remove the individual wires from the back of the

electrical connector.

Remove the control handle (joystick) assembly from the

excavator.

Installation: Use a small piece of wire and rebend the

tab on each wire before installing it in the electrical
connector.

20-111-3 E20 Service Manual

CONTROL LEVER (JOYSTICK) LEFT (CONT’D) Figure 20-111-9

Handle Removal And Installation (Cont’d)

Figure 20-111-7
1

P118638

Pull the boot down and pull the wire harness (Item 1) out
P-21668 of the boot. Loosen the nut (Item 2) [Figure 20-111-9]
and remove the handle.

Installation: The wires [Figure 20-111-7] must be Figure 20-111-10

installed in the proper locations in the wire connector,
listed below.

A Yellow
B Black 2
C Black

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D Red
E Brown

Check each wire to be certain the tab locks into position. 1

Figure 20-111-8

P-32521

Installation: Align the top of the dust boot (Item 1) with

the groove (Item 2) [Figure 20-111-10].

P118637

Raise the boot and pull the grommet (Item 1) [Figure 20-
111-8] out of the housing.

Remove the wire and grommet.

20-111-4 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-12

Joystick Assembly Removal and Installation

Lower the boom / bucket and blade to the ground.

Stop the engine.

Relieve hydraulic pressure.

Remove the left console cover. (See Removal And

Installation on Page 40-60-1.)

IMPORTANT P118487

When repairing hydrostatic and hydraulic systems, Mark and remove the hoses [Figure 20-111-12].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Remove the hoses while the control lever (joystick) is
tubelines and ports to keep dirt out. Dirt can quickly bolted to the console [Figure 20-111-12].
damage the system.
I-2003-0888 Figure 20-111-13

Figure 20-111-11

1
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P118486

P118488
Pull the boot (Item 1) [Figure 20-111-13] up from the
plate.
Disconnect the wire harness (Item 1) [Figure 20-111-
11]. Remove the bolts (Item 2) [Figure 20-111-13].

Remove the joystick assembly.

20-111-5 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D)

Parts Identification

1. Handle
2. Dust Boot
3. Coupler
4. Actuator Control Plate 1
5. U-Joint
6. Plate
7. Intermediate Plate
8. Bottom Plate
9. Plunger Assembly
10. Spool
11. Spring
12. Housing
2

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5

7
9

10
8

NA8316S

20-111-6 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-16

Disassembly

Remove the left handle. (See Handle Removal And

Installation on Page 20-111-2.)
2
Clean the outside of the control lever before disassembly.

Figure 20-111-14
1

2
P-32576

Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-111-16].

Figure 20-111-17

1
P118681

2
Remove the boot (Item 1) from the control lever (joystick)
(Item 2) [Figure 20-111-14].
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Figure 20-111-15
3

2
3

P118683

1
Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-111-17] for correct installation.

Remove the coupler from the control plate.

P118682

Mark the coupler (Item 1) nut (Item 2), and connector

(Item 3) [Figure 20-111-15] for correct assembly.

20-111-7 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-20

Disassembly (Cont'd)

Figure 20-111-18

P118686

Remove the plate (Item 1) [Figure 20-111-20].

P118684
Figure 20-111-21

Remove the control plate (Item 1) from the U-Joint (Item

2) [Figure 20-111-18].

Figure 20-111-19
1

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1

P118687

Remove the intermediate plate (Item 1) [Figure 20-111-

21].
P118685

Mark the plate and housing for correct installation.

Remove the U-joint (Item 1) [Figure 20-111-19].

NOTE: The plate (Item 2) [Figure 20-111-19] is spring

loaded and will come up as the U-joint is
removed.

20-111-8 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-24

Disassembly (Cont'd)
1
Figure 20-111-22 2
3

P-32587

Remove the O-ring (Item 1) and plunger (Item 2) from the

P118688 bushing (Item 3) [Figure 20-111-24].

NOTE: Mark the spool assemblies for installation in

Remove the bottom plate (Item 1) [Figure 20-111-22]. their original location.

Figure 20-111-23 Figure 20-111-25

1
1
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P118689 P118690

Remove the plunger assemblies (Item 1) [Figure 20-111- Remove the spool assemblies (Item 1) [Figure 20-111-
23]. 25].

20-111-9 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-28

Disassembly (Cont'd)
1
Figure 20-111-26

P118691

2
Remove the springs (Item 1) [Figure 20-111-28] from the
P-32591 housing.

Figure 20-111-29
Compress the spring (Item 1) and remove the seat (Item
2) [Figure 20-111-26].
2
Figure 20-111-27

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2 1
1

P-32594

Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

P-32590 111-29].

Remove the spring (Item 1) and shim (Item 2) from the

spool (Item 3) [Figure 20-111-27].

20-111-10 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-32

Assembly

Clean all parts in solvent and dry with compressed air. 2

Inspect all parts for wear or damage. Replace any worn

or damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. 1

Figure 20-111-30

P-32591
1

Compress the spring (Item 1) and install the spring seat

(Item 2) [Figure 20-111-32].

Figure 20-111-33

P118691
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Install the springs (Item 1) [Figure 20-111-30].

Figure 20-111-31

3
P118690
1
2
Install the spool assemblies (Item 1) [Figure 20-111-33]
into the housing.

P-32590

Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-111-31].

20-111-11 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-36

Assembly (Cont'd)

Figure 20-111-34 1

1
2

P118689

Install the plunger assemblies (Item 1) [Figure 20-111-

P-32586 36] into the housing.

Figure 20-111-37
Install the plunger (Item 1) into the bushing (Item 2)
[Figure 20-111-34].

Figure 20-111-35
1

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P118688

Install the bottom plate (Item 1) [Figure 20-111-37].

P-32584

Install the O-ring (Item 1) [Figure 20-111-35] on the

bushing.

20-111-12 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D) Figure 20-111-40

Assembly (Cont'd)
2
Figure 20-111-38

1
1

P118685

Press down on the plates (Item 1) to seat the plunger

P118687 assemblies. Install the U-Joint (Item 2) [Figure 20-111-
40].

Install the intermediate plate (Item 1) [Figure 20-111-38]. Figure 20-111-41

Figure 20-111-39

1
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P118684

P118686
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-111-
Install the top plate (Item 1) [Figure 20-111-39]. 41].

20-111-13 E20 Service Manual

CONTROL LEVER (JOYSTICK) (LEFT) (CONT’D)

Assembly (Cont'd)

Figure 20-111-42

4
1
5

3
P118683

Align the coupler (Item 1) with the control plate (Item 2)

and plate (Item 3) [Figure 20-111-42]. Tighten the
coupler.

Install the connector (Item 4) [Figure 20-111-42].

Align the connector with the coupler (Item 1) and tighten

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the nut (Item 5) [Figure 20-111-42].

Figure 20-111-43

P-32560

Install the tabs of the boot (Item 1) in between the joystick

flange and mounting plate (Item 2) [Figure 20-111-43].

Install the handle. (See Handle Removal And Installation

on Page 20-111-2.)

20-111-14 E20 Service Manual

HYDRAULIC FILTER MOUNT Figure 20-120-2

Description

The hydraulic filter removes contaminants from the 1

hydraulic fluid when the hydraulic systems are operating.

The hydraulic filter system consists of one main hydraulic

filter located behind the tailgate and removes the
contaminants after the oil cooler.

Removal And Installation

IMPORTANT P117824

Remove the two hoses (Item 1) [Figure 20-120-2].

When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Figure 20-120-3
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
1

Open the tailgate.

Remove air cleaner / fuel filter assembly and set aside.

(See Removal And Installation on Page 60-30-1.)
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Figure 20-120-1

P117823

1
Remove the two hoses (Item 1) [Figure 20-120-3].

Figure 20-120-4

2
P117821

Remove the coolant reservoir hose (Item 1), the clamp

(Item 2), and remove reservoir (Item 3) [Figure 20-120- 1
1].

P117826

Remove the two mounting nuts (Item 1) [Figure 20-120-

4] and remove the hydraulic filter mount assembly.

20-120-1 E20 Service Manual

20-120-2
E20 Service Manual
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HYDRAULIC RESERVOIR Figure 20-130-2

Description

The hydraulic reservoir is a storage container for the

excavators hydraulic fluid. The reservoir contains a
vented fill cap with a fluid screen to prevent contaminants
from entering the reservoir while adding fluid.

The hydraulic reservoir is located on the left side of the 1

excavator.

Removal And Installation

Remove the left side cover. (See Removal And

Installation on Page 40-60-1.) P120266

Open tailgate.
Remove the hose (Item 1) [Figure 20-130-2] from the
Drain hydraulic reservoir. (See Removing And Replacing hydraulic reservoir.
The Hydraulic Oil on Page 10-120-3.)
Figure 20-130-3
Remove the air cleaner assembly. (See Removal And
Installation on Page 60-30-1.)

Remove the muffler assembly. (See Removal And

Installation on Page 60-20-1.)

Figure 20-130-1
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1 P120267

Remove the hose (Item 1) [Figure 20-130-3] from the

bottom of the hydraulic reservoir.

P120264

Remove the hoses (Item 1) [Figure 20-130-1] from the

hydraulic reservoir tee fitting.

20-130-1 E20 Service Manual

HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-6

Removal And Installation (Cont’d)

Figure 20-130-4

1 2
1

1
P117800

Remove the two mounting bolts (Item 1), the mounting

P117798 bracket (Item 2) [Figure 20-130-6], and remove the
hydraulic reservoir.

Remove the three hoses (Item 1) [Figure 20-130-4].

NOTE: Bonnet removed for photo clarity.

Figure 20-130-5

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1

P120269

Cut the cable tie (Item 1) [Figure 20-130-6] for the fuel
filter.

20-130-2 E20 Service Manual

OIL COOLER

Removal And Installation

The oil cooler and radiator are removed from the

excavator as a unit. (See Radiator / Oil Cooler Removal
And Installation on Page 60-40-1.)
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20-140-1 E20 Service Manual

20-140-2
E20 Service Manual
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BLADE / TRACK EXPANSION SOLENOID BLOCK Figure 20-150-1

Description

The blade / track expansion solenoid block diverts

hydraulic fluid to either the blade or track expansion 1
function with the switch on the right hand console.

The blade / track expansion solenoid block is located

under the floor mat and floor panels on the right side of 1
the excavator.

Block Removal And Installation

Lower the boom / bucket and blade to the ground.

P117956
With the engine off, turn the start key to the ON position
and move blade lever to relieve hydraulic pressure.
Mark all tubelines / hoses for ease of assembly.

Disconnect the tubelines / hoses (Item 1) [Figure 20-

IMPORTANT 150-1] and [Figure 20-150-2] from the block.

Figure 20-150-2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
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I-2003-0888

Remove the floor mat and floor panel. (See Removal And
Installation on Page 40-140-1.)

WARNING 1

P117957
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

20-150-1 E20 Service Manual

BLADE / TRACK EXPANSION SOLENOID BLOCK
(CONT’D)

Block Removal And Installation (Cont’d)

Figure 20-150-3

P117954

Disconnect the wire harness (Item 1) [Figure 20-150-3]

from the excavator harness.

Figure 20-150-4

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2

P117959

Remove the bolts (Item 1) [Figure 20-150-4].

Remove the blade / track expansion solenoid block (Item

2) [Figure 20-150-4] from the excavator.

20-150-2 E20 Service Manual

BLADE / TRACK EXPANSION SOLENOID BLOCK Figure 20-150-5
(CONT’D)

Solenoid Removal And Installation 3

Lower the boom / bucket and blade to the ground.

1
With the engine off, turn the start key to the ON position
and move blade lever to relieve hydraulic pressure. 2

IMPORTANT
When repairing hydrostatic and hydraulic systems,
P117954
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 Disconnect the wire harness (Item 1) [Figure 20-150-5]
damage the system. from the excavator harness.
I-2003-0888

Remove the solenoid nut (Item 2) [Figure 20-150-5].

Remove the floor mat and floor panel. (See Removal And
Installation on Page 40-140-1.) Remove the coil (Item 3) [Figure 20-150-5] from the
solenoid stem.

Figure 20-150-6
WARNING
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Hydraulic fluid escaping under pressure can have

P117958

Remove the solenoid stem (Item 1) [Figure 20-150-6].

Installation: Tighten the solenoid stem to 50 N•m (37 ft-

lb) torque.

20-150-3 E20 Service Manual

BLADE / TRACK EXPANSION SOLENOID BLOCK Block Disassembly And Assembly
(CONT’D)

Solenoid Removal And Installation (Cont’d)

Figure 20-150-7 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

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts.
2
1
Always install new O-rings, back-up rings, and seals.
P117963
Lubricate all O-rings and back-up rings with clean
hydraulic fluid before installation.
Remove the O-ring (Item 1) and seals (Item 2) [Figure
20-150-7] from the solenoid stem. Figure 20-150-8

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1
P117960

Remove the nut (Item 1) [Figure 20-150-8] from the

solenoid.

20-150-4 E20 Service Manual

BLADE / TRACK EXPANSION SOLENOID BLOCK Figure 20-150-11
(CONT’D)

Block Disassembly And Assembly (Cont’d)

Figure 20-150-9

2
1
P117964

Remove the O-ring (Item 1) and seals (Item 2) [Figure

2 1 20-150-11].
P117961
Figure 20-150-12

Remove the O-ring (Item 1) and solenoid (Item 2)

[Figure 20-150-9].

Figure 20-150-10
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1 2

P117963

Remove the O-ring (Item 1) and seals (Item 2) [Figure

20-150-12].
2 P117962

Remove the solenoid stem (Item 1) and the blade relief

valve (Item 2) [Figure 20-150-10].

Installation: Tighten the solenoid stem to 50 N•m (37 ft-

lb) torque.

20-150-5 E20 Service Manual

20-150-6
E20 Service Manual
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UNDERCARRIAGE

BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Extension Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Blade Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2

TRACK UNDERCARRIAGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Track Tensioner Disassembly & Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8
Track Frame Guide Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9
Removal And Installation Of Expandable Track Frame . . . . . . . . . . . . . . . . . . . . . . . 30-20-9

TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

30-01 E20 Service Manual

30-02
E20 Service Manual
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BLADE Extension Removal And Installation

Description Figure 30-10-2

The blade extensions are used to match the blade width 2

to the track width. Secure the blade extensions in the
retracted position when transporting the excavator or
when narrow operating width is needed. Under normal
operating conditions, the blade width should match the 1
track width.

Figure 30-10-1 3

1
P113546

Raise the blade sightly and place a block under the

blade. Lower the blade fully.

Remove the blade retainer pin assembly (Item 1) [Figure

30-10-2].
2
Remove and reposition the blade extension (Item 2)
[Figure 30-10-2] to the outside blade position.

Reinstall the blade retainer pin assembly (Item 3) [Figure

P118557 30-10-2].
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The blade extensions (Items 1 and 2) [Figure 30-10-1]

are located on the blade.

30-10-1 E20 Service Manual

BLADE (CONT’D)

Blade Removal And Installation

Expand the tracks. (See the Operation & Maintenance

Manual for the Proper procedure.)

Lower the blade to the ground.

Remove the blade cylinder. (See Removal And

Installation on Page 20-24-2.)

Figure 30-10-3

P118556

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Remove the snap ring (Item 1) [Figure 30-10-3] and
washer from the blade arm pivot pins (both sides).

Remove the blade arm pivot pins (Item 2) [Figure 30-10-

3] (both sides).

Remove the blade from the excavator.

30-10-2 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS

Description

The track undercarriage components consist of the front

idler, top roller, bottom rollers, drive motor, and track
frame.

Track Lug Height

The lug height of a new rubber track is 23,0 mm (0.9 in).

Figure 30-20-1

Straight Edge

B-14489
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To find the percentage of wear on a excavator track,

measure the height of the lug by placing a straight edge
across the top of three lugs and measure the distance
from the base of the track to the bottom of the straight
edge [Figure 30-20-1].

Divide this measurement by the new track height and

multiply by 100. This will give the percentage of track lug
left.

Example: lug height 20,0 mm (0.787 in)

18,0 (0.7)
23,0 (0.9) x 100 = 78

78% of the track lug is remaining with 22% wear on the

track lugs.

30-20-1 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)

Checking Tension WARNING

NOTE: The wear of the pins and bushings on the
undercarriage vary with the working AVOID INJURY
conditions and the different types of soil Keep fingers and hands out of pinch points when
conditions. It is necessary to inspect track checking the track tension.
tension and maintain the correct tension. See W-2142-0903
SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page Track Clearance
10-60-1.)
Figure 30-20-4
Raise the side of the machine (approximately 102 mm [4
in]) using the boom and arm.

Figure 30-20-2
8,3 - 13,5 mm
(0.33 - 0.53”)

1
P113461

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Figure 30-20-5
P113459

Track
Figure 30-20-3 Frame

8,3 - 13,5 mm
(0.33 - 0.53 in)

Track
1 Roller

Track
B-14067

Measure the clearance at the middle track roller. Do not

P113460 get fingers into pinch points between the track and the
track roller. Use a bolt or a dowel of the appropriate size
to check the gap between the contact edge of the roller
Raise the blade fully and install the jackstands under the and the top edge of the track guide [Figure 30-20-4] and
blade and track frame (Item 1) [Figure 30-20-2] and [Figure 30-20-5].
[Figure 30-20-3]. Raise the boom until all machine
weight is on the jackstands. Track Clearance 8,3 - 13,5 mm
(0.33 - 0.53 in)
Stop the engine.

30-20-2 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-8

Adjusting Tension

WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension. 1
W-2142-0903
1

Figure 30-20-6
S6096

Loosen the two bolts (Item 1) [Figure 30-20-8] on the

cover. Pivot the cover downward.

Figure 30-20-9
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P113461
2
1
Figure 30-20-7

RUBBER
Track Frame
P113462

Rubber
Track Sag Increase Track Tension
8 - 13 mm
(0.33 - 0.53”) Add grease to the fitting (Item 1) [Figure 30-20-9] until
Track the track tension is correct.
Roller

Rubber
Track
B-14067

Measure the clearance at either middle track roller. DO

not get fingers into pinch points between the track and
the track roller. Use a bolt or a dowel of the appropriate
size to check the gap between the contact edge of the
roller and the top edge of the track guide [Figure 30-20-
6] and [Figure 30-20-7].

30-20-3 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)

Adjusting Tension (Cont’d) WARNING

Decrease Track Tension
AVOID INJURY OR DEATH
Do not loosen the grease fitting more than one
complete rotation. Also, be careful not to loosen any
part other than the grease fitting. If the grease fitting
WARNING or any part is loosened too much, it can fly off under
high pressure. If the grease does not ooze smoothly,
try moving the machine back and forth for a short
AVOID INJURY OR DEATH
distance.
If grease fitting is removed before pressure is W-2143-0189
released, the fitting can come off with great force and
cause serious injury or death.
W-2490-0104

Pressure must be released from the grease cylinder to

decrease track tension.
WARNING
Loosen the bleed fitting (Item 2) [Figure 30-20-9] (NOT HIGH PRESSURE GREASE CAN
the grease fitting) and release pressure until the track CAUSE SERIOUS INJURY
tension is correct. • Do not loosen grease fitting.
• Do not loosen bleed fitting more than 1 - 1/2
NOTE: DO NOT loosen the bleed fitting (Item 2) turns.
[Figure 30-20-9] for more than eight turns. W-2781-0109

Tighten the bleed fitting to 80 - 100 N•m (59 - 74 ft-lb)

torque.

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Pivot the access cover closed and tighten the access
cover bolts.

Repeat the procedure for the other side.

If the track tension is still loose after adjusting to the

mentioned limit, it indicates the track is worn.

30-20-4 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-12

Track Removal And Installation

Lift and block the side of the machine where the track will
be removed.

Figure 30-20-10

S35411
1

Turn the track until the bar contacts the frame [Figure 30-
20-12].

Pry the track off the idler wheel.

P113462
Remove the track from the drive sprocket.

Slowly loosen the bleed screw fitting (Item 1) [Figure 30- To install the rubber track:
20-10] (one turn maximum) to remove track tension.
Put the track over the rear drive sprocket lugs.
NOTE: Apply additional pressure to the track by
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standing on the lower track span so all the Put the front of the track onto the front idler wheel.
tension is released from the grease cylinder
for easier removal of the track. See Track Tension Adjustment for adding grease to the
grease spring and for checking track tension. (See
Figure 30-20-11 Checking Tension on Page 30-20-2.)

S6326

Install a round bar (approximately 30 mm [1.25 in])

diameter) between the drive lugs [Figure 30-20-11].

30-20-5 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-14

Idler Removal And Installation

Remove the track. (See Track Removal And Installation

on Page 30-20-5.)

Figure 30-20-13 1

P118942

Remove the track tensioner assembly (Item 1) [Figure

30-20-14].

P118941

Slide the track idler (Item 1) [Figure 30-20-13] out of the

track frame.

Track Tensioner Removal And Installation

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DO NOT DISASSEMBLE OR REPAIR THE COIL
SPRING ASSEMBLY (Item 1) [Figure 30-20-14].

WARNING

P-62574

AVOID INJURY OR DEATH

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly
W-2617-1004

30-20-6 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Roller Removal And Installation

Track Tensioner Disassembly & Assembly Figure 30-20-17

Figure 30-20-15

1
1

P118943

P118948
Loosen the bolts (Item 1) [Figure 30-20-17] on the track
roller on both sides of the track frame.
Remove the cylinder (Item 1) from the track tensioner
assembly (Item 2) [Figure 30-20-15]. Installation: Tighten the bolts to 190 - 210 N•m (140 -
155 ft-lb) torque.
Figure 30-20-16
Figure 30-20-18
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1
1

P118949

P-92379

Remove the seals (Item 1) [Figure 30-20-16].

Remove the bottom roller (Item 1) [Figure 30-20-18].

NOTE: The rollers are not serviceable. Replace the

roller if it is damaged.

30-20-7 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)

Sprocket Removal And Installation

Figure 30-20-19

P118947

Remove the drive sprocket bolts (Item 1) [Figure 30-20-

19].

Installation: Put thread adhesive (Loctite® 242) on the

bolts and tighten to 108 N•m (80 ft-lb) torque.

Remove the drive sprocket (Item 2) [Figure 30-20-19]

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from the travel motor.

30-20-8 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)

Track Frame Guide Inspection

Figure 30-20-20

S6331

Inspect the track guide (Item 1) [Figure 30-20-20] for

wear or damage.
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30-20-9 E20 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-22

Removal And Installation Of Expandable Track Frame

Remove the track expansion cylinder. (See Removal And

Installation on Page 20-25-2.)

Lift and block the track frame.

1
Remove the track. (See Track Removal And Installation
on Page 30-20-5.)

Remove the track frame expansion cylinder (See

Removal And Installation on Page 20-25-2.)

Figure 30-20-21 P118945

Remove the stop bolt (Item 1) [Figure 30-20-22] from the

track expansion frame.
1
1 NOTE: Front stop bolt shown is for the left track
frame. Rear stop bolt is for the right side.

Installation: Apply thread locking adhesive Loctite® 242.

Figure 30-20-23

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P118946

Remove the travel motor cover. Remove the hoses (Item

1) [Figure 30-20-21] from the travel motor.

S6332

Install a chain hoist on the track frame [Figure 30-20-23].

Lift the frame a small amount while pulling the frame
away from the excavator.

30-20-10 E20 Service Manual

TRACK MAINTENANCE Causes of the damage:

Track Damage Identification When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
The following pages show photos and illustrations of of the embedded steel cords causes steel cords to be
track damage and the probable cause of the damage. It cut:
is intended to be used for identifying the reason for track
damage and how to avoid future track damage. Figure 30-30-3

Cutting Of Steel Cords

Figure 30-30-1

PI-13035

When the rubber track is detracting, the idler or sprocket

P-3864 rides on the projections of the embedded metal [Figure
30-30-3].
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Figure 30-30-2 When the rubber track is detracted, projections of rubber

tracks get stuck between the frame of the undercarriage.

The rubber track is clogged with stones or foreign

obstacles.

When moisture invades through a cut on the lug side

rubber surface, the embedded steel cords will corrode.
The deterioration of the design strength may lead to the
breaking off of the steel cords.

Prevention:

The following preventions should be taken to minimize

Steel Cords the risk of this damage:
PI-13034
Periodical checking on site of the recommended track
tension.
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 avoid having stones and other
articles clog 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.

30-30-1 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Abrasion Of Embedded Metals inevitable. The following cases sometimes accelerate
their abrasion:
Figure 30-30-4
Rubber tracks are driven with an extraordinary heavy
load on them.

Rubber tracks are used on sandy fields.

Prevention:

As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.

P-3865

Damage:

In proportion to the service time, embedded metals will

gradually wear away by friction [Figure 30-30-4].

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Figure 30-30-5

Abrasion

D D1 = 0.67D
PI-13037

Replacement:

Replacement is required when the width of the

embedded metals (D1) becomes 67% of their original
width (D) [Figure 30-30-5].

30-30-2 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Embedded metals are adhered between the steel cords
and the rubber body. The following cases generate
Separation Of Embedded Metals external forces greater than the adhesion strength,
causing separation of the embedded metals:
Figure 30-30-6
Figure 30-30-7

Idler

Rubber
Track

P-4379

PI-13039

Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded metals embedded metals, the embedded metals will eventually
cause their separation from the rubber track's body peel off [Figure 30-30-7].
[Figure 30-30-6].
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Figure 30-30-8
Replacement:

Even a partial separation of embedded metals requires

replacement of the track.
Guide

PI-13040

When a rubber track is detracted, it becomes stuck

between the guide or the undercarriage frame, causing
the separation of embedded metals [Figure 30-30-8].

30-30-3 E20 Service Manual

TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Separation Of Embedded Metals

Figure 30-30-9

Abrasion

PI-13041

Abnormally worn sprockets will pull embedded metals out

[Figure 30-30-9].

Prevention:

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Similar to the prevention against the cutting of the steel
cords:

Track tension should be periodically checked.

Quick turns on bumpy and rocky fields should be

avoided.

If abnormal wear of sprockets is observed, they

should be immediately replaced.

30-30-4 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-11

Separation Of Embedded Metals Due To Corrosion Embedded metal

Figure 30-30-10
Good

Separation of
bonded
rubber cover

PI-13043

Embedded metals are bonded to the rubber body. The

P-4378 following operating conditions cause embedded metals to
corrode, causing deterioration of the bonding, and finally
resulting in separation of the embedded metals from the
Damage: rubber body [Figure 30-30-11].

Due to corrosion of embedded metals, the adhesion to Excessively salty fields, like the sea shore.
the rubber body deteriorates, resulting in complete
separation [Figure 30-30-10]. Strong acidic or alkali soil conditions
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Replacement: Compost spread grounds

Even a partial separation of embedded metals requires a On tracks that are out of adjustment, the track rollers,
rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.

Prevention:

If rubber tracks are used under such field conditions as

described under (Causes of the damage). The tracks
should be washed with plenty of water. After being
completely dried, they should be stored correctly.

When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacement of
the rubber track.

30-30-5 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-13

Cuts On The Lug Side Rubber

Figure 30-30-12 Cuts

PI-13045

When rubber tracks drive over projections or sharp

P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
Damage: will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
Cuts on the lug side rubber often occurs as one of the steel cords' breakage due to their corrosion. It is highly
most typical failure modes [Figure 30-30-12] recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 30-30-13].

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Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately repaired Machine operators are requested to drive with great
with cold vulcanization rubber. attention to the ground's surface especially in terrains of
the following type:

Construction sites

Demolition sites

Paths covered with rocks and wood

Concrete ridges

Stumpy fields

When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.

30-30-6 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 30-30-14 even small external cracks. When operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.

Prevention:

Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. External
injuries on the lug side rubber sometimes cause more
chance of cracking. Machine operators should observe
soil conditions when driving, so as not to cause external
injuries to the lug side rubber. In order to minimize the
occurrence of ozone cracks, attention should be paid to
the following instructions for maintenance:

P-4382 Avoid exposing stored tracks to direct sun light.

Avoid exposing stored tracks to direct rain and snow

Figure 30-30-15 fall.

Store tracks in well ventilated warehouses.

Use the tracks at least once a month.

P-4380

Damage:

Small cracks around the root of the lug as a result from

operation fatigue [Figure 30-30-14] and [Figure 30-30-
15].

Replacement:

When the cracks reach so deep that they expose the

steel cords, track replacement is required.

30-30-7 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Lug abrasion is inevitable. Even if lug abrasion is
proceeding, the rubber track can be used. As the traction
Lug Abrasion performance deteriorates accordingly, it is highly
recommended to replace the abraded tracks with new
Figure 30-30-16 ones when the lug height becomes less than 5 mm
(0.197 in).

Prevention:

In order to prevent the rubber track from abnormal or

premature abrasion, following operating conditions
should be avoided:

Making quick and repeated turns on concrete and

asphalt roads

Driving up and down hilly paths with slippage

Making frequent turns on paths covered with rocks

P-4381 and wood

Figure 30-30-17

Lug abrasion

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t

PI-13049

Damage:

As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 30-30-16] and [Figure 30-
30-17].

Replacement:

No replacement is required.

30-30-8 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-19

Track Damage Identification (Cont’d)

Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 30-30-18
embedded metal rubber

PI-13051

Causes of the damage:

When rubber tracks drive over sharp projections,

PI-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals
Damage: [Figure 30-30-19].

Sometimes cracks and cuts on the lug side rubber at the Prevention:
edges of the embedded metals can be observed [Figure
30-30-18]. To avoid extensive stress applied to the lug root
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where metals are embedded, machine operators are

Replacement: requested to avoid driving over stumps and ridges.

No replacement is required unless the cuts on the lug

side rubber are discovered all around the edges of the
embedded metals, as this will result in a complete cut off.

30-30-9 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-21

Track Damage Identification (Cont’d)

Abrasion Of The Track Roller Side Track roller

Figure 30-30-20 Abrasion

PI-13053

Causes of the damage:

The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against
Damage: the side of the rubber track to cause the abrasion [Figure
30-30-21].
The rubber surface on which track rollers run is gradually
abraded. It will end in the exposure of the embedded The level of abrasion is highly dependent on terrain
metals [Figure 30-30-20]. conditions. A higher level of abrasion will occur when the

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rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when more an extended period of abrasion, it will be more likely for
than half of the embedded metals are completely exposed embedded metals to catch moisture through the
exposed. inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.

Prevention:

After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

30-30-10 E20 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-24

Track Damage Identification (Cont’d)

Cuts On The Edges Of Track Roller Side

Figure 30-30-22

PI-13056

In case of damage by objects on the operating ground:

The edges of rubber track are often deformed largely

P-4384 due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. When a machine drives over
Figure 30-30-23 concrete ridges, this type of damage easily occurs
[Figure 30-30-24].

Figure 30-30-25
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Edge Edge

Cut

Tear
PI-13055

Damage:
PI-13057

Both edges of the rubber track have no special

reinforcements. It sometimes occurs during operation In case of damage by interference with the machine
that they are cut or torn off [Figure 30-30-22] and frame:
[Figure 30-30-23].
If a machine continues operating with rubber tracks
Replacement: being detracted, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
In such case, the rubber track does not have to be in damage. When a machine travels along side
replaced. slopes, the rubber tracks are deformed so much that
they come into contact with the machine frame and
Causes of the damage: undercarriage parts, which causes cutting, gouging
and rubbing of rubber tracks in the end [Figure 30-30-
This damage is caused by objects on the field or by 25].
interference with the machine frame.

30-30-11 E20 Service Manual

TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Cuts On The Edges Of Track Roller Side (Cont’d)

Prevention:

When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracking.

30-30-12 E20 Service Manual

SWING CIRCLE GEAR Figure 30-40-2

Removal And Installation 3

4 4
Remove the upperstructure from the swing circle gear.
(See Removal on Page 40-10-1.) 2

Figure 30-40-1

3 1
2

NA9401

Install the swing bearing with the outer soft zone (Item 1)
located to the left side of the track frame and the inner
soft zone (Item 2) [Figure 30-40-2] located to the right
side of the track frame.

Install the bolts (Item 3) [Figure 30-40-2] and nuts.

NA9402 Tighten the bolts to 105 - 115 N•m (78 - 85 ft-lb) torque.
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Install the dowel pins (Item 4) [Figure 30-40-2] in the

Remove the bolts (Item 1) and (Item 2) nuts [Figure 30- swing bearing.
40-1]. Remove the swing bearing (Item 3) [Figure 30-40-
1] from the track frame.

30-40-1 E20 Service Manual

30-40-2
E20 Service Manual
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UPPERSTRUCTURE & SWING

UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3

ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-5
Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-6
Right Side Sliding Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-30-9
Glass Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-9
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-10

SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Lock Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-3
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Console Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-3

LEFT UPPERSTRUCTURE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

RIGHT UPPERSTRUCTURE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-3

BLADE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

RIGHT PEDAL (BOOM SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-2

TRAVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-2

LEFT PEDAL (AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

40-01 E20 Service Manual

CONTROL LINKAGE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-2

FLOOR MAT AND FLOOR PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1

SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-3
Swing Frame Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-3
Swing Frame Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-4

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Boom Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-3

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ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-2
Arm To Bucket And Bucket Link Bushing Removal And Installation . . . . . . . . . . . . 40-190-3

BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1

TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1

OPERATOR BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230-1

40-02 E20 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240-6

QUICK COUPLER (LEHNHOFF® SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-1
Removal (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-2
Installation (MS03 And MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-3
Parts Identification (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-4
Disassembly And Assembly (MS03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-5
Parts Identification (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-6
Disassembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-7
Assembly (MS08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241-10

RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250-1
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40-03 E20 Service Manual

40-04
E20 Service Manual
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UPPERSTRUCTURE Figure 40-10-1

Description 2 1

The upperstructure includes all the components in or

attached to the frame and connects to the slew bearing.
The slew bearing divides the upperstructure from the
undercarriage, which includes the track frame
components.

Removal

Fully extend the cylinders of the bucket and arm. Fully

retract the cylinder of the boom.

Lower the blade to the ground. P117869

Remove the battery. (See Removal And Installation on

Page 50-20-2.) Install lifting brackets (Item 1) [Figure 40-10-1] in the rear
cab / canopy mounts.
Remove the cab or canopy. (See Removal And
Installation on Page 40-30-1.) Fasten the chain to the pin (Item 2) [Figure 40-10-1] in
the top of the boom.
Remove the operator bonnet. (See Removal And
Installation on Page 40-230-1.) Install the front and rear lifting chains to a lifting fixture
above the excavator.
Drain the hydraulic reservoir. (See Removing And
Replacing The Hydraulic Oil on Page 10-120-3.)

WARNING
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Remove the seat and seat mount. (See Removal And

Installation on Page 40-40-1.)
AVOID INJURY OR DEATH
Remove the floor mat and floor panels. (See Removal
• Use a lifting fixture with sufficient capacity for
And Installation on Page 40-140-1.)
the weight of the excavator plus any added
attachments.
Remove the control linkage assembly. (See Disassembly
• Maintain center of gravity and balance when
And Assembly on Page 40-120-1.)
lifting.
• Do not swing boom or upperstructure. Engage
Remove the hydraulic control valve. (See Removal And
the upperstructure slew lock.
Installation on Page 20-40-1.)
• Never lift with operator on machine.
W-2202-0607
Remove the swing motor. (See Removal And Installation
on Page 20-100-1.)

40-10-1 E20 Service Manual

UPPERSTRUCTURE (CONT’D)

Removal (Cont’d)

Figure 40-10-2

P118095

Mark the upperstructure to the swing bearing and to the

track frame for ease of assembly [Figure 40-10-2].

Figure 40-10-3

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1

P117868

Remove the hoses from the top of the swivel joint [Figure
40-10-3].

Remove the bolts (Item 1) [Figure 40-10-3] from the

upperstructure.

Lift the upperstructure off the swing bearing. Position the

upperstructure onto supporting stands or blocks.

40-10-2 E20 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-5

Installation

Figure 40-10-4 1 1

2
2

P118210

Lower the upperstructure frame onto the swing bearing

aligning the two pins (Item 1) [Figure 40-10-5]. Maintain
a slight amount of weight on the hoist.
1
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NA9401

Position the swing bearing with the soft zone (Item 1)

[Figure 40-10-4] located to the left side of the track
frame.

Install the dowel pins (Item 4) [Figure 40-10-4] in the

swing bearing.

40-10-3 E20 Service Manual

UPPERSTRUCTURE (CONT’D)

Installation (Cont’d)

Figure 40-10-6

7 3
6
8
9
5
10
1
2
15
11
12
14
4 13

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NA9403

Install and tighten the bolts as shown. Torque bolts 1 - 4 Install the floor mat and floor panels. (See Removal And
first, than torque all other bolts to 57 - 63 N•m (42 - 46 ft- Installation on Page 40-140-1.)
lb) torque. After the initial torque is applied to all the bolts,
re-torque bolts 1 - 4 [Figure 40-10-6]. Install the seat and seat mount. (See Removal And
Installation on Page 40-40-1.)
Install the swing motor. (See Removal And Installation on
Page 20-100-1.) Fill the hydraulic reservoir. (See Removing And
Replacing The Hydraulic Oil on Page 10-120-3.)
Install the operator bonnet. (See Removal And
Installation on Page 40-230-1.) Install the battery. (See Removal And Installation on
Page 50-20-2.)
Install the control linkage assembly. (See Disassembly
And Assembly on Page 40-120-1.) Install the cab or canopy. (See Removal And Installation
on Page 40-30-1.)

40-10-4 E20 Service Manual

ROPS CANOPY

Removal And Installation

Figure 40-20-1

777 mm
(30.58”)
584 mm
(23.00”)
66 mm 66 mm 51 mm
(2.58”) (2.58”) (2.00”) 76 mm
(3.00”)

25 mm 10 mm .19” TYP
(1.00”) (.40 TYP) .19” TYP 279 mm
.19” TYP (11.00”)
.19” TYP

6 mm R10 mm
76 mm (0.25” TYP) (R0.38”)
(3.00” TYP)

80° 25 mm
(1.00”)
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76 mm
(3.00”)
161 mm 369 mm
(6.32”) (14.52”)

1175 mm
(46.27”)
52 mm
(2.03”)
152 mm
(6.00”)
25 mm 80°
(1.00”)
Material: 2 X 2 - 0.25 in. wall hot rolled steel tubing
.25 in. hot rolled steel plate
MS1933A

Build the service lifting bracket used to remove and install the ROPS canopy. Use the dimensions shown in [Figure 40-
20-1] to build the service lifting bracket.

40-20-1 E20 Service Manual

ROPS CANOPY (CONT’D) Figure 40-20-3

Removal And Installation (Cont’d)

Remove the upperstructure light. (See Cab Light

Removal And Installation on Page 50-50-2.)

Figure 40-20-2 1

2
3

P118750

Figure 40-20-4

P-53290

Install the chain hoist (Item 1) in the end hole of the lifting 1
bracket (Item 2) [Figure 40-20-2].

Install the cab / canopy service lifting bracket on the cab

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[Figure 40-20-2].

NOTE: Use a lifting device of sufficient capacity.

Adjust the lifting bracket to the proper width by moving P118751

the bracket (Item 3) [Figure 40-20-2].

Remove the bolts, nuts, and washers (Item 1) [Figure

40-20-3] from the front of the canopy.
WARNING Installation: Tighten the bolts to 160 - 180 N•m (118 -
133 ft-lb) torque.
Never use the cab / canopy service lifting bracket to
lift the excavator. The bracket is not strong enough
and can fail causing serious injury or death.
W-2384-1000

40-20-2 E20 Service Manual

ROPS CANOPY (CONT’D)

Removal And Installation (Cont’d)

Figure 40-20-5

P118748

Remove the bolt and washer (Item 1) [Figure 40-20-5]

from the right rear of the canopy.

Installation: Tighten the bolt to 160 - 180 N•m (118 - 133

ft-lb) torque.

Figure 40-20-6
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P118749

Remove the bolt and washer (Item 1) [Figure 40-20-6]

from the left rear of the canopy.

Installation: Tighten the bolt to 160 - 180 N•m (118 - 133

ft-lb) torque.

Remove the canopy from the upperstructure.

40-20-3 E20 Service Manual

40-20-4
E20 Service Manual
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CAB

Removal And Installation

Figure 40-30-1

777 mm
(30.58”)
584 mm
(23.00”)
66 mm 66 mm 51 mm
(2.58”) (2.58”) (2.00”) 76 mm
(3.00”)

25 mm 10 mm .19” TYP
(1.00”) (.40 TYP) .19” TYP 279 mm
.19” TYP (11.00”)
.19” TYP

6 mm R10 mm
76 mm (0.25” TYP) (R0.38”)
(3.00” TYP)
25 mm
80° (1.00”)
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76 mm
(3.00”)
161 mm 369 mm
(6.32”) (14.52”)

1175 mm
(46.27”)
52 mm
(2.03”)
152 mm
(6.00”)
25 mm 80°
(1.00”)
Material: 2 X 2 - 0.25 in. wall hot rolled steel tubing
.25 in. hot rolled steel plate
MS1933A

Build the service lifting bracket used to remove and install the ROPS canopy. Use the dimensions shown in [Figure 40-
30-1] to build the service lifting bracket.

40-30-1 E20 Service Manual

CAB (CONT’D) Figure 40-30-3

Removal And Installation (Cont’d)

Figure 40-30-2
1
1

P120251

Adjust the lifting bracket to the proper width by moving

P117751 the bracket (Item 1) [Figure 40-30-3].

Install the chain hoist (Item 1) in the end hole of the lifting
bracket (Item 2) [Figure 40-30-2].

Install the cab / canopy service lifting bracket on the cab

[Figure 40-30-2].

NOTE: Use a chain hoist of sufficient capacity.

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WARNING
Never use the cab / canopy service lifting bracket to
lift the excavator. The bracket is not strong enough
and can fail causing serious injury or death.
W-2384-1000

40-30-2 E20 Service Manual

CAB (CONT’D) Figure 40-30-6

Removal And Installation (Cont’d)

Figure 40-30-4 1

1
1 P117749

Remove the bolt and washer (Item 1) [Figure 40-30-6]

P117752 from the right rear of the cab.

Figure 40-30-7
Disconnect the wire connectors (Item 1) and antenna
cable (Item 2) [Figure 40-30-4].

Figure 40-30-5
1
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P117750

Remove the bolt and washer (Item 1) [Figure 40-30-7]

P117753 from the left rear of the cab.

Remove the windshield washer hose (Item 1) [Figure 40-

30-5] from the nozzle.

40-30-3 E20 Service Manual

CAB (CONT’D) Figure 40-30-10

Removal And Installation (Cont’d)

Figure 40-30-8

1
1

P117754

Move the cab to the right to provide clearance from the

P117748 heater box (Item 1) [Figure 40-30-10].

Remove the bolts, nuts and washers (Item 1) [Figure 40-

30-8] from the front of the cab.

Installation: Tighten the bolts to 160 - 180 N•m (118 -

133 ft-lb) torque.

Figure 40-30-9

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P117751

Raise the hoist [Figure 40-30-9].

40-30-4 E20 Service Manual

CAB (CONT’D)

Door Removal And Installation

Figure 40-30-11
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P117747

The door can be removed from the cab by slowly

swinging the door back and forth while lifting up on the
door [Figure 40-30-11].

Installation: Align the hinges and swing the door back

and forth until the door weight settles the hinges to full
engagement.

40-30-5 E20 Service Manual

CAB (CONT’D) Figure 40-30-14

Front Window Removal And Installation

Figure 40-30-12

1
1

P118785

Raise the window and remove the lower pins (Item 1)

P118778 [Figure 40-30-14].

Figure 40-30-15
Disconnect the wire harness (Item 1) [Figure 40-30-12].

Figure 40-30-13

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1

2 2

1 P118784

P118779 Remove the clip (Item 1) and remove the gas strut (Item
2) [Figure 40-30-15].

Cut the cable ties and remove the wire harness (Item 1) Installation: The pivot linkage must be in the raised
from the arm (Item 2) [Figure 40-30-13]. position and the window removed to remove / install the
gas strut.

40-30-6 E20 Service Manual

CAB (CONT’D) Figure 40-30-18

Front Window Removal And Installation (Cont’d)

Lower the window.

7 5
6 4 3 2 1
Figure 40-30-16

P118782

1. Pivot bolt

2. Washer
P118781
3. Bushing

Remove the cap on the pivot bolt nut (Item 1) [Figure 40- 4. Jam nut
30-16] (both sides).
5. Nylon washer
Figure 40-30-17
6. Locknut
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7. Cap

Figure 40-30-19
1

P118780

Remove the pivot bolt assembly (Item 1) [Figure 40-30-

17].
P120253

Tilt the front window (Item 1) [Figure 40-30-19]. Remove

the front window from the cab.

40-30-7 E20 Service Manual

CAB (CONT’D)

Front Window Removal And Installation (Cont’d)

Figure 40-30-20

P118783

Installation: When installing the window check to see

that the guide is positioned as shown. The pivot hole is
offset and the ribs should be down [Figure 40-30-20].

40-30-8 E20 Service Manual

CAB (CONT’D) Glass Removal

Right Side Sliding Window Removal And Installation Use the following procedure to remove the glass from the
rear of the cab and right side window assembly.
Figure 40-30-21
Figure 40-30-22

1
P120009

P120252

The right side sliding window must be ordered as an

assembly [Figure 40-30-21]. Push a small diameter wire (Item 1) [Figure 40-30-22]
through the adhesive. Pull the wire around the perimeter
of the glass to cut the adhesive.

Remove the glass.

NOTE: The right side window frame is aluminum and

will be destroyed when removed.

40-30-9 E20 Service Manual

CAB (CONT’D) Figure 40-30-24

Glass Installation
1
Rear And Front Lower Glass

Remove the majority of the old urethane adhesive from

the perimeter of the cab.

NOTE: Leave a thin film of the old urethane on the

cab frame, fresh urethane will bond to the
remaining film. 1

Prime and paint any bare metal or scratches.

Clean the metal surfaces with general purposes adhesive MS1993

cleaner. Clean the glass surface with glass cleaner.

Figure 40-30-23 Apply a 0.3 x 0.25 in bead of urethane adhesive (Item 1)

[Figure 40-30-24] to the perimeter of the cab.
1
Allow 2 hours for curing at normal conditions (65×F, 75%
relative humidity).

Remove the tape after the adhesive is cured.

Top, Right Side And Left Side Glass

Remove the majority of the old urethane adhesive from

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the perimeter of the cab.

NOTE: Leave a thin film of the old urethane on the

cab frame, fresh urethane will bond to the
NA9471 remaining film.

Prime and paint any bare metal or scratches.

Apply the combo primer to the perimeter of the cab and
glass (Item 1) [Figure 40-30-23]. Apply the primer in one Clean the metal surfaces with general purposes adhesive
direction only, using a dauber. Do not dip the dauber in cleaner. Clean the glass surface with glass cleaner.
the primer more than once. Use multiple daubers if
needed. Shake the combo primer for 1 minute.

Allow the combo primer to dry for 5 minutes. Dry time

doubles if the primer is applied in two coats.

Cut the tip of the adhesive tube to the desired shape and
size to provide a bead height sufficient to give good
contact with the glass around the entire perimeter.

40-30-10 E20 Service Manual

CAB (CONT’D) Figure 40-30-26

Glass Installation (Cont’d)

1
Figure 40-30-25

1 1

MS1993

Apply a 7,6 x 6,4 mm (0.3 x 0.25 in) bead of urethane

adhesive (Item 1) [Figure 40-30-26] to the perimeter of
the cab.

Figure 40-30-27

1
2
NA9472
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Apply combo primer to the perimeter of the cab (Item 1)

and glass (Item 2) [Figure 40-30-25]. Apply the primer in
one direction only, using a dauber. Do not dip the dauber
in the primer more than once. Use multiple daubers if
needed.

Allow the combo primer to dry for 5 minutes. Dry time

doubles if the primer is applied in two coats.
MS1995

Cut the tip of the adhesive tube to the desired shape and
size to provide a bead height sufficient to give good Install the glass (Item 1) [Figure 40-30-27]. Press the
contact with the glass around the entire perimeter. glass into the cab to make complete contact with the
adhesive. Tape the glass in place.

Allow 2 hours for curing at normal conditions (65×F, 75%

relative humidity).

Remove the tape after the adhesive is cured.

Right Side Sliding Window, Door And Front Window

Glass

The right side sliding window, door, and front window

glass are not available separately.

Order and install the right side sliding window, door, or

front window frame and glass assembly.

40-30-11 E20 Service Manual

40-30-12
E20 Service Manual
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SEAT AND SEAT MOUNT Figure 40-40-3

Removal And Installation

Figure 40-40-1

1 1 1
P117756

Slide the seat forward and remove the two bolts (Item 1)
P117876 [Figure 40-40-3].

Remove the seat and seat mount.

Open the access cover (Item 1) [Figure 40-40-1].

Figure 40-40-2
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P117757

Remove the two bolts (Item 1) [Figure 40-40-2].

40-40-1 E20 Service Manual

40-40-2
E20 Service Manual
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LEFT CONSOLE Figure 40-50-3

Console Cover Removal And Installation

Figure 40-50-1

1
P118492

Remove the screw (Item 1) [Figure 40-50-3].

P118491
Figure 40-50-4

Remove the screw (Item 1) [Figure 40-50-1].

Figure 40-50-2
1
1
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2
1

2
P118490
1

Raise the top cover and disconnect the wire harness

P118493 (Item 1). Remove the cover (Item 2) [Figure 40-50-4].

Lower the console. Remove the nuts and bolts (Item 1).
Remove the arm rest (Item 2) [Figure 40-50-2].

40-50-1 E20 Service Manual

LEFT CONSOLE (CONT’D)

Console Cover Removal And Installation (Cont’d)

Figure 40-50-5

P118489

Pull down on the bottom cover (Item 1) [Figure 40-50-5]

and remove the cover from the console.

40-50-2 E20 Service Manual

LEFT CONSOLE (CONT’D) Figure 40-50-8

Gas Spring Removal And Installation

Figure 40-50-6

1
1

1 P118484

NOTE: Loosen the bolts (Item 1) [Figure 40-50-8] and

P118485 shift the console base to provide clearance to
install the gas spring / stud assembly.

Remove the bolt (Item 1) [Figure 40-50-6] and roller.

Figure 40-50-7
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2
P118483

Support the console and remove the clip and gas spring
(Item 1) [Figure 40-50-7] from the stud.

Remove the nut and gas spring / stud assembly (Item 2)

[Figure 40-50-7].

40-50-3 E20 Service Manual

LEFT CONSOLE (CONT’D) Console Removal And Installation

Lock Lever Removal And Installation Remove the joystick. (See Joystick Assembly Removal
and Installation on Page 20-111-5.)
Remove the gas spring. (See Gas Spring Removal And
Installation on Page 40-50-3.) Remove the gas spring. (See Gas Spring Removal And
Installation on Page 40-50-3.)
Remove the console cover. (See Console Cover
Removal And Installation on Page 40-50-1.) Remove the lock lever. (See Lock Lever Removal And
Installation on Page 40-50-4.)
Figure 40-50-9
Figure 40-50-11

1 1
2

P118481

P118479

Remove the bolt (Item 1), nut (Item 2), and lever (Item 3)

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[Figure 40-50-9]. Remove the bolt (Item 1) and nut (Item 2). Remove the
console (Item 3) [Figure 40-50-11] from the console
Installation: Apply thread adhesive (Loctite® 242) to the base.
bolt threads.
Figure 40-50-12
Figure 40-50-10

2
1

1 P118478
P118480

Remove the bushings (Item 1) [Figure 40-50-12] from

Remove the bushings (Item 1) [Figure 40-50-10] from the console base.
both sides of the lever.

40-50-4 E20 Service Manual

LEFT UPPERSTRUCTURE COVER

Removal And Installation

Figure 40-60-1

1 2

P118368

Remove the bolt (Item 1) and cover (Item 2) [Figure 40-

60-1].

Remove the three bolts (Item 3) and remove the cover

(Item 4) [Figure 40-60-1].
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40-60-1 E20 Service Manual

40-60-2
E20 Service Manual
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RIGHT UPPERSTRUCTURE COVER

Removal And Installation

Figure 40-70-1

2
1

P113450

Remove the three bolts (Item 1) and remove the right

side cover (Item 2) [Figure 40-70-1].
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40-70-1 E20 Service Manual

40-70-2
E20 Service Manual
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ENGINE SPEED CONTROL Figure 40-80-2

Removal And Installation

WARNING 1

AVOID INJURY OR DEATH

Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure. 1
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P118212
W-2019-0907

Remove the three mounting bolts (Item 1) [Figure 40-80-

Remove the right side cover (See Removal And 2].
Installation on Page 40-70-1.)
Figure 40-80-3
Figure 40-80-1

1
1
1
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2
1

P118221
P118211

In the engine compartment remove the two hold down

Remove the three bolts (Item 1) from the bracket (Item 2) clamps (Item 1) [Figure 40-80-3].
[Figure 40-80-1].

40-80-1 E20 Service Manual

ENGINE SPEED CONTROL (CONT’D)

Removal And Installation (Cont’d)

Figure 40-80-4

P118222

Remove the hold down clamp (Item 1) [Figure 40-80-4]

under the muffler.

Figure 40-80-5

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2
2

P118223

Remove the nut (Item 1) and loosen the jam nuts (Item 2)
[Figure 40-80-5].

40-80-2 E20 Service Manual

ENGINE SPEED CONTROL (CONT’D) Figure 40-80-8

Cable Adjustment

Figure 40-80-6

1 2

P120259

If adjustment is needed move the jam nuts (Item 1) at

P120255 bracket or the cable end (Item 2) [Figure 40-80-8] to
adjust.

Move control lever to the idle position and check stop

(Item 1) [Figure 40-80-6] that the lever is positioned
against it.

Figure 40-80-7
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P120257

Move control lever to the high idle position and check

stop (Item 1) [Figure 40-80-7] that the lever is positioned
against it.

40-80-3 E20 Service Manual

40-80-4
E20 Service Manual
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BLADE CONTROL Remove right side cover (See Removal And Installation
on Page 40-70-1.)
Removal And Installation
Figure 40-90-2

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

P118367
Figure 40-90-1

Disconnect the blade control wires (Item 1) [Figure 40-

90-2].

Remove radiator / oil cooler (See Radiator / Oil Cooler

Removal And Installation on Page 60-40-1.)

Remove engine speed control bracket (See Removal And

1
Installation on Page 40-80-1.)
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Figure 40-90-3

P113449
1

Disconnect the negative cable (Item 1) [Figure 40-90-1].

2
1
WARNING
1
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and P118226
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water. Remove the three bolts (Item 1) from the blade control
In case of eye contact get prompt medical attention housing (Item 2) [Figure 40-90-3].
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

40-90-1 E20 Service Manual

BLADE CONTROL (CONT’D)

Removal And Installation (Cont’d)

Remove floor mat and floor panels (See Removal And

Installation on Page 40-140-1.)

Figure 40-90-4

P118409

Remove cotter pin (Item 1), loosen jam nut (Item 2) and
remove the cable end from the control valve linkage (Item
3) [Figure 40-90-4].

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Figure 40-90-5

P118408

Remove the nut / bolt (Item 1) that is securing the cable

clamp (Item 2) [Figure 40-90-5].

Remove blade control cable from the machine.

40-90-2 E20 Service Manual

RIGHT PEDAL (BOOM SWING) Figure 40-100-3

Removal And Installation

Remove the control linkage assembly (See Removal And

Installation on Page 40-130-1.)

Figure 40-100-1

1 P118659

Remove the pedal assembly [Figure 40-100-3].

P118670

Remove the nut / bolt (Item 1) [Figure 40-100-1].

Figure 40-100-2
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P118671

Remove the nuts / bolts (Item 1) [Figure 40-100-2].

40-100-1 E20 Service Manual

RIGHT PEDAL (BOOM SWING) (CONT’D) Figure 40-100-6

Disassembly And Assembly

Figure 40-100-4

1
1

P118662

Remove the pedal from the mount bracket [Figure 40-

P118679 100-6].

Figure 40-100-7
Remove the roll pins (Item 1) [Figure 40-100-4].

Figure 40-100-5 1
1

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3 2

1 P118663

P118661 Remove the bushings (Item 1), washer (Item 2) and

spring washer (Item 3) [Figure 40-100-7].

Remove the shaft (Item 1) [Figure 40-100-5]. Inspect all parts and replace as needed.

40-100-2 E20 Service Manual

TRAVEL CONTROLS Figure 40-110-3

Removal And Installation

Remove the control linkage assembly (See Removal And 1

Installation on Page 40-130-1.)

Figure 40-110-1

2 2
1

1 P118678
1

Remove the bolts (Item 1) [Figure 40-110-3].

Figure 40-110-4

P118676

Remove the bolts (Item 1) and remove the control levers

(Item 2) [Figure 40-110-1].

Figure 40-110-2
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1 P118619

Remove the pedal assembly [Figure 40-110-1].

P118677

Remove the bolts (Item 1) [Figure 40-110-1].

40-110-1 E20 Service Manual

TRAVEL CONTROLS (CONT’D) Figure 40-110-7

Disassembly And Assembly

Figure 40-110-5

1
3

2
2 2 2

P118623

Remove the pivot shaft (Item 1) and remove the pedals

P118620 (Item 2) [Figure 40-110-7].

Figure 40-110-8
Remove the retaining clips / washers (Item 1), the pins
(Item 2) and the upper pedals (Item 3) [Figure 40-110-5].

Figure 40-110-6

1 1

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2 1 1

1
1 P118626

Remove the pedal stops (Item 1) [Figure 40-110-8].

P118622

Remove the roll pins (Item 1) and loosen the pedal stops
(Item 2) [Figure 40-110-6].

40-110-2 E20 Service Manual

TRAVEL CONTROLS (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 40-110-9

P118624

Remove the pedals [Figure 40-110-9].

Figure 40-110-10
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1 1

P118625

Remove the bushings (Item 1) [Figure 40-110-10] from

the pedal.

40-110-3 E20 Service Manual

40-110-4
E20 Service Manual
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LEFT PEDAL (AUXILIARY) Figure 40-120-3

Disassembly And Assembly

Remove the control linkage assembly (See Removal And

Installation on Page 40-130-1.)

Figure 40-120-1

P118659
1

Remove the left pedal assembly [Figure 40-120-3].

Figure 40-120-4

P118657

1
Remove the nut / bolt (Item 1) [Figure 40-120-1]
connecting the linkage to the left pedal.

Figure 40-120-2
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P118660
1

Remove the two roll pins (Item 1) [Figure 40-120-4].

P118658

Remove the nuts / bolts (Item 1) [Figure 40-120-2] for

the left pedal mounting bracket.

40-120-1 E20 Service Manual

LEFT PEDAL ASSEMBLY (AUXILIARY) (CONT’D) Figure 40-120-7

Disassembly And Assembly (Cont’d)

1 1
Figure 40-120-5 4

1
3 2

P118663

Remove the two bushings (Item 1), washer (Item 2),

P118661 spring washer (Item 3) from the pedals (Item 4) [Figure
40-120-7].

Remove the pedal pivot shaft (Item 1) [Figure 40-120-5].

Figure 40-120-6

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1

P118662

Remove the pedal from the mounting bracket (Item 1)

[Figure 40-120-6].

40-120-2 E20 Service Manual

CONTROL LINKAGE ASSEMBLY Figure 40-130-3

Removal And Installation

Remove the left upperstructure cover (See Removal And

Installation on Page 40-60-1.) 1
2
Remove the floor mat and floor panels. (See Removal
And Installation on Page 40-140-1.)

Figure 40-130-1

P118665

TOP VIEW Remove the nuts (Item 1) and the bolt (Item 2)[Figure
40-130-2] and [Figure 40-130-3].

Figure 40-130-4

1 1

SIDE VIEW P118680

Remove the four linkage to spool bolts (Item 1) [Figure

40-130-1].

Figure 40-130-2

P118669

1
Remove the control linkage assembly. [Figure 40-130-4].
1
1

P118664

40-130-1 E20 Service Manual

CONTROL LINKAGE ASSEMBLY (CONT’D) Figure 40-130-7

Disassembly And Assembly

Figure 40-130-5

1 1

P118611

Remove the bolts (Item 1) from the mounting bracket to

P118675 plate and remove the shaft assembly (Item 2) [Figure 40-
130-7].

The control linkage assembly will have four linkage shafts Figure 40-130-8
if equipped with the manual boom swing and auxiliary
pedals [Figure 40-130-5].

Figure 40-130-6 2

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1

P118613

Mark the shaft and arm (Item 1) [Figure 40-130-8] for

P118612 reference in assembly.

Loosen the bolts (Item 2) and remove the arm (Item 3)

If equipped with the electric boom swing and auxiliary [Figure 40-130-8].
controls there are two linkage shafts [Figure 40-130-6].

The following procedure will cover the disassembly and

assembly of one shaft. All of the components are the
same on all the shafts.

40-130-2 E20 Service Manual

CONTROL LINKAGE ASSEMBLY (CONT’D) Figure 40-130-11

Disassembly And Assembly (Cont’d)

Figure 40-130-9 2

1
1 1
2

P118617

Remove the retaining clips (Item 1) from the pins and

P118614 remove the linkage (Item 2) [Figure 40-130-11].

Figure 40-130-12
Remove the retaining clip (Item 1) on the shaft for the
bearing mount bracket (Item 2) [Figure 40-130-9] and
remove the bracket assembly.

Figure 40-130-10
2
1
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1
P118618

Remove the roll pin (Item 1) and the arm (Item 2) [Figure
40-130-12].
P118616
Inspect all parts and replace as needed.

Remove the bracket assembly (Item 1) [Figure 40-130-

10] from the other end of the shaft.

40-130-3 E20 Service Manual

40-130-4
E20 Service Manual
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FLOOR MAT AND FLOOR PANELS Figure 40-140-3

Description

The floor of the excavator (cab or canopy) is divided into

three floor panels covered by a mat. The rear floor panel
provides accessibility to the hydraulic components. The 1
front panel consists of the travel levers and foot pedals
and the side panel covers the control valve.

The rear and side floor panels are the only floor panels
that needs to be removed when servicing the hydraulic
components. The front floor panel only needs to be
removed when the travel levers and pedals and
upperstructure slew lock need servicing.
P118602
Removal And Installation

Figure 40-140-1 Remove the rear floor panel (Item 1) [Figure 40-140-3].

Figure 40-140-4

1
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2
P117742

P118603
Remove the rear floor mat (Item 1) [Figure 40-140-1].

Figure 40-140-2 Remove the two nuts (Item 1) and the side floor panel
(Item 2) [Figure 40-140-4].

P117746

Remove the front floor mat (Item 1) [Figure 40-140-2].

40-140-1 E20 Service Manual

40-140-2
E20 Service Manual
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FUEL TANK Figure 40-150-3

Removal And Installation

1
Remove the right upper structure cover. (See Removal
And Installation on Page 40-70-1.)

Open the right side cover. (See Opening And Closing

Right Side Cover on Page 10-50-2.) 2

Drain the fuel tank. 3

Figure 40-150-1

P117782

Disconnect the window washer pump wire (Item 1).

Remove the fuel tank vent hose (Item 2), filler hose (Item
1 3) [Figure 40-150-3] and remove the door assembly.

Figure 40-150-4

P117780
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Remove the door hinge mounting bolts (Item 1) [Figure 2

40-150-1].

Figure 40-150-2

2 1
P117874

Remove the nuts (Item 1) and mounting bracket (Item 2)

[Figure 40-150-4].

P117781

Remove the retaining clip (Item 1) and the latch (Item 2)

[Figure 40-150-2] from the door.

40-150-1 E20 Service Manual

FUEL TANK (CONT’D)

Removal And Installation (Cont’d)

Figure 40-150-5

P117873

Remove the bolt (Item 1) and bracket (Item 2) [Figure

40-150-5].

Figure 40-150-6

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2
4

P117872

Slide the fuel tank (Item 1) out the side opening enough
to remove the fuel supply and return hoses (Item 2 and
Item 3). Disconnect the fuel level sender harness (Item 4)
[Figure 40-150-6]. Remove the fuel tank from the
machine.

NOTE: Use caution to avoid damaging the sender

when installing the tank.

40-150-2 E20 Service Manual

HORN

Removal And Installation

Figure 40-160-1

P117722

The horn is located behind the front panel (Item 1)

[Figure 40-160-1].

Figure 40-160-2
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P117875

Remove the wires (Item 1) [Figure 40-160-2] from the

horn.

Remove the nut (Item 2) [Figure 40-160-2].

Remove the horn.

Travel control assembly removed for photo clarity.

40-160-1 E20 Service Manual

40-160-2
E20 Service Manual
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SWING FRAME Figure 40-170-2

Description

The swing frame is the casting connected to the boom

swing cylinder and the boom with top mounted boom
cylinder. The swing casting provides the pivot point for
the boom in the offset function and the up down motion of
the boom. The swing frame is connected to the
upperstructure by a top and bottom pivot pin.

Removal And Installation

Remove the boom. (See Removal And Installation on

Page 40-180-1.)
S35222
Figure 40-170-1

2 Install the pivot pin, bolt and nuts [Figure 40-170-2].

Install a chain hoist on the swing frame [Figure 40-170-

2].

Figure 40-170-3

1
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S35221

Remove the bolt and nuts (Item 1) [Figure 40-170-1]

from the cylinder pivot pin. 1

Remove the pivot pin (Item 2) [Figure 40-170-1].

S35223

Remove the bolt and nuts (Item 1) [Figure 40-170-3]

from the top pivot pin.

40-170-1 E20 Service Manual

SWING FRAME (CONT’D) Figure 40-170-6

Removal And Installation (Cont’d)

Figure 40-170-4

S35226

Remove the swing frame from the excavator [Figure 40-

S35224 170-6].

Remove the top pivot pin (Item 1) [Figure 40-170-3] from

the swing frame.

Figure 40-170-5

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1

2
S35225

Remove the bolt and nuts (Item 1) [Figure 40-170-5]

from the bottom pivot pin.

Remove the bottom pivot pin (Item 2) [Figure 40-170-5]

from the swing frame.

40-170-2 E20 Service Manual

SWING FRAME (CONT’D) Swing Frame Bushing Removal

Bushing Removal And Installation Figure 40-170-8

Figure 40-170-7

2 1

S35228

S35227
Remove the top pivot bushing (Item 1) [Figure 40-170-8].
The bushing will need to be pressed down to be removed
Remove the bottom bushing (Item 1) [Figure 40-170-7] from the swing frame casting.
from the upperstructure by driving the bushing down
through the casting. The following parts will be needed for removal and
installation of the swing frame bushing:
Remove the top bushing (Item 2) [Figure 40-170-7] from
the upperstructure by driving the bushing up through the Bolt -16 X 114 mm (0.625 x 4.5 in) long
casting.
Nut - 16 mm (0.625 in)
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During installation, center the bushing on the casting Washer - 16 mm I.D. x 59 mm O.D. x 6 mm thick or
hole. (0.625 in I.D. x 2.312 in O.D. x 0.25 in thick)
Washer - 16 mm I.D. x 89 mm).D. x 6 mm thick or
NOTE: Make sure the bushing is centered in the (0.625 in I.D. x 3.5 in O.D. x 0.25 in thick)
casting hole and is started in the hole evenly
and square. Spacer - 73 mm I.D. x 86 mm).D. x 38 mm thick or
(2.875 in I.D. x 3.375 in O.D. x 1.5 in thick)
Install the bushing so the flanged edge of bushing is
seated in the casting. The flanged edge of the bushings
must be installed from the top and bottom of the
upperstructure casting.

40-170-3 E20 Service Manual

SWING FRAME (CONT’D) Swing Frame Bushing Installation

Swing Frame Bushing Removal (Cont’d) Apply a film of grease to the outer diameter of the
bushing and the inner diameter of the casting.
Figure 40-170-9
Center the bushing on the casting hole.
3 4
NOTE: Make sure the bushing is centered in the
casting hole and is started in the hole evenly
and square.

Put the washer (Item 3) over the flanged end of the

bushing. Put the washer (Item 2) [Figure 40-170-9] over
1
the bushing hole casting, center the washer over the
bushing hole.

2 Install the bolt (Item 4) through the washers and the

bushing and install the nut (Item 5) [Figure 40-170-9].
5
S35764 Tighten the bolt and nut until the bushing is seated in the
casting.
Install the spacer (Item 1) and washer (Item 2) [Figure
40-170-9] over the flanged end of the bushing.

The spacer (Item 1) [Figure 40-170-9] and must be

centered over the bushing to avoid contact between the
bushing and the spacer during removal.

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Install the washer (Item 3) [Figure 40-170-9] on the
opposite end of the bushing. The washer must be
centered on the bushing and must not contact the
casting.

Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
170-9] through the washers and spacer.

Tighten the bolt and nut to remove the bushing from the
casting.

40-170-4 E20 Service Manual

BOOM Remove the bolt and nut (Item 2) [Figure 40-180-2] from
the bracket.
Description
Figure 40-180-3
The boom is the section that is connected to the swing
frame and the arm. The boom has the boom and arm
cylinders mounted on the top of the boom.

Removal And Installation

Figure 40-180-1 1

S35215

Pull the tubelines out of the boom and disconnect from

the hydraulic hoses (Item 1) [Figure 40-180-3].

Figure 40-180-4
P117808

Install a chain hoist on the boom [Figure 40-180-1].

Remove the arm. (See Removal And Installation on Page

40-190-1.)
2
Remove the arm cylinder. (See Removal And Installation
on Page 20-21-3.)

Remove the boom cylinder. (See Removal And

Installation on Page 20-20-3.)
1
Figure 40-180-2 S35216

1 Remove the tie strap (Item 1) on the light wire harness.

Disconnect the harness (Item 2) [Figure 40-180-4].

S35214

Disconnect the tubelines (Item 1) [Figure 40-180-2] from

the hydraulic quick couplers.

40-180-1 E20 Service Manual

BOOM (CONT’D) Figure 40-180-7

Removal And Installation (Cont’d)

Figure 40-180-5

S35219

Remove the bolt and nuts (Item 1) [Figure 40-180-7]

S35217 from the pivot pin.

Remove the pivot pin (Item 2) [Figure 40-180-7].

Remove the lock (Item 1) [Figure 40-180-5] from the
electrical connector. Figure 40-180-8

Figure 40-180-6

1
4
3

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1

2
S35220

S35218
Lift the boom from the swing frame [Figure 40-180-8].

With a small piece of wire, depress the wire terminal tabs Installation: Feed the two arm cylinder hoses and the
(Item 1) [Figure 40-180-6]. two auxiliary hoses (Item 1) through the inside of the
boom and comes out at the base pivot of the arm
Mark and remove the individual wires from the back of cylinder. Continue feeding the two bucket cylinder hoses
the electrical connector. (Item 2) and the boom cylinder hoses (Item 4) through
the end of the boom (Item 3) [Figure 40-180-8].

40-180-2 E20 Service Manual

BOOM (CONT’D)

Boom Bushing Removal And Installation

Remove the boom. (See Removal And Installation on

Page 40-180-1.)

Figure 40-180-9

P-68513A

Remove the bushings (Item 1) [Figure 40-180-9] from

both sides of the boom.

Install the new bushings in the boom.

Figure 40-180-10

P-60650

5 mm (0.197”)
TS-01614

Install the bushings until they are seated 5 mm (0.197 in)

in the pin boss [Figure 40-180-10].

NOTE: Install the new bushings with the tapered end

first (Item 1) [Figure 40-180-10].

40-180-3 E20 Service Manual

40-180-4
E20 Service Manual
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ARM Figure 40-190-2

Description

The arm is the section that is connected to the end of the

boom section and the bucket/bucket link. The excavator
comes with a standard length but has an optional long
arm.
1
Removal And Installation 2
3

IMPORTANT
S35209
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Remove the bolt (Item 1) and nuts (Item 2) [Figure 40-
tubelines and ports to keep dirt out. Dirt can quickly 190-2] from the rod end pivot pin.
damage the system.
I-2003-0888 Remove the pivot pin (Item 3) [Figure 40-190-2].

Figure 40-190-1 Remove the rod end of the cylinder from the arm.

Figure 40-190-3

1
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P117808

S35210
Support the boom with a chain hoist [Figure 40-190-1].

Remove the bucket. (See Removal And Installation on Install a chain (Item 1) [Figure 40-190-3] to support the
Page 40-200-1.) arm.

Remove the bucket cylinder. (See Removal And Move the bucket cylinder hoses (Item 2) [Figure 40-190-
Installation on Page 20-23-3.) 3] away from the arm.

40-190-1 E20 Service Manual

ARM (CONT’D) Arm To Boom Bushing Removal And Installation

Removal And Installation (Cont’d) Figure 40-190-5

Figure 40-190-4

3
2 S35212

S35211
Remove the dust seals and bushings (Item 1) [Figure 40-
190-5] from both sides of the arm.
Remove the bolt (Item 1) and nuts (Item 2) [Figure 40-
190-4] from the arm pivot pin. Figure 40-190-6

Remove the pivot pin (Item 3) [Figure 40-190-4].

1
Remove the arm.

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P-60650

5 mm (0.197”)
TS-01614

Install the new bushings until they are seated 5 mm

(0.197 in) in the pin boss [Figure 40-190-6].

NOTE: Install the new bushings with the tapered end

first (Item 1) [Figure 40-190-6].

Install new dust seals with the lip facing out.

40-190-2 E20 Service Manual

ARM (CONT’D)

Arm To Bucket And Bucket Link Bushing Removal

And Installation

Figure 40-190-7

1 1

S35213

Remove the dust seals and bushings (Item 1) [Figure 40-

190-7] from both sides of the arm.

Figure 40-190-8
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P-60650

5 mm (0.197”)
TS-01614

Install the bushings until they are seated 5 mm (0.197 in)

in the pin boss [Figure 40-190-8].

NOTE: Install the new bushings with the tapered end

first (Item 1) [Figure 40-190-8].

Install new dust seals with the lip facing out.

40-190-3 E20 Service Manual

40-190-4
E20 Service Manual
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BUCKET Figure 40-200-2

Removal And Installation

WARNING
1
AVOID INJURY OR DEATH 1
Stop the machine on a firm flat surface. When
removing or installing attachments (such as a
bucket), always have a second person in the 2
operator’s seat, give clear signals and work carefully. 3
W-2140-0189

2 S35383
Park the excavator on a flat surface and put the bucket on
the ground.
Remove the washers (Item 1) and pivot pins (Item 2)
Figure 40-200-1 [Figure 40-200-2].

Keep the pins clean. Do not damage the dust seals in the
arm when removing the bucket.
1
Install the arm into the bucket, align the hole, install the
pivot pin (Item 2) and washer (Item 1) [Figure 40-200-2].

Install the link (Item 3) into the bucket, align the hole,
install the pivot pin and washer (Item 2) [Figure 40-200-
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1 2].

Install the fasteners (Item 1) [Figure 40-200-1]. Add

grease to the pivot.

S35382

Remove the fasteners (Item 1) [Figure 40-200-1].

WARNING
AVOID INJURY OR DEATH
Never use attachments or buckets which are not
approved by Bobcat Company. Buckets and
attachments for safe loads of specified densities are
approved for each model. Unapproved attachments
can cause injury or death.
W-2052-0907

40-200-1 E20 Service Manual

40-200-2
E20 Service Manual
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TAILGATE Figure 40-210-3

Removal And Installation

Open the tailgate. 2

Figure 40-210-1

1
P117877

Remove the bolts (Item 1). Remove the latch assembly

(Item 2) [Figure 40-210-3] from the tailgate.

P117708

Remove the bolts (Item 1) [Figure 40-210-1] and remove

the tailgate.

Latch Removal And Installation

Open the tailgate.

Figure 40-210-2

P113431

For ease of assembly, mark around the outside edge

(Item 1) [Figure 40-210-2] of the latch bracket.

Remove the two bolts (Item 2) [Figure 40-210-2] and

washers.

See latch adjustment. (See Adjusting The Latch on Page

10-50-1.)

Remove the bracket (Item 1) [Figure 40-210-2].

40-210-1 E20 Service Manual

40-210-2
E20 Service Manual
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COUNTERWEIGHT Figure 40-220-3

Removal And Installation

Remove the cab. (See Removal And Installation on Page 2

40-30-1.)

Remove the operators bonnet. (See Removal And

Installation on Page 40-230-1.)
1
Remove the air cleaner assembly (See Removal And
Installation on Page 60-30-1.)

Remove the hydraulic reservoir (See Removal And

Installation on Page 20-130-1.)
P117830
Remove the hydraulic pump (See Removal And
Installation on Page 20-50-7.) Remove the two bolts (Item 1) and remove the tailgate
(Item 2) [Figure 40-220-3].
Figure 40-220-1
Figure 40-220-4

1
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P117803
P117827

Remove the two bolts (Item 1) [Figure 40-220-1]. Remove the upper fan shroud bolt (Item 1) [Figure 40-
220-4].
Figure 40-220-2
Figure 40-220-5

1
1

P117829
P117828

Remove the two bolts (Item 1) [Figure 40-220-2]. Remove the lower fan shroud bolt (Item 1) [Figure 40-
220-5].

40-220-1 E20 Service Manual

COUNTERWEIGHT (CONT’D) Figure 40-220-8

Removal And Installation (Cont’d)

Figure 40-220-6

1
2
1 1

P117805

Remove the right side mounting bolt (Item 1) [Figure 40-

P117831 220-8].

Figure 40-220-9
Install lifting brackets (Item 1) and chains (Item 2) [Figure
40-220-6].

Figure 40-220-7

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1

P117807

Remove the rear mounting bolt (Item 1) [Figure 40-220-

P117804 9].

Remove the counterweight.

Remove the left side mounting bolt (Item 1) [Figure 40-
220-7].

40-220-2 E20 Service Manual

OPERATOR BONNET Figure 40-230-2

Removal And Installation

3
Remove the ROPS canopy (See Removal And
Installation on Page 40-20-1.) or the cab (See Removal
And Installation on Page 40-30-1.)

Remove the seat and seat mount (See Removal And

Installation on Page 40-40-1.)

Remove the key switch (See Removal And Installation on 2

Page 50-90-1.) 1

Remove the left console frame (See Console Removal P117771

And Installation on Page 40-50-4.)

Remove the floor mat (See Removal And Installation on Remove the bolts (Item 1) and lower the standard / ISO
Page 40-140-1.) valve (Item 2) [Figure 40-230-2] into the engine
compartment.
Remove the right side cover. (See Removal And
Installation on Page 40-250-1.) Remove the bolt (Item 3) [Figure 40-230-2] and hose
retainer.
Figure 40-230-1
Figure 40-230-3
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1 1

1
2

P117758 P117772

Pull up on and remove the trim (Item 1) [Figure 40-230- Remove the nuts from the back of the bolts (Item 1)
1] from the heater. [Figure 40-230-3] and reposition hydraulic filter / air
cleaner mounting bracket.

40-230-1 E20 Service Manual

OPERATOR BONNET (CONT’D) Figure 40-230-6

Removal And Installation (Cont’d)

Figure 40-230-4

2
1
1

1
1

P117776

Remove the nuts (Item 1) and cover (Item 2) [Figure 40-

P117774 230-6].

Figure 40-230-7
Cut and remove the cable ties (Item 1) [Figure 40-230-
4].

Figure 40-230-5

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P117778

1 Remove the nut and bolt (Item 1). Remove the plate (Item
P117775 2) [Figure 40-230-7].

Figure 40-230-8
Remove the cover (Item 1) [Figure 40-230-5].

P117779

Remove the bolt (Item 1) [Figure 40-230-8].

40-230-2 E20 Service Manual

OPERATOR BONNET (CONT’D) Figure 40-230-11

Removal And Installation (Cont’d)

Figure 40-230-9

1 1
1 P117785

Figure 40-230-12
P117777

Remove the bolts (Item 1) and reposition the heater.

Remove the bolt (Item 2) [Figure 40-230-9].

Figure 40-230-10

1 1

1
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1 P117784

Remove the bolts (Item 1) [Figure 40-230-11] and

[Figure 40-230-12]. Reposition the fuse panel and
bracket.
2 Figure 40-230-13
P117783

Remove the bolts (Item 1) [Figure 40-230-10], washers

and set the throttle / blade lever mount to the side.

Remove the bolt (Item 2) [Figure 40-230-10] from the

fuse panel bracket.
1
1

P117786

Remove the bolts (Item 1) [Figure 40-230-13] and lower

the controller.

40-230-3 E20 Service Manual

OPERATOR BONNET (CONT’D) Figure 40-230-16

Removal And Installation (Cont’d)

Figure 40-230-14

1
1

P117789

1 Disconnect the auxiliary power outlet wire harness (Item

P117787 1) and two speed wire harness (Item 2) [Figure 40-230-
16].

Disconnect the wire harnesses (Item 1) [Figure 40-230- Figure 40-230-17

14].

Figure 40-230-15
1
1

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1

P117791

Tilt the bonnet forward. Cut and remove the cable ties
P117788
(Item 1) [Figure 40-230-17].

Disconnect the wire harness (Item 1) [Figure 40-230-15]

from the keyless start panel (if equipped).

Remove the three bolts (Item 2) [Figure 40-230-15] from

the joystick mount.

40-230-4 E20 Service Manual

OPERATOR BONNET (CONT’D)

Removal And Installation (Cont’d)

Figure 40-230-18

1
2

P117790

Remove the left joystick hoses (Item 1) and the wire

harness (Item 2) [Figure 40-230-18] from the bonnet.

Remove the bonnet from the machine.

40-230-5 E20 Service Manual

40-230-6
E20 Service Manual
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QUICK COUPLER (KLAC™ SYSTEM)

Troubleshooting

PROBLEM CAUSE CORRECTION

Coupler does not seat properly on the Mud, dirt, stones or debris are lodged Remove mud, dirt, stones and debris
attachment mounting frame. between the coupler and the from between the coupler and the
attachment mounting frame. attachment mounting frame.
Worn locking mechanism. Repair or replace worn pins and
locking mechanisms.
Attachment mounting frame damaged. Repair or replace the attachment
mounting frame.

Daily Inspection

Figure 40-240-1

1
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P-72274

Inspect the quick coupler for wear or damage. Inspect the

quick locking shaft (Item 1) and the hooks (Item 2)
[Figure 40-240-1] (on the attachment) for wear or
damage.

Repair or replace damaged parts.

40-240-1 E20 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-240-3

Removal And Installation

Figure 40-240-2
Unlatched Position Latched Position

P-72283

Install the tool (Item 1) [Figure 40-240-3] in the quick

P-72272 P-72272 coupler as shown. Push down on the tool until the latch
snaps closed.

Remove the attachment.

The quick coupler must be in the latched position [Figure

40-240-2] for disassembly.

Inspect the quick coupler to make sure the latch is in the

latched position.

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If the latch is in the unlatched position, see [Figure 40-
240-3] for additional information.

If the latch is in the latched position, proceed to [Figure

40-240-3].

WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
latching and unlatching the attachment quick
coupler.
W-2541-1106

40-240-2 E20 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-240-5

Removal And Installation (Cont’d)

WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist: 1
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-72269
W-2019-0907

Remove pins (Item 1) [Figure 40-240-5].

Figure 40-240-4
Figure 40-240-6

1
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P-72270 1
P-72265

Remove the bolts (Item 1) [Figure 40-240-4] and nuts.

Raise the arm and bucket link until the coupler is free
Installation: Align the holes of the connecting pins with [Figure 40-240-6].
the holes in the coupler. Install the two bolts (Item 1)
[Figure 40-240-4] and nuts. Tighten the nuts securely Installation: Align the arm and bucket link with the
against the couple. coupler [Figure 40-240-6]. Lower the arm and bucket link
into the coupler.

NOTE: Place the coupler on the ground with the

mounting pin (Item 1) [Figure 40-240-6] facing
towards the excavator.

40-240-3 E20 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT'D)

Parts Identification

1. Coupler Body
2. Spring
3. Locking Plate
4. Tool

4
2

P-88398

40-240-4 E20 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Figure 40-240-8

Disassembly
1

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present.
• Engine is running.
1
• Tools are being used.
W-2505-0604 P-72284

Figure 40-240-7 Remove the spring end hook (Item 1) [Figure 40-240-8]
from the quick coupler.
2 1 3
Figure 40-240-9

2
3 1
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1
P-72285

The two springs (Item 1) [Figure 40-240-7] have different P-72294

style of end hooks.

The spring hook (Item 2) [Figure 40-240-7] are full circle Remove the opposite end of the two springs (Item 1)
hooks. [Figure 40-240-9].

The spring hook (Item 3) [Figure 40-240-7] are partial

circle hooks.

The spring ends must be positioned as shown when

assembled.

40-240-5 E20 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D) Assembly

Disassembly (Cont’d) Figure 40-240-12

Figure 40-240-10

1 1 1

P-72296

P-72295
Install the latch (Item 1) [Figure 40-240-12].

Remove the two roll pins (Item 1) [Figure 40-240-10]. Figure 40-240-13
Drive the roll pins inwards to remove.

Figure 40-240-11

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1 1

1
P-72295

P-72296 Install the two roll pins (Item 1) [Figure 40-240-13]. Drive
the roll pins inwards until the roll pins are flush with the
outside edge of the quick coupler.
Remove the latch (Item 1) [Figure 40-240-11].

40-240-6 E20 Service Manual

QUICK COUPLER (KLAC™ SYSTEM) (CONT’D)

Assembly (Cont’d)

Figure 40-240-14

P-72294

Install the partial circle hook end of the spring (Item 1)

[Figure 40-240-14].

Figure 40-240-15

1
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1
P-72284

Install the full circle end of the spring hook (Item 1)

[Figure 40-240-15] on the quick coupler.

Do not lubricate the quick coupler. Lubrication will cause

dirt to collect and interfere with proper movement of the
quick coupler.

40-240-7 E20 Service Manual

40-240-8
E20 Service Manual
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QUICK COUPLER (LEHNHOFF® SYSTEM)

Troubleshooting

PROBLEM CAUSE CORRECTION

Daily Inspection

Figure 40-241-1

(MS03 & MS08)

2
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P-88183

Inspect the quick coupler for wear or damage. Inspect the

hooks (Item 1) and coupler locking shaft (Item 2) [Figure
40-241-1] (on the attachment) for wear or damage.

Repair or replace damaged parts.

40-241-1 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-241-4

Removal (MS03 And MS08)

Raise the arm and bucket link until the quick coupler is
Figure 40-241-2 free [Figure 40-241-4].

2
2

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1
1

P-88003

Remove the four nuts (Items 1). Remove the two bolts
(Item 2) [Figure 40-241-12].

Figure 40-241-3

1
P-88001

Remove the two connecting pins (Item 1) and O-rings

(Item 2) [Figure 40-241-3].

40-241-2 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-241-7

Installation (MS03 And MS08)

1
Figure 40-241-5 1

2
2

P-88003

1 Install the two bolts (Item 1) [Figure 40-241-7].

P-88000
Install nuts (Item 2) [Figure 40-241-7] just until contact is
made with the coupler.
Place the coupler on the ground with the hooks (Item 1)
[Figure 40-241-5] facing towards the excavator. NOTE: Do Not tighten nuts (Item 2) [Figure 40-241-7]
against the coupler. The retaining bolt must
Align the arm and bucket link with the coupler [Figure 40- rotate freely.
241-5].
Install and tighten nuts (Item 3) securely against the two
Figure 40-241-6 nuts (Item 2) [Figure 40-241-7]. The retaining bolts must
rotate freely.
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3
P-88001

Install the O-rings (Item 1) [Figure 40-241-6] between

the coupler pivot point and the arm and bucket link when
lowering into position.

NOTE: The O-rings will prevent dirt and debris from

entering the pivot points of the coupler.

Align the holes of the connecting pins with the holes

(Item 2) [Figure 40-241-6] in the coupler.

Install the two pins (Item 3) [Figure 40-241-6] through

the coupler, arm and bucket link.

40-241-3 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT'D)

Parts Identification (MS03)

1. Bolt
2. Lock Washer
3. Coupler Housing
4. Pressure Spring
5. Locking Mechanism 1

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5

P-88114

40-241-4 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D)

Disassembly And Assembly (MS03)

Figure 40-241-8

P-88004

Remove the two bolts (Item 1) [Figure 40-241-8] and

lock washers.

Figure 40-241-9

2
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P-88005

Turn the threaded spindle (Item 1) counterclockwise until

the locking mechanism (Item 2) [Figure 40-241-9] is free
from the housing.

40-241-5 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT'D)

Parts Identification (MS08)

1. Housing
2. Bushing
3. Bushing
4. O-ring
5. Cover
6. O-ring
7. O-ring 1
8. Reversing Lever
9. Threaded Pin
10. Pressure Spring 2
11. Pin
12. Pivoting Journal
13. Spring Washer
14. Bolt
15. Bearing Block 26 3
16. Locking Pin
4
17. Pressure Spring
18. Thrust Journal 3
19. Pin 25
20. O-ring 24
21. Driving Fork
22. Control Shaft
23. Bolt
24. Snap Ring 5
25. Bushing
6
26. Bushing

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7
23
22
8
9

21 10 11
20
19
12
20 17
19 18

16
15 13

P-88115

40-241-6 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) NOTE: Do not scratch the mounting surface while
removing sealant.
Disassembly (MS08)
Figure 40-241-12

WARNING 1

AVOID INJURY OR DEATH

Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
P-88010
Figure 40-241-10

Remove the two bolts (Item 1) [Figure 40-241-12].

2
Figure 40-241-13

1
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P-88009

2
Remove the eight bolts (Item 1) and cover (Item 2)
[Figure 40-241-10].
P-88011

Figure 40-241-11
Tilt the bearing block and pivoting journal (Item 1) up and
1 remove from the spring guide (Item 2) [Figure 40-241-
13].

P-88122

Remove all sealant (Item 1) [Figure 40-241-11] from the

housing and cover.

40-241-7 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-241-16

Disassembly (MS08) (Cont’d)

Figure 40-241-14

1
P-88013

Remove the snap ring (Item 1) [Figure 40-241-16].

P-88012
Figure 40-241-17

Remove the pivoting journal (Item 1) [Figure 40-241-14]

from the bearing block.

Figure 40-241-15

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1

P-88014

NOTE: Before removing the control shaft, note the

position of each of the components so that
when the coupler is reassembled all
P-88017
components are positioned correctly on the
control shaft [Figure 40-241-17].
Remove the pressure spring (Item 1) from the spring
guide (Item 2) [Figure 40-241-15].

40-241-8 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-241-20

Disassembly (MS08) (Cont’d)

4
Figure 40-241-18
1

1
3
2

P-88018

Remove the snap ring (Item 1) and pin (Item 2). Remove
the spring guide (Item 3) from the driving fork (Item 4)
P-88015
[Figure 40-241-20].

Remove the control shaft (Item 1) [Figure 40-241-18]. Figure 40-241-21

Figure 40-241-19

1
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P-88019

P-88016
Remove the locking pin assemblies [Figure 40-241-21].

Remove O-rings (Item 1) [Figure 40-241-19].

40-241-9 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Assembly (MS08)

Disassembly (MS08) (Cont’d) Figure 40-241-24

Figure 40-241-22

3
4 6
2 1

3
5
2 1 P-88022

P-88021
Install bushing (Item 1), O-ring (Item 2) and bushing (Item
3) [Figure 40-241-24] in both locking pin bores.
Remove the snap ring (Item 1) and pin (Item 2). Remove
the driving fork (Item 3) [Figure 40-241-22]. Figure 40-241-25

Remove the snap ring (Item 4) and pin (Item 5). Remove
the reversing lever (Item 6) [Figure 40-241-22]. 4
3 1
Repeat the procedure for the other locking pin.

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Figure 40-241-23

2
5 6
2 3
P-88021

Install reversing lever (Item 1), pin (Item 2) and snap ring
(Item 3) [Figure 40-241-25] on the locking pin.
1
Install the driving fork (Item 4), pin (Item 5) and snap ring
P-88022 (Item 6) [Figure 40-241-25] on the reversing lever.
Repeat the procedure for the other locking pin.

Remove the bushing (Item 1), O-ring (Item 2) and

bushing (Item 3) [Figure 40-241-23] from both locking
pin bores.

40-241-10 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-241-28

Assembly (MS08) (Cont’d)

Figure 40-241-26
1

P-88016

Install the O-rings (Item 1) [Figure 40-241-28].

P-88019
Figure 40-241-29

Install the locking pin assemblies [Figure 40-241-26].

NOTE: Position the locking levers with the flat side

down and away from the cover.

Figure 40-241-27 1
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P-88015

Install the control shaft (Item 1) [Figure 40-241-29].

4
2

P-88018

Install the driving fork (Item 1), pin (Item 2) and snap ring
(Item 3) on the spring guide (Item 4) [Figure 40-241-27].

40-241-11 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-241-32

Assembly (MS08) (Cont’d)

Figure 40-241-30

P-88025
1

Install the control shaft through the second locking lever

P-88023 driving fork (Item 1) [Figure 40-241-32].

NOTE: Check proper alignment of all three driving

Install the control shaft through the first locking lever forks on the control shaft. If not aligned
driving fork (Item 1) [Figure 40-241-30]. properly, repeat the procedure.

Figure 40-241-31 Figure 40-241-33

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1
1

P-88024 P-88013

Install the control shaft through the spring guide driving Install the snap ring (Item 1) [Figure 40-241-33].
fork (Item 1) [Figure 40-241-31].

40-241-12 E20 Service Manual

QUICK COUPLER (LEHNHOFF® SYSTEM) (CONT’D) Figure 40-241-36

Assembly (MS08) (Cont’d)

1
Figure 40-241-34

P-88026

1
Apply a bead of sealant around the cover mounting
P-88011 surface (Item 1) [Figure 40-241-36].

Figure 40-241-37
Install pressure spring (Item 1) on the spring guide. Tilt
the bearing block and pivoting journal (Item 2) [Figure
40-241-34] down and install on the spring guide.
1
Figure 40-241-35

2
1
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P-88009

Install the cover (Item 1) [Figure 40-241-37].

P-88010 Apply Loctite® 242 on the eight bolts.

Install the eight bolts (Item 2) [Figure 40-241-37].

Install the two bolts (Item 1) [Figure 40-241-35].

40-241-13 E20 Service Manual

40-241-14
E20 Service Manual
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RIGHT SIDE COVER Figure 40-250-3

Removal And Installation

2
Open the right side cover

Figure 40-250-1

2 3
1
1

2 3

P117780

Remove the fuel fill cap (Item 1) and the screws (Item 2)
[Figure 40-250-3].
2
P117782 Remove the cover hinge bolts (Item 3) [Figure 40-250-3].

Remove the cover assembly.

Disconnect the window washer wire harness (Item 1) and
washer fluid hose (Item 2) [Figure 40-250-1].

Figure 40-250-2
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P117781

Remove the retaining clip (Item 1) and the latch (Item 2)

[Figure 40-250-2] from the cover.

40-250-1 E20 Service Manual

40-250-2
E20 Service Manual
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ELECTRICAL SYSTEM

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
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LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Cab Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2

MAGNETIC LOCKOUT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

TWO-SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

50-01 E20 Service Manual

50-02
E20 Service Manual
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HARNESSES PN# DX17Z, E17, E17z, E19, E20
SCHEMATIC INDEX
OVERVIEW PAGE 1, 2, 3 HARNESS BOOM LIGHT 7135895
POWER PAGE 4
HARNESS DIFF SWITCH ZTS / CTS 7198838 / 7228452
GROUND PAGE 5
CAN BUS PAGE 6 HARNESS VALVE SWITCH (IF EQUIPTED) 7217804
ENGINE PAGE 7
HARNESS MOTION ALARM (IF EQUIPTED) 7217809
HYDRAULICS PAGE 8, 9
FRAME PAGE 10 HARNESS ENGINE 7217815
LIGHTS, BEACON, STROBE CAB PAGE 11
WIPER, HORN, OWD PAGE 12 HARNESS JUMPER (IF EQUIPTED) 7232729
RADIO, MA PAGE 13
HARNESS WASHER BOTTLE (IF EQUIPTED) 7238179
LIGHTS, BEACON, STROBE CANOPY PAGE 14
2ND AUX PAGE 15 HARNESS EH CONTROL (IF EQUIPTED) 7243646

HARNESS FRAME 7244548

HARNESS OWD (IF EQUIPTED) 7250792

HARNESS KEYED 7251398

HARNESS CAB KITS (IF EQUIPTED) 7266940

HARNESS REAR LIGHT (IF EQUIPTED) 7258225

HARNESS BEACON / STROBE (IF EQUIPTED) 7258226

HARNESS WORK LIGHT CANOPY (IF EQUPTED) 7258227

HARNESS LIGHT EXTENSION (IF EQUIPTED) 7258228

HARNESS CANOPY KITS (IF EQUIPTED) 7258229

HARNESS 2ND AUX (IF EQUIPPED) 7267960

HARNESS CAB (IF EQUIPTED) - FMS SUPPLIER BC7229928

HARNESS WIPER (IF EQUIPTED) - FMS SUPLLIER BC7230196

WIRING SCHEMATIC
E20 (S/N AWRH11001 - AWRH11829)
Printable Version Click Here

Sheet 1 of 14
(PRINTED MAY 2017)
Printed In U.S.A.
7258224 (0)
J1 CONNECTOR ASSIGNMENTS (CONTROLLER PRIMARY)
PIN FUNCTION PIN FUNCTION
A-01 AUX ROD RETURN B-01 LOAD SENSE PRESSURE SENSOR
A-02 OFFSET ROD RETURN B-02 UNSWITCHED BATTERY P1
A-03 FUEL PULL RELAY B-03 UNSWITCHED BATTERY P2
A-04 SWITCHED POWER OUT RELAY B-04 FUEL SOL HOLD
A-05 LIGHTS RELAY B-05 OFFSET ROD SOL
A-06 GLOW PLUG RELAY B-06 2 SPEED SOL
A-07 STARTER RELAY B-07 OFFSET BASE SOL
A-08 WARNING BUZZER B-08 CAN_LO_1
A-09 PB VALVE RELAY B-09 CAN_HI_1
A-10 OFFSET BASE RETURN B-10 OFFSET POT INPUT
A-11 SPARE B-11 CONSOLE POSITION SENSOR
A-12 AUX POT INPUT B-12 FUEL LEVEL SENSOR
A-13 2 SPEED SWITCH INPUT B-13 AUX ROD SOL
A-14 GLOW PLUG RELAY FDBK B-14 CAN_HI_2
A-15 ENGINE SPEED SENSOR B-15 GROUND P1

Page 488 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off
A-16 SPARE B-16 GROUND P2
A-17 SPARE B-17 SENSOR GROUND REFERENCE
A-18 AUX BASE RETURN B-18 ENGINE COOLANT TEMP SENSOR
A-19 SPARE B-19 AUX BASE SOL
A-20 OVERLOAD SENSOR B-20 CAN_LO_2
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY
A-22 STARTER RELAY FDBK B-22 KEY RUN
A-23 SPARE B-23 SENSOR SUPPLY 1 (8 VOLT)
A-24 CRANK INPUT B-24 SENSOR SUPPLY 1 (5 VOLT) WIRING SCHEMATIC
A-25 ENGINE OIL PRESSURE SWITCH B-25 BYPASS VALVE SOL
A-26 JOYSTICK LOCKOUT SOL RETURN B-26 JOYSTICK LOCKOUT SOL E20 (S/N AWRH11001 - AWRH11829)
A-27 BYPASS VALVE SOL RETURN Printable Version Click Here
A-28 OVERLOAD WARNING DEVICE ENABLE
A-29
A-30
AUX DETENT
FUEL PULL RELAY FDBK
Sheet 2 of 14
A-31 PB VALVE REALY FDBK (PRINTED MAY 2017)
A-32 SPARE
A-33 TRAVEL LEVER POS SWITCHES
Printed In U.S.A. 7258224 (0)
A-34 HYD OIL FILTER BYPASS SWITCH
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE PARTIAL CONNECTOR
1
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED 1
CONNECTOR
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
1
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
WIRE BREAK
(TWO WIRE BREAKS
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
JOIN ONE WIRE)
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL SHEET #

HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN

CONTROLLER SUPLY
5000 THROUGH 5999 YELLOW YEL
(5V, 8V)
LIGHTS 6000 THROUGH 6999 PINK PNK
Page 489 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off

OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT

ENGINE 8000 THROUGH 8999 TAN TAN

COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR

COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT

FUSE RELAY CENTER

WIRING SCHEMATIC
E20 (S/N AWRH11001 - AWRH11829)
Printable Version Click Here

Sheet 3 of 14
(PRINTED MAY 2017)
Printed In U.S.A. 7258224 (0)
POWER BATTERY
12.0 Volts
NEG POLE STARTER_B
SHEET 5
CABLE_NEG BLK BATT_CABLE_POS RED BATTERY CABLES
SHEET 7

BAT FEED RED

F1 10 A WIPER PWR
GATEWAY CONTROLLER 1510 RNG/WHT 1510 RNG/WHT
SHEET 12
J1A-21 J1A-4 WIPER PARK PWR
HARNESS 7120 WHT SHEET 12
FRAME 1540 RNG/WHT VALVE SWITCH PWR
SHEET 8
1620 RNG/WHT LH CONS PWR
SHEET 8

C025
1 F2 20 A 1520 RNG/WHT 2SPD PWR
1570 RNG/WHT
SHEET 10
SP6 RADIO PWR
1 1660 RNG/WHT
SHEET 13

3000 LBL

8000 TAN
MA PWR
1670 RNG/WHT SHEET 13
DETENT PWR
1680 RNG/WHT SHEET 8
ALTERNATOR
1530 RNG/WHT
SHEET 7
F3 25 A HEATER
1650 RNG/WHT
SHEET 10
1500 RNG/WHT
F4 25A 1580 RNG/WHT ACD SWITCH PWR
R5 SHEET 6
87 86
SWITCHED POWER SP17 DISPLAY SWITCH PWR
1585 RNG/WHT 1590 RNG/WHT SHEET 6
30
85 RELAY
1040 RED
1610 RNG/WHT KEYPAD SWITCH PWR
GND RELAYS SHEET 6
2030 BLK 2040 BLK
SHEET 7
RELAYS11GND
SHEET CONTROLLER PWR
1030 RED SP2 1480 RED/WHT SHEET 10

1070 RED F9 25A 1485 RED/WHT CONTROLLER PWR

SHEET 10

Page 490 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off
F10 25A ACD UNSWITCH PWR
1490 RED/WHT SHEET 6
1310 RED/WHT DISPLAY UNSWITCH PWR
SHEET 6

STARTER RELAY
1060 RED
SHEET 7
F5

F7 5A IGNITION PWR
1080 RED 1460 RED/WHT
SHEET 10
F8 25A 1470 RED/WHT FUEL SOL PWR
SHEET 7

F11 25A LIGHT PWR

1090 RED 1340 RED/WHT SHEET 11
6010 PNK BEACON PWR
SHEET 11
F12 15A 1350 RED/WHT AUX PWR
GATEWAY CONTROLLER SHEET 10
J1B-23 J1B-24
GLOW PLUG
1110 RED SHEET 7
5VDC
SHEET 8

428
0L
GN WIRING SCHEMATIC
5020 YEL SP15 5030 YEL 5VDC
5040
50 YEL
50
SHEET 8
5VDC
E20 (S/N AWRH11001 - AWRH11829)
YE SHEET 8
L Printable Version Click Here
5VDC
SHEET 8

8VDC
Sheet 4 of 14
5010 YEL SHEET 12
(PRINTED MAY 2017)
7258224 (0)
Printed In U.S.A.
RELAYS GND 2080 BLK
SHEET 7

GROUND
2SPD GND
2540 BRN
SHEET 8
RTR UC GND 2120 BLK
SHEET 8
PB SOLENOID GND 2130 BLK BATTERY CABLES
SHEET 8
ACD GND
HARNESS GATEWAY CONTROLLER SHEET 6
2140 BLK
FRAME J1B-17 DISPLAY GND
SHEET 6 2150 BLK

KEYPAD GND 2170 BLK

SHEET 6

2510 BRN
CONTROLLER GND
SHEET 10 2180 BLK
CONTROLLER GND
2190 BLK
SHEET 10 SP4
2090 BLK
SIG GND BUZZER GND
SHEET 7 2500 BRN SHEET 10 2200 BLK

SIG GND
SHEET 7 SP10 NEG POLE
16 BLK CABLE_NEG BLK
SIG GND AUX GND SHEET 4
4270 LGN 2210 BLK
SHEET 8 SHEET 10
WASHER GND
FUEL GND 2370 BLK
2570 BRN SHEET 12
SHEET 10
HORN GND 2260 BLK
SIG GND 2580 BRN SHEET 12
SHEET 12
FILTER GND 2350 BLK
SIG GND 2630 BRN SHEET 8
SHEET 12
HEATER GND

16 BLK
SIG GND SHEET 10 2270 BLK SP5
SHEET 12 2640 BRN
2100 BLK
SIG GND T014
2650 BRN
SHEET 12
FRAME GNG

BOOM LIGHT GND

2940 BLK
SHEET 11
MA GND
SHEET 13 2360 BLK
HARNESS
CAB LIGHT GND 2380 BLK
SHEET 11
CAB LIGHT GND
2220 BLK C008
SHEET 11 SP7
2340 BLK 2340 BLK
E E
LIGHTS GND
SHEET 11 2240 BLK

WIPER GND
SHEET 12 2250 BLK

RADIO GND
SHEET 13

2310 BLK
2900 BLK WIRING SCHEMATIC
C110

C109

6 6 E20 (S/N AWRH11001 - AWRH11829)

6 6 Printable Version Click Here
BEACON LOAD MOMENT
SWITCH SWITCH Sheet 5 of 14
(PRINTED MAY 2017)
7258224 (0)
Printed In U.S.A.
CAN BUS

C611
PANEL/DISPLAY
1 5 3 4 2
DISPLAY UNSWITCH PWR DISPLAY GND
SHEET 4 1310 RED/WHT 2150 BLK SHEET 5
DISPLAY SWITCH PWR 1590 RNG/WHT
SHEET 4

ACD UNSWITCH PWR ACD GND

SHEET 4 SHEET 5
ACD SWITCH PWR

9510 PUR/WHT
SHEET 4
GATEWAY CONTROLLER

9610 PUR
J1B-21 J1B-8 J1B-9

1580 RNG/WHT
1490 RED/WHT
2140 BLK 3040 LBL

9500 PUR/WHT SP23 9550 PUR/WHT SP21 9520 PUR/WHT

9600 PUR 9650 PUR 9620 PUR
SP24 SP22

A B C D E F G

ACD, Remote Tool KEYPAD SWITCH PWR

SHEET 4 KEYPAD GND
SHEET 5

9540 PUR/WHT
9640 PUR
1610 RNG/WHT

2170 BLK

WIRING SCHEMATIC
E20 (S/N AWRH11001 - AWRH11829)
Printable Version Click Here

KEYPAD Sheet 6 of 14
C029

1 5 2 4 3 6
OPTION
Printed In U.S.A. 1 5 2 4 3 6 (PRINTED MAY 2017)
7258224 (0)
ENGINE
GATEWAY CONTROLLER
J1B-4 J1A-30 J1A-3 J1A-6 J1A-14 J1B-18 J1A-15 J1A-25 J1A-22 J1A-7 J1A-16

8110 TAN
8120 TAN

8250 PUR
8140 TAN

8170 TAN

3010 LBL

3030 LBL

8270 TAN
3120 LBL
R4 R2 R1
8100 TAN

8130 TAN
87 86 FUEL 87 86
GLOW PLUG 87 86
STARTER
SOLENOID RELAY RELAY
85 85 85
8150 TAN

30 RELAY 30 30

2040 BLK 2050 BLK 2060 BLK 2070 BLK 2080 BLK

1470 RED/WHT
SHEET 4 SHEET 11 SHEET 11 SHEET 5

1110 RED

1060 RED
RELAYS GND RELAYS GND RELAYS GND SIG GND SIG GND ALTERNATOR RELAYS GND
SHEET 5 SHEET 5 SHEET 4

8260 TAN
1530 RNG/WHT
2500 BRN

2530 BRN
SHEET 4 SHEET 4
GLOW PLUG STARTER RELAY
SHEET 4
FUEL SOL PWR
HARNESS FRAME
C001

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14
HARNESS ENGINE

2500 BRN

2530 BRN

3120 LBL
3010 LBL

3030 LBL
8130 TAN

8260 TAN
8270 TAN
8150 TAN

8100 TAN

8170 TAN

C006
1 2 3
T002

C004

C005
1 2 A B 1 2 3
T001 1 2 A B IG L S
G B M
C003

A B C 1010 RED
B
A B C ENGINE OIL T004
SPEED PRESSURE
COMMON BLK

ENGINE COOLANT ALTERNATOR

SENSOR SWITCH (NC) STARTER
HOLD RED

PULL WHT

TEMPERATURE
SENSOR
GLOW PLUG
2020 BLK

STARTER_B BATT_CABLE_POS RED BATTERY CABLES

SHEET 4

FUEL SHUTOFF
SOLENOID WIRING SCHEMATIC
E20 (S/N AWRH11001 - AWRH11829)
Printable Version Click Here
CABLE_FRM BLK CABLE_FRM BLK

T008 Sheet 7 of 14
(PRINTED MAY 2017)
Printed In U.S.A. ENGINE GND STARTER GND ENGINE BAY
FRAME GND
FRAME GND
7258224 (0)
HYDRAULICS
GATEWAY CONTROLLER
J1A-33 J1A-31 J1A-9 J1B-25 J1A-27 J1B-26 J1A-26 J1B-6 J1A-34

3060 LBL

4090 LGN
VALVE SWITCH PWR
SHEET 4

LH CONS PWR

1540 RNG/WHT
SHEET 4
R7

4050 LGN
87 86
PB SOL

3080 LBL
RELAY
4070 LGN

30 85

2025 BLK FILTER GND

SP3 1550 RNG/WHT SHEET 4 SHEET 5
RELAYS GND
1560 RNG/WHT

2350 BLK
2110 BRN

2550 BRN
4010 LGN

4040 LGN

4060 LGN

C301
PB SOLENOID
C122

1620 RNG/WHT
GND A B
SHEET 5
B A
A B
B A

4120 LGN
HARNESS

RTR UC GND 2SPD GND

SHEET 5
4030 LGN

SHEET 5

2350 BLK
3080 LBL
4020 LGN

2120 BLK

2540 BRN
C030

C031

C032

C033

C034
1 2 1630 RNG/WHT 1 2 1 2 1 2 1 2
SP33 SHEET 12
1 2 1 2 1 2 1 2 1 2
SP34 LM PWR
T301 T302

C112
3 2 1 4 5 6
4230 LGN

4220 LGN

4430 LGN

4420 LGN

3 2 1 4 5 6
C125

C124

A B A B RETRACTABLE BY PASS JOYSTICK TWO

PB
SOLENOID UC VALVE ENABLE SPEED HYD FILTER SWITCH
A B A B SOLENOID SOLENOID SOLENOID SOLENOID (CLOGGING INDICATOR)
RETRACT UC
SWITCH

WIRING SCHEMATIC
LH TRAVEL RH TRAVEL
E20 (S/N AWRH11001 - AWRH11829)
SWITCH SWITCH
Printable Version Click Here

HARNESS VALVE
SWITCH
Sheet 8 of 14
(PRINTED MAY 2017)
7258224 (0)
Printed In U.S.A.
HYDRAULICS
GATEWAY CONTROLLER
J1B-1 J1B-10 J1A-29 J1A-12 J1B-13 J1A-1 J1B-19 J1A-18 J1B-5 J1A-2 J1B-7 J1A-10

SIG GND
SHEET 5
5VDC
SHEET 4
3500 LBL

2590 BRN

2600 BRN

2610 BRN

2620 BRN
4310 LGN

4320 LGN

4330 LGN

4340 LGN
4280 LGN

4080 LGN

4260 LGN

4250 LGN
4270 LGN

5VDC SIG GNG 5VDC SIG GNG

SHEET 8 SHEET 5 SHEET 8 SHEET 5
DETENT PWR

5040 YEL
5030 YEL
HORN PWR
C040

SHEET 8

2630 BRN
SHEET 8

C150
2640 BRN
1680 RNG/WHT
1690 RNG/WHT

B C A A B C D E F G H
B C A
HRNS A B C D E F G H
C040A

B C A MA
B C A 1640 RNG/WHT HORN PWR
SHEET 5 HARNESS
4280 LGN

4270 LGN
3500 LBL

EH CONTROL
C107

C009
B C D A E B C D A E

2590 BRN

2600 BRN

2610 BRN

2620 BRN
4310 LGN

4320 LGN

4330 LGN

OPTION
B C D A E B C D A E
C040B

B C A
B C A

C037

C038

C035

C036
B C A LEFT JOYSTICK RIGHT JOYSTICK 1 2 1 2 1 2 1 2
B C A
C040

1 2 1 2 1 2 1 2
4280 LGN

4270 LGN
3500 LBL

AUX AUX OFFSET OFFSET

ROD BASE ROD BASE
SOLENOID SOLENOID SOLENOID SOLENOID

WIRING SCHEMATIC
C045

B C A

B C A E20 (S/N AWRH11001 - AWRH11829)

Printable Version Click Here

Sheet 9 of 14
AUTOSHIFT SENSE
PRESSURE
HARNESS (PRINTED MAY 2017)
JUMPER 7258224 (0)
Printed In U.S.A.
FRAME
GATEWAY CONTROLLER
J1B-2 J1B-3 J1A-24 J1B-22 J1A-8 J1B-12 J1A-13 J1B-15 J1B-16

1480 RED/WHT

2180 BLK
1485 RED/WHT

2190 BLK
CONTROLLER GND
CONTROLLER PWR SHEET 5
SHEET 4
CONTROLLER PWR CONTROLLER GND
SHEET 4 SHEET 5

7010 WHT

4240 LGN
3300 LBL
2SPD PWR
8280 TAN

3050 LBL
SHEET 4

IGNITION PWR 1460 RED/WHT

1570 RNG/WHT
SHEET 4
HEATER
HEATER GND AUX PWR 6400 PNK CAB LIGHT PWR
BUZZER GND FUEL GND SHEET 4 SHEET 5 SHEET 4 SHEET 11

1350 RED/WHT
SHEET 5 SHEET 5
2210 BLK AUX GND

2270 BLK
2570 BRN
2200 BLK
SHEET 5

C014

C010

C019

C016
+ - A B A B A B 2 1

A B A B A B 2 1
C051

A B C BUZZER
FUEL LEVEL
A B C SENSOR
BLADE JOYSTICK HEATER
SUPPLY AUX SOCKET
1460 RED/WHT
8280 TAN

3050 LBL

HARNESS
KEYED
C011

1 2 3 4 5 6
WIRING SCHEMATIC
1 2 3 4 5 6
ST I E20 (S/N AWRH11001 - AWRH11829)
B Printable Version Click Here

IGNITION SWITCH
Sheet 10 of 14
(PRINTED MAY 2017)
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LIGHTS / BEACON / STROBE - CABIN
GATEWAY CONTROLLER
J1A-5

6200 PNK
HARNESS FRAME
6190 PNK
6210 PNK
R3 R6
87 86 87 86
LIGHT LIGHT
30 85 RELAY 30 85 RELAY
1340 RED/WHT 1345 RED/WHT
LIGHT PWR 2030 BLK
SHEET 4 LIGHT GND
SHEET 4 2060 BLK SHEET 5
RELAYS GND
2050 BLK 2025 BLK
SHEET 7
RELAYS GND RELAYS GND
RELAYS GND SHEET 7
SHEET 7

SP8
6260 PNK

2380 BLK
6250 PNK
6220 PNK

CAB LIGHT PWR BEACON PWR

SHEET 10 SHEET 4

C204
6400 PNK
2940 BLK 6310 PNK
1 2
SHEET 5
BOOM LIGHT
1 2
GND
C460

C008

6010 PNK

6260 PNK
A B A B C

SP11

6250 PNK

6310 PNK
2220 BLK 2240 BLK
SHEET 5 SHEET 5 SP12
CAB LIGHT GND LIGHTS GND
6400 PNK

2400 BLK
6270 PNK

6280 PNK
C706

2390 BLK
A B C

C110
1 2 3 4 5

C205

C206
A B C 1 2 3 4 5
A B A B
SP40 2240 BLK
HARNESS
A B A B
6250 PNK

CAB KITS BEACON

6310 PNK
2230 BLK

SWITCH

2870 BLK
LEFT RIGHT
T201 T202

HARNESS
C707

A B C705 1 2 CAB
CAB LIGHT
A B 1 2
6250 PNK

6310 PNK
2230 BLK

2870 BLK

WIRING SCHEMATIC
C709

C708

A B 1 2

A B 1 2 E20 (S/N AWRH11001 - AWRH11829)

Printable Version Click Here

HARNESS HARNESS Sheet 11 of 14

BOOM LIGHT CAB
HARNESS HARNESS
(PRINTED MAY 2017)
REAR LIGHT BEACON/STROBE
Printed In U.S.A. 7258224 (0)
WIPER / LH CONSOLE / HORN / OWD
WIPER PWR GATEWAY CONTROLLER
SHEET 4 J1B-11 J1A-28 J1A-20

1510 RNG/WHT
7030 WHT
WASHER GND
2370 BLK SHEET 5

C017
8VDC SIG GND
1 2 SHEET 4 SHEET 5

3410 LBL

3420 LBL
1 2
HARNESS LM PWR 5VDC SIG GNG
7030 WHT SHEET 8 SHEET 8 SHEET 5

2370 BLK
WASHER

1630 RNG/WHT

2650 BRN
BOTTLE

5050 YEL
3230 LBL
C018

1 2
1690 RNG/WHT

5010 YEL
SHEET 12

2580 BRN
1 2

C042
HORN PWR

C109
HORN PWR HORN GND 2 1 3 4 5 B C A
SHEET 4 SHEET 5
WASHER

1510 RNG/WHT
2 1 3 4 5 B C A
BOTTLE

2260 BLK
LOAD MOMENT
7110 WHT

SWITCH
C111

2 1 3 4 5 6 T100 T101

2 1 3 4 5 6

2650 BRN
5050 YEL
3420 LBL
7100 WHT

C108
A B C
OWD
A B C
WIPER SWITCH

C048
B C A
WIPER PARK PWR CONSOLE
SHEET 4 SENSOR
B C A
7120 WHT

HARNESS FRAME
C008

LOAD MOMENT
F G H SENSOR

F G H
HARNESS
CAB
7110 WHT
7100 WHT

7120 WHT

2250 BLK WIRING SCHEMATIC

SHEET 5
WIPER GND
E20 (S/N AWRH11001 - AWRH11829)
C628

1 2 3 4
Printable Version Click Here
1 2 3 4
Sheet 12 of 14
31b 53 31 53a (PRINTED MAY 2017)
WIPER
7258224 (0)
Printed In U.S.A.
RADIO / MA MA PWR MA GND
RADIO PWR SHEET 4 SHEET 5

1670 RNG/WHT
SHEET 4

2360 BLK
C040A C040
D E

1660 RNG/WHT
D E

D E
D E

2360 BLK

HARNESS
MA

1670 RNG/WHT
2420 BLK SP35
C008

HARNESS FRAME
D

1750 RNG/WHT
TM1 TM2
D

HARNESS RADIO GND

1660 RNG/WHT
SHEET 5
CAB ALARM

SP37 1760 RNG/WHT

7980 WHT

7990 WHT
C220

4 3 1 2 5 6
2980 BLK

2990 BLK
SP36

2410 BLK
4 3 1 2 5 6

1710 RNG/WHT

1730 RNG/WHT

1720 RNG/WHT

1740 RNG/WHT
1560 RNG/WHT

RADIO 4070 LGN

C125A

C124A

C122A
A B A B 85 30 86 87 87A
B A

A B A B 85 30 86 87 87A
B A
T204 T203 T205 T206

LEFT RIGHT
SPEAKER SPEAKER R9
RELAY

WIRING SCHEMATIC
E20 (S/N AWRH11001 - AWRH11829)
Printable Version Click Here

Sheet 13 of 14
(PRINTED MAY 2017)
Printed In U.S.A.
7258224 (0)
LIGHTS / BEACON / STROBE - CANOPY

C008A

C204A
B C E 1 2

B C E 1 2

HARNESS

6260 PNK

2380 BLK
LIGHT
EXTENSION

C200
2240 BLK
6250 PNK 1 2

1 2
SP40
2330 BLK HARNESS

6260 PNK

2380 BLK
CANOPY KITS

6310 PNK

2870 BLK
SP18
SP19
C707

C705

6270 PNK

2400 BLK
2390 BLK
A B 1 2
6250 PNK

6310 PNK
2330 BLK

2870 BLK

C202

C203
A B A B
C709

C708

A B 1 2 A B A B

A B 1 2 LEFT RIGHT

HARNESS
WORK LIGHT
HARNESS HARNESS CANOPY
REAR LIGHT BEACON/STROBE

WIRING SCHEMATIC
E20 (S/N AWRH11001 - AWRH11829)
Printable Version Click Here

Sheet 14 of 14
(PRINTED MAY 2017)
Printed In U.S.A. 7258224 (0)
SCHEMATIC INDEX
OVERVIEW PAGE 1, 2, 3
HARNESSES PN# E17, E19, E20, D17, D19
POWER PAGE 4 HARNESS BOOM LIGHT 7135895
GROUND PAGE 5
CAN BUS PAGE 6 HARNESS DIFF SWITCH ZTS / CTS 7198838 / 7228452
ENGINE PAGE 7
HARNESS VALVE SWITCH (IF EQUIPTED) 7217804
HYDRAULICS PAGE 8, 9
FRAME PAGE 10 HARNESS MOTION ALARM (IF EQUIPTED) 7217809
LIGHTS, BEACON, STROBE CAB PAGE 11
WIPER, HORN, OWD PAGE 12 HARNESS ENGINE 7217815
RADIO, MA PAGE 13
HARNESS JUMPER (IF EQUIPTED) 7232729
LIGHTS, BEACON, STROBE CANOPY PAGE 14
2ND AUX PAGE 15 HARNESS WASHER BOTTLE (IF EQUIPTED) 7238179

HARNESS EH CONTROL (IF EQUIPTED) 7243646

HARNESS FRAME 7244548

HARNESS OWD (IF EQUIPTED) 7250792

HARNESS KEYED 7251398

HARNESS CAB KITS (IF EQUIPTED) 7266940

HARNESS REAR LIGHT (IF EQUIPTED) 7258225

HARNESS BEACON / STROBE (IF EQUIPTED) 7258226

HARNESS WORK LIGHT CANOPY (IF EQUPTED) 7258227

HARNESS LIGHT EXTENSION (IF EQUIPTED) 7258228

HARNESS CANOPY KITS (IF EQUIPTED) 7258229

HARNESS 2ND AUX (IF EQUIPTED) 7267960

HARNESS CAB (IF EQUIPTED) - FMS SUPPLIER BC7229928

HARNESS WIPER (IF EQUIPTED) - FMS SUPLLIER BC7230196

WIRING SCHEMATIC
E20 (S/N AWRH11830 AND ABOVE)
(S/N B3BL11001 AND ABOVE)
Sheet 1 of 15 Printable Version Click Here

(PRINTED MAY 2017)

Printed In U.S.A. 7258224 (A)
J1 CONNECTOR ASSIGNMENTS (CONTROLLER PRIMARY)
PIN FUNCTION PIN FUNCTION
A-01 AUX ROD RETURN B-01 LOAD SENSE PRESSURE SENSOR
A-02 OFFSET ROD RETURN B-02 UNSWITCHED BATTERY P1
A-03 FUEL PULL RELAY B-03 UNSWITCHED BATTERY P2
A-04 SWITCHED POWER OUT RELAY B-04 FUEL SOL HOLD
A-05 LIGHTS RELAY B-05 OFFSET ROD SOL
A-06 GLOW PLUG RELAY B-06 2 SPEED SOL
A-07 STARTER RELAY B-07 OFFSET BASE SOL
A-08 WARNING BUZZER B-08 CAN_LO_1
A-09 PB VALVE RELAY B-09 CAN_HI_1
A-10 OFFSET BASE RETURN B-10 OFFSET POT INPUT
A-11 SPARE B-11 CONSOLE POSITION SENSOR
A-12 AUX POT INPUT B-12 FUEL LEVEL SENSOR
A-13 2 SPEED SWITCH INPUT B-13 AUX ROD SOL
A-14 GLOW PLUG RELAY FDBK B-14 CAN_HI_2
A-15 ENGINE SPEED SENSOR B-15 GROUND P1
A-16 SPARE B-16 GROUND P2

Page 502 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off
A-17 SPARE B-17 SENSOR GROUND REFERENCE
A-18 AUX BASE RETURN B-18 ENGINE COOLANT TEMP SENSOR
A-19 SPARE B-19 AUX BASE SOL
A-20 OVERLOAD SENSOR B-20 CAN_LO_2
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY
A-22 STARTER RELAY FDBK B-22 KEY RUN
A-23 SPARE B-23 SENSOR SUPPLY 1 (8 VOLT)
A-24 CRANK INPUT B-24 SENSOR SUPPLY 1 (5 VOLT)
A-25 ENGINE OIL PRESSURE SWITCH B-25 BYPASS VALVE SOL WIRING SCHEMATIC
A-26 JOYSTICK LOCKOUT SOL RETURN B-26 JOYSTICK LOCKOUT SOL
A-27 BYPASS VALVE SOL RETURN E20 (S/N AWRH11830 AND ABOVE)
A-28 OVERLOAD WARNING DEVICE ENABLE
A-29 AUX DETENT
(S/N B3BL11001 AND ABOVE)
A-30
A-31
FUEL PULL RELAY FDBK
PB VALVE REALY FDBK
Sheet 2 of 15 Printable Version Click Here
A-32 HYDRAULIC TEMP SENSOR
(PRINTED MAY 2017)
A-33 TRAVEL LEVER POS SWITCHES
Printed In U.S.A. A-34 HYD OIL FILTER BYPASS SWITCH
7258224 (A)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE PARTIAL CONNECTOR
1
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED 1
CONNECTOR
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
1
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
WIRE BREAK
(TWO WIRE BREAKS
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
JOIN ONE WIRE)
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL SHEET #

HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN

CONTROLLER SUPLY
5000 THROUGH 5999 YELLOW YEL
(5V, 8V)
LIGHTS 6000 THROUGH 6999 PINK PNK

OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT

ENGINE 8000 THROUGH 8999 TAN TAN

COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR

COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT

FUSE RELAY CENTER

WIRING SCHEMATIC
E20 (S/N AWRH11830 AND ABOVE)
(S/N B3BL11001 AND ABOVE)
Sheet 3 of 15 Printable Version Click Here

(PRINTED MAY 2017)

7258224 (A)
Printed In U.S.A.
POWER BATTERY
12.0 Volts
NEG POLE STARTER_B
SHEET 5
CABLE_NEG BLK BATT_CABLE_POS RED BATTERY CABLES
SHEET 7

BAT FEED RED

F1 10 A 1510 RNG/WHT 1510 RNG/WHT WIPER PWR
GATEWAY CONTROLLER SHEET 12
J1A-21 J1A-4 7120 WHT WIPER PARK PWR
HARNESS SHEET 12
FRAME 1540 RNG/WHT VALVE SWITCH PWR
SHEET 8
1620 RNG/WHT LH CONS PWR
SHEET 8

C025
1 F2 20 A 1520 RNG/WHT 1570 RNG/WHT 2SPD PWR
SHEET 10
SP6 RADIO PWR
1 1660 RNG/WHT SHEET 13

3000 LBL

8000 TAN
MA PWR
1670 RNG/WHT SHEET 13
1680 RNG/WHT DETENT PWR
SHEET 9
1530 RNG/WHT ALTERNATOR
SHEET 7
F3 25 A 1650 RNG/WHT HEATER
SHEET 10
1500 RNG/WHT
F4 25A 1580 RNG/WHT ACD SWITCH PWR
R5 SHEET 6
87 86
SWITCHED POWER 1585 RNG/WHT SP17 1590 RNG/WHT DISPLAY SWITCH PWR
85 RELAY SHEET 6
30
1040 RED
1610 RNG/WHT KEYPAD SWITCH PWR
GND RELAYS SHEET 6
2030 BLK 2040 BLK SHEET 7
RELAYS11GND
SHEET 1480 RED/WHT CONTROLLER PWR
1030 RED SP2 SHEET 10
F9 25A CONTROLLER PWR
1070 RED 1485 RED/WHT SHEET 10
F10 25A 1490 RED/WHT ACD UNSWITCH PWR

1060 RED STARTER RELAY

SHEET 7
F5

1080 RED F7 5A 1460 RED/WHT IGNITION PWR

SHEET 10
F8 25A 1470 RED/WHT FUEL SOL PWR
SHEET 7

1090 RED F11 25A 1340 RED/WHT LIGHT PWR

SHEET 11
6010 PNK BEACON PWR
SHEET 11
F12 15A 1350 RED/WHT AUX PWR
GATEWAY CONTROLLER SHEET 10
J1B-23 J1B-24

1110 RED GLOW PLUG

SHEET 7
5VDC
SHEET 9

428
0L
GN WIRING SCHEMATIC
5020 YEL SP15 5030 YEL 5VDC
5040
50 YEL
50
SHEET 9
5VDC
E20 (S/N AWRH11830 AND ABOVE)
YE SHEET 9
L
5VDC
SHEET 12
(S/N B3BL11001 AND ABOVE)
5010 YEL 8VDC
Sheet 4 of 15 Printable Version Click Here
SHEET 12
(PRINTED MAY 2017)
7258224 (A)
Printed In U.S.A.
RELAYS GND 2080 BLK
SHEET 7

GROUND
2SPD GND 2540 BRN
SHEET 8
RTR UC GND 2120 BLK
SHEET 8
PB SOLENOID GND
2130 BLK BATTERY CABLES
SHEET 8
ACD GND
HARNESS GATEWAY CONTROLLER SHEET 6
2140 BLK
FRAME J1B-17 DISPLAY GND 2150 BLK
SHEET 6

KEYPAD GND
2170 BLK
SHEET 6

2510 BRN
CONTROLLER GND
2180 BLK
SHEET 10
CONTROLLER GND
2190 BLK
SHEET 10 SP4
2090 BLK
SIG GND BUZZER GND
2500 BRN 2200 BLK
SHEET 7 SHEET 10
SIG GND
2530 BRN
SHEET 7 SP10 NEG POLE
16 BLK CABLE_NEG BLK
SIG GND AUX GND SHEET 4
4270 LGN 2210 BLK
SHEET 9 SHEET 10
WASHER GND
FUEL GND SHEET 12 2370 BLK
2570 BRN
SHEET 10
HORN GND
SIG GND 2260 BLK
2580 BRN SHEET 12
SHEET 12
FILTER GND
SIG GND 2350 BLK
2630 BRN SHEET 8
SHEET 9
HEATER GND

16 BLK
SIG GND 2270 BLK SP5
2640 BRN SHEET 10
SHEET 9 2100 BLK
SIG GND T014
2650 BRN
SHEET 12
FRAME GNG
Page 505 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off

FRAME GND
BOOM LIGHT GND 2940 BLK
SHEET 11
MA GND 2360 BLK
HARNESS SHEET 13
CAB LIGHT GND
2380 BLK
SHEET 11
CAB LIGHT GND
2220 BLK C008
SHEET 11 SP7
2340 BLK 2340 BLK
E E
LIGHTS GND
2240 BLK
SHEET 11
WIPER GND 2250 BLK
SHEET 12
RADIO GND
SHEET 13 2280 BLK

2310 BLK
WIRING SCHEMATIC
2900 BLK
E20 (S/N AWRH11830 AND ABOVE)
C110

C109

6 6
(S/N B3BL11001 AND ABOVE)
BEACON
6 6
LOAD MOMENT
Sheet 5 of 15 Printable Version Click Here
SWITCH SWITCH
(PRINTED MAY 2017)
Printed In U.S.A. 7258224 (A)
C611
PANEL/DISPLAY

CAN BUS DISPLAY UNSWITCH PWR

SHEET 4
DISPLAY SWITCH PWR
1310 RED/WHT
1 5 3 4 2

2150 BLK
DISPLAY GND
SHEET 5
1590 RNG/WHT
SHEET 4

ACD UNSWITCH PWR ACD GND

SHEET 4 SHEET 5
ACD SWITCH PWR

9510 PUR/WHT
SHEET 4
GATEWAY CONTROLLER

9610 PUR
J1B-21 J1B-8 J1B-9

1580 RNG/WHT
1490 RED/WHT
2140 BLK

3040 LBL

9500 PUR/WHT SP23 9550 PUR/WHT SP21 9520 PUR/WHT

9600 PUR 9650 PUR 9620 PUR
SP24 SP22

A B C D E F G

ACD, Remote Tool KEYPAD SWITCH PWR

SHEET 4 KEYPAD GND
SHEET 5

9540 PUR/WHT
9640 PUR
1610 RNG/WHT

2170 BLK

WIRING SCHEMATIC
E20 (S/N AWRH11830 AND ABOVE)
(S/N B3BL11001 AND ABOVE)
Sheet 6 of 15 Printable Version Click Here
(PRINTED MAY 2017)
KEYPAD
C029

1 5 2 4 3 6
OPTION 7258224 (A)
Printed In U.S.A. 1 5 2 4 3 6
ENGINE
GATEWAY CONTROLLER
J1B-4 J1A-30 J1A-3 J1A-6 J1A-14 J1B-18 J1A-15 J1A-25 J1A-22 J1A-7 J1A-16

8110 TAN

8120 TAN

8250 PUR
8140 TAN

8170 TAN

3010 LBL

3030 LBL

8270 TAN
3120 LBL
R4 R2 R1
8100 TAN

8130 TAN
87 86 FUEL 87 86
GLOW PLUG 87 86
STARTER
SOLENOID RELAY RELAY
85 85 85
8150 TAN

30 RELAY 30 30

2040 BLK 2050 BLK 2060 BLK 2070 BLK 2080 BLK

1470 RED/WHT
SHEET 4 SHEET 11 SHEET 11 SHEET 5

1110 RED

1060 RED
RELAYS GND RELAYS GND RELAYS GND SIG GND SIG GND ALTERNATOR RELAYS GND
SHEET 5 SHEET 5 SHEET 4

8260 TAN
1530 RNG/WHT
2500 BRN

2530 BRN
SHEET 4 SHEET 4
GLOW PLUG STARTER RELAY
SHEET 4
FUEL SOL PWR
HARNESS FRAME
C001

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14
HARNESS ENGINE

2500 BRN

2530 BRN

3120 LBL
3010 LBL

3030 LBL
8130 TAN

8260 TAN
8270 TAN
8150 TAN

8100 TAN

8170 TAN

C006
1 2 3
T002

C004

C005
1 2 A B 1 2 3
T001 IG L S
1 2 A B
B
G M
C003

A B C 1010 RED
B
A B C ENGINE OIL T004
SPEED PRESSURE
COMMON BLK

ENGINE COOLANT ALTERNATOR

SENSOR SWITCH (NC) STARTER
HOLD RED

PULL WHT

TEMPERATURE
SENSOR
GLOW PLUG
2020 BLK

STARTER_B BATT_CABLE_POS RED BATTERY CABLES

SHEET 4

FUEL SHUTOFF
SOLENOID
WIRING SCHEMATIC
E20 (S/N AWRH11830 AND ABOVE)
CABLE_FRM BLK CABLE_FRM BLK (S/N B3BL11001 AND ABOVE)
T008 Sheet 7 of 15 Printable Version Click Here
(PRINTED MAY 2017)
ENGINE GND STARTER GND ENGINE BAY FRAME GND
Printed In U.S.A. FRAME GND 7258224 (A)
HYDRAULICS
GATEWAY CONTROLLER
J1A-33 J1A-31 J1A-9 J1B-25 J1A-27 J1B-26 J1A-26 J1B-6 J1A-34

3060 LBL

4090 LGN
VALVE SWITCH PWR
SHEET 4

LH CONS PWR

1540 RNG/WHT
SHEET 4
R7
87 86
PB SOL

3080 LBL
RELAY
4070 LGN

30 85

2025 BLK FILTER GND

SP3 1550 RNG/WHT SHEET 11 SHEET 5
RELAYS GND
1560 RNG/WHT

4050 LGN

2350 BLK
2110 BRN

2550 BRN
4010 LGN

4040 LGN

4060 LGN

C301
PB SOLENOID
C122

GND A B

1620 RNG/WHT
SHEET 5
B A
A B
B A

4120 LGN HARNESS

DIFF

RTR UC GND 2SPD GND

SHEET 5
4030 LGN

SHEET 5

2350 BLK
3080 LBL
4020 LGN

2120 BLK

2540 BRN
1630 RNG/WHT
SHEET 12
LM PWR
C030

C031

C032

C033

C034
1 2 1 2 1 2 1 2 1 2
SP33
1 2 1 2 1 2 1 2 1 2
SP34
T021 T022 T301 T302
4230 LGN

4430 LGN

4420 LGN
4220 LGN
C125

C124

A B A B RETRACT UC
PB SWITCH RETRACTABLE BY PASS JOYSTICK TWO
SOLENOID UC VALVE ENABLE SPEED HYD FILTER SWITCH
A B A B SOLENOID SOLENOID SOLENOID SOLENOID (CLOGGING INDICATOR)

WIRING SCHEMATIC
LH TRAVEL RH TRAVEL
E20 (S/N AWRH11830 AND ABOVE)
SWITCH SWITCH
(S/N B3BL11001 AND ABOVE)
HARNESS VALVE
SWITCH Sheet 8 of 15 Printable Version Click Here
(PRINTED MAY 2017)
7258224 (A)
Printed In U.S.A.
HYDRAULICS
GATEWAY CONTROLLER
J1B-1 J1B-10 J1A-29 J1A-12 J1B-13 J1A-1 J1B-19 J1A-18 J1B-5 J1A-2 J1B-7 J1A-10

SIG GND
SHEET 5

3500 LBL
5VDC
SHEET 4
4280 LGN

4270 LGN

2590 BRN

2600 BRN

2610 BRN

2620 BRN
4310 LGN

4320 LGN

4330 LGN

4340 LGN
C040

B C A

4080 LGN

4260 LGN

4250 LGN
B C A
C040C

B C A
B C A
5VDC SIG GNG 5VDC SIG GNG
4270 LGN

SHEET 4 SHEET 5 SHEET 4 SHEET 5

DETENT PWR

5040 YEL
HORN PWR
SHEET 4

2630 BRN
SHEET 12

C150
2640 BRN
1680 RNG/WHT
1690 RNG/WHT

5030 YEL
4280 LGN

3500 LBL

SP52 A B C D E F G H

2660 BRN HYD TEMP GND A B C D E F G H

4275 LGN

SHEET 15

HORN PWR
1640 RNG/WHT
SHEET 12 HARNESS
C040D

HRNS C107
EH CONTROL

C009
B C D A E B C D A E

2590 BRN

2600 BRN

2610 BRN

2620 BRN
4310 LGN

4320 LGN

4330 LGN

B C A
C040A

B C A

HRNS
4280 LGN

4270 LGN
3500 LBL

C037

C038

C035

C036
LEFT JOYSTICK RIGHT JOYSTICK 1 2 1 2 1 2 1 2
MA
1 2 1 2 1 2 1 2
C040B

B C A
B C A

B C A
C040

B C A

AUX AUX OFFSET OFFSET

ROD BASE ROD BASE
4280 LGN

4270 LGN
3500 LBL

SOLENOID SOLENOID SOLENOID SOLENOID

WIRING SCHEMATIC
C045

B C A

B C A E20 (S/N AWRH11830 AND ABOVE)

(S/N B3BL11001 AND ABOVE)
Sheet 9 of 15 Printable Version Click Here
AUTOSHIFT SENSE
PRESSURE (PRINTED MAY 2017)
HARNESS 7258224 (A)
JUMPER

Printed In U.S.A.
FRAME
GATEWAY CONTROLLER
J1B-2 J1B-3 J1A-24 J1B-22 J1A-8 J1B-12 J1A-13 J1B-15 J1B-16

1480 RED/WHT

2180 BLK
1485 RED/WHT

2190 BLK
CONTROLLER GND
CONTROLLER PWR SHEET 5
SHEET 4
CONTROLLER PWR CONTROLLER GND
SHEET 4 SHEET 5

7010 WHT

4240 LGN
3300 LBL
2SPD PWR
8280 TAN

3050 LBL
SHEET 4

IGNITION PWR

1570 RNG/WHT
1460 RED/WHT
SHEET 4
HEATER
HEATER GND AUX PWR 6400 PNK CAB LIGHT PWR
BUZZER GND FUEL GND

1350 RED/WHT
1650 RNG/WHT
SHEET 4 SHEET 5 SHEET 4 SHEET 11
SHEET 5 SHEET 5
AUX GND

2270 BLK
2210 BLK

2570 BRN
2200 BLK
SHEET 5

C014

C010

C019

C016
+ - A B A B A B 2 1

A B A B A B 2 1
C051

A B C BUZZER

FUEL LEVEL
A B C SENSOR
BLADE JOYSTICK HEATER
SUPPLY AUX SOCKET
1460 RED/WHT
8280 TAN

3050 LBL

HARNESS
KEYED
C011

1 2 3 4 5 6
WIRING SCHEMATIC
1 2 3 4 5 6
ST I E20 (S/N AWRH11830 AND ABOVE)
B (S/N B3BL11001 AND ABOVE)
IGNITION SWITCH
Sheet 10 of 15 Printable Version Click Here
(PRINTED MAY 2017)
7258224 (A)
Printed In U.S.A.
LIGHTS / BEACON / STROBE - CABIN
GATEWAY CONTROLLER
J1A-5

6200 PNK
HARNESS FRAME
6190 PNK
6210 PNK
R3 R6
87 86 87 86
LIGHT LIGHT
30 85 RELAY 30 85 RELAY
1340 RED/WHT 1345 RED/WHT
LIGHT PWR 2030 BLK
SHEET 4 LIGHT GND
SHEET 4 SHEET 5
2060 BLK RELAYS GND
2050 BLK 2025 BLK
SHEET 7
RELAYS GND RELAYS GND
RELAYS GND SHEET 8
SHEET 7

SP8
6260 PNK

2380 BLK
6250 PNK
6220 PNK

CAB LIGHT PWR BEACON PWR

SHEET 10 SHEET 4

C204
6400 PNK
2940 BLK 6310 PNK
1 2
SHEET 5
BOOM LIGHT
1 2
GND
C460

C008

6010 PNK

6260 PNK
A B A B C

A B A B C

SP11

6250 PNK

6310 PNK
2220 BLK 2240 BLK
SHEET 5 SHEET 5 SP12
CAB LIGHT GND LIGHTS GND
6400 PNK

2400 BLK
6270 PNK

6280 PNK
C706

2390 BLK
A B C

C110
1 2 3 4 5

C205

C206
A B C 1 2 3 4 5
A B A B
SP41 2240 BLK
HARNESS
A B A B
6250 PNK

CAB KITS BEACON

6310 PNK
2230 BLK

SWITCH

2870 BLK
LEFT RIGHT
T201 T202

HARNESS
C707

C705
A B 1 2 CAB
CAB LIGHT
A B 1 2
6250 PNK

6310 PNK
2230 BLK

2870 BLK

WIRING SCHEMATIC
C709

C708

A B 1 2
E20 (S/N AWRH11830 AND ABOVE)
A B 1 2
(S/N B3BL11001 AND ABOVE)
Sheet 11 of 15 Printable Version Click Here
HARNESS HARNESS
BOOM LIGHT CAB (PRINTED MAY 2017)
HARNESS HARNESS
REAR LIGHT BEACON/STROBE 7258224 (A)
Printed In U.S.A.
WIPER / LH CONSOLE / HORN / OWD
WIPER PWR GATEWAY CONTROLLER
SHEET 4 J1B-11 J1A-28 J1A-20

1510 RNG/WHT
7030 WHT
WASHER GND
2370 BLK SHEET 5

C017
8VDC SIG GND
1 2 SHEET 4 SHEET 5

3410 LBL

3420 LBL
1 2
HARNESS LM PWR 5VDC SIG GNG

7030 WHT
SHEET 8 SHEET 4 SHEET 5

2370 BLK
WASHER

1630 RNG/WHT

2650 BRN
BOTTLE

5050 YEL
3230 LBL
C018

1 2
1690 RNG/WHT

5010 YEL
SHEET 9

2580 BRN
1 2
HORN PWR

C042
C109
HORN PWR HORN GND 2 1 3 4 5 B C A
SHEET 9 SHEET 5

1640 RNG/WHT
WASHER

1510 RNG/WHT
BOTTLE 2 1 3 4 5 B C A

2260 BLK
LOAD MOMENT
7110 WHT

SWITCH
C111

2 1 3 4 5 6 T100 T101

2 1 3 4 5 6

2650 BRN
5050 YEL

3420 LBL
7100 WHT

C108
A B C
OWD
A B C
WIPER SWITCH

C048
B C A
WIPER PARK PWR CONSOLE
SHEET 4 SENSOR
B C A
7120 WHT

HARNESS FRAME
C008

LOAD MOMENT
F G H SENSOR

F G H
HARNESS
CAB
7110 WHT
7100 WHT

7120 WHT

WIRING SCHEMATIC
2250 BLK E20 (S/N AWRH11830 AND ABOVE)
SHEET 5
WIPER GND (S/N B3BL11001 AND ABOVE)
C628

1 2 3 4

1 2 3 4 Sheet 12 of 15 Printable Version Click Here

(PRINTED MAY 2017)
31b 53 31 53a
7258224 (A)
Printed In U.S.A. WIPER
MA PWR 1670 RNG/WHT 2360 BLK MA GND
SHEET 4 SHEET 5

RADIO / MA

C040C C040
D E
D E

D E
RADIO PWR D E
SHEET 4
HRNS

1670 RNG/WHT
2nd AUX

2360 BLK
SP50 1780 RNG/WHT 2AUX PWR
SHEET 15 2AUX GND
SP51 2710 BLK SHEET 15

1770 RNG/WHT
1660 RNG/WHT
2AUX SOL GND

2700 BLK
2720 BLK
SHEET 15

C040D
D E
D E

C040A
D E
D E
2360 BLK

2420 BLK SP35

1670 RNG/WHT
C008

HARNESS FRAME HARNESS

D MA
D

1750 RNG/WHT
TM1 TM2
HARNESS RADIO GND

2280 BLK
ALARM
7980 WHT

7990 WHT
C220

SP37 1760 RNG/WHT

4 3 1 2 5 6
2980 BLK

2990 BLK
SP36

2410 BLK
4 3 1 2 5 6

1710 RNG/WHT

1730 RNG/WHT

1720 RNG/WHT

1740 RNG/WHT
1560 RNG/WHT

RADIO 4070 LGN

C125A

C124A

C122A
A B A B 85 30 86 87 87A
B A

A B A B 85 30 86 87 87A
B A
T204 T203 T205 T206

LEFT RIGHT
SPEAKER SPEAKER R9
RELAY

WIRING SCHEMATIC
E20 (S/N AWRH11830 AND ABOVE)
(S/N B3BL11001 AND ABOVE)
Sheet 13 of 15 Printable Version Click Here
(PRINTED MAY 2017)
Printed In U.S.A.
7258224 (A)
LIGHTS / BEACON / STROBE - CANOPY

C204A
C008A
B C E 1 2

B C E 1 2

HARNESS

6260 PNK

2380 BLK
LIGHT
EXTENSION

C200
2240 BLK
1 2

6250 PNK 1 2
SP40
2330 BLK HARNESS

6260 PNK

2380 BLK
CANOPY KITS

6310 PNK

2870 BLK
SP18
SP19
C707

C705

6280 PNK
A B 1 2

6270 PNK

6310 PNK
2230 BLK

2870 BLK

C202

C203
A B A B
C709

C708

A B 1 2 A B A B

A B 1 2 LEFT RIGHT

HARNESS
WORK LIGHT
HARNESS HARNESS CANOPY
REAR LIGHT BEACON/STROBE

WIRING SCHEMATIC
E20 (S/N AWRH11830 AND ABOVE)
(S/N B3BL11001 AND ABOVE)
Sheet 14 of 15 Printable Version Click Here
(PRINTED MAY 2017)
Printed In U.S.A. 7258224 (A)
GATEWAY CONTROLLER
J1A-32

2nd AUX

3020 LBL
C040
HARNESS FRAME F
F

C040C
F
HRNS F
2nd AUX

2AUX GND 2710 BLK

SHEET 13

2AUX PWR 1780 RNG/WHT

C114

1 2 3 4 5 6

3020 LBL
4130 LGN

1 2 3 4 5 6

HYD TEMP GND

2AUX SOL GND 2nd AUX SWITCH SHEET 9
SHEET 13

2660 BRN
2720 BLK

WIRING SCHEMATIC
E20 (S/N AWRH11830 AND ABOVE)
C300
C120

A B
A B
(S/N B3BL11001 AND ABOVE)
A B A B
Sheet 15 of 15 Printable Version Click Here
(PRINTED MAY 2017)
HYD TEMP
Printed In U.S.A. 2ND AUX
SOLENOID
7258224 (A)
ELECTRICAL SYSTEM INFORMATION

Glossary Of Electrical Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107

3520 C C 3520 harness to a component. The internally grounded.

3510 B B 3510
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
pins can be numbered alphabetical
C107
A A (shown) or numerical (1, 2, 3 etc.).
3500 3500
3520
C C
3520
The harness wires numbers are
B B
3510 3510 called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.

COMPONENTS

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- + BATTERY - Used for supplying and SWITCH - Single Pole - Double
storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT -
Indicates battery ground circuit.
on switch application.)

SWITCH - Double Pole - Double

Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.

GROUND - Used to represent an

external ground connection.

50-10-1 E20 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

COMPONENTS SOLENOID - Fuel and Traction Lock -

HOLD PULL
15 ohm B Dual solenoids. (The ohm rating of
I
SWITCH - Ignition - Multi position the solenoid coils are listed next to
B
switch to activate various start 0.5 ohm A the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.

HORN - Audible alarm. Sound is

START
RUN activated manually by a switch to
OFF
warn personnel.

BUZZER - Audible alarm. Sounds at a

1 SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
positions.
3

4 5 RESISTOR - Limits current flow.

DIODE - Allows electrical current to

ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
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H M
GRD

87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
control a high amp component. A speed motor.
30 85 B

FUSE - Used to protect the wire MOTOR - Washer - Single speed.

harness from an overloaded circuit. M
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL

3700 3710
SPLICE (•) - Used to show when
3110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
7.7 o h m - +
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.

SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7 .5 o h m magnetically. (The ohm rating and gauge are marked with a icon that
12V S
voltage of the solenoid coil is listed I
represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

50-10-2 E20 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION

SENDERS AND SENSORS

+ PRESSURE SENDER - Provides a

A
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B listed to show volts at high and low
0.5 - 7.5 V
setting.)

B PRESSURE SWITCH - Switch opens

A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)

to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at
high and low setting.)

A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active

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a function or to turn on a warning
light. (Switch is shown in the closed
position.)

FUEL SENDER - Provides a variable

B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)

C
HALL EFFECT SENSOR - Detects
B linear or rotary position and provides
A a proportional variable voltage.

A SPEED SENSOR - magnetic pickup -

detects rpm.
B

50-10-3 E20 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
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

KEY TO CORRECT THE CAUSE

1. Engine accessory drive belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
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5. The alternator is damaged.

6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

50-10-4 E20 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Location / Identification

Description A decal is inside the fuse cover to show location and amp
ratings.
Figure 50-10-1
Remove the cover to check or replace the fuses and
1 relays.

The location and sizes are shown in [Figure 50-10-2].

Always replace fuses using the same type and capacity.

P113448

The excavator has a 12 volt, negative ground electrical

system. The electrical system is protected by fuses
located under the right side cover of the excavator (Item
1) [Figure 50-10-1]. The fuses will protect the electrical
system when there is an electrical overload. The reason
for the overload must be found and corrected before
starting the engine again.

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The battery cables must be clean and tight. Check the
electrolyte level in the battery. Add distilled water as
needed. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution.

Put Battery Saver P/N 6664458 or grease on the battery

terminals and cable ends to prevent corrosion.

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

50-10-5 E20 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuse And Relay Location / Identification (Cont’d)

Figure 50-10-2

1 5 17
9 11 13 15
2 6 18

3 7 19
10 12 14 16

4 8 20

The location and amperage ratings are shown in the table below and on the decal [Figure 50-10-2]. Relays are identified
by the letter “R” in the AMP column.

REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP
1 NOT USED 9 Switched Power R 17 Panel / Display 25
Controller

2 NOT USED 10 Fuel Shutoff R 18 ACD Unswitched 25

3 Start Key 5 11 Heater Fan R 19 LIGHTS 20

4 Fuel Shutoff 25 12 Lights R 20 Power Port 15

5 Wiper / Washer 10 13 Hydraulic By-Pass R

/ Power Beyond

6 Switched Power 20 14 Glow Plugs R

7 Alternator Excite / 25 15 NOT USED R

Heater

8 ACD Switched 25 16 Starter R

Power

50-10-6 E20 Service Manual

BATTERY The original equipment battery is maintenance free. If a
replacement battery is installed, check the electrolyte
Servicing level in the battery.

Open the right side cover. If the electrolyte level is lower than 13 mm (0.50 in) above
the plates, add distilled water only.
Figure 50-20-1

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
1 rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
P113449
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
The battery (Item 1) [Figure 50-20-1] is located in the prompt medical attention.
right side upperstructure below the oil cooler. W-2065-0807

Figure 50-20-2

The battery cables must be clean and tight [Figure 50-

20-2]. Remove acid or corrosion from the battery and
cables using a sodium bicarbonate and water solution.
Cover the battery terminals and cable ends with battery
saver grease to prevent corrosion.

Check for broken or loose connections.

If the battery cables are removed for any reason,

disconnect the negative (-) cable first. When installing the
battery cables, make the last connection the negative (-)
cable to the battery.

50-20-1 E20 Service Manual

BATTERY (CONT’D) Figure 50-20-5

Removal And Installation

1
Figure 50-20-3

1 2 1

P113453
1
Disconnect the negative (-) cable (Item 1) [Figure 50-20-
5] first.
P113450
Disconnect the positive (+) cable (Item 2) [Figure 50-20-
5].
Remove the three bolts (Item 1) and remove the right
side lower cover (Item 2) [Figure 50-20-3]. Remove the battery.

Open the right side cover. Always clean the terminals and the cable ends, even
when installing a new battery.
Figure 50-20-4
Position the battery into the battery box.
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Connect the battery cables. Connect the negative (-)

cable (Item 1) [Figure 50-20-5] last to prevent sparks.
Reinstall the battery post covers and slide the battery in
fully.

Tighten the terminal clamp nuts to 7 N•m (5 ft-lb) torque.

Install the hold down plate (Item 2) and the two bolts
(Item 1) [Figure 50-20-4]. Reinstall the lower cover
[Figure 50-20-3].
1
1

2
P113451 WARNING
Remove the two bolts (Item 1) and remove the battery AVOID INJURY OR DEATH
hold down plate (Item 2) [Figure 50-20-4]. Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
Slide the battery to the right to access the battery cables. rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

50-20-2 E20 Service Manual

BATTERY (CONT’D) NOTE: To access the battery for jump starting, the
battery hold down will need to be removed
Using A Booster Battery (Jump Starting) and the battery moved outward to access the
positive battery post.

Figure 50-20-6
IMPORTANT
If jump starting the excavator from a second
machine:

When jump starting the excavator from a battery

installed in a second machine, make sure the engine
is NOT running while using the glow plugs. High 1 1
voltage spikes from a running machine can burn out
the glow plugs.
I-2060-0906 1

If it is necessary to use a booster battery to start the

engine. BE CAREFUL! There must be one person in the P113450
operator's seat and one person to connect and
disconnect the battery cables.
Remove the three bolts (Item 1) and remove the right
Engage the upperstructure slew lock. Be sure the key side lower cover (Item 2) [Figure 50-20-6].
switch is OFF. The booster battery must be 12 volt.
Open the right side cover.
Open the tailgate.
Figure 50-20-7

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WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention 1
and wash eye with clean, cool water for at least 15 1
minutes.
2
P113451
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Remove the two bolts (Item 1) and remove the battery
W-2065-0807 hold down plate (Item 2) [Figure 50-20-7].

50-20-3 E20 Service Manual

BATTERY (CONT’D)

Using A Booster Battery (Jump Starting) (Cont’d)

Figure 50-20-8

2
P113452

Connect one end of the first cable to the positive (+)

terminal of the booster battery. Connect the other end of
the same cable to the positive (+) terminal (Item 1)
[Figure 50-20-8] on the excavator battery.

Connect one end of the second cable to the negative (-)

terminal of the booster battery. Connect the other end of
the same cable to the negative cable (Item 1) [Figure 50-
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20-8] on the excavator engine.

Start the engine. After the engine has started, remove

the negative (-) cable first (Item 2) [Figure 50-20-8].

Disconnect the cable from the excavator starter (Item 1)

[Figure 50-20-8].

Replace the positive battery cable cover and push the

battery in fully. Reinstall the battery hold down plate (Item
2) and the two bolts (Item 1) [Figure 50-20-7].

Reinstall the lower right side cover [Figure 50-20-6].

IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2223-0903

50-20-4 E20 Service Manual

ALTERNATOR Figure 50-30-2

Belt Adjustment
2
Stop the engine and open the tailgate.

Figure 50-30-1

1
2

P113464
1

NOTE: The seat is shown removed for photo clarity.

The alternator adjusting bolts can be
accessed by removing the belt guard (Item 2)
P113431 [Figure 50-30-2] and reaching around the
engine.

Remove the belt guard (Item 2) [Figure 50-30-1]. If the belt tension is not correct, loosen the bolt and nut
(Item 1) and the bolt (Item 2) [Figure 50-30-2] until the
Measure the belt (Item 1) [Figure 50-30-1] tension at the alternator can be moved toward the engine.
middle of the belt span.
Adjust belt tension to correct specifications [Figure 50-

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If a belt tension tool is available, move the alternator until 30-1].
the belt has (new belt = 272 - 292 N [61 - 65 lbf] or used
belt = 233 - 252 N [53 - 57 lbf]) tension. Tighten the mounting and adjustment bolts.

If a belt tension tool is not available, move the alternator Close the access door.
until the belt has 8,0 mm (5/16 in) movement at the
middle of the belt span with 66 N (15 lbf) of force. Belt Replacement

Open the access door. Open the access door.

Loosen the bolt and nut (Item 1) and the bolt (Item 2)
[Figure 50-30-2] until the alternator can be moved
toward the engine.

Remove the old belt and install a new belt.

Adjust belt tension to correct specifications [Figure 50-

30-1].

Tighten the mounting and adjustment bolts.

Close the access door.

Reinstall the belt guard (Item 2) [Figure 50-30-1].

Close the tailgate.

50-30-1 E20 Service Manual

ALTERNATOR (CONT’D) Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
Charging System Inspection corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
WARNING terminal.

BATTERY GAS CAN EXPLODE AND CAUSE

SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
WARNING
from batteries. When jumping from booster battery
make final connection (negative) at machine frame. AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
Do not jump start or charge a frozen or damaged contact. Wear goggles, protective clothing and
battery. Warm battery to 16°C (60°F) before rubber gloves to keep acid off body.
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never In case of acid contact, wash immediately with water.
lean over battery while boosting, testing or charging. In case of eye contact get prompt medical attention
W-2066-0910 and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get

IMPORTANT prompt medical attention.

W-2065-0807

Damage to the alternator can occur if: Figure 50-30-3

• Engine is operated with battery cables

disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2223-0903

If the charging system malfunctions check the following:

Inspect the condition and tension of the alternator belt.

(See Belt Adjustment on Page 50-30-1.) If belt is worn or
deteriorated replace.
1
P-97993
Inspect the alternator wiring harness and connectors at
alternator. Harness and connectors must be clean and
tight. With the key in the run position and the engine off, the
icon (Item 1) [Figure 50-30-3] will illuminate momentarily.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free With the engine running, the icon will flash if system
batteries.) voltage is low or high.

Verify the charge of the battery. Make sure battery is fully

charged.

50-30-2 E20 Service Manual

ALTERNATOR (CONT’D) Alternator Voltage Testing

Charging System Inspection (Cont’d) Figure 50-30-6

Figure 50-30-4

1 2

1
P113451

P113431
Run the engine at rated speed. Check to make sure that
all accessories are turned OFF. Connect the positive lead
Start the engine. At low idle, the icon must be OFF. If the of the voltmeter to the positive terminal (Item 1) of the
icon is flashing, inspect the alternator belt (Item 1) battery. Connect the negative lead of the volt meter to the
[Figure 50-30-4] for correct tension. negative terminal (Item 2) [Figure 50-30-6]. If the
reading on the voltmeter is less than 13 volts or more
Figure 50-30-5 than 15.5 volts, replace the alternator.

P113451

Increase engine speed approximately 1500 rpm.

If the icon is flashing, measure the voltage at the battery

(Item 1) [Figure 50-30-5].

Battery voltage should be between 13 and 15 volts.

If voltage is less than 13 volts or over 15.5 volts, replace

the alternator.

50-30-3 E20 Service Manual

ALTERNATOR (CONT’D)

Parts Identification

1. Alternator 15. Nut

2. Frame Assy. 16. Insulator
3. Plate 17. Bolt
4. Screw 18. Screw
5. Bearing 19. Nut
6. Stud 20. Nut
7. Frame End 21. Rotor Assy.
8. Holder 22. Bearing
9. Holder 23. Cover
10. Seal 24. Pulley
11. Brush 25. Spacer
12. Spring 26. Bolt
13. Regulator 27. Screw
14. Cover 28. Screw

4
6 3 23
2 5 22

24
14
26
27
25 10
20 9
15
16
19 28
12
7 11
18
1
13
17 8

C-3456

50-30-4 E20 Service Manual

ALTERNATOR (CONT’D)

Removal And Installation

Disconnect the negative (-) cable from the battery. (See

Removal And Installation on Page 50-20-2.)

Open the access door under the seat.

Figure 50-30-7

3
2

P113464

Disconnect the wire harness (Item 1) and output wire

(Item 2). Remove the bolt (Item 3) and nut / bolt (Item 4)

50-30-5 E20 Service Manual

50-30-6
E20 Service Manual
STARTER

Testing

Figure 50-40-1

Bat
S
M

Cranking
Motor

A-1992

The key switch must be in the OFF position.

The battery must be at full charge.

The cable connections on the battery must be clean and

tight.

Connect a jumper wire between S terminal and BAT

If the starter turns but does not turn the engine, the
starter drive has a defect.

Figure 50-40-2

Bat
S
M

Cranking
Motor

A-1991

Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 50-
40-2].

If the starter turns, the defect is in the solenoid.

If the starter does not turn, the starter is defective.

50-40-1 E20 Service Manual

STARTER (CONT’D) Figure 50-40-5

Removal And Installation

Open the right side cover.

Figure 50-40-3

P117887

Remove the top bolt (Item 1) [Figure 50-40-5] and the

1
bottom bolt (Item 1) [Figure 50-40-6].

P117953 Figure 50-40-6

Disconnect the negative (-) battery cable (Item 1) [Figure

50-40-3] from the battery.

Open the tailgate. 1

Figure 50-40-4

2
1

P117888
2
NOTE: The bottom bolt is also used to attach the
frame to engine ground strap (Item 2) [Figure
50-40-6].

Remove the starter.

P117886

Remove the positive (+) cable (Item 1) and the solenoid

wire (Item 2) [Figure 50-40-4] from the starter.

50-40-2 E20 Service Manual

STARTER (CONT’D)

Parts Identification

Figure 50-40-7

1. Starter
2. Frame
3. Brush
4. Armature
5. Yoke
6. Housing 1
7. Pinion
8. Clutch
9. Housing
2
10. Plunger

B-19162

50-40-3 E20 Service Manual

50-40-4
E20 Service Manual
LIGHTS Boom Light Bulb Replacement

Boom Light Removal And Installation Figure 50-50-3

Figure 50-50-1

1
1

P120254

P120254
Disconnect the wire harness (Item 1) [Figure 50-50-3].

Disconnect the wire harness (Item 1) [Figure 50-50-1]. Rotate light bulb assembly (Item 2) counterclockwise and
pull straight out from the boom light (Item 3) [Figure 50-
Figure 50-50-2 50-3].

Figure 50-50-4
3
2

P120256

P120258
Remove the nut (Item 1) and bolt (Item 2). Remove the
boom light (Item 3) [Figure 50-50-2] from the boom light
guard. NOTE: Do not touch glass of halogen bulb with your
fingers or allow bulb to come in contact with
oils. If contaminated, the bulb should be
cleaned with mild alcohol and a clean cloth
[Figure 50-50-4].

50-50-1 E20 Service Manual

LIGHTS (CONT’D) Cab Light Bulb Replacement

Cab Light Removal And Installation Figure 50-50-7

Figure 50-50-5

1
1

P117883

P117883
Disconnect the wire harness (Item 1). Rotate light bulb
assembly (Item 2) [Figure 50-50-7] counterclockwise
Disconnect the wiring harness (Item 1) [Figure 50-50-5]. and pull straight out from the cab light.

Figure 50-50-6 Figure 50-50-8

1 1

P117882 P117884

Remove the mounting bolt (Item 1) [Figure 50-50-6]. Remove the light bulb assembly (Item 1) [Figure 50-50-
8].

NOTE: Don not touch glass of halogen bulb with your

fingers or allow bulb to come in contact with
oils. If contaminated, the bulb should be
cleaned with mild alcohol and a clean cloth.

50-50-2 E20 Service Manual

MAGNETIC LOCKOUT SENSOR Figure 50-60-3

Removal And Installation

Lower the control console.

Figure 50-60-1
1

1 P118584

Loosen the screws (Item 1) and remove the magnet (Item

2) [Figure 50-60-3].

P118583

Loosen the screws (Item 1) [Figure 50-60-1].

Figure 50-60-2

P118585

Remove the switch (Item 1) [Figure 50-60-2] from the

wire harness.

50-60-1 E20 Service Manual

50-60-2
E20 Service Manual
TWO-SPEED SWITCH Figure 50-70-3

Removal And Installation

Figure 50-70-1

P118494

Remove the screws (Item 1) [Figure 50-70-3] from the

P118495 blade handle.

Figure 50-70-4
Open the right side cover and disconnect the wire
harness (Item 1) [Figure 50-70-1].

Figure 50-70-2

P118497

Remove the two speed switch (Item 1) [Figure 50-70-4]

P118496 and wire harness from the blade handle.

Remove the lock (Item 1) [Figure 50-70-2] from electrical

connector.

Using a small piece of wire, depress the wire terminal

tabs.

Carefully remove the individual wires from the back of the

electrical connector.

A Red
B Green

Check each wire to be certain it locks into place.

50-70-1 E20 Service Manual

50-70-2
E20 Service Manual
FUEL LEVEL SENDER Testing

Removal And Installation Use an ohmmeter to test the resistance of the fuel level
sender.
Remove the fuel tank (See Removal And Installation on
Page 40-150-1.) Figure 50-80-3

Figure 50-80-1
INSERT ONE
OHM TESTER
FUEL SENDER LEAD INTO
TOP VIEW EACH OF THE
FUEL SENDER
CONNECTIONS

FUEL SENDER
TOP VIEW

P117872

Disconnect the wire harness (Item 1) [Figure 50-80-1]

from the fuel level sender.

Figure 50-80-2

B-14140

Insert one of the ohm tester leads into each of the fuel
P117885
sender electrical connectors in the end of the fuel sender
[Figure 50-80-3].

Remove the sender (Item 1) [Figure 50-80-2] from the With the fuel sender in the position shown [Figure 50-80-
fuel tank. 3], read the ohms in the empty position. Slide the float
upwards and the ohm reading will decrease. See
resistance chart below.

The approximate resistance should read as follows:

FULL: 15 - 35 ohm
HALF: 120 - 145 ohm
EMPTY: 230 - 250 ohm

50-80-1 E20 Service Manual

50-80-2
E20 Service Manual
KEY SWITCH Figure 50-90-2

Removal And Installation

Figure 50-90-1

P118293
1

Shown is keyless, the keyed switch is the same

P113449 procedure.

Remove the keypad (Item 1) and knob (Item 2) [Figure

Disconnect the negative (-) cable (Item 1) [Figure 50-90- 50-90-2].
2] from the battery.
Figure 50-90-3

WARNING

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AVOID INJURY OR DEATH 1
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
P118292
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Remove the nut (Item 1) [Figure 50-90-3] from the switch
W-2065-0807 and pull the switch out through the keypad opening.

50-90-1 E20 Service Manual

KEY SWITCH (CONT’D)

Removal And Installation (Cont’d)

Figure 50-90-4

P118295

Disconnect the wire harness (Item 1) from the switch

50-90-2 E20 Service Manual

WIPER MOTOR Figure 50-100-3

Removal And Installation

Figure 50-100-1
1

P118793
1

Open the wiper arm cover (Item 1) [Figure 50-100-3].

P118786
Figure 50-100-4

Remove the wiper motor cover screws (Item 1) and the 2

cover (Item 2) [Figure 50-100-1].

Figure 50-100-2 1

P118792

Remove the nut and washer (Item 1) and the wiper arm
assembly (Item 2) [Figure 50-100-4].
P118794

Disconnect the wire harness (Item 1) [Figure 50-100-2].

50-100-1 E20 Service Manual

WIPER MOTOR (CONT’D) Figure 50-100-7

Removal And Installation (Cont’d)

Figure 50-100-5

P118787

Remove the wiper motor assembly [Figure 50-100-7].

P118791

Remove the cover on the wiper arm shaft and the

mounting stud (Item 1) [Figure 50-100-5].

P118789

Remove the nuts (Item 1) [Figure 50-100-6].

50-100-2 E20 Service Manual

ENGINE

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-14
Engine Compression - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-15

SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Radiator / Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Water Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-6
Thermostat - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-6

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LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Oil Pump - Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Fuel Injection Pump - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-4
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-6
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-7
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-8
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-8
Fuel Injector Nozzle Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-9

60-01 E20 Service Manual

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-5
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-6
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-7
Valve Guide - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-7
Valve And Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-10
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-11
Rocker Arm And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-12

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-3
Cylinder Bore - Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-5
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Timing Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
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Timing Gears Measuring Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3

Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Idler Gear and Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-6

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Flywheel Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Hydraulic Pump Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Rear End Plate Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3

60-02 E20 Service Manual

ENGINE INFORMATION

Description

The E20 Bobcat Excavator has a Kubota direct injected

D722-E4B diesel engine with a displacement of 0,719 L
(43.88 in3). The engine is rated at 9,9 kWh (13.3 hp) and
has a closed crankcase ventilation system.

The engine has three cylinders and the rotation is

counter-clockwise (viewed from the flywheel side).
Engine block heaters are also available from Bobcat
Parts.

The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.

The engine is liquid cooled with a propylene glycol / water

mixture. The cooling fan is belt driven. The speed of the
fan is determined by the engine speed.

60-10-1 E20 Service Manual

ENGINE INFORMATION (CONT'D)

Specifications

Fuel Injector Nozzles

Opening Pressure 13727 - 14713 kPa (137 - 147 bar) (1991 - 2134 psi)
Fuel Tightness Nozzle Seat 12748 kPa (127 bar) (1849 psi)

Fuel Injection Pump

Fuel Tightness of Pump Element 13727 kPa (137 bar) (1991 psi)
Fuel Tightness of Delivery Valve (factory spec) 10 Second Initial Pressure Drop From 13727 - 1 2748 kPa
(137 - 127 bar) (1991 - 1849 psi)
Fuel Tightness of Delivery Valve Limit Permitted 5 Second Initial Pressure Drop From 14713 - 13727 kPa
(137 - 127 bar) (2134 - 1991 psi)
Injection Timing @ 3600 rpm 19 - 21 degrees B.T.D.C.

Cylinder Head

Cylinder Head Distortion Limit 0,05 mm (0.002 in)

Thickness of Gasket Free 1,15 - 1,30 mm (0.0415 - 0.0512 in)
Thickness of Gasket Tightened 1,05 - 1,15 mm (0.0413 - 0.0453 in)
Top Clearance 0,50 - 0,70 mm (0.0197 - 0.0276 in)
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Valves

Valve Seat Angle 45 degrees

Valve Seat Width 2,12 mm (0.084 in)
O.D. of Valve Stem 5,968 - 5,980 mm (0.2350 - 0.2354 in)
I.D. of Valve Guide 6,01 - 6,025 mm (0.2366 - 0.2372 in)
Clearance between Valve Stem and Guide 0,03 - 0,057 mm (0.0012 - 0.0022 in)
Limit Permitted 0,1 mm (0.004 in)
Depth of Valve -0,10 - 0,10 mm (-0.004 - 0.004 in)
Limit Permitted 0,30 mm (0.0118 in)
Valve Clearance (Cold) (Intake and Exhaust) 0,145 - 0,185 mm (0.006 - 0.007 in)

Valve Springs

Free Length 31,3 - 31,8 mm (1.232 - 1.252 in)

Limit Permitted 28,4 mm (1.118 in)
Fitted Length 27 mm (1.063 in)
Load to Compress to Fitted Length 6,6 kg (14.6 lb)
Limited Permitted 5,6 kg (12.3 lb)
Limited Permitted for Spring Tilt 1,2 mm (0.047 in)

60-10-2 E20 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont'd)

Rocker Arms

O.D. of Rocker Arm Shaft 10,47 - 10,48 mm (0.4123 - 0.4128 in)

I.D. of Rocker Arm Bushing 10,5 - 10,52 mm (0.4134 - 0.4141 in)
Clearance between Rocker Arm Shaft and Bushing 0,016 - 0,045 mm (0.0006 - 0.0018 in)
Limit Permitted 0,15 mm (0.006 in)

Camshaft

O.D. of Camshaft Bearing Journal 32,93 - 32,95 mm (1.2966 - 1.2972)

I.D. of Camshaft Bearing 33,00 - 33,025 mm (1.2992 - 1.3002 in)
Clearance between Camshaft Bearing and Journal 0,05 - 0,91 mm (0.002 - 0.004 in)
Limit Permitted 0,15 mm (0.006 in)
Alignment of the Camshaft Limit Permitted 0,01 mm (0.0004 in)
Cam Lobe Height 26,88 mm (1.0583 in)
Limit Permitted 26,83 mm (1.0563 in)
Idle Gear to Cam Gear Backlash 0,041 - 0,123 mm (0.002 - 0.005 in)
Limit Permitted 0,15 mm (0.006 in)

I.D. of Cylinder Liner 67,000 - 67,019 mm (2.6378 - 2.6385 in)

Limit Permitted 67,169 mm (2.6445 in)
Rebore Size for Oversize Piston 67,250 - 67,269 mm (2.6476 - 2.6484 in)

Piston Rings

Ring Gap, Top and Oil 0,15 - 0,30 mm (0.0059 - 0.0118 in)
Ring Gap, 2nd 0,30 - 0,45 mm (0.0118 - 0.0177) in
Limit Permitted 1,20 mm (0.0472 in)
Side Clearance of Ring in Groove;
Top Ring Because of top ring design, measurement does not apply
2nd Ring 0,085 - 0,12 mm (0.0033 - 0.0045 in)
Oil Ring 0,02 - 0,06 mm (0.0016 - 0.0031 in)
Limit Permitted 0,15 mm (0.006 in)

60-10-3 E20 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont'd)
Pistons

I.D. of Piston Pin Bore 20,00 - 20,013 mm (0.7874 - 0.7879 in)

Limit Permitted 20,05 mm (0.7894 in)
O.D. of Piston Pin 20,002 - 20,011 mm (0.7875 - 0.7878 in)

Connecting Rods

I.D. of Connecting Rod Bushing (Small End, Fitted) 20,03 - 20,04 mm (0.7884 - 0.7890 in)
Clearance between Piston Pin and Bushing 0,014 - 0,038 mm (0.0006 - 0.0015 in)
Clearance between Piston Pin and Bushing Limit 0,10 mm (0.004 in)
Permitted
Connecting Rod Alignment Limit Permitted 0,05 mm (0.002 in)

Crankshaft

Crankshaft Alignment Limit Permitted 0,02 mm (0.0008 in)

O.D. of Crankshaft Journal No. 1 (Water Pump Side) 39,93 - 39,95 mm (1.5722 - 1.5728 in)
I.D. of Crankshaft Bearing No. 1 39,98 - 40,04 mm (1.5715 - 1.5764 in)
Clearance between No. 1 Crankshaft Journal and Bearing 0,03 - 0,11 mm (0.0013 - 0.0042 in)
Limit Permitted 0,20 mm (0.008 in)
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O.D. of Crankshaft Journal No. 2 (Flywheel Side) 43,93 - 43,95 mm (1.7297 - 1.7303 in)
I.D. of Crankshaft Bearing No. 2 43,98 - 44,03 mm (1.7317 - 1.7333 in)
Clearance between No. 2 Crankshaft Journal and Bearing 0,03 - 0,05 mm (0.0011 - 0.0020 in)
Limit Permitted 0,20 mm (0.008 in)
O.D. of Crankshaft Journal No. 3 (Intermediate) 39,93 - 39,95 mm (1.5722 - 1.5728 in)
I.D. of Crankshaft Bearing No. 3 39,98 - 40,03 mm (1.5742 - 1.5758 in)
Clearance between No. 3 Crankshaft Journal and Bearing 0,03 - 0,05 mm (0.0011 - 0.0020 in)
Limit Permitted 0,20 mm (0.008 in)
O.D. of Connecting Rod Journals 33,96 - 33,98 mm (1.3370 - 1.3376 in)
I.D. of Connecting Rod Bearings` 33,99 - 34,01 mm (1.3389 - 1.3390 in)
Clearance between Connecting Rod Journal and Bearing 0,02 - 0,051 mm (0.0008 - 0.0020 in)
Limit Permitted 0,15 mm (0.006 in)
Crankshaft End Play 0,15 - 0,31 mm (0.006 - 0.012 in)
Limit Permitted 0,50 mm (0.020 in)

Oil Pump

Oil Pressure At Rated rpm 193 - 441 kPa (2 - 4 bar) (28 - 64 psi)
Limit Permitted 145 kPa (1 bar) (21 psi)
Oil Pressure And Idle Speed 48 kPa (0,5 bar) (7 psi)
Clearance between Outer Rotor and Pump Body 0,07 - 0,15 mm (0.003 - 0.006 in)
End Clearance between Inner Rotor and Cover 0,08 - 0,14 mm (0.003 - 0.005 in)
Clearance between Inner Rotor and Outer Rotor 0,03 - 0,14 mm (0.0012 - 0.006 in)

60-10-4 E20 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont'd)

Thermostat

Opening Temperature
Starting 70 - 73°C (157 - 163°F)
Full Open 85°C (185°F)

Engine Bolt Torque

N•m ft-lb
Camshaft Retainer Plate Bolts 18 - 21 14 - 15
* Connecting Rod Bolts 27 - 30 20 - 22
* Crankshaft Bolt 98 - 108 72 - 80
* Cylinder Head Bolts 38 - 42 28 - 31
* Flywheel Bolts 53,9 - 58,8 39.8 - 43.4
Fuel Camshaft Retainer Bolts 6,8 - 8,1 5-6
Fuel Injection Tubeline Fittings 25 - 34 18 - 25
Glow Plugs 8 - 15 6 - 11
* Idle Gear Shaft Bolt 10 - 11 7-8
Injection Nozzle 49 - 69 36 - 51

Page 554 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off
Injection Pump Mounting Nuts 24 - 27 18 - 20
* Main Bearing Bolts 27 - 30 20 - 22
* Main Bearing Case Bolts 13 - 16 9 - 12
Oil Switch 15 - 20 11 - 15
Rear Bearing Case Cover Bolts 10 - 11 7-8

* Lightly Oiled Threads

60-10-5 E20 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-1

Crankshaft Re-Grind Data B

6 1
3
If the standard size bearing cannot be used due to 1
excessive wear of the crank pin and crank journal use
undersize or oversize bearings.

For undersize or oversize bearing use, follow the

A
precautions noted below.

Grind the crankpin and journal with a wheel which has 4

C
specified round corner and width without shoulder 2
D
[Figure 60-10-1].
1 5
1. 1,8 - 2,2 mm (0.071 - 0.087 in) B-5928

2. 2,3 - 2,7 mm (0.091 - 0.106 in)

3. Be sure to chamfer the oil hole circumference to 1,0 -
1,5 mm (0.04 - 0.06”) radius with an oil stone.
4. The crankpin must be fine-finished to higher than
(0,4-S).
5. The crank journal must be fine-finished to higher than
(0,4-S).
6. The crank journal side surface must be fine-finished
to higher than (1,6-S).

SIZE CODE NO. NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM
-0,2 mm 15861-23911 Crankshaft Bearing 1 020 US
(-0.008”) 0.008” minus (0,2 minus) 39,734 - 39,750 mm
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-0,2 mm 15694-23931 Crankshaft Bearing 2 020 US (1.5643 - 1.5650”)

(-0.008”) 0.008” minus (0,2 minus)
-0,2 mm 15861-23861 Crankshaft Bearing 3 020 US 43,734 - 43,750 mm
(-0.008”) 0.008 minus (0,2 minus) (1.7218 - 1.7224 in)
-0,4 mm 15861-23921 Crankshaft Bearing 1 040 US A 39,534 - 39,550 mm
(-0.016”) 0.016” minus (0,4 minus) (1.5565 - 1.5571”)
-0,4 mm 15699-23941 Crankshaft Bearing 2 040 US
(-0.016”) 0.016” minus (0,4 minus)
-0,4 mm 15861-23871 Crankshaft Bearing 3 040 US 43,534 - 43,550 mm
(-0.0016”) 0.016 minus (0,4 minus) (1.7139 - 1.7146”)
-0,2 mm 15861-22971 Crank Pin Bearing 020 US 33,759 - 33,775 mm
(-0.008”) 0.008” minus (0,2 minus) (1.3291 - 1.3297”)
-0,4 mm 15861-22981 Crank Pin Bearing 040 US B 33,559 - 33,575 mm
(-0.016”) 0.016” minus (0,4 minus) 1.3212 - 1.3219”

+0.008” 15261-23951 Thrust Bearing 1 020 OS

(-0,2 mm) 0.008” plus (0,2 plus) 46,1 - 46,3 mm
15261-23971 Thrust Bearing 2 (1.815 - 1.823”)
0.008” plus (0,2 plus)
C
+0.016” 15261-23961 Thrust Bearing 1 040 OS
(+0,4 mm) 0.016 plus (0,4 plus) 46,3 - 46,5 mm
15261-23981 Thrust Bearing 2 (1.823 - 1.831”)
0.016” (0,4 plus)
0,2 mm Crankshaft over size 46,1 - 46,3 mm
(0.008”) Dimension D (1.815 - 1.823”)
0,4 mm 46,3 - 46,5 mm
(0.016”) (1.823 - 1.831”)

60-10-6 E20 Service Manual

ENGINE INFORMATION (CONT’D)

Torque Values

GRADE STANDARD SCREW AND BOLT SPECIAL SCREW AND BOLT

4 7

NOMINAL
UNIT N•m KFG M ft-lb N•m KFG M ft-lb
DIAMETER
M6 7,9 - 9,3 0.80 - 0.95 5.8 - 6.9 9,8 - 11,3 1.00 - 1.15 7.23 - 8.32
M8 18 - 20 1.8 - 2.1 13.0 - 15 24 - 27 2.4 - 2.8 18 - 20
M10 40 - 45 4.0 - 4.6 29 - 33 49 - 55 5.0 - 5.7 37 - 41
M12 63 - 72 6.4 - 7.4 47 - 53 78 - 90 7.9 - 9.2 58 - 66

60-10-7 E20 Service Manual

ENGINE INFORMATION (CONT’D)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop 9, 10, 11

KEY TO CORRECT THE CAUSE

2. Bad electrical connections 29. Broken or worn piston rings

3. Faulty starter motor 30. Worn valve stems or guides
4. Incorrect grade of oil 31. Worn or damaged bearings
5. Low cranking speed 32. Not enough oil in the oil pan
6. Fuel tank empty 33. Switch is defective
7. Faulty stop control operation 34. Oil pump worn
8. Plugged fuel line 35. Relief valve is stuck open
9. Plugged fuel filter 36. Relief valve is stuck closed
10. Restriction in the air cleaner 37. Broken relief valve spring
11. Air in the fuel system 38. Faulty suction pipe
12. Faulty fuel injection pump 39. Plugged oil filter
13. Faulty fuel injectors 40. Piston seizure
14. Broken injection pump drive 41. Incorrect piston height
15. Incorrect injection pump timing 42. Faulty engine mounting
16. Incorrect valve timing 43. Incorrect alignment of flywheel
17. Poor compression 44. Faulty thermostat
18. Plugged fuel tank vent 45. Restriction in water jacket
19. Incorrect grade of fuel 46. Loose alternator belt
20. Exhaust pipe restriction 47. Plugged radiator
21. Cylinder head gasket leaking 48. Plugged breather pipe
22. Over heating 49. Plugged breather pipe
23. Cold running 50. Damaged valve stem oil deflectors
24. Incorrect tappet adjustment 51. Coolant level too low
25. Sticking valves 52. Plugged oil pump pipe strainer
26. Incorrect high pressure fuel lines 53. Broken valve spring
27. Worn cylinder bores

60-10-8 E20 Service Manual

ENGINE INFORMATION (CONT'D) Figure 60-10-2

Engine Removal And Installation 2

Remove bonnet. (See Removal And Installation on Page

40-230-1.)

Open the tailgate. (See Opening And Closing on Page 3

10-50-1.)

Remove air cleaner. (See Removal And Installation on 1

Page 60-30-1.)

Drain and remove the hydraulic reservoir. (See Removal

And Installation on Page 20-130-1.)
P117833
Remove the hydraulic filter mount. (See Removal And
Installation on Page 20-120-1.)
Remove the bolt (Item 1), exhaust pipe clamp (Item 2),
Remove the hydraulic pump. (See Removal And and the tailpipe (Item 3) [Figure 60-10-2] from the
Installation on Page 20-50-7.) machine.

Drain the cooling system. (See Removing And Replacing Figure 60-10-3
Coolant on Page 10-90-3.)
1

IMPORTANT

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

P117834

IMPORTANT Remove the return fuel line (Item 1) and starter cable
(Item 2) [Figure 60-10-3].

Fluid such as engine oil, hydraulic fluid, coolants,

grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499

60-10-9 E20 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-6

Removal And Installation (Cont’d)

Figure 60-10-4

2
2
1

3
P117888

Remove the block ground cable bolt (Item 1) [Figure 60-

P117835 10-6].

Remove the lower starter bolt (Item 2) [Figure 60-10-6].

Remove the throttle cable (Item 1). Loosen the cable jam
nuts (Item 2) [Figure 60-10-4]. Figure 60-10-7

Disconnect the fuel line (Item 3) [Figure 60-10-4].

P117838

Remove the two bolts (Item 1) and the latch assembly

P117836 (Item 2) [Figure 60-10-7].

Cut and remove the two cable ties (Item 1) [Figure 60-
10-5].

60-10-10 E20 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-10

Removal And Installation (Cont’d)

Figure 60-10-8
1

P117841

Disconnect the wire harness (Item 1) [Figure 60-10-10].

P117839

Remove th lower radiator hose (Item 1) [Figure 60-10-8]

and clamp.

Figure 60-10-9

P117840

Remove the two hoses (Item 1) [Figure 60-10-9] from

the top of the engine.

60-10-11 E20 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-13

Removal And Installation (Cont’d)

Figure 60-10-11

P117844

Remove the rear engine mount (Item 1) [Figure 60-10-

P117842 13].

Figure 60-10-14
Remove the front engine mount (Item 1) [Figure 60-10-
11].

Figure 60-10-12

1
P117845

Install lifting chain to lifting brackets (Item 1) [Figure 60-

P117843 10-14].

Remove the left side engine mount (Item 1) [Figure 60-

10-12].

60-10-12 E20 Service Manual

ENGINE INFORMTION (CONT’D)

Removal And Installation (Cont’d)

Figure 60-10-15

P117846

Install chain hoist to lifting chain [Figure 60-10-15].

P117847

Remove the engine from the machine [Figure 60-10-16].

60-10-13 E20 Service Manual

ENGINE INFORMTION (CONT’D) Figure 60-10-18

Engine Mount Replacement

Figure 60-10-17
8

7
7
6 6
5 5
4 4 3
3 2
2
1 1
P-68740

Use the following procedure to install new side engine

P-68741 mounts:

Remove the existing side mount from the engine. Refer to

Use the following procedure to install new front and rear engine removal and installation for engine mount
engine mounts: locations.

Remove the existing mount from the engine. Refer to Use the parts shown to install the new engine mount for
engine removal and installation for engine mount the side engine mount [Figure 60-10-18].
locations.
Item 1 - Mounting Bolt
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Replace the two front and rear engine mounts. Item 2 - Mount Washer
Item 3 - Flat Washer
Use the parts shown to install the new engine mounts for Item 4 - Nut
the front and rear engine mounts [Figure 60-10-17]. Item 5 - Spacer
Item 6 - Mount
Item 1 - Mounting Bolt Item 7 - Screw
Item 2 - Mount Washer Item 8 - Nut
Item 3 - Flat Washer
Item 4 - Spacer Tighten the mounting bolt to 43 - 47 N•m (32 - 35 ft-lb)
Item 5 - Mount torque.
Item 6 - Screw
Item 7 - Nut

Tighten the mounting bolts to 43 - 47 N•m (32 - 35 ft-lb)

torque.

60-10-14 E20 Service Manual

ENGINE INFORMATION (CONT’D) Turn the engine with the starter at 200 - 300 rpm. Run the
test for each cylinder more than twice for 5 to 10 seconds
Engine Compression - Testing each time and take the average reading. Make sure you
are using a fully charged battery.
The tool listed will be needed to do the following
procedure: The correct compression for the engine is 2840 - 3234
kPa (28 - 32 bar) (412 - 469 psi) with no more than 10%
MEL10630 - Engine Compression Test Kit difference between the cylinders.
Warm the engine.
If the pressures are not within 10% of each other, apply a
Remove the glow plugs, muffler and air cleaner from the small amount of oil in the cylinders and retest.
engine. (If testing through glow plug hole.)
If the pressures increase after applying oil, check cylinder
Remove the air cleaner, muffler, and all injector nozzles. walls and piston rings.
(If testing through injector nozzle hole.)
If the pressures do not increase after applying oil, check
Install the compression adapter in the cylinder head. top clearance, valve clearance and cylinder head.

Figure 60-10-19

Connect the compression gauge to the adapter [Figure

60-10-19].

Ensure the speed control lever is set at the low idle

setting.

Hold fuel shut off lever to no fuel (shutoff). See arrow,

[Figure 60-10-19]. Shut off solenoid does not need to be
removed.

60-10-15 E20 Service Manual

60-10-16
E20 Service Manual
SPARK ARRESTER MUFFLER

Removal And Installation WARNING

Open the tailgate.
AVOID INJURY OR DEATH
Remove the air cleaner. (See Removal And Installation When an engine is running in an enclosed area, fresh
on Page 60-30-1.) air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
Figure 60-20-1 outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807

WARNING
1
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285

P117833

WARNING
Loosen the exhaust extension clamp nuts (Item 1)
[Figure 60-20-1]. Never use machine in atmosphere with explosive

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dust or gases or where exhaust can contact
Installation: Tighten clamp to 8 - 10 N•m (5.90 - 7.37 ft- flammable material. Failure to obey warnings can
lb) torque. cause injury or death.
W-2068-1285
Figure 60-20-2

1
P117708

Remove the bolt (Item 1) [Figure 60-20-2] from the

exhaust extension mounting bracket.

Slide exhaust extension (Item 2) [Figure 60-20-2] off

muffler and remove from excavator.

60-20-1 E20 Service Manual

SPARK ARRESTER MUFFLER (CONT’D) Figure 60-20-4

Removal And Installation (Cont’d)

Open access door under seat.

1
Figure 60-20-3
1

1
1

P117706

1
Remove the three bolts (Item 1) [Figure 60-20-4].

Remove the muffler.

P117707
NOTE: Plug the exhaust manifold hole after muffler
removal so no contamination can get into the
Remove the four bolts (Item 1) [Figure 60-20-3] from the engine.
muffler mount flange.

Installation: Torque sequence instructions for muffler

1: Torque four manifold bolts [Figure 60-20-3].

2: Torque three mounting bolts [Figure 60-20-4].

3: Torque exhaust extension bracket (Item 1) [Figure 60-

20-2].

60-20-2 E20 Service Manual

AIR CLEANER Figure 60-30-3

Removal And Installation

Open the tailgate.

2
3
Figure 60-30-1

2
2

P117870

1
Remove the nut / bolt (Item 1) from the side of the air
cleaner, the two fuel filter hoses (Item 2) and the two
mounting bracket nuts (Item 3) [Figure 60-30-3].
P117812
Remove the air cleaner and fuel filter assembly from the
excavator.
Loosen the hose clamp (Item 1) [Figure 60-30-1] on the
air intake hose.

Remove the hose (Item 2) [Figure 60-30-1].

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NOTE: Plug the intake manifold hole to prevent any
contamination from getting into the engine.

Figure 60-30-2

Clamp orientation

10° Reference

Clamp orientation

NA9396

60-30-1 E20 Service Manual

60-30-2
E20 Service Manual
ENGINE COOLING SYSTEM Remove the right side cover. (See Removal And
Installation on Page 40-250-1.)
Radiator / Oil Cooler Removal And Installation
Remove the battery. (See Removal And Installation on
Page 50-20-2.)

WARNING Drain the hydraulic fluid. (See Removing And Replacing

The Hydraulic Oil on Page 10-120-3.)

AVOID INJURY OR DEATH Drain the engine coolant. (See Removing And Replacing
Wear safety glasses to prevent eye injury when any Coolant on Page 10-90-3.)
of the following conditions exist:
• When fluids are under pressure. Figure 60-40-1
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

IMPORTANT 1
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly P118065
damage the system.

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I-2003-0888
Disconnect lower coolant hoses (Item 1) [Figure 60-40-
1].

Figure 60-40-2
IMPORTANT 1
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499
1

IMPORTANT P118057

Contain and dispose of any oil leakage in an Disconnect the hydraulic oil lines (Item 1) [Figure 60-40-
environmentally safe manner. 2].
I-2066-0395

Remove the right upperstructure cover. (See Removal

And Installation on Page 40-70-1.)

60-40-1 E20 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-40-5

Radiator / Oil Cooler Removal And Installation

(Cont’d) 3 2

Figure 60-40-3 2
1

4 3
1

2
P118058

1 Loosen the hose clamps (Item 1) and remove the hoses

(Item 2). Remove the nuts (Item 3) from the radiator / oil
P117879 cooler (Item 4). Lift, tilt, and pull out the radiator / oil
cooler (Item 4) [Figure 60-40-5].

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

[Figure 60-40-3] and let hang out of the way.

P118061

Remove the nut (Item 1) [Figure 60-40-4] from the

bottom of the radiator / oil cooler.

60-40-2 E20 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Fan Removal

Remove the radiator / oil cooler. (See Radiator / Oil

Cooler Removal And Installation on Page 60-40-1.)

Figure 60-40-6

P118064

Remove the fan blade bolts (Item 1) and remove the fan
blade (Item 2) [Figure 60-40-6]. The fan can now be
pulled off.

60-40-3 E20 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-40-9

Water Pump Removal and Installation

Remove the radiator / oil cooler (See Radiator / Oil

Cooler Removal And Installation on Page 60-40-1.)

Figure 60-40-7

1
2
1 2

P118528

1 Remove the nut (Item 1) holding the lower coolant line to

block and remove the lower hose (Item 2) [Figure 60-40-
9].

P118526 Figure 60-40-10

Remove the fan blade bolts (Item 1) and remove the fan
blade (Item 2) [Figure 60-40-7]. 1
Figure 60-40-8
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1
P118529

Remove the upper hose (Item 1) [Figure 60-40-10].

P118527

Remove the water pump pulley (Item 1) and the drive belt
(Item 2) [Figure 60-40-8].

60-40-4 E20 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Water Pump Removal and Installation (Cont’d)

Figure 60-40-11

1
1

P118529

Remove the seven mounting bolts (Item 1) [Figure 60-

40-11].

Remove the water pump.

60-40-5 E20 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Thermostat - Testing

Thermostat Removal and Installation Hang the thermostat in a suitable container filled with
coolant.
Figure 60-40-12
Heat the coolant gradually. Use a thermometer to
measure the temperature when it starts to open and
when it’s fully open.
1
2 If the thermostat does not operate correctly it must be
replaced.
2
NOTE: See specifications on the thermostat. (See
Specifications on Page 60-10-2.)

P118530

Drain the engine coolant until it is below the thermostat

level [Figure 60-40-12].

Remove the hose (Item 1) [Figure 60-40-12].

Remove the bolts (Item 2) [Figure 60-40-12], the

Installation: Make sure all gasket surfaces are clean.

Replace the gasket before installing the thermostat
housing. Install liquid gasket to thermostat housing.

60-40-6 E20 Service Manual

LUBRICATION SYSTEM Figure 60-50-4

Oil Pan Removal And Installation 2

1
Remove the engine from the excavator. (See Engine
Removal And Installation on Page 60-10-9.)
Figure 60-50-1

P-62187

Installation: Replace the O-ring (Item 1) on strainer and

use hole 3 (Item 2) [Figure 60-50-4] when installing
P-68742
strainer. Install the oil strainer, using care not to damage
the O-ring.

Unscrew the oil pan mounting screws (Item 1) and Apply liquid gasket to the oil pan (Item 1) [Figure 60-50-
remove the oil pan (Item 2) [Figure 60-50-1]. 2].

Figure 60-50-2 Confirm that the liquid gasket coating surface is free of
water, dust, and oil in order to maintain sealing effect.

NOTE: When mounting the adhesive-applied parts,

1 take care to fit them to the mating parts.

Assemble the adhesive-applied parts within

10 minutes.

To avoid uneven tightening, tighten mounting

screws in diagonal order from the center.
P-68745
After cleaning the oil strainer, install it.
Figure 60-50-3
Attach the oil pan with its central drain plug
facing toward the air suction side.
1

P-62179

Remove the oil pump strainer (Item 1) [Figure 60-50-3].

60-50-1 E20 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Pump - Service

Oil Pump Removal And Installation Figure 60-50-6

Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 60-
90-1.)

Remove the crankshaft gear.

Figure 60-50-5

B-3616

Measure the clearance between the lobes of the inner

2 rotor and outer rotor with a feeler gauge [Figure 60-50-
6].

Figure 60-50-7
B-3658

remove the oil pump gear (Item 1) [Figure 60-50-5].

Remove the oil pump mounting bolts. Remove the oil

pump (Item 2) [Figure 60-50-5].

Installation: Tighten the oil pump mounting bolts to 6,9 -

8,1 N•m (60 - 72 in-lb) torque.

A-2732

Measure the clearance between the outer rotor and

pump body with a feeler gauge [Figure 60-50-7].

If the clearance exceeds the factory limit, replace the oil

pump rotor assembly.

Clearance Between Inner and Outer Rotor

0,03 - 0,14 mm (0.001 - 0.006 in)
Clearance Between Outer Rotor and Body
0,07 - 0,15 mm (0.003 - 0.006 in)

60-50-2 E20 Service Manual

LUBRICATION SYSTEM (CONT’D) Engine Oil Pressure - Testing

Oil Pump - Service (Cont’d) Figure 60-50-9

Figure 60-50-8

B-14876

PI-10009
Remove the oil pressure sensor.

Put a piece of press gauge on the rotor face [Figure 60- Install a pressure gauge [Figure 60-50-9].
50-8].
Start the engine and run until it is at operating
Install the cover and tighten the bolts. temperature.

Remove the cover carefully. Measure the width of the Measure oil pressure at both idling and rated speeds.
press gauge [Figure 60-50-8].

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If the oil pressure is less than the allowable limit, check
If the clearance exceeds the factory limit replace the oil the following item:
pump rotor assembly.
• Engine Oil Insufficient
End Clearance 0,08 - 0,14 mm (0.003 - 0.005 in) • Oil Pump Defective
• Oil Galley Plugged
• Oil Strainer Plugged
• Excessive Oil Clearance
• Foreign Matter in Relief Valve
• Oil Filer Cartridge plugged

At Idle Speed Allowable Limit 48 kPa (0,48 bar) (7 psi)

At Rated Speed 200 - 400 kPa (2 - 4 bar)
(28 - 64 psi)
Allowable Limit 100 kPa (1 bar) (21 psi)

Installation: After testing engine oil pressure, tighten oil

pressure sensor to 15 - 20 N•m (11 - 15 ft-lb).

60-50-3 E20 Service Manual

60-50-4
E20 Service Manual
FUEL SYSTEM

Fuel Shutoff Solenoid Removal And Installation

Figure 60-60-1

1 2

P117965

Disconnect the wire harness from the solenoid (Item 1)

[Figure 60-60-1].

Remove the solenoid mounting bolts (Item 2) [Figure 60-

60-1].

Remove the solenoid (Item 3) [Figure 60-60-1].

60-60-1 E20 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-2

Fuel Injection Pump - Testing

NOTE: Never try to disassemble the injection pump

assembly. For repairs, you should contact a
Kubota-authorized pump service shop.

Remove the air cleaner. (See Removal And Installation

on Page 60-30-1.)

Remove the hydraulic filter mount. (See Removal And

Installation on Page 20-120-1.) 1

Remove the fuel shutoff solenoid. (See Fuel Shutoff

Solenoid Removal And Installation on Page 60-60-1.) P117966

The tools listed will be needed to do the following

procedure: To test the initial discharge pressure, remove a high
pressure tubeline (Item 1) [Figure 60-60-2] from the fuel
MEL1237 - Adapter Fuel Line injection pump.
MEL1173-1 - Pressure Gauge
Loosen the other end of the tubeline at the injector, so
that the tubeline can be turned away from the fitting.

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

60-60-2 E20 Service Manual

FUEL SYSTEM (CONT’D)

Fuel Injection Pump - Testing (Cont’d)

Figure 60-60-3

2 3

B-8235

Connect a pressure gauge (Item 1) to the long leg of the

test tubeline (Item 2) [Figure 60-60-3] and tighten.

Connect the short leg of the tubeline to the fitting at the

fuel injection pump (Item 3) [Figure 60-60-3].

Set the speed control lever to the maximum engine

Fuel Tightness of Pump Element

With the starter, rotate the engine to increase the

pressure to 13727 kPa (137 bar) (1991 psi).

If the pressure cannot be reached, replace the pump with

a new one or send to a Kubota-authorized pump service
shop.

Fuel Tightness of Delivery Valve

Manually turn the flywheel to raise the pressure to

approx. 13727 kPa (137 bar) (1991 psi). Now turn the
flywheel back about 1/2 turn (to keep the plunger free),
and clock the time taken for the pressure to drop from
13727 - 12748 kPa (137 - 127 bar) (1991 - 1849 psi).

The pressure should hold at 13727 kPa (137 bar) (1991

psi), for at least 5 seconds or more.

If the time is less than the allowable limit, replace the

pump with a new one, or send to a Kubota - authorized
pump service shop.

60-60-3 E20 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-4

Fuel Injection Pump Removal And Installation

IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment. 1
I-2028-0289

Clean the injection pump and area around it with a

cleaning solvent or steam cleaning.
P-69728

Remove the fuel line clamps (Item 1) [Figure 60-60-4].

IMPORTANT Figure 60-60-5

Never steam clean or put cold water on an injection

pump while the engine is running or while it is hot. If
you do it will cause serious damage to the injection
pump.
2
I-2135-0997
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1
3
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. P-68729
I-2029-0289

Disconnect the high pressure lines (Item 1) [Figure 60-

Remove the air cleaner. (See Removal And Installation
60-5] from the fuel injector and fuel injection pump.
on Page 60-30-1.)
Installation: Tighten the pipe retaining nuts to 25 - 34
Remove the hydraulic filter mount. (See Removal And
N•m (18 - 25 ft-lb) torque.
Installation on Page 20-120-1.)
Disconnect the fuel return hose (Item 2) and the fuel feed
hose (Item 3) [Figure 60-60-5].

60-60-4 E20 Service Manual

FUEL SYSTEM (CONT’D)

Fuel Injection Pump Removal And Installation

(Cont’d)

Figure 60-60-6

1
1

P118533

Remove the four injection pump mounting bolts (Item 1)

[Figure 60-60-7].

Figure 60-60-7

B-14423

Align the pin (Item 1) [Figure 60-60-7] in the control rack

with the slot in the engine block.

Remove the injection pump.

Installation: When the injection pump is installed, make

sure the pin (Item 1) [Figure 60-60-7] on the control rack
is correctly installed on the fork lever. If the slot is not
installed correctly, the engine will run over maximum
speed and serious damage can result.

NOTE: Make sure the same number shims are

installed under the injection pump. The shims
are used for engine timing.

60-60-5 E20 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-9

Fuel Injection Pump - Timing

Timing the injection pump is done by changing the

1
number of shims between the injection pump and the
injection pump mounting surface.

Figure 60-60-8

2 P-13132

Install a short plastic tube (Item 1) [Figure 60-60-9] in

the number one cylinder port of the injection pump. The
tube should fit tight in the port and point upward.

NOTE: The fuel must be in the tube before attempting

P-68728 timing.

Move the fuel lever on the injection pump to full fuel

Remove the fuel line clamp (Item 1) [Figure 60-60-8]. position (or full throttle).

Remove the number one cylinder high pressure line (Item Turn the flywheel counterclockwise (facing the flywheel)
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2) [Figure 60-60-8] from the injection pump. slowly until the start of fuel rise in the plastic tube (Item 1)
[Figure 60-60-9].

Figure 60-60-10

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

IMPORTANT 1

Do not attempt to maintain or adjust unless you are

trained and have the correct equipment. S6275
I-2028-0289

At this point look at the timing mark (located on the

flywheel) for proper alignment (Item 1) [Figure 60-60-
10]. When the timing mark is aligned as shown the timing
is correct for the injection pump, which is 19 - 21°
B.T.D.C.

60-60-6 E20 Service Manual

FUEL SYSTEM (CONT’D) Fuel Camshaft Removal And Installation

Fuel Injection Pump - Timing (Cont’d) Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 60-
Figure 60-60-11 90-1.)

Remove the idler gear. (See Cylinder Head Removal And

Installation on Page 60-70-3.)

Figure 60-60-12

1
1

B-14422

The correct engine timing for all Kubota D722-E2B

engines is 19-21° B.T.D.C. Add or subtract shims (Item 1)
[Figure 60-60-11] to time the engine to 19-21° B.T.D.C. B-14342
The engine is correctly timed when the 19-21° B.T.D.C.
mark on the flywheel is aligned with the notch in the
timing hole. Remove the bolt (Item 1) from the retainer plate (Item 2)
[Figure 60-60-12].

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NOTE: Adding or reducing the shim thickness by
0,05 mm retards or advances the injection Installation: Tighten the bolt to 6,8 - 8,1 N•m (60 - 72 in-
timing by approximately 0.5°. lb) torque.

Some problems caused by faulty injector nozzles: Remove the fuel camshaft retainer plate (Item 2) [Figure
60-60-12].
• The engine is hard to start or will not start.
• Rough engine operation at idle. Remove the fuel camshaft and fork lever assembly at the
• The engine will not have full power. same time.
• The engine exhaust smoke is black, white, or blue.

60-60-7 E20 Service Manual

FUEL SYSTEM (CONT'D) Fuel Injector Removal And Installation

Fuel Camshaft Governor

The governor serves to keep the engine speed constant

by automatically adjusting the amount of fuel supplied to IMPORTANT
the engine according to changes in the load.
Do not bend the high pressure fuel injection tubes
Figure 60-60-13 when removing or installing them.
I-2029-0289

2 Figure 60-60-14

4
1

3
11
10 1
6
9
8
7
1. Start Spring P-68728
2. Governor Spring
3. Fork Lever
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4. Fork Lever Remove the high pressure fuel line clamps (Item 1)
5. Fork Lever shaft [Figure 60-60-14].
6. Governor Sleeve
7. Retaining Plate Figure 60-60-15
8. Bearing
1
9. Fuel Camshaft
10. Bearing
11. Snap Ring B-14875
3
4
Disassemble and assemble the governor and fuel 1
camshaft as shown [Figure 60-60-13].

Inspect all the parts for wear or damage and replace as 3

needed.
2

P-68729

Disconnect the high pressure fuel lines from the fuel

injectors (Item 1) [Figure 60-60-15].

Disconnect the fuel lines (Item 2) [Figure 60-60-15] from

the injection pump.

60-60-8 E20 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-16

Fuel Injector Removal And Installation (Cont’d)

Remove the high pressure fuel lines.

Disconnect the return fuel hoses (Item 3) [Figure 60-60-

15].

Remove the retainer nut from the top of the fuel injectors.

Remove the fuel return pipe (Item 4) [Figure 60-60-15].

1
Loosen the injector nozzle.

Installation: Tighten the injector nozzle to 49 - 69 N•m

(36 - 51 ft-lb) torque. 2

Remove the injector nozzle from the cylinder head. 3

4 (1) Nozzle Holder

NOTE: Be sure to replace the copper washer and
5 (2) Adjusting Washer
nozzle cap anytime new or reconditioned fuel
(3) Nozzle Spring
injectors are installed.
6 (4) Push Rod
(5) Distance Piece
(6) Nozzle Piece
WARNING 7
(7) Nozzle Retaining Nut

AVOID INJURY OR DEATH

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Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or PI-9981
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 The nozzle release pressure can be adjusted by adding
enters skin or eyes, get immediate medical attention or removing washer(s) (Item 2) from the top of the nozzle
from a physician familiar with this injury. spring (Item 3) [Figure 60-60-16].
W-2072-0807

Fuel Injector Nozzle Pressure - Testing

IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
I-2027-0284

The tool listed will be needed to do the following

procedure:

4200 - Injector Nozzle Tester

4201 - Injector Nozzle Tester Adapter Set

60-60-9 E20 Service Manual

FUEL SYSTEM (CONT’D)

Fuel Injector Nozzle Pressure - Testing (Cont’d) WARNING

Each spacer will change the release pressure by about
234 kPa (2,3 bar) (34 psi). AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
Fuel Injection Pressure. 13727 - 14713 kPa (137 - 147 penetrate skin or eyes, causing serious injury or
bar) (1991 - 2134 psi) 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
Figure 60-60-17
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Figure 60-60-18

CORRECT WRONG

A-2513

Assemble the injector nozzle. Connect the nozzle to the

tester with the nozzle down [Figure 60-60-17].

A-2621
Operate the hand lever at a slow rate and record the
opening pressure. If the pressure is not correct,
disassemble the nozzle and add or remove the spacer Check that the spray pattern is correct [Figure 60-60-18]:
(Item 2) [Figure 60-60-16] as needed.
1. Fuel does not come out the side of the nozzle.
NOTE: When assembling the injector nozzle, tighten 2. Drops of fuel are not present at the nozzle.
the retainer nut (Item 1) [Figure 60-60-16] to 3. The injector has an even flow coming from the nozzle.
25,3 - 28,9 N•m (23.5 - 28.9 ft-lb) torque. Any
higher torque will cause slow action of the
valve.

When the injector nozzle is assembled, tighten the nozzle

body to 49 - 69 N•m (36 - 51 ft-lb) torque.

Check for inside leakage. Operate the hand lever until the
pressure 12748 kPa (127 bar) (1849 psi). Keep the
nozzle under this pressure for 10 seconds, check to see if
fuel leaks from the nozzle. If fuel leaks, replace the
nozzle.

60-60-10 E20 Service Manual

CYLINDER HEAD Figure 60-70-3

Glow Plug Removal And Installation

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

1
Figure 60-70-1

P118536

Remove the glow plugs (Item 1) [Figure 60-70-3] from

the cylinder head.

Installation: Tighten the glow plugs to 8 - 15 N•m (6 - 11

ft-lb) torque.
1
Figure 60-70-4

P118534

Figure 60-70-2

2
1
1 B-15856

Connect an ohmmeter to the terminal end of the glow

plug, touch the other lead from the ohmmeter to the
heating end of the glow plug [Figure 60-70-4].

The reading will be approximately 0.9 ohm. If the

resistance is 0 ohm, the glow plug has a short circuit. If
P118535 the resistance is infinite, the coil of the glow plug is
broken.

Remove the nuts (Item 1) [Figure 60-70-2].

Remove the glow plug connector (Item 2) [Figure 60-70-

2].

60-70-1 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-6

Valve Clearance Adjustment

NOTE: The valve clearance must be checked and

adjusted when the engine is cold.

Remove the cylinder head cover and the glow plugs.

Adjust the valve clearance as follows:

Figure 60-70-5

P-62023

2 With No. 1 piston at TDC (compression) both the intake

1 and exhaust valves are up. Set both No. 1 valves, No. 2
3 exhaust valve, and No. 3 intake valve. [Figure 60-70-6].

Rotate the flywheel 360°, No. 1 (overlap position). Set

No. 2 intake valve and No. 3 exhaust valve. [Figure 60-
70-6].

P-62022 Figure 60-70-7

Loosen the locknut (Item 1) [Figure 60-70-5]. 0,145-0,185 mm

(0.0057-0.0073 in)
Turn the adjustment screw (Item 2) [Figure 60-70-5] until
the correct clearance is obtained.

NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
60-70-9].

If adjustments are necessary, tighten locknut before

moving on to the next rocker arm.

A-2730

Make sure the piston is at TDC when adjusting the

clearance at the valves. The correct clearance is 0,145 -
0,185 mm (0.0057 - 0.0073 inch) cold clearance [Figure
60-70-7].

60-70-2 E20 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head Removal And Installation

Valve Timing - Checking Figure 60-70-9

Stop the engine and open the rear door. 2 3

Remove the engine. (See Engine Removal And

Installation on Page 60-10-9.)

Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 60-
90-1.)
1
Figure 60-70-8

4
3 P-62177

5 Remove the breather hose (Item 1) [Figure 60-70-9].

Remove the bolts (Item 2) from the valve cover and

1 remove the valve cover and gasket (Item 3) [Figure 60-
2 70-9].
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring Installation: Tighten the bolts to 7 - 11 N•m (5 - 8 ft-lb)
(4) Cam Gear torque. Gradually tighten center bolts before the end
(5) Camshaft B-14341 bolts to avoid cracking valve cover.

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Remove the fuel injector nozzles. (See Fuel Injector
Make sure the timing marks are in correct alignment Removal And Installation on Page 60-60-8.)
[Figure 60-70-8].
Remove the glow plugs. (See Glow Plug Removal And
Installation on Page 60-70-1.)

Remove the alternator. (See ALTERNATOR on Page 50-

30-1.)

60-70-3 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-12

Cylinder Head Removal And Installation (Cont’d)

Figure 60-70-10

2 1

B-14490

Remove the cylinder head bolts in order of #14 to #1

3 P-62176 [Figure 60-70-12].

Installation: Put oil on the bolt threads. Tighten the bolts

Remove the rocker arm bracket screws (Item 1) and shaft in the correct sequence of #1 to #14 38 - 42 N•m (28 - 31
assembly (Item 2) [Figure 60-70-10]. ft-lb) torque.

Installation: Tighten the nuts to 9,8 - 11,3 N•m (7 - 8 in- NOTE: Re-tighten the cylinder head bolts in the
lb) torque. correct sequence after the engine has been
run for 30 minutes.
Remove the push rods (Item 3) [Figure 60-70-10].
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Remove the cylinder head from the engine block.

Remove the intake and exhaust manifolds.
Figure 60-70-13
Figure 60-70-11

1
2

P-62175
P-62174

Installation: Always use a new head gasket and new O-

Remove the water return hose [Figure 60-70-11]. ring. Make sure the O-ring (Item 1) [Figure 60-70-13] is
seated over the dowel.

60-70-4 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-16

Cylinder Head Disassembly And Assembly

Figure 60-70-14

3
1
2 B-3643

5
Remove the thermostat cover and thermostat from the
4 B-14418 cylinder head. Remove the thermostat housing (Item 1)
[Figure 60-70-16].

Use a valve spring compressor to compress the valve Installation: Apply Liquid-Type Gasket (Three Bond
spring [Figure 60-70-14]. 1215 or equivalent) to both sides of the new thermostat
cover gasket and new thermostat housing gasket.
Figure 60-70-15

1 2 3 4 5 6

B-4122

Remove the valve cap (Item 1) [Figure 60-70-15] and

valve spring collect (Item 2) [Figure 60-70-14] and
[Figure 60-70-15].

Remove the valve spring retainer (Item 3) [Figure 60-70-

14] and [Figure 60-70-15] and the spring (Item 4)
[Figure 60-70-14] and [Figure 60-70-15].

Remove the valve (Item 5) [Figure 60-70-14] and

[Figure 60-70-15].

Remove the seal (Item 6) [Figure 60-70-15].

60-70-5 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-18

Cylinder Head - Servicing

Figure 60-70-17

PI-9988

Put the straight edge on the cylinder head's four sides

A-2735 and two diagonal as shown in figure [Figure 60-70-18].

The maximum distortion of the head surface ± 0,05 mm

Clean the surface of the cylinder head. (± 0.002 in). If the measurement is more than the
specification, remove the combustion chambers, then
Put a straight edge (Item 1) [Figure 60-70-17] on the grind the cylinder head. Grind the same amount of
cylinder head. material from the bottom of the combustion chambers as
was removed from the head.
NOTE: Do not put the straight edge across
combustion chambers.
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Put a feeler gauge (Item 2) [Figure 60-70-17] between

the straight edge and the surface of the cylinder head.

60-70-6 E20 Service Manual

CYLINDER HEAD (CONT’D) Valve Guide - Servicing

Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Removal And Installation on Page
Figure 60-70-19 60-70-3.)

Clean the valve seat and combustion chamber.

2
Figure 60-70-20

1
3

PI-9989

Install the cylinder head gasket. Put the piston (Item 1)

[Figure 60-70-19] being checked at T.D.C.
B-3634

Put 3 pieces of 1,5 mm (0.06 in) diameter solder (Item 2)

[Figure 60-70-19] on the top piston. Use grease to hold Install the valve into the guide. Measure the valve
them in position. recessing with a depth gauge [Figure 60-70-20].

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NOTE: Put the solder in position so they do not touch Figure 60-70-21
the valves.
2
Turn the piston to bottom dead center.

Install the cylinder head and tighten to the correct torque

in the correct sequence. (See Cylinder Head Removal
1
And Installation on Page 60-70-3.)

Turn the crankshaft until the piston exceeds T.D.C.

Remove the cylinder head.
1. Cylinder Head
Remove the solder wire (Item 3) [Figure 60-70-19] and
Surface
measure it.
2. Recessing
If the measurement exceeds the specifications, check the PI-9990
oil clearance of the crank pin journal or the piston pin

Top clearance 0,50 - 0,70 mm (0.0197 - 0.0276 in) If the measurement exceeds the allowable limit, replace
the valve or cylinder head [Figure 60-70-21].

Recessing 0,10 mm (0.004 in)

Allowable Limit (Recessing) 0,30 mm (0.012 in)

Remove the carbon from the valve guide.

60-70-7 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-24

Valve Guide - Servicing (Cont’d)

Figure 60-70-22

PI-9992

Press the used valve guide out of the cylinder head using
B-14335 the special driver tool [Figure 60-70-24]. (See previous
page for tool dimensions.)

Measure the valve stem O.D. [Figure 60-70-22]. Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
Measure the valve guide I.D. [Figure 60-70-22]. top side. Use the special driver tools (Item 1 and 2)
[Figure 60-70-24], press the new guide until the tools
Calculate the clearance. If the clearance exceeds the contact the cylinder head.
allowable limit, replace the valve and / or valve guide.
Ream the valve guide to the correct specifications.
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Valve Guide I.D 6,01-6,025 mm (0.2366-0.2372 in)

Valve Stem O.D 5,968-5,980 mm (0.2350-0.2354 in) NOTE: Valve guide I.D. (Intake and Exhaust) factory
spec. is 6,01 - 6,025 mm (0.2366 - 0.2372 in)
Clearance Between Valve Stem and Guide
0,03-0,057 mm (0.0012-0.0022 in)
Allowable Limit 0,10 mm (0.0039 in)

Figure 60-70-23

200 mm (7.87 in)

20 mm 80mm (3.15 in) 40mm
9,96-9,98 mm
(0.79 in) (0.1.57 in)
(0.392-0.393 in)

5,5-5,7 mm
(0.2165-0.2244 in)
7 mm
5,0 mm 18,0 mm
(0.2 in) (0.276 in)
(0.71 in)

6,0-6,1 mm 15,0 mm 10,6-10,7 mm

(0.236-0.240 in) (0.59 in)
(0.417-0.421 in)
MC-1364

To remove and replace the valve guide, make the driver

tools as shown in figure [Figure 60-70-23].

60-70-8 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-27

Valve And Valve Seat Reconditioning 1 2

Figure 60-70-25
15°

2,12 mm (0.0835 in)

PI-9995

Check the seat surface and valve face (Item 1) [Figure

PI-9993 60-70-27].

If the seat surface is too wide, use a 15 degree cutter

Grind the valve face to the correct angle using a valve (Item 2) to get the correct width (Item 3) [Figure 60-70-
refacer [Figure 60-70-25] and [Figure 60-70-27]. 27].

Figure 60-70-26 Valve Seat Width

Intake 2,12 mm (0.0835 in)

Exhaust 2,12 mm (0.0835 in)

Intake 45°
15° 30°(45°) Exhaust 45°

PI-9994

Grind the valve surface in the cylinder head to the correct

angle [Figure 60-70-26].

60-70-9 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-29

Valve Spring

Figure 60-70-28

A-2759

Put the spring on a tester and compress to specified

B-3680 length [Figure 60-70-29].

Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the spring.
measurement is less than the allowable limit, replace the
spring [Figure 60-70-28]. Setting Length 27 mm (1.063 in)
Setting Load 64,7 N (14.6 lb)
Free Length 31,3 - 31,8 mm (1.232 - 1.252 in)
Allowable Limit (setting load)
Allowable Limit 28,4 mm (1.118 in)
54,9 N (12.3 lb)
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Put the spring on a flat surface, place a square on the

side of the spring [Figure 60-70-28].

Rotate the spring and measure the maximum tilt. If the

measurement is in excess of the allowable limit, replace
the spring.

Tilt 1,2 mm (0.047 in)

60-70-10 E20 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-31

Valve Tappets

Figure 60-70-30

P-37174

Measure the tappet O.D. with an outside micrometer

P-37202 [Figure 60-70-31].

Measure the I.D. of the tappet guide bore with a cylinder

Remove the tappets (Item 1) [Figure 60-70-30] from the gauge, and calculate the oil clearance [Figure 60-70-31].
crankcase.
If the oil clearance exceeds the allowable limit or the
When reassembling replace the head gasket with a new tappet is damaged, replace the tappet.
one.
Oil clearance Factory 0,016 - 0,052 mm
Before installing the tappets (Item 1) [Figure 60-70-30], between tappet spec. (0.00063 - 0.00205 in)

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apply engine oil thinly around them. and guide Allowable 0,10 mm
NOTE: Mark the cylinder number to the tappets to limit (0.0039 in)
prevent interchanging.
Tappet O.D. Factory 17,966 - 17,984 mm
spec. (0.70732 - 0.70803 in)
Tappet guide Factory 18,000 - 18,018 mm
I.D. spec. (0.70866 - 0.70937 in)

60-70-11 E20 Service Manual

CYLINDER HEAD (CONT’D)

Rocker Arm And Shaft - Servicing

Figure 60-70-32

2 1

B-3697

Measure the rocker arm I.D. (Item 1) [Figure 60-70-32]

with an inside micrometer.

Measure the rocker shaft O.D. (Item 2) [Figure 60-70-32]

with an outside micrometer.

If the clearance exceeds the allowable limit, replace the

rocker arm and measure the clearance again.

If the clearance still exceeds the allowable limit after the

rocker arm is replaced, replace the rocker arm shaft.

Oil Clearance Between Rocker Arm and Shaft

0,016 - 0,045 mm (0.0006 - 0.0018 in)
Allowable 0,15 mm (0.0059 in)
Limit
Rocker Arm 10,47 - 10,48 mm (0.4123 - 0.4128 in)
Shaft
Rocker Arm 10,5 - 10,52 mm (0.4134 - 0.4141 in)
I.D.

60-70-12 E20 Service Manual

CRANKSHAFT AND PISTONS Repeat the procedure to remove the other piston /
connecting rod assemblies from the engine block.
Piston And Connecting Rod Removal And
Installation Figure 60-80-3

Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 60-70-3.) 6 1
4
Remove the top edge from the cylinder bore with a ridge
reamer. 5 2
Figure 60-80-1 4

B-3621

Remove the first compression ring (Item 1) [Figure 60-

80-3].

Remove the second compression ring (Item 2) [Figure

60-80-3].
PI-10013
Remove the oil ring (Item 3) [Figure 60-80-3].

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Remove the rod cap and bearing [Figure 60-80-1]. Remove the snap ring (Item 4) and piston pin (Item 5)
[Figure 60-80-3].
Use a hammer handle and push the piston connecting
rod assembly out of the cylinder bore [Figure 60-80-1]. Separate the piston (Item 6) from the connecting rod
(Item 7) [Figure 60-80-3].
NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore. NOTE: Make sure the piston and rod assembly is
marked so as not to change the piston rod
Figure 60-80-2 assembly with another piston or connecting
rod.
828

1
828

A-2903

Installation: Make sure the marks (Item 1) on the

connecting rod and bearing are aligned when installing
the bearing cap [Figure 60-80-2].

60-80-1 E20 Service Manual

RECONDITIONING THE ENGINE (CONT’D)

Piston And Connecting Rod Removal And

Installation (Cont’d)

Figure 60-80-4

180°

PI-10015A PI-10015

Installation: When installing new rings, assemble the

ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 60-80-4].
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Figure 60-80-5

3 4

1
2

PI-10014B 5 PI-10014A

Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
piston in oil to 80°C (176°F) for 10 to 15 minutes and tap
the piston pin into position. Place the piston rings so that
there are gaps every 120° (Items 3, 4 and 5) [Figure 60-
80-5] with no gap facing the piston pin in the cylinder.

60-80-2 E20 Service Manual

RECONDITIONING THE ENGINE (CONT’D) Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
Piston And Connecting Rod - Servicing specifications, replace the piston pin.

Figure 60-80-6 Piston Pin O.D. 20,002-20,011 mm (0.7875-0.7878 in)

Bushing I.D. 20,025-20,04 mm (0.7884-0.7890 in)
Oil Clearance between Piston Pin and Bushing
0,014-0,038 mm (0.0006-0.0015 in)
Allowable Limit 0,10 mm (0.004 in)

Figure 60-80-8

20 mm (0.79 in)

145 mm (5.7 in)

25 mm
A-2733 (0.98 in) 25 mm
(0.98 in)

Measure the I.D. of the piston pin bore in both horizontal

and vertical direction [Figure 60-80-6]. (21,9-21,96 mm)
0.8622-0.8642 in 19,9-19,95 mm
If the measurement exceeds the allowable limit, replace (0.7835-0.7854 in)
the piston.
MC-1366
Piston Pin Bore I.D. 20,00 - 20,013 mm

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(0.7874 - 0.7879 in) To replace the connecting rod small end bushing, make a
Allowable Limit 20,05 mm (0.789 in) driver tool as shown in figure [Figure 60-80-8].

Figure 60-80-7

1
B-3633

Measure the O.D. of the piston pin (Item 1) [Figure 60-

80-7].

Measure the I.D. of the connecting rod small end (Item 2)

[Figure 60-80-7].

60-80-3 E20 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) If the gap exceeds the allowable limit, replace the piston
ring.
Piston And Connecting Rod - Servicing (Cont’d)
Top Compression Ring and Oil Ring
Figure 60-80-9
0,15 - 0,30 mm (0.006 - 0.012 in)
Second Compression Ring
Removing Installing
0,30 - 0,45 mm (0.012 - 0.018 in)
Allowable Limit 1,2 mm (0.047 in)

Figure 60-80-11

PI-10016

Use a press and special driver tool to remove the small

end bushing [Figure 60-80-9].

Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until B-14475
it is flush [Figure 60-80-9].

Remove the carbon from the ring grooves. Measure the

Figure 60-80-10
clearance between the ring and groove with a feeler
gauge [Figure 60-80-11].

Second ring 0,09 - 0,12 mm (0.0033 - 0.0045 in)

Oil ring 0,04 - 0,08 mm (0.0016 - 0.0031 in)
Allowable limit second ring
0,15 mm (0.0059 in)
Allowable limit oil ring
0,15 mm (0.0059 in)

If the clearance exceeds the allowable limit, replace the

piston.
B-3622

Install a new piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [Figure
60-80-10].

60-80-4 E20 Service Manual

CRANKSHAFT AND PISTONS (CONT'D)

Cylinder Bore - Measuring

Figure 60-80-12

B-10073

Measure the inside diameter of the cylinder bore [Figure

60-80-12].

Figure 60-80-13

To find the maximum wear measure the inside diameter

in different locations [Figure 60-80-13].

When the cylinder bore is not within specifications, bore

and hone the cylinder for an oversize piston.

Cylinder Bore I.D. 67,0 - 67,02 mm (2.638 - 2.639 in)

Allowable Limit 67,17 mm (2.644 in)

NOTE: Make sure you use the correct oversize

pistons and rings.

60-80-5 E20 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft Gear Removal And Installation

Connecting Rod Alignment Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 60-
NOTE: The small end bushing is the basis of this 90-1.)
check, check the bushing for wear before
doing this check. Remove the idler gear. (See Idler Gear And Camshaft
Removal And Installation on Page 60-90-3.)
Install the piston pin into the connecting rod.
Figure 60-80-15
Install the connecting rod on an alignment tool.

Put the gauge over the piston pin and move it against the
face plate.

Figure 60-80-14

B-3686

Remove the crankshaft gear with a puller [Figure 60-80-

B-4067 Remove the crankshaft key.

If the gauge does not fit squarely against the face place,
measure the space between the gauge and face plate
[Figure 60-80-14].

If the measurement exceeds the allowable limit, replace

the connecting rod.

Rod Alignment Allowable Limit

0,05 mm (0.002 in)

60-80-6 E20 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 60-80-17

Crankshaft And Bearings Removal And Installation

Remove the piston and connecting rod assemblies. (See 3

Piston And Connecting Rod Removal And Installation on 2
Page 60-80-1.)
1
Remove the engine flywheel. (See Cylinder Head
Removal And Installation on Page 60-70-3.)

Remove the bolts which fasten the bearing case cover to

the block.
4
Installation: Tighten the bearing case cover bolts to 10 -
11 N•m (7 - 8 ft-lb) torque. Tighten bolts with even force P-62185
on the diagonal line.

Figure 60-80-16 Installation: When installing the cover (Item 4), make
sure the casting mark (Item 3) [Figure 60-80-18] is in the
up position. Lightly oil inside lip of oil seal (Item 3)
[Figure 60-80-17].

Figure 60-80-18

Install two bolts into the bearing case cover and pull the
cover out [Figure 60-80-16]. 2 1
P-62181

Installation: When installing the bearing case gasket

(Item 1) [Figure 60-80-17] and [Figure 60-80-18], and
the bearing case cover gasket (Item 2) [Figure 60-80-17]
and [Figure 60-80-18] make sure the mark (Item 3)
[Figure 60-80-18] is in the up position.

60-80-7 E20 Service Manual

RECONDITIONING THE ENGINE (CONT’D) Figure 60-80-20

Crankshaft And Bearings Removal And Installation

(Cont’d)

Figure 60-80-19 2

1
B-14346

Remove the main bearing case bolt (Item 1) [Figure 60-

80-20].
B-9565
Installation: Align the bearing case hole (Item 2) [Figure
60-80-20] with the hole in the block. Put oil on the bolt
Before removing the crankshaft / main bearings, check threads and tighten to 27 - 30 N•m (20 - 22 ft-lb) torque.
the end play. Install a dial indicator. Measure the end play
by moving the crankshaft back and forth [Figure 60-80- Figure 60-80-21
19].

If the measurement exceeds the allowable limit, replace

the thrust washers.

End Play 0,15 - 0,31 mm (0.006 - 0.012 in)

Allowable Limit 0,5 mm (0.020 in)

B-14878

Remove the crankshaft / main bearing assembly from the

engine block [Figure 60-80-21].

Mark the bearing case halves for correct installation.

60-80-8 E20 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings - Servicing

Crankshaft And Bearings Removal And Installation Figure 60-80-24

(Cont’d)

Figure 60-80-22

A-2763

B-4092 Put the crankshaft on V-blocks. Install a dial indicator on

the center journal [Figure 60-80-24].

Remove the two bearing case bolts [Figure 60-80-22]. Turn the crankshaft at a slow rate.

Remove the bearing case and bearing. If the misalignment exceeds the allowable limit, replace
the crankshaft.
Installation: Tighten the bearing case bolts (Item 1)
[Figure 60-80-23] to 13 - 16 N•m (9 - 12 ft-lb) torque. Alignment 0,02 mm (0.0008 in)

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Figure 60-80-23
Tighten the connecting rod cap bolts 27 - 30 N•m (20 - 22
ft-lb) torque.
1
Figure 60-80-25

2
120°
3
P-62182

Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel A-2727

side of the engine block [Figure 60-80-23]. Be sure the

thrust washer with its oil grooves face outward.
Measure the crankpin bearing I.D. [Figure 60-80-25].
Identification marks on the main bearing case
assemblies are the alignment number (Item 2) and the
marking “1” or “2” (Item 3) [Figure 60-80-23] can be
found on the main bearing case assemblies to ensure
proper assembly.

60-80-9 E20 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-27

Crankshaft And Bearings - Servicing (Cont’d)

Figure 60-80-26

1
PI-10024B

Figure 60-80-28
A-2716
130 mm
(5.12”)
Measure the crankpin O.D. [Figure 60-80-26]. 40 mm
(R 1.57”)
Calculate the oil clearance.
20mm 39,90-39,95mm
Crankpin Bearing I.D. (0.79”) (1.5709-1.5728”)
33,99 - 34,01 mm (1.3389 - 1.3390 in)
72 mm
Crankpin O.D. 33,96 - 33,98 mm (1.3370 - 1.3376 in) (2.83”)
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Oil Clearance 0,020 - 0,051 mm (0.0008 - 0.0020 in) 68 mm 24 mm

(2.68”) (0.95”)
Allowable limit 0,15 mm (0.0059 in)
9.mm
(0.35”) B-14879

Remove the bearing (Item 1) [Figure 60-80-27] from the

front of the engine block with the removal tool shown in
[Figure 60-80-28].

Installation: Clean the new bearing and bore and apply

oil to them. Install the new bearing with the installation
driver tool [Figure 60-80-27].

Clean the crankshaft journal and bearing. Put a strip of

press gauge on the center journal.

Install the main bearing case halves and tighten the bolts
to 12,7 - 15,7 N•m (9 - 12 ft-lb) torque. Remove the
bearing case halves.

60-80-10 E20 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Crankshaft And Bearings - Servicing (Cont’d)

Figure 60-80-29

PI-10025

Measure the flattened press gauge [Figure 60-80-29].

If the clearance exceeds the allowable limit, replace the

crankshaft bearing.

Crankshaft Journal O.D. (Flywheel side)

43,93 - 43,95 mm (1.7297 - 1.7303 in)

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Bearing I.D. 43,98 - 44,03 mm (1.7317 - 1.7333 in)
Crankshaft Journal O.D. (Middle)
39,93 - 39,95 mm (1.5722 - 1.5728 in)
Bearing I.D. 39,98 - 40,03 mm (1.5742 - 1.5758 in)
Crankshaft journal O.D. (Front)
39,93 - 39,95 mm (1.5722 - 1.5728 in)
Bearing I.D. 39,98 - 40,04 mm (1.5714 - 1.5764 in)
Oil Clearance 0,034 - 0,106 mm (0.0013 - 0.0042 in)
Allowable Limit 0,2 mm (0.008 in)

60-80-11 E20 Service Manual

60-80-12
E20 Service Manual
CAMSHAFT AND TIMING GEARS Figure 60-90-3

Timing Gearcase Cover Removal And Installation

Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 60-60-4.)

Figure 60-90-1 1

2
2
B-14870

Remove the bolt (Item 1) and disconnect the shaft spring

(Item 2) [Figure 60-90-3].
1
Figure 60-90-4
B-14868

Remove the cylinder head, rocker arms, and push rods.

(See Cylinder Head Removal And Installation on Page
60-70-3.)

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Remove the screws (Item 1) from the speed control plate
(Item 2) [Figure 60-90-1].

NOTE: Take care not to damage the spring.

Figure 60-90-2

B-14871

Remove the crankshaft pulley bolt.

1
Installation: Tighten the bolt 98 - 108 N•m (72 - 80 ft-lb)
torque.

Use a puller and remove the crankshaft pulley [Figure

60-90-4].

B-14869

Separate the speed control plate from the engine and

remove the spring (Item 1) [Figure 60-90-2].

Remove the speed control plate.

60-90-1 E20 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-7

Timing Gearcase Cover Removal And Installation

(Cont’d)

Figure 60-90-5

Oil Seal O-rings

B-3617

Installation: Install three new O-rings and the oil seal

into the timing gear case cover [Figure 60-90-7].
B-14872

When installing the crank shaft pulley, make sure the

alignment marks are aligned [Figure 60-90-5].

Remove the timing gear case cover bolts.

Installation: Tighten the bolts to 10 - 11 N•m (7 - 8 ft-lb)

torque.

Figure 60-90-6

B-14873

Remove the timing gear case [Figure 60-90-6].

60-90-2 E20 Service Manual

CAMSHAFT AND TIMING GEARS (CONT'D) Idler Gear And Camshaft Removal And Installation

Timing Gears Measuring Backlash Figure 60-90-9

Figure 60-90-8

B-14341

PI-10005
Remove the snap ring (Item 1) and collar (Item 2) from
the idler gear shaft (Item 3) [Figure 60-90-9].
When the gears are installed, measure the backlash of
the gears. Figure 60-90-10

Install a dial indicator with its tip on a gear tooth [Figure

60-90-8]. 1

Hold one gear while turning the other gear [Figure 60-

If the backlash exceeds the allowable limit, measure the

oil clearance of the shaft and gear. If the oil clearance is
correct, replace the gears.

Crank Gear and Idler Gear. 2

0,043 - 0,124 mm (0.002 - 0.005 in)
Allowable Limit 0,15 mm (0.006 in)
Cam Gear and Idler Gear B-3699
0,047 - 0,12 mm (0.002 - 0.005 in)
Allowable Limit 0,15 mm (0.006 in)
Injection Pump Gear and Idler Gear Remove the idler gear (Item 1) [Figure 60-90-10].
0,046 - 0,124 mm (0.006 in)
Allowable Limit 0,15 mm (0.006 in) Remove idler gear mounting screws (Item 2) [Figure 60-
Oil Pump Gear and Crankshaft Cover 90-10].
0,041 - 0,123 mm (0.002 - 0.005 in)
Allowable Limit 0,15 mm (0.006 in) Installation: Tighten screws to 10 - 11 N•m (7 - 8 ft-lb)
torque.

60-90-3 E20 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-13

Idler Gear And Camshaft Removal And Installation

(Cont’d)

Figure 60-90-11

B-3620

Measure the camshaft bearing in the engine block

[Figure 60-90-13].
B-14874
Figure 60-90-14

Installation: Make sure the timing marks are in correct

alignment when installing the timing gears [Figure 60-90-
11].

Align the holes on the camshaft gear with the camshaft

Remove the bolts.

Figure 60-90-12

A-2761

Measure the camshaft journal [Figure 60-90-14].

Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the camshaft.

Bearing I.D. 33,00 - 33,03 mm (1.299 - 1.300 in)

Journal O.D. 32,93 - 32,95 mm (1.2966 - 1.2972 in)

B-3655
Clearance of Camshaft Journal
0,05 - 0,09 mm (0.002 - 0.004 in)

Remove the camshaft from the engine block [Figure 60- Allowable Limit 0,15 mm (0.006 in)
90-12].

Installation: Tighten the camshaft retainer bolts to 18 -

21 N•m (14 - 15 ft-lb) torque.

60-90-4 E20 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-16

Idler Gear And Camshaft Removal And Installation

(Cont’d)

Figure 60-90-15

A-2760

Put the camshaft in V-blocks. Install a dial indicator

[Figure 60-90-16].
B-5001
Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Measure the cam lobes at their highest point [Figure 60-
90-15]. Camshaft Alignment Allowable Limit

If the measurement is less than the allowable limit, 0,01 mm (0.0004 in)
replace the camshaft.

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Cam Lob Height 26,88 mm (1.058 in)
Allowable Limit 26,83 mm (1.056 in)

60-90-5 E20 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-18

Idler Gear and Shaft - Servicing

20 mm (0.79 in)
Figure 60-90-17
150 mm (5.91 in)
25 mm
(0.98 in) 30 mm
(1.18 in)

(21,9-21,95 mm)
0.862-0.864 in 19,9-19,95 mm
(0.784-0.785 in)

MC-1366A
MC-1366

To replace the idler gear bushing, make a driver tool as

PI-10003 shown in figure [Figure 60-90-18].

Figure 60-90-19
Measure the O.D. of the idler gear shaft [Figure 60-90-
17].

Measure the I.D. of the idler gear bushing [Figure 60-90-

17].

If the clearance exceeds the allowable limit, replace the

bushing.

Idler Gear Shaft 19,97 - 19,98 mm

O.D. (0.786 - 0.787 in)
Idler Gear Shaft 20,00 - 20,05 mm 0-0,2 mm
I.D. (0.787 - 0.789 in) (0.008”)
Oil Clearance between Idler Shaft and Gear Bushing
PI-10004
0,020 - 0,084 mm (0.0008 - 0.0033 in)
Allowable Limit 0,10 mm (0.004 in)
Use a press and special driver tool, to remove the old
bushing and install the new bushing [Figure 60-90-19].

60-90-6 E20 Service Manual

FLYWHEEL AND HOUSING Figure 60-100-2

Flywheel Housing Removal And Installation

Remove the operator bonnet. (See Removal And

Installation on Page 40-230-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Oil on Page 10-120-3.)

Remove the hydraulic pump. (See Removal And 1

Installation on Page 20-50-7.)

Remove the spark arrester muffler. (See Removal And

Installation on Page 60-20-1.)
S6210
Remove the starter. (See Removal And Installation on
Page 50-40-2.)
Remove the mount bolt and nut (Item 1) [Figure 60-100-
Figure 60-100-1 2] from the engine mount.

Installation: Tighten the bolt and nut to 43 - 47 N•m (32 -

35 ft-lb) torque.

Figure 60-100-3
1

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1
P-59315
1
Install a chain hoist to the engine lifting eye to support the
engine (Item 1) [Figure 60-100-1].
S6211

Remove the five flywheel housing bolts (Item 1) [Figure

60-100-3].

Installation: Tighten the bolts to 24 - 26 N•m (18 - 19 ft-

lb) torque.

Remove the flywheel housing.

NOTE: Check that the alignment dowel pins are

installed in the flywheel housing for
assembly.

60-100-1 E20 Service Manual

FLYWHEEL AND HOUSING (CONT’D) Flywheel Removal

Hydraulic Pump Coupler Removal And Installation Remove the flywheel housing. (See Flywheel Housing
Removal And Installation on Page 60-100-1.)
Remove the flywheel housing. (See Flywheel Housing
Removal And Installation on Page 60-100-1.) Remove the hydraulic pump coupler. (See Hydraulic
Pump Coupler Removal And Installation on Page 60-100-
Figure 60-100-4 2.)

1 Figure 60-100-5

1
2

S6212
1
S6214
Remove the three bolts (Item 1) [Figure 60-100-4] from
the hydraulic pump coupler.
Remove the five bolts (Item 1) [Figure 60-100-5] from
Installation: Apply Loctite® 242 (Blue) to bolts and the flywheel.
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tighten the bolts to 71 - 79 N•m (52.5 - 58.5 ft-lb) torque.

Also lubricate the bolt heads prior to installation. Remove the flywheel (Item 2) [Figure 60-100-5].

NOTE: Apply anti-seize compound on spline teeth

prior to pump installation.

Remove the hydraulic pump coupler (Item 2) [Figure 60-

100-4].

60-100-2 E20 Service Manual

FLYWHEEL AND HOUSING (CONT’D) Rear End Plate Removal And Installation

Flywheel Installation Remove the flywheel housing. (See Flywheel Housing

Removal And Installation on Page 60-100-1.)
Figure 60-100-6
Remove the hydraulic pump coupler. (See Hydraulic
Pump Coupler Removal And Installation on Page 60-100-
2.)

Remove the flywheel. (See Flywheel Removal on Page

60-100-2.)

Figure 60-100-8

1 2

2
1

P-68763

Mark the flywheel (Item 1) and the plate (Item 2) before

[Figure 60-100-6] the flywheel is removed.

Figure 60-100-7

P-68764

2
2
1

1
S6214

Apply engine oil to the five bolt threads and underside of

bolt heads before installation.
P-68765
Install the five bolts (Item 1) [Figure 60-100-7] on the
flywheel.
Remove the bolts (Item 1) from the rear end plate (Item
Tighten the bolts to 53,9 - 58,8 N•m (39.8 - 43.4 ft-lb) 2) [Figure 60-100-8] and [Figure 60-100-9]. Remove
torque. end plate from the side of the engine.

60-100-3 E20 Service Manual

60-100-4
E20 Service Manual
HEATING AND VENTILATION

HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Filter Element Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

HEATER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

70-01 E20 Service Manual

70-02
E20 Service Manual
HEATER SYSTEM Figure 70-10-3

Description

The heater system includes the heater unit which is

located on the floor on the right side of excavator cab.
The heater unit includes the heater coil, fan motor, blower
cage, a temperature switch, fan switch, filter, and louvers.
3
Components
1
Figure 70-10-1
2

P118718

Control Panel: The panel (Item 1) [Figure 70-10-3] has

two separate components:

Fan Switch: This is a four position rotary switch (Item

2) [Figure 70-10-3].
1
Temperature Switch: The temperature switch (Item 3)
[Figure 70-10-3] controls the heat valve from fully
P118717 OFF to fully ON.

Figure 70-10-4

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Heater Unit: The heater unit (Item 1) [Figure 70-10-1] is
located on the floor on the ride side of the excavator cab.
The unit delivers the warm air for heat into the cab.

Figure 70-10-2

1
1

P118719

2 Heater Valve: The heater valve (Item 1) [Figure 70-

10-4] manually controls the amount of engine coolant
P118730 that flows to the heater coil.

Heater Coil: The heater coil (Item 1) [Figure 70-10-2]

supplies the warm air into the cab by passing air through
the coil.

Heater Fan: The fan (Item 2) [Figure 70-10-2] is used to

push air through the heater coil and into the cab.

70-10-1 E20 Service Manual

70-10-2
E20 Service Manual
REGULAR MAINTENANCE

Filter Element Removal And Installation

The fresh air filter must be cleaned regularly. (See AIR

CLEANER SERVICE on Page 10-70-1.)

The fresh air filter is located on the right front corner of

the cab.

Fresh Air Filter

Figure 70-20-1

2
1
1
1

P113435

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Remove the four screws (Item 1) and remove the cover
(Item 2) [Figure 70-20-1].

Figure 70-20-2

P113436

Pull the filter (Item 1) [Figure 70-20-2] out of the housing.

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

Reinstall the cover (Item 2) and the four screws (Item 1)

[Figure 70-20-1].

70-20-1 E20 Service Manual

Heater Coil Figure 70-20-5

Remove the heater unit. (See Removal And Installation

on Page 70-30-1.)

Figure 70-20-3

P118727

Raise the cover to disconnect the fan motor switch

harness (Item 1) [Figure 70-20-5].
1 P118724
Remove the cover.

Remove the four bolts (Item 1) [Figure 70-20-3]. Figure 70-20-6

P118734

1 P118726
The heater coil (Item 1) [Figure 70-20-6] can now be
cleaned with low pressure water or air.
Remove the four bolts (Item 1) [Figure 70-20-4].
NOTE: High pressure may damage the fins of the
heater coil.

70-20-2 E20 Service Manual

HEATER UNIT Figure 70-30-3

Removal And Installation

Drain the engine coolant. (See Removing And Replacing

Coolant on Page 10-90-3.)

Remove the floor mats. (See Removal And Installation on

Page 40-140-1.)
1 1
Figure 70-30-1

P118722

1 Remove the two clamps (Item 1) for the heater hoses

[Figure 70-30-3].

Figure 70-30-4

P118717 1

Remove the rear cover of heater unit (Item 1) [Figure 70-

P118723
1
Remove the two mounting nuts (Item 1) [Figure 70-30-
4].

Figure 70-30-5

P118720

Disconnect the fan switch harness (Item 1) [Figure 70-

30-2].

P118724

Remove the heater unit assembly [Figure 70-30-5].

70-30-1 E20 Service Manual

70-30-2
E20 Service Manual
HEATER COIL Figure 70-40-3

Removal And Installation

Remove the heater unit. (See Removal And Installation 1

on Page 70-30-1.)

Figure 70-40-1 2

1
P118727

Raise the cover (Item 1) to disconnect the fan switch

harness (Item 2) [Figure 70-40-3].

Remove the cover assembly.

1 P118724
Figure 70-40-4

Remove the four bolts (Item 1) [Figure 70-40-1].

Figure 70-40-2

P118725

Remove the screws (Item 1) [Figure 70-40-4].

1 P118726

Remove the four bolts (Item 1) [Figure 70-40-2].

70-40-1 E20 Service Manual

HEATER COIL (CONT’D) Figure 70-40-7

Removal And Installation (Cont’d)

Figure 70-40-5

1
1 1

P118730

Remove the screws (Item 1) [Figure 70-40-7].

P118728
Figure 70-40-8

Remove the screws (Item 1) [Figure 70-40-5].

1
1

P118731

Remove the cover (Item 1) [Figure 70-40-8].

P118729

Remove the screws (Item 1) [Figure 70-40-6].

70-40-2 E20 Service Manual

HEATER COIL (CONT’D) Figure 70-40-11

Removal And Installation (Cont’d)

1
Figure 70-40-9

1
1

P118734

Remove the screws (Item 1) and remove the heater coil

P118732 mount (Item 2) [Figure 70-40-11].

Figure 70-40-12
Remove the screws (Item 1) [Figure 70-40-9].

Figure 70-40-10

2
P118735

P118733 If the heater coil needs replacement it must be replaced

as a complete unit [Figure 70-40-12].

Cut and remove the cable tie (Item 1) and remove the
harness (Item 2) [Figure 70-40-10] from the heater coil
assembly.

70-40-3 E20 Service Manual

70-40-4
E20 Service Manual
HEATER FAN Figure 70-50-3

Removal And Installation

Remove the heater coil. (See Removal And Installation

on Page 70-40-1.)

Figure 70-50-1

P118738

Remove the heater fan assembly [Figure 70-50-3].

Figure 70-50-4

P118736

Remove the screws (Item 1) [Figure 70-50-1] and

[Figure 70-50-2].
1
Figure 70-50-2 1

P118739

Remove the screws (Item 1) [Figure 70-50-4] from the

mounting bracket.

P118737

70-50-1 E20 Service Manual

HEATER FAN (CONT’D)

Removal And Installation (Cont’d)

Figure 70-50-5

P118740

Remove the heater fan assembly [Figure 70-50-5].

The heater fan assembly is not repairable. Order the

70-50-2 E20 Service Manual

HEATER VALVE

Removal And Installation

Remove the heater unit. (See Removal And Installation

on Page 70-30-1.)

Figure 70-60-1

P118742

Remove the lower hose clamp (Item 1) [Figure 70-60-1]

and remove the heater valve [Figure 70-60-2].

Figure 70-60-2

70-60-1 E20 Service Manual

70-60-2
E20 Service Manual
SPECIFICATIONS

EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Slew System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6

TECHNICAL SERVICE GUIDE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Excavator Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

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Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-4

HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1

SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1

Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-5
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7

SPEC-01 E20 Service Manual

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.
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SPEC-02 E20 Service Manual

EXCAVATOR SPECIFICATIONS

Machine Dimensions

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

476 mm
690 mm (18.7 in)
(27.1 in)

1532 mm
(60.3 in)
1370 mm
(53.9 in)
638 mm
(25.1 in)

131 mm
(15.1 in)
1190 mm
(46.8 in)

3669 mm 980 mm
(144.4 in) (38.6 in)

1138 mm
(44.8 in)

2297 mm
(90.4 in)

419 mm
(16.5 in)

1252 mm 230 mm
(49.3 in) (9.1 in)
25 mm
(1.0 in) 1258 mm 235 mm 980 mm
(49.5 in) (9.6 in) (38.6 in)

1620 mm 1360 mm
(63.8 in) (53.5 in)

NA9376

SPEC-10-1 E20 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Machine Dimensions (Cont’d)

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

4307 mm
(169.6 in)
4264 mm
(167.9 in)

1611 mm
(63.4 in)
196° 3701mm
(145.7 in)

300 mm
(11.8 in) 118°

903 mm
(35.5 in)
254 mm
(10.0 in)
2115 mm
27°
(83.3 in)

2565 mm
(101.0 in)

NA9376

SPEC-10-2 E20 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Performance

Operating weight (canopy w/ rubber

tracks, counterweight, basic seat and 1953 kg (4306 lb)
standard bucket)
If equipped with the following, add: Cab w/ Heater, add 81 kg (178 lb);
Standard Seat, add 8 kg (18 lb)
Suspension Seat, add 14 kg (30 lb)

Maximum Approved Attachment Weight 300 kg (661 lb)

Travel Speed (Low / High) 2,5 km/h / 4,0 km/h (1.5 mph / 2.5 mph)

Digging Force (per ISO 6015)

With Long Arm Arm - 9279 N (2086 lb)
Bucket - 20835 N (4684 lb)

Controls

Steering Two hand levers (optional foot pedals)

Hydraulics Two hand operated levers (joysticks) control boom, bucket, arm and
upperstructure slew
Blade Hand lever
Two Speed Switch on blade lever

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Boom Swing Electric switch in left joystick
or R.H. foot pedal
Auxiliary Hydraulics Electric switch in right joystick
or L.H. foot pedal
Auxiliary Pressure Release Electric switch in right joystick
or L.H. foot pedal
Engine Engine speed control lever, key type start switch
Starting Aid Glow Plugs - activated by key switch
Brakes
Travel
Service and Parking Hydraulic lock in motor circuit
Slew
Service Hydraulic lock on motor
Holding Spring applied - hydraulic release

SPEC-10-3 E20 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Engine

Make / Model Kubota D722-E4B-BCZ-7 Tier 4

Fuel / Cooling Diesel NO.2-D / Liquid
Horsepower (SAE Net) @ 2500 rpm 9,9 kW (13,3 hp)
Torque @ 2000 rpm (SAE) 42,3 N•m (31.9 ft-lb)
Number Of Cylinders 3
Displacement 0,719 L (43.9 in³)
Bore / Stroke 67 x 68 mm (2.64 x 2.68 in)
Lubrication Forced Lubrication / Cartridge type
Crankcase Ventilation Closed breathing
Air Cleaner Dual dry replacement paper elements
Ignition Diesel-Compression
Low Idle Speed 1200 ± 50 rpm
High Idle Speed 2650 ± 20 rpm
Engine Coolant Propylene Glycol / water mixture (53% PG / 47% water)

Hydraulic System

Pump Type Engine driven, dual outlet, variable displacement,

load sensing, torque limited, piston pump with gear pump
Pump Capacity 
Piston Pump 2 x 15 L/min (2 x 4.0 U.S. gpm)
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Gear Pump 11,3 L/min (3.0 U.S. gpm)

Auxiliary Flow 
Standard Flow 30,0 L/min (7.9 U.S. gpm)
Hydraulic Filter Full flow replaceable, 3 micron synthetic media element
Control Valve 9 spool, parallel series type, open center.

System Relief Pressure

Blade 20600 kPa (206 bar) (2987 psi)

Slew Relief Pressure 13700 kPa (137 bar) (1987 psi)

Boom Swing, Boom
Arm, Bucket, and Travel  23097 kPa (231 bar) (3350 psi)

Joystick Control Pressure 3103 kPa (31 bar) (450 psi)
Auxiliary Relief 17995 kPa (180 bar) (2610 psi)
Arm Port Relief Base And Rod End 24994 kPa (250 bar) (3625 psi)
Boom Port Relief Base End, 21000 kPa (210 bar) (3046 psi)
Boom Port Relief Rod End 24994 kPa (250 bar) (3625 psi)
Bucket Port Relief Base And Rod End 24994 kPa (250 bar) (3625 psi)
Blade Port Relief Base End and 
Track Expansion Port Relief Base
End 29000 kPa (290 bar) (4206 psi)
Main Hydraulic Filter Bypass 345 kPa (3,4 bar) (50 psi)

SPEC-10-4 E20 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic Cylinders

Cylinder Bore Rod Stroke

Boom (cushion up) 69,9 mm (2.75 in) 41,3 mm (1.63 in) 445,0 mm (17.5 in)
Arm (cushion retract / 60,3 mm (2.375 in) 38,1 mm (1.50 in) 424,9 mm (16.75 in)
extend)
Bucket 57,1 mm (2.25 in) 31,8 mm (1.50 in) 385,0 mm (15.16 in)
Boom Swing 60,3 mm (2.375 in) 31,8 mm (1.25 in) 411,2 mm (16.19 in)
Blade 63,5mm (2.5 in) 34,9 mm (1.375 in) 107,9 mm (4.25 in)
Track Expansion 44,5mm (1.75 in) 25,4 mm (1.00 in) 385,0 mm (15.16 in)

Hydraulic Cycle Times

Bucket Curl 2,00 seconds

Bucket Dump 1,20 seconds
Arm Retract 2,40 seconds
Arm Extend 2,00 seconds
Boom Raise 4,40 seconds
Boom Lower 3,80 seconds
Boom Swing Left (80°) 2,90 seconds
Boom Swing Right (60°) 3,60 seconds
Blade Raise 2,60 seconds

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Blade Lower 2,60 seconds
Track Expand 4,10 seconds
Track Retract 3,50 seconds

Electrical

Starting Aid Glow Plugs

Alternator 12 volt, 40 Amp open frame w/ internal regulator
Battery 12 volt - 530 CCA @ -18°C (0°F)
Starter 12 volt; gear reduction 1,4 kW (1.4 hp)
Instrumentation Fuel gauge, audible alarm, visual warning for engine functions and hourmeter
Lights
Work Lights 65 watt (2)
Boom Light (If Equipped) 35 watt

Drive System

Final Drive Each track is driven by hydrostatic axial piston motor

Drive Reduction 30,36:1 two stage planetary
Gradeability 30*
Brakes Hydraulic lock on motor

SPEC-10-5 E20 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Slew System

Slew Drive Orbital motor, direct drive

Slew Circle Single row shear type ball bearings with internal gear
Gear Reduction 21.5:1
Brake Spring applied, pressure released
Slew Speed 8,4 rpm

Undercarriage

Crawler Track Design Sealed track rollers with boxed section track roller frame,
grease type track adjuster with shock absorbing recoil spring
Width of crawler - Retracted 980 mm (38.6 in)
Width of crawler - Expanded 1360 mm (53.5 in)

Capacities

Fuel Tank 19,0 L (5.0 U.S. gal)

Hydraulic Reservoir Only (Center of Tank Cap. 14,3 L (3.78 U.S. gal)
Sight Glass)
Hydraulic System (with Reservoir) 19,0 L (5.0 U.S. gal)
Cooling System 3,3 L (0.87 U.S. gal)
Engine Oil and Filter 3,3 L (3.5 qt)
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Final Drive (each) 0,4 L (0.11 qt)

Tracks

Type Rubber
Width 230 mm (9.0 in)
Number Of Shoes Single Assembly
Number of Track Rollers (per side) 3

Ground Pressure

Rubber Tracks 30,1 kPa (0,301 bar) (4.36 psi)

SPEC-10-6 E20 Service Manual

TECHNICAL SERVICE GUIDE SPECIFICATIONS

Engine

Engine Oil Pressure at Low Idle 49 kPa (49 bar) (7.1 psi)
Engine Oil Pressure at High Idle 197 - 441 kPa (1,97 - 4,41 bar) (28.5 - 64 psi)
Location of Number 1 Cylinder Closest to water pump
Crankshaft Rotation (Facing
Clockwise
Crankshaft Pulley)
Valve Clearance (Cold) Intake 145 - 185 mm (.005 - 007 in)
Valve Clearance (Cold) Exhaust 145 - 185 mm (.005 - 007 in)

NOTE: For additional engine specifications, (See Specifications on Page 60-10-2.)

Engine Torques

Fuel Injection Tubeline Nuts 29,4 N•m (21.7 ft-lb)

Glow Plugs 8 - 14 N•m (5.8 - 10 ft-lb)
Injection Pump Mounting Nuts 22 N•m (16 ft-lb)
Valve Cover Bolts 9 - 11 N•m (7.3 - 8.4 ft-lb)
Head Bolts 38 - 42 N•m (28 - 31 ft-lb)

NOTE: For additional engine torques, (See Engine Removal And Installation on Page 60-10-9.)

Cooling System

Coolant Type and Mix 47% Water and 53% Propylene Glycol

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Radiator Cap Pressure 89 kPa (0,9 bar) (13 psi)
Thermostat Fully Open at 85°C (185°F)

NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 60-40-1.)

Excavator Torques

Drive Motor To Frame Bolt 40 - 50 N•m (29 - 37 ft-lb)

Sprocket To Drive Motor 65 - 75 N•m (48 - 55 ft-lb)
Swing Bearing To Frame Bolt 105 - 115 N•m (78 - 85 ft-lb)
Swing Bearing To Upperstructure Bolt 105 - 115 N•m (78 - 85 ft-lb)
Swing Motor Mounting Bolts 115 N•m (85 ft-lb)
Swivel Joint Mounting Bolts 105 - 115 N•m (78 - 85 ft-lb)

SPEC-20-1 E20 Service Manual

SPEC-20-2
E20 Service Manual
TORQUE SPECIFICATIONS FOR BOLTS

Torque For General SAE Bolts

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

THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9 - 10 13 - 14
N•m (80 - 90) (110 - 120)
(in-lb) 0.3125 21 - 23 24 - 27
(180 - 200) (215 - 240)
0.375 34 - 38 48 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 82 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 125 - 135
(65 - 70) (90 - 100)
0.5625 125 - 135 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 190
(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)

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1.000 645 - 710 985 - 1085
N•m (475 - 525) (725 - 800)
(ft-lb) 1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

SPEC-30-1 E20 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)

Torque For General Metric Bolts

Thread Size Material

(Dia.) 8.8 10.9 12.9
M4 2,5 - 3,5 N•m 3,8 - 4,2 N•m 4,7 - 5,3 N•m
(2.0 - 2.5 ft-lb) (2.8 - 3.1 ft-lb) (3.5 - 3.9 ft-lb)
M5 5,5 - 6,5 N•m 8,4 - 7,6 N•m 8,5 - 9,5 N•m
(4.0 - 5.0 ft-lb) (5.6 - 6.2 ft-lb) (6.2 - 7.0 ft-lb)
M6 9,5 - 10,5 N•m 12,2 - 13,7 N•m 14,2 - 15,8 N•m
(7.0 - 7.5 ft-lb) (9.1 - 10.1 ft-lb) (10.4 - 11.6 ft-lb)
M7 15 - 17 N•m 20 - 22 N•m 23,7 - 26,3 N•m
(11.0 - 12.5 ft-lb) (16.2 - 14.7 ft-lb) (17.5 - 19.5 ft-lb)
M8 24 - 26 N•m 29,4 - 32,6 N•m 35 - 39 N•m
(18 - 19 ft-lb) (21.7 - 24.0 ft-lb) (25.5 - 28.5 ft-lb)
M10 43 - 47 N•m 57 - 63 N•m 71 - 79 N•m
(32 - 35 ft-lb) (42.0 - 46.5 ft-lb) (52.5 - 58.5 ft-lb)
M12 75 - 85 N•m 105 - 115 N•m 91 - 110 N•m
(55 - 60 ft-lb) (78 - 85 ft-lb) (91 - 110 ft-lb)
M14 125 - 140 N•m 118 - 133 N•m 140 - 155 N•m
(100 - 90 ft-lb) (118 - 133 ft-lb) (140 - 155 ft-lb)
M16 190 - 210 N•m 255 - 285 N•m 300 - 330 N•m
(140 - 155 ft-lb) (188 - 210 ft-lb) (225 - 245 ft-lb)
M18 260 - 290 N•m 345 - 385 N•m 420 - 460 N•m
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(190 - 215 ft-lb) (255 - 285 ft-lb) (210 - 340 ft-lb)

M20 370 - 410 N•m 490 - 550 N•m 590 - 650 N•m
(275 - 300 ft-lb) (360 - 405 ft-lb) (440 - 490 ft-lb)
M22 500 - 550 N•m 740 - 760 N•m 800 - 880 N•m
(370 - 400 ft-lb) (554 - 560 ft-lb) (590 - 650 ft-lb)
M24 640 - 700 N•m 850 - 950 N•m 1000 - 1120 N•m
(470 - 520 ft-lb) (625 - 700 ft-lb) (730 - 830 ft-lb)
M27 930 - 1030 N•m 1230 - 1370 N•m 1470 - 1630 N•m
(680 - 760 ft-lb) (900 - 1000 ft-lb) (1100 - 1200 ft-lb)
M30 1260 - 1400 N•m 1700 - 1900 N•m 2000 - 2200 N•m
(930 - 1030 ft-lb) (1250 - 1400 ft-lb) (1500 - 1600 ft-lb)
M33 1720 - 1900 N•m 2300 - 2500 N•m 2700 - 3100 N•m
(1270 - 1400 ft-lb) (2300 - 2500 ft-lb) (2000 - 2300 ft-lb)
M36 200 - 2450 N•m 2900 - 3200 N•m 3500 - 3900 N•m
(1620 - 1800 ft-lb) (2200 - 2400 ft-lb) (2600 - 2900 ft-lb)

SPEC-30-2 E20 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-2
O-ring Face Seal Tightening Torque
O-ring Face Seal Connection
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)

IMPORTANT 1/4”
3/8”
9/16” - 18
11/16” - 16
18 (13)
30 (22)
When repairing hydrostatic and hydraulic systems, 1/2” 13/16” - 16 54 (40)
clean the work area before disassembly and keep all 5/8” 1” - 14 81 (60)
parts clean. Always use caps and plugs on hoses,
3/4” 1-3/16” - 12 114 (84)
tubelines and ports to keep dirt out. Dirt can quickly
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 Vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].

SPEC-40-1 E20 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)

Straight Thread O-ring Fitting

Figure SPEC-40-3

Nut Nut

Washer
Washer
O-ring

O-ring

A-1852

Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
3].

Tubelines And Hoses

Replace any tubelines that are bent or flattened. They will

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

Replace hoses which show signs of wear, damage or

weather cracked rubber.

Always use two wrenches when loosening and tightening

hose or tubeline fittings.

SPEC-40-2 E20 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-5
(CONT’D) Flare Fitting Tightening Torque
Flare Fitting Tubeline x TORQUE
Outside x N•m
Figure SPEC-40-4 Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
1 3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)
TS-1619A

Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-4]

Use the chart [Figure SPEC-40-5] to find the correct

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tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.

SPEC-40-3 E20 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-7
(CONT'D) Port Seal and O-ring Boss
Tightening Torque
Port Seal Fitting
x TORQUE
Figure SPEC-40-6 x ft-lb
Thread Size (N•m)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” - 16 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
Nut Seals
To Fitting 1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)
Nut Seals
To Port
Use the following procedure to tighten the port seal
fitting:

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

fittings use the same tightening torque valve chart.
Secondary O-ring Seal P-13008

The nut is the primary seal, the O-ring is the secondary

the connection [Figure SPEC-40-6].

The hex portion of the nut does not contact the surface of
the component when the nut is tight.

SPEC-40-4 E20 Service Manual

HYDRAULIC FLUID SPECIFICATIONS

Specifications WARNING
Use Bobcat hydraulic fluid (P/N 6903117 - 2, 2 1/2 U.S.
gal), (P/N 6903118 - 5 U.S. gal), (P/N 6903119 - 55 U.S. During cold weather (0°C [32°F] and below), do not
gal). operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.

When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311

DO NOT use automatic transmission fluids in the

excavator or permanent damage to the hydraulic system
will result.

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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
from a physician familiar with this injury.
W-2072-0807

When temperatures below -18°C (0°F) are common, the

excavator must be kept in a warm building. Extra warm-
up time must be used each time the excavator is started
during cold temperature conditions. Cold fluid will not flow
easily and it makes action of the hydraulic function
slower. Loss of fluid flow to the hydraulic system can
cause damage in less than 60 seconds.

SPEC-50-1 E20 Service Manual

SPEC-50-2
E20 Service Manual
CONVERSIONS

U.S. To Metric Conversion Chart

Decimal And Millimeter Equivalent Chart

SPEC-60-1
E20 Service Manual
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SPEC-60-2
E20 Service Manual
SERVICE TOOLS REQUIRED

The following is a list of service tools required for servicing excavators.

Remote Start Tools

TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool E20 - E55 This tool has been replaced by
the new remote start tool
7003031, see below. MEL1563
includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness Used with MEL1563 to connect
remote start tool to machine

MEL1566 Service Tool Harness Used with MEL1563 to connect

Communicator remote start tool to PC

7217666 Remote Start Tool Kit E20 - E55 This tool replaced the original
 remote start tool kit MEL1563
(Was 7003031) and 7003031. Kit 7217666
 includes: 7022042, 6689747,
(Was 6689779) 6689746 and 6689745.

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7022042 Remote Start Tool This tool replaces remote start
 tool 6689778 and 7003030.
(Was 7003030)

(Was 6689778)
6689747 Remote Start Tool Used with 7003030 to connect
Harness remote start tool to excavator.

6689746 Remote Start Tool Used with 7003030 to connect

Harness Service PC to remote start tool.

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST EXC-0118

SPEC-70-1 E20 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1744 Hydraulic Tester E08 - E85 Hydraulic tester MEL1744, MEL10003
(Flow Meter) or TWX-RFIK200-S-6 can be used for
hydraulic testing.

MEL10003 Hydraulic Tester MEL10003 and TWX-RFIK22-S-6 are

(Flow Meter) no longer available, order MEL1744.

TWX-RFIK200- Hydraulic Tester

S-6 (Flow Meter)

MEL1074 O-Ring Seal Hook

MEL1075 Adjustable Gland Nut Includes MEL1075-1 and MEL1075-2

MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075-1 for disassembling
various cylinders
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075-1 for disassembling
various cylinders
MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2

MEL1396-2 Piston Ring

Compressor

MEL1418 Cylinder Hone =

2.00 in
OEM6275 Cylinder Hone =
2.75 - 3.00 in
OEM6270 Cylinder Hone =
3.00 - 3.50 in
OEM6271 Cylinder Hone =
3.50 - 4.00 in

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST EXC-0118

SPEC-70-2 E20 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1033 Rod Seal Installation E08 - E85
Tool

MEL1355 Hydraulic Test Kit This test kit includes various gauges,
adapters, couplers and hoses that are
used when testing hydraulic functions.
MEL1355 Includes: MEL1355-1 thru
MEL1355-12

MEL1355-2 1000 psi gauge

MEL1355-3 5000 psi gauge

MEL1355-12 Coupler

MEL1412 Seal Installation Tool E32, E35 Used for installing Travel Motor Seal

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MEL1413 Seal Installation Tool E26 Used for installing Travel Motor Seal

MEL1553 Travel Motor Tool Kit E42 - E55 MEL1553 Includes:

MEL1553-1 thru MEL1553-4

MEL1553-1 Motor Seal Included with MEL1553

Installation Tool

MEL1553-2 Motor Seal Included with MEL1553

Installation Tool

MEL1553-3 Motor Seal Included with MEL1553

Installation Tool

MEL1553-4 Motor Seal Included with MEL1553

Installation Tool

6675936 Bleed Tool E08 - E55 Machines with two track tension
(MEL1560) fittings.


See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST EXC-0118

SPEC-70-3 E20 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7277225 Bleed Tool E08 - E85 Machines with one track tension
fitting.

MEL1713 Hydraulic Fitting Kit E60, E63, This test kit includes various adapters
E80, E85 and couplers that are used when
testing hydraulic functions. MEL1713
Includes: MEL1713-1 thru MEL1713-
12

MEL1727 Spanner Wrench E60, E63 Used for removing and installing
bearing nut used in the Travel Motor

MEL1728 Seal Installation Tool E60, E63 Used for installing Travel Motor Seal

7323185 Spanner Wrench E32, E32i, Used for removing and installing
E35 & E35i bearing nut used in the Travel Motor

7335495 Hydraulic Fitting Kit E85 This test kit includes various adapters
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and couplers that are used when

testing hydraulic functions. 7335495
Includes: 7335499 thru 7335505

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST EXC-0118

SPEC-70-4 E20 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7009358 Bobcat Diagnostic E63, E85 Interface for using Yanmar SA-D No Image Available
Interface Box SmartAssist-Direct diagnostic service
software.
7031222 Bobcat Engine T4 Bobcat Includes: Diagnostic Service Tool
Analyzer Diagnostic Engine (7031223), Vehicle Cable 6 pin
Tool Kit Applications (7031398), Vehicle Cable 14 pin
(7031356), USB Cable (7031357) 


7031370 Rear Main Seal T4 Bobcat Used for installing rear main seal
Installer Engine
Applications

7031369 Front Seal Installer T4 Bobcat Used for installing front seal
Engine
Applications

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7031371 Valve Spring T4 Bobcat Used for compressing valve springs
Compressor Engine
Applications

MEL10630 Engine Compression E08 - E55 Includes: MEL1352, MEL1433,

Test Kit MEL1489, MEL1546, MEL1551,
MEL1594, MEL1594,
MEL10630-1 - MEL10630-11 and
MEL10630-14


MEL1352 Compression E26, Used in glow plug port for testing

Adapter E42 - E55 compression - Included with
MEL10630
MEL1631 Compression E32, E35 Used in glow plug port for testing
Adapter compression, NOT included with
MEL10630
MEL1743 Compression E63, E85 Used in glow plug port for testing
Adapter compression, NOT included with
MEL10630

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST EXC-0118

SPEC-70-5 E20 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1237 Fuel Line Adapter E25 - E55 Adapter used to test delivery valve at
the injection pump (Used with
pressure gauge MEL1173-1)

MEL1173-1 Pressure Gauge

10000 psi

4200 Injector Nozzle

Tester

7268212 Valve Lash Adjusting All Bobcat

Wrench Engine
Models

7255632 Valve Stem Seal Tool

Compression Tool Bobcat compression.

Engine
Models
7299831 Injector Compression All Bobcat Used in injector port for testing
Tool Engine compression.
Models
7332314 Turbo and Oil Sensor All Bobcat 7332314 includes: 7332313 - Oil
Block Adapter Kit Engine Sensor Block Adapter and 7332298 -
Models Turbo Oil Adapter.

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST EXC-0118

SPEC-70-6 E20 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Electrical Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7313846 Injector Signal Tester Excavators Used to test injector signal on
Was 7292829 equipped with Bobcat 1.8L and 2.4L engines.
Bobcat
engines

MEL1712 Push Button Starter E17 - E55

Switch

HVAC Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1581 HVAC Recover, E25 - E85 MEL1581 is no longer available,
Recycling, order MEL1735 or MEL1736
Recharging Machine

MEL1735 Deluxe HVAC

Recover, Recycling,

MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine

MEL1592 HVAC Refrigerant

Identification Tool

MEL1595 AC Compressor
Pulley Puller

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST EXC-0118

SPEC-70-7 E20 Service Manual

SPEC-70-8
E20 Service Manual
ALPHABETICAL INDEX

ACCUMULATOR . . . . . . . . . . . . . . . . . 20-70-1 ENGINE LUBRICATION SYSTEM

AIR CLEANER SERVICE . . . . . . . . . . . 10-70-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 60-30-1 ENGINE SPEED CONTROL . . . . . . . .40-80-1
ALTERNATOR BELT . . . . . . . . . . . . . 10-160-1 EXCAVATOR IDENTIFICATION . . . . . . . . 1-15
ALTERNATOR . . . . . . . . . . . . . . . . . . . 50-30-1 EXCAVATOR SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
EXCAVATOR STORAGE AND RETURN TO
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 SERVICE . . . . . . . . . . . . . . . . . . . . . .10-200-1
BLADE / TRACK EXPANSION SOLENOID FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11
BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
FLOOR MAT AND FLOOR PANELS
BLADE CONTROL . . . . . . . . . . . . . . . . 40-90-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-140-1
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 FLYWHEEL AND HOUSING . . . . . . .60-100-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
BUCKET . . . . . . . . . . . . . . . . . . . . . . . 40-200-1 FUEL LEVEL SENDER . . . . . . . . . . . .50-80-1
CAB FILTER . . . . . . . . . . . . . . . . . . . . . 10-80-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .60-60-1
CAMSHAFT AND TIMING GEARS FUEL TANK . . . . . . . . . . . . . . . . . . . .40-150-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
HEATER COIL . . . . . . . . . . . . . . . . . . .70-40-1
CONTROL CONSOLE LOCKOUTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1 HEATER FAN . . . . . . . . . . . . . . . . . . . .70-50-1
CONTROL LEVER (JOYSTICK) (LEFT) HEATER SYSTEM . . . . . . . . . . . . . . . .70-10-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1 HEATER UNIT . . . . . . . . . . . . . . . . . . .70-30-1

Page 668 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off
CONTROL LEVER (JOYSTICK) (RIGHT) HEATER VALVE . . . . . . . . . . . . . . . . . .70-60-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1 HORN . . . . . . . . . . . . . . . . . . . . . . . . .40-160-1
CONTROL LINKAGE ASSEMBLY HYDRAULIC CONNECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . SPEC-60-1 HYDRAULIC CONTROL VALVE . . . . . .20-40-1
COUNTERWEIGHT . . . . . . . . . . . . . . 40-220-1 HYDRAULIC FILTER MOUNT . . . . . .20-120-1
CRANKSHAFT AND PISTONS . . . . . . 60-80-1 HYDRAULIC FLUID SPECIFICATIONS
CYLINDER (ARM) . . . . . . . . . . . . . . . . 20-21-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CYLINDER (BLADE) . . . . . . . . . . . . . . 20-24-1 HYDRAULIC PUMP . . . . . . . . . . . . . . .20-50-1
CYLINDER (BOOM SWING) . . . . . . . . 20-22-1 HYDRAULIC RESERVOIR . . . . . . . . .20-130-1
CYLINDER (BOOM) . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC SYSTEM INFORMATION
CYLINDER (BUCKET) . . . . . . . . . . . . . 20-23-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
CYLINDER (TRACK FRAME EXPANSION) HYDRAULIC SYSTEM . . . . . . . . . . . .10-120-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1 KEY SWITCH . . . . . . . . . . . . . . . . . . . .50-90-1
CYLINDER HEAD . . . . . . . . . . . . . . . . 60-70-1 LEFT CONSOLE . . . . . . . . . . . . . . . . .40-50-1
DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14 LEFT PEDAL (AUXILIARY) . . . . . . . .40-120-1
ELECTRICAL SYSTEM INFORMATION LEFT UPPERSTRUCTURE COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-60-1
EMERGENCY EXIT . . . . . . . . . . . . . . 10-220-1 LIFTING AND BLOCKING THE EXCAVATOR
ENGINE COOLING SYSTEM . . . . . . . 10-90-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1
ENGINE COOLING SYSTEM . . . . . . . 60-40-1 LIFTING THE EXCAVATOR . . . . . . . . .10-20-1
ENGINE INFORMATION . . . . . . . . . . . 60-10-1 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1

INDEX-01 E20 Service Manual

LUBRICATING THE EXCAVATOR TORQUE SPECIFICATIONS FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-130-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
LUBRICATION SYSTEM . . . . . . . . . . .60-50-1 TRACK MAINTENANCE . . . . . . . . . . 30-30-1
MAGNETIC LOCKOUT SENSOR . . . .50-60-1 TRACK UNDERCARRIAGE COMPONENTS
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
MANIFOLD ASSEMBLY / ACCUMULATOR TRANSPORTING THE EXCAVATOR ON A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1 TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
OIL COOLER . . . . . . . . . . . . . . . . . . .20-140-1 TRAVEL CONTROLS . . . . . . . . . . . . 40-110-1
OPERATOR BONNET . . . . . . . . . . . .40-230-1 TRAVEL MOTOR . . . . . . . . . . . . . . . 10-140-1
OPERATOR CAB (ROPS / TOPS) . . . .10-30-1 TRAVEL MOTOR . . . . . . . . . . . . . . . . 20-80-1
OPERATOR CANOPY (ROPS / TOPS) TWO-SPEED SWITCH . . . . . . . . . . . . 50-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-31-1 UPPERSTRUCTURE . . . . . . . . . . . . . 40-10-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . .10-190-1 VALVE (CROSS PORT RELIEF) . . . . 20-32-1
QUICK COUPLER (KLAC™ SYSTEM) VALVE (MAIN RELIEF) . . . . . . . . . . . . 20-30-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-240-1 VALVE (PORT RELIEF) . . . . . . . . . . . 20-31-1
QUICK COUPLER (LEHNHOFF® SYSTEM) VALVE (PRESSURE REDUCING)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-241-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33-1
REGULAR MAINTENANCE . . . . . . . . .70-20-1 WIPER MOTOR . . . . . . . . . . . . . . . . 50-100-1
REMOTE START TOOL (SERVICE TOOL) KIT
- 7217666 . . . . . . . . . . . . . . . . . . . . . .10-231-1
REMOTE START TOOL KIT - MEL1563
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-230-1
RIGHT PEDAL (BOOM SWING) . . . .40-100-1
RIGHT SIDE COVER . . . . . . . . . . . . .40-250-1
Page 669 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off

RIGHT UPPERSTRUCTURE COVER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-70-1
ROPS CANOPY . . . . . . . . . . . . . . . . . .40-20-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
SEAT AND SEAT MOUNT . . . . . . . . . .40-40-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . .10-170-1
SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
SERVICE SCHEDULE . . . . . . . . . . . . .10-60-1
SERVICE TOOLS REQUIRED . . . . SPEC-70-1
SPARK ARRESTER MUFFLER . . . . .10-150-1
SPARK ARRESTER MUFFLER . . . . . .60-20-1
STARTER . . . . . . . . . . . . . . . . . . . . . . .50-40-1
STOPPING THE ENGINE AND LEAVING THE
EXCAVATOR . . . . . . . . . . . . . . . . . . .10-210-1
SWING CIRCLE GEAR . . . . . . . . . . . .30-40-1
SWING FRAME . . . . . . . . . . . . . . . . .40-170-1
SWING MOTOR . . . . . . . . . . . . . . . . .20-100-1
SWIVEL JOINT . . . . . . . . . . . . . . . . . .20-90-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . . .10-50-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . .40-210-1
TECHNICAL SERVICE GUIDE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-20-1

INDEX-02 E20 Service Manual

Page 670 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off
Page 671 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:39 - Produced by Ken Cook Co. with media1off

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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